description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND
1. Field of Invention
This invention relates to detachable insulating covers that are particularly suited for use in connection with windows and entrances of residential and commercial dwellings.
2. Prior Art
It is known from prior art that heat transfer through the windows and entrances of residential and commercial dwellings can be greatly reduced through the use of insulating covers.
Prior art has shown application of thin sheets of transparent plastic material and the like affixed to the windows and entrances. This method does offer some thermal insulation properties; however, in older dwellings with inept windows and entrances this method will have very little if any effect. In addition this application has problems with condensation build-up when in use.
Another solution of prior art in U.S. Pat. No. 4,610,292 (1986) suggested the use of insulated window shades and curtains. In this method window shades have a separate or detachable insulating layer behind the cloth fabric of shade or curtain. The insulating layer could be added during winter months and removed during the warmer months. This method did offer a portable way of insulating window areas; however this method did very little for drafty inept window systems for older dwellings. In cold weather months if a furnace is used to heat the dwelling, the produced warm air will rapidly escape through the drafty windows making it uncomfortable and thereby lowering the efficiency of the furnace or requiring a greater increase in fuel consumption to warrant eliminating the problem.
Another solution of prior art in U.S. Pat. No. 4,131,150 (1978) suggested the use of a window enclosure that is permanently mounted inside of window framing. The window enclosure used siding panels to remove or add insulating material. This method required a permanent alternation to the window framing.
These methods listed above are known to suffer from the following disadvantages:
a) poor thermal protections during cold weather months, by permitting warm air to escape between small crevices in inept window systems; (b) neither system is designed to have an insulating layer fit firmly inside the window framing while utilizing surrounding wall element for fastening without altering the window and/or framing itself.
SUMMARY OF THE INVENTION—OBJECTS AND ADVANTAGES
A need for a long period of time has existed for a portable window insulating system that is simple and cost effective to install at first application, which will not alter the current window or entrance framing.
An important object of the present invention is to enable a person to remove the cover from the window framing is a simple manner.
Another important object of this invention is to provide a thermal barrier which seals around the edges of the window framing with an insulating layer and which may be adjusted to overlap around window framing edges onto the adjacent wall area.
During cold weather months the present invention, when installed inside a dwelling, will greatly restrict warm air and radiant heat from escaping between small crevices in inept window systems by fitting firmly into window framing using an insulating material.
This lightweight portable and removable insulating cover is placed over the interior-side generally (or the exterior) of typical commercial and residential building windows and entrances, providing added thermal protection inside of the dwelling, whereby creating a thermal barrier.
The present invention could be modified to have a viewer's opening for viewing out of the window/entrance when cover is installed. The present invention can also be modified to have decorative designs or embroidery on the exterior of device that is attractive and decorative to the eye of the beholder on the interior or exterior of the house.
This insulating cover can also be fabricated as a solid one-piece pre-molded insulating material using various molding/casting manufacturing techniques or using various fibrous felt-type insulating materials.
It is still another object of this invention to provide a complete window assembly that is simple, reusable, easy and economical to maintain.
This invention will be better understood and appreciated from the following detailed description of one embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the portable insulation device of the present invention.
FIG. 2 is a partial elevation view showing the installation of the present invention covering the interior side of a window unit 21 inside a building.
FIG. 2A is a modified version of FIG. 2 showing an option for the present invention wherein a viewer's opening is provided.
FIG. 3 is a cross sectional transverse view of a window unit showing the insulating cover insertion wherein the view is taken along lines 3 — 3 of FIG. 2 .
FIG. 4 is a detailed orthographic view of the portable insulation device illustrated in FIG. 1 .
FIG. 5 is a typical installation and application method for the present invention.
FIG. 6 is a cross-sectional view showing the portable insulation device insertion along lines 6 — 6 of FIG. 2 .
FIG. 6A is an alternative method of installing the present invention by using an extension adapter, whereby permitting the present invention to be installed over irregular, large and over-sized window units.
FIG. 6 b is a perspective view of the extension adapter identified in FIG. 6 A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the portable insulation device of the present invention. Shown in this view is an insulating core-element fabricated utilizing two functional sections which are the outer portion attachment pad section 01 and the inner portion insert pad section 02 . Both the outer and inner portions or pads are illustrated here as completely and individually encased in a fabric material 03 . As illustrated, the outer portion attachment pad section 01 is larger than the inner portion insert pad section in at least two dimensions, namely for example in height and width as viewed. Thus the attachment pad section effectively overlaps the insert pad section, and on this overlap segment are shown fasteners as will be further described herebelow. Said inner portion insert pad section is seen to protrude or jut out from the outer portion attachment pad section. All seams, corners, and edges of the fabric material 03 are bound together using heavy-duty nylon threading material 04 . Spaced uniformly along the topside of the inner portion pad 02 are buttons associated with threading holes 05 . Another set buttons associated with threading holes 05 is located on the backside of the outer portion pad 01 , and spaced in a manner in that they are directly aligned with buttons and threading holes 05 of the inner portion pad 02 . The buttons with threading holes 05 on both the outer portion pad 01 and the inner portion Pad 02 are illustrated as laced together by tightly drawn heavy-duty nylon threading material or lacing 04 . The tightly drawn lacing passes through both the outer portion pad 01 and the inner portion pad 02 . Along the perimeter of the outer portion pad 01 where it overlaps the inner portion pad 02 are uniformly spaced Velcro® hook and loop fasteners 06 . Besides hook and loop fasteners, these may also include any other conventional fastening means, for example, snaps or hooks.
FIG. 2 is a partial elevation view showing an inside building wall structure 20 with the portable insulation device installed over a window unit 21 . The inner portion of pad 02 is fitted inside of the window framing area. The Outer portion pad 01 overlaps onto building wall structure 20 along the edges of the window framing.
FIG. 2A is a modified version of FIG. 2 , which is a partial elevation view showing a building wall structure 20 with the portable insulation device installed over a window unit 21 . The inner portion pad 02 is fitted inside of the window framing area. The Outer portion pad 01 overlaps onto the building wall structure along the edges of the window framing.
This drawing also shows a viewer's opening 22 which allows the viewer inside a dwelling to view the environment on the outside of the dwelling when the present invention is installed. The viewer's opening shall be fabricated, for example, by providing an opening completely through the insulating cover then sealing the exposed fiberglass insulation 09 and polyester filler batting 07 by encasing them with fabric material 03 . All seams shall be bound together by using heavy duty nylon threading Material 04 .
FIG. 3 is a cross sectional transverse view of window unit 21 and the portable insulation device taken along 3 — 3 of FIG. 2 . The inner portion pad 02 is fitted inside of the window framing area and is seen as substantially filling said surrounding framing area. The outer portion pad 01 overlaps onto the building wall structure 20 along the edges of the window unit 21 framing. Along the perimeter of the building wall structure 20 encircling the window unit 21 are mounted fasteners 06 . These fasteners 06 are firmly attached using matching spacing to fasteners 06 attached to the topside of the outer portion pad 01 . All
Sides and corners of outer portion pad 01 are checked to make sure that all fasteners 06 are attached to corresponding fasteners mounted to building wall structure 20 encircling the window unit 21 .
FIG. 4 is a detailed orthographic and cross-sectional view of the portable insulation device. The orthographic view shows the relationship and arrangement of an embodiment of the outer portion attachment pad section 01 to the inner portion insert pad section 02 .
Cross-sectional view taken along lines 4 — 4 shows the internal features of an embodiment of the present Invention. The inner portion pad 02 internally may be fabricated mostly of Polyester filler Batting 07 . A sheet of general use grade aluminum foil 08 may be sandwiched between polyester filler batting 07 and fiberglass felt type insulation 09 . In this embodiment, the outer surfaces of both the outer portion pad 01 and inner portion pad 02 are completely encased in a fabric material 03 . Spaced uniformly along the topside of the inner portion pad 02 are buttons with threading holes 05 . A second set of buttons with threading holes 05 is placed on the backside of the outer portion pad 01 , which is spaced in a manner in that they are directly aligned with buttons with threading holes 05 of the inner portion pad 02 . The buttons with threading holes 05 on both the outer portion pad 01 and the inner portion pad 02 are laced together by tightly drawn heavy duty nylon threading material 04 . This sectional view shows the tightly drawn lacing passing through both the outer portion pad 01 and the inner portion pad 02 . Along a substantial portion of the perimeter of outer portion attachment pad section 01 are uniformly spaced fasteners 06 , for example Velcro® hook and loop fasteners.
FIG. 5 shows the portable insulation device typical installation method. The present invention is mounted over the window unit 21 with the inner portion pad 02 fitting inside window unit 21 framing. This embodiment shows an elevation view of Velcro® hook and loop type fasteners 06 installed on the building wall structure 20 which surround the Window Unit 21 .
FIG. 6 is a longitudinal cross-section view of the building wall structure 20 and window unit 21 taken along 6 — 6 of FIG. 2 . This view shows the insertion of the portable insulation device into the framing of window unit 21 . This cross-sectional view also shows the alignment of the fasteners 06 surrounding the window unit 21 framing and fasteners 06 attached to the top-side of outer portion pad 01 .
FIG. 6A is a modified version of the embodiment illustrated in FIG. 6 which is a longitudinal cross-section view of the building wall structure 20 and window unit 21 taken along 6 — 6 of FIG. 2 . This view shows the insertion of the portable insulation device into the framing of window unit 21 . In addition to the features explained in FIG. 6 , this modified version shows the present invention insertion for an over-sized window unit 21 using the extension adapter 10 . This is a bridging device to attach two insulating covers, whereby permitting the present invention to be expandable and extendable for installation over irregular, large or over-sized window unit 21 . The extension adapter 10 is rectangular and elongated in proportion with one elongated side having a fastener 06 attached to its exterior surface. The general length of the extension adapter 10 shall be proportional to the length of the joining inner port on pads 02 of the present invention. The general width of the extension adapter 10 shall be proportional to general distance between the joining inner portion pads 02 of the present invention while the joining outer portion pads 01 of the present invention are directly in contact. The elongated side of extension adapter 10 with the attaching fastener 06 shall be firmly connected to the corresponding fastener 06 attached along the common perimeter on the topside of the joining outer portion pads 01 of the present invention.
FIG. 6B is a perspective view of the extension adapter 10 identified in FIG. 6 A. The extension adapter 10 includes a fiberglass felt type insulation 09 core element which is encased in fabric material 03 . All seams, corners, and edges of the Fabric Material 03 are bound together using Heavy-duty nylon threading material 04 . The extension adapter 10 is rectangular and elongated in proportion with one elongated side having a fastener 06 attached to its outer surface along its length.
Summary, Ramifications, and Scope
As previously mentioned the following reference part numerals have additional advantages in that;
Fabric material 03 may be made of any suitable material such as flame-retardant material, cotton, plastic, polyester, paper with aluminum foil backing, nylon, and the like.
The fiberglass felt-type insulation 09 may be any conventional type of insulation such as fiberglass, fiberglass sheets with aluminum foil or its equivalent, various plastic foams, foam rubber, and any conventional insulation material including flame retardant material, which can control the transfer of heat and prevent the escape of warm air from the interior of the dwelling.
In addition to Velcro® hook and loop fasteners 06 , other fasteners could be used such as snaps, hooks, or any other types of conventional fastening means.
While nylon threading material 04 has been mentioned, it will be obvious that in addition to nylon threading material 04 , snap fasteners, staples, epoxy or other glue-like material or heat seals can be used.
A particular advantage of the present invention lies in the fact that edge portion of the outer pad 01 proficiently seals around the edges of the window unit 21 . This seal greatly restricts the passage of warm air from inside the dwelling and is easily removable. If the fasteners 06 are appropriately spaced along the window unit framing 21 , the insulating section of the present invention will greatly improve the air tightness of the space between the window unit 21 and the insulating cover.
Referring to FIG. 5 fasteners 06 are shown attached to the wall area surrounding window unit 21 . These fasteners could also be mounted directly to the window unit 21 framing. This method could benefit fixed sash commercial window units with metal framing.
The outer portion pad 01 could be constructed omitting the fiberglass insulation 09 shown in FIG. 4 , thus just using a layer of fabric material 03 or vinyl and plastic-like materials. This method would provide a smooth, flush and sleek appearance inside of the dwelling, thus lending itself to various decorative and ornamental designs, patterns, pictures, textures, writings and embroidery.
Also an additional advantage of the present invention lies in the fact that the materials selected to manufacture this device; when used in combination could produce stain resistant, water-resistant and moisture-resistant properties which would improve the effectiveness of the device. This could include the fabric material 03 , fibrous polyester filler batting 07 , and fiberglass insulation 09 .
Also an additional advantage of the present invention lies in the fact that the materials selected to manufacture this device; when used in combination could make the device a bullet-proof or resistant barrier when installed at windows and entrances. This ramification could have great law enforcement and military potential.
Although the description above contains many specifics, these should not construed as limiting the scope of the present invention but as merely providing illustrations of the presently preferred embodiments.
Thus the scope of this invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | An inexpensive, lightweight, reusable and detachable or removable insulation device for residential and commercial dwellings and similar heated structures. The device has an inner-portion insulating pad adapted to fit inside of a typical entrance or window unit framing. The device further has an outer-portion insulating pad adapted to overlap the window or entrance framing. The outer-portion insulating pad is provided fasteners so as to be secured to the building wall structure outside of the framing and surrounding the window or entrance framing by. During cold weather months, the present invention will greatly restrict warm air from escaping between small crevices in inept window systems by fitting firmly into window framing using a insulating material, thus creating a thermal barrier and improving the efficiency of the furnace by reducing the demand for electricity or fuel consumption. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a method for the production of a formed sheet-metal component which is formed by internal high-pressure forming. The invention also relates to a formed component produced according to the method.
It is known to shape components by internal high-pressure forming of butt-welded tubular preforms which are cut from corresponding bar stock to the length required. From EP-A-0620056 it is also known to weld together a number of such butt-welded tubular preforms of different diameter and thickness into a single tube which is then formed into a tubular component by internal high-pressure forming.
Extended formed components made from tubular preforms may especially be used as components in motor vehicle construction. Here, these components usually have to be joined to other components, eg. by further welding or by bonding. For certain purposes, it is then necessary for one component to be provided with at least one attachment flange. At least one operation is required to add such a flange to the said components, which is a disadvantage in terms of cost, so that, in this case, several components formed by deep-drawing or pressing are usually welded together in a conventional manner into one formed component.
From EP-A-0589370 it is known to provide two essentially flat metal sheets with a conduit for introducing the fluid for the internal high-pressure forming, and to weld the sheets together at their edges; the result is a formed body with a surrounding flange, which is not desired in edges; the result is a formed body with a surrounding flange, which is not desired in many applications in motor vehicle construction. DE-C-900085 likewise discloses the internal high-pressure forming of two essentially flat metal sheets which have been both welded together and which have a chamber in the middle formed from two domes for the introduction of the pressure fluid. This also produces a formed body with a surrounding flange. Similarly, DE-A 3418691 shows the forming of two or four flat metal sheets which are joined together at their edges. U.S. Pat. No. 5,070,717 shows a flangeless butt-welded tube being formed in such a way that a flange is produced in the forming process. In this way it is possible to produce an extended formed body with a flange on one side only, but additional cutting and welding operations are necessary to obtain a flange form with a straight end face.
SUMMARY OF THE INVENTION
Therefore, the problem which the invention by internal high-pressure forming, provides a component which can easily be produced and be joined to other components, in particular an elongate component with a flange on one side only, or with two flanges on opposite sides of the component.
This object is achieved by forming a body from sheet metal with at least one flange extending outwardly from an edge region of the sheet metal, the flange being welded, and then transforming the body into a preform by means of internal high-pressure forming.
By firstly forming, by rounding, a tubular body with an outwardly directed flange, production is facilitated, since the flange serves as a welding flange which can be welded by conventional low-cost methods at a high rate of production. In the completed formed component, this already existing flange serves as an attachment point for other components, which makes the use of such a formed component advantageous in many applications in comparison with conventional bodies formed by internal high-pressure forming.
In an alternative solution, two half-rounded metal sheets each provided with two projecting flat tongues are first of all joined to form one essentially tubular body with two flanges.
Another object of the invention is to provide a component formed by internal high-pressure forming which can be easily joined to other components. This object is achieved with a formed component made from a sheet metal body provided with an outwardly projecting flange and molded into a shape by the application of internal high-pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described in detail by way of example, with reference to the drawings, in which:
FIGS. 1 a - 1 e show schematically the steps in the production of a formed component produced in accordance with the invention;
FIG. 2 shows in profile a formed component according to the invention, and its use as a roof edge section for a motor vehicle;
FIG. 3 shows in profile a formed component according to the invention, and its use as a door sill section for a motor vehicle;
FIG. 4 shows in profile a formed component according to the invention, and its use as a door post for a motor vehicle;
FIG. 5 shows in profile a formed component according to the invention, and its use as a hinge bracket or lock bracket for a motor vehicle; and
FIG. 6 shows a further embodiment of formed component according to the invention prior to internal high-pressure forming.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 a - 1 e show schematically a sequence of process steps in the production of a formed component or body according to the invention. In FIG. 1 a , 1 denotes a sheet-metal blank from which the body will be formed. This blank 1 may be homogeneous, eg. a wholly steel or aluminium blank consisting of a single piece of the requisite size and with uniform thickness, as illustrated in FIG. 1 a . The blank may, however, consist of two or more sheet-metal portions joined together by welding, so that the blank 1 has portions of different thickness and/or with other dissimilarities of material characteristics or properties, which impart to the subsequent formed component local differences in characteristics or properties. Such blanks consisting of portions joined together (so-called tailored blanks) are known, and are used eg. in motor vehicle construction, where they are formed into components in a known manner. The “tailored blank” can be assembled in any desired direction and using any desired welding processes.
As shown in FIG. 1 b the blank is formed into an essentially cylindrical tube 2 , two margins 3 and 4 of the blank being formed into tongues projecting from the tubular part 2 , these tongues together constituting a flange 7 projecting from the tube. The forming of the blank 1 into the tubular part 2 may be performed on a rounding machine in a conventional manner, with unrounded margins 3 , 4 forming the tongues.
Fabrication of the tubular body 2 continues with the welding together of the tongues 3 , 4 to constitute the flange 1 (FIG. 1 c ). This may be performed eg. by lap seam welding with welding rollers 5 and 6 , a wire electrode being provided in a known manner at each of the welding rollers 5 , 6 . This has the advantage that coated metal blanks, eg. tinned or galvanized blanks, can be welded without any problem, as the wire electrode is continuously replenished from a spool. Alternatively the flange 7 may be welded eg. by edgewise laser welding, as illustrated in FIG. 1 c by the additional arrow A symbolically representing the laser beam impinging on the tongues 3 , 4 . Both roller seam welding and laser beam welding allow lengthy flanges 7 to be continuously welded at a high rate of feed and with high weld quality. It is also possible to employ laser welding in which the flange is through-welded from above or below. Alteratively the margins may be joined together edgewise by other known welding processes such as MIG, MAG, plasma or oxyacetylene welding. Electron-beam welding is also possible. By employing these processes, practically all kinds of sheet metal including, in particular, coated sheet-metal blanks, can be welded with high quality. The welded body 2 has an essentially tubular form with open ends and with a sealingly welded flange 7 .
In a next step (FIG. 1 d ) the body 2 thus formed is placed in a mould 8 for internal high-pressure forming. The inner surface of this mould has a configuration which corresponds to the shape of the formed body to be produced. The mould also has means for closing off the open ends of the tubular body 2 and means for introducing—usually via the end—a fluid at high pressure. The fluid for forming may also be introduced through an orifice or nozzle within the cylindrical portion of the preform. The process of internal high-pressure forming is known in itself and the corresponding devices for carrying out this process are likewise known and available on the marker, and will therefore not be described in further detail here. In the present case, however the mould 8 is configured so that the flange 7 can be clamped in the mould by the mould itself or by additional means, so that the flange 7 is impinged on both faces, over as nearly as possible its entire length, and preferably its full width, during the internal high-pressure forming process, so that the weld seam of the flange is not subjected to opening or pealing forces due to the pressure exerted in the interior of the body 2 .
FIG. 1 e shows the resulting formed body 10 , which has the desired shape imparted by internal high-pressure forming, and is provided with a flange 7 which can be used for attaching be body 10 to another component.
FIG. 2 shows as an example a formed body 11 which has been produced by the steps 1 a to 1 e described above, used as a roof edge section for a car roof 15 . FIG. 2 shows this application in schematic and highly simplified form. It will be seen that the formed body 11 is attached to the roof 15 by its flange 7 , eg. by a laser-welded joint (seam 16 ). Of course, other known attachment techniques (such as spot welding or bonding) might be employed.
FIG. 3 shows a further formed body 12 produced in accordance with the invention. This body—likewise shown only in simplified form—is used as a door sill section for a motor vehicle. 17 denotes a part of the vehicle floor to which the formed body 12 is attached by the flange 7 , eg. by spot welding or laser welding.
FIG. 4 shows schematically an end view of a formed body 13 according to the invention, which can be used as a door post (B-pillar) of a motor vehicle.
FIG. 5 shows a further formed body 14 fitted as a formed section in the hinge or lock region of a car engine bonnet or boot lid. The formed body 14 is attached by the flange 7 to the bent-over end 21 of the outer skin 19 of the bonnet or lid. The inner skin is fitted to the outer skin on interposed rubber mountings, and stiffeners 22 are provided.
FIG. 6 shows a tubular body 25 made up of two half-round formed blanks 26 and 27 . Each blank has two projecting margins or tongues which are paired to provide flanges 28 and 29 . These are welded as described above with reference to the flange 7 of FIG. 1 . The body 25 is also formed by internal high-pressure forming, the two flanges 28 and 29 being gripped over as nearly as possible their entire area. After forming, a formed body 30 with two flanges 28 and 29 results.
Of course, the method according to the invention can be used for producing a large number of formed components for other applications besides motor vehicle construction, such as eg. railcar building or aircraft construction. | The invention relates to a molded part which is configured by initially forming a tubular body with a welded flange. Subsequently, the body is shaped in a mold placing the body under internal pressure to form a part or preform. Thus, preforms with a welded flange can be obtained and connectedn with other parts. | 1 |
[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 62/087,071, filed Dec. 3, 2014, the disclosure of which is incorporated by reference in its entirety.
FIELD
[0002] Embodiments relate to an apparatus and methods for improving ion beam quality in an ion implantation system, and more particularly, improving boron ion beam quality by using a co-gas.
BACKGROUND
[0003] Semiconductor workpieces are often implanted with dopant species to create a desired conductivity. For example, solar cells may be implanted with a dopant species to create an emitter region. This implant may be done using a variety of different mechanisms. In one embodiment, an ion source is used.
[0004] In an effort to improve process efficiency and lower cost, in some embodiments, the ions extracted from the ion source are accelerated directly toward the workpiece, without any mass analysis. In other words, the ions that are generated in the ion source are accelerated and implanted directly into the workpiece. A mass analyzer is used to remove undesired species from the ion beam. Removal of the mass analyzer implies that all ions extracted from the ion source will be implanted in the workpiece. Consequently, undesired ions, which may also be generated within the ion source, are then implanted in the workpiece.
[0005] This phenomenon may be most pronounced when the source gas is a halogen-based compound, such as a fluoride. Fluorine ions and neutrals (metastable or excited) may react with the inner surfaces of the ion source, releasing unwanted ions, such as silicon, oxygen, carbon, and aluminum and heavy metals present as impurity elements. Additionally, halogen ions may also be implanted into the workpiece.
[0006] Therefore, an apparatus and a method which improves beam quality, particular for embodiments in which halogen based source gasses are employed, would be beneficial.
SUMMARY
[0007] An apparatus and methods of improving the ion beam quality of a halogen-based source gas are disclosed. Unexpectedly, the introduction of a noble gas, such as argon or neon, to an ion source chamber may increase the percentage of desirable ion species, while decreasing the amount of contaminants and halogen-containing ions. This is especially beneficial in non-mass analyzed implanters, where all ions are implanted into the workpiece. In one embodiment, a first source gas, comprising a processing species and a halogen is introduced into a ion source chamber, a second source gas comprising a hydride, and a third source gas comprising a noble gas are also introduced. The combination of these three source gases may produce an ion beam having a higher percentage of pure processing species ions than would occur if the third source gas were not used.
[0008] In one embodiment, a method of implanting a workpiece is disclosed. The method comprises energizing a first source gas, comprising a processing species and fluorine, and neon in a chamber to form a plasma in the chamber; and extracting ions from the plasma and directing the ions toward the workpiece, wherein an amount of pure processing species ions extracted from the plasma as a percentage of all processing species-containing ions increases by at least 5%, as compared to a baseline when neon is not used. In certain embodiments, an amount of pure processing species ions extracted from the plasma as a percentage of all processing species-containing ions increases by at least 10%, as compared to the baseline. In certain embodiments, a ratio of fluorine ions to processing species ions extracted from the plasma is decreased by at least 5%, as compared to the baseline. In certain embodiments, a beam current of pure processing species ions increases by at least 10%, as compared to the baseline.
[0009] In another embodiment, a method of implanting dopant into a workpiece is disclosed. The method comprises energizing a first source gas, comprising dopant and fluorine, a second source gas, comprising hydrogen and at least one of germanium and silicon, and neon in a chamber to form a plasma in the chamber; and accelerating ions from the plasma toward the workpiece, without using mass analysis, wherein between 20% and 90% of a total volume of gas introduced comprises neon and wherein a composition of the ions extracted from the plasma is affected by an introduction of neon. In certain embodiments, between 25% and 50% of the total volume of gas introduced comprises neon. In certain embodiments, the dopant comprises boron.
[0010] In another embodiment, an apparatus for processing a workpiece is disclosed. The apparatus comprises an ion source, having a chamber defined by chamber walls, wherein the ion source generates a plasma in the chamber; a first source gas container, containing a processing species and fluorine, in communication with the chamber; a second source gas container, containing hydrogen and at least one of silicon and germanium, in communication with the chamber; a third source gas container, containing neon, in communication with the chamber; and a workpiece support to hold the workpiece, wherein the apparatus is configured to introduce neon into the chamber in an amount sufficient to increase an amount of pure processing species ions extracted from the plasma as a percentage of all processing species-containing ions by at least 5%, as compared to a baseline when neon is not used. In certain embodiments, the dopant comprises boron. In certain embodiments, ions from the plasma are directed toward the workpiece without being mass analyzed. In certain embodiments, between 20-90% of a total amount of gas introduced to the chamber comprises neon. In certain embodiments, neon is introduced in an amount sufficient to increase a beam current of pure processing species ions by at least 10% relative to the baseline.
BRIEF DESCRIPTION OF THE FIGURES
[0011] For a better understanding of the present disclosure, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:
[0012] FIGS. 1A-C show workpiece processing systems according to different embodiments;
[0013] FIG. 2A is a representative graph of ion beam current as a function of argon gas concentration;
[0014] FIG. 2B is a second graph of ion beam current as a function of argon gas concentration;
[0015] FIG. 3 shows an implant system according to another embodiment;
[0016] FIG. 4A is a representative graph of the ion current as a function of neon gas concentration;
[0017] FIG. 4B is a second graph of the ion current as a function of neon gas concentration;
[0018] FIG. 5 is another embodiment of a workpiece processing system; and
[0019] FIG. 6 is another embodiment of a workpiece processing system.
DETAILED DESCRIPTION
[0020] As described above, ionization of halogen-based species, such as fluorides, may cause particles released from the inner surfaces of the ion source to be implanted in the workpiece. These contaminants may include aluminum, carbon, oxygen, silicon, fluorine-based compounds, and other unwanted species (including heavy metals present as impurity elements). One approach to address the damage caused by free halogen ions may be to introduce additional source gasses.
[0021] FIGS. 1A-1C show various embodiments of a workpiece processing system in which multiple source gasses may be introduced to an ion source. In each of these figures, there is an ion source 100 . This ion source 100 includes a chamber 105 defined by plasma chamber walls 107 , which may be constructed from graphite or another suitable material. This chamber 105 may be supplied with one or more source gasses, stored in one or more source gas containers, such as a first source gas container 170 , via a gas inlet 110 . This source gas may be energized by an RF antenna 120 or another plasma generation mechanism to generate a plasma. The RF antenna 120 is in electrical communication with a RF power supply (not shown) which supplies power to the RF antenna 120 . A dielectric window 125 , such as a quartz or alumina window, may be disposed between the RF antenna 120 and the interior of the chamber 105 . The chamber 105 also includes an aperture 140 through which ions may pass. A negative voltage is applied to extraction suppression electrode 130 disposed outside the aperture 140 to extract the positively charged ions in the form of an ion beam 180 from the plasma in the chamber 105 through the aperture 140 and toward the workpiece 160 , which may be disposed on a workpiece support 165 . A ground electrode 150 may also be employed. In some embodiments, the aperture 140 is located on the side of the chamber 105 opposite the side containing the dielectric window 125 . As shown in FIG. 1A , a second source gas may be stored in a second source gas container 171 and introduced to the chamber 105 through a second gas inlet 111 . A third source gas may be stored in a third source gas container 172 and introduced to the chamber 105 through a third gas inlet 112 . In another embodiment, shown in FIG. 1B , a second source gas may be stored in a second source gas container 171 and a third source gas may be stored in a third source gas container 172 . The second source gas and the third source gas may both be introduced to the chamber 105 through the same gas inlet 110 used by the first source gas. In yet another embodiment, shown in FIG. 1C , the second source gas and the third source gas may be mixed with the first source gas in a single gas container 178 . This mixture of gasses is then introduced to the chamber 105 through gas inlet 110 .
[0022] In any of these embodiments, the first source gas, the second source gas and the third source gas may be introduced simultaneously or sequentially to the chamber 105 . While these figures show the use of three different source gasses, the disclosure is not limited to any particular number. These figures intend to show various embodiments where multiple source gasses may be introduced to a chamber 105 . However, other embodiments are also possible and within the scope of the disclosure.
[0023] FIGS. 1A-1C shows embodiments of a workpiece processing system. However, the disclosure is not limited to these embodiments. For example, FIG. 5 shows another embodiment of a workpiece processing system, which may be a beam line implanter 500 . The beam line implanter 500 comprises an ion source 510 , where source gasses are introduced. The ion source 510 may comprise a chamber having an aperture through which ions may be extracted. The first source gas may be stored in first source gas container 170 , the second source gas may be stored in second source gas container 171 and the third source gas may be stored in third source gas container 172 . These sources gasses may be introduced to the ion source 510 through gas inlet 110 . Of course, these source gasses may be introduced in other ways, such as those shown in FIGS. 1A and 1C .
[0024] The ion source 510 generates ions by energizing the source gasses into a plasma. In certain embodiments, an indirectly heated cathode (IHC) may be used, although other mechanisms may be used to generate the plasma. Ions from the plasma are then accelerated through an aperture in the ion source 510 as an ion beam 180 . This ion beam 180 is then directed toward a set of beam line components 520 , which manipulate the ion beam 180 . For example, the beam line components 520 may accelerate, decelerate or redirect the ions from the ion beam 180 . In certain embodiments, the beam line components 520 may include a mass analyzer. The mass analyzer may be used to remove unwanted species from the ion beam 180 before they impact the workpiece 160 . The workpiece 160 may be disposed on a workpiece support 165 .
[0025] FIG. 6 shows another workpiece processing apparatus that may be used with the present disclosure. This workpiece processing apparatus 600 includes a chamber 605 defined by plasma chamber walls 607 . Like FIG. 1B , the chamber 605 may be in communication with a first source gas container 170 , a second source gas container 171 and a third source gas container 172 via gas inlet 110 . However, in other embodiments, the source gasses may be configured as shown in FIG. 1A or 1C . Further, like FIG. 1B , the apparatus may include a dielectric window 625 having an RF antenna 620 disposed thereon. Like FIG. 1B , the RF antenna is used to generate a plasma within the chamber 605 . Of course, other plasma generators may also be used. In this workpiece processing apparatus 600 , the workpiece 160 is disposed within the chamber 605 . A platen 610 is used to hold the workpiece 160 . In certain embodiments, the platen 610 may be biased to accelerate ions from the plasma toward the workpiece 160 in the form of an ion beam 180 .
[0026] The first source gas, also referred to as the feed gas, may comprise a dopant, such as boron, in combination with fluorine. Thus, the feed gas may be in the form of DF n or D m F n , where D represents the dopant atom, which may be boron, gallium, phosphorus, arsenic or another Group 3 or Group 5 element. In other embodiments, the first source gas may comprise a processing species in combination with fluorine. Thus, although the term “dopant” is used throughout this disclosure, it is understood that there are other processing species that may be used which may not be dopants. Thus, the first source gas comprises a processing species and fluorine. In certain embodiments, the processing species is a dopant.
[0027] The second source gas may be a molecule having a chemical formula of XH n or X m H n , where H is hydrogen. X may be a dopant species, such as any of those described above. Alternatively, X may also be an atom that does not affect conductivity of the workpiece 160 . For example, if the workpiece 160 comprises silicon, X may be a Group 4 element, such as silicon and germanium. The third source gas may be a noble gas, such as helium, argon, neon, krypton and xenon.
[0028] In other words, the first source gas may be BF 3 or B 2 F 4 , while the second source gas may be, for example, PH 3 , SiH 4 , NH 3 , GeH 4 , B 2 H 6 , or AsH 3 . The third source gas may be a noble gas, such as helium, argon, neon, krypton or xenon, in each of these embodiments. This list represents possible species that may be used. It is understood that other species are also possible.
[0029] By combining the first source gas with the second source gas, the deleterious effects of the fluorine ions may be reduced. For example, without being limited to any particular theory, the introduction of hydrogen may create a film or coating on the dielectric window 125 . This serves to protect the dielectric window 125 , which reduces the amount of contaminants originating from the dielectric window 125 that are contained in the extracted ion beam 180 . In addition, the second source gas may coat the inner surfaces of the plasma chamber walls 107 , which may be another source of contaminants. This coating may reduce the interaction between fluorine ions and the inner surfaces of the plasma chamber walls 107 , reducing the amount of contaminants generated.
[0030] The introduction of the second source gas may reduce the creation of contaminants and the incorporation of these contaminants in the ion beam 180 . However, in some embodiments, the resulting ion beam produced using the first source gas and the second source gas may not contain a sufficient quantity of the desired ions.
[0031] FIG. 2A shows a plurality of bar graphs which show the ion species produced by an ion source using BF 3 as the first source gas and GeH 4 as the second source gas, with a varying amount of argon, which serves as the third source gas in this embodiment. In each of these bar graphs, the RF power was 8 kW, and the combined flow rate of the BF 3 and GeH 4 was 18 sccm. Additionally, the ratio of BF 3 to GeH 4 was held constant at 9:1.
[0032] In each of the bar graphs, it can be seen that the ion source 100 ionizes the BF 3 to form boron ions (i.e. B + ), as well as BF x + ions, where BF x includes BF, BF 2 and BF 3 . Additionally, fluorine ions are created. Finally, a plurality of other ion species, which may be components of the second source gas or may be impurities, is also created.
[0033] As described above, the introduction of the second source gas may reduce the amount of contaminants introduced in the ion beam. As stated above, this may be significant when the ion beam is used to implant the workpiece without mass analysis.
[0034] Bar graph 250 shows the composition of an ion beam where no argon is introduced, also referred to as the baseline. As seen in line 200 , in this configuration, nearly 69% of the ions in the ion beam are dopant-containing ions, where, in this example, the dopant is boron. This metric is referred to as the boron fraction, or the dopant fraction. However, many of the dopant-containing ions also contain fluoride, such as in the form of BF + , BF 2 + and BF 3 +. In fact, as shown in line 210 , only about 45% of the dopant-containing ions are pure dopant (i.e. B + ). This ratio is referred to as the boron purity percentage, or the dopant purity percentage. In other embodiments, this ratio may be referred to as the processing species purity percentage. Lastly, while 69% of the ion beam contains boron, a very large percentage of the ions also contain fluorine. In fact, line 220 shows the ratio of fluorine ions extracted as part of the ion beam 180 to dopant ions. The fluorine ions used in this ratio are a measure of all of the fluorine ions that are extracted. In other words, this includes pure fluorine ions (F x + ), as well as ions that include other species, such as BF x + . Each fluorine ion is individually counted; thus, for example, BF 2 + is counted as two fluorine ions. The number of dopant ions is calculated in the same way. Line 220 shows that there are actually more fluorine ions than boron ions. This metric is referred to as the F/B ratio.
[0035] Bar graph 260 shows the composition of an ion beam where approximately 19% of the total gas introduced to the ion chamber is the third source gas, which may be argon in this embodiment. Note that the total beam current of dopant-containing ions (i.e. B + and BF x + ) remains almost unchanged at about 360 mA. However, there is a change in the composition of the ion beam. Specifically, as seen on line 200 , the boron fraction has decreased slightly, mostly due to the additional argon ions that have been created. However, surprisingly, as shown in line 210 , the percentage of pure dopant ions as compared to the total number of dopant-containing ions (the boron purity percentage or dopant purity percentage) has actually increased! In fact, the beam current of pure boron ions has also increased. Additionally, the ratio of fluorine ions to boron ions extracted as part of the ion beam (i.e. the F/B ratio), as shown in line 220 , has also decreased unexpectedly to about 100%. Additionally, the beam current of fluoride ions has decreased as well. In other words, the introduction of argon as a third source gas affected the composition of the resulting ion beam. Specifically, the introduction of argon has increased the formation of pure boron ions relative to the total number of boron-containing ions. Interestingly, the introduction of argon has also decreased the ratio of fluorine ions to boron ions. As stated above, in embodiments where mass analysis is not performed, these changes may improve the performance of the implanted workpiece.
[0036] Many of these trends continue as a greater percentage of argon is introduced. Bar graph 270 shows the composition of the ion beam where about 32% of all gas introduced into the chamber 105 comprises argon. At this concentration, the beam current of boron-containing ions begins to decrease slightly, from 360 mA to about 320 mA. The boron fraction has also decreased slightly due to the increased number of argon ions. However, other metrics have improved. Specifically, the boron purity percentage actually increased to nearly 50%. Additionally, the F/B ratio decreased to about 95%. Interestingly, the amount of other species, which includes all ions that are not boron-containing ions, fluorine ions or argon ions, actually decreases at this argon percentage. The beam current of fluorine ions also decreases to less than about 20 mA.
[0037] Bar graph 280 shows the composition of the ion beam where about 48% of all gas introduced into the chamber 105 comprises argon. At this concentration, the beam current of boron-containing ions again decreases slightly, from 320 mA to about 290 mA. The boron fraction has also decreased slightly to about 60% due to the increased number of argon ions. However, other metrics have continued to improve. Specifically, the boron purity percentage actually increased to about 50%. Additionally, the F/B ratio decreased to about 90%. Again, the beam current of the other species has decreased as well. The beam current of fluorine ions also decreases to about 10 mA.
[0038] Surprisingly, the introduction of argon in very large percentages, such as up to about 50%, still results in improvements in many of the ion beam metrics. FIG. 2B shows many of these metrics represented in a different format. Specifically, the total beam current of boron-containing ions is shown in line 290 . Note that the total boron-containing beam current remains above about 290 mA, even as the amount of argon increases to about 47% of the total gas introduced into the chamber 105 . However, there is a decrease in the total boron-containing beam current as the amount of argon exceeds about 20%. Interestingly, the beam current of pure boron-containing ions, shown in line 291 , increases as the amount of argon introduced into the chamber 105 increases to about 20%. However, at larger percentages of argon, the beam current of pure-containing ions decreases slightly. In fact, the pure boron beam current is about 160 mA with no argon, and increases to about 172 mA when about 20% of the total gas is argon. The pure boron beam current then decreases to about 145 mA as the argon percentage continues to increase. The F/B ratio is shown as line 292 , which is identical to line 220 in FIG. 2A . As described above, the F/B ratio decreases as the amount of argon increases throughout the range. Similarly, the boron fraction is shown as line 293 , is identical to line 200 in FIG. 2A . Finally, the boron purity fraction is shown in line 294 and is identical to line 410 in FIG. 2A . FIG. 2B shows that, as the percentage of argon introduced into the chamber 105 increases, the total beam current of the boron-containing ions (line 290 ) decreases as the percentage of argon exceeds about 20%. The beam current of pure boron (line 291 ) also decreases as the percentage of argon exceeds about 20%. However, the boron purity fraction (line 294 ) increases throughout this entire range. Additionally, the ratio of fluorine ions to boron ions (the F/B ratio shown as line 292 ) decreases throughout this range. Finally, while there is a steady decrease in the boron fraction (line 293 ), the percentage of ions that contain boron remains above about 60% throughout the entire range.
[0039] Other noble gasses may also be used. For example, rather than using argon, neon may be used as the third gas.
[0040] FIGS. 4A-4B show a plurality of bar graphs that show the ion species produced by an ion source using BF 3 as the first source gas and GeH 4 as the second source gas, with a varying amount of neon, which serves as the third source gas in this embodiment. Like argon, the introduction of neon as the third gas has positive benefits on ion beam composition and other metrics. However, surprising, the amount of neon which may be introduced while still achieving these benefits is much greater than for argon. In fact, as shown in more detail below, positive benefits are achieved even when over 80% of the total gas introduced to chamber 105 is neon!
[0041] In each of these bar graphs, the RF power was 8 kW, and the combined flow rate of the BF 3 and GeH 4 was 18 sccm. Additionally, the ratio of BF 3 to GeH 4 was held constant at 9:1.
[0042] As described above, in each of the bar graphs, it can be seen that the ion source 100 ionizes the BF 3 to form boron ions (i.e. B + ), as well as BF x + ions, where BF x includes BF, BF 2 and BF 3 . Additionally, fluorine ions are created. Finally, a plurality of other ion species, which may be components of the second source gas or may be impurities, is also created.
[0043] Bar graph 450 shows the composition of an ion beam where no neon is introduced, also referred to as the baseline. As seen in line 400 , in this configuration, nearly 75% of the ions in the ion beam are dopant-containing ions, where, in this example, the dopant is boron. As described above, this metric is referred to as the boron fraction, or the dopant fraction. However, many of the dopant-containing ions also contain fluoride, such as in the form of BF + , BF 2 + and BF 3 + . In fact, as shown in line 410 , only about 41% of the dopant-containing ions are pure dopant (i.e. B + ). This ratio is referred to as the boron purity percentage, or the dopant purity percentage. In other embodiments, this ratio may be referred to as the processing species purity percentage. Lastly, while 75% of the ion beam contains boron, a very large percentage of the ions also contain fluorine. In fact, line 420 shows the ratio of fluorine ions to dopant ions that are extracted as part of ion beam 180 . The fluorine ions used in this ratio are a measure of all of the fluorine ions that are extracted. In other words, this includes pure fluorine ions (F x + ), as well as ions that include other species, such as BF x + . Each fluorine ion is individually counted; thus, for example, BF 2 + is counted as two fluorine ions. The number of dopant ions is calculated in the same way. Line 420 shows that there are actually more fluorine ions than boron ions. This metric is referred to as the F/B ratio.
[0044] Bar graph 455 shows the composition of an ion beam where approximately 37.8% of the total gas introduced to the ion chamber is the third source gas, which may be neon in this embodiment. While FIG. 4A shows data using at least 37.8%, it is noted that positive benefits are observed where the percentage of neon is as low as 20% Note that the total beam current of dopant-containing ions (i.e. B + and BF x + ) has increased from about 420 mA when no neon is used, to about 440 mA. Additionally, there is a change in the composition of the ion beam. Specifically, as seen on line 400 , the boron fraction has decreased slightly, mostly due to the additional neon ions that have been created. However, surprisingly, as shown in line 410 , the percentage of pure dopant ions as compared to the total number of dopant-containing ions (the boron purity percentage or dopant purity percentage) has actually increased! In fact, the beam current of pure boron ions has also increased. Additionally, the ratio of fluorine ions to boron ions (i.e. the F/B ratio), as shown in line 420 , has also decreased unexpectedly to about 105%. Additionally, the beam current of fluoride ions has decreased as well. In other words, the introduction of neon as a third source gas affected the composition of the resulting ion beam extracted from the plasma. Specifically, the introduction of neon has increased the formation of pure boron ions relative to the total number of boron-containing ions. Interestingly, the introduction of neon has also decreased the ratio of fluorine ions to boron ions. As stated above, in embodiments where mass analysis is not performed, these changes may improve the performance of the implanted workpiece.
[0045] Each of these trends continues as a greater percentage of neon is introduced. Bar graph 460 shows the composition of the ion beam where about 54.9% of all gas introduced into the chamber 105 comprises neon. At this concentration, the beam current of boron-containing ions begins to decrease slightly, from 440 mA to about 430 mA. However, the beam current of boron-containing ions is still greater than the baseline. The boron fraction, shown as line 400 , has also decreased slightly due to the increased number of neon ions. However, other metrics have improved. Specifically, the boron purity percentage, shown in line 410 , actually increased to nearly 50%. Additionally, the F/B ratio, shown in line 420 , decreased to about 100%. Interestingly, the amount of other species, which includes all ions that are not boron-containing ions, fluorine ions or neon ions, actually decreases at this neon percentage. The beam current of fluorine ions also decreases to less than about 40 mA.
[0046] Bar graph 465 shows the composition of the ion beam where about 64.6% of all gas introduced into the chamber 105 comprises neon. At this concentration, the beam current of boron-containing ions again decreases slightly, from 430 mA to about 420 mA. However, the beam current of boron-containing ions is still greater than in the baseline. The boron fraction, shown in line 400 , has also decreased slightly to about 70% due to the increased number of neon ions. However, other metrics have improved. Specifically, the boron purity percentage, shown in line 410 , actually increased to about 48%. Additionally, the F/B ratio, shown in line 420 , decreased to under 100%. Again, the beam current of the other species has decreased as well. The beam current of fluorine ions also remains relatively constant at about 20 mA.
[0047] Bar graph 470 shows the composition of the ion beam where about 70.9% of all gas introduced into the chamber 105 comprises neon. At this concentration, the beam current of boron-containing ions remains relatively constant at about 420 mA. However, the beam current of boron-containing ions remains greater than in the baseline. The boron fraction has also decreased slightly to about 70% due to the increased number of neon ions. However, other metrics have improved. Specifically, the boron purity percentage, shown in line 410 , actually increased to over 50%. Additionally, the F/B ratio, shown in line 420 , decreased to about 95%. Again, the beam current of the other species has decreased as well. The beam current of fluorine ions also remains relatively constant at about 20 mA.
[0048] Bar graph 475 shows the composition of the ion beam where about 75.3% of all gas introduced into the chamber 105 comprises neon. At this concentration, the beam current of boron-containing ions remains relatively constant at about 420 mA. The boron fraction, shown in line 400 , has also decreased slightly to slightly under 70% due to the increased number of neon ions. However, other metrics have improved. Specifically, the boron purity percentage, shown in line 410 , actually increased to about 52%. Additionally, the F/B ratio, shown in line 420 , decreased to about 90%. Again, the beam current of the other species has decreased as well. The beam current of fluorine ions also decreased slightly to about 15 mA.
[0049] Bar graph 480 shows the composition of the ion beam where about 83.0% of all gas introduced into the chamber 105 comprises neon. At this concentration, the beam current of boron-containing ions decreases slightly to about 410 mA. The boron fraction, shown in line 400 , has also decreased slightly to about 68% due to the increased number of neon ions. However, other metrics have improved. Specifically, the boron purity percentage, shown in line 410 , actually increased to about 56%. Additionally, the F/B ratio, shown in line 420 , decreased to about 80%. Again, the beam current of the other species has decreased as well. The beam current of fluorine ions also decreased slightly to about 15 mA. Surprisingly, even when 83% of the total gas is neon, the neon ion beam remains less than about 40 mA. This may be due to the high ionization energy of neon.
[0050] Surprisingly, the introduction of neon in very large percentages, such as between 20 and 90%, still results in improvements in many of the ion beam metrics. This is in contrast to argon, where the introduction of argon improved beam metrics up to a certain percentage, and then degraded those metrics. The fact that the amount of neon can be as great as 83% or more is an unexpected result. FIG. 4B shows many of these metrics represented in a different format. Specifically, the total beam current of boron-containing ions is shown in line 490 . Note that the total boron-containing beam current remains above 400 mA, even as the amount of neon increases to about 83% of the total gas introduced into the chamber 105 . Interestingly, the beam current of pure boron-containing ions, shown in line 491 , increases as the amount of neon introduced into the chamber 105 increases. In fact, the pure boron beam current is about 175 mA at the baseline, which is when no neon is used, and increases to about 230 mA when 83% of the total gas is neon. More specifically, when 37.8% neon is introduced, the pure boron beam current increases more than 10% relative to the baseline. At the baseline, the pure boron beam current is about 175 mA. This increases to about 195 mA when 37.8% neon is introduced. This trend continues with increasing amounts of neon. For example, there is a 15% increase in pure boron beam current, relative to the baseline, when 64.6% neon is introduced. This increase is 20% or more for increased levels of neon. The F/B ratio is shown as line 492 , which is identical to line 420 in FIG. 4A . As described above, the F/B ratio decreases as the amount of neon increases throughout the range. Specifically, the F/B ratio is 112.6% at the baseline, when no neon is used. That F/B ratio drops more than 6% to 105.7% with the introduction of 37.8% neon. As the amount of neon increases, the F/B ratio continues to drop. For example, at 54.9% neon, the F/B ratio is nearly 10% lower as compared to the baseline. At 75.3% neon, the F/B ratio drops more than 20% relative to the baseline. Similarly, the boron fraction is shown as line 493 , is identical to line 400 in FIG. 4A . Finally, the boron purity fraction is shown in line 494 and is identical to line 410 in FIG. 4A . This boron purity fraction, which represents the ratio of pure processing species ions to total processing species ions, increases by more than 6% when 37.8% neon is introduced, as compared to the baseline. At 54.9% neon, the boron purity fraction increases nearly 10% relative to the baseline. In fact, at high levels of neon dilution, the improvement in boron purity fraction relative to the baseline is more than 20%! Additionally, the number of pure dopant ions, or pure processing species ions, as a percentage of the total ions, referred to as pure dopant ratio, also increases as neon is introduced in greater quantities. This pure dopant ratio is shown in line 495 . For example, at the baseline, about 31% of all of the ions are pure dopant ions. However, at 37.8% neon, that pure dopant ratio increases by about 4% to 32.2%. At higher levels of neon, the percentage of pure dopant ions may increase by 10% or more, relative to the baseline. FIG. 4B shows that, as the percentage of neon introduced into the chamber 105 increases, the total beam current of the boron-containing ions (line 490 ) remains roughly constant. However, metrics, such as the beam current of pure boron (line 491 ), the boron purity fraction (line 494 ), and the pure dopant ratio (line 495 ) all improve throughout this entire range. Additionally, the ratio of fluorine ions to boron ions (the F/B ratio shown as line 492 ) decreases throughout this range, with a large decrease as the percentage of neon exceeds about 60%. Finally, while there is a steady decrease in the boron fraction (line 493 ), the percentage of ions that contain boron remains above 70% throughout the entire range.
[0051] These unexpected results, shown in FIGS. 2A-2B and 4A-4B , have many benefits.
[0052] First, heavier dopant-containing ions, such as BF + , BF 2 + and BF 3 + tend to be implanted at a more shallow depth than pure dopant ions, such as B + . During the subsequent thermal treatment, these shallowly implanted ions are more likely to diffuse out of the workpiece. In other words, the total beam current of all dopant-containing ions may not be indicative of the amount of dopant that is actually implanted and retained in the workpiece. Without wishing to be bound to any particular theory, it is believed that the argon and neon metastables in the plasma may break down the larger dopant-containing ions into more desirable pure dopant ions.
[0053] Secondly, the implanting of fluorine, in any form, may be deleterious effects. The implanting of fluorine ions may cause defects in the workpiece, which affects its performance. The implanted fluorine may also cause the dopants to diffuse out from the workpiece. Fluorine is also known to retard the dopant diffusion into the workpiece, making the annealed dopant profile shallow, which is not preferable for solar cell applications.
[0054] Third, the introduction of argon and/or neon has a limiting effect on the generation of other species, also referred to as contaminants, that are generated. Without wishing to be bound to any particular theory, it is believed that these gasses stabilize the plasma, resulting in a reduction in chamber wall sputtering. Due to its large ionization cross-section, argon and neon are relatively easy to ionize and stabilize the discharge. Because of this, the plasma is maintained at relatively low plasma potential, so that ion sputtering from the wall material can be reduced.
[0055] Fourth, during the implanting of the workpiece, the argon and/or neon ions may sputter on the surface deposition layer of the workpiece. This may serve to remove any materials that are deposited during the implant process. Some of these materials may be difficult to remove via a wet chemistry process after the implant.
[0056] Fifth, in the case of neon, high ionization energy implies that few neon ions are created. Further, these ions have a relatively low mass and therefore cause minimal damage to the workpiece. Thus, neon may be used to improve the beam composition, without having few adverse effects.
[0057] Thus, an ion beam having reduced beam impurity and increased dopant purity can be created by using three source gasses. The first source gas, or feedgas, may be a species that contains both a dopant and fluorine, such as BF 3 or B 2 F 4 . The second source gas may be a species that contains hydrogen and either silicon or germanium, such as silane (SiH 4 ) or germane (GeH 4 ). The third source gas may be argon, neon or another noble gas. These three source gasses are introduced into a chamber 105 of an ion source 100 , either simultaneously or sequentially, where they are ionized. The ion source may use RF energy generated by RF antenna 120 . In another embodiment, the ion source may utilize the thermionic emission of electrons using an IHC. Other methods of ionizing a gas may also be used by the ion source. Ions from all three source gasses are directed toward a workpiece 160 , where they are implanted into the workpiece 160 . As described earlier, these ions may not be mass analyzed, meaning that all extracted ions are implanted into the workpiece 160 .
[0058] In another example, the second source gas may include a dopant having the opposite conductivity. For example, the first source gas, or feedgas, may be a species than contains both boron and fluorine, such as BF 3 or B 2 F 4 . The second source gas may be a species that contains hydrogen and a Group V element, such as phosphorus, nitrogen or arsenic.
[0059] While FIGS. 2A-2B and 4A-4B shows the results when boron is used as the dopant in the first source gas, the disclosure is not limited to this embodiment. Other dopants, such as gallium, phosphorus, arsenic or other Group 3 and Group 5 elements, may be used.
[0060] The above disclosure discusses that the third source gas may be introduced in amounts ranging from about 19% to about 48% for argon and from about 20% to 90% for neon. However, the disclosure is not limited to this range. In some embodiments, the third source gas may be introduced in amounts ranging from about 15% to about 90%. In other embodiments where the third source gas is argon, the third source gas may be introduced in amounts ranging from about 15% to about 40%. In other embodiments where the third source gas is argon, the third source gas may be introduced in amounts ranging from about 15% to about 50%. In certain embodiments where the third source gas is neon, the third source gas may be introduced in amounts ranging from about 20% to about 90%. In certain embodiments where the third source gas is neon, the third source gas may be introduced in amounts ranging from about 25% to 60%. In certain embodiments, where the third source gas is neon, the third source gas may be introduced in amount greater than 40%, such as between 40% and 90%. Additionally, the ratio of the first source gas to the second source gas may be about 9:1, although other ratios may also be used. The combined flow rate of the first source gas and the second source gas may be between 10 and 20 sccm.
[0061] While the above description discloses the use of three source gasses, in other embodiments, two source gasses may be used. For example, in some embodiments, as described above, the first source gas may be in the form of DF n or D m F n , where D represents the dopant (or processing species) atom, which may be boron, gallium, phosphorus, arsenic or another Group 3 or Group 5 element. In certain embodiments, the second source gas is not used. Instead, only the first source gas and the third source gas are combined in the ion source 100 . In this embodiment, the flow rate of the first source gas may be between 10 and 30 sccm. In one embodiment where the third gas is argon, the third source gas may constitute between 15% and 40% of the total gas introduced to the chamber 105 . In some embodiments where the third gas is argon, the third source gas may be introduced in amounts ranging from about 15% to about 30%. In other embodiments where the third gas is argon, the third source gas may be introduced in amounts ranging from about 15% to about 40%. In other embodiments where the third gas is argon, the third source gas may be introduced in amounts ranging from about 15% to about 50%. In certain embodiments where the third gas is neon, the third gas may be introduced in amounts ranging from about 20% to about 90%. In certain embodiments where the third source gas is neon, the third source gas may be introduced in amounts ranging from about 25% to 60%. In certain embodiments, where the third source gas is neon, the third source gas may be introduced in amount greater than 40%, such as between 40% and 90%.
[0062] As described above, the introduction of a third gas, such as argon or neon, with the BF x gas may affect the composition of the resulting ion beam. Specifically, the boron purity percentage may be increased, while the F/B ratio may decrease. In other words, the change in the composition of the ion beam may occur without the use of the second source gas.
[0063] FIG. 3 shows another embodiment. In this embodiment, the ion source 300 has a chamber separator 390 disposed within the chamber, effectively separating the chamber into a first sub-chamber 305 a and a second sub-chamber 305 b . Each of first sub-chamber 305 a and second sub-chamber 305 b has a respective aperture 340 a , 340 b . Additionally, the ground electrode 350 and extraction suppression electrode 330 may be modified to have two openings, corresponding to apertures 340 a , 340 b . As before, the chamber has a dielectric window 125 and an RF antenna 120 disposed thereon. In this embodiment, the first source gas is stored in first source gas container 170 and is introduced to the second sub-chamber 305 b through the gas inlet 110 . The first source gas may be any of the species described above. The second source gas is stored in the second source gas container 171 and is introduced to the second sub-chamber 305 b through the second gas inlet 111 . The second source gas may be any of the species described above. As described with respect to FIG. 1B , in some embodiments, the first source gas container 170 and the second source gas container 171 may be connected to a single gas inlet. In another embodiment, illustrated in FIG. 1C , the first and second source gasses may be mixed in a single source gas container. Additionally, in some embodiments, the second source gas is not used, as described above. As described above, the ratio of the first source gas to the second source gas may be about 9:1, although other ratios may be used. The combined flow rate may be between 10 and 20 sccm. Argon may be stored in third source gas container 172 and introduced to the first sub-chamber 305 a through the third gas inlet 112 .
[0064] In this embodiment, an argon ion beam 380 a is extracted through aperture 340 a . Concurrently, a dopant ion beam 380 b is extracted through aperture 340 b . This dopant ion beam 380 b contains boron-containing ions, as well as fluorine ions, and other ion species.
[0065] In FIG. 3 , the argon ion beam 380 a and the dopant ion beam 380 b are parallel to one another so that they strike the workpiece 160 at different locations. In this embodiment, the workpiece is scanned in the direction indicated by arrow 370 . In this way, each location on the workpiece 160 is first implanted by dopant ion beam 380 b , and then struck by argon ion beam 380 a . As described above, the argon ion beam 380 a may serve to sputter deposition layer material from the surface of the workpiece 160 , which was deposited during the implant of dopant ion beam 380 b.
[0066] As explained above, the argon implant may remove material from the surface deposition layer, which is difficult to remove using wet chemistry.
[0067] In another embodiment, the argon ion beam 380 a and the dopant ion beam 380 b are directed or focused so that they simultaneously strike a location on the workpiece 160 . In this embodiment, the workpiece 160 can be scanned in any direction.
[0068] In yet another embodiment, the two implants may be sequentially, such that the entire workpiece 160 is implanted by the dopant ion beam 380 b . At a later time, an argon ion beam 380 a is directed toward the workpiece 160 .
[0069] In each of the embodiments described herein and associated with FIG. 3 , the implants may be performed without mass analysis, such that all of the extracted ions strike the workpiece.
[0070] While the embodiment of FIG. 3 was described using argon, it is possible that other gasses, such as neon, may be substituted for argon to achieve the same effect.
[0071] Furthermore, although the embodiments disclosed herein describe the use of argon and neon as the third source gas, the disclosure is not limited to this embodiment. As stated above, other noble gasses, such as helium, krypton and xenon, may also be used as the third source gas. Alternatively, a combination of noble gasses may serve as the third source gas.
[0072] Additionally, the embodiments disclosed herein describe an implant process where a processing species, such as a dopant, is implanted into the workpiece 160 . However, the disclosure is not limited to this embodiment. For example, other processes may be performed on a workpiece using the combinations of source gasses described herein. For example, deposition or etching processes may also be performed on the workpiece using the disclosed combination of source gasses.
[0073] The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein. | An apparatus and methods of improving the ion beam quality of a halogen-based source gas are disclosed. Unexpectedly, the introduction of a noble gas, such as argon or neon, to an ion source chamber may increase the percentage of desirable ion species, while decreasing the amount of contaminants and halogen-containing ions. This is especially beneficial in non-mass analyzed implanters, where all ions are implanted into the workpiece. In one embodiment, a first source gas, comprising a processing species and a halogen is introduced into a ion source chamber, a second source gas comprising a hydride, and a third source gas comprising a noble gas are also introduced. The combination of these three source gases produces an ion beam having a higher percentage of pure processing species ions than would occur if the third source gas were not used. | 2 |
RELATED U.S. APPLICATION DATA
[0001] This application claims the benefit of U.S. Provisional Application No. 60/649,505 filed Feb. 3, 2005 which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the manufacture of tufted fabrics, and particularly to an improved gate apparatus to allow a looper to tuft either loop pile or cut pile stitches.
BACKGROUND OF THE INVENTION
[0003] In the field of tufting, there have been a variety of efforts made to enable both cut pile and loop pile tufts or bights of yarn to be placed in the same row of stitches. In some instances, the structures utilized for this purpose did not allow effective control of the height of stitches and, for instance, the cut pile stitches might always be of greater height than the loop pile stitches. The use of pivoting gate structures on the loopers was proposed in Jolley, U.S. Pat. No. 4,134,347 and Crumbliss, U.S. Pat. No. 4,353,317.
[0004] Later sliding gate structures were proposed as typified by Bennett, U.S. Pat. No. 6,155,187. When properly implemented, sliding gate structures may provide rapid response and avoid moving the entire pneumatic activation assembly with the loopers. However, Bennett taught the use of internal biasing elements in pneumatic cylinders and the use of blocks of cylinders to improve efficiencies in assembly. In practice, the use of internal biasing elements limits the size and corresponding force that the biasing elements may provide. In turn, this limits the speed with which the gate can return to the open position after pressure to its corresponding pneumatic cylinder is stopped. Furthermore, the internal biasing elements are not visible to inspection and if rust beings to form due to moisture in the cylinder, for instance, there will be no way to detect the problem until performance degrades to the point where defective carpet patterns are produced, with resulting waste carpet and the need to replace an entire cylinder block rather than merely a spring or biasing element.
[0005] Finally, it is desirable to assemble the pneumatic cylinders used to operate the gates in a tight array to permit their use with fine gauge tufting machines. Constructing the cylinders in arrays of removable cylinders stacked four high in nearly vertical columns and designing corresponding gate structures permits this density to be achieved.
SUMMARY OF THE INVENTION
[0006] Therefore, it is a primary object of the invention to provide an improved sliding gate structure for use in tufting both loop pile and cut pile stitches from yarns seized by the same looper.
[0007] It is another object of the invention to provide a pneumatically activated sliding gate structure with external biasing means to return the gates to their open and unactivated positions.
[0008] It is yet another object of the invention to provide discrete pneumatic cylinders and biasing means so that a defective element may be replaced without the need for replacing an entire module or block of components.
[0009] It is still a further object of the invention to provide an array of pneumatic cylinders and corresponding activated sliding gates in a compact form so as to be effectively employed with narrow gauge needle configurations according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The particular features and objects of the invention as well as other advantages will be appreciated from the following description in connection with the drawings of an embodiment of the invention in which:
[0011] FIG. 1 is a sectional end view of a multiple needle tufting machine constructed for use with the sliding gate assembly of the present invention.
[0012] FIG. 2 is a sectional view of a representative pneumatic cylinder that may be adapted for use in the present invention.
[0013] FIG. 3A is a perspective partial sectional view of an embodiment of two columns of four cylinders and the corresponding gates and loopers according to the present invention.
[0014] FIG. 3B is a rear perspective view of the assembly of FIG. 3A .
[0015] FIG. 4A is a perspective partial sectional view of an embodiment of two columns of four cylinders and the corresponding gates and loopers according to the present invention.
[0016] FIG. 4B is a rear perspective view of the assembly of FIG. 4A .
[0017] FIG. 5 is an exploded rear perspective view of an embodiment of an eighteen column array of pneumatic cylinders and corresponding gates, loopers and related gauge components.
[0018] FIG. 6 is a side view of an embodiment of the invention in position on the rocker bar of a tufting machine.
[0019] FIG. 7 is a detailed exploded view of a slider and biasing spring according to a preferred embodiment of the invention.
[0020] FIG. 8A is another embodiment of the invention in perspective view on the rocker bar.
[0021] FIG. 8B is an exploded perspective view of the cylinder and slider assembly of the embodiment of FIG. 8A .
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 discloses a tufting machine 10 including transversely supported needle bar 12 which in turns supports a row of transversely spaced needles 14 . The needle bar carrier 11 is connected to push rod 16 adapted to be vertically reciprocated by a conventional needle drive mechanism, not shown. Front yarns 18 are supplied to the needles 14 through apertures 19 in the front yarn guide plate 20 from a source of yarn supply, not shown, such as yarn feed rolls, creels, or other known yarn supply means. Preferably the front yarns pass through a yarn feed pattern control mechanism 21 adapted to feed the appropriate length of individual yarns 18 to corresponding needles 14 in accordance with a pre-determined pattern. Any one of several pattern control mechanisms may be incorporated in the mechanism 21 such as those disclosed in U.S. Pat. Nos. 6,244,203 and 6,283,053, or earlier mechanisms, and typically attach to the head 26 of tufting machine 10 .
[0023] When needed, rear yarns may be correspondingly fed through apertures 23 in rear yarn guide plates 24 from another source or supply of yarns. If desired, the needle bar 12 may be slideably mounted and shifted by appropriate pattern control means in a well known manner, such as by cams, roller drives, or hydraulic shifters.
[0024] Supported upon a needle plate 32 and fixed to bed frame 33 are a plurality of straight rearward projecting transversely spaced needle plate fingers 34 extending between the vertical needle paths of the reciprocal needles 14 . The substrate or base fabric 35 is supported for longitudinal rearward movement over the needle plate 32 . The base fabric is drawn by conventional fabric feed mechanism or substrate drive such as a belt and pulley mechanism or servo motors powering spiked substrate drive rolls 27 , 28 .
[0025] The needle drive mechanism, not shown, is designed to actuate push rod 16 to vertically reciprocate the needle bar 12 and to cause the needles 14 to simultaneously penetrate the substrate 35 far enough to carry the yarns 18 through the substrate 35 to form loops therein. After the loops are formed, the needles 14 are vertically withdrawn to their elevated retracted position disclosed in FIG. 1 .
[0026] A looper apparatus 40 made in accordance with the invention and shown in greater detail in FIG. 6 , includes a plurality of transversely spaced hooks 41 , there being at least one hook 41 for each needle 14 in the usual case. The hooks 41 are arranged so that the bill 42 of a hook 41 will cross and engage each needle 14 when the needle 14 is in its lowermost position and in a well known manner seize the yarn 18 and form a loop therein. The bills of the hooks 41 point forward opposite the direction of the fabric feed as indicated by the arrow 30 . Hooks 41 are mounted in hook bars as shown in greater detail in FIGS. 3 through 6 , and secured at the upper end of rocker arm 47 . Any conventional means to oscillate the rocker arm 47 may be provided. In a customary embodiment, the lower end of the rocker arm 47 is clamped to laterally extending rock shaft 49 . Pivotably connected to the upper portion of the rocker arm 47 is one end of a connecting link 48 having its other end pivotably connected to a jack shaft rocker arm 25 (shown in FIG. 6 ) mounted on a jack shaft 22 which has an oscillating motion imparted thereto by a drive means, such as a cam and lever apparatus in communication with the main drive shaft, so that the jack shaft 22 oscillates in timed relationship to the reciprocation of the needles 14 . The tufting machine 10 also incorporates a plurality of knives 36 which may cooperate with the hooks to cut selected loops to form cut pile tufts or bights of yarn as hereinafter described. The knives 36 may be mounted in knife blocks 37 and then mounted to a knife shaft rocker arm 39 which is clamped to knife shaft 38 . Oscillatory movement is imparted to the knife shaft 38 to conventionally drive the knives into engagement with one side of the respective hooks 41 as known in the art to provide a scissors-like cutting action.
[0027] In conventional tufting machine operation, the yarn feed pattern control mechanism 21 is programmed to feed selected yarns 18 at varying lengths in order to produce a desired high-low pattern of tufted bights of yarn. The yarns 18 can be selected from different colors or varying size or physical characteristics. Additional patterning capability may be provided by shifting the needle bar 12 as the substrate 35 moves in the direction of arrow 30 rearwardly through the machine 10 . The patterns formed on the substrate 35 appear on the bottom surface 45 while the upper surface 44 of the substrate 35 contains the back stitching necessary to permit needles 14 to move from one tufting location to another. After passing through the tufting zone, the backing fabric 35 is directed under a presser foot 22 and upward away from the tufting zone to provide space for the gated looper apparatus 40 of the present invention.
[0028] Central to the operation of gated loopers is the use of pneumatic cylinders 50 as shown in FIG. 2 . Cylinder 50 has a rear portion with inlet opening 51 to receive pressurized gas, cylinder wall 53 defining a cylinder in which piston 52 may move reciprocally, and head 55 which stops the forward movement of piston 52 in response to the pneumatic force of the pressurized gas. A drive rod 54 extends from the piston 52 forward and out through the head 55 to a rod tip 59 . Piston seals 56 and rod seals 57 help insure the smooth movement of piston 52 within the cylinder without excess loss of pneumatic force. The tip 58 of head 55 is preferably threaded to enhance the ease of securely mounting cylinder 50 . Clippard Model EP2064-P10 air cylinders are the preferred pneumatic cylinders to utilize to practice the invention.
[0029] FIGS. 3 and 4 show a first embodiment of a sliding gate mechanism according to the invention. Pneumatic cylinders 50 are mounted to the rear of apertures 73 extending through rear mounting plate 61 . The forward ends 59 of rods 54 of pneumatic cylinders 50 engage with the rear of the sliders 75 a , 75 b , 75 c , 75 d . Sliders 75 extend forward to detents 74 , through springs 70 and into slots 77 . Because cylinders 50 and sliders 75 are configured on four levels, upon entering slots 77 , the sliders 75 engage with a translation section such as compensating plates 78 in order that movement imparted by drive rods to sliders 75 will be translated to a plane of motion approximate the bottom of hook bills 42 . Compensating plates 78 engage looper clips 67 so that forward motion imparted by rod 54 is communicated to slider bar 75 and via compensating plate 78 to looper clip 67 which causes looper clip front end 68 to close the lip formed by the hook bill 42 of a corresponding hook 41 . When pneumatic pressure is released from cylinder 50 , the action of spring 70 pushing against front mounting plate 62 and detent 74 moves all of rod 54 , slider 75 , compensating plate 78 , and looper clip 67 rearward which again exposes the lip of loop hook 41 formed by hook bill 42 .
[0030] In FIG. 3A , it can be seen that cylinders 50 corresponding to slider 75 c and 75 d are activated so that pistons 52 have pushed rods 54 forward thereby pushing sliders 75 c , 75 d forward and compressing springs 70 c and 70 d . The corresponding compensating plates 78 are pushed forward, as are the looper clip fronts 68 c and 68 d . FIG. 3B shows the reverse angle view of the same configuration. Accordingly, in this configuration when loop hooks 41 rock forward to seize loops of yarn from needles 14 , the loops of yarn seized on the first two hooks covered by looper clip fronts 68 c , 68 d will be seized and released while the yarns seized by hooks with hook bills not closed by sliders 68 a and 68 b will be retained on the lips formed by hook bills 42 and ultimately dragged into contact with knives 36 (shown in FIG. 1 ) where the loops of yarn will be cut. Thus, loops of yarn seized over closed gated hooks will form loop pile bights and loops of yarn seized over open gated hooks will form cut pile bights of yarn on the face 45 of the carpet.
[0031] FIG. 4A shows the same configuration of pneumatic cylinders 50 , slider bars 75 , compensating plates 78 , and looper clips 67 . However, in the illustrated configuration, it is sliders 75 a , 75 b and both sliders 75 c that are activated by pneumatic pressure in corresponding cylinders 50 thereby closing the lips corresponding to hooks 41 that are matched with looper clip fronts 68 c , 68 a and 68 b . Thus, a stitch tufted with yarns seized by the six illustrated loopers will tuft four loop pile bights and two cut pile bights. FIG. 4B is a reverse angle illustration of the same configuration. Because the pattern of gated and ungated hooks can be changed with each stitch of the tufting machine, a wide variety of patterns of loop and cut pile bights of yarn may be produced. Because the springs 70 are not placed within cylinders 50 to act upon pistons 52 but instead are placed about the slider bars 75 , not only is it possible to use larger and more powerful springs, but any deterioration of spring function can be readily observed, and springs are not susceptible to retained moisture and rusting inside a confined cylinder space. The use of more powerful springs 70 provides faster return response to reopen the gated hooks at the conclusion of a stitch cycle, and permits faster operation of the tufting machine.
[0032] FIGS. 5 and 6 show an alternative preferred construction of gated loopers of the present invention. In this instance, rather than using slots 77 and compensating plates 78 to translate the movement of the cylinder rods 54 into the plane of the looper clips 67 , sliders 75 are constructed with a rear combination rod tip engaging portion 72 and detent, proceeding to a relatively straight spring bearing portion, then to a translation portion, and finally to a forward hook portion 71 . Forward hook portions 71 are designed to engage with rear hook portions 69 of looper clips 67 . The slider bars 75 a connecting with pneumatic cylinders 50 are positioned along the top of the array of pneumatic cylinders in a four by eighteen configuration as illustrated in FIG. 5 , translate the motion imparted by piston rods 54 downward as shown in slider bar 75 a . Similarly, the slider bar 75 d which engages with a pneumatic cylinder at the bottom of the array translates the motion imparted by piston rod 54 upward. In the illustrated embodiment, the slider bars 75 b and 75 c which translate motion from piston rods 54 of intermediate rows of pneumatic cylinders translate that motion slightly downward, but less so than by the slider bars 75 a for the cylinders 50 placed at the top of the array.
[0033] Pneumatic cylinders 50 have their threaded heads 58 fixed in rear openings 73 of rear mounting plate 61 . Piston rod ends 59 engage with slider bar rear tip engaging portions 72 which are received into the forward openings of apertures 73 of the rear mounting plate. The translation and front tip 71 portions of slider bar 75 extend forward through apertures 79 in front mounting plate 620 n the relatively straight portions of the slider bars 75 intermediate front and rear mounting plates 61 , 62 are mounted springs 70 . Slider tips 71 have upward facing lips that engage with downward facing lips of the rear 69 of looper clips 67 , such engagement preferably being within slots of clip guard 63 . Looper clips 67 extend forward into slots within hook blocks 73 so that a looper clip front end or gate 68 is adjacent to each hook 41 in the block. Pneumatic pressure applied to a cylinder 50 causes the piston rod 54 and corresponding rod end 59 to move forward thereby pushing corresponding slider ends 72 and sliders 75 with front end 71 forward and compressing the springs 70 on any activated slider 75 against the front mounting plate 62 . Slider front 71 pushes corresponding looper clip rear end 69 and looper clip 67 with gate 68 forward to cause gate 68 to cover the lip formed by hook bill 42 of its adjacent hook 41 . When pneumatic pressure in cylinder 50 is relaxed, the biasing force of compressed spring 70 on the activated slider bar 75 tends to return the looper clip 67 , slider bar 75 and piston rod 54 to their original positions, again opening the lips formed by the hook bills 42 and permitting yarns to be seized on the hooks 41 and brought into contact with an associated knife 36 .
[0034] Again, the placement of spring 70 external the slider bar 75 rather than internal the pneumatic cylinder 50 permits the use of more powerful springs and reduces maintenance issues associated with a gated looper apparatus. Furthermore, the use of individually attached cylinders 50 permits defective cylinders or other defective components to be replaced individually rather than requiring replacement of an entire array of components. This facilitates product service and reduces maintenance costs for both parts and labor. Front and rear mounting plates 61 , 62 are positioned by spacer bolts 81 affixed in threaded apertures on the rear of front mounting plate 62 and extending rearward and bolts 80 extending through washers 82 and apertures in rear mounting plate and are received within spacer bolts 81 . Housing 66 is secured by bolts 83 through apertures 84 in the tops of front and rear mounting plates 61 , 62 . The face 45 of tufted carpet may pass over housing 66 without interfering in any way with the operation of the gated looper apparatus.
[0035] The control of the pneumatic cylinders 50 and thus the gates 68 is preferably accomplished by a computer controlled array of valves with the number of valves corresponding to the number of cylinders, so that each hook 41 in a tufting machine and its corresponding looper clip 67 is controlled individually. In response to signals from the computer or controller, valves open and close communication between a compressor and air conduits communicating from the valves to each cylinder 50 in the arrays. When a valve is closed to prevent communication of pressurized air to a corresponding cylinder 50 , the valve vents the pressurized air so that spring 70 may return the gate apparatus to its inactivated open form, in which case the associated hook will tuft cut pile bights of yarn.
[0036] The guideway 64 is preferably made of aluminum which, in comparison to steel, will remove between about 35 to 60 pounds of weight from the looper apparatus over a 165″ to 195″ wide tufting machine. Additional weight savings are accomplished by utilizing aluminum and other lightweight metals for base 65 . By removing over 100 pounds of weight from the reciprocating looper apparatus, the tufting machine is subject to less vibration during operation and can be run at higher speeds.
[0037] A preferred slider and biasing spring is shown in FIG. 7 with slider 175 having a front end 87 for translating motion to looper clips 67 and rear end 89 for engaging with drive rods of pneumatic cylinders. Over the rear end 89 is mounted ferule 90 having a base flange 92 , body 93 and lumen 91 to receive slider end 89 . A preferred biasing spring 70 preferably has a slightly tapered configuration from forward end 85 that rests on the base flange 92 to rearward end 86 and the pitch of the spring 70 is slightly less at the forward end. Forward end 85 fits over body 93 of ferule 90 and spring 70 is restrained in place on the slider 175 by a detent, here created by the insertion of pin 95 through aperture 96 at the rearward end 89 of slider 75 . The lessened pitch of spring 70 causes less deformation of the spring through the many repetitive cycles of compression and expansion. In addition ferule 90 protects spring 70 from uneven wear from repeated friction on the rearward end of slider 75 . Additional weight savings may also be accomplished by cut outs in slider 175 as shown in phantom.
[0038] FIG. 8A shows an alternative embodiment of the invention in which the columns of cylinders are stacked at a slight angle to the vertical. These are referred to as substantially vertical offset columns. In this fashion, it is not necessary to have a transition section as is required when the column of cylinders 50 is entirely vertical. Cylinders 50 are screwed into openings on rear mounting plate which covers sliders 175 a , 175 b , 175 c , 175 d each configured with slightly different rear portion to connect at the appropriate height to the forward ends 59 of pneumatic cylinders 50 at an appropriate height. Sliders 175 a , 175 b , 175 c , 175 d engage with the rear of looper clips 68 within guideway 65 . The slider connections are covered by housing cover 66 which helps direct tufted fabric over the pneumatic gated looper assembly. An exploded view of the structure is shown in FIG. 8B more clearly showing a different rear end 89 positioning of sliders 175 a , 175 b , 175 c , 175 d.
[0039] Although preferred embodiments of the present invention have been disclosed in detail herein, it will be understood that various substitutions and modifications may be made to the disclosed embodiment described herein without departing from the scope and spirit of the present invention as recited in the appended claims. | A gated looper apparatus has an array of individually mounted pressurizable air cylinders with piston rods acting against biased slider bars in communication with looper gates. Baising elements are mounted external of pneumatic cylinders about slider bars with protective ferules to provide greater responsiveness and ease of maintenance. | 3 |
BACKGROUND OF THE INVENTION
The invention is directed to an improved apparatus for injecting a fuel/gas mixture in an internal combustion engine.
An apparatus for injecting a fuel/gas mixture is already known from German patent application No. 36 09 798 Al, in which the fuel injection valve protrudes by its valve end into a stepped longitudinal bore of a gas distributor part. The gas therein envelops the injected fuel in its flow direction and leads to the formation of a fuel/gas mixture. However, this apparatus has the disadvantage that because of the uniform flow of gas extending approximately in the direction of the injected fuel, only an inadequate turbulence is created in the fuel, so that a relatively nonhomogeneous fuel/gas mixture is formed, resulting in a relatively large fuel droplet size. For the sake of both exhaust emissions and fuel consumption, however, it is desirable to make the fuel intensively turbulent, thus producing fine droplets of fuel.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the apparatus according to the invention to provide the advantage that as the gas emerges from the at least one curved flow conduit into the mixing opening of the swirl element, it meets the injected fuel already in a swirling form. As a rule, the fuel is made particularly intensively turbulent and is finely atomized, so that a very homogeneous fuel/gas mixture forms. A homogeneous fuel/gas mixture assures low exhaust emissions, good acceleration performance, and low fuel consumption on the part of the internal combustion engine.
It is another object of the invention to provide an apparatus having a simple mechanical structure that can be manufactured simply and economically.
It is still another object of the invention and particularly advantageous for the at least one flow conduit of the swirl element to have a helical curvature, and for its cross-sectional area to narrow toward the mixing opening. The gas flowing into the mixing opening then has a pronounced swirl and a high flow velocity.
It is yet another object of the invention to provide, in order for the gas upon flowing into the mixing opening to strike the injected fuel directly, that the at least one flow conduit discharges radially into the mixing opening.
Another object of the invention provides the advantage that the gas delivery conduit communicates with the longitudinal opening of the gas distributor part at a tangent, so that the delivered gas flows swirlingly into the longitudinal opening and into the flow conduits of the swirl element.
In still another object of the invention, it is advantageous if a compression spring is disposed between a downstream retaining shoulder of the longitudinal opening of the gas distributor part and an end face, remote from the end of the fuel injection valve, of the swirl element that is axially displaceable. The compression spring not only enables axial compensation for positional tolerances between the fuel injection valve and the gas distributor part or its longitudinal opening, but also makes for a uniform pressure on the swirl element as it is pressed against the fuel injection valve.
In yet an additional object of the invention, it is advantageous if the swirl element is secured against torsion relative to the longitudinal bore of the gas distributor part so that the gas flowing through the swirl element cannot twist the swirl element; this assures exact positioning of the exit location of the gas. When two-stream fuel injection valves are used, for instance for four-valve internal combustion engines, this feature is especially important.
In yet another object of the invention, it is advantageous if a retaining protrusion that cooperates with a recess formed in the wall of the longitudinal opening of the gas distributor part is formed on the circumference of the swirl element.
In still a further object of the invention, it is especially advantageous if a plurality of stepped longitudinal openings, each having one swirl element, are formed in the gas distributor part and communicate with a common gas delivery conduit; this makes for a compact unit that can be manufactured economically.
In still another object of the invention, it is advantageous if the gas distributor part, which has a plurality of longitudinal bores, can be made to communicate with a fuel distributor part that serves to deliver fuel and receives fuel injection valves which correspond in number to the number of longitudinal openings of the gas distributor part and are arranged concentrically with these openings.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of a preferred embodiment taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplary embodiment of the invention with a fuel injection valve shown in fragmentary form along with a fuel distributor part, also shown in fragmentary form, and
FIG. 2 is a section taken along the line II--II of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus shown by way of example in FIG. 1 for injecting a fuel/gas mixture into an intake manifold or directly into a combustion chamber of a mixture-compressing internal combustion engine with externally supplied ignition has a fuel injection valve I with a valve end 3. The fuel injection valve 1 is partly surrounded in the axial direction by a stepped receiving bore 5 that extends concentrically with a longitudinal valve axis 4 in a fuel distributor part 7; for instance, this part 7 has a number of stepped receiving openings 5 matching the number of cylinders of the engine. The fuel injection valve 1 protrudes by its end 3 into a stepped longitudinal opening, extending concentrically with respect to the longitudinal axis 4 of the valve, of a gas distributor part 11, for instance formed as a plastic injection molded part. The gas distributor part 11 has a number of longitudinal openings 9, for instance corresponding to the number of engine cylinders, and can be connected to the fuel distributor part 7. The stepped longitudinal openings 9 are arranged in the gas distributor part 11 such that they extend concentrically with the receiving openings 5 of the fuel distributor element 7, once the fuel distributor element 7 and gas distributor part 11 are joined together, as shown in FIG. 1.
A flat seal 12 is disposed between a end face 10 of the gas distributor part 11 oriented toward the fuel distributor part 7 and an opposed stop face 8 of the fuel distributor part 7. One gas delivery conduit 13, for instance, is formed in the gas distributor part 11, communicating at a tangent with the various longitudinal openings 9 of the gas distributor part 11. In this way the delivered gas is already swirling as it arrives in the longitudinal openings 9.
At one end 3, the fuel injection valve 1 has one valve closing element 17, for instance, cooperating with a fixed valve seat 15 narrowing frustroconically in the direction of fuel flow. On its opposite end, remote from the fixed valve seat 15, the valve closing element 17 is joined to an armature 19, which cooperates with a magnet coil 21 partly surrounding the armature 19 in the axial direction and a core 23 opposite the armature 19 in the direction remote from the fixed valve seat 15. A sealing segment 25 of the valve closing element 17 cooperates with the fixed valve seat 15 and is frustroconical, for example. A restoring spring 26 that tends to move the valve closing element 17 toward the fixed valve seat 15 rests on the end of the valve closing element 17 joined to the armature 19.
A small perforated plate 29 rests directly on one end face 27 of the valve end 3. The perforated plate 29 has injection ports 31, for example two in number, through which the fuel flowing past the fixed valve seat 15 when the valve closing element 17 is raised from its seat is ejected.
A cup-shaped protective cap 33 can be disposed on the end 3 of the fuel injection valve 1, resting with a bottom portion 35 on the perforated plate 29. The bottom portion 35 has a flow opening 36, through which the fuel flowing out of the injection ports 31 is ejected. In the direction toward the magnet coil 21, the bottom portion 35 of the protective cap 33 is adjoined first by an axially extending parallel segment 38 and then by a radially outwardly protruding lip segment 40. The protective cap 33 is joined to the circumference of the valve end 3 by a detent connection 42.
A retaining ring 43 is disposed about the circumference of the end 3 of the fuel injection valve 1. A sealing ring 44 is disposed radially of the valve engaging the circumference of the valve end 3 and the wall of the receiving opening 5 of the fuel distributor part 7. The axial displaceability of the sealing ring 44 on the circumference of the valve end 3 is limited both by the radial lip segment 40 of the protective cap 33 and by the retaining ring 43, so that a secure, reliable seal between the valve end 3 and receiving opening 5 of the fuel distributor part 7 is assured.
On their end remote from the fuel distributor part 7, the longitudinal openings 9 of the gas distributor part 11 have a retaining shoulder 45 pointing radially inward and defining an outflow segment 46, concentric with the longitudinal valve axis 4, that widens, for instance frustroconically, remote from the fuel injection valve 1. With a centering element 48 oriented toward the retaining shoulder 45 of the gas distributor part 11, the fuel distributor part 7 protrudes with little radial play into a centering segment 50 of the longitudinal opening 9 of the gas distributor part 11, so that the receiving opening 5 of the fuel distributor part 7 and the fuel injection valve 1 disposed in it are centered relative to the longitudinal opening 9 of the gas distributor part 11.
A swirl element 55 is disposed in the longitudinal opening in the axial direction between the end 3 of the fuel injection valve 1 and the retaining shoulder 45 of the gas distributor part 11. Concentric with the longitudinal valve axis 4, the swirl element 55 has a continuous mixing opening 57 that widens frustroconically in the flow direction toward the retaining shoulder 45; the swirl element is displaceable in the axial direction, because of the disposition of a compression spring 63, which is in the form of a cup spring, for instance, and as a mass-produced product can be obtained inexpensively, between a retaining face 59 of the retaining shoulder 45 oriented toward the swirl element 55 and a end face 61 of the swirl element 55 oriented toward the retaining shoulder 45. The compression spring 63 rests with an outer radial segment 65 axially on the retaining face 59 of the retaining shoulder 45 and radially, by its circumference formed by the outer rim of the radial segment 65, on a parallel wall segment 67 of the longitudinal opening 9 of the gas distributor part 11. By its end 70 oriented axially toward the fuel injection valve 1, an inclined, radially inwardly pointing segment 69 of the compression spring 63 rests on the end face 61 of the swirl element 55. When the apparatus according to the invention has been installed, the compression spring 63 is elastically deformed axially, or in other words prestressed, so that the compression spring 63 presses the axially displaceable swirl element 55, by its end face 64, toward the protective cap 33, against the bottom portion 35 of the protective cap 33 secured to the end 3 of the fuel injection valve 1. In this way the compression spring 63 enables axial compensation for the positional tolerances of the fuel injection valve 1 and the gas distributor part 11 or its longitudinal opening 9. It is sufficient for the compression spring 63 to have only a relatively low spring constant, thereby averting the danger of damage to the swirl element 55, which for instance is embodied as a plastic injection molded part.
On its circumference, adjacent the compression spring 63, the swirl element 55 has a first cylindrical segment 72, the diameter of which is slightly smaller than the diameter of the parallel wall segment 67 of the longitudinal opening 9 surrounding the swirl element 55, so that a narrow radial gap is formed between the first cylindrical segment 72 of the swirl element 5 and the longitudinal opening 9 of the ga distributor part 11. As a result, and because of the axial contact of the compression spring 63 with the end face 61 of the swirl element 55 and with the retaining face 59 of the retaining shoulder 45, as well as the radial contact of the compression spring on the parallel wall segment 67 of the longitudinal opening 9, a flow of gas past the circumference of the swirl element 55 as far as the outflow segment 46 of the retaining shoulder 45 is prevented.
As shown in FIG. 2, a retaining protrusion 74 is formed on the circumference of the first cylindrical segment 72 of the swirl element 55 to extend axially over the entire length, for instance, of the first cylindrical segment 72. A complemental recess 76 is formed in the wall of the parallel wall segment 67 of the longitudinal bore 9 and cooperates with the retaining protrusion 74 of the swirl element 55 in such a way that the retaining protrusion 74 protrudes into the recess 76 of the longitudinal bore 9 of the gas distributor part 11, so that the swirl element 55 is secured against torsion relative to the longitudinal bore 9. This arrangement assures that the gas will exit at a defined location, which is important if multi-stream injection valves are used, for instance for four-valve internal combustion engines.
The first cylindrical segment 72 is adjoined by a plane radial segment 78 of the swirl element 55, which on its end toward the valve end 3 is oriented radially inward and extends to a second cylindrical segment 77. Extending in the axial direction, a flow segment 80 narrowing toward the longitudinal valve axis 4 is formed in the axial direction between the second cylindrical segment 77 and the end face 64 of the swirl element 55 that rests on the protective cap 33. The flow segment 80 is defined so as to be concave in shape, for instance, on its circumference; in other words it is recessed so that it curves radially outward away from the valve end 3. Referring again to FIG. 2, at least one flow conduit 82, but in the exemplary embodiment shown a plurality of flow conduits 82, is formed in the wall of the flow segment 80 of the swirl element 55. These flow conduits take the form of grooves 83 extending for instance up to the inside of the second cylindrical segment 77; from the second cylindrical segment 77, they extend with a helical curvature as far as the end face 64 of the swirl element 55, and there, as shown in FIG. 2 in a section taken along the line II--II of FIG. 1, they discharge radially into the mixing opening 57 of the swirl element 55. The flow conduits 82 are embodied such that the flow cross sections narrow or taper continuously in the direction of the end face 64 to the mixing opening 57 of the swirl element 55. The flow conduits 82 are laterally defined by flow vanes 85, which serve to guide the gas flowing in the direction of the mixing opening 57. As a result of the narrowing flow cross section, the gas is accelerated sharply, and it attains its maximum velocity upon exiting from the flow conduits 82. The flow conduits 82, or the grooves 83 forming them, have the same axial length, for instance, on their groove bottoms 84 as the second cylindrical segment 77 of the swirl element 55, as shown in FIG. 1. The bottom walls of the grooves 84 extend with the same concave curvature as the circumference of the flow segment 80 in the direction of the end face 64 of the swirl element 55.
The quantity of gas delivered to the mixing opening 57 of the swirl element 55 is determined by the size of the flow cross sections of the flow conduits 82. Radially delivering the gas at high velocity through the mixing opening 57 to the fuel dispensed from the injection ports 31 leads to the formation of the most homogeneous possible fuel/gas mixture, with especially fine fuel droplets. As a result, during engine operation, substantial improvements can be attained in terms of exhaust emissions, acceleration performance, and fuel consumption.
As the gas for forming the fuel/gas mixture, both fresh air and an inert gas, or a mixture of the two, may be used. Fresh air is for instance diverted from the intake manifold upstream of an arbitrarily adjustable throttle device and delivered to the gas delivery conduit 13. For the inert gas, the exhaust gas of the engine can for instance be used, so that with this exhaust gas recirculation, the toxic emissions from the engine are reduced. Alternatively, the gas can be pumped by a supplementary pump.
The apparatus according to the invention also has the advantage of simple structure and low manufacturing costs. A system unit comprising the fuel distributor part 7, fuel injection valves 1, gas distributor part 11 having the swirl elements 55, and a pressure regulator for the fuel can be mounted simply and therefore economically on the intake line of an internal combustion engine.
The foregoing relates to a preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | In known equipment for injecting a fuel/gas mixture, having a fuel injection valve protruding into a stepped longitudinal bore of a gas distributor part, the formation of as homogeneous as possible a fuel/gas mixture and the fine atomization of the fuel are not assured if the gas envelops the injected fuel approximately in the flow direction of the fuel. The novel apparatus has a swirl element in the longitudinal opening of the gas distributor part, the swirl element having a mixing opening extending concentrically with the longitudinal valve axis; at least one curved, groovelike flow conduit, formed in the wall of the swirl element, discharges into this mixing opening. As a result, particularly fine atomization of the fuel and the formation of the most homogeneous possible fuel/gas mixture are assured. The embodiment of the apparatus is especially suitable for use in mixture-compressing internal combustion engines with externally supplied ignition. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent application 61/472,987 filed on Apr. 7, 2011.
FIELD OF THE INVENTION
[0002] This invention relates to chemical processes to produce an inorganic chemical surface acting agent chemical mixture which can be used to extract and recover oil and oil products from oil sand, tar sand, petroleum tailings or other types of oil containing terra.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. No. 4,117,099 issued to Merkl first explained that water soluable multi-metal inorganic complexes can be used to remove sulfur dioxide from effluent gas streams. Subsequently, U.S. Pat. No. 5,084,263 issued to McCoy explained a more elaborate method of preparing inorganic polymetric water complexes for a variety of uses, including removal of organic material from soil (in particular clay), but provides no theory on concentrations or how to accomplish this efficiently. Rather, McCoy raises the possibility of hydrocarbon removal from soil, but leaves it to future inventors to develop the process.
[0004] Czarnekia, et al. propose in “On the nature of Athabasca Oil Sands” (2005) notes that it is theoretically possible to remove bitumen (a heavy form of oil) from inorganic solids due to the chemistry of the substances, but offers no theory on how to accomplish this. Similarly, Bunger in “Compound types and proper ties of Utah and Athabasca tar sand bitumens,” notes that naturally occurring alcohols can remove some hydrocarbons from sand, but offers no theory on how using a sodium silicate solution to do this might work.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention proceeds in two parts to finish the work of McCoy and resolve the questions in the literature. The first part explains a chemical process to produce an inorganic chemical surface acting agent chemical mixture with enhanced and synergistic inorganic surface acting agent characteristics. The second part explains how to use the mixture of the first part in a process to extract and recover oil and oil products from hydrocarbon containing terra such as oil sand, tar sand, petroleum tailings or other types of hydrocarbon containing terra based upon the utilization of the above identified inorganic chemical surface acting agent.
[0006] One skilled in the science and technologies of surface acting agents and the associated chemicals utilized in this invention, which are associated with the separation, extraction and recovery of oil and oil products from oil sands, tar sands, petroleum tailings or others types of hydrocarbon containing terra, will quickly perceive the embodiment of this invention and understand its particular characteristic and apparent advantages.
[0007] The key feature of this invention is that the chemical mixture with enhanced and synergistic inorganic surface acting agent characteristics can be combined and diluted with water and then mixed in with oil sands, tar sands, oil shale, petroleum tailings or with other types of oil containing terra to create a slurry blend where terra and oil based hydrocarbons can be easily extracted and recovered.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Embodiments of the present invention overcome many of the obstacles associated with removing hydrocarbons from tar/oil sands and terra, and now will be described more fully hereinafter with reference to the accompanying drawings that show some, but not all embodiments of the claimed inventions. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.
[0009] The inorganic polymeric water complex surface acting agent to create the chemical surface acting agent chemical is directly based upon McCoy (cited above) that identifies a family of chemical compositions of matter prepared by reacting, in the presence of aqueous ammonia or other source of reactive NH.sub.2 groups, an alkali metal hydroxide to raise pH above 12, and further reacting with the addition of a mineral acid.
[0010] These chemical compounds formed by highly exothermic reactions, contacting a mineral acid with ammonium hydroxide and an alkali metal hydroxide in an aqueous solution, the resultant complexes so generated by the described reactions, and the aqueous solutions containing same. Classical chemistry teaches that when an alkali metal hydroxide is introduced into an aqueous solution which contains ammonium hydroxide a reaction occurring reducing ammonium hydroxide (NH 4 OH) to ammonia gas (NH 3) which is then expelled from the solution.
[0011] A quantity of an alkali metal hydroxide, preferably potassium hydroxide ammonia hydroxide is first introduced into an aqueous medium in an open reaction vessel creating an initial solution. Next, ammonia hydroxide is mixed with the by pouring until such time as a stoichiometric quantity of ammonia hydroxide exists. The reaction is slightly exothermic and at end point, remains an aqueous solution, which can be clear, and an ammonia gas smell. This aqueous solution can then be contacted with amounts of any mineral acid species which could be a phosphorus containing acid, a halogen containing acid, a carbon containing acid, a sulfur containing acid, a nitrogen containing acid, or combination of these acids to create a highly exothermic reaction and to continue the reaction until such time as the ammonia gas smell is no longer present creating an inorganic polymeric water complex similar to McCoy. Differing from McCoy's solution is the addition of a sodium silicate additive that provides substantially greater ability to remove hydrocarbons from terra as explained below.
[0012] The adding of the strong acid and the alkali hydroxide mixture results in highly exothermic reactions with temperatures immediately rising to over 180 degrees Fahrenheit. These reactions run from a violent exothermic reaction when sulfuric is the reacted acid and a less violent exothermic reaction when a phosphorus or carbon acid is reacted or a controlled reaction when a halogen acid is the reactant.
[0013] Laboratory studies concluded that use of an open reaction vessel was best suited for the reaction due to the violent evolution of heat and gases would give rise to explosive reactions in closed or narrow necked reactor vessels. The reaction does not become unstable, but is controllable when reactants are added in the prescribed manner. After initial introduction of the acid into the bases the pH starts to change, then the pouring can be accelerated as a pH of 12 is approached from the alkaline side. The reaction calms down between a pH of 4 on the acidic side and pH of 10 on the alkaline side. The reaction can then be brought to a desired end point of a pH of 7, and clear stable solutions exist.
[0014] The inorganic polymeric water complex is then further reacted by the addition of an alkali metal hydroxide until the inorganic polymeric water complex surface acting agent pH is raised to any a desired end point on 12.
[0015] The chemical surface acting agent chemical mixture provides many advantages. First, the sodium silicate additive of the chemical mixture has natural occurring bond to sand and other terra thus converting the surface hydrophobic to hydrophilic and the oil or tar is released from the terra material surface. Second, this chemical mixture breaks tight oil/water emulsions that have clay in the matrix based upon the theory that these new compounds have a more positive charge that then unites with the OH-groups on the clay, thereby releasing the oil and water.
[0016] Turning to the process, the chemical surface acting agent chemical mixture is applied to tar sands, oil sands, oil shale, petroleum tailings or others types of hydrocarbon containing terra. This creates a slurry blend derived from the mixing of the inorganic chemical surface acting agent chemical mixture, water and materials from either oil sands, tar sands, oil shale, petroleum tailings or others types of hydrocarbon containing terra. In some embodiments, this inorganic chemical surface acting agent chemical mixture concentration level within the slurry blend ranges from 1,500 ppm to 15,000 ppm. At this point, kinetic energy by mechanical agitation or some other method is utilized to achieve maximum material separation within the slurry blend. This process works most effectively when the mechanical energy and environmental conditions cause the slurry blend temperature to rise above 50 degrees Fahrenheit. | This is directed to a novel chemical mixture process resulting in the production of an inorganic polymeric water complex with enhanced surface acting agent characteristic derived from the synergistic effects caused by individual chemical mechanisms within the mixture that is capable of separating, extracting and recovering hydrocarbons from tar/oil sands, oil shale, petroleum tailings or other types of terra based hydrocarbons. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/236,531 filed on Jan. 25, 1999, now pending, which is a continuation of application Ser. No. 08/680,452 filed on Jul. 15, 1996, now U.S. Pat. No. 5,864,623 which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1.0 Field of the Invention
[0003] The present invention generally relates to an identification system for documents. More particularly, the present invention relates to a programmable apparatus for authenticating drivers' licenses used for identification purposes. Specifically, the present invention relates to a programmable apparatus that identifies the contents of the driver licenses used for identification purposes without any human error and allows the information carried by the driver licenses to be transferred to a remote location for further identification purposes.
[0004] 2.0 Description of Related Art
[0005] The problem of rampant and readily available fake identification cards, more particularly, driver licenses/identification cards, has caused many retailers fines, sometimes imprisonment, loss of tobacco and liquor licenses, and has even subjected them to other forms of civil and criminal liability. Over the course of years, various attempts have been made to prevent or detect the use of fake identification cards, but not with a great deal of success. To help prevent the use of fake identification, since 1992 the United States and Canada have been issuing new driver licenses in accordance with an international North American Free Trade Agreement (NAFTA) standard created and enforced by the American Association of Motor Vehicle Administrators (AAMVA). These new driver licenses/identification cards have embedded coded, or even encrypted coded information, with machine readable formats that conform to the NAFTA standards. It is desired that means be provided that authenticate the contents of these identification cards so as to safeguard the retailer against the penalties that may otherwise be encountered by fake identification cards.
[0006] The use of driver licenses has expanded over the years to serve as identification for various applications, such as for the purchase of alcohol, tobacco or lottery products, as well as for gambling in casinos, off-track betting (OTB), movie theaters and user-definable events, such as allowing the ingress into liquor establishments. All of these fields have an age requirement for the purchase of a product at the point-of-transaction or for ingress into an establishment and the driver license is the document used to provide age identification and all age verification is commonly accomplished in a relatively quick manner. It is desired that means be provided that easily decides a driver licenses authenticity so that any purchase of a product having an age requirement is satisfied at the time of purchase and in a quick and convenient manner.
[0007] As is known, driver licenses are accompanied with photo identification of the particular driver, and in addition to the identification supplied by a driver license to a liquor retailer, the driver license is frequently used for other identification purposes, such as for providing proper identification for check cashing. The frequent use of driver licenses allows the licenses to serve as tools to detect or uncover individuals who are being sought out because of being subject to pending criminal prosecution. It is desired that means be provided to allow the information on the driver licenses to be transferred to a local or remote jurisdiction to help identify and detect individuals that may be classified as being offenders against the criminal law of the associated jurisdiction.
[0008] Driver licenses not only serve for identification for commercial transactions, but also serve a humanitarian need of identifying predrdained organ donors that may be involved in tragic accidents. It is desired for humanitarian purposes that means be provided to transfer the organ donor information commonly present on driver licenses to a local or remote jurisdiction so that an available organ donor may be quickly matched to an individual in need of the now-available organ.
[0009] Driver licenses are commonly used in places of business, such as convenience stores, liquor stores, entertainment centers which also have personal computers for use in business purposes, such as inventory management. It is desired that means be provided so that personal computers may be readily adapted to serve as an integral part of an authentication system for driver licenses.
OBJECTS OF THE INVENTION
[0010] It is a primary object of the present invention to provide an authentication system to authenticate driver licenses that are coded with machine readable information conforming to AAMVA standards.
[0011] It is a further object of the present invention to provide an authentication system for not only verifying the contents of a driver license, but also allowing for the information to be transferred to a local or remote jurisdiction so that it may be identified for criminal prosecution purposes or, conversely, for humanitarian purposes, such as for identifying preordained organ donors.
[0012] It is another object of the present invention to provide an identification system that utilizes personal computers that are commonly found in places of business having a need for authenticating the contents of a driver license used for identification purposes.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to an authentication system that verifies the contents of documents, such as driver licenses.
[0014] The authentication system comprises a programmable apparatus that verifies the contents of the document embodying both human recognizable information and machine recognizable coded information. The apparatus comprises means for reading, means for parsing, means for comparing and means for displaying. The information of the document is read by the means for reading and directed into the programmable apparatus. The means for parsing reads the information of the document in the programmable apparatus and parses such information into the jurisdictional segments each having predetermined values. The means for comparing analyze the information against the predetermined values and generates a verification signal if the information and the values match. The means for displaying displays the verification signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a block diagram of the programmable apparatus of the present invention.
[0016] [0016]FIG. 2 is composed of
[0017] FIGS. 2 (A) and 2 (B) that illustrate the human recognizable and machine recognizable formats carried by driver licenses related to the present invention.
[0018] [0018]FIG. 3 is a flow diagram of the overall operation of the programmable apparatus.
[0019] [0019]FIG. 4 is composed of
[0020] FIGS. 4 (A), 4 (B), 4 (C) and 4 (D), that respectively illustrates one of the four (4) primary program subroutines making up the overall operation illustrated in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] With reference to the drawing, wherein the same reference numbers indicate the same elements throughout, there is shown in FIG. 1 a block diagram of a programmable apparatus comprising a computer 12 , more particularly, a central processing unit and arithmetic logic unit whose actions are directed by computer programs comprising a series of operational steps performed on information read into the computer 12 .
[0022] In general, the programmable apparatus authenticates a document embodying information comprising both human recognizable information and machine recognizable information comprising a series of codes. The programmable apparatus comprises means for reading the information of the document into the programmable apparatus, means for parsing the read document information into jurisdictional segments each having predetermined values, and means for comparing the read information of the document against the predetermined values and generating at least a verification signal on a display means, if the information of the document and the predetermined values match. The programmable apparatus comprises a plurality of conventional elements arranged in a non-conventional manner with all elements being listed in Table 1.
TABLE 1 REFERENCE NO. ELEMENT 12 CENTRAL PROCESSING UNIT (CPU) AND ARITHMETIC LOGIC UNIT (ALU) 14 KEYBOARD 16 POINTER DEVICE 18 PRINTER 20 NON-VOLATILE STORAGE 22 REMOVABLE STORAGE 24 VOLATILE STORAGE 26 MODEM 28 REMOTE COMPUTER 30 DIGITAL SCANNER 32 MAGNETIC READER 34 BAR CODE SCANNER 36 DECODER 38 CLOCK SOURCE 40 DECRYPTER ROUTINE 42 PARSER ROUTINE 44 CRT DISPLAY 46 DIGITAL-TO-ANALOG (D/A) CONVERTER 48 D.C. VOLTAGE SUPPLY 50 WIRELESS TRANSMITTER 52 WIRING HUB 54 USER'S CONSOLE 56 CRT DISPLAY 58 LIGHT EMITTING DIODES (LEDs) 60 SPEAKER 62 WIRELESS RECEIVER
[0023] The keyboard 14 and the pointer device 16 , such as a mouse, provide a means for the operator or user to enter information, via signal path 64 , into the CPU 12 . The printer 18 converts the outputs, present on signal path 66 , of the central processing unit 12 into printed images.
[0024] The non-volatile storage 20 , the removable storage 22 , and the volatile storage 24 are all storage mediums, whose contents are controlled and updated by the central processing unit 12 , via signal path 68 , 70 and 72 respectively. The non-volatile storage 20 and the removable storage 22 provide for permanent recordings of every transaction involved with or determined by the CPU 12 , whereas the volatile storage 24 provides temporary storage of information while it is being processed by the CPU 12 . The removable storage 22 may be a disk that is insertable and removable from the CPU 12 .
[0025] The modem 26 is interconnected to the CPU 12 by way of signal path 74 and allows the CPU 12 to share its input and manipulated data, as well as the contents of its storage information, with the remote computer 26 , via the signal path 76 , which is typically established by a telephone communication link.
[0026] The digital scanner 30 , magnetic reader 32 , and bar code scanner 34 are each capable of reading the information on the identification card 78 , to be more fully described with reference to FIG. 2, that is routed to these reading devices, via path 80 . The digital scanner 30 converts the information on identification card 78 to machine understandable codes via a conventional optical character recognition technique and routes such converted information to the CPU 12 via the signal path 82 . The magnetic reader 32 and the bar code scanner 34 each read the information present on the identification card 78 and supply respective output signals that are routed to decoder 36 , via signal path 84 which, in turn, supplies machine readable signals to the CPU 12 via signal path 86 . The signal paths 82 and 86 may be provided by wireless devices, such as, the wireless transmitter 50 and wireless receiver 62 both being conventional and both to be further described hereinafter. The usage of wireless devices may be advantageous if the digital scanner 30 , magnetic reader 32 and bar code scanner 34 are remotely located relative to the CPU 12 .
[0027] A clock source 38 supplies the clock signal, via signal path 88 , to the CPU 12 that, in response to an appropriate computer program routine, establishes the time and date in which the information present on signal path 82 , 84 , 86 or 88 is read into and/or stored on the storage medium 20 , 22 or 24 . The CPU 12 under the direction of its computer programs, to be more fully described with reference to FIGS. 3 and 4, routes the information of the identification card 78 , preferably encrypted as to be described hereinafter, via signal path 90 to the decrypter routine 40 . The decrypter routine 40 decrypts the information and routes its noncrypted information, via signal path 92 , to a parser routine 42 which parses the information into jurisdictional segments, to be further described with reference to FIGS. 3 and 4, each having predetermined values. The parsed information is directed back to the CPU 12 via signal path 94 . The CPU 12 , performs a series of operations, under the direction of its computer programs, and provides, among other things, at least a verification signal, as well as human recognizable information that is placed on signal path 96 and routed to a first CRT display 44 via signal path 98 and to a second CRT display 56 via signal path 100 .
[0028] The human recognizable information on signal path 98 also preferably contains a digital signal representation that is routed to the digital-to-analog (D/A) converter 46 , which converts the digital representation into an analog signal representative of an audio signal. The digital signal representation also contains at least three bits each representative of verification signal conditions, such as YES, NO, and UNKNOWN to be used to respectfully flash GREEN, RED and AMBER LEDs of the LED array 58 to be further described with reference to FIG. 4(C). The digital-to-analog converter 46 is preferably excited by a D.C. voltage supply 48 which is also routed, via signal path 102 , to a wiring hub 52 that also accepts the audio signal and the three bits (YES, NO and UNKNOWN) developed by the D/A converter 46 . The wiring hub 52 is of a conventional type that arranges the received power and signal sources into appropriate cables, such as cable 104 , that routes the representative audio signal from the D/A converter 46 to the speaker 60 and the three digital bits (YES, NO and UNKNOWN) as well as the excitation signal of the D.C. voltage supply 48 to the light emitting diode array 58 . The wiring hub 52 may also include a switch that controls the on-off state of the excitation signal of the D.C. power supply 48 applied to one of the light emitting diodes 58 (and also to the CRT display 56 and speaker 60 ) so that the on-off power state of all elements 56 , 58 and 60 may be remotely controlled from the wiring hub 52 .
[0029] The speaker 60 may be a piezoelectric device that when activated by the audio signal developed by D/A converter 46 generates a buzzing sound that alerts an individual at the user's console 54 that the information (to be further described with reference to FIGS. 3 and 4) being displayed on either or both of the CRT displays 44 and 56 is not authentic. The CRT displays 44 and 56 are preferably of the type that is capable of handling text and graphics of the Super Video Graphics Array (SVGA) and/or National Television Standards Committee (NTSC).
[0030] The audio signal and the three bits (YES, NO and UNKNOWN) of the D/A converter 46 previously discussed and a signal representative that power is available from the D.C. voltage supply 48 may also be applied to the speaker 60 and light emitting diode array 58 , by way of the wireless transmitter 50 cooperating with the wireless receiver 62 and interconnected thereto by signal path 106 , with the output of the wireless receiver 62 being routed, via signal path 108 , to speaker 60 and the light emitting diode array 58 . The wireless transmitter 50 , wireless receiver 62 and signal paths 106 and 108 are shown in phantom to indicate the alternate embodiment formed by the conventional wireless devices 50 and 62 .
[0031] The speaker 60 , and the CRT display 56 are both part of a user's console 54 and allow a user, such as a retailer to visually verify the authenticity of the information present on the identification card 78 , such as a driver license, embodying human recognizable information and machine recognizable information generally illustrated in FIG. 2 which is comprised of FIGS. 2 (A) and 2 (B) that respectively show the front face 78 A and the rear face 78 B, each embodying information that is given in Table 2.
TABLE 2 REFERENCE NO. INFORMATION 112 JURISDICTION (U.S. (STATE) OR CANADA (PROVINCE)) 114 GRAPHIC OR LOGO OF JURISDICTION 116 DOCUMENT TYPE 118 NAME AND ADDRESS OF INDIVIDUAL OF THE DOCUMENT 120 PARTICULARS OF THE INDIVIDUAL OF THE DOCUMENT 122 SIGNATURE OF INDIVIDUAL OF THE DOCUMENT 124 PHOTOGRAPH OF INDIVIDUAL OF THE DOCUMENT 126 IDENTIFICATION NUMBER OF DOCUMENT 128 DATE OF BIRTH (DOB) 130 US128 BAR-CODE 132 MAGNETIC STRIP 134 ANSI-20.1; 1993 CHARACTER SET OR 2D BAR CODE PDF-417 136 JURISDICTIONAL TEXT
[0032] The information given in Table 2 is read into the CPU 12 via signal paths 82 or 86 and the machine readable information 130 , 132 and 134 on face 78 B is preferably encrypted in a format preferably specified by ANSI-20.1; 1993 character set. The information 134 may also be encrypted in a format in accordance to a 2D bar code known as PDF-417 defined by the Symbol Technology Corporation of New York. The information 132 is also preferably decrypted and readable by the ANSI-20.1; 1993 Character Set and more fully described in “Recommendation for use of Magnetic Stripe on Drivers License” which is part of the NAFTA standard created and enforced by AAMVA which has been in existence in the United States and Canada since 1992 and is herein incorporated by reference.
[0033] In general, the operating programs residing in the CPU 12 authenticate the information embodied in the document, such as a driver license 78 , having the particulars given in Table 2 each located at a predetermined region of the driver license 78 and corresponding to those of an individual and to those of a state or province in the United States or Canada, respectively, in which the individual legally resides but which are generally referred to herein as a jurisdiction. The particulars of the individual include height, weight, date of birth, sex and organ donor consent, whereas the particulars of the jurisdiction may include the state or province emblem or voting information. Further, the driver license 78 also includes graphics defining a background and/or a logo of the driver license 78 . The operating program residing in the CPU 12 that authenticates these particulars and are comprised of a plurality of program segments represented by an overall sequence 140 illustrated in FIG. 3 and tabulated in Table 3.
TABLE 3 REFERENCE NO. PROGRAM SEGMENT 142 START EVENT 144 DATA INPUT 146 DECODE DATA INPUT 148 SUBROUTINE FOR HANDLING OF LICENSE FORMAT 150 LICENSE FORMAT 152 DECRYPT DECODED INFORMATION 154 LICENSE FORMAT DETECT 156 DISPLAY ERROR MESSAGE 158 SAVE ERROR INFORMATION WITH TIME AND DATE 160 SUBROUTINE FOR HANDLING OF JURISDICTION FORMAT 162 JURISDICTION FORMATS 164 PARSE DECRYPTED INFORMATION 166 JURISDICTION FORMAT DETECT 168 SUBROUTINE FOR HANDLING OF LEGAL AGES 170 JURISDICTION LEGAL AGE 172 DETERMINE LEGAL AGES 174 OF LEGAL AGE 178 SUBROUTINE FOR HANDLING OF LICENSE BACKGROUND 180 LICENSE BACKGROUNDS 182 GENERATE LICENSE GRAPHICS 184 DISPLAY DATA 186 SAVE TRANSACTION WITH TIME AND DATE
[0034] The overall sequence 140 of FIG. 3 comprises the plurality of elements and has four ( 4 ) major subroutines 148 , 160 , 168 and 178 to be further described hereinafter respectively with reference to FIGS. 4 (A), 4 (B), 4 (C) and 4 (D). As used herein with reference to FIGS. 3 and 4, the program segments, sometimes referred to herein as processing segments, are shown as being interconnected by signal path and control is passed from one program segment to another when the output information of one program segment is placed on the signal path connected to the other program segment.
[0035] As seen in FIG. 3, and with simultaneous reference to FIG. 1, the overall program 140 is started by event 142 which initiates the reading of input data via signal path 82 or 86 of FIG. 1. With again reference to FIGS. 1, 2 and 3 , the information embodied in driver license card 78 is read into CPU 12 via the digital scanner 30 , magnetic reader 32 or bar code scanner 34 and represents the program segment 144 (input data) of FIG. 3. The operating program of CPU 12 routes the input data to program segment 146 via signal path 190 which, in turn, decodes the input data 144 and supplies the decoded information on signal path 192 to program segment 152 .
[0036] The program segment 152 is part of subroutine 148 , to be further described, that receives license format information from license format 150 and decrypts the information therein and provides such as the output of subroutine 148 .
[0037] The output of subroutine 148 is applied to signal path 194 to program segment 154 which, like program segments 166 and 174 , is a decisional segment which detects if the license format of the driver license 78 is correct, and if the format of the driver license 78 is correct, supplies the license format information to the processing segment 164 via signal path 196 , but if the driver license 78 format is invalid, supplies the invalid license format on signal path 198 so that it is displayed on both CRT displays 44 and 56 shown in FIG. 1 as a display error message 156 . The activation of the CRT displays 44 and 56 for the display error message 156 , as well as other error displays and messages, is controlled by the CPU 12 servicing the input/output ports connected to the CRT displays 44 and 56 . The displayed error message 156 is placed on signal path 200 which is routed to program segment 158 so that the error message is saved along with its time and date and the program segment 158 returns control to the start event 142 via signal path 202 .
[0038] The program segment 164 is part of subroutine 160 , to be further described, and receives jurisdiction formats information that is decrypted from program segment 162 which is also part of subroutine 160 . The program segment 164 parses the decrypted information into jurisdictional segments having predetermined values, to be described with reference to FIG. 4(B). The program segment 164 supplies the decrypted information via signal path 204 to jurisdiction format detect program segment 166 which, in turn, detects if the jurisdictional format information 162 is correct, and if the information is correct, then the correct information is routed to program segment 172 via signal path 206 , but if the information is incorrect then, the incorrect information is routed, via signal path 208 , to the display error message program segment 156 which displays such an error on the CRT displays 44 and 56 of FIG. 1 and supplies that display error message to signal path 200 previously described.
[0039] The processing segment 172 is part of subroutine 168 , to be further described, and receives jurisdictional legal ages information from program segment 170 which is also part of subroutine 168 . Program segment 172 determines if the legal age requirements of the jurisdiction are met by the date of birth information of the driver license 78 and then sends its determined information, via signal path 210 to decisional segment 174 . If the decisional segment 174 detects that the legal age has been satisfied, it routes this information onto program segment 182 via signal path 212 , but if the legal age information is incorrect, then an error notification (display error message) is routed to program segment 156 via signal path 204 . Program segment 156 responds in a manner as previously described.
[0040] The processing segment 182 is part of subroutine 178 , to be further described, and receives the license background of the particular jurisdiction from program segment 180 , also part of subroutine 178 . The program segment 182 generates license graphics and places such on signal path 216 applied to program segment 184 which, in turn, is transferred as output displays to the CRT displays 44 and 56 of FIG. 1. Program segment 184 applies its output on signal path 218 which in turn, is routed to program segment 186 which saves the transaction along with its time and date. The processing segment 186 provides notification, via signal path 219 to the next start event 142 which, in turn, causes the sequence of the next overall segment 140 having four subroutines, the first of which may be further described with reference to FIG. 4(A) which is comprised of a plurality of program segment tabulated in Table 4.
TABLE 4 REFERENCE NO. PROGRAM SEGMENT 220 GET DECODED DATA 222 GET UNENCRYPTED JURISDICTION FROM DECODED DATA 224 LOAD STORED JURISDICTION “KEYS” 226 DECRYPT DATA 228 PARSE DATA INTO 3-5 TRACKS DEPENDING ON JURISDICTION 230 READING TRACK DATA LOOP 232 GET NEXT TRACK OF DATA 234 TRACK BLANK 236 STORE VALUES FOR TRACK 238 STORE BLANK VALUES FOR TRACK 240 ALL TRACKS BLANK 242 ANY TRACKS BLANK 244 DISPLAY “BLANK CARD” MESSAGE 246 DISPLAY “INVALID LICENSE” MESSAGE 248 STORE ERROR INFORMATION
[0041] The subroutine 148 of FIG. 4(A) is initiating with start procedure event 192 and is terminated with the end procedure event 194 , wherein events 192 and 194 correspond to the signal paths shown in FIG. 3. It should be noted that program segments 150 and 152 shown in FIG. 3 as making up subroutine 148 are not shown in the programming functions performed by segments 150 and 152 are integrated and blended into the plurality of elements of FIG. 4(A). This same rationale is applicable to the program segments 162 - 164 , 170 - 172 and 180 - 182 of FIG. 3 that have been blended into the program segments of FIGS. 4 (B), 4 (C), and 4 (D) respectively to be further described hereinafter.
[0042] With reference to FIG. 4(A), the output of start procedure event 192 is applied to signal path 250 which is routed to program segment 220 . The program segment 220 retrieves the decoded data shown in FIG. 3 as program segment 146 (decode data input) and provides such information on signal path 252 which is applied to program segment 222 .
[0043] Program segment 222 retrieves the unencrypted jurisdiction data specified in the decoded data of program segment 220 and routes such information on signal path 254 which is applied to program segment 224 . Program segment 224 loads the jurisdiction “keys” which identifies a record for the jurisdictional segment. More particularly, the “keys” identify the tracks on the storage mediums 20 , 22 , 24 where jurisdiction segments are stored so that the license format of the jurisdiction segment under consideration may serve as the predetermined values of subroutine 148 to which the format of the data of the driver license 78 read into the CPU 12 may be compared and authenticated as being correct. The comparison and authentication of the predetermined values of the jurisdictional segments is also accomplished for subroutines 160 , 168 and 178 to be described.
[0044] The information loaded by program segment 224 is applied to signal path 256 that is routed to program segment 226 which decrypts the data it receives from program segment 224 and routes such decrypted data on signal path 258 which, in turn, is applied to program segment 228 .
[0045] The program segment 228 parses the data into 3-5 tracks, dependent on the jurisdictional segment specified by the decoded data of program segment 220 . The parsed data of program segment 228 is applied to signal path 260 which, in turn, is applied to program segment 232 which is part of the reading track data loop 230 which is repetitively repeated 3-5 times dependent upon the jurisdictional segment specified by the data of program segment 220 . More particularly, for example, if one jurisdiction (representative of a state in the United States or of a province in Canada) requires three (3) tracks of storage, loop 230 is repetitively repeated three (3) times.
[0046] The first program segment 232 of loop 230 retrieves the next or first track of data of the information present on signal path 260 and routes such information to decisional segment 234 which, if the track information is blank, provides that determination on signal path 264 and, conversely, if the track is not blank provides that determination on signal path 266 which is applied to program segment 236 . Program segment 236 stores the values for the retrieved track of data and after it is stored applies an appropriate signal on signal path 268 to pass control to program segment 238 that also has signal path 264 from program segment 234 applied thereto.
[0047] Program segment 238 stores the blank value for the retrieved track. If all blank values have not been stored then program segment 238 returns control to program segment 232 by way of signal path 270 but, if all blank values have been stored then program segment 238 passes control to program segment 240 via signal path 272 .
[0048] Program segment 240 determines if all the tracks assigned for the particular jurisdiction under consideration are blank and if so provides knowledge thereof on signal path 274 . Conversely, if all tracks are not blank, the program segment 240 passes control, via signal path 276 , to program segment 242 .
[0049] Program segment 242 determines if any tracks are blank and if the answer is yes then provides a notification thereof on signal path 280 however, if the answer to the question “any tracks blank” is no, (which signifies a correct condition) then program segment 242 passes control to the end procedure event 194 via signal path 278 which, in turn, returns to the overall step-by-step procedure 140 shown in FIG. 3. If signal path 274 or 280 is activated, then program segment 244 or 246 , respectively, is activated and an alarm message is displayed on the CRT displays 44 and 56 of FIG. 1 and then control is passed to program segment 248 . Program segment 248 stores the alarm message of program segment 244 or 246 and then passes control to signal path 284 which, in turn, provides notification to the end procedure event 194 which allows the program to return to the overall procedure 140 of FIG. 3. The program segment 140 of FIG. 3 sequences until it reaches signal path 196 which initiates the subroutine 160 of FIG. 4(B) that is comprised of a plurality of program segments that are tabulated in Table 5.
TABLE 5 REFERENCE NO. PROGRAM SEGMENT 286 GET DECRYPTED DATA 288 LOAD STORED JURISDICTION FORMAT 290 PROGRAM LOOP FOR GATHERING TRACK DATA FOR JURISDICTION FORMAT 292 GET NEXT TRACK OF DATA 294 PARSE TRACK DATA ACCORDING TO JURISDICTION FORMAT 296 DATE MATCHED JURISDICTION FORMAT 298 DISPLAY “FRAUDULENT CARD” MESSAGE 300 STORE INDIVIDUAL VALUES INTO DRIVER LICENSE FIELDS 302 STORE ERROR INFORMATION WITH TIME & DATE 304 LOAD STORED JURISDICTION DATA FRAUD CHECKSUM 306 PROGRAM LOOP FOR PERFORMING PARITY CHECKSUM 308 PERFORM PARITY CHECKSUM ON TRACK DATA 310 DATA MATCHED JURISDICTION FORMAT 312 DISPLAY “TAMPERED CARD” MESSAGE 314 STORE ERROR INFORMATION WITH TIME & DATE
[0050] As seen in FIG. 4(B) the subroutine 160 is initiated by start procedure event 196 and terminated by end procedure event 204 each of which events corresponds to the signal path having the same reference number shown in FIG. 3. The notification of the start procedure event 196 is applied on signal path 316 which is routed to program segment 286 which, in turn, retrieves the decrypted data originally loaded into the CPU via program segment 144 of FIG. 3. Program segment 286 activates signal path 318 that is routed to program segment 288 which loads the stored jurisdictional format defining the format related to the jurisdiction of the individual specified in the driver license 78 loaded into the CPU 12 . After such loading, program segment 288 passes control over to program loop 290 via signal path 320 .
[0051] The first segment of loop 290 is program segment 292 which retrieves the first or next track of data defined by program segment 288 and passes control over to program segment 294 via signal path 322 . Program segment 294 parses the retrieved track data according to the particular jurisdictional format under consideration and passes control over to program 296 via signal path 324 .
[0052] Program segment 296 is a decisional segment that matches the data from program segment 292 to the jurisdictional format under consideration, and if a proper match exists passes control over to program segment 300 via signal path 326 , but if a match does not occur, passes control over to program segment 298 via signal path 328 .
[0053] Program segment 298 causes the display of the message “fraudulent card” on the CRT displays 44 and 56 of FIG. 1 and then passes control over to program segment 302 via signal path 330 . Program segment 302 stores the error information along with its time and date and passes control over to program segment 304 via signal path 332 .
[0054] Program segment 300 receive control from signal paths 326 and 332 and stores the individual values of the driver license data read into the CPU 12 into the driver license fields in the CPU 12 .
[0055] Program segment 300 returns control, via signal path 334 , to program segment 292 which, as previously mentioned, is the first step of loop 290 . Loop 290 has a repetitive cycle between 3 to 5 times dependent on the jurisdictional segment and for each repetitive cycle program segment 300 passes control over to program segment 292 via signal path 334 , and when loop 290 is complete, program segment 300 passes control over to program segment 304 via signal path 332 . The interaction of loop 290 serves as a fraudulent check which in actuality detects any counterfeit documents.
[0056] Program segment 304 loads the stored jurisdiction checksum and and passes control over to program loop 306 having a first program segment, that is, program segment 308 . The checksum determines if the data has been tampered with or altered after having been officially issued.
[0057] Program segment 308 performs the parity checksum on the track data received from program segment 304 and then passes control onto program segment 310 via signal path 338 .
[0058] Program segment 310 performs a data match of the jurisdictional format and if the data is not correct passes control over to program segment 312 via signal path 340 . Program segment 312 causes the CPU 12 to activate the CRT displays 44 and 56 of FIG. 1 and display the error message “tampered card” and then passes control over to program segment 314 via signal path 342 . Program segment 314 stores the error information along with its time and date and passes control to end procedure event 204 via signal path 344 . End procedure event 204 also receives control from program segment 310 via signal path 346 if the data match jurisdictional format performed by program segment 310 is correct. End procedure event 204 returns control back to the overall program segment 140 of FIG. 3 which sequences to subroutine 168 of FIG. 4(C) which is comprised of a plurality of program segments which are tabulated in Table 6.
TABLE 6 REFERENCE NO. PROGRAM SEGMENT 348 LOAD STORED CATEGORY AGENTS 350 GET INDIVIDUAL'S AGE 352 PROGRAM LOOP FOR GATHERING CATEGORY AGE 354 GET CATEGORY AGE 356 AGE => CATEGORY AGE 358 SET CATEGORY RESULTS TO FALSE 360 SET CATEGORY RESULTS TO TRUE 362 GET PRIMARY AGE CATEGORY 364 AGE => PRIMARY CATEGORY AGE 366 FLASH AMBER LED 368 FLASH RED LED's 370 FLASH GREEN LED's
[0059] As seen in FIG. 4(C), the subroutine 168 is initiated by the start procedure event 206 and is terminated by the end procedure event 212 , with the events corresponding to signal paths 206 and 212 of FIG. 3. The occurrence of the start procedure event 206 is applied upon signal path 374 which notifies program segment 348 . Program segment 348 loads the stored category ages related to the particular jurisdictional segment under consideration, and then passes control over to program segment 350 via signal path 376 . The category ages may include the legal age for drinking and voting.
[0060] Program segment 350 retrieves the individual's age from the initial data read into the CPU 12 by program segment 144 of FIG. 3. The program segment 350 passes, via signal path 378 , control over to the program loop 352 which is repetitively performed 5 times and has a first program segment 354 .
[0061] Program segment 354 retrieves or gets the next or first category age of program segment 350 and passes, via signal path 380 , control over to program segment 356 . Program segment 356 determines if the age of the individual is within the category of ages for the jurisdictional segment, and if the answer is yes, then passes control over to program segment 360 via signal path 382 and, conversely, if the category age is not correct passes control over to program segment 358 via signal path 384 . Program segment 358 sets the category results false, and then passes, via signal path 386 , control back to program segment 354 which, as previously discussed, is the first program segment of the loop 352 .
[0062] Once the loop is iterated 5-times, then either program segment 358 or 356 passes control over to program segment 362 , via signal path 388 .
[0063] Program segment 362 retrieves the primary age category, that is, for example, the legal age of drinking in the particular jurisdiction, and then passes control to program segment 364 via signal path 390 .
[0064] Program segment 364 determines the age of the individual designated by the contents of the driver license 78 read into the CPU 12 , and, more particularly, determines if the age is below the required legal age. Program segment 364 in its determination sets one of the three (3) digital bits previously discussed with regard to the D/A converter 46 that is past onto the LED array 58 , both previously described with reference to FIG. 1. If the age of the individual does not at least equal that required by the jurisdiction for the selected category, such as drinking, program segment 364 passes control over to the program segment 368 , via signal path 392 A, which causes the CPU 12 to have a RED indicator of the LED array 58 flashed. If program segment 364 is unable to determine the age category, it passes, via signal path 392 B, control over to program segment 366 which, in turn, causes the CPU 12 to have the amber LED of the LED array 58 flashed. If program segment 364 determines the primary age to be correct, program segment 364 passes control over to program segment 370 , via signal path 392 C. Program segment 370 causes the CPU 12 to have the green LED of the LED array 58 flashed. Once the LED flashing is completed, program segment 370 passes, via signal path 394 , control over to the end procedure event 212 which, in turn, allows the subroutine 168 to be returned to the overall program segment 140 of FIG. 3 which, in turn, allows the program segment 140 to sequence to subroutine 178 which may be further described with reference to FIG. 4(B) comprised of a plurality of program segments that are tabulated in Table 7.
TABLE 7 REFERENCE NO. PROGRAM SEGMENT 396 GET JURISDICTION ID & CODE 398 LOAD STORED LICENSE BACKGROUND 400 DISPLAY LICENSE BACKGROUND 402 UNDER LEGAL AGE 404 LOAD STORED UNDER AGE GRAPHICS 406 DISPLAY UNDER AGE GRAPHICS 408 DETERMINE AGE LOOP 410 PROGRAM LOOP FOR DETERMINE AGE CATEGORY 412 GET NEXT CATEGORY AGE 414 AGE => CATEGORY AGE 416 DISPLAY “NO” SYMBOL 418 DISPLAY “YES” SYMBOL 420 GET DRIVER CLASS 422 LOAD STORED CLASS GRAPHICS 424 DISPLAY CLASS GRAPHICS
[0065] As seen in FIG. 4(D), the subroutine 178 is initiated with the start procedure event 212 and terminated with the end procedure event 216 which correspond to the signal paths 212 and 216 of FIG. 3. The occurrence of the start procedure event 212 is passed to the program segment 396 by way of signal path 426 .
[0066] Program segment 396 retrieves the jurisdiction identification (ID) and the code of the driver license 78 , which is a code indicating the AAMVA assigned Jurisdiction Number and a Code which denotes which security encryption key was used by that jurisdiction at the time of encrypting. Program segment 396 , after its completion, passes control over to program segment 398 via signal path 428 .
[0067] Program segment 398 loads the stored license background that was read into CPU 12 by the program segment 144 of FIG. 3. Program segment 398 passes control over to program segment 400 by way of signal path 430 .
[0068] Program segment 400 displays the license background on the CRT displays 44 and 56 of FIG. 1 and passes control over to program segment 402 via signal path 432 .
[0069] Program segment 402 determines if the age on the driver license is, for example, under 21 (Legal Age) and if the answer is yes, passes control over to program segment 404 via signal path 434 , but if the answer is no, passes control to program segment 408 via signal path 436 .
[0070] Program segment 404 loads the stored under age graphics and passes control over to program segment 406 via signal path 438 which causes the CPU 12 to have the CRT displays 44 and 56 of FIG. 1 display the under age graphics. The under age graphics may be selected to attract the attention of the user of the authentication system 10 of the present invention. After such display the program segment 406 passes control over to program segment 408 via signal path 440 .
[0071] Program segment 408 is an age determining segment loop which is accomplished by a program loop 410 interlinked to program segment 408 via signal paths 442 and 444 .
[0072] The first program segment of program loop 410 is program segment 412 which retrieves the next age category which, for example, may be the age for smoking and passes control over to program segment 414 via signal path 446 .
[0073] Program segment 414 determines if the age of the individual of the driver license 78 read into the CPU 12 is equal to or greater than the category age. The categories include alcohol, tobacco, lottery, gambling and custom guidelines used for casino or for entrance into an entertainment facility. If the answer of program segment 414 is yes, program segment 414 passes control over to program segment 418 via signal path 448 , but if the answer is no, program segment 414 passes control over to program segment 416 via signal path 450 .
[0074] Program segment 416 causes the CPU to provide the “no” symbol on the CRT displays 44 and 56 of FIG. 1, whereas program segment 418 causes the CPU 12 to cause the display of the “yes” symbol on the same CRT displays 44 and 56 . The “yes” and “no” symbols may be selected to attract the attention of the user of the authentication system 10 of the present invention. The program loop 410 is typically and repetitively repeated five (5) times and upon such completion passes control back to the program segment 408 via signal path 444 .
[0075] Program segment 408 after its completion passes control over to program segment 420 via signal path 454 .
[0076] Program segment 420 retrieves the driver class designation and passes control over to program segment 422 via signal path 456 . Program segment 422 loads the stored driver class graphics and passes control over to program segment 424 via signal path 458 .
[0077] Program segment 424 causes the CPU 12 to display the class graphics on the CRT displays 44 and 56 of FIG. 1 and upon its completion passes, via signal path 460 control to end procedure event 216 which is also shown as signal path 216 of FIG. 3.
[0078] As seen in FIG. 3, the signal path 216 notifies the program segment 184 of the generation of license graphics which, in turn, passes control over to program segment 186 via signal path 218 which, in turn, passes control back to the start event 142 , via signal path 220 so that the overall program 140 of FIG. 3 may be repeated, if necessary.
[0079] It should now be appreciated that the practice of the present invention provides for an authentication system 10 to authenticate driver licenses that are coded with machine readable information in accordance with AAMVA standards, as well as coded with human recognizable information.
[0080] It should be further appreciated that the present invention, not only verifies the contents of driver licenses but also allows the information contained in the CPU 12 to be transferred to a remote or local jurisdiction, via modem 26 , to remote computer 28 so that the information may be identified for criminal prosecution purposes or, conversely, for humanitarian purposes, such as, for identifying preordained organ donors. The identification for criminal or humanitarian purposes may be accomplished in a manner similar to that hereinbefore described with reference to FIGS. 1 - 4 .
[0081] Furthermore, it should be appreciated that the present invention provides the means for not only rapidly authenticating a document, such as a driver license, but also allowing the driver license to serve as a convenient means for rapidly verifying that age requirements are satisfied in any purchase at the point-of-transaction or in allowing ingress into establishments having their own age requirements.
[0082] Further still, it should be appreciated that the practice of the present invention utilizes a personal computer, such as CPU 12 , commonly found in many places of businesses used for inventory purposes but also having a need to authenticating the contents of a driver license, such as authenticating identification for credit card and check writing at the point-of-sale. Further uses could be to authenticate driver licenses in police cars, ports of entry such as domestic and internal airports, sea ports, rail stations and border check-points. Attached to existing locking mechanisms, could be integrated into lottery, tobacco and alcohol vending machines and to points of entry to buildings and other sensitive areas. Verifying identity is also important: to other areas such as child day care centers and Post Offices to verify parcel pick-up and drop-off. | An apparatus that authenticates the contents of identification documents provided by different issuers having machine-readable and/or human readable information is disclosed. The contents of the identification documents are verified without encountering any human error. The verified contents of the identification documents may be used for identification purposes such as age restricted purchases, preordained organ donors or possible criminal prosecution. The verified contents of the identification documents may be logged to provide ID checking compliance and/or may be transferred to a remote computer for additional processing or logging. | 6 |
BACKGROUND OF THE INVENTION
This invention was supported in part by the United States Government (USPHSRO1- CA37395) and the Government has certain rights in the invention.
This invention relates to the general field of controlling angiogenesis--i.e., preventing or treating undesired angiogenesis.
Various diseases are angiogenesis-dependent, i.e., they are related to the process by which new capillary blood vessels are formed. Uncontrolled and rampant capillary growth can cause extensive tissue damage, e.g. in diabetic retinopathy where neovascularization in the retina may lead to blindness and in rheumatoid arthritis where new vessels in the joint may destroy articular cartilage. Moreover, the progressive growth of tumors generally depends upon continuous induction of angiogenesis by the tumor.
Folkman, "Tumor Angiogenesis" in Advance in Cancer Research, Vol. 43, pp. 175-203 (Klein and Weinhouse, Eds.) generally reviews efforts to find angiogenesis inhibitors which might be used therapeutically, in an effort to control angiogenesis-dependent diseases. Specifically, mixtures of cortisone (or hydrocortisone) and heparin (or heparin fragments) inhibit angiogenesis, as measured by regression of growing capillaries in chick embryo, cessation of tumor-induced capillary growth in rabbit cornea, and regression of some tumors in mice. Folkman et al. Science 221:719 (1983). This anti-angiogenic activity is not dependent upon the anticoagulant activity of heparin, nor upon the glucocorticoid or mineralocortocoid activity of steroids. Crum and Folkman, J. Cell Biol. 99:158a, Abstr. #581,(1984); and Crum et al. Science 230:1375 (1985). The same effect is observed with several natural and synthetic steroids, and they appear to act by inducing basement membrane breakdown, endothelial cell rounding, and capillary retraction. Ingber et al. Endocrinology 119:1768 (1986). Heparin or heparin-like molecules are known to be present on the surface of vascular endothelial cells Buonassi et al. Biochem. Biophys. Acta 385:1 (1975); and Castellot et al. J. Biol. Chem. 257:11256 (1982). The anticoagulant and antilipidemic functions of heparin depend on the number and position of heparin sulfate groups. Danishefsky Fed. Proc. 36:33 (1977); Levy and Petracek Proc. Soc. Exp. Biol. Med. 109:901 (1962); and McDuffie "Heparin: Structure, Cellular Function and Clinical Applications", p. 167, Academic Press Inc., N.Y. 1979.
SUMMARY OF THE INVENTION
We have discovered that a certain class of compounds, known as sulfatase inhibitors, will potentiate the angiostatic activity of steroids. We do not wish to be bound to a specific mechanism, but it appears that sulfatase activity is endogenous to the mammal in question, and that the inhibitor inhibits desulfation of heparin components, particularly heparin and heparan sulfate present on the surface of vascular endothelial cells and in the extracellular matrix beneath endothelial cells. The desulfated heparin shows reduced angiostatic activity in combination with angiostatic steroids, thus reducing the effectiveness of steriod-heparin compositions, particularly where the heparin dosage is limiting.
Accordingly, one aspect of the invention features a method for controlling angiogenesis in a mammal by administering to the mammal an effective amount of an inhibitor of arylsulfatase. Preferably, the arylsulfatase inhibitor is administered in a pharmaceutically acceptable vehicle in combination with an angiostatic steroid and (optionally) heparin (by which term we include all forms and fragments of heparin having the desired angiostatic activity). Suitable angiostatic steroids include those described by Ingber et al. (cited above) and by Crum et al. (cited above). Hydrocortisone is one specifically preferred steroid. The preferred arylsulfatase inhibitor is a carboxylic acid ester of a benzylic alcohol or a toluenesulfonate, most preferably the esters and toluenesulfonates defined more particularly below. The arylsulfatase inhibitor is preferably administered locally to the tissue experiencing undesired angiogenesis.
A second aspect of the invention features a composition of matter for use in the above method, comprising an arylsulfatase inhibitor and an angiostatic steroid as described above, in a pharmaceutically acceptable vehicle. The composition preferably includes heparin.
A third aspect of the invention features the recognition that arylsulfatase inhibitors potentiate the anticoagulation effect of heparin (which term includes all forms and fragments of heparin with anti-coagulating ability). Specifically, this aspect of the invention features a method of inhibiting coagulation of blood (e.g. in vitro) by adding a composition comprising an arylsulfatase inhibitor and a heparin to the blood. The invention also features the anticoagulant composition. Other features and advantages of the invention will be apparent from the following description of the preferred embodiment and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
We describe first the preferred angiostatic compositions and methods; then we describe the anticoagulation feature of the invention.
DRAWINGS
FIGS. 1a-1c are bar graphs demonstrating anti-angiogenic activity of arylsulfatase inhibitor at varying heparin concentrations.
FIG. 2 is a graph demonstrating the effect of arylsulfatase inhibitor on clotting.
ANGIOSTATIC METHODS AND COMPOSITIONS
The preferred angiostatic composition comprises an arylsulfatase inhibitor and an angiostatic steroid, as described below.
The arylsulfatase inhibitor is preferably an analog of a natural substrate of arylsulfatase, particularly esters of benzylic alcohols and toluenesulfonates. Particularly, preferred compounds are those represented by the following formula: ##STR1## where R 1 is a C 1 or C 2 alkylene group, X is --O--CO--R 7 or --SO 3 , R 2 -R 6 are independently selected from the group consisting of H, alkyl, nitro, and hydroxyl functions and R 7 is an alkyl group. (preferably C 5 or less). In particular R 1 is CH 2 , R 2 is OH, R 5 is NO 2 , and X is --SO 3 . Particularly suitable inhibitors are analogs of the substrate p-nitrocatechol sulfatase. One such analog is sodium 2-hydroxy-5-nitro-alpha-toluene sulfonate (HNT).
Compounds described above can be screened for the ability to block the activity of an arylsulfatase, such as commercially available arylsulfatase purified from limpets (Sigma, St. Louis), or arylsulfatase activity of chick chorioallantoic membrane. Other arylsulfatases suitable for screening inhibitors include arylsulfatase in NK cells or commercially available abalone-derived arylsulfatase. See Zucker-Franklin et al. (1985) Biochem. Biophys. Res. Commun. 126:540.
An optional confirmatory test of inhibitory activity includes the ability to inhibit hydrolysis of heparin by a mammalian arylsulfatase, e.g. by measuring the effect of the inhibitor on the clotting time of heparinized blood as described below.
In addition to the arylsulfatase inhibitor, the preferred angiostatic composition includes an agiostatic steroid. Preferred angiostatic steroids are those described in Crum et al. Science 230:1375 (1985) and Ingber et al. Endocrinology 119:1768 (1986), including cortisone, epicortisol, hydrocortisone, tetrahydrocortisone S, 17 α-hydroxyprogesterone, cortexolone, corticosterone, desoxycorticosterone, hydrocortisol, 6 α-fluororo-7,21-dihydroxy-16β-methylpregna-4,9-(11)-dione-3,20-dione; 11 α-hydrocortisone, 11-desoxycortisol, and 4,9(11) pregnadien-17α, 21 diol-3,20 dione. Other angiostatic steroids are listed in Table I.
Heparin can also be added to the composition. Heparin, an α, β glycosidically linked highly sulfated copolymer of uronic acid and glucosamine, has been used clinically as an anticoagulant for half a century. Despite its importance and widespread use, both the exact structure of heparin and the precise nature by which it acts in blood anticoagulation have not been eludicated. Much of the difficulty in determining the structure of heparin is because it is not a homogeneous substance. Heparin is polydisperse with a molecular weight range from 5,000 to 40,000. Within a given chain, there are also structural variations such as varying degrees of sulfation, N-acetylation, and C-5 epimerization in the uronic acid residue.
Consequently, the precise composition of commercial heparin varies depending on its source and method of purification. Heparin has been degraded by treatment with heparinase (an enzyme of bacterial origin, Langer et al., U.S. Pat. No. 4,341,869) which cleaves the molecule at the α-glycosidic linkages between N-sulfated-D-glucosamine 6-sulfate and L-iduronic acid 2-sulfate to form fragments including disaccharide, tetrasaccharide, hexasaccharide, and larger oligosaccharides, each being simply a chain-shortened heparin fragment with minor end group modification (the degradation results in a Δ-4,5 site of unsaturation in the terminal uronic acid residue). Linhardt et al., J. Biol. Chem., Vol. 257, 7310-13 (1982) By the term "heparin", we mean to include all forms of heparin, and all fragments of heparin having angiostatic effect. See generally Folkman et al., Science 221:719-725 (1983). We specifically mean to include heparin fragments which are hexasaccharides or larger, or analogous compounds having one of the following structures: ##STR2##
In the preferred composition, the above active ingredients are formulated with a physiologically acceptable carrier, depending on the condition being treated and the route of administration. The arylsulfatase inhibitor is present in a concentration of 5 μg/10 μl-200 μg/10 μl depending on its inhibitory activity (k i , described below) its lifetime, and the route of administration.
In the present invention, a free form or a salt of arylsulfatase inhibitor may be used. As the salt, inorganic salts such as alkali metal salt, e.g. sodium salt, potassium salt, alkaline-earth metal salt, e.g. calcium salt, and ammonium salt may be exemplified.
On the basis of their strong angiogenesis inhibitory activity, arylsulfatase inhibitors are useful for prophylaxis and treatment of diseases in the fields of ophthalmology, dermatology, pediatrics, surgery and cardiology.
Thus, arylsulfatase inhibitors may be used for prophylaxis and treatment of neovascularization in diabetic retinopathy, retrolental fibroplasia, corneal graft neovascularization, neovascular glaucoma, ocular tumors, and trachoma; dermatological psoriasis and pyogenic granuloma; childrens hemangioma, angiofibroma and hemophiliac joints; and hypertrophic scars, would granulation, vascular adhesions, rheumatoid arthritis, scleroderma and atherosclerotic plaque.
The preferred arylsulfatase inhibitory compositions are low in toxicity and safely administered orally or parenterally to mammals (e.g. rat, rabbit, monkey man) in forms of e.q. tablets, granules, capsules, injectable solutions, topical creams, and eye-drops.
To treat diabetic retinopathy, for example, an arylsulfatase inhibitor composition can be administered orally or intravenously in the form of a pharmaceutical composition.
Alternatively, arylsulfatase inhibitor especially as a salt, can be administered in the form of eye-drops, i.e one to a few drops per dose can be instilled in the eye with a frequency of 1 to about 4 times a day according to the patient's condition.
For oral administration, 5 mg to 100 mg of the arylsulfatase inhibitor or its salts can be formulated as a tablet or a capsule together with carrier, diluent or vehicle.
For eye-instillation, a arylsulfatase inhibitor salt can be dissolved in distilled water to make a concentration of 0.5 mg/ml to 5 mg/ml (w/v); the solution may also contain an isotonizing agent, a preservative, or a thickening agent and is adjusted to pH 5 to 9.
EXAMPLE 1
Screening Inhibitors
By way of example, and not as a limitation, the following experiments demonstrate the protocol for screening inhibitors, using the natural substrate, p-nitrocatechol sulfate and arylsulfatase from the chick choriollantoic membrane. Specifically, arylsulfatase activity is measured, with and without the inhibitor.
As described below in detail, the activity of arylsulfatase in the chorioallantoic membrane was measured with the substrate p-nitrocatechol sulfate, using the extinction coefficient of the product p-nitrocatechol in 1N NaOH using 12670 M -1 ). The specific activity of the arylsulfatase in the membrane was 0.015 U/mg protein when bovine serum albumin was used as a protein standard. One unit of activity is that amount of enzyme sufficient to hydrolyze 1 μM of sulfatase per hour.
An homogenate of chorioallantoic membrane was prepared by pooling ten 8-day old chorioallantoic membranes which had been excised from the rest of the embryo and rinsed in 0.9% NaCI at 4° C. to remove blood and amniotic fluid. The membranes were transferred to a glass homogenizer in 2 ml of iced sodium-acetate buffer (0.2M, pH 5.0) which also contained 0.1M ethylenediamine tetra-acetate. The membranes were homogenized manually and then sonicated (VibraCell, Sonics and Materials, Danbury, Conn.) until no intact cells were identified by microscopic examination. The homogenate was then centrifuged and the supernate collected for enzymatic assays.
P-nitrocatechol sulfate (Sigma Chemical Company, St. Louis, Mo.) was dissolved in 0.2M acetate buffer (pH 5.0) to yield a 6.25 mM solution. In a test tube, 200 ul or 0.2M acetate buffer, 160 ul of the p-nitrocatechol solution, and 40 ul of the sample were mixed and incubated at 37° C. for 30 minutes. The reaction was quenched by addition of 1N NaOH (2 ml) which also developed the color of the product, p-nitrocatechol. The blank was prepared similarly, except that NaOH was added immediately after mixing the sample and the substrate. Absorbance at 515 nm was measured with a Beckman DU-6 spectrophotometer (Beckman Instrument, Inc., Irvine, Calif.). The extinction coefficient of p-nitrocatechol was calculated from its absorption at 515 nm p-nitrocatechol (Aldrich, Milwaukee, Wis.) at various concentrations.
To measure the ability of candidates to inhibit, the following enzyme kinetic study can be used, yielding a value for k i . The substrate (p-nitrocatechol sulfate), and solutions of potential inhibitors (in this case HNT) were prepared with the acetate (0.2M) and EDTA (0.1M) buffer adjusted to pH 5.0. The homogenate of the chorioallantoic membrane was incubated with p-nitrocatechol sulfate solution at 37° C. in the presence of various concentrations of HNT. NaOH solution was used to quench the reaction, and the absorption was read at 515 nm. The results were plotted according to Lineweaver and Berk (Lehninger, Biochemistry 2nd Ed. Worth Publishers, New York, N.Y. p. 195 (1975)).
The inhibitor should have a k i of at least 1.0 μM and preferably at least 5.0 μM. Using commercially available arylsulfatase from limpets (Sigma), the k i for HNT with p-nitrocatechol sulfate was 8.4 μM, where the k m for the substrate was calculated to be 0.73 mM. See Zucker-Franklin, cited above, regarding similar studies on commercially available arylsulfatase derived from abalone.
EXAMPLE 2
Inhibition of Angiogenesis
The ability of arylsulfatase inhibitors to potentiate the angiostatic effect of steroids, as demonstrated in the chick embryo choriallontic membrane assay, is shown below in an HNT/hydrocortisone system.
Hydrocortisone was held constant at an optimum concentration (50 ug/embryo) while heparin and HNT concentrations were varied independently. The ability of HNT to potentiate the inhibition of angiogenesis was inversely proportional to the concentration of added heparin. In other words, HNT potentiation was greater at lower concentrations of heparin, but HNT did not potentiate optimal concentrations of heparin. In the presence of hydrocortisone, HNT inhibited angiogenesis in a dose-dependent fashion without the addition of exogenous heparin. Neither HNT alone (i.e., up to 200 μg/embryo, administered in vitro, in the absence of endogenous heparin activity), hydrocortisone alone, nor heparin alone inhibited angiogenesis.
The specific assay for angiogenesis in the chick embryo choriallantoic membrane is described in detail in Crum et al. 1985, cited above, and need not be repeated here.
FIG. 1 demonstrates the anti-angiogenic activity of combinations of various concentrations of heparin and HNT in the presence of hydrocortisone. The black portion of each bar represents the percentage of avascular zones greater than 2 mm diameter and the hatched area represents avascular zones equivalent to 2 mm diameter. Each methylcellulose disk also contains 50 ug of hydrocortisone, one methylcellulose disk/embryo, approximately 16-20 embryos/bar. (a) No heparin present. The anti-angiogenic activity is positively correlated with a concentration of HNT p=less than 0.0001). 50% of the chorioallantoic membranes yielded avascular zones at an HNT concentration of 200 ug/disck without the administration of heparin. (b) Heparin concentration at 10 ug/disk. Anti-angiogenic activity and HNT concentration are positively correlated (p=less than 0.000003). (c) At 50 μg/disk, there is no significant correlation between the anti-angiogenic activity and HNT concentration (p=greater than 0.26). Not shown are the following concentrations of HNT: 5 μg of heparin/disk: the correlation between anti-angiogenic activity and HNT concentration was significant at p=0.04. At a heparin concentration of 25 ug/disk, there was no significant correlation between anti-angiogenic activity and HNT concentration (p=greater than 0.3).
Control of Blood Clotting
Aryl sulfatase inhibitors can be added to blood to prolong the anti-coagulant effect of heparin. Specifically, the above-described arylsulfatase inhibitors are generally useful for this purpose. Preferably the arylsulfatase inhibitor is added in a composition that includes heparin. For example, a concentration of at least 10 μM of arylsulfatase inhibitor can be included in the standard heparin additive to be used with whole blood.
The following specific example of anti-coagulant activity of arylsulfatase inhibitor is provided by way of illustration and not as a limition on the invention.
The activated clotting time of heparinized rabbit blood was 4.75 minutes. As the concentration of HNT in heparinized blood was increased up to 10 mM, the activated clotting time exceeded 120 minutes, representing more than a 25-fold increase over heparinized blood not treated with HNT. To determine the effect of HNT on non-heparinized blood, we carried out a separate study using clotting time (without activation by siliceous earth); an activated clotting time of non-heparinized blood was too short to measure accurately. The clotting time of non-heparinized blood was not significantly lengthened except for a minimal increase in clotting time at the highest concentration of HNT tested (10 mM). In the heparinized blood, clotting time was increased by greater than 7.5-fold in the presence of only 1 uM HNT.
Heparinized blood standing in vitro will clot eventually because platelet-derived enzymes and other enzymes in the plasma will degrade heparin. Because the clotting time of heparinized blood is increased significantly by HNT, but the clotting time of non-heparinized blood is not.
Heparin (Hepar, Franklin, Ohio, Lot PM12583, activity 160 U/mg) was administered to New Zealand white rabbits (Pine Acres, Norwell, Mass.) via the auricular vein in physiologic saline at either 80 or 160 U/kg body weight. After 20 minutes, approximately 20 ml of blood was drawn from the central artery of the ear with a #19 butterfly needle into a plastic syringe. In order to determine activated clotting time, the syringe containing heparinized blood was immersed immediately in an ice bath at 4° C. Aliqouts of 1.9 ml of the chilled blood were then added to vacutainer tubes (75×13 mm, Becton-Dickinson Co., Rutherford, N.J.) containing 12 mg siliceous earth and 0.1 ml of the various concentrations of HNT in saline. Thus, the final volume of 2.0 ml contained HNT concentrations from 0 to 10 mM (FIG. 1). The contents were mixed and timing was begun when the vacutainer tubes were placed in a constant temperature bath at 37° C. The endpoint of this assay was the time required to obtain immobilization of the blood column upon inversion of the tube. The pH of the serum was measured in each tube after clotting.
In order to determine clotting time, the blood was transferred immediately in aliquots of 2.7 ml to vacuated silicone-coated glass tubes (Monojet red-top tubes, Sherwood Medical, St. Louis, Mo.) which had been pre-warmed to 37° C. and which contained 0.3 ml of HNT-saline solution as described in FIG. 1. The final volume of 3.0 ml contained HNT concentrations of 0 to 10 mM.
To demonstrate the effect of the arylsulfatase inhibitor, HNT, on activated clotting time of heparinized blood, blood was drawn 20 minutes after a rabbit had received 160 U of heparin/kg of body weight intravenously. The time required for blood to clot in a glass-tube containing siliceous earth and HNT of a given concentration was recorded. HNT (at concentrations up to 10 mM), did not prolong the clotting of unheparinized blood.
FIG. 2 demonstrates the effect of the arylsulfatase inhibitor, HNT, on the clotting time of heparinized blood. Blood was drawn from rabbits having either no heparinization (white bars), or 20 minutes after receiving either 80 U (hatched bars) or 160 U heparin/kg (solid bars). The clotting time was determined in silicone-coated tubes.
Other embodiments are within the following claims.
TABLE I
Angiostatic Steroids
17α,21-dihydroxy-4-pregnene-3,11,20-trione and its 21-acetate (or cortisone)
11α,17,21-trihydroxypregn-4-ene-3,20-dione (or 11α-hydrocortisone)
11β,17α,21-trihydroxypregn-4-ene-3,20-dione (or hydrocortisone)
17α,21-dihydroxypregna-4,9(11)-diene 3,20-dione
15α,17α,21-trihydroxy-4-pregnene-3,20-dione
16α,17α,21-trihydroxy-6α-methylpregn-4-ene-3,20-dione-21-acetate-16,17 cyclic ketal of acetone
6α-fluoro-17α,21-dihydroxy-16β-methylpregna-4,9(11)-diene-3,20-dione
6α-fluoro-17α, 21-dihydroxy-16β-methylpregna-4,9(11)-diene-3,20-dione-17,21-diacetate
6α,17α,21-trihydroxypregn-4-ene-3,20-dione
17α,21-dihydroxypregn-4-ene-3,20-dione-21-acetate
17α,21-dihydrcxypregn-4-ene-3,20-dione
9β,11β-epoxy-17α,21-dihydroxy-2α-methylpregn-4-ene-3,20-dione-21-acetate | Anigiogenesis is controlled by administering to a mammal an effective amount of an inhibitor of arylsulfatase. Preferably, the arylsulfatase inhibitor is administered in a pharmaceutically acceptable vehicle in combination with an angiostatic steroid and (optionally) heparin (by which term we include all forms and fragments of heparin having the desired angiostatic activity). Hydrocortisone is one specifically preferred steroid. The preferred arylsulfatase inhibitor is a carboxylic acid ester or a sulfuric acid ester of a benzylic alcohol, most preferably the esters defined more particularly below. The arylsulfatase inhibitor is preferably administered locally to the tissue experiencing undesired angiogenesis. Arylsulfatase inhibitor and an angiostatic steroid are included in a pharmaceutically acceptable vehicle, preferably also with heparin, to yield an angiostatic thereapeutic composition. Also, coagulation of blood is inhibited by adding a composition comprising an arylsulfatase inhibitor and heparin to the blood. Such compositions are also disclosed. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to baffles for locating in tanks for containing liquid.
BACKGROUND
[0002] A high speed projectile on impact with and penetration into a liquid containing tank generates very high pressure in the liquid. This phenomenon, known as hydrodynamic ram, typically includes the generation of shock waves and subsequent pressure pulses in the liquid. These pressures combined with the penetration damage from the projectile, can cause damage to the tank structure and frequently are the cause of catastrophic failure of the tank. The hydrodynamic ram pressure pulses are intense but of short duration which propagate through the liquid in the tank.
[0003] There is thus a need for means for reducing hydrodynamic ram pressure in the liquid in such a tank and for a generally improved tank which has an improved ability to sustain projectile impact without catastrophic failure.
SUMMARY OF THE INVENTION
[0004] In a first aspect, the present invention provides a baffle for locating in a tank for containing liquid. The baffle comprises a baffle wall enclosing an internal cavity, and one or more openings in the baffle wall configured to permit the flow of a fluid between the internal cavity of the baffle and a volume external to the baffle wall. The baffle wall comprises a first portion providing an outer wall, and a second portion located within the first portion and providing an inner wall. The first portion comprises one or more openings. The second portion comprises one or more openings. The number of openings in the second portion are equal to the number of openings in the first portion. Each of the openings in the first portion is attached to a respective opening in the second portion via a respective opening side wall. The first and second portions are spaced apart to define therebetween a chamber.
[0005] The chamber may be a sealed chamber.
[0006] An outer surface defined by the first portion may be substantially spherical in shape.
[0007] The chamber may be filled with a compressible gas or gaseous mixture.
[0008] The baffle may have been produced using an Additive Manufacturing process.
[0009] The baffle may comprise multiple component sections that have been produced and subsequently attached together.
[0010] The baffle may be made of a material selected from the group of materials consisting of carbon fibre composite and plastic.
[0011] The baffle may have an external diameter less than or equal to 10 cm.
[0012] In a further aspect, the present invention provides a liquid storage tank and baffle system comprising a tank for containing a liquid and enclosing a liquid storage space, and one or more baffles located within the liquid storage space. The one or more baffles are in accordance with any of the above aspects.
[0013] The first portion and the second portion may be sufficiently strong to resist at least the maximum & minimum hydrostatic pressure of a liquid in the tank. The chamber may have a volume sufficient to allow a shock wave or waves in the liquid in the tank resulting from compression of the liquid by impact of a projectile on the tank and thus on the liquid to be reduced by expansion of the compressed liquid into the chamber.
[0014] The chamber may contain a material having a density sufficiently different from the density of a liquid in the tank to provide substantially total reflection within the baffle of the shock wave or waves impinging on the baffle thereby to reduce the hydraulic ram pressure in the liquid.
[0015] The one or more baffles may substantially fill the liquid storage space within the tank.
[0016] The total cavity volume of the baffles in the liquid storage space may be less than or equal to 15% by volume of the liquid storage space volume.
[0017] The tank may be an aircraft fuel tank.
[0018] In a further aspect, the present invention provides a vehicle (e.g. an aircraft) comprising a liquid storage tank and baffle system in accordance with any of the above aspects.
[0019] In a further aspect, the present invention provides a liquid storage tank and baffle system comprising a tank for containing a liquid, said tank enclosing a liquid storage space, and a plurality of baffles located within the liquid storage space. Each baffle comprises a baffle wall that encloses a respective internal cavity. Each baffle further comprises a one or more openings in the baffle wall of that baffle such that a fluid may flow between the internal cavity of that baffle and the liquid storage space.
[0020] An outer surface defined by the baffle wall may be substantially spherical in shape (i.e. the baffles may be “baffle balls”).
[0021] A baffle wall may comprise a first portion providing an outer wall, and a second portion located within the first portion and providing an inner wall. The first portion may comprise one or more openings. The second portion may comprise one or more openings, the number of openings in the first portion being equal to the number of openings in the second portion. Each of the openings in the first portion may be attached to a respective opening in the second portion via a respective opening side wall. The first and second portions may be spaced apart to define therebetween at least one sealed chamber.
[0022] The first portion and the second portion may be sufficiently strong to resist at least the maximum & minimum hydrostatic pressure of a liquid in the tank. The at least one chamber may have a volume sufficient to allow a shock wave or waves in the liquid in the tank resulting from compression of the liquid by impact of a projectile on the tank and thus on the liquid to be reduced by expansion of the compressed liquid into the chamber.
[0023] The at least one chamber may contain a material having a density sufficiently different from the density of a liquid in the tank to provide substantially total reflection within the baffle of the shock wave or waves impinging on the baffle thereby to reduce the hydraulic ram pressure in the liquid.
[0024] The chamber may be filled with a compressible gas or gaseous mixture
[0025] The baffles may be objects that have been produced using an Additive Manufacturing process.
[0026] Each baffle may comprise multiple component sections that have been produced and subsequently attached together.
[0027] Each baffle may be made of a material selected from the group of materials consisting of carbon fibre composite and plastic.
[0028] Each baffle may have an external diameter less than or equal to 10 cm.
[0029] The baffles may substantially fill the liquid storage space within the tank.
[0030] The total cavity volume of the baffles in the liquid storage space may be less than or equal to 15% by volume of the liquid storage space volume.
[0031] The tank may be an aircraft fuel tank.
[0032] In a further aspect, the present invention provides a vehicle comprising a liquid storage tank and baffle system in accordance with the preceding aspect.
[0033] In a further aspect, the present invention provides a baffle for locating in a tank for containing liquid. The baffle comprises a baffle wall enclosing an internal cavity, and a one or more openings in the baffle wall configured to permit the flow of a fluid between the internal cavity of the baffle and a volume external to the baffle wall. The baffle wall comprises a first portion providing an outer wall, and a second portion located within the first portion and providing an inner wall. The first portion comprises one or more openings. The second portion comprises one or more openings, the number of openings in the second portion being equal to the number of openings in the first portion. Each of the openings in the first portion is attached to a respective opening in the second portion via a respective opening side wall. The first and second portions are spaced apart to define therebetween at least one sealed chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a schematic illustration (not to scale) of an exploded view of an example aircraft wing in which an embodiment of a baffle is implemented;
[0035] FIG. 2 is a schematic illustration (not to scale) showing a cross section through a fuel tank in which an embodiment of a hydrodynamic ram reducing baffle is implemented;
[0036] FIG. 3 is a schematic illustration (not to scale) showing a hydrodynamic ram reducing baffle;
[0037] FIG. 4 is a schematic illustration (not to scale) illustrating effects of a projectile impacting with an external surface of the fuel tank of FIG. 2 ; and
[0038] FIG. 5 is a schematic illustration (not to scale) showing a cross section through a further hydrodynamic ram reducing baffle.
DETAILED DESCRIPTION
[0039] In the following description, like reference numerals refer to like elements.
[0040] The following description is based on embodiments of the invention and should not be taken as limiting the invention with regard to alternative embodiments that are not explicitly described herein. Structural material types and methods of construction provided herein are examples only.
[0041] It will be appreciated that relative terms such as top and bottom, upper and lower, and so on, are used merely for ease of reference to the Figures, and these terms are not limiting as such, and any two differing directions or positions and so on may be implemented.
[0042] FIG. 1 is a schematic illustration (not to scale) of an exploded view of an example aircraft wing 2 in which an embodiment of a hydrodynamic ram reducing baffle is implemented.
[0043] The aircraft wing 2 comprises a substructure 4 comprising a plurality of spars 6 and ribs 8 . The spars 6 are spaced apart from one another and are aligned along the length of the aircraft wing 2 . The spars 6 are coupled together by the spaced apart ribs 8 which are substantially perpendicular to the spars 6 . The spars 6 and ribs 8 are connected together by fasteners (not shown in the Figures). The spars 6 and ribs 8 are made of carbon fibre composite (CFC) material, i.e. a composite material comprising a polymer matrix reinforced with carbon fibres. In other examples, the spars 6 and ribs 8 are made of a different appropriate material, for example, aluminium.
[0044] The aircraft wing 2 further comprises external skins, namely an upper skin 10 and a lower skin 12 . The upper skin 10 comprises a plurality of panels made of CFC material. The upper skin 10 is attached to an upper surface of the substructure 4 by fasteners (not shown in the Figures). The lower skin 12 comprises a plurality of panels made of CFC material. The lower skin 12 is attached to a lower surface of the substructure 4 by fasteners (not shown in the Figures). The external skin 10 , 12 may each be, for example, 8 mm thick.
[0045] When the substructure 4 and the external skins 10 , 12 are attached together (and, for example, bonded with a sealant), a cavity defined by the substructure 4 and skins 10 , 12 is formed. Such a cavity is used as a fuel tank for storing aircraft fuel and is indicated in FIG. 1 by the reference numeral 14 . The fuel tank is described in more detail later below with reference to FIG. 2 .
[0046] The aircraft wing 2 further comprises a leading edge structure, a trailing edge structure and a wing tip structure, which are not shown in FIG. 1 for reasons of clarity.
[0047] FIG. 2 is a schematic illustration (not to scale) showing a cross section through the fuel tank 16 in the aircraft wing 2 .
[0048] In this embodiment, the outer walls of the fuel tank 16 are provided by spars 6 , ribs 8 , and the upper and lower skins 10 , 12 . Aircraft fuel is stored in the cavity 14 defined by the fuel tank outer walls.
[0049] In this embodiment, the fuel tank 16 comprises hydrodynamic ram reducing baffles 20 .
[0050] FIG. 3 is a schematic illustration (not to scale) showing a perspective view of a baffle 20 . Preferably, the baffles 20 are substantially identical to each other.
[0051] In this embodiment, each baffle 20 is a baffle ball being substantially spherical, although other shapes are within the disclosure of this invention.
[0052] Preferably, the outer diameter of each baffle 20 is less than 10 cm. More preferably, the outer diameter of each baffle 20 is less than 5 cm. More preferably, the outer diameter of each baffle 20 is between 3 cm and 5 cm e.g. 4 cm.
[0053] In this embodiment, each baffle 20 is hollow and comprises an outer skin 20 a enclosing an internal cavity.
[0054] In this embodiment, the outer skins 20 a of the baffles 20 are relatively thin. For example, the thickness of the outer skin 20 a may be less than 3 mm. In other embodiments the thickness of the outer skin 20 a is a different appropriate value. In some embodiments, the thickness of the outer skin 20 a is between 0.25 mm and 1 mm. In some embodiments, the thickness of the outer skin 20 a is between 1 mm and 3 mm. Preferably, the thicknesses of the outer skins 20 a of the baffles 20 are such that the baffles 20 occupy less than 15% of the total internal volume (i.e. capacity) of the fuel tank 16 . In other embodiments, the baffles 20 occupy a different proportion of the fuel tank capacity.
[0055] Each baffle 20 comprises a plurality of openings 20 b in its outer skin 20 a such that the internal cavity of the baffle 20 is in fluid communication with the volume outside the outer skin 20 a of the baffle 20 . Thus, the liquid in the fuel tank 16 tends to be able to move freely in and out of the baffles 20 . Advantageously, the openings 20 b tend not to detrimentally affect the structural integrity of the baffles 20 to a significant degree. In some embodiments, each baffle 20 includes eight openings 20 b. However, in other embodiments, one or more of the baffles 20 include a different number of openings. In some embodiments, the diameter of each opening 20 b is approximately 10%-20% of the outer diameter of the baffle 20 , however openings having different diameters may be implemented.
[0056] In some embodiments, one or more of the baffles 20 comprise one or more support ribs integral with their internal or external surface to provide additional structural stability.
[0057] In this embodiment, the baffles 20 are made of a strong, tough, non-reactive material, for example CFC or a plastic such as high density polyethylene. Preferably, the baffles 20 are made of a material that is fuel resistant at high temperatures. In this embodiment, each baffle 20 is formed as a single integral unit. The baffles 20 may be produced using any appropriate process, such as moulding or an Additive Manufacturing process. However, in other embodiments, the baffles 20 are formed in multiple sections, e.g. as half-sphere shapes which may be subsequently joined together by any appropriate joining process.
[0058] In this embodiment, the baffles 20 are not fixedly attached together. In other words, the baffles 20 are arranged in the fuel tank 16 such that they may move, at least to some extent, with respect to one another. However, in other embodiments, the baffles 20 are attached to one another so that the relative positions of the baffles 20 are fixed.
[0059] In this embodiment, the baffles 20 are not fixedly attached to the spars 6 . Thus, the baffles 20 are free to move, at least to some extent, within the fuel tank 16 relative to the spars 6 . Also, in this embodiment, the baffles 20 are not fixedly attached to the ribs 8 . Thus, the baffles 20 are free to move, at least to some extent, within the fuel tank 16 relative to the ribs 8 . Also, in this embodiment, the baffles 20 are not fixedly attached to the upper skin 10 . Thus, the baffles 20 are free to move, at least to some extent, within the fuel tank 16 relative to the upper skin 10 . Also, in this embodiment, the baffles 20 are not fixedly attached to the lower skin 12 . Thus, the baffles 20 are free to move, at least to some extent, within the fuel tank 16 relative to the lower skin 12 .
[0060] Preferably, the number and arrangement of the baffles 20 within the fuel tank 16 is such that there is insufficient space in the fuel tank 16 in which to place a further baffle 20 . In other words, preferably the fuel tank 16 is “filled” with baffles 20 so that a further baffle does not fit into the fuel tank 16 . In other words, preferably the baffles 20 fill the entire liquid volume space in the fuel tank 16 .
[0061] As will now be described in more detail, the baffles 20 are operable to reduce hydrodynamic ram pressure in the fuel contained within the fuel tank 16 resulting from impact of a projectile with an external surface of the fuel tank 16 .
[0062] FIG. 4 is a schematic illustration (not to scale) illustrating effects of a projectile 24 impacting with the lower skin 12 of the fuel tank 16 . The path of the projectile through the lower skin 12 is indicated in FIG. 3 by the reference numeral 26 .
[0063] The projectile 24 may be any appropriate projectile or foreign object such as a bullet, warhead fragment, a vehicle part, a rock, a maintenance tool, hail, ice, a bolt, etc. An example projectile has a weight of approximately 3.5 g, is substantially spherical in shape having a diameter of approximately 9.5 mm, and travels with a velocity of 1500 m/s. A further example projectile is a 44 g 12.5 mm bullet that travels with a velocity of 500 m/s.
[0064] In this example, the projectile 24 initially impacts with an external surface of the lower skin 12 and travels through the lower skin 12 . The projectile 24 causes high strain rate shear damage to the lower skin 12 resulting in a hole in the lower skin 12 approximately the size of the projectile 24 .
[0065] In this example, after passing through the lower skin 12 , the projectile 24 impacts with and travels through (i.e. pierces or penetrates) multiple baffles 20 (i.e. the outer skins 20 a of multiple baffles 20 ). In other examples, the projectile 24 may impact with only a single baffle 20 . In other examples, the projectile 24 does not pierce an outer skin 20 a of a baffle 20 or only pierces a single outer skin 20 a of a baffle 20 .
[0066] The projectile impacting with a baffle 20 tends to cause that baffle 20 to deflect and accelerate within the fluid at least to some extent. Also, the projectile 24 impacting with a baffle 20 tends to cause that baffle 20 to move within the fluid in the fuel tank 16 with respect to the walls of the fuel tank 16 . This in turn tends to cause deflection and/or movement of multiple other baffles 20 within the fuel tank 16 , for example, due to the impinged upon baffle 20 being in contact with multiple other baffles 20 . Thus, impact kinetic energy of the projectile 24 tends to be used to deflect and accelerate the baffles 20 through the fluid in the fuel tank 16 , thereby reducing the energy introduced into the fluid.
[0067] Moving the baffles 20 through the fluid tends to provide that, in effect, the projectile 24 experiences a greater drag force when moving through the fluid in the fuel tank 16 compared to that that would be experienced were the baffles 20 not present. Thus, the passage of the projectile 24 through the fluid in the fuel tank 16 tends to be retarded. The retardation of the passage of the projectile 24 through the fluid tends to decrease the likelihood of the projectile 24 impacting with the upper skin 10 . Thus, the likelihood of a hole being formed in the upper skin 10 tends to be reduced. Furthermore, the increase in drag on the projectile 24 tends to mean that a greater portion of the impact energy is absorbed by the fluid in the fuel tank 16 . Thus, forces exerted on the walls of the fuel tank 16 tend to be reduced.
[0068] Also, in this example, when the projectile 24 travels through the outer skin 20 a of a baffle 20 , impact energy of the projectile 24 tends to be used to pierce that outer skin 20 a. Thus, the energy introduced into the fluid by the projectile 24 tends to be reduced, and the passage of the projectile 24 into the fluid is retarded at least to some extent.
[0069] At least some of the impact energy of the projectile 24 tends to be absorbed by the baffles 20 and therefore not transferred to the aircraft substructure 4 .
[0070] In this example, on piercing baffle outer skin 20 a, the projectile 24 impacts with the fluid within that baffle 20 , thereby generating one or more high pressure shock waves 30 within the fluid within that baffle 20 . In this example, a respective shockwave 30 or set of shockwaves 30 may be generated within the fluid within each baffle 20 that is penetrated by the projectile 24 . The outer skins 20 a of the baffles 20 tend to reflect incident shock waves 30 at least to some extent. Also, the walls of the baffles 20 tend to be relatively poor transmitters of impinging shock waves 30 . Thus, each baffle 20 tends to restrain or retain shockwaves 30 generated therein at least to some extent. Through multiple shockwave reflections in the fuel tank 16 and the attenuation properties of the liquid, the amplitude of the shock waves 30 tends to be reduced and consequently the pressure experienced by the substructure 4 tends to be diminished by the presence of the baffles 20 .
[0071] Also, the shock waves 30 generated within the baffles 20 tend to be of lower energy than a shock wave or shock waves 30 experienced in a conventional system due to at least some of the impact energy of the projectile 24 being absorbed by the baffles 20 . In addition, each baffle tends to limit the distance over which the shockwave 30 can develop. Furthermore, the baffles 20 tend to disrupt the shockwaves 30 travelling through the fluid in the fuel tank 16 and thereby tend to insulate the upper and lower skins 10 , 12 at least to some extent. Thus, pressures resulting from the shock waves 30 exerted on the walls of the fuel tank 16 tend to be lower than the shock wave pressures experienced in conventional fuel tanks. Thus, the likelihood of damage to the walls of the fuel tank 16 (e.g. decoupling of the external skin 10 , 12 from the spars 6 or ribs 8 ) tends to be reduced.
[0072] In this example, as the projectile 24 passes through the fluid in the fuel tank 16 , a cavitation “wake” may form behind the projectile 24 , i.e. a region of low pressure (e.g. a vapour or a vacuum) may form in the wake of the projectile 24 . This causes a fluid displacement and an increase in the pressure of the fluid in the fuel tank 16 . The baffles 20 tend to prevent or oppose the formation of a single large cavity in the wake of the projectile 24 , i.e. the baffles 20 tend to disrupt cavity formation. Instead, multiple smaller cavities may be formed in the fluid within each of the baffles 20 through which the projectile 24 passes. Thus, the increased fluid pressure resulting from cavitation caused by the projectile 24 tends to be constrained within each baffle and decreased compared to conventional systems. This tends to be facilitated by the passage of the projectile 24 through the fuel tank 16 being retarded at least to some degree by the baffles 20 . As a result, pressures resulting from cavitation exerted on the walls of the fuel tank 16 tend to be lower than in conventional systems. Consequently, the likelihood of damage to the walls of the fuels tank 16 (e.g. decoupling of the external skin 10 , 12 from the spars 6 or ribs 8 ) tends to be reduced.
[0073] Advantageously, the baffles 20 are located in the fuel tank 16 so that a shock wave or waves 30 resulting from compression of the liquid in the tank resulting from impact of the projectile 24 on the external surface of the fuel tank 16 impinges on at least one of the baffles 20 and so that the shock wave or waves 30 interact with at least one baffle 20 before impinging on the tank external boundary surfaces.
[0074] An advantage provided by the above described baffle is that hydrodynamic ram damage to a fuel tank caused by an object impacting with an external surface of the fuel tank tends to be reduced or eliminated. Hydrodynamic pressures and their associated structural responses tend to be reduced or eliminated. Thus, the likelihood of catastrophic failure of the fuel tank structure and corresponding aircraft loss tends to be reduced or eliminated.
[0075] The above described baffle advantageously tends to be relative easy and cheap to manufacture.
[0076] The above described baffle tends to be relatively easy to retrofit to existing aircraft fuel tanks.
[0077] The above described baffle tends to provide protection against hydrodynamic ram damage whilst occupying a relatively small amount of the fuel tank's capacity.
[0078] The above described baffle tends to be relatively lightweight so as not to be a significant burden to the aircraft.
[0079] In the above embodiments, the baffles are implemented in an aircraft wing fuel tank. However, in other embodiments, the baffles are used in a different type of container for containing fluid. In some embodiment, one or more walls of the container may be made of a different material to that described above.
[0080] In the above embodiments, the outer skins of the baffles are a single relatively thin layer of material. However, in other embodiments, the outer skins of the baffles are of a different construction, for example, as will now be described.
[0081] FIG. 5 is a schematic illustration (not to scale) showing a cross section through a further embodiment of hydrodynamic reducing baffle, hereinafter referred to as the “further baffle”) and indicated by the reference numeral 40 .
[0082] In this further embodiment, the outer skin of the further baffle 40 comprises an outer wall 42 and an inner wall 44 which are spaced apart to define therebetween at least one sealed chamber 46 . The outer skin of the further baffle 40 encloses an internal cavity 48 . The outer skin of the further baffle 40 comprises a plurality of openings 50 therethrough such that the internal cavity 48 of the further baffle 40 is in fluid communication with the volume outside the outer skin of the further baffle 40 . Thus, the liquid in the fuel tank 16 tends to be able to move freely in and out of the baffles 20 .
[0083] In this further embodiment, the outer wall 42 is substantially spherical in shape having a substantially circular cross section and within which is located the inner wall 44 and the chamber 46 . In other alternative embodiments the cross section may be an alternative shape.
[0084] In this further embodiment, the inner wall 44 is substantially spherical in shape having a substantially circular cross section. In other alternative embodiments the cross section may be an alternative shape.
[0085] The inner wall 44 is located within the outer wall 42 . The outer wall 42 and the inner wall 44 may be connected together at the openings 50 by opening walls.
[0086] In this further embodiment, the or each chamber 46 contains a compressible gas or gaseous mixture such as air at reduced, atmospheric, or enhanced pressure. In some embodiments, the or each chamber 46 contains a different material, such as a liquid or a solid instead of or in addition to the compressible gas or gaseous mixture. For example, in some embodiments, the or each chamber 46 contains a compressible or crushable foam.
[0087] The external diameter of the further baffle 40 may be the same as that of the baffle 20 which is described in more detail above with reference to FIGS. 2 and 3 .
[0088] The material from which the outer and inner walls 42 , 44 of the further baffle 40 are made may be the same as that from which the outer skin 20 a of the baffle 20 is made.
[0089] The arrangement of the further baffles 40 within the fuel tank 16 may be the same as that of the baffles 20 , which are described in more detail above with reference to FIGS. 2 to 4 .
[0090] In this further embodiment, the walls 42 , 44 of the further baffles 40 are sufficiently strong to withstand the pressure of the gas or gaseous material contained in the chamber 46 and are spaced apart in each further baffle 40 by an amount sufficient to provide at least one chamber 46 with a volume sufficient to allow a shock wave or waves in the liquid in the fuel tank 16 , resulting from compression of the liquid by impact of a projectile on the tank external surface and thus in the liquid, to be reduced by expansion of the compressed liquid into the chamber volume, thereby to reduce the hydraulic ram pressure in the liquid in the fuel tank 16 . Additionally, the gas or gaseous mixture in the or each chamber 46 has a density sufficiently different from the density of the liquid in the fuel tank 16 to provide substantially total reflection within the further baffle 40 of the shock wave or waves impinging on that further baffle 40 thereby to reduce the hydraulic ram pressure in the liquid in the fuel tank 16 .
[0091] Additionally, the walls 42 , 44 of the further baffles 40 are sufficiently strong to withstand the maximum and minimum hydrostatic pressure of the liquid in the fuel tank 16 at least up to maximum aircraft manoeuvre rate.
[0092] In this further embodiment, the further baffles 40 are placed in the fuel tank 16 such that a shock pulse generated by a projectile impacting the tank walls will impinge on at least one further baffle 40 before impinging upon an opposing tank wall. In defeating the hydraulic ram pressure the further baffles 40 serve at least two functions. Firstly energy from the hydraulic ram shock wave tends to be absorbed by expansion of the liquid into the space created by irreversible or reversible compression of the further baffle 40 , i.e. movement of the outer wall 42 and/or the inner wall 44 of a further baffle 40 into the chamber 46 of that further baffle 40 . Secondly, each further baffle 40 due to the large shock impedance mismatch between the further baffle 40 and the liquid in the fuel tank 16 behaves as a good shock wave reflector and a poor shock wave transmitter. Through multiple shock wave reflections in the fuel tank 16 and the attenuation properties of the liquid, the shock wave amplitude is reduced and consequently the pressure experienced by the substructure 4 is diminished.
[0093] In this embodiment, the further baffle 40 is formed as a single integral unit. The further baffle 20 may be produced using any appropriate process. For example, an Additive Manufacturing (AM) process (also known as Additive Layer Manufacture (ALM), 3D printing, etc.) may be used. Certain AM processes, such as Laser Blown Powder and Laser Wire Feed process, tends to be particularly well suited for the production of relatively complex objects such as the “double-skinned” further baffle 40 . Typically, such processes include providing material (e.g. plastic) in the form of a powder or a wire and using a powerful heat source such as a laser beam, Electron Beam (EB) or an electric or plasma welding arc, to melt an amount of that material and deposit the melted material as a bead (e.g. on a base plate of a work piece). Subsequent layers/beads are then built up upon preceding layers/beads.
[0094] However, in other embodiments, the further baffles 40 are formed in multiple sections, e.g. as half-sphere shapes which may be subsequently joined together by any appropriate joining process. The multiple sections may be produced using any appropriate process. For example, an AM process (such as a Laser Powder Bed process) or a moulding process may be used.
[0095] An advantage provided by the “double-skinned” further baffles 40 is that the further baffles 40 tend to be equally compressible by shock waves impinging on the further baffles 40 from different directions. This tends to be at least partially due to the spherical symmetry of the further baffles 40 . In other words, the further baffles 40 being substantially spherical in shape and exhibiting spherical symmetry tend to provide that the further baffles 40 are equally compressible from all directions. Thus, the further baffles 40 tend to be equally effective irrespective of the shock wave direction, i.e. irrespective of which surface of the fuel tank 16 is impacted by the projectile 24 .
[0096] In the above embodiments, the baffles are implemented in an aircraft wing fuel tank. However, in other embodiments, the baffles are used in a different type of container for containing fluid. In some embodiments, one or more walls of the container may be made of a different material to that described above. | Disclosed is a baffle ( 40 ) for locating in a tank ( 16 ) for containing liquid. The baffle ( 40 ) comprises: a baffle wall enclosing an internal cavity ( 48 ); and one or more openings ( 50 ) in the baffle wall configured to permit the flow of a fluid between the internal cavity ( 48 ) of the baffle ( 40 ) and a volume external to the baffle wall. The baffle wall comprises an outer wall ( 42 ), and an inner wall ( 44 ) located within the outer wall ( 42 ). The outer and inner walls ( 42, 44 ) each comprise one or more openings. Each of the openings in the outer wall ( 42 ) is attached to a respective opening in the inner wall ( 44 ) via a respective opening side wall. The outer and inner walls ( 42, 44 ) are spaced apart to define therebetween a chamber ( 46 ). | 1 |
FIELD OF THE INVENTION
This invention relates to surgical stapling instruments. More specifically, this invention relates to pneumatically powered surgical staplers. Most specifically, this invention relates to the driving mechanism used in connection with pneumatically powered surgical staplers.
BACKGROUND OF THE INVENTION
Pneumatic surgical staplers have become one of the preferred alternative methods to manually driven surgical staplers. An advantage of a pneumatic surgical stapler is that the force needed to fire the stapler is controlled by the driving mechanism, and not the strength of the user. In a pneumatic stapler, a compressed gas line or compressed gas cartridge releases gas pressure in order to activate the driving mechanism in the surgical stapler. In a reliable pneumatically driven surgical stapling mechanism, the force required to fire the staple is repeatably derived within a very refined tolerance. Thus, in a pneumatic surgical stapler there is the assurance that a repeatable force-to-fire is derived.
One of the ways in which pneumatic surgical staplers operate is through means of an inflatable elastomeric bladder. Bladders convert pneumatic pressure into motion within the limitably accessible head of the surgical stapler. A bladder operates by expanding from pressurized fluid inserted into an opening in the bladder. The fluid is generally carbon dioxide gas and is introduced through a tube inserted in the opening in one end of a sock-like bladder. The tube and bladder have previously been connected to each other by means of a mechanical clamp. The bladder forms a type of gasket between the clamping parts and the tube.
Introduction of carbon dioxide causes inflation of the bladder and can be converted to movement of various mechanisms in, for example, the head of a linear surgical stapler.
For the stapler to be a limited access device, the combination of bladder, tubing and stapling head must meet severe dimensional constraints. The bladder, tubing and driving mechanism must all fit within a linear stapling head which fits within the body. In general, the typical bladders used have a bottle-necked configuration which permits the smallest union between tube, bladder and clamping mechanism.
Bladders are made in a variety of ways including a latex dipping process using a mandrel. The mandrel has the configuration of the interior of the bladder and is dipped into liquid latex. The later is allowed to cure or solidify around the mandrel, resulting in a bladder.
A manufacturing problem is encountered in the necked region of the bladder. At this neckdown, it is extremely difficult to remove the bladder from the mandrel. The generally elastomeric latex bladder must be stretched over the shoulders of a mandrel and pulled from the bottom of the necking configuration. This procedure is time consuming and labor intensive and adds to the cost of making the part.
In addition, this assembly must be made in a tight fit, particularly since addition of any lubricant for tube insertion within the bladder combination may jeopardize later function of the stapling assembly.
Also, after firing, rapid deflation of the bladder in the stapling head can result in bladder material closing the orifice of a supply tube. Fluid becomes trapped when this orifice is blocked before complete deflation/inflation. Total deflation is limited due to the sealing off of the bladder material.
Additionally, dimensional interference between the clamping mechanism which holds the bladder on the tube and the tubing mechanism which inflates the bladder can result in crimping of the tubing mechanism. This results in flow restriction and decreased speed of closure of the clamping mechanism.
It is necessary to correct these problems for pneumatic stapling to be a desirable alternative procedure.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a bladder and mandrel combination useful in a pneumatic surgical stapler.
It is further an object of the invention to provide a bladder and mandrel combination useful within a typical linear surgical stapler head.
It is yet another object of the invention, to provide a bladder and mandrel combination useful in a pneumatic surgical stapler wherein the mandrel and bladder are configured so as to prevent clogging, improper clamping, non-vacating of the mechanism, collapsing of the bladder, and other functional problems.
These and other objects of the invention are accomplished in a bladder and mandrel combination wherein the mandrel and bladder are permanently incorporated with one another. Supply line tubing of the mandrel forms an integral part of the mandrel and it becomes permanently bonded to a bladder sub-assembly. Elastomeric bladder material is coated on the mandrel by means of any suitable fabrication technique. The bladder material is bonded to the mandrel neck while permitting inflation separation in the functional areas of the bladder. The loosened fit on the stapler clamping mechanism on the bladder also results in improved flow.
These and other objects of the invention are realized in the accompanying Detailed Description of the Drawings taken in connection with the Detailed Description of the Invention which follows.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a typical pneumatic linear surgical stapler;
FIG. 2 is a cross-section of the firing mechanism along lines 2--2 of FIG. 1;
FIG. 3 is a partially cut away side plan view of a linear surgical stapler head;
FIG. 4 is a cross-sectional view of a bladder combination;
FIG. 4a is a cross-sectional view of the connection of the stapling head as seen in FIG. 3;
FIG. 4b is a cross-sectional view of the head in FIG. 3;
FIG. 5 is a view of the bladder and mandrel of the invention;
FIG. 6 is a similar view as in FIG. 5 showing an alternate connection; and
FIG. 7 is a cross-sectional view of the mandrel as seen in FIG. 6 showing locations of orifices within the mandrel.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, a gas-powered surgical stapler of the invention is shown. The stapler includes three major components: a handle portion 10, a neck portion 108, and a stapler head 110. The three components are joined at their interconnecting points by pneumatic quick-disconnect fittings which allow the components to be disconnected and interchanged. Also located at the joints are pneumatic rotating unions, which allow free rotation of the components with respect to each other, as indicated by the arrows in FIG. 1.
As in FIGS. 1 and 2, the handle portion 10 is a sub-assembly which contains a pressurization indicator 20, a pressure regulator 30, a pressure distribution spool 50 and a firing sequence mechanism 70. The lower pistol grip section 12 of the handle 10 contains a compartment for a pressurized carbon dioxide gas cylinder 14. The cylinder 14 is inserted into the pistol grip section from the bottom, and a threaded cap 16 is tightened to secure the cylinder in its compartment. As the cap is tightened the top of the cylinder is pierced and pressurized gas is released into the stapler. Pressurized gas is released at the cylinder pressure (approximately 800 psi) and initially the gas pressurizes a chamber 34 within the stapling handle 10. This gas pressure passes through a passageway 22 to pressurization indicator 20.
The pressurization indicator 20 includes a cylinder 24 located in a chamber at the rear of the handle which is sealed in the chamber by an O-ring 26 prior to pressurization. The end 25 of the cylinder is flush with the outer surface of the handle and is retained in this position by the force of the spring 28.
The pressure distribution spool 50 provides a means for applying pressurized gas to operative parts of the stapler during a stapling procedure. Pressurized gas is needed during two phases of operation. One is the clamping cycle, when tissue being stapled is clamped between the jaws or other closing parts of the stapler head. The other is the staple cycle, when staples are driven through the tissue and formed in fixed positions in the tissue.
As in FIGS. 2 and 3, the pressurized gas in passageway 90 and 92 of the handle portion 10 is conducted via passageways 90a, 92a to the clamping and stapling mechanisms in the stapler head 110 through pneumatic tubing and joints which connect the handle portion of the stapler to the stapler head through an interchangeable neck portion 108, as shown in FIGS. 1, 2 and 3. The neck portion 108 is connected to the handle portion and the stapler head 110 by conventional snap-lock fittings similar to those found on many pneumatic instruments, and by rotating unions, the latter being shown in FIG. 3. The rotating tube-passage unions allow the stapler head 110 and neck portion 108 to be rotated with respect to the handle portion 10 while maintaining the integrity of the pressurized gas lines.
FIGS. 2, 3, 4a and 4b are cross-sectional illustrations of a piston drive stapler head 110. The stapler head 110 includes jaw 200 which carries a plurality of staples 202 in a movable clamping and stapling mechanism. Opposite the jaw 200 is a stationary opposing jaw 204. The face of the stationary jaw which opposes the stapling mechanism comprises an anvil which clinches or bends the legs of metal staples which pass through the tissue between the jaws. When the staples are formed of absorbable polymeric materials, the stationary jaw will carry a cartridge of receivers which mate and retain the legs of the polymeric fasteners.
The staples 202 are located in pockets formed in a staple cartridge 206 on the jaw 200, with the legs of the staples directed towards stationary jaw 204. Behind the staple cartridge 206 is a staple pusher 210. The staple pusher 210 has fingers 212 directed toward the crowns of respective staples in the staple cartridge. Behind the staple pusher 210 is a driver piston 214. The driver piston is located inside a clamping piston 220, and is pneumatically sealed therein by two circumferential O-rings 216 and 218. The clamping piston 220 is located inside a piston housing 230. The clamping piston 220 is pneumatically sealed inside the piston housing by two circumferential O-rings 222 and 224. Between the O-rings are ports 226 and 228 which pass through the clamping piston. These ports are symmetrically located so that the clamping piston can be inserted into the piston housing with either end at the bottom.
Located at the rear of the piston housing is a passageway 232. This passageway 232 is connected to the right angle union 150 by a pneumatic tubing segment 234. Toward the front of the piston housing is a secondary passageway 236. This passageway is connected to union 150 by tubing segment 238. To the lower left of the staple head is the neck portion 108 of the stapler. The tubing in the neck portion is connected to the inlet ports of the right angle union 150 by pneumatic snap-fits 106.
When tissue to be stapled is located between the jaws 200 and 204 and it is desired to clamp the tissue between the jaws, the slide 70 is depressed and pressurized gas flows through the passageway 92 of the handle. The pressurized gas is carried through tubing in the neck portion 108 through the central passageway of the right angle union 150. The pressurized gas passes through tubing segment 234 and passageway 232 to the rear of the clamping piston 220. There, the gas is forced into the interface 240 between the clamping piston and the piston housing, where it expands and pushes the clamping piston forward toward the stationary jaw. As the clamping piston moves, it carries the driver piston, staple pusher, and staple cartridge with it. This will clamp the tissue between the staple cartridge and the stationary jaw. The clamping piston 220 is now in a position as indicated in phantom in FIG. 4a.
When the tissue is securely clamped between the jaws, the user unlocks a trigger safety and pulls the trigger 72 to implant staples. Pressurized gas flows through passageways 90, 90a, passageway 168 in union 150, and tubing segment 238 to passageway 236. Pressurized gas then flows through port 228 in the clamping piston and then to space 242 at the rear of the driver piston. When the expanding gas in this space pushes the driver piston 214 forward against the rear of the staple pusher 210, uniform pressure is applied to the pusher and its fingers. The fingers then drive the staples out of the pockets of the staple cartridge, through the tissue, and against the anvil or into the receivers of the stationary jaw. When the trigger is released, the pressurized gas to the driver piston and clamping piston is vented, releasing the jaw 200 from the stapled tissue.
FIG. 4 is similar to FIGS. 2, 3, 4a and 4b, but shows an alternate stapler head embodiment using balloon-like bladders. A driver bladder 250 is connected to tubing segment 238 and is located behind the driver piston 214 inside the clamping piston 220. A clamping bladder 252 is connected to tubing segment 234 and is located behind the clamping piston 220 inside the piston housing 230. As the clamping bladder 252 is inflated when the slide 70 is depressed, it expands and pushes the clamping piston 220 forward to clamp the tissue. When the trigger 72 is further depressed the driver bladder 250 is inflated, driving the driver piston 214 against the staple pusher and implanting staples in the tissue. The use of bladders obviates needs for O-ring seals around the pistons, which in this embodiment have no pneumatic properties. This embodiment allows the use of fully rectangular pistons, as the tolerancing of the bladder actuated pistons can be such as to prevent piston binding.
The embodiments of FIGS. 2, 3 and 4 are advantageous over pneumatic staplers which deliver pressurized gas to mechanical stapling mechanisms in the handle portion. In such staplers considerable energy is expended in actuating mechanical linkages extending from the handle and through the neck to the stapler head. In this invention, the pressurized gas is delivered directly at the stapler head. Thus, there is no ambiguity as to the force delivered during the clamping and stapling since the pressure regulated gas is delivered directly at the clamping and stapling members without energy loss.
An alternate embodiment of the tubing and bladder configurations displayed in FIG. 4 is shown in FIG. 5. This bladder combination leading from either tubing segment is made so that the tube 300 extends into bladder 400 walls, as seen in FIG. 5. Thus, the chamber walls 500, created to fit the bladders within the stapler head 108, clamp the bladder 400 to the tube 300. Accordingly, there is reduced possibility of bladder material closing off the orifice of the pressurized supply tube. Additionally, there is no possibility of dimensional interference between the clamping mechanism and the tube 300 in that the wall size 500 is the same size as the outer diameter of bladder 400, which fits within the cavity formed for the bladder 400.
Alternately, as in FIG. 6, the proximal end of a mandrel 475 is configured with an orifice 501 so as to accept the fluid supplied. A tube 300 can be attached by either chemical or mechanical means. Chemical means include such techniques as solvent bonding of the tube 300 to the mandrel 475 within the bladder 400. This is dependent upon appropriate selection of tube 300 and mandrel 475 materials as well as solvent. An appropriate supply tube might be polyurethane, and an appropriate mandrel material might be a polycarbonate. These could be attached through the use of solvents such as methylene chloride. Other polymer solvent choices should be apparent to those experienced in solvent bonding technology.
Connection is made as in FIG. 6. There, the supply tube 300 is flared at its end 302, and is introduced as in a reverse funnel receptacle in the mandrel 475, so that it is held in place. The tube 300 and mandrel 475 combination could then be processed by dipping it in a latex material so that latex material captures the tube 300 within the mandrel 475. Appropriate orientation of the tube 300 and mandrel 475 then restricts the connection and makes it impossible for the tube 300 to become dislodged. Of course, further consideration is that the supply tube 300 is part of the mandrel 475 itself.
As seen in FIG. 7, an orifice or orifices 450 could be introduced into the distal end of the mandrel 475 for the purpose of allowing flow of inflation fluid through the mandrel and into the bladder. Size and location of these holes is dependent upon material properties of the bladder 400 and the mandrel 475. Hole location must allow structural integrity of the mandrel while permitting maximum introduction of fluid in a minimum amount of time. Hole placement is crucial for elimination of any bladder seal-off problem. Mold release or talc could be selectively coated on the mandrel prior to bladder material addition. This allows bonding of the bladder material to the mandrel neck while permitting inflation separation in the functional area of the bladder 400.
In summary therefore, the tubing mandrel may be injection molded, or fabricated in some other means that would allow it to be permanently incorporated within the bladder. Supply line tubing is an integral part of the mandrel or could be permanently bonded to the bladder sub-assembly.
It is to be noted that the invention described herein is to be understood by the attached claims and their equivalents. | A disposable mandrel and bladder is shown in which the mandrel is injected molded or machine fabricated in some other way that allows it to be permanently incorporated within the driver bladder of a surgical stapling mechanism. Supply line tubing is an integral part of the mandrel and would thus be permanently bonded to the bladder sub-assembly. Such configuration prevents tube clogging, bladder folding over infusion lines, and produces reliable firing of the stapler while using pneumatic driving mechanism. | 0 |
This application is a continuation of application Ser. No. 08/536,998, filed on Sep. 29, 1995, now U.S. Pat. No. 5,829,174, which is a continuation-in-part of application Ser. No. 08/225,215, filed Apr. 8, 1994, and which is now abandoned, which is a continuation-in-part of application Ser. No. 08/053,060, filed Apr. 26, 1993 and which is now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of snow-plows and specifically to articulated snow plows. Generally the snow plow system disclosed herein is intended for use on vehicles like trucks, tractors, skid loaders, pick up trucks, sports utility vehicles, etcetera. However, the snow plow system disclosed herein, or at least some aspects of the snow plow system disclosed herein, is also viewed as having application on all types of snow removal vehicles.
Plows with blades that hinge have a number of advantages over plows with straight nonpivotable blades. A lightweight vehicle, carrying a plow cannot easily push deep, particularly hard, or heavy snow with a straight blade. A centrally hinged plow blade or moldboard (sometimes called an apex type plow because the hinge is at the apex of the V formed when the arms or wings of the plow are in a swept back position) allows the operator of the vehicle a greater mechanical advantage since a plow moldboard, with its wings in the swept back, V shaped position, will act like a wedge into the snow. Each wing of the plow moldboard acting like an inclined plane depositing the snow to either side of the vehicle. A plow with a straight blade or moldboard also has difficulty in pushing a mound of snow to an out of the way location. Snow will spill out the sides of a plow with a straight moldboard while a hinged plow that can be articulated can have its wings or arms swept forward to form a V-shaped cup like area between the moveable arms of the moldboard. This swept forward position allows for better containment of the snow so that the snow may be moved out of the way without significant spillage.
Unfortunately, despite the many advantages that hinged plows have there are also disadvantages. For example, when the arms of the plow are in the swept forward position the volume of snow that can be moved is somewhat reduced. Additionally, the single center hinge of hinged snow plows can undergo tremendous stress during plowing, e.g., hitting curbs, rocks, or other objects, and thus the single hinge has a tendency to bend or even break after repeated encounters with such objects. Further, many such plows have very complicated designs which make them difficult or expensive to repair.
Additionally, hinged plows are generally not able to trip effectively when they are in the swept back or swept forward positions. This means that hinged plows have difficulty tipping or tilting in response to encountering a solid object like a curb, an elevated portion of the road bed, a manhole cover, etc. This can lead to jarring impacts which are not desirable and which may adversely affect both the structural integrity of the vehicle and the plow. To attempt to compensate for this problem hinged plows are usually provided with extra mass to prevent damage.
However, additional weight or mass can adversely affect the fuel economy, the handling, and/or the structural integrity of the vehicle to which the plow is mounted and does not make the hinged plow trip in a more effective manner.
It is an object of the present invention to produce an articulated plow system having a center section with at least two or a plurality of pivot points (hinge points) instead one pivot point. The system disclosed herein will thus have a moldboard which can articulate. This means that the moldboard will have a plurality of joints or hinge areas about which portions of the moldboard can pivot.
It is a further object of the present invention to provide a pivot between the main frame and the central section of the blade assembly pivot to allow a few degrees of motion about a horizontal axis. The object is to provide a limited amount of float to permit the blade assembly to follow ground contours and allow for some variations in the mounting height of the vehicle mounting points.
It is a general goal of the present invention to produce an articulated plow system, a plow system having at least two or a plurality of joints, having features which overcome the above noted problems and at the same time provide a snow plow having the advantages of a hinged plow and a regular straight plow.
Further, hinged plows as previously noted, typically have a point, the apex, where the hinge is located. The apex does not have a wearstrip in front of it to contact snow when plowing. Consequently, when a hinged plow is in the position or the swept back position this results in some snow being missed and a trail of unplowed snow being left behind the vehicle. This is not desirable because it requires that the driver make another sweep of the area just plowed to remove the trail of snow left. This wastes both the time and energy of the driver and the vehicle.
Thus, it is a further object of the present invention to provide a center section which can allow for the installation of a center wearstrip in a such a way that the center and wing wearstrips can overlap. Additionally, it is an object of this invention that the center strip be wide enough to accommodate such overlapping but also be narrow enough to allow for free flow of material across the wearstrip and moldboard surface when the blade assembly is angled fully to the right or to the left.
Further, it is an object of the present invention to use a center wearstrip that sufficiently angled with respect to the road or surface to be plowed so that a wedge or chisel affect to provide additional mechanical advantage to break up hard packed snow.
It is a further object of the present invention to include trip springs and pivots mounted to the center section independent of the main frame to allow for float between the main frame and the blade assembly section. Additionally, it is an object of the present invention to provide a center section having a width substantially greater than the single hinge width of apex type plows to provide more stability to the articulated plow system disclosed herein, greater resistance to side loading, and more durability. Further, by increasing the size of the center section more space is provided on the plow body itself for the tripping structure without any compromise to the structural integrity of the plow or its ability to pivot as desired.
It is a further objective of the present invention to permit blade tripping when the articulated plow disclosed herein is in the scoop position; with the wings of the plow swept forward.
It is a further object of the present invention to produce a plow system that may also be used on vehicles that are not well suited to heavy plows or to be used on vehicles where fuel economy is a consideration. Accordingly, the articulated plow blade of the present invention is designed so that it may be lighter in weight than prior art apex type plows.
It is a further object of the present invention to have a self-contained power unit and means of attaching the power unit mounted on the articulated plow and not the vehicle. This has the advantage of requiring less modification to the vehicle upon which the plow will be used. This will also aid in maintaining the center of gravity of the vehicle to help make the vehicle more stable since the majority of the weight added to the vehicle will be as part of the articulated plow located in front of the vehicle generally below the passenger compartment or cab. This allows the weight of the power unit to become an effective weight at the wearstrip rather than being fixed weight at the vehicle which is not desirable.
It is a further object of the present invention to address the problem of excess, performance reducing, weight on hinged snow plow. The present invention includes a reactive controlled pressure system that places a controlled predetermined pressure upon the moldboard of the plow system so that a portion of the weight of the vehicle to which the plow system is attached is actually transferred to the bottom edge of the plow moldboard and the plow moldboard acts as a moldboard weighing 2 to 3 times its actual weight. This allows the articulated plow blade of the present invention to be lighter in weight but to be as effective or even more effective in plowing as a hinged plow system.
It is a further objective of the present invention to provide the flexibility of having, in effect, both a light weight articulated plow (which is advantageous for certain conditions such as plowing light snow on a gravel driveway) and a heavy weight plow (which is advantageous for plowing drifted and hard packed snow and for scraping hard surfaces). This flexibility is obtained by having a reactive controlled pressure system which can be activated and de-activated by means of a simple electric control switch. The controlled pressure mechanism maintains a pressure within a certain predetermined low pressure and high pressure limit with a predetermined nominal pressure within these limits.
It is a further objective of the present invention to provide an articulated plow having a bell crank lift arm combination for lifting the articulated plow.
It is a further object of the present invention to have only a small mounting subframe located beneath the front bumper of the vehicle which is attached to the vehicle frame. All other components of the snow plow system are mounted to this mounting subframe so that they can be easily and quickly removed from the vehicle. Consequently, there is no substantial amount of mounting equipment covering the front end of the vehicle and little added weight permanently attached to the vehicle.
It is a further objective of the present invention to include a quick connecting/disconnecting structure to make it very easy to attach or disengage the snow-plow system from the vehicle. This saves the operator of the vehicle both time and effort when installing and removing the snow plow system.
Further, the present invention addresses the problem of lights mounted to vehicles for plowing. Typically an additional set of headlights and parking lights are mounted to the front end of a vehicle for plowing. This is because the regular headlights and parking lights of the vehicle are usually hidden behind the plow moldboard and thus are obstructed by the plow moldboard especially in the raised position. As such, the lights are rendered ineffective. Consequently it has been the case that an additional set of lights are mounted either upon the hood or up on the front grill of the vehicle so that they project over the front edge of the plow moldboard. The problem with this procedure is that these lights and their housings in and of themselves create obstructions in the driver's field of vision due to the fact that they are mounted on the vehicle. To overcome this problem it has been attempted in the prior art, in straight or traditional plows, to move the lighting system to a position off the vehicle and onto the plow structure itself. The device of the present invention moves these lights off of the vehicle and positions them so that they shine over the top edge of the moldboard, while presenting a minimal obstruction to the field of vision of the driver or operator of the vehicle. Since the additional lights are mounted on the plow and not on the vehicle they are removed when the snow plow is removed. This eliminates having a second set of lights permanently mounted on the vehicle. Further, it is an objective of the present invention to allow these lights to be mounted to a fixed position or mounted to a telescoping mount so that their position may be independently adjusted.
It is a further object of the present invention to provide a simplified structure for moldboard attachment to an articulated plow system wherein the moldboard is retained to the moldboard structure by a special retaining means that allows for easy replacement of the moldboard.
Finally, it is an object of the present invention to provide a U shaped articulated plow form so that a greater volume of snow can be collected between the wings or arms of the plow. This also makes it possible to contain and control the snow mass better and lends itself to ease of cleaning up the surface area from which the snow is being removed.
The inventors do not know of any prior art that either teaches or discloses the unique features of the present invention.
SUMMARY OF THE INVENTION
The present invention is an articulating snow plow system having several major features: a lighting system, a quick and easy connect/disconnect system, a reactive controlled pressure mechanism for applying a controlled pressure to the bottom edge of the moldboard of the plow, a simple electric control to activate or deactivate the reactive controlled pressure mechanism, a bell crank system for adjusting the attitude of the moldboard, a special retaining system for retaining the moldboard, a reactive pressure mechanism for articulating the wing segments of the snow plow in response to obstacles encountered by the plow, and a floating mechanism designed to provide the plow blades with a few degrees of float independent of the main support structure or frame.
Accordingly, the present invention may be summarized as an articulated snow plow system for use with a motorized vehicle. The articulated snow plow system comprising an articulated snow plow coupled to a reactive controlled pressure snow plow system for use with the articulated snow plow. The articulated snow plow having a moldboard and the reactive controlled pressure snow plow system including a reactive controlled pressure mechanism mechanically coupled to the vehicle and to the moldboard of the articulated snow plow. A reactive controlled pressure system for controlling the reactive controlled pressure mechanism by supplying and removing a non-compressible fluid from the reactive controlled control mechanism in response to changes exceeding a predetermined pressure range within the reactive controlled pressure mechanism. The reactive controlled pressure system being connected to the reactive controlled pressure mechanism.
The present invention may alternatively be described as an articulated snow plow system for use with a motorized vehicle comprising an articulated snow plow coupled to a quick mount system for mounting an articulated snow plow to a vehicle, the quick mounting system including a support mechanism coupled to the articulated snow plow and having at least three mounting points. A frame structure having at least three mounting points. A connecting mechanism connecting the mounting points of the frame structure to the mounting points of the support mechanism. The mounting points of the frame structure being connected to the mounting points of the support mechanism by the connecting mechanism. The support mechanism being connected to the vehicle and the frame structure being connected to the articulated snow plow.
The mounting system further including a lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
The reactive controlled pressure system further including a lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
The reactive controlled pressure system further including a quick mount system for mounting the articulated snow plow system to a vehicle, the quick mounting system comprising a support means for supporting the snow plow, the support means having at least three mounting points. A frame having at least three mounting points. A connecting means for connecting the mounting points of the frame to the mounting points of the support means. The mounting points of the frame being connected to the mounting points of the support means by the connecting means. The support means being connected to the vehicle and the frame being connected to the snow plow.
The reactive controlled pressure system further including a lighting system for connecting to the articulated snow plow system for use with a motorized vehicle, the lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means. The reactive controlled pressure snow plow system can be activated or de-activated by an electric control switch.
Alternatively, the present invention may be described as a lighting system for use with an articulated snow plow system for use with a motorized vehicle, the lighting system comprising at least one light connected to a telescopically adjustable support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
Also the present invention may be described as an articulated snowplow system for use with a vehicle comprising a mounting plow blade section having a moldboard section, at least two mounting sides, and at least one mounting structure located on each of the mounting sides. A plurality of extending plowblade sections each having a moldboard section and an engagement mechanism capable of engaging the mounting structure located on each of the mounting sides. An extending plowblade section being pivotally coupled to each mounting structure at the engagement mechanism.
The articulated snow plow system further including the combination of the engagement mechanism and the mounting structure, pivotally connected to each other, comprise: a hinge mechanism.
The articulated snow plow system further including the engagement mechanism and the mounting structure each comprise a series of sockets having openings. The sockets being aligned so that the spatial orientation of the openings of each socket is aligned along a substantially vertical axis; and a pin structure extending through each opening.
The articulated snow plow system further including an A-frame structure; (Any person reading or interpreting this patent should note that sometimes in this specification the plow support frame is referred to as the A-frame structure but it is not intended that the scope of the invention disclosed and claimed herein be limited to that structure and that other frame structures could be substituted. Thus any frame structure which functions in a manner equivalent to the present structure should be considered to be literally within the definition of A-frame as used herein) at least one trip spring, and at least one pivot. The trip spring and the pivot being mounted to the mounting plowblade section independent of the A-frame.
The articulated snow plow system further including a support bracket mechanism on the vehicle for receivably accepting a plow support frame. A plow support frame adapted for being coupled to the vehicle bracket mechanism and including an adjusting mechanism for adjusting the angular orientation of the mounting plowblade section and the extending plowblade sections. The mounting plowblade section coupled to the plow support frame and to the adjusting mechanism. A bell crank mechanism coupled between the front of the vehicle and a forward portion of the frame to permit vertical adjustment of the mounting plowblade section and the extending plowblade sections. A cylinder mechanism mounted to the frame and having a piston rod structure coupled to the bell crank mechanism for moving same to cause vertical adjustment, and fluid for extending and retracting the piston rod mechanism. A first bell crank coupling structure for coupling the bell crank mechanism to the vehicle bracket structure above the snow plow support frame structure (A-frame) and a second bell crank coupling structure on the frame generally adjacent the plow blade. The bell crank mechanism including a first link member which is coupled, at its first end, to the vehicle bracket structure by the first bell crank coupling structure and a second generally L-shaped link member having first and second ends. The second end of the first link member and the first end of the second link member being pivotally coupled to each other. The second end of the second link member being pivotally coupled to the piston rod of the first cylinder. The angular corner of the second link member being pivotally coupled to the second bell crank coupling bracket mechanism.
Alternatively, the above noted structure of the present invention could also be defined as a direct linkage system in which a short stroke actuator (e.g., a hydraulic cylinder) is used to provide a greater lift height to the snow plow as a result of the leverage of the linkage mechanism. For example, the actuator stroke could be limited four inches but the leverage could be adjusted so that the four inch stroke results in snow plow being lifted 20 inches. The amount of leverage affecting how much the snow plow may be raised could be varied depending upon the amount of additional linkage structure used or the length of the lever arm.
Consequently, an support frame structure used in the structure of the present invention which functions in a manner equivalent to the present structure should be considered to be literally with in the definition of support frame bracket mechanism of the present invention.
The articulated snow plow system having a substantially U shape when the extending plowblade sections are swept forward.
The articulated snow plow system further including a plurality of wearstrips. At least one wearstrip being mounted to the moldboard section of the mounting plowblade section and each extending plowblade section. The wearstrips being spatially orientated to overlap. The wearstrip of the mounting plowblade section has two ends and each end of the wearstrip overlaps a portion of the wearstrip of each extending plowblade section. The wearstrip of the mounting plowblade section having thickness of approximately of one (1) inch. Of course, this dimension is not critical. It is only important to note that the dimension should, preferably, be sufficient to prevent interference with the flow of snow across the moldboards of the plow when they are articulated to be angled either filly to the right or to the left.
The articulated snow plow system further including a plurality of hydraulic extension and retraction mechanisms each having a first end and a second end. The first end of each hydraulic extension and retraction mechanism being coupled to the mounting plowblade section. The second end of each hydraulic extension and retraction mechanism being coupled to a respective extending plow blade section. The hydraulic extension and retraction mechanisms being dual or double acting hydraulic cylinders.
The articulated snow plow system wherein the hydraulic extension and retraction mechanisms are coupled, via a plurality of hydraulic line structures, to a hydraulic control system. The hydraulic control system comprising a plurality of pressure switches, relief valves, and a reservoir. A hydraulic fluid being contained in both the hydraulic extension and retraction mechanisms, the hydraulic line structures, and the hydraulic control system. The hydraulic fluid capable of flowing into and out of the hydraulic extension and retraction mechanisms via the hydraulic line structures. At least one pressure switch mechanism being coupled to a valve mechanism. The valve mechanism being coupled to the hydraulic line structures and located between each the hydraulic extension and retraction mechanism and the reservoir. Each pressure switch mechanism capable of being actuated at predetermined pressure to actuate the valve mechanism coupled to a hydraulic line structure coupled to the reservoir. The hydraulic fluid capable of moving into the reservoir when the valve mechanism is open. The pressure switch mechanism (typically a pressure switch) is actuated by a predetermined increase in pressure greater than the forces encountered in normal plowing. In the specific structure disclosed herein this is a force exceeding approximately 1600 pounds per square inch of hydraulic fluid pressure.
The system of the present invention further includes pressure relief valves to permit hydraulic fluid to be directed to the reservoir in the unlikely event that a pressure switch fails and does not activate the valve mechanism to allow fluid to move into the reservoir. The pressure relief valve will, activate if the system pressure reaches a level significantly higher than the pressure switch setting. For example, in the present system a 2000 psi pressure relief valve is used in conjunction with a 1600 psi pressure switch setting. When the hydraulic pressure exceeds the relief valve pressure limit the valve will open and dump the hydraulic fluid into the reservoir.
The articulated snow plow system further including a moldboard section of the mounting plowblade section having an upper edge and a lower edge. The moldboard sections of the plurality of extending plowblade sections having an upper edge and a lower edge. The moldboard sections having an upper portion and a lower portion and being fastened to the blade structure by a retaining mechanism, the retaining mechanism comprising a fastener and at least one lower retaining channel structure located on each the mounting plowblade section and on each the extending plowblade section, respectively. The fastener fastening the upper edge of the moldboard to the upper portion of the blade structure. The lower retaining channel structure comprises a channel presented between a wearstrip, coupled to the lower portion of the blade frame, and the blade frame. Additionally, a second or even a third moldboard could be placed between the moldboard and the blade frame. It should be noted that in the presently proposed commercial embodiment of the present invention the center section of the articulated plow is not designed to have a retained moldboard but that other embodiments could contain this feature without departing from the invention as disclosed and claimed herein.
The articulated snow plow system additionally including having a moldboard section of the mounting plowblade section having an upper edge and a lower edge. The moldboard sections of the plurality of extending plowblade sections have an upper edge and a lower edge. The moldboard sections being fastened to the blade structure by a retaining mechanism, the retaining mechanism comprising at least one upper retaining channel structure and at least one lower retaining channel structure located on each the mounting plowblade section and on each the extending plowblade section.
The mounting plowblade section and the extending plow blade sections each having an upper edge and a lower edge and a blade frame, respectively. The upper retaining channel comprising a channel presented between a retaining strip fastened to each respective upper edge and the blade frame.
Alternatively, the mounting plowblade section and the extending plow blade sections each having an upper edge and a lower edge and a blade frame, respectively. The lower retaining channel structure including a channel presented between a wearstrip mounted to the lower edge and the blade frame.
Alternatively, at least one of the moldboard section is comprised of a substantially clear material like LEXAN brand clear plastic material.
DESCRIPTION OF THE DRAWINGS
FIGS. 1-10 show various views of some of the features of the present invention in conjunction with a standard non-articulable plow blade system to provide background and to illustrate by comparison the advantages of the present invention.
FIG. 1 is a top plan view of a nonarticulable snow plow system.
FIG. 2 is a side plan view of the nonarticulable snow plow system.
FIG. 3 is a schematic view showing the valve block and the main hydraulic or reactive constant pressure cylinder.
FIG. 4 is a rear plan view of the lighting system.
FIG. 5 is a schematic view of the electrical control circuit showing the circuit engaged in the blade down and float configuration.
FIG. 6 is a schematic view of the electrical control circuit showing the circuit engaged in the pressure down configuration.
FIG. 7 is a schematic view of the electrical control circuit showing the circuit engaged in the raise configuration.
FIG. 8 is a schematic view of the electrical control circuit showing the circuit engaged in the hold configuration.
FIG. 9 is a schematic view showing the hydraulic control system in the blade float configuration.
FIG. 10 is a schematic view showing the hydraulic control system in the pressure down configuration.
FIG. 11 is a schematic view showing the hydraulic control system in the raise and hold position.
FIG. 12 is side plan view of the vehicle bracket or subframe.
FIG. 13 is a schematic view of the hydraulic system of the articulated plow system.
FIG. 14 is a schematic view of the electrical system of the articulated plow system.
FIG. 15 is a side elevational view showing a retaining structure for retaining the moldboard on the articulated plow system.
FIG. 16 is a side elevational view showing the bottom portion of the retaining structure for retaining the moldboard on the articulated plow system.
FIG. 17 is a side elevational view showing an alternative retaining structure for retaining the moldboard on the articulated plow system.
FIG. 18 is a side elevational view of the bell crank lifting system used in combination with the articulated plow system in the lowered position.
FIG. 18A is a side elevational view of the bell crank lifting system used in combination with the articulated plow system in the raised position.
FIG. 19 is a schematic view showing the relationship of the hydraulic lines of the dual acting cylinders, which extend from the mounting plowblade section to the extending plowblade sections, and the valve block.
FIG. 20 is a side elevational view showing the blade center section (the mounting plowblade section), the pivot between the center blade section and the carrier, and the pivot and rubber torsion bushing carrier structure.
FIG. 20A is an exploded view showing the blade center section (the mounting plowblade section), the pivot between the center blade section and the carrier, and the pivot and rubber torsion bushing carrier structure.
FIG. 21 is a perspective view of the articulated plow system in the swept forward position.
FIG. 22 is a top plan view of the articulated plow system in straight plowing position.
FIG. 23 is a top plan view of the articulated plow system exaggerating the space between the wearstrip of the mounting plowblade section and the wearstrips of the plurality of extending plowblade sections to illustrate that the wearstrip of the mounting plowblade section overlaps the wearstrips of the extending plow blade sections.
FIG. 24 is a top plan view of the articulated snow plow system showing the extending plow blade sections in the swept forward position.
FIG. 25 is a top plan view of the articulated snow plow system showing the extending plow blade sections in the swept back position.
FIG. 26 is a top plan view of the articulated snow plow system showing one extending plow blade section in the swept back position and one extending plow blade section in the swept forward position for pushing snow off to one side of the plow vehicle.
DETAILED DESCRIPTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
Referring to FIGS. 1-12 , some of the features of the present invention may be seen in combination with a nonarticulated plow system as previously disclosed in U.S. Patent application Ser. No. 08/225,215, filed on Apr. 8, 1994, now abandoned.
The main features of the nonarticulated snow plow system 10 are a lighting system 20, a mounting system 40, a reactive controlled pressure system 60, and an electronic control for engaging and disengaging the controlled pressure system 70. The nonarticulated snow plow system 10 further includes a moldboard 100 and an A-frame 14 for supporting and connecting the components of the nonarticulated snow plow system 10.
The nonarticulated snow plow system 10 is connected to the frame of the vehicle 11 with mounting system 40. Referring to FIGS. 2 and 12 the nonarticulated snow plow system 10 may be seen to be connected to the vehicle 11 by a mounting subframe 12 that is fixedly connected to the frame of the vehicle 11.
The mounting system 40 is integral to the A-frame 14 as shown in FIG. 1. The subframe 12 has mounting points 16-18 having openings 50-52 as shown in FIG. 12. The mounting system 40 has three mounting points 41-43, having openings 44-46, and three mounting pins 47-49. Mounting points 16-18 of the subframe 12 correspond to mounting points 41-43 of the mounting system 40 so that openings 50-52 align respectively with openings 44-46. Pins 47-49 pass through the aligned openings 50-52 and 44-46. Locking pins 53-55 are respectively used to hold the pins 41-43 in place in the openings 50-52 and 44-46 during operation of the vehicle 11. In this manner the nonarticulated snow plow system 10 of the present invention is quickly and easily mounted to the vehicle 11 so that there is a rigid and fixed connection between the vehicle 11 and the nonarticulated snow plow system 10 through the mounting subframe 12 which is attached to the frame of the vehicle 11.
Referring now to FIGS. 1, 2, and 4 the lighting system 20 may be seen to comprise a set of high intensity light road lights 22 mounted to a support frame 24. Any type of lights 22 providing sufficient illumination could be used. The lights 22 are powered from the vehicle 11 in a known manner. The support frame 24 has two mounting points 25-26 having openings 28-29. As specifically shown in FIGS. 1 and 2 the mounting points 25-26 line up with the mounting points 41 and 42 of the mounting system 40. Accordingly, the support frame 24 is fixedly and rigidly mounted to the subframe 12 by the same mounting system 40 as is the rest of the nonarticulated snow plow system 10 by the pins 47 and 48 of the mounting system 40. In this manner the lighting system 20 is rigidly and fixedly mounted to the vehicle 11 with the lights 22 positioned to shine over the top edge 102 of the moldboard 100 and at the same time being set off from the body of the vehicle 11 to minimize any obstructions to the vehicle operator's field of vision.
Further, referring specifically to FIG. 2, the support frame 24 may be seen to include two posts 36 that are telescopically adjustable to move the lights 22 vertically up or down with respect to the plow system 10. A plurality of openings 37 extend up and down the sides of the posts 36. Once the proper height for the lights 22 has been determined the openings 37 in the telescoping posts 36 are aligned with openings 39 in support frame 24 and bolts 38 are passed through the openings 37 and 39. Each bolt 38 is secured by using a nut. This holds the lights 22 in the vertical position desired. Accordingly, the lighting system 20 of the present invention may be easily adjusted to the needs of the individual vehicle operator and in order to obtain maximum illumination of the area in front of the vehicle regardless of the snow plow position.
Referring to FIGS. 1-3 and 5-12 the reactive controlled pressure system 60 may be seen to comprise an electrical control unit 70, a hydraulic control/power unit 80, and a hydraulic cylinder linkage 90. As can be seen in FIG. 2, hydraulic cylinder linkage 90 includes a bell crank 95 to aid in the effective transference of weight or force from the mass of the vehicle 11 to the bottom edge 101 of the moldboard 100. While a bell crank 95 is the means of mechanical linkage disclosed, it is not the only possible means for accomplishing the same function.
The electrical control unit 70 is shown schematically in FIGS. 5-8. The electrical control unit 70 operates off the battery power of the vehicle 11 and is energized when the vehicle ignition key is turned to the accessory setting or when the engine of the vehicle 11 is running. The electrical control wiring harness 65 includes a plug 66 and a receptacle 67 that can be separated when the snow plow system 10 is removed from vehicle 11. As shown in FIGS. 5-8, the electrical control unit 70 has two switches 61 and 62 that control the hydraulic lift and reactive pressure control unit 80.
The hydraulic control/power unit 80 is connected to the reactive controlled pressure mechanism or hydraulic cylinder 91 by hoses 81 and 82. The hydraulic control unit 80 supplies non-compressible fluid, hydraulic oil, to the cylinder 91. Hydraulic cylinder linkage 90, a bell crank, is connected to hydraulic cylinder 91. The hydraulic control/power unit 80 is located in cradle 80a, best seen in FIGS. 18 and 18a, and is positioned to be forward and of the vehicle to which the present invention is mounted. This removes effective weight from the vehicle and to the wearstrip of the plow as well as aiding in maintaining the vehicle's center of gravity, as designed in the vehicle by the vehicle manufacturer.
The reactive constant pressure system works as follows:
To raise the plow moldboard 100 the operator actuates switch 61 as shown in FIG. 7 to the up position. Now referring to FIG. 11, the four way valve 110 and the two way valve 111 are de-energized. The switch 62 can be in either position when the switch 61 energizes the pump 112, valve 111 blocks the flow to the reservoir 120. This causes the oil to flow into valve 110 from port 3 and out of valve 110 through port 2 into the rod end 92 of the cylinder 91. This lifts the plow moldboard 100. The opposite end of the cylinder 91 is open to the reservoir 120 through ports 4 to 1. When the cylinder 91 is completely extended the pump 112 is turned off by releasing the control switch 61.
To hold the plow moldboard 100 in a raised position for transport, the switch 61 is held in a neutral position and the switch 62 can be in either position as shown in FIG. 8. This position de-energizes the pump 112 and the valves 110 and 111. Valve 111 blocks oil flow to the reservoir so that the raised position of the plow is maintained. See FIG. 11.
To float the plow moldboard 100 so that it is in the down position but has no down pressure on it, the control switch 61 is depressed to the down position and control switch 62 is depressed to the float position. See FIG. 5. Referring to FIG. 9, this energizes valve 111 and de-energizes valve 110. Energizing valve 111 opens the rod end 92 of the cylinder 91 to the reservoir 120. Thus both ends of the cylinder 91 are connected to the reservoir 120 and the moldboard 100 will float.
To apply a predetermined down pressure to the plow moldboard 100, the control switch 61 is depressed to the down position and control switch 62 is depressed to the pressure position as shown in FIG. 6. This energizes the four way valve 110 and connects a pressure switch 121 to the pump activating circuit as shown in FIG. 10. Energizing valve 110 reverses the flow of oil from the pump 112 to the opposite end 93 of the cylinder 91 putting a predetermined amount of pressure upon the bottom edge 101 of the plow moldboard 100.
When the pressure on the piston 94 of the hydraulic cylinder 91 reaches the predetermined pressure that has been set, the pressure switch 121 activates and opens the circuit stopping the pump 112. The check valve 130 in the line prior to valve 110 retains the oil in the piston 94 so that the there is a controlled predetermined pressure maintained on the bottom edge 101 of the moldboard 100.
If the bottom edge 101 of the moldboard 100 rises, e.g. due to a change in road surface, sufficient to increase the pressure within the cylinder 91 beyond a predetermined high pressure setting, then the relief valve 122 opens and oil is allowed to flow back into the reservoir 120 until the pressure in the cylinder 91 drops down to below the predetermined high pressure setting.
Once the situation causing the high pressure abates, the pressure can drop down to a predetermined low pressure setting when the bottom edge 101 of the moldboard returns to a normal plowing position. At this predetermined low pressure the pressure switch 121 again activates the pump 112 and oil is pumped from the reservoir 120 into the cylinder 91 until the predetermined nominal pressure is again reached.
It should be noted that is not necessary for there to be a pressure increase before there is a pressure drop. If the plow moldboard 100 drops into a depression on the surface being plowed, the oil pressure in the cylinder 91 could drop below the predetermined minimum setting. This drop would also be sensed by the pressure switch 121 and cause activation of the pump 112 to increase the pressure in the cylinder 91 back up the predetermined nominal pressure setting.
Furthermore, it should be noted that the plow moldboard 100 can be raised without releasing control switch 62 from the pressure position. By merely depressing control switch 61 to the up position, the plow moldboard 100 is lifted without disengaging the down pressure system. When the moldboard 100 is subsequently lowered, the predetermined downward pressure is again applied to the bottom edge 101 of the plow moldboard 100.
In its specific embodiment the pressure differential is set so that the difference between the highest internal pressure in the cylinder 91 and the lowest internal pressure will allow the plow moldboard 100 to follow the surface contour of the road over small variations without activating the pump 112 or relief valve 122 and yet react to maintain a nearly constantly controlled pressure upon the bottom edge 101 of the plow moldboard 100.
In the preferred embodiment, the nominal pressure setting is 500 psi, the low pressure setting is 450 psi, and the high pressure setting is 600 psi. It is to be understood, however, that different pressure settings can be used to obtain the optimum weight transfer if this system is used with heavier or lighter weight snow plow or if the geometry of the lift mechanism is changed.
Referring now to FIGS. 13-26, it may be seen how the above noted innovations, as well as other novel concepts, may be combined with an articulated plow system 500.
Referring to FIG. 13, the hydraulic control unit or system 80 may be seen to be modified from the hydraulic control system 80 previously discussed in FIGS. 9-11. As may be seen FIG. 13, the hydraulic control unit 80 for the articulated plow system 500 now further includes, in addition to the structures disclosed in FIGS. 9-11, a left angle cylinder 220, a right angle cylinder 221, 1600 psi pressure switches 222 and 223, four 1500 pound per square inch (psi) crossover relief solenoid valves 224-227, two 2000 psi reservoir dump valves 222a and 223a, a left angle cylinder extension solenoid 228, a left angle cylinder retract solenoid 230, a right angle cylinder extension solenoid 229, a right angle cylinder retract solenoid 231, a 1750 psi system relief solenoid valve 232 (previously disclosed in FIGS. 9-11), and an intake filter 240 (previously disclosed in FIGS. 8-10).
Referring now to FIG. 14, a wiring schematic for the articulated plow system 500 may be seen. As may be understood by reference to FIGS. 5-8 the wiring schematic for the electrical control unit 70 has been modified to provide for the desired unique functions of the articulated plow system 500.
The electrical control unit 70 for the articulated plow system 500 includes an ignition 250, a control box 260, a right cylinder extend and retract switch 261 having a toggle 261a and a retract contact 263 and an extend contact 265, a left cylinder extend and retract switch 262 having a toggle 262a and a retract contact 264 and an extend contact 266, a left cylinder pressure switch 222, a right cylinder pressure switch 223, a system indicator light 251, the vehicle battery 252, the vehicle ground 253, a hydraulic power unit ground 254, and a hydraulic power unit 255. Further, it should be noted that switch 61 has a plow down position contact 61a, a toggle 61b, and a plow up contact 61c. Switch 62 has a down pressure engagement contact 62a, a toggle 62b, and plow down and float contact 62c.
Referring now to FIGS. 15-17, a unique combination of the articulated plow system 500 with a mounting system for mounting the moldboard 100 may be seen. The combination may be seen to be comprised of the moldboard 100 having a top edge 102 and a bottom edge 101, a retainer strip 180, a wearstrip 182 having a bottom edge 181, a channel 190, a blade frame 184 having an upper edge 195 and a lower edge 194, bolts 186 and 188, nut 187, slot 189, and ribs 183. Each section 300, 350, and 400 of the articulated plow system 500 is collectively identified in FIGS. 15-17 by blade section 185 since this mounting system may be used individually on each respective section 300,350, or 400 of the articulated plow system 500. Reference number 185a indicates the lower edge of each plow blade section 185. However, it should be noted that in the presently proposed commercial embodiment of the present invention 10 only sections 300 and 400 are envisioned to use the above noted mounting system.
Referring specifically to FIG. 15, the retaining system works by sliding the moldboard 100 into the channel 190 and then placing retainer strip 180 over the top edge 102 of the moldboard 100 by mounting it to the upper edge 195 of the blade frame 184 with the bolt 188. Alternatively, the moldboard 100 may be retained by sliding the moldboard 100 into the channel 190, as noted above, but providing slots or openings 189 along the top edge 102 of the moldboard 100 through which the retaining bolt 188 may pass directly into the upper edge 195 of the blade frame 184.
Referring to FIG. 16, the channel or gap 190 presented between the lower edge 194 of the blade frame 184 and the wearstrip 182 may be seen. This mounting system presents a unique mounting structure for mounting a moldboard 100 to an articulated plow system 500. It allows a person using the plow system 500 to easily replace a moldboard 100 on any section 185 of the plow system 500 or to even stack moldboards 100, if desired, on the plow system 500.
Referring now FIGS. 1,2, 18, 18A, and 21 the bell crank lift system used in combination with the present invention may be seen. The bell crank lift system is specifically disclosed in FIGS. 18 and 18A but reference should also be made to FIGS. 1,2, and 21 to understand the relationship of the various parts of the bell crank lift system as disclosed herein.
The bell crank lift system of the articulated snow plow system 500 is coupled between the front of the vehicle (not shown), at the subframe 12, and a forward portion of the A-frame 14 to permit vertical adjustment of the mounting plowblade section 400 and the extending plowblade sections 300 and 350. A cylinder 91 has a piston rod 774 The cylinder 91 is coupled at an end 773 to end 773c of bell crank 95 and at end 775 to the A-frame 14 for moving the bell crank 95 to cause vertical adjustment of the articulated plow system 500 of the present invention. Hydraulic fluid for extending and retracting the piston rod 774 is supplied to the cylinder 91 through hoses 81 and 82, shown best in FIG. 2. The bell crank lift system of the present invention further includes a first link 787 which is coupled, at point 43, to the vehicle subframe 12. First link 787 is also coupled to a second generally L-shaped link member 95, having end 773b, end 773c, and corner structure 773a, at end 773b. First link 787 being pivotally coupled to L-shaped link member 95 at end 773b. End 773c, as noted above, is pivotally coupled to the cylinder 91 at end 773. The angular corner 773a of the L-shaped linkage 95 is pivotally coupled to a bell crank coupling bracket structure 775 at corner 773a. Accordingly, hydraulic fluid may be added to or removed from the cylinder 91 through hoses 81 and 82 in order to raise or lower the A-frame 14 and the plow system 500 is response to the conditions presented.
Referring now to FIG. 19 an exploded schematic view of the hydraulic system of the articulated snow plow system 500 may be seen. FIG. 19 shows that the hydraulic system includes right cylinder retraction line 304, left cylinder retraction line 354, right cylinder extension line 306A and 306, left cylinder extension line 356A and 356, pump line 308 to pressure switch 223, pump line 358 to pressure switch 222, right wing cylinder 302, left wing cylinder 352, pump line 360 to the down pressure valve block 362, drain line 364 to reservoir 120, hydraulic line 81 to cylinder 91 for providing hydraulic fluid to extend cylinder 91, and hydraulic line 82 to cylinder 91 for providing hydraulic fluid to retract cylinder 91. Further, 2000 psi relief valves 222A and 223A are provided between lines 356A, 356 and 306A, 306, respectively. Lines 356A,356 and 306A,306 each respectively and effectively operate as one contiguous hydraulic line, however, when there is a substantial pressure within the hydraulic system (in the specific embodiment disclosed herein the specific pressure is in excess of 2000 psi) either or both relief valves 222A and 223A will open to line 357A which is connected to hydraulic line 357. This will dump excess hydraulic fluid into the system reservoir 120 and relieve the excess pressure within the system.
Referring now to FIGS. 20, 20A, and 21, blade center section 400 may be seen to include pivot 402, spring mounting plate 424 having opening 424a, left hinge set 430, right hinge set 432, right cylinder coupling 436, and left cylinder coupling 435. Intermediate pivot assembly 450 may be seen to comprise pivot 402a, pivot 404, rubber torsion bushing 406, mounting plate 415 having openings 415a. Also springs 410 with hooks 420 and 422, adjustment bolts 412, adjusting nuts 414 and 416, mounting plate 418 (integral to bolt 412) having opening 418a may also be seen as well as the front portion of A-frame 14 with pivots 404a and the noted gaps 408 between A-frame 14 and intermediate pivot assembly 450.
Springs 410 are mounted on hooks 420 and 422 and extend from mounting plate 424 to mounting plate 418. Mount plate 418 is integral to bolt 412. Tension on springs 410 can be adjusted by use of adjusting nuts 414 and 416 which secure bolt 412 in opening 415a of mounting plate 415. Accordingly, pivot 402 allows the center section 400 to pivot when the articulated plow 500 trips and spring 410 and its mounts will bias the center section 400 back to operating position.
Additionally, pivot 404 of intermediate pivot assembly 450 acts as an intermediate pivot between the center section 400 and the A-frame 14 which allows a few degrees of motion about a horizontal axis defined by the pivot 404 and 404a to permit, in combination with gap 408, a limited amount of float, roughly 5-6 degrees, which allows the articulated plowblade sections 300 and 350 and the blade center section 400 to follow the contour of the ground and also allows for some variation in the mounting height of the vehicle mounting points, rubber torsion bushings 406 provide some resistance to float and reduce the probability of unnecessary motion of the plowblade sections 300, 350, and 400.
Referring now to FIGS. 21-26, the articulated snow plow system 500 may be seen to generally comprise a center section 400 hingedly mounted to a right wing plowblade section 300 and a left wing plow blade 350 by hinges 432 and 430, respectively. As these drawings clearly show the center section of the system 500 has two pivots at hinges 432 and 430 instead of one pivot as shown in the prior art.
The center section 400 right wing section 300, and left wing section 350 each include a wearstrip 182. Referring to FIG. 23, it may be seen that the wearstrip 182 of the center section 400 has side portions 182a and 182c which respectively overlap end portions 182b and 182d of the wearstrips 182 of the right wing 300 and the left wing 350. Accordingly, the overlapping wearstrips 182 give complete coverage of the ground surface in front of the plow system 500. No gaps are presented so there is no missed coverage and/or strips of snow remaining on the ground surface.
As illustrated in FIGS. 21-26, the wearstrip 182 of the center section 400 is positioned forward of the wearstrips 182 of the left and right plowblade sections 300 and 350. This allows the wearstrips 182 of the plowblade sections 300 and 350 to move without presenting gaps. Also, it is preferred, but not necessary, that the wearstrip 182 of the center section 400 be positioned at a shallower angle, roughly 45 degrees from vertical, than the wearstrips 182 of plowblade sections 300 and 350, which are positioned approximately 25 degrees from vertical, to permit better lifting of hard packed snow at the center section 400. Consequently, in a swept back position, as illustrated in FIG. 25, there would be greater mechanical advantage given to the center section in making the initial contact with the snow or other material to be plowed.
With respect to the actuation of the down pressure system with respect to the articulated plow system 500, the down pressure system is actuated in the same manner as described with respect to FIGS. 1-11 supra. Further, the lifting of the plow system 500 is the same as described with respect to the plow system disclosed in FIGS. 1-11. However, the present plow system 500 also has a pressure sensing ability to permit blade tripping when in the scoop position, as shown in FIG. 24, or when in the system 500 is fully angled in a particular direction as illustrated in FIG. 26.
When one or both wings 300 or 350 are swept forward and in that position strike an object the force from striking the object increases the pressure on the cylinder of the respective wing struck. This results in increased hydraulic pressure in the particular cylinder and hydraulic line on the extend side 228 or 229 (see FIG. 13). When this pressure exceeds 1600 psi (this value may vary depending upon the size and type of system that is used to achieve the desired function) in pressure the contacts of the respective pressure switch, 222 and/or 223 close. This completes the circuit illustrated in FIG. 14 to the two solenoid valves 228 and 229 which allows the hydraulic fluid to be dumped into the reservoir 120. This causes the wings 300 and 350 to be retracted to more straight position like those shown in FIGS. 22 and 23. In this position the normal mechanical tripping action can occur.
Additionally, this allow a wing 300 or 350 to react to the striking an object by pulling away from that object with a movement that is opposite to the forward motion of the vehicle. This allows some relief from the force of the object struck by the wing. This feature can be used on a plow having a single pivot point as well as the plow system 500 disclosed herein.
The above described embodiments of this invention are merely descriptive of its principles and are not to be limited. The scope of this invention instead shall be determined from the scope of the following claims, including their equivalents. | An articulated snow plow system for use with a vehicle includes a blade center section having a moldboard section and left and right extending plowblade sections which are wider than the blade center section. The extending plowblade sections each include a moldboard section and are mounted to the blade center section at opposite sides thereof and pivotable relative to the center blade section about a substantially vertical pivot axis, to swept forward and swept backward positions. The snowplow assembly includes a support frame, the blade center section being coupled to the support frame through an intermediate pivot assembly which permits a limited amount of float to allow the blade center section, and the extending plowblade sections pivoted thereto, to follow the contour of the ground. Pressure sensors associated with hydraulic cylinders which move the extending plowblade sections between extended and retracted position, respond to pressure within the hydraulic cylinder for the associated extending plowblade section exceeding a trip point to cause both of the extending plowblade sections to be retracted to a more straight position. | 4 |
FIELD OF THE INVENTION
The present invention relates to the field of strip doors used primarily for providing a flexible barrier across entry and exit openings in commercial and industrial facilities and equipment.
BACKGROUND OF THE INVENTION
Vertically hanging plastic strips arranged side-by-side, or in an overlapping arrangement, are used in many industrial and commercial applications to provide a flexible barrier to air, insects, noise, vapors, moisture, etc. A strip door system, which provides such barrier, only minimally disrupts the passage of product, personnel or vehicles through a doorway, or the like, as the vertically hanging plastic strips are easily bent to provide an opening for entry or exit. An important application for strip door systems, which provide a significant savings in energy consumption, is on openings into freezers and coolers in warehouse facilities, food processing areas, restaurants, etc.
Strip door systems are typically assembled by hanging a plurality of flexible plastic strips, having a width of 8-16 inches and a thickness of 0.060 to 0.160 inches, which are produced from PVC material. The strips typically are hung to span a vertically oriented plane, such as between side jams of a doorway. The strips typically have an overlap of 25-100%, for example, for a 50% overlap, on a given strip, 25% of its width, at each edge, would be overlapped with an adjacent strip.
The vertically hanging strips are usually hung from a uniformity spaced series of studs disposed at or near a header of a doorway. The studs are most often fixed to a plate, or the like, to form a hanger, and the hanger is attached to the header or a wall above the doorway. Many different hangers are known for hanging the plastic strips.
FIG. 1 shows a known flexible strip door system for describing a general configuration of a strip door system in which a hanger of the present invention would be used. In FIG. 1 , an opening 1 in wall 2 is provided with a flexible plastic strip door 3 having elongated flexible plastic strips 4 arranged in an overlapping pattern with areas of overlapping indicated at 5 . The strips 4 are hung from a hanger 6 having protruding studs 7 arranged in a uniform spacing along the length of the hanger. The plastic strips 4 have uniformily spaced apertures 8 , along an upper portion, which correspond in spacing with the studs 7 of the hanger. The spacing arrangement of the studs and the apertures allow for overlap of 25 to 100%, or no overlap, wherein edges of the strips are placed abutting edges of adjacent strips.
The system depicted in FIG. 1 has an overlap of about 50%, that is 50% of each strip is overlapped by other strips. Although not shown, some type of retaining device is necessary to prevent the strips from sliding off the studs when the strips are encountered by personnel or equipment passing through the opening. In U.S. patent application Ser. No. 10/406,527 entitled “Flexible-Strip Hanger for a Strip Door System and Method of Making Same”, filed Apr. 3, 2003, a hinged cover prevents the plastic strips from sliding off the studs.
Plastic strip door systems, as described above are very durable as they can be subjected to heavy usage by personnel or equipment passing through them. In particular, fork lifts or other commercial and industrial type equipment often subject the plastic strips to harsh usage, including tearing away of the strips, if caught on such equipment or caught on the product being moved. Such harsh usage, as well as normal everyday usage, necessitates the plastic strips being replaced from time to time. Because of the typical locations of the hangers, that is at a location requiring the use of a ladder, and/or at cold or below freezing environments, replacement is often difficult and dangerous, and can require the use of more than one person to carry out the replacement.
One known hanger has spaced studs on a backing plate along with a strip retaining bar, which requires the use of tools to secure the bar in place. Another known hanger, although it requires no tools for installing the strips, relies solely on studs having an enlarged end to prevent the strips from sliding off. In such a system an aperture in the plastic strip, which slides over the stud, must be very accurately formed so as to fit over the stud, yet be retained by the enlarged end. In the same system, a strip having the properly sized aperture can be difficult to slide over the enlarged end, if the material of the strip is at a low temperature in a cooler or freezer application. Many retaining systems are known, however they all have undesirable features.
OBJECTS OF THE INVENTION
It is the object of the present invention to provide a hanger for plastic strips of a strip door system which is of durable construction and configured for convenient initial installation.
It is another object of the present invention to provide a hanger which enables easy replacement of worn or damaged plastic strips, without the use of hand tools.
It is still another object of the present invention to provide a hanger having a positive retaining device to prevent the plastic strips from sliding off the studs, which does not rely solely on an enlarged portion of a stud and the elasticity of the plastic strip.
It is yet a further object of the present invention to provide an adjustable effective stud length to better accommodate plastic strips of various thicknesses arranged to have various amounts of overlap.
SUMMARY OF THE INVENTION
The present invention is a hanger for use in a strip door system for supporting vertically hanging flexible plastic strips, wherein each strip has a row of uniformily spaced apertures along an upper end portion. The hanger has an elongated backing plate portion for attaching the hanger to a structure above an opening, a plurality of uniformily spaced studs fixed along the length of the backing plate, for supporting the plastic strips by engagement through the strip apertures, and an elongated retaining plate for locking with the studs to prevent the engaged strips from sliding off the studs. Each stud has a plurality of locking grooves along its length for locking the retaining plate with the studs so as to provide an adjustable effective stud length between the backing plate and the retaining plate .
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more readily apparent from the following description of preferred embodiments thereof, shown, by way of example only, in the accompanying drawings, wherein:
FIG. 1 is a prior-art strip door system wherein flexible plastic strips having uniformily spaced apertures are supported on a hanger having uniformily spaced protruding studs;
FIGS. 2A and 2B are respectively, a front view and an end view of a backing plate of a first embodiment of the invention;
FIGS. 3A and 3B are respectively, a front view and an end view of a retaining plate of the invention;
FIGS. 4A and 4B are respectively, a front view and an end view of the backing plate of FIGS. 2A and 2B , having the retaining plate of FIGS. 3A and 3B in an engaged position;
FIGS. 5A and 5B are respectively, a front view and an end view of the retaining plate of FIGS. 3A and 3B as disposed when sliding the retaining plate onto studs of the backing plate;
FIGS. 6A and 6B are respectively, a front view and an end view of the hanger of the first embodiment of the invention having flexible plastic strips in place on the hanger;
FIGS. 7A and 7B are respectively, a front view and an edge view of a retaining disc of the invention;
FIGS. 8A and 8B are respectively a front view and an end view of the hanger of the first embodiment of the invention having the flexible plastic strip in place on the hanger and retaining discs in place on studs of the hanger.
FIGS. 9A and 9B are respectively, a front view and an end view of a backing plate of a second embodiment of the invention, for use when mounting the hanger on a header;
FIGS. 10A and 10B are respectively, a front view and an end view of a universal backing plate of a third embodiment of the invention, for either wall or header mounting of the hanger.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 2A and 2B show a front view and an end view, respectively, of an elongated backing plate of the first embodiment of the invention. The three embodiments of the invention, discussed below, are distinct only in the shape of the backing plate which is provided for mounting: 1) on a vertically oriented wall above an opening, 2) on a horizontally oriented header of an opening, and 3) on either a vertically oriented wall or a header of an opening.
The first embodiment, shown in FIGS. 2A and 2B , is for use in mounting on a wall above an opening which is to be provided with a strip door system. Shown is an elongated backing plate 9 of the hanger having apertures 10 for attaching the hanger to a vertically oriented wall above an opening to which the strip door is to be installed. Protruding from a front face 11 of the backing plate are a plurality of uniformily spaced studs 12 for supporting the flexible plastic strips of the strip door system. Apertures provided along a top portion of each strip are slid over the uniformily spaced studs to install the strips on the hanger. The studs, which preferably have a cylindrical shape, feature annularly shaped grooves 13 spaced along the length of each stud. The grooves have a major diameter D which corresponds to the surface of the stud, and a minor diameter d as measured at the base of a groove. To insure a tight attachment to the backing plate, the studs preferably extend through the backing plate 9 and have a head portion 14 which rests against back face 15 of the backing plate. Any known method, such as a press fit, brazing, or the like, can be used to maintain a tight attachment of the studs to the backing plate. Preferably the backing plate includes bent portions, such as at 16 and 17 to give rigidity to the backing plate and to provide a spacing for the head portions 14 of the studs. The hanger can be of any length required to span the opening being addressed.
FIGS. 3A and 3B show an elongated retaining plate 18 of the hanger which prevents the installed flexible plastic strips from sliding off studs 12 . Retaining plate 18 features apertures 19 , having a minor portion 20 , and a major portion 21 which communicate with each other. Apertures 19 have centerlines 22 which correspond in spacing with center lines 23 of the studs of backing plate 9 . The apertures 19 of retaining plate 18 are configured such that the major portion of the aperture is slideable along the length of the studs, and the minor portion is slideable into one of the grooves 13 , but not slideable along the length of the stud. Thus the grooves of the studs act as a locking mechanism for the retaining plate 18 .
FIGS. 4A and 4B show the retaining plate 18 in an engaged position, that is minor portions 20 of the apertures are seated in the grooves 13 of the studs 12 . FIGS. 5A and 5B show retaining plate 18 in a state whereat the major portion 21 of the aperture is being slid over the stud 12 to a position at which the retaining plate 18 is aligned with a groove 13 of the stud, and whereat by solely the force of gravity, the retaining plate 18 becomes locked on the stud 12 by engagement of the minor portion 20 of the aperture with the groove 13 as shown in FIGS. 4A and 4B .
As indicated earlier, a plurality of grooves are disposed along the length of each stud. Such arrangement enables the use of various thicknesses of plastic strips in either an overlapping or non-overlapping side-by-side hanging pattern. FIGS. 6A and 6B show the hanger of the invention having plastic strips 23 hanging from the studs 12 in an overlapping arrangement. As shown in FIG. 6B , having retaining plate 18 in a selected groove 13 of the stud provides an effective stud length, as measured between the backing plate 9 and the retaining plate 18 , such that the strips are prevented from moving backward and forward along the length of the stud. The spacing of the grooves need not be uniform along the length of the stud, however all of the studs of a hanger must have the same groove pattern. As can be seen in FIG. 6B , if thinner or thicker plastic strips are desired, or if no overlap is desired, the various grooves provide for flexibility by enabling an adjustment of the effective length of each stud. The grooves preferably have side walls which are perpendicular to the central axis of the stud, so as to more securely hold the retaining plate. As in the backing plate 9 , a bend 25 is provided in the retaining plate 18 in order to provide rigidity. When the retaining plate is engaged in the grooves 13 of the studs along the length of the hanger, normal passage through the strip door will not cause disengagement.
As an added safety feature, a retaining disc, 26 , as shown in FIGS. 7A and 7B can be used with the backing plate 9 and the retaining plate 18 . Referring to FIGS. 8A and 8B , the retaining disc 26 is shown as disposed on stud 12 . The retaining disc 26 is fabricated of a material having elasticity, yet some stiffness, in order that an aperture 27 formed in the retaining disc can be slid over a stud and be retained by elastic forces in a groove of the stud, that is one of the same grooves used for the retaining plate 18 . Preferably the aperture 27 is formed to have a diameter corresponding to the diameter d of the base of the groove. The disc is positioned on the stud, extending downward to contact a ridge 29 along a bottom portion of the retaining plate as shown in FIGS. 8A and 8B . Preferably the disc 26 has a thickness approximately equal to a width of the grooves to assure that the disc hangs vertically downward without a clearance between the disc and the groove with would enable easy movement of the disc away from its preferred vertical orientation. The disc 26 is placed in the groove which is adjacent to the groove occupied by the retaining plate. Also, in order to facilitate use of the retaining disc, a tab 28 extending from the body of the disc, is provided. In use of the invention, at least one of the retaining discs is used to assure that the retaining plate, due to an occurrence other than normal use of the strip door, does not move upwardly so as to become disengaged from the studs. The elimination of upwardly movement is assured by the disc 26 making contact with the ridge 29 .
FIGS. 9A and 9B show a front view and an end view respectively of a second embodiment of the invention for use in mounting a hanger to a horizontally oriented header of a doorway, for example. Shown in FIGS. 9A and 9B is backing plate 30 having a portion 31 , which is oriented horizontally when installed, which can be attached to a horizontally oriented surface for installation. Apertures 32 are provided to facilitate the installation. In the second embodiment, shown in FIGS. 9A and 9B all remaining features and operation are as described in the description of the first embodiment.
FIGS. 10A and 10B show a front view and an end view respectively of a third embodiment of the invention, which can be used for mounting the backing plate 33 to either a horizontally or vertically oriented surface. The backing plate 33 provides apertures 34 in portion 35 and web 36 of the backing plate 33 . In the third embodiment, shown in FIGS. 10A and 10B , all remaining features and operation are as described in the description of the first embodiment.
In all of the embodiments of the invention, because of the typically moist environment of the installation, galvanized steel or stainless steel is the preferred material for the components, however other materials are available in practice of the invention. The backing plate and retaining plate are preferably formed of 10 to 20 gauge sheet material. The studs preferably have a diameter of ¼-⅜ inches and a length of ¾-1¼ inches. The depth of the grooves is preferably about 0.07 inch.
While specific materials, dimensional data, etc. have been set forth for purposes of describing embodiments of the invention, various modifications can be resorted to, in light of the above teachings, without departing from Applicant's novel contributions; therefore in determining the scope of the present invention, reference shall be made to the appended claims. | A hanger for plastic strips having uniformity spaced apertures along an end portion thereof, to form a strip door across an opening. Uniformily spaced studs are provided on a mountable backing plate to support the plastic strips. A retaining plate retains the strips on the studs which have locking means along the length thereof, so as to provide an adjustable effective length for each of the studs. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional application 61/839,174 (Attorney Docket No. 44832-703.201), filed on Jun. 25, 2013, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to medical devices and methods and more particularly to the endoscopic treatment of obesity.
[0004] Obesity is one of the leading preventable causes of death worldwide and has become a global epidemic affecting more than 400 million people. In the United States alone, approximately 300,000 obesity-linked deaths occur annually, and obesity-related co-morbidities lead to nearly $150 billion in healthcare spending. Obesity is a medical condition associated with many subsequent diseases, including type-2 diabetes, cardiovascular disease, sleep apnea and certain types of cancer. These conditions often have severe adverse effects on overall health, reduce quality of life, limit productivity, lead to significant medical costs, and can ultimately lead to reduced life expectancy.
[0005] The primary treatment for obesity is dieting, routine physical exercise, and in some cases pharmacologic therapy. Obesity surgery, including gastric bypass laparoscopic banding, involves surgical restriction of the stomach to reduce the caloric intake of the patient by triggering the satiety impulse more rapidly, physically remove the ability of the individual to ingest more than a limited amount of food, and/or inhibit the ability of the individual's digestive system to extract the full caloric value of the food being eaten.
[0006] Such surgical treatments for obesity, although often effective in achieving sustainable weight loss, involve gross anatomical reconstruction of the digestive system, which may be irreversible. Unfortunately, such surgeries can cause significant adverse events, complications, and/or mortality. Thus, there is a growing need for effective and safe alternatives to obesity surgery for the obese patient population worldwide.
[0007] Type 2 diabetes is a disorder that is characterized by high blood glucose resulting from insulin resistance and relative insulin deficiency. There are approximately 30 million diabetics in the U.S., 90% of whom are type-2. Traditionally considered a disease of adults, type 2 diabetes is increasingly diagnosed in children in parallel to rising obesity rates due to alterations in dietary patterns as well as in life styles during childhood.
[0008] Type 2 diabetes is a chronic, progressive disease that has no established cure, but does have well-established treatments which can delay or mitigate the inevitable consequences of the condition. Type 2 diabetes is initially treated by adjustments in diet and exercise, and by weight loss, most especially in obese patients.
[0009] Endoscopic and other minimally invasive procedures have been proposed for treating both obesity and type-2 diabetes. For example, gastric balloons may be implanted for extended periods of time and can reduce patient appetite leading to weight loss. Alternatively, duodenal sleeves may be placed in the upper duodenum to reduce nutrient uptake, also leading to weight loss and possibly having a more direct impact on blood sugar levels and diabetes.
[0010] While very promising, the use of both gastric balloons and duodenal sleeves is limited by the difficulty of anchoring the one or more balloon(s) and/or the sleeve within the target anatomy. In particular, it is very difficult to staple or otherwise attach one or more balloon(s) within the stomach. Introduction and removal of both gastric balloons and duodenal sleeves can also be problematic.
[0011] For these reasons, it would be desirable to provide improved gastric balloon and/or duodenal sleeve anchoring systems and methods for their deployment. It would be particularly desirable to provide improved anchors capable of stably maintaining one or more gastric balloon(s) and/or a duodenal sleeve in the stomach and/or duodenum for extended periods of time. Such anchoring systems should be compatible with a variety or endoscopic introduction and removal systems and should preferably be capable of introduction in a low profile configuration where they self-expand to a deployed configuration when released in the stomach and/or duodenum. The following inventions will meet at least some of these objectives.
[0012] 2. Description of the Background Art
[0013] Devices which anchor in or around the pyloric valve are described in U.S. Pat. No. 4,878,905; U.S. Pat. No. 8,147,561; U.S. Pat. No. 8,403,877; US 2011/0066175; and US 2012/0095385.
SUMMARY OF THE INVENTION
[0014] In a first aspect of the present invention, a suprapyloric anchor assembly comprises an antral cap having at least three stabilizing members configured to reside in an antrum and engage tissue circumscribing a pyloric valve. A duodenal member is configured to reside at least partially in a duodenal bulb, and one or more tethers connect the antral cap to the duodenal member. The tether(s) is/are configured to allow passage of stomach contents through the pyloric valve.
[0015] In specific aspects of the assembly, the antral cap comprises a collar with a central passage, and the stabilizing members comprise elongate legs joined to the collar at their proximal ends. The elongate legs preferably have atraumatic distal ends which engage the tissue circumscribing the pyloric valve when the legs are deployed radially outwardly. Typically, the legs are spring-mounted (self-opening) at their proximal ends to the collar so that the legs may be radially constrained to have a reduced collective diameter to facilitate introduction and may be released from constraint to assume a deployed (radially outward relative to a center axis of the anchor) configuration where the atraumatic distal ends are spaced-apart from each other. In still further specific aspects, the duodenal member may comprise a funnel section configured to reside in the duodenal bulb and a cylindrical sleeve membrane configured to reside in the duodenum below the duodenal bulb. Specific system configurations may further comprise one or more gastric balloon(s) connectable to the antral cap.
[0016] In a second aspect of the present invention, a method for deploying a suprapyloric anchor comprises providing a suprapyloric anchor including an antral cap connected to a duodenal member by one or more tethers. The suprapyloric anchor is endoscopically introduced with three constrained stabilizing members. The duodenal member is positioned in a duodenal bulb with the tethers passing through a pyloric valve. The duodenal member is released in a duodenal bulb with the tethers passing through a pyloric valve. The expanded stabilizing members are engaged against tissue circumscribing the pyloric valve such that the duodenal member is tensioned to hold the stabilizing members against the circumscribing tissue.
[0017] In specific aspects of the method, one or more gastric balloon(s) attached to the suprapyloric anchor is inflated with the gastric cavity (stomach). Optionally, a duodenal sleeve attached to the suprapyloric anchor may be deployed in the duodenum. The one or more gastric balloon(s) act to decrease the effective volume of the stomach to induce a feeling of satiety in the patient, and the duodenal sleeve acts to reduce the absorption of nutrients to decrease caloric intake by the patient. In the exemplary embodiments, the suprapyloric anchor is endoscopically introduced, typically while located coaxially over an endoscope. The anchor and endoscope will usually be passed through an overtube which has been transesophageally introduced into the gastric cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 A and 1 AA illustrate a first exemplary embodiment of a suprapyloric anchor assembly constructed in accordance with the principles of the present invention.
[0019] FIGS. 1 B and 1 BB illustrate a second exemplary embodiment of a suprapyloric anchor assembly constructed in accordance with the principles of the present invention.
[0020] FIGS. 2A and 2B illustrate the deployment of a tripod anchor of the suprapyloric anchor assembly in accordance with the principles of the present invention.
[0021] FIGS. 3A and 3B illustrate full deployment of the suprapyloric anchor assembly including an antral anchor, a bulb funnel, a duodenal membrane, and uninflated gastric balloons in accordance with the principles of the present invention.
[0022] FIG. 4 illustrates inflation of the gastric balloons in accordance with the principles of the present invention.
[0023] FIG. 5 is a detailed view of the end of a membrane and elastic release elastic ring.
[0024] FIG. 6 illustrates preparation for balloon removal.
[0025] FIG. 7 illustrates removal of the balloon system using a gastroscope.
[0026] FIG. 8 illustrates further removal of the antral anchor, the bulb funnel, and the duodenal membrane.
[0027] FIG. 9 illustrates final removal progression of the the antral anchor, the bulb funnel, and the duodenal membrane as the scope is withdrawn.
[0028] FIGS. 10A through 10D illustrate a further exemplary embodiment of a suprapyloric anchor assembly having constrained tethers constructed in accordance with the principles of the present invention.
[0029] FIGS. 11A through 11D further illustrate the constrained tethers of FIGS. 10A through 10D .
[0030] FIGS. 12A and 12B illustrate a further exemplary embodiment of a tripod base of a suprapyloric anchor assembly having self-adjusting struts constructed in accordance with the principles of the present invention.
[0031] FIGS. 13A and 13B illustrate a further exemplary embodiment of a tripod base of a suprapyloric anchor assembly having gel-pad feet constructed in accordance with the principles of the present invention.
[0032] These and other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The following reference numbers are used herein: 10-gastroscope; 12-duodenal impermeable membrane; 13-elastic retention ring; 14-elastic ring string; 15-forceps (via scope); 16-overtube; 17-bulb funnel; 18-duodenal straps/tethers; 19-anchor legs (tripod); 20-antral anchor cap; 21-balloon cap; 22-superior balloon inflation valve; 23-superior balloon inflation chamber/tube; 14-catheter (via scope); 25-inferior balloon valve; 26-inferior balloon inflation chamber/tube; 27-balloon cap swivel joint; 28-balloon cap disengagement port; 29-balloon support w/inflation chambers; 30-inferior balloon; 31-inferior balloon inflation port; 32-superior balloon chamber; 33-superior balloon; 34-superior balloon port; 35-antral anchor foot base; 36-silicone gel pads; 37-flexible antral foot joint; 38-catheter (via scope); 39-endoscopic balloon (inflated); 40-duodenum; 31-duodenal bulb; 32-pylorus; 33-pre-pyloric stomach region; 34-gastric antrum; 35-gastric angularis; 46-gastric lesser curve; 47-gastric cardia; 48-gastric fundus; 49-gastric greater curve; 50-lower esophageal sphincter; 51-esophagus (distal); 62-small bowel barrier/membrane wrap (removable); 63-small bowel barrier/membrane (compressed and contained within overlying wrap); 63a-small bowel barrier/membrane (released by removing/pulling out the wrap); 63b-small bowel barrier/membrane (spontaneously opening); 63c-small bowel barrier/membrane (further spontaneous and propulsive extension); 64-duodenal bulb barrier/membrane funnel (released within the duodenal bulb); 65-elastic binding ring (unbound); 65b-elastic binding ring (bound); 66-silicone gel footpad; 66a-silicone gel footpad (non-compressed); 66b-silicone gel footpad (compressed); 67-strap/tether attached to the inner diameter of the bulb funnel ( 64 ); 68-inner tube which allows gastroscope ( 1 ) to pass; 69-outer tube which compresses antral anchor components; 70-antal anchor cap; 71-balloon cap; 72-anchor leg (a tripod leg); 73-balloon (one or more balloons may be used); 74-pyloric sphincter; 76-compressible antral anchor lower leg; and 77-compression spring.
[0034] FIGS. 1 A and 1 AA illustrate the device components contained within a delivery overtube ( 16 ). A standard adult gastroscope ( 10 ) is preloaded by traversing the core of the system. A duodenal impermeable membrane ( 12 ) is bunched up at the end of the scope held on the scope tip by an elastic retention ring ( 13 ) to prevent premature deployment. A standard gastroscope forceps ( 15 ) grasps an elastic ring string ( 14 ) for later release.
[0035] FIGS. 1 B and 1 BB illustrate a system similar to that of FIGS. 1 A and 1 AA with a bulb funnel ( 17 ) positioned over the distal end of the overtube ( 16 ) rather than inside of the distal end of the overtube 1 ( 6 ).
[0036] FIGS. 2A and 2B illustrate release of a bariatric component as the overtube ( 16 ) is retracted. The gastroscope ( 10 ) allows the operator to visually observe the deployment. Three duodenal straps ( 18 ) are each attached at one end to the bottom of an antral anchor ( 21 ) and at the other end to a junction between the membrane ( 12 ) and the bulb funnel ( 17 ). An anchor comprises three anchor legs ( 19 ) (forming a tripod) each of which is attached to a foot base ( 35 ) by a flexible or pivotable joint ( 37 ). The foot bases ( 35 ) may comprise silicone gel pads ( 36 ) to provide atraumatic contact to the stomach surface. As illustrated in FIGS. 2A and 2B , the tripod legs have expanded to their unconstrained configuration once the overtube ( 16 ) has been retracted, releasing them from their constrained configurations. It may in some cases be preferable to preload the bulb funnel ( 17 ) outside the overtube ( 16 ).
[0037] FIGS. 3A and 3B illustrates full release of the bariatric components. Two uninflated balloons ( 30 and 33 ) are in the process of being inflated via a scope catheter ( 24 ) inserted into a superior balloon port ( 22 ). An inferior balloon port ( 25 ) is located opposite to the superior balloon port on the rim of balloon cap ( 21 ). The balloons may be filled with either air or water, and inflation can be adjusted to add or remove volume. A balloon cap disengagement port ( 28 ) can be depressed with a catheter to either remove or replace the balloons. The balloon cap can rotate or swivel via a joint ( 27 ) between the antral anchor cap ( 20 ) and balloon cap ( 21 ).
[0038] FIG. 4 illustrates full deployment and removal of the delivery system. The superior balloon ( 33 ) is inflatable to 7-9 cm diameter (180-382 cc volume) and the inferior balloon ( 30 ) is expandable to 8-10 cm dia. (268-523 cc vol.). The duodenal membrane ( 12 ) is 60 cm in length.
[0039] FIG. 5 illustrates the detail of the end of the duodenal membrane ( 12 ) which may be formed from a fluropolymer. The released elastic ring ( 13 ) is attached to membrane. The ring also serves as a weight which may assist in the small bowel propagation of the 60 cm membrane.
[0040] FIG. 6 illustrates the initial steps for balloon removal. A catheter ( 38 ) is inserted into the balloon cap release port ( 28 ) releasing the balloon cap ( 21 ) from the antral anchor ( 20 ). The balloons ( 30 and 33 ) can be deflated by either puncture or volume removal via the balloon ports ( 22 and 25 ).
[0041] FIG. 7 illustrates further steps for removal of the balloon system using a standard gastroscope ( 10 ) in a through-the-scope (TTS) balloon ( 39 ). The balloon is typically 17 mm ( 54 French). The deflated TTS balloon ( 39 ) is advanced through the bariatric balloon cap ( 21 ), and the TTS balloon is then inflated using standard endoscopy equipment. The cap ( 21 ) and balloons ( 30 and 33 ) are removed by withdrawing the scope ( 10 ) through the esophagus ( 51 ) and mouth.
[0042] FIG. 8 illustrates removal of the antral anchor ( 20 ), bulb funnel ( 17 ), and duodenal membrane ( 12 ) using the same techniques shown in FIG. 7 .
[0043] FIG. 9 illustrates the removal progression of the antral anchor ( 20 ), bulb funnel ( 17 ), and duodenal membrane ( 12 ) as the scope ( 10 ) and TTS balloon ( 39 ) are being withdrawn. The tripod anchor legs ( 19 ) and anchor foot bases ( 35 ) passively collapse as they are pulled through a narrow space i.e. esophagus. The bulb funnel ( 17 ) may evert upon withdrawal through the more narrow esophagus. The balloon cap system ( 21 , 30 , and 33 ) and antral anchor system ( 20 , 17 , and 12 ) may be removed with method above; however, both systems may be also pulled into an overtube as alternative method.
[0044] FIGS. 10A-10D illustrate an alternative delivery system and method with sequential removal of a wrap ( 62 ), the gastroscope ( 10 ), the inner tube ( 68 ), and the outer tube ( 69 ). In contrast to previously described embodiments, an elastic binding ring 65 ( FIGS. 10C and 10D ) constrains tethers 67 to reduce potential obstruction of or interference with the pyloris when the system is deployed. The membrane is constrained by the wrap ( 62 ) which extends over the overtube and is pulled back to release the membrane. A pull back of 5 cm to 10 cm may be sufficient to release the bundled membrane.
[0045] FIGS. 11A-11D illustrate use of the elastic binding ring ( 65 ) a method to secure the straps/tethers ( 67 ) to a focal point within a pyloric sphincter ( 74 ). The elastic binding ring ( 65 ) is pre-loaded over an inner tube ( 68 ) which holds the ring ( 65 ) open as shown in FIG. 11B . One elastic binding ring is illustrated put two or more rings could be used to create a bound linear segment (rather than a sole focal point). The purpose of the constraint is to reduce or eliminate stress on the pyloric sphincter ( 74 ) that may result from unbound tethers/straps that traverse the pyloric opening.
[0046] FIGS. 12A and 12B illustrate spring-loaded antral anchor legs ( 76 ) which absorb the impact of antral (lower stomach) contractions (also known as antral peristalsis or lower stomach contraction waves). The legs ( 76 ) comprise an upper potion ( 76 a ) and a lower potion ( 76 b ) coupled by spring ( 77 ), typically a coil spring, which can compress and extend as axial load varies. Alternatively, the antral anchor legs may have an “accordion-like” structure to absorb the impact of antral contraction waves.
[0047] FIGS. 13A and 13B illustrate silicone gel footpads in the non-compressed state ( 66 a ) and compressed state ( 66 b ) which allows for distribution of force/pressure from the antral anchor legs on the antral (stomach) surface. | A suprapyloric anchor assembly includes an antral cap having at least three stabilizing members configured to reside in an antrum and engage tissue circumscribing a pyloric valve. A duodenal member is configured to reside at least partially in a duodenal bulb, and one or more tethers connect the antral cap to the duodenal member. The tether(s) is/are configured to allow passage of stomach contents through the pyloric valve. Optionally, one or more gastric balloon(s) may attached to the suprapyloric anchor and be inflated with the gastric cavity. | 0 |
RELATED APPLICATION INFORMATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/684,255, filed on May 25, 2005, the disclosure of which is incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the provision of electronic books and, more particularly, to a system and method for merchandising and distributing electronic books.
BACKGROUND OF THE INVENTION
[0003] The use of digital or electronic textbooks, particularly in the collegiate environment, is expanding. The majority of electronic textbooks and other electronic course materials that are being sold to college students are merchandised by the respective publishers of the material, by-passing the conventional retailer, such as an on-campus college bookstore. Thus, in a conventional electronic textbook distribution model, the publisher is acting as both the distributor and the retailer, and is faced with the inherent problems of trying to market to the end-user student as well as providing customer service and support to such students. Publishers, however, are not the traditional contact point with the students for college course materials and, thus, have no direct marketing access to the consumer. Textbook publishers, schools, professors, and students all typically rely on the college bookstore for delivery of required course materials. With direct to consumer selling by publishers, the college bookstore retailer is no longer a part of the traditional delivery channel, denying them of the associated revenues and profits that may accrue from the sale of electronic course materials. In addition to the potential lost revenues facing the retailer, there is no practical way for a publisher to market electronic product directly to the consumer.
[0004] Moreover, a substantial number of students rely on some form of third party funding for textbooks and course materials. Publishers wanting to make electronic materials available to the consumer generally have no readily available mechanism for accepting third party payment options, eliminating what could be a significant portion of the potential market for electronic course materials.
[0005] A need exists, therefore, for an improved method and system for merchandising and distributing electronic books and other related digital content, including electronic books and course materials to students. Preferably, the method and system would include means for properly authorizing and securing access to the electronic books.
SUMMARY OF THE INVENTION
[0006] The present invention includes a method for distributing and facilitating access to electronic books and other similar digital materials. The method includes first providing a digital book card having a card identification number and an activation code corresponding to the card identification number. The digital book card is also associated with an electronic book having an electronic book number. A retail store transaction is processed for the purchase of the electronic book associated with the digital book card. The retail store transmits the card identification number and the electronic book number to a central processor associated with a program administrator. The program administrator approves or declines the request and returns a receipt code to the retail store, which is then provided to the purchaser. A purchaser accessing a website associated with the central processor enters the card identification number, the activation code, and the receipt code. The purchase of the electronic book is authenticated in order to activate access to the electronic book by determining whether the card identification number entered by the purchaser corresponds to the activation code entered by the purchaser and whether the receipt code entered by the customer corresponds to the receipt code transmitted by the central processor to the retail store. If the authentication process is successful, access to the electronic book having the electronic book number associated with the card identification number is provided.
BRIEF DESCRIPTION OF THE FIGURES
[0007] These and other features, aspects and advantages of the invention will become more fully apparent from the following detailed description, appended claims, and accompanying drawings, wherein the drawings illustrates a feature of the system and method in accordance with an exemplary embodiment of the present invention, and wherein:
[0008] FIG. 1 illustrates a representative digital book card that may be used with one embodiment of the system and method of the present invention;
[0009] FIG. 2 illustrates the reverse side of the representative digital book card of FIG. 1 ;
[0010] FIG. 3 is a flow chart depicting the principal steps in one embodiment of the method of the present invention;
[0011] FIG. 4 is a screen capture illustrating the initial home page for a website used in one embodiment of the method of the present invention;
[0012] FIG. 5 is a screen capture illustrating the activation page for a website used in one embodiment of the method of the present invention; and
[0013] FIG. 6 is a screen capture illustrating a detail page for a website used in one embodiment of the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] As used herein, the term electronic book or e-book includes all forms of digital books and related content, such as electronic or digital books, textbooks, workbooks, study aids and course materials. The term electronic book may also refer to other forms of digital content such as software, games, movies, music, and the like.
[0015] The method of the present invention for merchandising and distributing electronic books includes interaction among three principal entitles. First, there is a program administrator having responsibility for overall program management, including authenticating and providing access to the electronic books. The program administrator operates one or more computer systems having a database to store authorizing information. The computer system operated by the program administrator also operates a website used in the preferred method. Second, there is a conventional retailer who offers access to the electronic books for purchase. Third, there are the purchasers of the electronic books. The purchaser buys access to the electronic books from the retailer, who provides the purchaser with a series of access numbers or codes. The purchaser then makes contact with the program administrator, for example through the website maintained by the program administrator, and provides the access numbers or codes. The program administrator authenticates the purchase and, if appropriate, provides access to the electronic books to the purchaser.
[0016] FIG. 1 illustrates a digital book card 10 that may be used in conjunction with the method for distributing electronic books. The initially generic card 10 may be made available to prospective purchasers of electronic or digital books and related materials or content. For example, in the college textbook scenario, the cards 10 may be placed in the textbook department of a conventional college bookstore, on the bookshelves adjacent to the used and new versions of the corresponding printed textbooks. The cards 10 may be displayed in a shelf merchandiser that is appropriately designed to show limited information about the electronic book represented by the card 10 . In an alternative embodiment, the cards 10 may be stored within a dispenser or kiosk and only dispensed upon purchase. Preferably, the cards 10 are designed so that the retailer may create and place a label containing indicia representing the associated electronic book on the card 10 . Placing the cards 10 strategically in the textbook department, displaying them along with the bound copies of the text, offers the consumer a choice between used print, new print, digital format, or a combination of print and digital format. With three products to choose from, and three price points, the student or other consumer is offered a choice that is an attractive alternative to higher priced new books.
[0017] The card 10 may be sufficiently sized to display marketing information on both sides of the card 10 . For example, the card 10 may be approximately four inches wide and seven and three-quarters inches in length. If desired, the bottom portion 12 of the card 10 may be reduced in width to resemble a non-detachable credit card or gift card.
[0018] The card 10 contains various indicia to secure and authenticate the purchase of the electronic books. Each card 10 has a combination of unique identification numbers or codes, one of which associates the card 10 to a specific retailer. Each card is later associated with a specific sales transaction and an electronic book product.
[0019] A supply of cards 10 may be provided to retailers who agree to participate in the system managed by the program administrator. The retailer is typically responsible for associating an electronic book product to each card 10 , although this may be accomplished by the program administrator or book publisher. For example, the retailer may affix or print a retailer-generated label 14 representing a specific electronic book product onto the bottom portion 12 of the card 10 . The label 14 may identify the book by author, title, course name or number or any other related information. The retailer may use its inventory management system to create the label 14 containing the identity information as well as a bar code 16 representing the electronic book number, such as the International Standard Book Number (ISBN) assigned to the electronic book product. The retailer selects the electronic book number from a list provided by the program administrator or from a preexisting list of known book numbers, such as the ISBN system. As the card 10 is initially generic, any bar code 16 representing a specific book or electronic course materials ISBN may be placed on the bottom portion 14 of the card 10 . The assignment of a specific textbook to a given card is accomplished at the time of purchase as described below. Alternatively, the assignment of a particular electronic book to a particular card may be accomplished during the purchase phase by the retailer's point-of-sale assembly or kiosk. The bar code 16 may be swiped, scanned or otherwise entered at the point-of-sale assembly as a part of the electronic book purchase and activation process. As will be appreciated by those skilled in the art, other means of identifying the electronic book may be used other than a bar code, such as a magnetic strip, RFID or means that may be detected optically. Alternatively, the electronic book may be designated by printed title or number on the card and manually entered into the point-of-sale assembly.
[0020] In addition to further marketing information, the reverse side of the card 10 may contain instructions for activating access to the electronic book product. As illustrated in FIG. 2 , the card 10 may contain, for example, a card identification number 18 , which may be represented in both numeric and bar code form or other computer or electronically readable form. Each card 10 used in the system bears a unique card identification number 18 . The card identification number 18 may be placed on the card 10 as printed text, as a bar code, as a magnetic imprint, or by one or more other similar means. In addition, the card 10 contains a hidden activation code 20 , which may also be placed on the reverse side of the card 10 . The activation code 20 may be viewed, for example, by removing a scratch-off coating. As those skilled in the industry will appreciate, there are a number of other methods for hiding the activation code until the card is purchased. The activation code 20 may be randomly chosen and assigned to (corresponds with) one and only one card identification number 18 by the program administrator. Thus, the program administrator has a central processor that contains a database of card identification numbers and their corresponding activation codes. Preferably, both the card identification number 18 and the activation code 20 are placed on the card by the program administrator prior to delivery of the cards 10 to the retailer. In this manner, the program administrator may track the identity of the cards delivered to a particular retailer.
[0021] A card 10 is available for activation through a real-time point-of-sale activation process that may be accomplished through a secure TCP/IP connection from the retailer to the program administrator. The same process may also handle voids within the point-of-sale transaction and returns. Integration of the process to a retailer point-of-sale system may be accomplished using a socket application that allows for implementation to an existing installed base of retail bookstore management software. Alternatively, the application may be integrated with other conventional point-of-sale software, or even as a stand-alone application.
[0022] FIG. 3 is a flow chart depicting the principal steps in one embodiment of the method of the present invention. Initially, in step 22 , the program administrator prepares a supply of cards 10 , each having a unique card identification number 18 and a hidden, corresponding activation code 20 printed thereon. The pre-printed cards 10 are then distributed to retail locations such as college bookstores in step 24 . Using the retailer's inventory management system, the retailer creates the label 14 that includes the identification of a particular book, e.g., bar code 16 and, if desired, other information related to an electronic book and, thus, places a label on each card in step 26 .
[0023] The retailer then merchandises by electronic book by displaying the cards 10 as a conventional product available for purchase in step 28 . When a purchaser such as a student desires to purchase access to the electronic book, he or she brings the appropriate card 10 to the retailer's point of sale system, which may include a conventional check-out register with an attendant or an operator-less kiosk or other form of self-checkout register (step 30 ). At the point of sale, the card 10 is presented to the point-of-sale system such as, for example, being passed through a card scanner or reader, by keying the card identification number, or any other means of entering the unique card identification number 18 into the point-of-sale system (step 32 ). Entering the card identification number into the point-of-sale system prompts the cashier or automated kiosk to associate the card 10 to a unique item, e.g., an electronic textbook. This may be accomplished by scanning in the bar code 16 on the front of the card 10 in step 34 , which represents the specific book. Again, any other means of entering in the identification of the electronic book into the point-of-sale system may be used. At this point, a particular electronic book product is associated with a particular card identification number and activation code.
[0024] The retailer then notifies the program administrator with details of the transaction in step 36 . For example, the transaction details may include the identify of the particular electronic book or other materials that was purchased and the particular card identification number associated with the purchase process. This information may be electronically transmitted to a central processor associated with the program administrator using, for example, a TCP/IP or UDP protocol connection. As this point, the program administrator has three pieces of information associated together: the card identification number, the activation code, and the identification of the electronic book. The program administrator returns an approval or decline code to the retailer, along with a unique receipt code. A receipt may be generated with the receipt code that will be used in order for the purchaser to later gain access to the electronic book (step 38 ). The receipt is generated (e.g., printed) by the retailer's point-of-sale assembly, which now contains a card identification number, a book identification number, and a receipt code, all of which correspond to one another. In the event the purchaser opts to purchase more than one electronic book in a single transaction, a single receipt code may apply for access to all of the purchased electronic books. The purchaser then completes the transaction in order to pay for the book(s) or other materials in a conventional manner. A student in a college setting may use conventional third-party funding means to complete the transaction.
[0025] In an alternative embodiment, the purchaser may use a card dispenser or kiosk to select the desired electronic book. The kiosk or dispenser may include conventional means for accepting payment from the purchaser, such as from a credit or debit card, or a bill and coin acceptor. Upon acceptance of the form of payment from the purchaser, the kiosk may dispense a card 10 , having printed or otherwise affixed thereon the card identification number and activation code (which may or may not be hidden). A receipt may also be supplied having the receipt code printed thereon. Alternatively, the receipt code may be placed on the dispensed card 10 . In this embodiment, the kiosk may be considered the “retailer.”
[0026] In step 40 , the purchaser accesses a website affiliated with the program administrator. Preferably, the purchaser may gain information regarding the website (such as its web address) from the card 10 she acquired as part of the electronic book purchase at the retailer. Alternatively, the retailer may provide the purchaser with information regarding the website from other sales information posted in the store, from information printed on the receipt, on a brochure handed out with the purchase, or other means. The purchaser uses the website as a means of providing the program administrator with the card identification number, the hidden activation code, and the receipt code, which may then be used by the program administrator to authenticate and provide access to the electronic book (step 42 ).
[0027] FIG. 4 depicts a representative screen shot for an initial home page 50 of a website operated by the program administrator. The initial home page 50 allows the purchaser to log in as an existing customer by, for example, providing an e-mail address and password or, alternatively, to register as a first time user by providing an e-mail address and adopting a password. After successfully completing the log-in or registration process, the purchaser is directed to an activation page 60 as depicted in FIG. 5 . The activation page 60 has windows 62 and 66 for allowing the purchaser to enter in the receipt code, and the card identification number(s) and activation code(s) for each electronic book purchased. In addition, for added security, the activation page 60 may require the purchaser to replicate a randomly generated numerical code shown in an image box 68 in the box 64 . Upon entering in the required information, the purchaser may click on an icon 70 to continue the activation process. The program administrator operating the website authenticates access to the electronic book by ensuring that the card identification number entered by the purchaser corresponds to the activation code entered by the purchaser and that the receipt code entered by the purchaser corresponds to the receipt code transmitted by the retail store to the program administrator. This access authentication is preferably performed by software executing in a central processor associated with the program administrator. Upon the successful entry of all four numerical identifiers, the purchaser is provided with instructions for accessing the electronic book, for example, by downloading the book to the purchaser's computer equipment or accessing it as online content. Upon activating access to a particular digital book, the purchaser may be provided with a book detail page 72 such as illustrated in FIG. 6 , which provides further detailed information on the electronic book. For example, the book detail page 72 may inform the purchaser as to her rights to copy or print portions of the book or materials, the length of time that access to the book is active, the devices that are compatible with the electronic book format, and the like. The electronic book may be provided in an Adobe® PDF format, which may have built-in functions for highlighting, underlining, note creation, read-aloud capability, and other useful functions.
[0028] The program administrator may also provide an administrative page for retailers to assist in the management, activation, loss and return of electronic book cards.
[0029] The system and method of the present invention may be adapted for use with a retailer's on-line store. For example, a college student may access a college bookstore's website to purchase her books. If she elects to purchase an electronic book or digital course materials, she may pay for the book(s) and materials through the college bookstore's on-line store. She may then be presented or receive a receipt containing a combination of the above-described card identification number, activation code, and receipt code. With this information, she may then access the program administrator's website, present the numbers and codes as previously described, and gain access to the electronic book or other materials.
[0030] The method described herein enables college bookstores and other retailers to pro-actively market and sell electronic books and other course materials. The system and method allows the retailer to participate in the traditional, long-standing sales and marketing channel. The books and materials may either be downloaded to a computing device and accessed by means of existing computer or electronic book readers, or the books and materials may be accessible as on-line content from various secure web sites. In addition, the system and method described herein allows a purchaser to purchase an electronic book from a retailer using third-party funding, thus addressing the publishers general inability to accept methods of payment other than credit card or electronic check.
[0031] Although the invention has been described with reference to specific embodiments, as will be understood by those skilled in the art, other embodiments and variations may be made without departing from the spirit or scope of the invention. The many aspects and benefits of the invention are apparent from the detailed description, and thus, it is intended for the following claims to cover all such aspects and benefits of the invention which fall within the scope and spirit of the invention. For example, although most of the embodiments discussed herein relate to the distribution of digital textbooks in a collegiate setting, the method disclosed herein may also be used to distribute other forms of digital content, such as software, games, movies, music, and the like. In addition, because numerous modifications and variations will be obvious and readily occur to those skilled in the art, the claims should not be construed to limit the invention to the exact construction and operation illustrated and described herein. Accordingly, all suitable modifications and equivalents should be understood to fall within the scope of the invention as claimed herein. | A method for facilitating access to electronic books and other similar digital materials includes first providing a digital book card having a card identification number and an activation code corresponding to the card identification number. The digital book card is also associated with an electronic book having an electronic book number. A retail store transaction is processed for the purchase of the electronic book associated with the digital book card. The transaction processing includes generating a receipt code that is associated with the card identification number. The retail store transmits the card identification number and the electronic book number to a central processor associated with a program administrator. The program administrator approves the transaction and provides a receipt code. A purchaser accessing a website associated with the central processor enters the card identification number, the activation code, and the receipt code. The purchase of the electronic book is authenticated in order to activate access to the electronic book by determining whether the card identification number entered by the purchaser corresponds to the activation code entered by the purchaser and whether the receipt code entered by the customer corresponds to the receipt code transmitted to the retail store by the central processor. If the authentication process is successful, access to the electronic book having the electronic book number associated with the card identification number is provided. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of Ser. No. 671,453, filed Mar. 29, 1976, now U.S. Pat. No. 4,051,319, which is a divisional of Ser. No. 548,469, filed Feb. 10, 1975, now U.S. Pat. No. 3,957,833, which is a divisional of Ser. No. 312,074, filed Dec. 4, 1972, now U.S. Pat. No. 3,880,935, which is a divisional of Ser. No. 123,060, filed Mar. 10, 1971, now U.S. Pat. No. 3,718,686.
SUMMARY OF THE INVENTION
In accordance with this invention, it has been found that compounds of the formula: ##STR1## wherein R 1 , R 3 and R 5 are methyl or ethyl; R 2 and R 4 are hydrogen or methyl; R 6 is lower alkynyl; A, B, C, D, E and F are individually hydrogen or A and B taken together form a carbon to carbon bond or an oxygen bridge, C and D taken together form a carbon to carbon bond, and E and F taken together form a carbon to carbon bond; Z is oxygen or sulfur; Y and Y' are hydrogen, halogen, lower alkyl or lower alkoxy; X is oxygen, --CH 2 O-- or --COO--; and m, n and p are integers of from 0 to 1, with at least one of m, n and p being 1; with the proviso that when m and n are O, E and F are individually hydrogen, or taken together form a carbon to carbon bond or an oxygen bridge; upset the hormone balance of pests such as insects to prevent them from growing and reproducing.
The compounds of formula I are prepared by reacting a compound of the formula: ##STR2## wherein R 1 , R 2 , R 3 , R 4 , R 5 , A, B, C, D, E, F, Z, Y, Y', X, m, n and p are as above and M is an alkali metal or, where X is oxygen, an alkali metal or hydrogen;
with an alkynyl halide of the formula:
R.sub.6 --Hal III
wherein R 6 is as above and Hal is a halogen.
The compounds of formula I are also prepared by reacting a halide of the formula: ##STR3## wherein R 1 , R 2 , R 3 , R 4 , R 5 , A, B, C, D, E, F, Hal, m, n and p are as above;
with a compound of the formula: ##STR4## wherein R 6 , X, Y, Y' and Z are as above and M' is an alkali metal or, where Z is oxygen, an alkali metal or hydrogen.
The compounds of formula I, wherein X is ##STR5## are further prepared by reacting a compound of the formula: ##STR6## wherein R 1 , R 2 , R 3 , R 4 , R 5 , A, B, C, D, E, F, Z, Y, Y', m, n and p are as above and R 7 is hydrogen, lower alkyl or aralkyl;
with an alcohol of the formula:
R.sub.6 --OH VII
wherein R 6 is as above.
In the case where, in the compound of formula I, A and B taken together form a carbon to carbon bond, this compound can be epoxidized to a compound of formula I wherein A and B taken together form an oxygen bridge.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As used throughout this application, the term "lower alkyl" comprehends both straight-chain and branched-chain, saturated alkyl hydrocarbon groups having from 1 to 6 carbon atoms, such as methyl, ethyl, propyl, isopropyl, etc. As used herein, the term "lower alkoxy" comprehends loweralkyloxy groups wherein a "lower alkyl" is defined as above, such as methoxy, ethoxy propoxy, etc. Similarly, as used herein, the term "lower alkynyl" includes straight-chain and branched-chain, acetylenically unsaturated hydro carbon groups having from 2 to 6 carbon atoms, such as ethynyl, propargyl, butynyl, etc. As also used herein, the term "halogen" or "halo" comprehends, when not expressly stated otherwise, all four halogens, i.e., fluorine, chlorine, bromine and iodine. As further used herein, the term "alkali metal" comprehends the alkali metals of the first group of the periodic chart, such as sodium and potassium. As still further used herein, the term "aralkyl" comprehends aryl lower alkyl groups wherein "aryl" comprehends mono-nuclear aromatic hydrocarbons, such as phenyl, tolyl, etc., which can be substituted or unsubstituted in one or more positions, and polynuclear aromatic groups, such as naphthyl phenanthyl, etc., which can also be substituted or unsubstituted in one or more positions, with a nitro, halo, lower alkyl or lower alkoxy substituent, and wherein "lower alkyl" is as defined above. The preferred aralkyl group is benzene.
The compounds of formula I are useful in the control of and in combatting invertebrate animals, such as arthropods and nematodes. The compounds of formula I are especially useful against insects, particularly Tenebrio molitor, Tineola biselliella, Carpocapsa pomonella, Leptinotarsa decemlineata, Calandra granaria, Dysdercus cingulatus and Ephestia kuhniella.
In contrast to most of the known pest-control agents which kill, disable or repell the pests by acting as contact-poisons and feed-poisons, the compounds of formula I above prevent maturation and proliferation of these pests by interfering with their hormonal system. In insects, for example, the transformation to the imago, the laying of viable eggs and the development of laid normal eggs is distrubed. Furthermore, the sequence of generations is interrupted and the insects are indirectly killed.
The compounds of formula I above are practically non-toxic to vertebrates. The toxicity of the compounds of formula I is greater than, 1,000 mg/kg body weight. Moreover, these compounds are readily degraded and the risk of accumulation is therefore excluded. Therefore, these compounds can be used without fear of danger in the control of pests in animals; plants, foods; and textiles.
Generally, in controlling invertebrate animals, the compounds of formula I are applied to the material to be protected, e.g. foodstuffs, feeds, textiles, plants, in concentrations of from about 10 -3 to 10 -6 gm/cm 2 of the material to be protected. Generally, it is preferred to utilize the compounds of formula I above in a composition with a suitable inert carrier. Any conventional inert carrier can be utilized.
The compounds of formula I can, for example, be used in the form of emulsions, suspensions, dusting agents, solutions or aerosols. In special cases, the materials to be protected (e.g., foodstuffs, seeds, textiles and the like) can also be directly impregnated with the appropriate compound or with a solution thereof. Moreover, the compounds can also be used in a form which only releases them by the action of external influences (e.g., contact with moisture) or in the animal body itself. It is also possible to use the compounds in admixture with other known pesticides.
The compounds of formula I above can be used as solutions suitable for spraying on the material to be protected which can be prepared by dissolving or dispersing these compounds in a solvent such as mineral oil fractions; cold tar oils; oils of vegetable or animal origins; hydrocarbons such as napthalenes; ketones such as methyl ethyl ketone; or chlorinated hydrocarbons such as tetrachloroethylene, tetrachlorobenzene, and the like. Such sprays suitably have a concentration of the compound of formula I of 0.01% to 5% by weight, with a concentration of 0.1% being preferred. The compounds of formula I above can also be prepared in forms suitable for dilution with water to form aqueous liquids such as, for example, emulsion concentrates, pastes or powders. The compounds of formula I above can be combined with solid carriers for making, dusting or strewing powders as, for example, talc, kaolin, bentonite, calcium carbonate, calcium phosphate, etc. The compositions containing the compounds of formula I above can contain, if desired, emulsifiers, dispersing agents, wetting agents, or other active substances such as fungicides, bacteriacides, nematocides, fertilizers and the like. The materials which are to be protected act as bait for the insect. In this manner, the insect, by contacting the material impregnated with a compound of formula I above, also contacts the compound itself.
In accordance with this invention, representative examples of the preferred compounds of formula I are as follows:
1-[(1,5-dimethylhexyl)oxy]-4-(propargyloxy)benzene;
1-[(3-methyl-2-butenyl)oxy]-4-propargyloxybenzene;
p-[(1,5-dimethylhexyl)oxy]-α-propargyloxytoluene;
p-[(3-methyl-2-butenyl)oxy]-α-propargyloxytoluene;
p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester;
p-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid propargyl ester;
p-[(2,3-epoxy-3-methylbutyl)oxy]benzoic acid propargyl ester
p-[(4,5-epoxy,-1,5-dimethylhexyl)oxy]benzoic acid propargyl ester;
p-[(1-ethyl-5-methyl-4-heptenyl)oxy]benzoic acid propargyl ester;
p-[(6,7-epoxy-3,7-dimethyl-2-octenyl)oxy]benzoic acid propargyl ester;
p-[(2,3-epoxy-3-methylbutyl)oxy]-α-propargyloxytoluene;
1-[(2,3-epoxy-3-methylbutyl)oxy]-4-propargyloxybenzene;
p-[(3,7,11-trimethyl-dodeca-2,6,10-trienyl)oxy]benzoic acid propargyl ester;
p-[(1,5-dimethyl-4-hexenyl)oxy]benzoic acid propargyl ester;
p-[(1,5-dimethylhexyl)thio]-α-propargyloxytoluene;
1-[(1,5-dimethylhexyl)oxy]-4-(propargyloxy)benzene;
p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester;
4-[(1,5-dimethylhexyl)oxy]-α-(propargyloxy)toluene;
p-[(4,5-epoxy-1,5-dimethylhexyl)oxy]benzoic acid propargyl ester;
p-[(1,5-dimethylhexyl)oxy]benzoic acid-2-pentynyl ester;
p-[(1,4,5-trimethylhexyl)oxy]benzoic acid propargyl ester;
p-[(1,5-dimethylhexyl)thio]benzoic acid propargyl ester;
p-[(3,6,7-trimethylocta-2,6-dienyl)oxy]benzoic acid propargyl ester;
p-[(3,6,7-trimethyloctyl)oxy]benzoic acid propargyl ester;
4-[(1,5-dimethylhexyl)oxy]-3-chlorobenzoic acid propargyl ester;
p-[(1,5-dimethylhexyl)oxy]vanillic acid propargyl ester;
3-methyl-4-[(3,7-dimethylocta-2,6-dienyl)oxy]benzoic acid propargyl ester;
3-bromo-4-[(6,7-dimethyl-2,6-octadienyl)oxy]-5-methoxybenzoic acid propargyl ester; and
4-[(3,7-dimethyl-2,6-octadienyl)oxy]-3,5-dimethoxy-benzoic acid propargyl ester.
Especially preferred are the compounds of formula I having the formula: ##STR7## wherein R 1 , R 2 , R 5 , A, B, X, Y, Y' and Z are as above. Particularly preferred are the compounds of formula Ia wherein Z is oxygen, Y is hydrogen, and A and B individually are hydrogen or taken together form an oxygen bridge. Quite particularly preferred are the following compounds of formula Ia:
1-[(1,5-dimethylhexyl)oxy]-4-propargyloxy benzene;
p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester;
4-[(1,5-dimethylhexyl)oxy]-α-(propargyloxy)toluene;
p-[(4,5-epoxy-1,5-dimethylhexyl)oxy]benzoic acid-propargyl ester; and
p-[(1,4,5-trimethylhexyl)oxy]benzoic acid propargyl ester.
Also especially preferred are the compounds of formula I having the formula: ##STR8## wherein R 1 , R 2 , R 5 , A, B, E, F, X, Y, Y' and Z are as above.
Further especially preferred compounds are the compounds of formula I wherein R 1 , R 2 , and/or R 5 are methyl; R 2 and/or R 4 is hydrogen; Z is oxygen, and/or Y and Y' are hydrogen.
One method for preparing the compounds of formula I involves reacting, in a well known manner, a compound of formula II with the alkynyl halide of formula III. This reaction is suitably conducted in an inert solvent and preferably in the presence of an aprotonic solvent. In carrying out this reaction, any conventional inert organic solvent can be utilized, with benzene, toluene, dioxane, 1,2-dimethoxymethane and tetrahydrofuran being preferred and tetrahydrofuran being especially preferred. In this reaction, any conventional aprotonic solvent may be utilized, with hexamethyl phosphoric acid triamide being preferred. In this reaction, temperature and pressure are not critical, and the reaction can be suitably carried out in a temperature range of 0° C. to the boiling point of the reaction mixture. In a preferred embodiment of this reaction, the reaction is carried out at ca 70° C., the reflux temperature of the especially preferred solvent.
Another method for preparing the compounds of formula I involves reacting, in a well known manner, the compounds of formulas IV and V. This reaction is also suitably carried out in an inert solvent, preferably in the presence of an aprotonic solvent. In carrying out this reaction, any conventional inert organic solvent can be utilized, with benzene, toluene, dioxane, 1,2-dimethoxymethane and tetrahydrofuran being preferred and tetrahydrofuran being especially preferred. In this reaction, any conventional aprotonic solvent may be utilized, with hexamethyl phosphoric acid triamide being preferred. In this reaction, temperature and pressure are not critical, and the reaction can be suitably carried out in a temperature range of 0° C. to the boiling point of the reaction mixture. In a preferred embodiment of this reaction, as in the above reaction, the preferred temperature is ca 70° C.
The reaction mixtures from the reactions of either a compound of formula II with a compound of formula III or a compound of the formula IV with a compound of formula V can be worked up in a conventional manner to obtain the compounds of formula I. A preferred method of working up includes: pouring the reaction mixture onto ice; extracting the compound of formula I with a conventional inert organic solvent, preferably diethyl ether; washing the solvent extract with water; drying the solvent and evaporating the solvent. The residual compound of formula I can be further purified by adsorption, preferably on Kieselgel or aluminum oxide.
The above reactions of a compound of formula II, wherein M is hydrogen, with an alkynyl halide of formula III and of a compound of formula V, wherein M' signifies hydrogen, with a compound of formula IV are expediently effected in the presence of an acid binding agent. In these reactions, any conventional acid binding agent may be utilized. The preferred acid binding agents are the carbonates and organic bases, such as pyridine, triethylamine and quinoline with the carbonates being especially preferred, particularly potassium carbonate. Further, in these reactions, wherein M of the compound of formula II and M' of the compound of formula V are hydrogen, the preferred solvents are acetone and methyl ethyl ketone.
Still another method for preparing the compounds of formula I, involves the esterification of an acid of the compound of formula VI where R 7 is hydrogen with an alcohol of formula VII. In carrying out this reaction, the acid is expediently converted, initially, in an inert solvent and in the presence of an acid binding agent into the corresponding acid halide by treatment with a halogenating agent. In this reaction, any conventional inert organic solvent can be used, with petroleum ether, benzene and hexane being preferred solvents. Also, in this reaction, any conventional acid binding agent, such as the organic bases, can be used, with pyridine, triethylamine, and quinoline being preferred and pyridine being especially preferred. Further, in this reaction, any conventional halogenating agent such as thionyl chloride, phosphorus trichloride, thionyl bromide, and phosphorus oxychloride can be used, with thionyl chloride being preferred. In this reaction, temperature and pressure are not critical, and the reaction may be suitably carried out at room temperature (25° C.).
The resulting acid halide and the alkynyl alcohol of formula VII are then reacted in an inert solvent and in the presence of an acid binding agent. In this reaction, any conventional inert organic solvent can be utilized with benzene, toluene, hexane, iso-octane, chloroform, carbon tetrachloride and ethylene glycol dimethyl ether being preferred solvents. Also in this reaction, any conventional acid binding agent may be utilized, with the organic bases, such as pyridine, triethylamine and quinoline being preferred and pyridine being especially preferred. In carrying out this reaction, temperature and pressure are not critical, and the reaction can be suitably carried out at room temperature.
Still another method for preparing the compounds of formula I involves the trans-esterification of a compound of formula VI wherein R 7 is alkyl or aralkyl utilizing an alcohol of formula VII. This reaction is expediently effected in an excess of the alcohol, in which case this alcohol can also serve as the solvent. However, the reaction can also be conducted in an inert organic solvent, any conventional inert organic solvent being suitable and the hydrocarbons, particularly benzene and toluene, being preferred. Temperature and pressure are not critical to this reaction, and the reaction can be expediently carried out in a temperature range between room temperature and the reflux temperature of the reaction mixture, with the reflux temperature being preferred. This reaction is preferably carried out in the presence of a catalyst such as sodium, sodium methoxide, or p-toluene-sulphonic acid.
The epoxidation of a compound of formula I wherein M is 1, Z is oxygen, and A and B taken together form a carbon to carbon bond can expediently be carried out by treating the compound in an inert solvent with a peracid. In carrying out this reaction, any conventional inert organic solvent may be utilized with the halogenated hydrocarbons such as methylene chloride or chloroform being preferred. Any conventional peracid may be utilized in this reaction. Among the preferred peracids are perbenzoic acid, peracetic acid, pertungstic acid, performic acid, m-chloroperbenzoic acid and perphthalic acid, with m-chloroperbenzoic acid being especially preferred. In carrying out this reaction, temperature and pressure are not critical, the preferred temperature range being -10° C. to room temperature.
Another method for epoxidizing the compound of formula I, where M is 1, wherein Z is oxygen or sulfur, and A and B taken together form a carbon to carbon bond, involves first treating the compound with water and an N-halosuccinimide, "halo" being chlorine, bromine, or iodine, with N-bromosuccinimide being preferred to obtain a halohydrin of the formula: ##STR9## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , C, D, E, F, X, Y, Y' Z, n and p are as above, and Hal' is chlorine, bromine or iodine. In this reaction, temperature and pressure are not critical, the reaction being preferably carried out between 0° C. and 25° C. In carrying out this reaction, the unsaturated compound of formula I is preferably initially suspended in water. Then an inert organic solvent is added to the suspension to give a homogeneous concentrated solution of the compound of formula I in water and organic solvent. Any conventional inert organic solvent can be utilized in this reaction, dioxane, tetrahydrofuran and 1,2-dimethoxyethane being preferred. The N-halosuccinimide is then introduced portionwise into this homogeneous solution to yield the halohydrin of formula VIII.
These halohydrins can then be converted by the action of a base to the corresponding epoxide. In carrying out this reaction, any conventional base is suitable, with the alkali metal alkanolate being preferred, especially sodium methylate in methanol. In this reaction, temperature and pressure are not critical, the reaction being preferably carried out between 0° C. and 25° C. Any conventional inert organic solvent can be utilized in this reaction, dioxane, tetrahydrofuran and 1,2-dimethoxymethane being preferred.
The compounds of formulas II and VI can be obtained by first reacting a compound of formula IV with a compound of the formula: ##STR10## wherein Z, M', Y and Y' are as above; R 6 is hydrogen, hydroxymethyl, formyl or --COOR 9 , and R 9 is lower alkyl, aryl or aralkyl.
This reaction can be carried out in the same manner described above for the reaction between the compounds of formulas IV and V to yield a compound of the formula: ##STR11## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , A-F, Y, Y', Z, m, n and p are as above.
The compound of formula X, wherein R 6 is formyl or --COOR 9 , is then reduced to a compound of the formula: ##STR12## wherein R 1 , R 2 , R 3 , R 4 , R 5 , A-F, Y, Y', Z, m, n and p are as above and R 6 ' is --CH 2 OH.
Alternatively, the compound of formula X, wherein R 6 is --COOR 9 , is then saponified or the compound of formula X, wherein R 6 is formyl, is then oxidized to a compound of the formula: ##STR13## wherein R 1 , R 2 , R 3 , R 4 , R 5 , A-F, Y, Y', Z, m, n and p are as above and R 6 " is --COOH.
The compound of formula X, wherein R 6 is formyl or --COOR 9 , can be converted to the compound of formula XI, wherein R 6 is --CH 2 OH, by reduction. This reduction reaction can be carried out in a conventional manner with a metal hydride, such as an alkali metal hydride, in an inert organic solvent. In carrying out this reaction, any conventional metal hydride can be used, with the preferred hydrides being mixed metal hydrides, particularly sodium borohydride or lithium aluminum hydride, and alkylated metal hydrides, particularly, dialkyl aluminum hydrides. Especially preferred hydrides are di-isobutyl aluminum hydride and bis-(methoxy-ethyleneoxy) sodium aluminum hydride. In this reaction, any conventional, inert organic solvent can be used, with the preferred solvents being: the alkanols, especially methanol, in the presence of sodium borohydride; the ethers, especially tetrahydrofuran or dioxane, in the presence of lithium aluminum hydride; and the ethers and the hydrocarbons, especially hexane, benzene or toluene, with the alkylated metal hydrides, particularly di-isobutyl aluminum hydride. Also, in carrying out this reaction, temperature and pressure are not critical, with a temperature range of -20° C. to 50° C. being preferred.
The compound of formula X, wherein R 6 is --COOR 9 can be converted to the compound of formula XII, wherein R 6 ' is --COOH, by saponification. This saponification reaction can be carried out in a conventional manner using an alkali metal hydroxide, such as sodium or potassium hydroxide. In carrying out this reaction, temperature and pressure are not critical, and the reaction can be carried out at elevated temperature. In this reaction, any conventional inert solvent which dissolves both the alkali metal hydroxide and the compound of formula X may be utilized with diethylene glycol/water or methanol/water (1:1) being preferred.
The compound of formula X, wherein R 6 is formyl, can be converted to the compound of formula XII, wherein R 6 " is --COOH, by oxidation. This oxidation reaction can be carried out in a conventional manner using silver oxide. In carrying out this reaction temperature and pressure are not critical, and the reaction can be carried out at room temperature. The silver oxide, preferably Ag 2 O, is preferably formed in situ in an aqueous solution of silver nitrate and caustic soda (NaOH). This reaction is carried out in water or in an organic solvent miscible with water. Any conventional organic solvent miscible with water may be used, with the following solvents being preferred: the lower alcohols, particularly methanol, ethanol and isopropanol; the ethers, particularly, 1,4-dioxane; and the ether alcohols, particularly 2-methoxy-ethanol and 2-ethoxy-ethanol.
When the compounds of formulas X, XI, and XII, wherein Z is oxygen, are unsaturated, they can, if desired, be hydrogenated in a conventional manner by, for example, hydrogenating in the presence of a conventional hydrogenation catalyst. In carrying out this reaction, temperature and pressure are not critical, a temperature range between about 25° C. and the boiling temperature of the reaction mixture and atmospheric or elevated pressures being preferred. Suitable as hydrogenation catalysts are, for example, Raney-nickel or preferably the noble metals, with palladium and platinum being especially preferred. Suitable as solvents are acetic acid ethyl ester and the alkanols such as methanol and ethanol.
When the compounds of formulas X, XI, and XII, are unsaturated, they can, if desired, be epoxidized in the same manner described above for the epoxidation of the compounds of formula I.
The compounds of formula X, wherein R 6 is hydroxy or hydroxymethyl, of formula XI wherein R 6 ' is --CH 2 OH and of formula XII, wherein R 6 " is --COOH, can be directly converted to the alkali metal salt of formula II. This reaction can be expediently effected by treatment with an alkali metal hydride, alkali metal alcoholate or an alkali metal hydroxide, sodium being the preferred alkali metal. The reaction is preferably carried out in the presence of an inert organic solvent. Any conventional inert organic solvent may be utilized, with dioxane, tetrahydrofuran, dimethylformamide or diethyl ether being the preferred solvents with an alkali metal hydride, with a lower alkanol, especially methanol, being the preferred solvent with an alkali metal alcoholate, and with methanol, ethanol, acetone or the like being the preferred solvent with an alkali metal hydroxide.
In the species of the compounds of formulas I, II, IV, VI, X, XI and XII of this invention, wherein the side-chain is unsaturated or epoxidized, these species exist as a cis/trans isomer mixture. The isomer mixture can be separated into the all cis or all trans isomers in a conventional manner by, for example, gas chromatography.
By this method, the isomer mixture is dissolved in an inert organic solvent, hexane, diethyl ether or acetic acid ethyl ester being preferred solvents, and then adsorbed on Kieselgel. The isomers adsorbed in different zones can be eluted with one of the aforesaid solvents or solvent mixtures and isolated.
The isomer mixtures can, in individual cases, also be separated by fractional distillation methods or possibly also by fractional crystallization methods.
The following examples illustrate the invention. All temperatures are stated in degrees centigrade. The inert gas atmosphere is nitrogen. The term "hexane/15% acetic ester" as used in Examples 5 and 41 encompasses a solution consisting of 85% hexane and 15% ethyl acetate (by volume). The term "70% bis(2-methoxy-ethoxy) sodium aluminium hydride" as used in Example 27 comprehends a benzenic solution of 70% by weight of bis(2-methoxy-ethoxy) sodium aluminium hydride. The term "80% by weight m-chlorperbenzoic acid" as used in Examples 31, 33 and 34 means that the m-chlorperbenzoic acid contains 20% m-chlorbenzoic acid and that the percentage of m-chloroperbenzoic acid present in the mixture was determined by titration in the usual manner.
EXAMPLE 1
11.8 g of a 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 50 ml of tetrahydrofuran each time and then added to 150 ml of tetrahydrofuran. A solution of 36.5 g of hydroquinone monopropargyl ether dissolved in 80 ml of tetrahydrofuran is then added dropwise to the sodium hydride mixture. 47.5 g of 2-bromo-6-methylheptane in 80 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual, oily, 1-[(1,5-dimethylhexyl)oxy]-4-(propargyloxy)-benzene is purified by adsorption on Kieselgel; B.P. 150°-152° C./1 mmHg.
EXAMPLE 2
By utilizing the procedure of Example 1, by reacting hydroquinone monopropargyl ether with 3-methyl-2-butenyl bromide, there is obtained 1-[(3-methyl-2-butenyl)oxy]-4-propargyloxy-benzene; B.P. 145°-148° C./1 mmHg.
EXAMPLE 3
By utilizing the procedure of Example 1 by reacting syringic acid propargyl ester with geranyl bromide, there is obtained 4-[(3,7-dimethyl-2,6-octadienyl)oxy]-3,5-dimethoxy benzoic acid propargyl ester; n D 21 = 1.5320
EXAMPLE 4
By utilizing the procedure of Example 1, by reacting 5-bromovanillic acid propargyl ester and geranyl bromide, there is obtained 3-bromo-4-[(6,7-dimethyl-2,6-octadienyl)oxy]-5-methoxybenzoic acid propargyl ester; n D 28 = 1.5440.
EXAMPLE 5
43.5 of a 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 100 ml of tetrahydrofuran each time and then, added to 150 ml of tetrahydrofuran. A solution of 100 g of hydroquinone in 100 ml of tetrahydrofuran is added dropwise to the sodium hydride mixture. 108 g of propargyl bromide in 150 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual mixture is separated by chromatography on Kieselgel. Hydroquinone dipropargyl ether is eluted with 10% acetic ester. M.P. 50° C. With hexane/15% acetic ester there is eluted hydroquinone monopropargyl ether. B.P. 100°-102° C./1.0 mmHg.
EXAMPLE 6
By utilizing the procedure of Example 5, by reacting syringic acid and propargyl bromide, there is obtained syringic acid propargyl ester, F.P. 105°-106° C.
EXAMPLE 7
By utilizing the procedure of Example 5, by reacting 5-bromovanillic acid with propargyl bromide, there is obtained 5-bromovanillic acid propargyl ester; M.P. 121°-122° C.
EXAMPLE 8
4.0 g of a 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 25 ml of tetrahydrofuran each time and then, added to 100 ml of tetrahydrofuran. A solution of 20.6 g of p-[(1,5-dimethylhexyl)oxy] benzoic acid in 100 ml of tetrahydrofuran is then added dropwise to the sodium hydride mixture. 10 g of propargyl bromide in 40 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual oily p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester is purified by adsorption on Kieselgel; B.P. 207°-210° C./1 mmHg.
EXAMPLE 9
By utilizing the procedure of Example 8, by reacting p-farnesyloxybenzoic acid with propargyl bromide, there is obtained p-farnesyloxybenzoic acid propargyl ester; B.P. 245°-250° C./0.1 mmHg.
EXAMPLE 10
By utilizing the procedure of Example 8, by reacting p-[(1,5-dimethyl-4-hexenyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(1,5-dimethyl-4-hexenyl)oxy]benzoic acid propargyl ester; n D 22 = 1.5252.
EXAMPLE 11
By utilizing the procedure of Example 8, by reacting p-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid propargyl ester; B.P. 135°-137° C./0.01 mmHg.
EXAMPLE 12
By utilizing the procedure of Example 8, by reacting p-[(3,6,7-trimethylocta-2,6-dienyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(3,6,7-trimethylocta-2,6-dienyl)oxy]benzoic acid propargyl ester; n D 24 = 1.5349.
EXAMPLE 13
By utilizing the procedure of Example 8, by reacting p-[(1,5-dimethylhexyl)oxy]-3-chlorobenzoic acid with propargyl bromide, there is obtained 4-[(1,5-dimethylhexyl)oxy]-3-chlorobenzoic acid propargyl ester; n D 26 = 1.5155.
EXAMPLE 14
By utilizing the procedure of Example 8, by reacting p-[(1,5-dimethylhexyl)oxy]vanillic acid with propargyl bromide, there is obtained p-[(1,5-dimethylhexyl)oxy]vanillic acid propargyl ester; n D 24 = 1.5151.
EXAMPLE 15
By utilizing the procedure of Example 8, by reacting p-[(1,4,5-trimethylhexyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(1,4,5-trimethylhexyl)oxy]benzoic acid propargyl ester; n D 22 = 1.5050.
EXAMPLE 16
By utilizing the procedure of Example 8, by reacting p-[(1,5-dimethylhexyl)oxy]benzoic acid with 1-bromo-2-pentyne, there is obtained p-[(1,5-dimethylhexyl)oxy]benzoic acid-2-pentynyl ester; n D 24 = 1.5078.
EXAMPLE 17
By utilizing the procedure of Example 8, by reacting p-[(1-ethyl-5-methyl-4-heptenyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(1-ethyl-5-methyl-4-heptenyl)oxy]benzoic acid propargyl ester; n D 21 = 1.5200.
EXAMPLE 18
By utilizing the procedure of Example 8, by reacting 3-methyl-4-[(3,7-dimethylocta-2,6-octadienyl)-oxy]-benzoic acid with propargyl bromide, there is obtained 3-methyl-4-[(3,7-dimethylocta-2,6-dienyl)oxy]benzoic acid propargyl ester; n D 28 = 1.5331.
EXAMPLE 19
13.7 g of a 50% suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 70 ml of tetrahydrofuran each time and then, added to 100 ml of tetrahydrofuran. A solution of 40 g of p-hydroxybenzoic acid methyl ester in 250 ml of tetrahydrofuran is then added dropwise to the sodium hydride mixture. 50 g of 2-bromo-6-methylhept-5-ene in 80 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual oily p-[(1,5-dimethyl-4-hexenyl)oxy]benzoic acid methyl ester is purified by adsorption on Kieselgel; n D 25 = 1.5109.
EXAMPLE 20
By utilizing the procedure of Example 19, by reacting p-hydroxybenzoic acid methyl ester with 2-bromo-6-methyl heptane, there is obtained p-[(1,5-dimethylhexyl)oxy]benozic acid methyl ester; B.P. 132°-134° C./0.1 mmHg.
EXAMPLE 21
By utilizing the procedure of Example 19, by reacting p-hydroxybenzoic acid methyl ester with 2-bromo-5,6-dimethyl heptane, there is obtained p-[(1,4,5-trimethylhexyl)oxy]benzoic acid methyl ester; n D 25 = 1.4938.
EXAMPLE 22
By utilizing the procedure of Example 19, by reacting p-hydroxybenzoic acid methyl ester with 3-bromo-7-methylnon-6-ene, there is obtained p-[(1-ethyl-5-methyl-4-haptenyl)oxy]benzoic acid methyl ester; B.P. 202°-205° C./12 mmHg.
EXAMPLE 23
By utilizing the procedure of Example 19, by reacting 3-methyl-4-hydroxybenzoic acid methyl ester with 1-bromo-3,7-dimethyl-2,6-octadiene, there is obtained 3-methyl-4-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid methyl ester; n D 28 = 1.5248.
EXAMPLE 24
7.2 g of p-[(1,5-dimethyl-hex-4-enyl)oxy]-benzoic acid methyl ester is dissolved in 30 ml of 2-N aqueous caustic soda, diluted with 50 ml of an aqueous solution of 50% by volume methanol and heated under reflux for 11/2 hours. The reaction solution is then cooled, treated with 200 ml of water and exhaustively extracted with diethyl ether. The alkaline aqueous phase is acidified with 2-N hydrochloric acid and exhaustively extracted with diethyl ether. The latter ether extract is dried over sodium sulfate and evaporated under reduced pressure. The residual p-[(1,5-dimethylhex-4-enyl)oxy]benzoic acid is purified by crystallization from benzene; M.P. 57°-59° C.
EXAMPLE 25
By utilizing the procedure of Example 24, the following acids can be obtained from their corresponding methyl esters:
p-[(1,5-dimethylhexyl)oxy]benzoic acid; M.P. 55° C.;
p-[(3,7,11-trimethyl-dodeca-2,6,10-trienyl)oxy]benzoic acid; M.P. 80°-81° C.;
p-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid; M.P. 118°-120° C.;
p-[(3,6,7-trimethylocta-2,6-dienyl)oxy]benzoic acid; M.P. 128°-129° C.;
p-[(1,5-dimethylhexyl)oxy]-3-chlorobenzoic acid; n D 26 = 1.5231;
p-[(1,5-dimethylhexyl)oxy]vanillic acid; M.P. 69°-70° C.;
p-[(3-methyl-2-butenyl)oxy]benzoic acid; M.P. 153°-154° C.;
p-[(1,4,5-trimethylhexyl)oxy]benzoic acid; n D 21 = 1.5082;
p-[(1-ethyl-5-methyl-4-heptenyl)oxy]benzoic acid; n D 21 = 1.4891; and
3-methyl-4-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid; F.P. 93°-94° C.
EXAMPLE 26
4.1 g of a 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 25 ml of tetrahydrofuran each time and then, added to 50 ml. of tetrahydrofuran. A solution of 20 g of p-[(1,5-dimethylhexyl)oxy]benzyl alcohol in 100 ml of tetrahydrofuran is then added dropwise to this mixture. 10.3 g propargyl bromide in 40 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual oily p-[(1,5-dimethylhexyl)oxy]-α-propargyloxytoluene is purified by adsorption on Kieselgel; B.P. 170°-175° C./1.0 mmHg.
EXAMPLE 27
42 g of p-[(1,5-dimethylhexyl)oxy]benzoic acid methyl ester is dissolved in 250 ml of benzene and, with stirring, treated dropwise with 50 g of 70% bis(2-methoxy-ethoxy)sodium aluminum hydride. The reaction solution is further stirred at 25° C. for 5 hours and thereafter treated with water. The organic phase is separated off, dried under sodium sulfate, carefully filtered (using a filter aid) and evaporated under reduced pressure. There is obtained a residual of p-[(1,5-dimethylhexyl)oxy]benzyl alcohol; B.P. 180°-182° C./1.0 mmHg.
EXAMPLE 28
By utilizing the procedure of Example 26, by reaction p-[(3-methyl-2-butenyl)oxy]benzyl alcohol with propargyl bromide, there is obtained 1-[(3-methyl-2-butenyl)oxy]-4-propargyloxy-toluene; B.P. 146°-149° C./1 mmHg.
EXAMPLE 29
10.1 g of a 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 50 ml of tetrahydrofuran each time and then, introduced into 100 ml of tetrahydrofuran. A solution of 32 g of p-hydroxybenzoic acid methyl ester in 200 ml of tetrahydrofuran is then added dropwise to the sodium hydride mixture. 40.5 g of 1-bromo-3-methylbut-2-ene in 80 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual oily p-[(3-methyl-2-butenyl)oxy]benzoic acid methyl ester is purified by adsorption on Kieselgel. M.P. 45°-46° C.
By utilizing the procedure of Example 27, p-[(3-methyl-2-butenyl)oxy]benzoic acid methyl ester is converted into p-[(3-methyl-2-butenyl)oxy]benzyl alcohol; M.P. 41°-42° C.
EXAMPLE 30
2.2 g of 50% by weight suspension of sodium hydride in mineral oil is washed twice in an inert gas atmosphere with 25 ml of tetrahydrofuran each time and then added to 30 ml of tetrahydrofuran a solution of 9.9 g of p-[(2,3-epoxy-3-methylbutyloxy)benzoic acid in 100 ml of tetrahydrofuran is then added dropwise to the sodium hydride mixture 5.5 g of propargyl bromide in 20 ml of hexamethyl phosphoric acid triamide is subsequently added dropwise to the mixture. The reaction mixture is heated under reflux conditions for 2 hours, then cooled, poured onto ice and exhaustively extracted with diethyl ether. The ether extract is washed with water, dried over sodium sulfate and evaporated under reduced pressure. The residual oily p-[(2,3-epoxy-3-methylbutyloxy)benzoic acid propargyl ester is purified by adsorption on Kieselgel; M.P. 80°-81° C.
EXAMPLE 31
3.9 g of p-[(1,5-dimethyl-hex-4-enyl)oxy]benzoic acid propargyl ester is dissolved in 150 ml of methylene chloride. The solution is treated dropwise at 0° C. with a solution of 3.0 g of 80% by weight m-chloroperbenzoic acid in 100 ml of methylene chloride. After 15 mins., the reaction mixture is successively washed with an aqueous solution of 2% by weight sodium bisulphite with an aqueous solution of 5% by weight sodium bicarbonate and with water. The organic phase is separated off, washed over sodium sulphate and evaporated under reduced pressure. The residual p-[(4,5-epoxy-1,5-dimethylhexyl)oxy]benzoic acid propargyl ester is purified by adsorption on Kieselgel; B.P. 120°-123° C./0.05 mmHg.
EXAMPLE 32
By utilizing the procedure of Example 31, 2.0 g of p-[(3,7-dimethyl-2,6-octadienyl)oxy]benzoic acid propargyl ester is converted into p-[(6,7-epoxy-3,7-dimethyl-2-octenyl)oxy]benzoic acid propargyl ester; n D 24 = 1.5362.
EXAMPLE 33
1.15 g of p-[(3-methyl-2-butenyl)oxy]-α-propargyloxy-toluene is dissolved in 40 ml of methylene chloride and cooled to 0° C. (ice-bath cooling). 1.5 g of 80% by weight m-chloroperbenzoic acid is added portionwise to this mixture and the solution is thereafter stirred at 0° C. for 2 hours. The mixture is worked up as follows: diluted with 350 ml of methylene chloride; washed with ice-cold 1-N caustic soda; washed with saturated aqueous sodium chloride solution; dried over sodium sulfate; and evaporated. By chromatography on Kieselgel, there is obtained p-[(2,3-epoxy-3-methylbutyloxy]-α-propargyloxy-toluene; B.P. 120°-123° C./0.1 mmHg.
EXAMPLE 34
6.4 g of 1-[(3-methyl-2-butenyl)oxy]-4-propargyloxy-benzene is dissolved in 80 ml of methylenechloride and cooled to 0° C. (ice-bath cooling). 7.15 g of 80% by weight m-chloroperbenzoic acid is added portionwise to this mixture and the solution is thereafter stirred at 0° C. for 2 hours. The mixture is worked up as follows: diluted with 350 ml of methylene chloride; washed with ice-cold 1-N caustic soda; washed with saturated aqueous sodium chloride solution; dried over sodium sulfate; and evaporated. By chromatography on Kieselgel, there is obtained 1-[(2,3-epoxy-3-methylbutyl)oxy]-4-propargyloxy-benzene; M.P. 72°-73° C.
EXAMPLE 35
By utilizing the procedure of Example 26, by reacting p-[(1,5-dimethylhexyl)thio]benzyl alcohol with propargyl bromide, there is obtained p-[(1,5-dimethylhexyl)thio]-α-propargyloxy-toluene; n D 29 = 1.5243.
EXAMPLE 36
By utilizing the procedure of Example 27, p-[(1,5-dimethylhexyl)thio]benzoic acid methyl ester is converted into p-[(1,5-dimethylhexyl)thio]benzyl alcohol; n D 29 = 1.5270.
EXAMPLE 37
By utilizing the procedure of Example 19, by reacting p-thio benzoic acid methyl ester with 2-bromo-6-methylheptane, there is obtained p-[(1,5-dimethylhexyl)-thio]benzoic acid methyl ester; B.P. 168°-170° C./0.5 mmHg.
EXAMPLE 38
By utilizing the procedure of Example 8, by reacting p-[(1,5-dimethylhexyl)thio]benzoic acid and propargyl bromide, there is obtained p-[(1,5-dimethylhexyl)thio]benzoic acid propargyl ester M.P. 130°-131° C./0.03 mmHg.
EXAMPLE 39
By utilizing the procedure of Example 24, p-[(1,5-dimethylhexyl)thio]benzoic acid methyl ester is converted into p-[(1,5-dimethylhexyl)thio]benzoic acid; M.P. 63°-65° C.
EXAMPLE 40
By utilizing the procedure of Example 8, by reacting p-[(3,6,7-trimethyloctyl)oxy]benzoic acid with propargyl bromide, there is obtained p-[(3,6,7-trimethyloctyl)oxy]benzoic acid propargyl esters; B.P. 153°-154° C./0.05 mmHg.
EXAMPLE 41
5 g of p-[(3,6,7-trimethylocta-2,6-dienyl)oxy]benzoic acid is dissolved in 20 ml of acetic ester and hydrogenated under normal pressure and at a temperature of about 25° C. in the presence of 0.2 g of platinum oxide. The hydrogenation is terminated after the uptake of 2 mols of hydrogen, and the catalyst is filtered off from the reaction mixture. The clear solution is evaporated under reduced pressure. The residual p-[(3,6,7-trimethyloctyl)oxy]benzoic acid is purified by crystallization from petroleum ether; M.P. 89°-90° C.
EXAMPLE 42
10 g of p-[(1,5-dimethylhexyl)oxy]benzoic acid is heated to 70° C. with 20 ml of thionyl chloride for 10 mins. The clear yellow-colored solution is evaporated at 50° C. under water-jet pump vacuum. After the addition of 40 ml of propargyl alcohol, the mixture is heated to 70° C. for 15 min. After evaporation in water-jet pump vacuum, the residue is chromatographed on Kieselgel, yielding p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester; B.P. 207°-210° C./1.0 mmHg.
EXAMPLE 43
10 g of p-[(1,5-dimethylhexyl)oxy]benzoic acid methyl ester, 30 ml of propargyl alcohol and 0.5 g of sodium methoxide are heated to reflux for 1/2 an hour. The excess propargyl alcohol is thereupon slowly (5 hrs.) distilled off. The residue is poured onto water and extracted with diethyl ether. The ether solution is dried with sodium sulfate and evaporated. The dark-yellow p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester obtained is purified over kieselgel.
EXAMPLE 44
13 g of p-[(1,5-dimethylhexyl)oxy]benzoic acid methyl ester is heated to reflux with 9 g of propargyl alcohol and 0.1 g of p-toluenesulphonic acid. The excess propargyl alcohol is thereupon slowly (5 hrs.) distilled off. The residue is poured onto water and extracted with diethyl ether. The ether phase is dried with sodium sulfate and evaporated. There is obtained dark-yellow p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester which is purified on Kieselgel.
The experiments described in the following examples are carried out with the following representative examples of the propargyloxy derivatives of this invention as the active substances.
(I) p-[(1,5-dimethylhexyl)oxy]-α-propargyloxytoluene
(II) p-[(1,5-dimethylhexyl)oxy]benzoic acid propargyl ester
(III) p-[(1,5-dimethyl-4-hexenyl)oxy]benzoic acid propargyl ester
(IV) 1-[(2,3-epoxy-3-methylbutyl)oxy]benzoic acid propargyl ester
(V) 1-[(1,5-dimethylhexyl)oxy]-4-(propargyloxy)benzene
(VI) 1-[(2,3-epoxy-3-methylbutyl)oxy]-4-(propargyloxy)-benzene.
EXAMPLE 45
2 filter paper discs [24 cm 2 ] are sprayed with an acetonic solution of the active substance, and after drying, the discs together with an untreated paper disc and with a paper disc soaked only with acetone, are each so fixed together that there is formed a tunnel for the shelter of 10 cockroaches (Blattella germanica) each. The cockroaches are in the last larval stage. They remain in permanent contact with the treated paper and are provided with water and food.
The development of the larvae set out is registered daily. 100% disturbance of metamorphosis: A normal animal develops from none of the larvae
______________________________________ Amount of Number Number active Number of ofActive substance of normal normal Activitysubstance 10.sup.-x g/cm.sup.2 larvae imagos animals %______________________________________I 10.sup.-4 10 1 5 83Control with acetone 10 10 -- --Control with acetone 10 10 -- --______________________________________
EXAMPLE 46
A disc of cotton material [10 cm 2 ] is sprayed with an acetonic solution of the active substance, and after drying, the disc, together with an untreated disc of material and a disc of material soaked only with acetone, are each occupied by 30-60 freshly laid eggs of the meal moth (Ephestia kuhniella). The disc is placed in a cage and held at 25° C. and 90% rel. humidity.
The development of the eggs is registered over a few days. 100% mortality of the eggs: No development of the embryos in the eggs layed on discs of material soaked with active substance.
______________________________________ Amount of active Number NumberActive substance of of Mortalitysubstance 10.sup.-x g/cm.sup.2 eggs larvae %______________________________________I 10.sup.-5 32 0 100 10.sup.-6 33 0 100II 10.sup.-5 32 0 100 10.sup.-6 30 0 100III 10.sup.-4 40 0 100 10.sup.-5 36 0 100 10.sup.-6 36 0 100IV 10.sup.-5 47 0 100 10.sup.-6 33 0 100V 10.sup.-5 44 0 100 10.sup.-6 34 0 100Control with acetone 50 50 0Control with acetone 49 46 6______________________________________
EXAMPLE 47
A disc of woollen material [10 cm 2 ] is sprayed with an acetonic solution of the active substance, and the disc, together with an untreated disc of material and a disc of material soaked only with acetone, are each hung in a cage occupied by 20 young cloths moth (Tineola biselliella).
The development of the eggs layed at 25° C. is registered for 4 days. 100% sterilant action: larvae hatch from none of the eggs laid on treated and untreated discs of woollen material. 100% ovicidal action: larvae hatch from none of the eggs laid on treated discs of woollen material.
______________________________________ Amount of active Sterilant substance action Ovicidal actionActive substance 10.sup.-x g/cm.sup.2 % %______________________________________VI 10.sup.-3 0 100 10.sup.-4 0 100Control with acetone 0 0Control with acetone 0 0______________________________________
EXAMPLE 48
A filter paper strip [90 cm 2 ] is sprayed with an acetonic solution of the active substance and, after drying, the strip, together with an untreated paper strip and a paper strip soaked only with acetone, are each occupied by 3-4 pairs of freshly moulted images of the cotton bug (Dysdercus cingulatus).
The development of the eggs laid daily is registered. 100% mortality of the eggs: no development of the embryos in the eggs laid on strips soaked with active substance.
______________________________________ Amount of activeActive substance Number of Number of Mortalitysubstance 10.sup.-x g/cm.sup.2 eggs larvae %______________________________________I 10.sup.-5 380 -- 100 10.sup.-6 50 -- 100II 10.sup.-5 430 -- 100III 10.sup.-5 311 4 99IV 10.sup.-5 392 60 83Control with acetone 270 262 3Control with acetone 41 390 5______________________________________
EXAMPLE 49
1 g of p-[(3-methyl-2-butenyl)oxy]-α-(2-propynyloxy)toluene was dissolved in a mixture of 80 ml of dioxane and 40 ml of water. To this solution there was added under cooling with ice (10° C.) portionwise 0.85 g of N-bromosuccinimide. After this addition the mixture was stirred at room temperature for 15 hours and then diluted with 80 ml of water. Thereafter 2.5 g of sodium sulfite are added and the solution exhaustively extracted with ether. The combined ether extracts were washed with water, dried over sodium sulfate and evaporated. By chromatography on Kieselgel with hexane/ethyl acetate (85:15 parts by volume) there was obtained p-[(3-bromo-2-hydroxy-3-methylbutyl)oxy]-α-(2-propynyloxy)toluene. n D 22 : 1.5374. | Alkynyl, benzyl or phenyl, ethers and esters which are ring substituted with an oxy or a thio aliphatic chain. These ethers and esters are usful in killing and preventing the proliferation of insects by upsetting their hormonal balance. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention is instrumental chemistry as it relates to integrated systems for carrying out combined separation and analytical operations. More specifically, this invention relates to an apparatus and method for integrating a capillary electrophoresis apparatus with an off-column detection system, particularly detection systems using pyro-chemiluminescent techniques.
2. Description of the Prior Art
Capillary electrophoresis (CE) has been highly praised for its capacity to separate sample components using only minute volumes of sample and reagents and yet providing highly resolved separations in extremely short analysis times. The limitation of this technique lies in the relatively few means available with which to conduct highly sensitive analyses on those separated sample components. At present, on-line detection techniques employed with CE can be described based on the location of their analysis as on-column, end-column or off-column.
On-column analytical methods are typically conducted across the capillary either through a window or an opening provided in the capillary wall. On-column techniques such as ultraviolet-visible absorption are in common use because they do not interfere with the separatory operation of the CE and require simple instrumentation. However, as is described in Analyst, "Time-resolved Luminescence Detection of Europium(III) Chelates in Capillary Electrophoresis," Latva, M. et al., Vol. 120, 367-372 (February 1995), the detection limits of the absorption methods are poor due to their dependence on optical path length which is very short across the capillary. The inner diameter of the capillary of a CE is typically in the range of 25 to 100 micrometers.
Alternatively, on-column amperometric detection may provide relatively good detection limits. However, periodic cleaning of the working electrode is required to maintain the detector's performance. This cleaning requirement is accompanied by the additional problem of electronically isolating the working electrode from the high potential field that is applied across the CE capillary during its operation. One solution for isolating the working electrode from the applied potential is to convert the on-column amperometric technique to an end column method. As is described in Analytical Chemistry, "End-Column Detection for Capillary Zone Electrophoresis," Huang, X. and Zare, R. N., Vol. 63, 189-192 (1991) the working electrode may be completely removed from the potential field of the CE by locating a microelectrode adjacent the capillary outlet at the end of the column. However, Huang recognizes that although this arrangement resolves the isolation problem, it is accompanied by losses in both sensitivity and resolution.
Fluorescence is another photometric method for conducting on-column analyses. Conventional fluorescent methods are described in Analytical Chemistry, "Fluorescence Detection in Capillary Electrophoresis: Evaluation of Derivatization Reagents and Techniques," Albin, M. et al., Vol. 63, 417-422 (1991). It is well established that although fluorescent methods can be highly sensitive and selective, the techniques require that the sample components be fluorescent or chemically convertible to a fluorescing compound. These tagging and/or derivatization procedures can be particularly difficult when performed at the low analyte concentrations that are characteristic of CE. Further, these processes can be complex and greatly increase the risk of contaminating the sample. It is also noteworthy with respect to laser induced fluorescence, that the number of fluorescing compounds available for derivatization procedures is further limited by the number of excitation wavelengths of available lasers.
The problem that accompanies any attempt to integrate two or more systems is the interfering effect the systems may have on one another. Background on the mechanism by which CE separates samples into individual components is helpful in understanding the problems that accompany the integration of CE with an off-column detection system.
CE separates the components of a sample on the basis of the electrical properties of those components. A capillary, typically of fused silica, is filled with an ionic buffer solution and the ends of the capillary are emersed in reservoirs containing additional buffer solution. Electrodes are provided at the opposite ends of the capillary and a high voltage potential in the range of 20 to 30 kilovolts is applied. The sample components are caused to migrate under the influence of the applied potential in what is commonly referred to as electroosmotic flow. The unique feature of electroosmotic flow is that it produces a flat profile in the migrating sample across the capillary. Conversely, when a sample is driven through a capillary by hydrostatic pressure, the sample front will have a parabolic profile which increases the occurrence of band broadening and diminishes resolution. The flat profile generated by CE provides enhanced resolution in sample separation over and above that obtainable from chromatographic techniques. Naturally, any convection, currents or pressure differentials existing or created within the CE system will adversely affect the flat profile of the sample as it travels through the capillary. In order to avoid these adverse affects most detection systems employed with CE use either an on-column or end-column approach.
Detectors and methods that require the analyte to be transferred from the capillary outlet to a detector for analysis are referred to as off-column systems. Off-column systems are less known in the art because the connections between the capillary outlet and the detection systems have introduced problems that interfere with the separatory operation of the CE. In addition to the problems discussed above, transfer of CE eluent for off-column detection may include the problems of dead volume and band dispersion due to turbulence and/or resistances to mass transfer. Further still, the transfer is complicated by the fact that the volume of CE eluent will typically be only in the nanoliter range.
Instrumentation Science & Technology, "Fabrication And Evaluation Of Post-Capillary Junctions Via Micro-scale Molding For Use As Reactors And Flow Multiplexers In Capillary Electrokinetic Separations," Staller, T. D. and Sepaniak, M. J., 23(4), 235-254 (1995) describes methods for making and using junctions for integrated systems. The junctions are molded from polymers such as polyimides and epoxys. Specifically, the CE in Staller is integrated with a chemiluminescent/fluorescent technique wherein the chemiluminescent reaction occurs within the molded junction and the light generated by the reaction is transferred by optical fiber to a photomultiplier tube for detection. The problems of dead volume and turbulence due to the addition of reagents are addressed in terms of the geometries of the junction's structure. The junction between the CE and the detection apparatus is described as a closed system, and no means are suggested or disclosed for preventing pressure differentials across the junction or between the CE and detector instrumentation.
Earlier efforts directed at coupling CE to a detector for conducting off-column analysis have been with respect to mass spectrometry, or CE-MS systems. These developments are well documented in Analytical Chemistry, "Capillary Electrophoresis/Mass Spectrometry," Smith, R. D. et al., Vol. 65, No. 13 (Jul. 1, 1993). The CE-MS systems developed have largely relied on an electrospray ionization (ESI) method in which the CE eluent is converted to an electrospray that can be drawn into the mass spectrometer by a high vacuum provided at the mass spectrometer inlet. Recent developments have focused on eliminating the sheathing solution that is used to facilitate the conversion of the CE eluent to a spray. However, because the mass spectrometer operates under an extremely high vacuum, these integrated systems are not capable of controlling the pressure within the interfacing apparatus. Further, these systems generally require a gap between the nebulizer and inlet to the mass spectrometer and thus do not provide a closed interface between the two instruments.
Therefore it is a feature of the present invention to provide an apparatus and method for interfacing a capillary electrophoresis apparatus with an off-column detection system that will not create convection, currents or pressure differentials that would otherwise adversely affect the electroosmotic flow in the capillary of the CE.
It is another feature of the present invention to provide an apparatus and method for interfacing a CE apparatus with an off-column detection system of the type described above in which the pressure within the interfacing apparatus may be adjusted by the introduction and venting of gases of which one may be an inert gas.
It is yet another feature of the present invention to provide an apparatus and method for interfacing a CE apparatus with an off-column detection system of the type described above in which an exit housing is attached to the capillary above the capillary outlet wherein a flow of ionic sheathing buffer is used to complete the electrical circuit of the CE apparatus and to carry the CE eluent into the off-column detector apparatus.
It is still yet another feature of the present invention to provide an apparatus and method for interfacing a CE apparatus with an off-column detection system of the type described above in which the detector is a chemiluminescent detector utilizing pyro-chemiluminescent technique, the furnace of which introduces pressure variations within the interface apparatus which would otherwise interfere with the operation of the CE.
It is still yet another feature of the present invention to provide an apparatus and method for interfacing a capillary electrophoresis apparatus with an off-column detection system of the type described above in which the head pressure at the inlet of the capillary of the CE is equalized with the pressure within the interface apparatus so that a pressure gradient or differential is not created within the CE capillary.
It is still another feature of the present invention to provide an apparatus and method for interfacing a capillary electrophoresis apparatus with an off-column detection system of the type described above in which the head pressure at the capillary inlet of the CE apparatus is controlled so that analyses may be performed at other than atmospheric pressure conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular description of the invention briefly summarized above may be had by reference to the exemplary preferred embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only typical preferred embodiments of the invention and are therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is a schematic view of an integrated capillary electrophoresis--chemiluminescent nitrogen detector in accordance with the present invention.
FIG. 2 is a detailed diagrammatic view of an integrated capillary electrophoresis--chemiluminescent nitrogen detector in accordance with the present invention.
FIG. 3 is a detailed diagrammatic view of an integrated capillary electrophoresis--chemiluminescent nitrogen detector in accordance with the present invention wherein means are provided for controlling the head pressure at the capillary inlet.
FIG. 4a is a graphical representation of the results of an analysis of a sample solution containing L-phenylalanine and para-amino salicylic acid as conducted on the apparatus of FIG. 2.
FIG. 4b is a graphical representation of the results of an analysis of a sample containing a standard solution of L-phenylalanine as conducted on the apparatus of FIG. 2.
FIG. 4c is a graphical representation of the results of an analysis of a sample containing a standard solution of para-amino salicylic acid as conducted on the apparatus of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The development of the present invention is directed to interfacing a capillary electrophoresis (CE) apparatus with a chemiluminescent nitrogen detector (CLND) that is capable of detecting chemically bound nitrogen in organic compounds. It is anticipated that this integrated CE-CLND system will have significant commercial value in that it is appropriate for use in clinical, pharmaceutical, industrial, educational and environmental fields. However, the scope of the present invention is not limited to a CE integrated with an off-column nitrogen detector but will include other off-column detectors including without limitation those capable of analyzing carbon compounds using infrared methods, chlorine and fluorine compounds using element selective electrodes and sulfur compounds using sulfur chemiluminescent methods.
Now referring to the drawings, FIG. 1 is a schematic representation of an apparatus of the present invention. A capillary electrophoresis apparatus, noted generally at reference number 1, has capillary 2 that is made from open blank fused silica capillary tubing approximately 80 centimeters in length and having an inner diameter of 50 micrometers. The inner surface of capillary 2 may optionally be coated with a suitable stationary phase as determined by the sample to be separated. For instance, when using the apparatus of the present invention to separate and analyze proteins it is preferable that the inner surface of capillary 2 be coated with a stationary phase containing amino groups (--NH 2 ).
As shown in more detail in FIG. 2, the CE apparatus includes the inlet of capillary 2 emersed in a reservoir containing ionic buffer solution 9. Reference number P1 indicates the head pressure on ionic buffer solution 9 and thus the pressure at the capillary inlet. Also in contact with ionic buffer solution 9 is electrode 10. In a typical CE analysis, electrode 10 would be the positive electrode while the electrode at the outlet, electrode 12, would be the negative electrode. In this arrangement, the sample components will be separated according to their electronic properties and the components bearing positive charges will emerge from the capillary first, followed by the neutral components and then the negatively charged components.
Electrodes 10 and 12 are arranged at opposite ends of capillary 2 and a potential of about 30 kilovolts is applied by high voltage power source 8. This voltage level will result in a steady current of nearly 10 microamps. The circuit between the electrodes is completed through capillary 2 by ionic buffer solution 9 that fills the capillary. This solution may be any ionic buffer. An example of this invention using a solution consisting of 0.3% sodium borate and 0.4% boric acid in water is presented herein. The results of this example are presented graphically as FIGS. 4a, 4b and 4c.
Detector 7 in FIG. 1 is a chemiluminescent nitrogen detector that is connected to the CE via the interfacing apparatus. As noted above, the specific type of detection system employed will depend upon the chemical element or compound that is of interest. While it is anticipated that almost any type of detector may be interfaced with CE using an apparatus of the present invention, those off-column detectors that are destructive of the sample such as those which employ furnaces as in pyro-chemiluminescent techniques and those which require that the sample be volatilized in carrying out the analysis will receive the greatest benefit from the apparatus and method of the present invention. The adverse effects of these types of detectors on the CE operation can be minimized if not eliminated altogether.
Interfacing apparatus 32 is shown in more detail in FIG. 2 and is composed of a number of elements that complete and maintain the electrical circuit of the CE and provide a carrier for the CE eluent. Sheathing buffer reservoir 3 contains a sheathing buffer which is preferably identical to ionic buffer solution 9. Pump 4 is utilized to deliver an adjustable flow of sheathing buffer to exit housing 5. Pump 4 should have flow rates adjustable from 1 to at least 500 microliters per minute. Exit housing 5 is shown as a cylindrical structure that encloses the lower end of capillary 2 and forms a closed connection between the capillary 2 and detector 7. However, the configuration of exit housing 5 should not be considered to be restricted to this cylindrical structure. Housing 5 is attached to the external surface of the capillary 2 above capillary outlet 6 and extends below that outlet to connect with detector inlet 35.
Electrode 12 of the CE is attached to high voltage power supply 8 via electrical lead 11. Electrode 12 is attached to the external surface of capillary 2 just above capillary outlet 6. The electrical connection and thus the potential applied across capillary 2 is maintained by the flow of sheathing buffer that is directed across electrode 12 and across capillary outlet 6. Reference P2 is the pressure within interface apparatus 32 adjacent capillary outlet 6.
As shown in FIG. 2, capillary outlet 6 is in fluid communication with the furnace 15 of detector 7 via detector inlet 35. CE eluent is carried away from the capillary outlet 6 as it emerges from the outlet. The eluent is carried out of the exit housing and into detector inlet 35 leading directly into furnace 15. Also connected to inlet 35 is inert gas source 13. The flow of gas from source 13 is controlled by valve 14. Further, furnace 15 is connected to oxygen source 16 with the flow of oxygen controlled by valve 20.
Connected to furnace 15 is flow splitter 17. Splitter 17 is capable of directing the combusted products exiting the furnace to dryer 21 and through valve 33 to an exit vent. The dried combusted products are then directed to detector assembly 22 where they pass through porthole 23 located in the wall of reaction chamber 25. Entering chamber 25 through porthole 24 is ozone (O 3 ) that has been generated by ozone generator 19. Ozone generator 19 is supplied with oxygen (O 2 ) by oxygen supply source 16, the flow from source 16 being regulated by valve 18.
Where the CE has been used to separate nitrogen containing compounds, the combustion products of furnace 15 will include nitric oxide gas that will react with the ozone in reaction chamber 25. The products of this reaction are nitrogen dioxides in the excited state. As the excited nitrogen dioxides relax to the ground state, they spontaneously emit photons in an amount that is proportional to the number of nitrogen atoms in the components of the CE separation. The radiation of the photons passes through filter 26 which allows the passage of light having wavelengths within the range of 600 to 900 nanometers. The light that passes through filter 26 is detected by photomultiplier tube 27 which generates an electrical signal which is sent to signal integrator 29. Integrator 29 includes amplifier 30 and V/F converter 31.
Variations in pressure within interface 32 are mostly due the operation of furnace 15. The pressure inside the furnace may under one operating condition result in a back-flush of positive pressure causing P2 to be greater than P1, and under another operating condition, generate negative pressure that causes P1 to be greater than P2. In either case, the electroosmotic flow is adversely affected and little or no separation of sample components can be obtained from the CE. There are several means disclosed in the present invention with which to adjust the pressure within a closed interface between CE and detector apparatuses. Variables affecting the pressure within interface 32 include the flow rate of the sheathing buffer as controlled by pump 4, the flow rate of inert gas from source 13 into inlet 35, the oxygen flow rate from source 16 and the rate at which combusted products are removed from furnace 15. With respect to the removal of combusted products from the furnace, as shown in FIGS. 2 and 3, flow splitter 17 and valve 33 are provided for diverting a portion of the combusted products from the furnace directly to an exit vent. By opening valve 33 and directing a portion of the combusted products to the outside vent, the internal pressure within furnace 15 is reduced and the potential for back flush is removed. Additional adjustments of the other variables affecting the interface pressure may be required to balance P2 with P1. When this balance is achieved, the separatory operation of the CE will not be interrupted by the operation of the furnace or some other off-column detector.
As shown in FIG. 3, pressure control means may also be used to adjust the head pressure on the ionic buffer solution 9 at the capillary inlet. Gas source 13 is shown to be connected to the closed reservoir containing buffer solution 9. Gas source 13 is preferably an inert gas, however, it may also be oxygen, air or any mixture thereof. Valve 34 is shown as the means for controlling the flow of inlet gas from source 13 into the reservoir. Not shown is a vent to the reservoir which may be used to release excess head pressure. Conventional CE operations using open capillary tubing is conducted with inlet and outlet reservoirs largely open to atmospheric conditions. By having a closed system and means for controlling and balancing pressures at either end of the CE apparatus, the integrated separation and analysis technique of the present invention may be performed at conditions varying from standard and/or atmospheric without adversely affecting the function of the individual systems.
FIG. 4a is a graphical representation of results obtained from an apparatus having the features of the present invention. In the procedure employed in obtaining FIG. 4a, an open capillary tube approximately 80 centimeters in length and having an inner diameter of 50 micrometers was used. The CE apparatus was obtained from Helena Laboratories of Beaumont, Tex., and the chemiluminescent nitrogen detector is manufactured by Antek Instruments, Inc. of Houston, Tex. The separation and detection results achieved using the principles of the present invention were confirmed by results obtained from identical analyses performed on sample standards. These confirming results are presented graphically in FIGS. 4b and 4c.
The ionic buffer solution was a 0.3% sodium borate and 0.4% boric acid in water. A discrete sample of a solution containing the amino acid, L-phenylalanine, and para-amino salicylic acid was injected into the capillary inlet. The inlet of capillary 2 was then emersed in ionic buffer solution 9. Pressure at P1 and P2 was adjusted to about 50 millibars. Equalization at this pressure was obtained by adjusting the head pressure on the ionic buffer solution at the capillary inlet, adjusting the flow rate of the sheathing buffer into exit housing 5 and by adjusting the opening at flow spitter 17 for products coming off the furnace. Generally, to reduce the pressure at P2 to a satisfactory level it was found that flow splitter 17 should be substantially open so that a large amount of combustion gases are directed out of the furnace.
A voltage of 30 kilovolts was applied to the capillary to induce the electroosmotic flow. The measured current obtained from the applied potential was a steady 9.8 microamps. The flow rate of the sheathing buffer was adjusted to be sufficiently high to maintain the electrical circuit and to carry the CE eluent into the detector apparatus. However, as noted above the contribution of the flow rate to the pressure within the interface apparatus should be the determining factor regarding the sheathing buffer flow rate.
The results of the separation and analysis of the L-phenylalanine/para-amino salicylic acid solution are presented graphically in FIG. 4a. Peak A represents the L-phenylalanine component of the sample solution while peak B represents the para-amino salicylic acid component. The identity of these peaks is confirmed by the separate analyses performed on standards of these two components using the same procedure and conditions. The results of these two additional analyses are presented in FIGS. 4b and 4c, representing L-phenylalanine and para-amino salicylic acid respectively.
In terms of the method of the present invention, off-column detection is shown to be a reliable and accurate method for conducting an integrated analysis following sample separation by CE. This analysis is made possible by creating a closed system that interfaces the instrumentation of the two systems and allows for pressure control either within the interface or more preferably within the interface and at the CE inlet. It is this pressure control that enables pressure equalization at either end of the CE apparatus and compensates for any adverse affects originating from the operations of an integrated detector.
Further additional optional embodiments can be chosen by using pyro-chemiluminescent detector 7 directed to different chemical elements and by using different types of detectors which would otherwise interfere with the operation of the CE 1 without the closed pressure controlled interface 32 in accordance with the present invention. However, the general principles of operation are applicable as discussed above even though the combinations available are more complex. Thus while several embodiments have been discussed and other embodiments have been generally described, it is understood that the invention is not limited thereto, since many modifications may be made and will become clear to those skilled in the art. | An apparatus and method for interfacing a capillary with a detector is disclosed. In particular, a capillary that is used in a capillary electrophoresis technique is interfaced with an off-column detector that is destructive of the sample or that will otherwise create adverse affects on the operations of the capillary electrophoresis. By way of example only, a nitrogen chemiluminescent detector using pyro-chemiluminescent techniques is discussed. An interface between the separation and detection systems is essential to prevent interference between the two systems. The interface apparatus and method are achieved by creating a closed connection between the two systems within which the pressure and sample flow rate can be controlled. Pressure control is achieved through the introduction and venting of gas into and from the integrated system. Interference between interfaced systems is then prevented by equalizing the pressure in the interface apparatus with the head pressure on the inlet end of the capillary. Also disclosed is a device for controlling the head pressure and sample flow within the capillary thereby enabling operation of an interfaced system at non-atmospheric pressure conditions. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of U.S. patent application Ser. No. 12/512,147, filed Jul. 30, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to individually packaged disposable absorbent articles, and in particular to a method of individually packaging an absorbent article and attaching the absorbent article to an undergarment.
BACKGROUND OF THE INVENTION
[0003] Individually packaged disposable absorbent articles are well known in the art. For example, feminine sanitary napkins are often sold in such a configuration. Commercially available sanitary napkins are commonly folded in three overlapping sections along the length of the napkin (“tri-folded”) and such tri-folded napkin is arranged in a sealed pouch to thereby maintain the napkin sanitary prior to use. Sanitary napkins of this type conventionally include an adhesive arranged on a garment-facing side of the napkin (“garment attachment adhesive”) to enable the user to attach the napkin to an undergarment during use. Prior to use, the garment attachment adhesive is covered by a removable release paper that is intended to protect the adhesive and prevent the garment attachment adhesive from adhering to the pouch prior to use. Alternatively, the release paper may by omitted, and the interior surface of the pouch may include a non-stick coating (e.g. silicone) to prevent the garment attachment adhesive from adhering to the pouch. When ready for use, a user removes the napkin from the pouch, unfolds the napkin, removes the release paper (if such paper is employed) and attaches the napkin to the undergarment.
[0004] The inventor of the present invention has discovered that a problem with the above described configuration is that the user must completely remove the napkin from the pouch, and remove the release paper if such release paper is present, prior to attaching the napkin to the undergarment. The above described process can be cumbersome and may cause the user to inadvertently attach the napkin at the wrong location in the undergarment and/or contaminate the garment attachment adhesive before the user attaches the napkin to the undergarment.
[0005] In view of the foregoing, the inventor has disclosed herein an improved method of individually packaging an absorbent article and method for attaching such absorbent article to an undergarment.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing the present invention provides, according to a first aspect of the invention, a method of individually packaging an absorbent article and attaching the absorbent article to an undergarment including the steps of providing a tri-folded absorbent article including a garment-facing surface having a garment attachment adhesive, a body-facing surface, a first fold line, a second fold line, a first end portion, a second end portion, and an intermediate portion arranged between the first end portion and the second end portions, the first end portion being separated from the intermediate portion by the first fold line, the second end portion being separated from the intermediate portion by the second fold line, and the intermediation portion being located between the first fold line and the second fold line, providing a pouch for containing the tri-folded absorbent article, the pouch formed from a sheet material having a first terminal edge and a second terminal edge, opening the pouch along the first terminal edge of the sheet material and lifting the sheet material to expose a garment-facing surface of the intermediate portion of the article prior to exposing the garment-facing surface of the first end portion and the garment-facing surface of the second end portion.
[0007] The present invention provides, according to a second aspect of the invention, a method of individually packaging an absorbent article and attaching the absorbent article to an undergarment including the steps of providing a tri-folded absorbent article including a garment-facing surface, a body-facing surface, a first fold line, a second fold line, a first end portion, a second end portion, and an intermediate portion arranged between the first end portion and the second end portions, the first end portion being separated from the intermediate portion by the first fold line, the second end portion being separated from the intermediate portion by the second fold line, and the intermediation portion being located between the first fold line and the second fold line, providing a pouch for containing the tri-folded absorbent article, the pouch formed from a sheet material having a first terminal edge, a second terminal edge and a line of weakness arranged between the first terminal edge and the second terminal edge, opening the pouch along the line of weakness and lifting the sheet material to expose a garment-facing surface of the intermediate portion of the article prior to exposing the garment-facing surface of the first end portion and the garment-facing surface of the second end portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a top perspective view of an individually packaged absorbent article assembly according to a first embodiment of the present invention showing the exterior surface of the pouch that forms part of the assembly;
[0009] FIG. 2 is bottom perspective view of an individually packaged absorbent article assembly according to the present invention;
[0010] FIG. 3 is a partially exploded view of the of the absorbent article assembly shown in FIGS. 1 and 2 revealing the first and second sheets of material that define the pouch and the absorbent contained within such pouch;
[0011] FIGS. 4-11 depict the manner in which the absorbent article is removed from the pouch and applied to an undergarment;
[0012] FIG. 12 is a bottom perspective view of an individually packaged absorbent article assembly according to a second embodiment of the present invention showing the exterior surface of the pouch that forms part of the assembly;
[0013] FIG. 13 is a detailed top perspective view of a portion of the individually packaged absorbent article assembly shown in FIG. 12 ;
[0014] FIG. 14 is detailed view of a portion of the individually packaged absorbent article assembly shown in FIG. 13 depicting the manner in which pouch is opened to obtain access to the absorbent article; and
[0015] FIG. 15 is a partially exploded view of the of the absorbent article assembly shown in FIG. 12 revealing the sheet of material that forms the pouch and the absorbent article contained within such pouch.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring now to the drawings there is shown an individually packaged disposable absorbent article assembly embodying the teachings of the present invention. As used herein “disposable absorbent articles” includes articles such as sanitary napkins, pantiliners, absorbent products for incontinence, and other disposable absorbent articles worn close to a wearer's body. Although the invention will be described herein with reference to a sanitary napkin, the invention may be utilized with other disposable sanitary absorbent articles such as absorbent products for incontinence, diapers, pantiliners and the like.
[0017] An individually packaged absorbent article assembly 10 according to a first embodiment of the present invention is shown in FIGS. 1-3 . The individually packaged absorbent article assembly 10 generally includes a sanitary napkin 12 and a pouch 14 .
[0018] Prior to removal from the pouch 14 , the sanitary napkin 12 is tri-folded such that three portions of the napkin 12 are defined. Specifically, referring to FIG. 3 , the napkin 12 in its folded state prior to use includes a first end portion 16 , a second end portion 18 , and an intermediate portion 20 arranged between the end portions 16 and 18 . The first end portion 16 is separated from the intermediate portion 20 by fold line 19 and the second end portion 18 is separated from the intermediate portion 20 by fold line 21 . The napkin 12 further includes a body-facing surface 22 and a garment-facing surface 24 . The terms “body-facing” and “garment-facing” as used herein are intended to indicate the final orientation of the napkin after the napkin has been attached to an undergarment by the user.
[0019] As shown in FIG. 3 , the first end portion 16 is folded toward the body-facing surface 22 and then the second end portion 18 is folded on top of and in overlapping relationship to the first end portion 16 . The napkin 12 also includes a garment attachment adhesive 26 that is applied to the garment-facing surface 24 of the napkin that functions to attach the napkin 12 to an undergarment during use.
[0020] In the specific embodiment of the invention shown in FIGS. 1-3 , the pouch 14 is defined by two lengths of a sheet material 29 that are attached to one another to form the final pouch 14 . However, the pouch 14 could alternatively be formed from a single length of the sheet material 29 . The sheet material 29 may be a plastic film sheet or a paper sheet material. The paper or plastic film sheet is coated on its inwards facing surface thereof with a coating of silicone polymer to prevent the adhesive 26 on the garment-facing surface of the napkin 12 from adhering to the pouch 14 . Other non-stick coatings may be employed provided that they effectively prevent the napkin 12 from adhering to the pouch 14 .
[0021] In the specific embodiment of the invention shown in FIGS. 1-3 , the pouch is formed by a first length of sheet material 30 and a second length of sheet material 31 . The first length of material 30 defines a first end section 32 of the sheet material 29 and the second length of material 31 defines a second end section 34 of the sheet material 29 . The first length of material 30 further defines an intermediate section 36 of the sheet material 29 arranged between the end sections 32 and 34 . The first length of material 30 includes a first terminal transverse edge 37 and a second terminal transverse edge 39 . The second length of material 31 includes a first terminal transverse edge 47 and a second terminal transverse edge 49 .
[0022] As shown in FIG. 3 the first length of material 30 partially overlaps the second length of material 31 adjacent terminal edges 39 and 47 and the two lengths of material are permanently secured to one another by a strip of adhesive or the like. Thus, in the final pouch configuration the sheet material 29 has two terminal edges, i.e. terminal edges 37 and 49 .
[0023] As shown in FIG. 3 , the first end section 32 of the sheet material 29 extends over and corresponds in location to the intermediate portion 20 of the napkin 12 . The intermediate section 36 of the sheet material 29 extends over and corresponds in location to the second end portion 18 of the napkin 12 . The second end section 34 of the sheet material 29 extends over and corresponds in location to the first end portion 16 of the napkin 12 .
[0024] It is noted that in the final pouch 14 configuration the first terminal edge 37 of the first length of material 30 is substantially aligned with the fold line 19 of the napkin 12 that separates the intermediate portion 20 of the napkin 12 from the first end portion 16 of the napkin 12 .
[0025] Along the first terminal edge 37 , the first length of material 30 may optionally be provided with a tab 41 . The tab 41 may be formed from the first length of material 30 or may constitute a separate piece of material permanently attached to the first length of material 30 . As show in FIG. 2 , the tab 41 overlaps the end section 34 of the pouch 14 and is secured to the external surface of the end section 34 by adhesive arranged on a bottom surface 43 of the tab 41 . The adhesive provided on the bottom surface 43 of the tab 41 should be selected so as to enable a user to selectively open the pouch 14 by pulling on the tab 41 , as will be described herein in greater detail below.
[0026] As shown in FIGS. 1 and 2 , the pouch 14 also includes side seams 40 defined by embossments running along and defining opposite longitudinal edge zones of the pouch. The side seams 40 function to seal the overlapping portions of the sheet material 29 and thereby form a sealed enclosure for the napkin 12 . The embossments may be formed by any suitable known means to provide such embossments, such as heated embossing rolls or the like. Alternatively, in lieu of embossments, other means such as glue or tape may be used to seal the pouch.
[0027] The manner of deploying the napkin 12 from the pouch 14 , and attachment of the napkin to an undergarment 60 of a user, will now be described with reference to FIGS. 4-11 . As shown in FIGS. 4 and 5 the user first grasps the tab 41 and pulls the tab 41 to separate the same from the external surface of the end section 34 of the pouch 14 . As the user pulls the tab 41 and lifts the first end section 32 of the pouch 14 , the embossments defining the side seams 40 separate thereby exposing the intermediate portion 20 of the napkin 12 , and more specifically exposing the garment-facing surface 24 of the intermediate portion 20 . Thereafter, as shown FIG. 6 , the user may then attach the intermediate portion 20 of the napkin 12 to the undergarment 60 with the garment-facing surface 24 of the napkin 12 in abutting relationship to the undergarment 60 .
[0028] As the user continues to pull on the tab 41 , and/or the portion of the pouch 14 now separated from the napkin 12 , the second end portion 18 of the napkin is released from the pouch 14 as shown in FIG. 7 . Thereafter, the user may then attach the second end portion 18 of the napkin to the undergarment 60 as shown in FIG. 8 . As the user continues to pull on the tab 41 , and/or the portion of the pouch 14 now separated from the napkin 12 , the first end portion 16 of the napkin 12 is release from the pouch as shown in FIG. 9 . Thereafter, the user may then attach the first end portion 16 of the napkin 12 to the undergarment 60 as shown in FIG. 10 .
[0029] The napkin 12 may optionally be provided with wings 50 and 52 that extend out from the main body of the napkin 12 and are adapted to be folded over the edges of the undergarment 60 and attached to the crotch portion of the undergarment 60 by means of adhesive provided on the garment-facing surface of the wings 50 and 52 . Prior to deployment of the wings 50 and 52 the wings 50 and 52 may be folded toward the body-facing surface 22 of the napkin 12 and the adhesive on the wings 50 52 may be covered by a release paper 54 . When the user is ready to attach the wings 50 and 52 to the undergarment the release paper 54 may be removed and the wings 50 and 52 folded around the edges of the undergarment 60 and attached to the crotch portion of the undergarment 60 , as shown in FIG. 11 .
[0030] It is noted that that the individually packaged absorbent article assembly 10 as described above enables the intermediate portion 20 of the napkin, and particularly the garment-facing surface 20 thereof, to be first exposed prior to exposing the garment-facing surfaces of the other portions of the napkin 12 . This enables the user to easily attach the intermediate portion 20 of the napkin to the undergarment before the other portions of the napkin are deployed form the pouch 14 . This significantly simplifies the attachment process and represents a significant improvement over prior art assemblies.
[0031] Another embodiment of an individually packaged absorbent article assembly 100 will now be described with reference to FIGS. 12-15 . In those instances where the same or similar structural elements are present in the second embodiment of the invention as those described above with regard to the first embodiment the same or similar reference numerals will be employed. The individually packaged absorbent article assembly 100 generally includes a sanitary napkin 12 and a pouch 14 .
[0032] In the specific embodiment of the invention shown in FIGS. 12-15 , the pouch 14 is defined by a single piece of sheet material 29 . The sheet material may be a plastic film sheet or a paper sheet material. The sheet material 29 includes a first end section 132 , a second end section 134 , and an intermediate section 136 arranged between the end sections 132 and 134 .
[0033] In the second embodiment of the invention 100 , the intermediate section 136 of the sheet material 29 extends over and corresponds in location to the intermediate portion 20 of the napkin 12 . The second end section 134 of the sheet material 29 extends over and corresponds in location to the second end portion 18 of the napkin 12 . The first end section 132 of the sheet material 29 extends over and corresponds in location to the first end portion 16 of the napkin 12 . The sheet material 29 includes a first terminal edge 137 and a second terminal edge 149 . The sheet material 20 is also provided with a score line or other line of weakness 180 arranged between the first terminal edge 137 and the second terminal edge 149 .
[0034] It is noted that in the final pouch 14 configuration the score line 180 is substantially aligned with the fold line 19 of the napkin 12 that separates the intermediate portion 20 of the napkin 12 from the first end portion 16 of the napkin 12 . The pouch 14 may optionally be provided with a tab 41 that is formed from a separate piece of material that is permanently attached to the pouch in a location adjacent the score line 180 . As shown in FIG. 14 , when a user desires to open the pouch 14 the user grasps the tab 41 and pulls the tab in an upward direction causing the pouch 14 to open along the score line 180 , i.e. by forming a “free end” 182 of the sheet material 29 along the score line 180 .
[0035] As shown in FIG. 12 , the side seams of the pouch 14 are designated by the numeral 40 and are defined by embossments running along and defining opposite longitudinal edge zones of the pouch. The side seams 40 function to seal the overlapping portions of the sheet material 29 . As shown in FIG. 15 , the second end section 134 of the sheet material partially overlaps the first end section 132 of the sheet material adjacent terminal edges 149 and 137 and the two ends of the sheet material 29 are permanently secured to one another by a strip of adhesive or the like. In this manner, the pouch 14 provides a sealed enclosure for the tri-folded napkin 12 prior to use of the napkin 12 .
[0036] The manner of deploying the napkin 12 from the pouch 14 in the individually packaged absorbent article assembly 100 is substantially identically to the manner employed in the first embodiment of the invention 10 described above with reference to FIGS. 4-11 . However, with the absorbent article assembly 100 the user initiates opening the pouch 14 by opening the pouch along the score line 180 . Specifically, the user grasps the tab 41 and pulls the tab 41 in an upward direction to thereby open the pouch 14 along the score line 180 .
[0037] It is noted that that the individually packaged absorbent article assembly 100 as described above, like the first embodiment of the invention 10 , enables the intermediate portion 20 of the napkin, and in particularly the garment-facing surface 20 thereof, to be first deployed prior to the deployment of the other portions of the napkin 12 . This enables the user to easily attach the intermediate portion 20 of the napkin to the undergarment before the other portions of the napkin are deployed form the pouch 14 . This significantly simplifies the attachment process and represents a significant improvement over prior art assemblies. | A method of individually packaging an absorbent article and attaching the absorbent article to an undergarment including the steps of providing a tri-folded absorbent article having two end portions and an intermediate portion, providing a pouch containing the tri-folded absorbent article, opening the pouch to thereby expose a garment-facing surface of the intermediate portion of the absorbent article prior to exposing a garment facing surface of either of the end portions of the absorbent article. | 0 |
BACKGROUND
1. The Field of the Invention
The present invention relates to doorstop devices. More particularly, the present invention is directed to a configuration of doorstop which readily permits the attachment and interchange ability of the decorative portion of the doorstop to be compatible with room decor or change in room decor.
2. The Background Art
Many different doorstops have been devised for use in preventing damage to walls caused by the impact of door knobs. As a result, various configurations have attempted to provide a doorstop which is not only aesthetically pleasing, but permanently installed and tamper-proof. As a result, the currently available devices have offered doorstops which attempt to conceal or otherwise secret the manner in which the doorstop is and/or may be attached to or may be removed from the wall or other support surface.
In order to permanently secure door stops to support surfaces, various configurations of currently available doorstops employ a variety of schemes and devices, such as: hooks, latches, lugs, set-screws, the deformation of doorstop members, the nonreversible interlocking of members, non-reusable members, and the nonreversible integration of members. As a result, entire or partial configurations of some doorstops remain, absent destruction or deformation of some component members, unremovably and permanently attached to other members or to the doorstop configuration as a whole.
Other currently available doorstops are designed to provide a device which, in light of its concealed assembly configuration, inhibits the removal of the product absent particularized know-how, techniques, or equipment. The currently available doorstops are designed to be permanent installations inhibiting tampering, vandalism, theft, or any other undesired or unauthorized removal. The currently available devices are also configured to hinder the disassembly of the doorstop, or obtaining of knowledge as to the method of disassembly of the doorstop to anyone other than authorized or knowledgeable persons. As a result, once installed, the currently available doorstops, and their component parts, are generally intended to be permanent fixtures.
The currently available devices do not offer the combination of readily removable and interchangeable doorstop elements adaptable to the decor of the room or to permit compatibility with the variation of decor from room-to-room while also providing a readily separable integral bumper housing securing the position of the cushioning bumper element in the doorstop.
The currently available doorstop devices also require that the cushioning bumper member be specially configured to be compatible with other internal members and that the cushioning bumper provide special operative functions, particularized structural configurations, or be structured in such a manner so as to not inhibit other internal structures or operative features of the doorstops.
In view of the state of the art, what is needed is a doorstop which is economical to produce, does not require special tooling or equipment for installation or removal, a doorstop whose design permits the ready removal or interchange ability of component parts for convenience in making the doorstop compatible with the decor or changing decor in which the doorstop is used, and which doorstop is of such lightweight construction that the installation does not require special fastening mechanisms or equipment.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The present invention is directed to doorstops. More particularly, the present invention is directed to doorstops which permit ready installation and removal. The doorstops of the present invention are designed to permit ready and immediate interchange ability of parts in order to be compatible with the immediate decor or change in decor of the space in which they are used, or to permit the doorstops to be compatible with the decor of each space notwithstanding the variability of decor from space-to-space in immediately or connecting rooms or spaces.
The present invention is directed to a doorstop having an interchangeable decorative retaining shield, a cushioning bumper member, and a receiving member. The interchangeable decorative retaining shield is provided with an aperture through which the cushioning member may protrude in order to act as the interface against which the door knob may impact. The interchangeable decorative retaining shield also comprises fastening means compatible with the receiving member so as to permit ready and immediate fastening of the interchangeable shield to and removal from the receiving member. When fastened to the receiving member, the interchangeable retaining shield completely covers and secrets the receiving member and the fastening means.
The cushion bumper is preferably dome-shaped, or the equivalent, so as to protrude through the aperture of the interchangeable retaining shield to function as the impact surface of the doorstop which engages the door knob. The base portion of the cushioning member is configured such that when the interchangeable decorative shield is fastened to the receiving member the base portion of the cushioning bumper is held securely in place and rigidly held between the interchangeable retaining shield and the receiving member.
The receiving member comprises fastening means compatible with and/or adaptable to the fastening means integral with the interchangeable retaining shield. The receiving member has a recess which receives the base portion of the cushion member such that upon fastening of the interchangeable retaining shield to the receiving member the base portion of cushioning bumper is confined between the interchangeable retaining shield and the receiving bracket.
The fastening means may comprise any conventional means which readily permits the assembly or disassembly of the doorstop without the need of any particular tool, preferably with the means not blemishing the aesthetic appearance of the outer or viewable surface of the interchangeable retaining shield. It is preferred that conventional threads function as the fastening means.
The receiving member may be attached to any surface by any suitable means. The preferred embodiment of the invention is made of such light-weight materials that the receiving member may be attached to the respective surface by adhesive means. Mechanical fasteners may also be used where desired or appropriate.
It is therefore an object of the present invention to provide a doorstop which may be readily assembled or disassembled without the necessity of specialized equipment, know-how, or techniques.
Another object of the present invention is to provide a doorstop whose retaining shield, when in place, is not blemished by any mechanisms required to conceal the receiving member but offers an aesthetically pleasing appearance over the unmarred and continuous surface of the entire retaining shield.
Another object of the present invention is to provide a doorstop whose retaining shield may be readily interchanged so as to be compatible with the decor of the space or room in which the doorstop is used.
Still another object of the present invention is to provide a doorstop whose assembly and disassembly do not require deformation, destruction, or reconfiguration of any doorstop component in order to assure the intended operation of the doorstop.
Yet another object of the present invention is to provide a doorstop whose material and construction permit the doorstop to be installed by any conventional means, including adhesion.
Another object of the present invention is to provide a doorstop in which the configuration of the cushioning member may vary to accommodate door knobs with passage locks and wherein such a combination does not require any change in the configuration of the interchangeable retaining shield or the receiving member which is secured to the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited invention and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered below by reference to a specific embodiment thereof which is illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a perspective view of one embodiment of a doorstop of the present invention.
FIG. 2 is an exploded view of one embodiment of the doorstop of the present invention.
FIG. 3 is a cross-sectional view of one embodiment of the doorstop of the present invention taken along line 3--3 of FIG. 1.
FIG. 4 illustrates another embodiment including a cushioning bumper compatible with door knobs having passage locks.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to doorstops. More particularly, the present invention comprises a doorstop which permits the ready and immediate assembly, disassembly, or interchange of the component parts of the doorstop consistent with the decor or change in decor of the room in which the doorstop is used. The configuration of the doorstop of the present invention permits the assembly, disassembly, or interchange of component parts without the use of specialized equipment, techniques, or know-how, and without deforming or otherwise disfiguring doorstop members so as to render the members incapable of being reused.
The doorstop contemplated by the present invention comprises a readily interchangeable, decorative retaining shield, a cushioning bumper, and a receiving member. When assembled, an aperture in the face of the interchangeable retaining shield permits the protrusion of the cushioning bumper while completely encasing the receiving member concealing it from view. The protruding portion of the cushioning bumper acts as the structural interface between the doorstop device and the door knob or handle.
The doorstop device 10 is shown in a general perspective view in FIG. 1 installed on a wall and ready to receive the impact of a door knob or a door handle (not represented in the figures). The preferred doorstop 10, shown in FIG. 2, comprises a substantially circular interchangeable decorative retaining shield 20. The retaining shield 20 is provided with an aperture 26 through which a bulb or impact portion 32 of a cushioning bumper 30 protrudes. The receiving member 40 receives the base portion 36 of the cushioning bumper 30 into a recess 48 formed by the perimeter sidewall 46 of the receiving member 40.
The receiving member 40 can receive any one of a number of interchangeable retaining shields, such as interchangeable retaining shield 20, by accepting threads 28 of interchangeable retaining shield 20 which are compatible with threads 42 of the receiving member 40. The receiving member 40 receives the retaining shield 20 viewable to the sidewall 46 so as to completely conceal or hide the receiving member 40 from the casual viewer.
The interchangeable retaining shield 20 comprises a circumferential sidewall portion 24 and a radially inwardly extending face portion 22. Sidewall 24 and face 22 provide an unblemished annular ring or shield which can be treated with a suitable motif which desirably is compatible with the motif of the room in which the doorstop 10 is installed. As a result, the interchangeable retaining shield 20 may be constructed of, or be made to have the appearance of, any material, color, or design compatible with the surrounding decor.
Outer surfaces of the face 22 and sidewall 24 are the viewable surface or surfaces of the interchangeable retaining shield 20. The interior surface of the sidewall 24 is preferably adapted with any suitable and readily removable fastening means which, in conjunction with a compatible fastening means provided on a sidewall 46 of the receiving member 40 (as discussed below), to secure the interchangeable retaining shield 20 to the receiving member 40. It is preferred that conventional threads 28 and 42 be used as a fastening means.
As shown in FIG. 3, the interior surface of the face 22 is configured to include an protruding annular ring 29. The annular ring 29 functions in conjunction with the base portion 36 (see FIG. 2) of cushion bumper 30 as discussed below. The face 22 of the interchangeable retaining shield 20 is also configured annularly such that it extends radially inwardly from the sidewall 24 a predetermined distance such that the aperture 26 (see FIG. 2) is formed.
The cushioning bumper 30 comprises both the bulb or impact portion 32 and the base portion 36. The bulb portion 32 is preferably substantially semi-spherical. The base portion 36 is contiguous to the bulb portion 32 and preferably comprises a flange 34 extending radially outward. It will be appreciated that due to the configuration of the present invention, the cushioning bumper 32 efficiently functions as a doorstop. The cushioning bumper 30 need not be extruded with recesses, gaps, chambers, or any special grooves or the like necessitated by its integral compatibility with other doorstop components, and remains at all times undeformed or otherwise unpunctured, and its structural integrity is not comprised in any other manner.
The cushioning bumper 30 serves as a bumper only. The cushioning bumper 30 does not provide structural support for any other component of the doorstop. As a result, the cushioning bumper 30 is also immediately, readily, and universally interchangeable with another cushioning bumper without the necessity of removing or disassembling any other parts fixed permanently or temporarily to it. Furthermore, no special tool, technique, or particularized know-how is necessary to effectively interchange the cushioning bumper 30.
Referring next to FIG. 4, the cushioning bumper 30 may also be configured to provide a passage lock recess 33 in the impact portion 32 which is compatible with a door knob 70 having a passage lock 72. As a result, the cushioning effect of impact portion 32 desirably does not register against passage lock 72 but against door knob 70.
The cushioning bumper 30 should also be structurally compatible with the interchangeable retaining shield 20 as will now be described. The bulb portion 32 of the cushioning bumper 30 should have a diameter at or near the interface between the bulb portion 32 and the base portion 36 which is compatible with the diameter of the aperture 26 provided in the interchangeable retaining shield 20 such that the bulb portion 32 fits closely within the aperture 26 and protrudes through the aperture 26. In addition, the flange 34 should extend radially outward a sufficient distance such that the protruding annular ring 29 contacts surface 37 of the flange 34 such that decorative retaining shield 20 defines the relative position of cushioning bumper 30, as shown in FIG. 3.
As shown best by reference to both FIGS. 2 and 3, the receiving member 40 comprises a substantially circular base member 44 and a circumferential sidewall 46 at or near the perimeter of the base member 44. The exterior surface of the sidewall 46 is adapted with fastening means such as threads 42 compatible with the threads 28 of the interchangeable retaining shield 20. The sidewall 46 and the base member 44 form a substantially cylindrical recess which receives the base portion 36 of the cushioning bumper 30. While not necessary for the optimum operation of a doorstop embodying the present invention, face member 44 may be provided with an opening 50. The opening 50 is optimally placed in the center of the base member 44. The opening 50 may be used as a means for positioning the receiving member 40 on the wall 60 (FIG. 3), and/or for use in attaching the receiving member 40 to the wall 60 if conventional mechanical fastening means are employed to secure the receiving member 40 to a support surface such as a wall 60. Additionally, openings 52 may be provided to further secure receiving member 40 to a support surface and/or prevent any rotation of receiving member 40. It is preferred to secure the receiving member 40 to a support surface by adhesive means, such as a double sided adhesive patch 54, rather than mechanical fastening means, as depicted in FIG. 3.
The cushioning bumper 30 is also preferably compatible with the receiving member 40 as will now be described. The diameter of base portion 36 of cushioning bumper 30 must be compatible with the diameter of recess 48 such that the base 36 may be received into recess 48 with suitable tolerance. In addition, height 38 (see FIG. 2) of the flange 34 must be such that upon the reception of the base 36 into the recess 48, the annular ring 29 functions as a confining stop adjacent to surface 37 and opposite base member 44 so as to retain or confine the cushioning bumper 30 as best illustrated in FIG. 3.
In accordance with the present invention, the decorative interchangeable retaining shield 20 and the cushioning bumper 30 can be readily removed and interchanged whenever suitable or desired to match the surrounding decor without the need of any particularized tools, know-how or techniques, and without compromising the structural integrity of the interchangeable retaining shield 20 or the cushioning bumper 30 in any fashion so as to render the interchangeable retaining shield 20 or the cushioning bumper 30 unsuitable for reuse.
It will be appreciated that the interchangeable retaining shield 20 does not become integral with the cushioning bumper 30. Similarly, the cushioning bumper 30 does not become integral with the receiving member 40. As a result, the preferred embodiments of the present invention provide doorstop component parts which wholly and effectively function independent of any other structural element and thus can be readily interchanged.
It will be appreciated, therefore, that the interchangeable retaining shield 20 may be made of any appropriate material or be colored in any color or fashion suitable or desirable for the decorative needs of the environs in which the doorstop is used. Similarly, the only limitation on the composition of the cushioning bumper 30 is that the cushioning effect be a desirable one. In addition, the cushioning bumper 30 may be provided in any color suitable to surrounding decor or change its surrounding decor.
It will also be appreciated that while the preferred embodiment contemplates doorstop component parts which in plan view are substantially circular, as illustrated in the drawings, any configuration or design compatible with readily reversible fastening and securing means as heretofore set forth is to be considered within the scope of the present invention.
It will further be appreciated that because of the simplicity and reliability of the doorstop of the present invention the components of the doorstop device are capable of being reused and capable of aesthetically blending with any imaginable decor or change in decor. The embodiments of the present invention require no special tools, techniques, know-how or other apparatus to assemble, install, disassemble, and interchange the operative and decorative components thereof.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respect only as illustrative and not restrictive. The scope of the invention, is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | The present invention is directed to a doorstop whose component parts readily permit the removal and interchange of component parts which are visible. The present invention provides a device which offers its user the ability to readily interchange those visible component parts such that they are compatible with the surrounding decor and which permit such interchange without requiring any special tools, equipment, know-how or technique. | 4 |
FIELD OF THE INVENTION
This invention relates generally to tristate circuitry.
BACKGROUND
Tristate driver circuits are used to conditionally drive a signal onto a wire that is shared by multiple resources. Tristate driver circuits are sometimes used in conjunction with multiplexer circuits. The multiplexer may provide a selected input to the tristate driver which in turn drives the signal onto the shared resource wire. Multiplexers can be built in various ways. A multiplexer may be constructed from pass transistors. A multiplexer may also be constructed from a plurality of internal tristate circuits. A multiplexer may be a constructed from smaller multiplexer circuits which form stages of a larger multiplexer.
FIGS. 1A and 1B illustrate two different prior art tristate circuits. FIG. 1A illustrates a known inverting tristate driver 101 . Circuit 101 is constructed from two stacked PMOS transistors, 11 P and 12 P and two stacked NMOS transistors 11 N and 12 N coupled as shown. The circuit is enabled as follows: A high enable signal at input en and a corresponding low negative enable signal at input n-en turn on, respectively, transistor 12 N and transistor 11 P which allows the signal at IN 1 A to drive an inverted signal at output OUT 1 A through transistors 12 P and 11 N. The opposite signals at input en and input n-en would turn off, respectively, transistor 12 N and transistor 11 P which in turn would prevent an input signal at input IN 1 A from driving a signal at output OUT 1 A.
FIG. 1B illustrates a known non-inverting tristate driver 102 . Tristate driver 102 includes PMOS transistors 13 P, 14 P, 15 P, and 16 P and NMOS transistors 13 N, 14 N, 15 N, and 16 N. Circuit 102 is enabled as follows: A high enable signal at input en turns on transistor 13 N and turns off transistor 14 P and a low negative enable signal at input n-en turns off transistor 15 N and turns on transistor 15 P which allows the signal at IN 1 B to drive a non-inverted signal at output OUT 1 B through transistors 13 P, 14 N, 16 P, and 16 N. The opposite signal (i.e., a low) at enable input en would turn off transistor 13 N and turn on transistor 14 P and the opposite signal (i.e. a high) at negative enable input n-en would turn on transistor 15 N and turn off transistor 15 P which will prevent a signal at input IN 1 B from driving a signal at output OUT 1 B.
SUMMARY
The transistor arrangement shown in FIG. 1A requires that the output node be charged and discharged through two series transistors. When a tristate driver such as inverting tristate driver 101 is used to drive a signal on a shared resource wire, this arrangement requires use of relatively larger transistors (roughly twice a large) for a given drive strength than would be required for a normal two-transistor CMOS inverter at the output (in which charging and discharging of the output node occurs through a single transistor). In view of the significant output load at outputs to some shared resource wires, the required drive strength, and thus the corresponding transistor size difference required using the FIG. 1A arrangement at an output, can be significant. Non-inverting tristate driver 102 shown in FIG. 1B , which just has a complimentary CMOS pair including 16 P and 16 N driving the output at OUT 1 B, allows use of relatively smaller drive transistors at that output. However, in this circuit, on currents for charging or discharging the gates of the output drive transistors (Ipon turns on transistor 16 P and Inon turns on transistor 16 N) both have to go through two transistors (in the case of Ipon, transistors 13 N and 14 N and in the case of Ion, transistors 13 P and 13 N) whereas the corresponding off currents for these transistors (Ipoff turns of transistor 16 P and Inoff turns off transistor 13 N) only have to go through one transistor (in the case of Ipoff, transistor 13 P and in the case of Inoff, transistor 14 N). This causes the transistors 16 P and 16 N to turn on more slowly than they turn off. Since 16 P is turning on when 16 N is turning off and vice versa, this can cause transitions in output signal wave forms to have longer rise/fall times than a simple inverter. Also, using a circuit such as circuit 102 of FIG. 1B to build all the input circuits of a tristate multiplexer requires 8 N transistors where “N” is the number of selectable inputs.
One embodiment of the present invention provides a selection circuit in which selectively enabled input circuits are coupled to an output circuit through an output enable circuit such that a selected one of the selectively enabled input circuits is operable to provide a pathway for charging and discharging currents used to charge and discharge an output circuit transistor gate. In some embodiments, at least some of the selectively enabled input circuits comprise inverting tristate circuits including stacked PMOS and stacked NMOS transistors. In some embodiments, the output circuit comprises a two-transistor inverting CMOS stage such that an output node is charged and discharged through one transistor (e.g., charged through a PMOS transistor and discharged through an NMOS transistor). In one embodiment a gate of an output PMOS transistor is connected to a drain of a PMOS transistor in each of the plurality of input circuits and a gate of an output NMOS transistor is connected to a drain of an NMOS transistor in each of the plurality of input circuits. In another embodiment, a gate of an output PMOS transistor is connected to a drain of an NMOS transistor in each of the plurality of input circuits and a gate of an output NMOS transistor is connected to a drain of a PMOS transistor in each of the plurality of input circuits.
These and other embodiments are described more fully below. For purposes of illustration only, several aspects of particular embodiments of the invention are described by reference to the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a prior art inverting tristate driver.
FIG. 1B illustrates a prior art non-inverting tristate driver.
FIG. 2 illustrates an exemplary tristate multiplexer consistent with one embodiment of the present invention,
FIG. 3 illustrates an exemplary tristate multiplexer consistent with another embodiment of the present invention.
FIG. 4 illustrates an exemplary data processing system including a field programmable gate array (“FPGA”) that includes exemplary selection circuits in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The following description is presented to enable any person skilled iii the art to make and use the invention, and is provided in the context of particular applications and their requirements. Various modifications to the exemplary 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.
FIG. 2 illustrates a first embodiment of the present invention. Tristate multiplexer circuit 2000 comprises selectable input circuits 200 , 201 , and 202 , output enable circuit 203 , and output drive circuit 204 . Selectable input circuits 200 , 201 , and 202 each include stacked PMOS transistors and stacked NMOS transistors as follows: Circuit 200 includes PMOS transistors P 21 and P 22 and NMOS transistors N 21 and N 22 ; circuit 201 includes PMOS transistors P 23 and P 24 and NMOS transistors N 23 and N 24 ; and circuit 202 includes PMOS transistors P 25 and P 26 and NMOS transistors N 25 and N 26 . Enable circuit 203 comprises PMOS transistors P 27 and P 28 and NMOS transistors N 27 and N 28 . Output circuit 204 comprises a CMOS pair including PMOS transistor P 29 and NMOS transistor N 29 .
Tristate multiplexer 2000 has selectable inputs in 0 , in 1 , and in 2 corresponding to input circuits 200 , 201 , and 202 . Each selectable input circuit has enable and corresponding negative enable inputs. When input en 0 is high (so that transistor N 22 is on and input n-en 0 is low (so that transistor P 21 is on), then circuit 200 is enabled and a signal at input in 0 is selected to drive output at output OUT 2000 . Similarly, when input en 1 is high (so that transistor N 24 is on) and input n-en 1 is low (so that transistor P 23 is on), then circuit 201 is enabled and a signal at input in 1 is selected to drive output at output OUT 2000 . When input en 2 is high (so that transistor N 26 is on) and input n-en 2 is low (so that transistor P 25 is on), then circuit 200 is enabled and a signal at input in 2 is selected to drive output at output OUT 2000 .
The transistors of output enable circuit 203 are coupled to output circuit 204 and to each of selectable input circuits 200 , 201 , and 202 in a manner such that when signal en is high (so that transistor N 27 is on and transistor P 27 is off) and signal n-en is low (so that transistor N 28 is off and transistor P 28 is on), switching currents for switching on and off output drive transistors P 29 and N 29 flow through transistors of a selected input circuit. For example, if output enable circuit 203 is enabled as described above and selectable input circuit 201 is also enabled, a signal at input in 1 drives output at output OUT 2000 through transistors P 29 and N 29 and the switching currents for those output transistor currents flow through selected input circuit 201 as follows: The discharge current for turning on transistor P 29 flows through transistor N 27 of enable circuit 203 and through transistors N 23 and N 24 of input circuit 201 . The discharge current for turning off transistor N 29 flows through transistors N 23 and N 24 of input circuit 201 . The charging current for turning on transistor N 29 flows through transistor P 28 of enable circuit 203 and through transistors P 23 and P 24 of input circuit 201 . The charging current for turning off transistor P 29 flows through transistors P 23 and P 24 of input circuit 201 .
As those skilled in the art will appreciate, operation occurs in a comparable fashion if another of the inputs is selected. In each case, discharge current for turning on output transistor P 29 flows through transistor N 27 of output enable circuit 203 and charging current for turning on transistor N 29 flows through transistor P 28 of output enable circuit 203 . If input in 0 is selected, then discharge currents for turning on output transistor P 29 and turning off output transistor N 29 flow through transistors N 21 and N 22 of input circuit 200 . In that case, charging currents for turning on output transistor N 29 and turning off output transistor P 29 flow through transistors P 21 and P 22 of input circuit 200 . If input in 2 is selected, then discharge currents for turning on output transistor P 29 and turning off output transistor N 29 flow through transistors N 25 and N 26 of input circuit 202 . In that case, charging currents for turning on output transistor N 29 and turning off output transistor P 29 flow through transistors P 25 and P 26 of input circuit 202 .
In this sense, the illustrated embodiment, when enabled by enable circuit 203 , “merges” tristate input and tristate output circuitry to form a tristate multiplexer. In other words, transistors of a tristate input circuit used tier selectable input are also used as pathways for the charging and discharging current of the tristate output driver circuit transistor gate voltages. The illustrated arrangement can be applied to a multiplexer with any number of inputs. It can also be applied as just part of a larger multiplexer that uses different types of selectable input circuitry. In other words, although in the illustrated embodiment, all of the selectable input circuits are constructed from inverting tristate circuit structures (modified to be coupled through an output enable circuit), in alternative embodiments, some multiplexer input circuits may be constructed differently. Also, some inputs may be higher speed inputs than others, passing through few stages before driving output circuitry.
FIG. 3 illustrates an alternative embodiment of the present invention. Tristate multiplexer 3000 includes input circuits 300 , 301 , and 302 , output enable circuit 303 and output circuit 304 . The difference between circuit 3000 of FIG. 3 and circuit 2000 of FIG. 2 is that the circuit of FIG. 3 implements a “twisted” connection between input circuits and output PMOS and NMOS output drive transistors as will be further explained below.
Selectable input circuits 300 , 301 , and 302 each include stacked PMOS transistors and stacked NMOS transistors as follows: Circuit 300 includes PMOS transistors P 31 and P 32 and NMOS transistors N 31 and N 32 ; circuit 301 includes PMOS transistors P 33 and P 34 and NMOS transistors N 33 and N 34 ; and circuit 302 includes PMOS transistors P 35 and P 36 and NMOS transistors N 35 and N 36 . Enable circuit 303 comprises PMOS transistors P 37 and P 38 and NMOS transistors N 37 and N 38 . Output circuit 304 comprises a CMOS pair including PMOS transistor P 39 and NMOS transistor N 39 .
Tristate multiplexer 3000 has selectable inputs in 0 ′, in 1 ′, and in 2 ′ corresponding to input circuits 300 , 301 , and 302 . Each selectable input circuit has enable and corresponding negative enable inputs (en 0 ′ and n-en 0 ′ for input circuit 300 , en 1 ′ and n-en 1 ′ for input circuit 301 , and en 2 ′ and n-en 2 ″ for input circuit 302 ). These operate to enable or non-enable the selectable input circuits in the same manner already described in the context of the embodiment of FIG. 2 and so will not be further described herein.
The transistors of output enable circuit 303 are coupled to output circuit 304 and to each of selectable input circuits 300 , 301 , and 302 in a manner such that when signal en′ is high (so that transistor N 37 is on and transistor P 37 is off) and signal n-en′ is low (so that transistor N 38 is off and transistor P 38 is on), switching currents for switching on and off output drive transistors P 39 and N 39 flow through transistors of a selected input circuit. For example, if output enable circuit 303 is enabled as described above and selectable input circuit 301 is also enabled, a signal at input in 1 ′ drives output at output OUT 3000 through transistors P 39 and N 39 and the switching currents for those output transistor currents flow through selected input circuit 301 as follows: The discharge current for turning on transistor P 39 flows through transistors N 33 and N 34 of input circuit 301 . The discharge current for turning off transistor N 39 flows through transistor N 37 of output enable circuit 303 and through transistors N 33 and N 34 of input circuit 301 . The charging current for turning on transistor N 39 flows through transistors P 33 and P 34 of input circuit 301 . The charging current for turning off transistor P 39 flows through transistor P 38 of output enable circuit 303 and through transistors P 33 and P 34 of input circuit 301 . As those skilled in the art will appreciate, operation occurs in a comparable fashion if another of the inputs is selected: On currents will flow through either PMOS transistors (if charging to turn on output transistor N 39 ) or NMOS transistors (if discharging to turn on output transistor P 39 ) of the corresponding selected input circuit. Off currents will similarly flow through PMOS (if charging to turn off P 39 ) or NMOS (if discharging to turn off N 39 ) transistors of the selected input circuit (i.e., for input circuit 300 , P 31 and P 32 or N 31 and N 32 and for input circuit 302 , P 35 and P 36 or N 35 and N 36 ). Off currents will also flow through a transistor of output enable circuit 303 , i.e., through P 38 if a charging off current or through N 37 if a discharging off current.
Thus a difference between the embodiments of FIG. 2 and FIG. 3 is the following: In multiplexer 2000 of FIG. 2 , the on switching currents for driving the output transistor gates travel through three transistors while the off currents travel through two transistors. By contrast, in multiplexer 3000 of FIG. 3 , the on switching currents only travel through two transistors while the off currents travel through three transistors. The embodiment of FIG. 3 thus may provide somewhat less signal delay than the embodiment of FIG. 2 , however it also has the possibility of greater short circuit current at the output since one transistor may turn on before its complement turns off.
Tristate multiplexer circuitry embodying the principles illustrated by the circuitry of FIG. 2 and/or FIG. 3 may be implemented as part of any IC. A specific example of an IC is a field programmable gate array (“FPGA”). FPGAs (also referred to as programmable logic devices (“PLDs”), complex PLDs, programmable array logic, programmable logic arrays, field PLAs, erasable PLDs, electrically erasable PLDs, logic cell arrays, or by other names) provide the advantages of fixed ICs with the flexibility of custom ICs. FPGAs have configuration elements (i.e., programmable elements) that may be programmed or reprogrammed. Placing new data into the configuration elements programs or reprograms the FPGA's logic functions and associated routing pathways. Such configuration may be accomplished via data stored in programmable elements on the IC. Programmable elements may include dynamic or static RAM, flip-flops, electronically erasable programmable read-only memory (EEPROM) cells, flash, fuse, anti-fuse programmable connections, or other memory elements. Configuration may also be accomplished via one or more externally generated signals received by the IC during operation of the IC. Data represented by such signals may or may not be stored on the IC during operation of the IC. Configuration may also be accomplished via mask programming during fabrication of the IC. While mask programming may have disadvantages relative to some of the field programmable options already listed, it may be useful in certain high volume applications.
FIG. 4 illustrates an exemplary data processing system 4000 including an FPGA 4010 . FPGA 4010 includes several selection circuits such as selection circuit 4001 in accordance with an embodiment of the present invention.
Data processing system 4000 may include one or more of the following additional components: processor 4040 , memory 4050 , input/output (I/O) circuitry 4020 , and peripheral devices 4030 and/or other components. These components are coupled together by system bus 4065 and are populated on circuit board 4060 which is contained in end-user system 4070 . A data processing system such as system 4000 may include a single end-user system such as end-user system 4070 or may include a plurality of systems working together as a data processing system.
System 4000 can be used in a wide variety of applications, such as computer networking, data networking, instrumentation, video processing, digital signal processing, or any other application where the advantage of using programmable or reprogrammable logic in system design is desirable. FPGA 4010 can be used to perform a variety of different logic functions. For example, FPGA 4010 can be configured as a processor or controller that works in cooperation with processor 4040 (or, in alternative embodiments, an FPGA might itself act as the sole system processor). FPGA 4010 may also be used as an arbiter for arbitrating access to shared resources in system 4000 . In yet another example, FPGA 4010 can be configured as an interface between processor 4040 and one of the other components in system 4000 . It should be noted that system 4000 is only exemplary.
While the present invention has been particularly described with respect to the illustrated embodiments, it will be appreciated that various alterations, modifications and adaptations may be made based on the present disclosure, and are intended to be within the scope of the present invention. While the invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the present invention is not limited to the disclosed embodiments but only by the following claims. | Various methods and structures related to tristate multiplexer circuits are disclosed. An embodiment provides a selection circuit in which selectively enabled input circuits are coupled to an output circuit through an output enable circuit such that a selected one of the selectively enabled input circuits is operable to provide a pathway for charging and discharging currents used to charge and discharge an output circuit transistor gate. This and other detailed embodiments are described more fully in the disclosure. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority benefit of U.S. Application. No. 61/912,958, filed Dec. 6, 2013, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Oral administration of drugs and vaccines offers several advantages. Dosages could be administered to a large number of animals via the food or water with minimal restraint and labor. Restraint also stresses animals rendering the drug or vaccination less effective and increasing the risk of infectious disease. For meat-producing animals, oral administration has another advantage in that it avoids injection site reactions. Broken needles, contamination of the injection site, or the use of highly reactive adjuvants can induce abscesses that damage the carcass and the skins. These reactions decrease the value of the animal at slaughter. This is also an issue in fish vaccination programs where fish need to be harvested from their tanks or open sea cages and injected individually. Oral inoculation is quick and efficient and eliminates the need for multiple handling of animals to administer subsequent booster inoculations. Adverse immune reactions following oral administration are also much less likely to occur and are therefore safer.
[0003] Oral vaccination is a particularly cost effective way to vaccinate or treat a large number of fish at one time in fish aquaculture systems, with minimal stress or labor. This is especially true when oral administration of the vaccine can be effected through ingestion during the course of feeding/drinking. Further, oral vaccines can be manufactured more cost effectively than injectable vaccine formulations because of the fewer purification steps needed to generate an oral vaccine. Oral vaccination also offers the advantage of fewer side effects such as stress or other reactions to the injection.
[0004] Despite the advantages of oral administration of drugs and particularly vaccines, the development of the technology has been delayed by the lack of adequate vaccine delivery systems. In the absence of suitable delivery systems, most oral vaccines undergo degradation in the gastrointestinal (GI) tract, especially under low-pH stomach conditions, resulting in limited absorption, which in turn results in insufficient immune responses.
[0005] Historically, immunization has relied on the induction of humoral immunity by parenteral administration of vaccines. Antibodies induced by parenteral administrations do not, however, necessarily reach mucosal surfaces, the sites of entry of most infectious agents. Mucosal immunity, which develops at mucosal surfaces including the intestine, lung, mouth, eye, mammary gland, and the genitourinary tract, and also skin and gill in fish, as a result of contact of antigen with mucosal tissues, is an important first line of defense against infectious agents.
[0006] Various vehicles have been developed to deliver drugs or vaccines to the gut-mucosal tissues. Biodegradable polymers, such as poly-(DL-lactide) and poly-(DL-lactide-co-glycolide), have been used to produce compositions for oral administration of antigens. However, production of these polymer particles requires the use of solvents that can harm fragile antigens. Furthermore, the use of solvents prevents the incorporation of attenuated live organisms, such as viruses or bacteria, within those compositions.
[0007] Other challenges of developing adequate oral delivery systems include the need to select only food or feed grade and biodegradable compounds and adjuvants, and the need for a long-lasting and robust immune response.
SUMMARY OF THE INVENTION
[0008] In one aspect, the invention provides a composition for oral administration of a bioactive agent to aquatic or terrestrial species, including particles each of which includes a bioactive agent dispersed in oil droplets, the oil droplets being dispersed in a matrix including an enteric coating polymer, wherein the particles each further include a mucoadhesive polymer.
[0009] In another aspect, the invention provides a method of post gastric delivery of a bioactive agent to an animal, including a step of orally administering to the animal a composition as described above, wherein the bioactive agent is an immunogen.
[0010] In another aspect, the invention provides a method of vaccinating aquatic or terrestrial species, including a step of orally administering to the species a composition as described above, wherein the composition is a delivery vehicle for a vaccine.
[0011] In another aspect, the invention provides a method of preparing a composition. The method includes, in sequence:
[0012] (a) forming an aqueous mixture including a dispersed or dissolved bioactive agent;
[0013] (b) homogenizing the aqueous mixture of step (a) in oil to produce an emulsion of the aqueous mixture in the oil;
[0014] (c) forming a slurry of the product of step (b) in an aqueous solution including an enteric coating polymer; and either
[0015] (d1) spraying, dropping or injecting the slurry of step (c) into an aqueous solution containing a crosslinking agent for the enteric coating polymer to form the particles, wherein the aqueous mixture of step (a) further includes a mucoadhesive polymer, or
[0016] (d2) forming the particles from the slurry of step (c), wherein step (b) further includes forming droplets of the emulsion in aqueous mucoadhesive polymer and crosslinking the mucoadhesive polymer to form intermediate particles.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Unless otherwise defined herein, scientific and technical terminologies employed in the present disclosure shall have the meanings that are commonly understood and used by one of ordinary skill in the art. Also, as used herein and in the claims, the terms “at least one” and “one or more” have the same meaning and include one, two, three or more. Unless otherwise indicated, percentages or parts of components in compositions are on a weight basis. The term “dispersed” means suspended and/or dissolved.
[0018] “Oral vaccination” is defined as the oral administration through the diet of immunogenic material to stimulate the systemic immune system of an animal to develop a specific immune response to a pathogen.
[0019] “Crosslink” and variants thereof refers to the linking of two or more materials and/or substances, including any of those disclosed herein, through one or more covalent and/or non-covalent (e.g., ionic) associations. Crosslinking may be effected naturally (e.g., disulfide bonds of cystine residues) or through synthetic or semi-synthetic routes. Crosslinking of charged polymers can be effected by ionic association with a polyvalent counterion of opposite charge. Firm, solid structures, for example hydrogels, can be prepared by such crosslinking.
[0020] “Gastric protection” refers to the protection of a bioactive agent from gastric destruction and loss of activity.
[0021] The compositions of the invention include particulate materials comprising a bioactive agent and a mucoadhesive polymer, wherein the bioactive agent is dispersed in an oil. The oil droplets are in turn embedded in, or coated by, an external matrix of an enteric coating polymer. The external matrix surrounds the oil droplets, protecting the contents from exposure to low pH conditions in the animal's stomach, since the polymer remains insoluble at low pH and remains intact as a protective coating or layer. The particles typically have an average geometric size (sometimes referred to as diameter) in a range of 10 to 5000 μm, and may either be formed directly in that size range or reduced to that size by milling, grinding, or other means. Usually, the particles have a diameter of less than 100 μm, preferably less than 50 μm.
[0022] In some embodiments, the mucoadhesive polymer and the bioactive agent are mixed together and in mutual contact, associated together within particles that are in turn dispersed in the oil droplet. One or more of these particles are present within a single oil droplet, and one or more oil droplets are present within the external matrix. The mucoadhesive polymer and/or the enteric coating polymer may be crosslinked or not.
[0023] In other embodiments, the bioactive agent is dispersed as above within oil droplets, and these are then embedded in the mucoadhesive polymer. The resulting particles are in turn embedded in the external matrix of enteric coating polymer. The mucoadhesive polymer and/or the enteric coating polymer may be crosslinked or not.
[0024] In some embodiments the invention provides a composition for oral administration of a vaccine to stimulate an immune response in aquatic and terrestrial species against specific diseases. The composition comprises an effective amount of an antigen as the bioactive agent. The present compositions are designed to present the bioactive material for contact with the gut mucosa of the animal to stimulate uptake and mucosal immunity. Compositions according to this invention are administered orally, typically with a feed or pharmaceutically acceptable carrier, including, for example, water (e.g., animal drinking water), tablets, capsules, bolus dosage forms, feed pellets or as a food additive to carry the composition into the gut of the targeted species.
[0025] The compositions of the invention provide several advantages in delivering a bioactive agent to a subject. First, the method of making the delivery system eliminates the use of organic solvents or high temperature and pH which are often required for the preparation of particles by other methods. By maintaining an aqueous environment at mild pH conditions and low temperatures throughout the preparation of the present composition, sensitive bioactives such as live attenuated bacteria or viruses can be orally delivered. Second, the additional layer of enteric coating polymer protects the bioactive agent against degradation in the gastrointestinal tract. In the case of an immunogen, this allows stimulation of the same immune response with a smaller amount of antigen/vaccine. Third, the oil dispersion encloses the bioactive agent, preventing small bioactive molecules such as proteins, peptides and drugs from leaching to an aqueous environment during preparation, as well as during gastric exposure. Further, mucoadhesive polymer itself provides an adjuvant effect. Finally, the delivery system can be easily formulated for efficient delivery to both aquatic and terrestrial species.
[0026] Typically, all components used in preparing the inventive compositions are food grade, non-toxic and biodegradable, and typically naturally occurring. A description of materials useful for preparing the compositions follows.
Bioactive Agent
[0027] The bioactive agent may be a naturally occurring, synthetic, or semi-synthetic material (e.g., compounds, fermentates, extracts, cellular structures) capable of eliciting, directly or indirectly, one or more physical, chemical, and/or biological effects. The bioactive agent may be capable of preventing, alleviating, treating, and/or curing abnormal and/or pathological conditions of a living body, such as by destroying a parasitic organism, or by limiting the effect of a disease or abnormality. Depending on the effect and/or its application, the bioactive agent may be a pharmaceutical agent (such as a prophylactic agent or therapeutic agent), a diagnostic agent, and/or a cosmetic agent, and includes, without limitation, vaccines, drugs, prodrugs, affinity molecules, synthetic organic molecules, hormones, antibodies, polymers, enzymes, low molecular weight molecules proteinaceous compounds, peptides, vitamins, steroids, steroid analogs, lipids, nucleic acids, carbohydrates, precursors thereof, and derivatives thereof. The bioactive agent may also be a nutritional supplement. Non-limiting nutritional supplements include proteins, carbohydrates, water-soluble vitamins (e.g., vitamin C, B-complex vitamins, and the like), fat-soluble vitamins (e.g., vitamins A, D, E, K, and the like), minerals, and herbal extracts. The bioactive agent may be commercially available and/or prepared by known techniques.
[0028] Bioactive agents in the present invention include, without limitation, vaccines (vaccines can also be delivered as part of immune-stimulating complexes, conjugates of antigens with cholera toxin and its B subunit, lectins and adjuvants), antibiotics, affinity molecules, synthetic organic molecules, polymers, low molecular weight proteinaceous compounds, peptides, vitamins, steroids, steroid analogs, lipids, nucleic acids, carbohydrates, precursors thereof, and derivatives thereof. The bioactive agent may also be a pesticide, for example a rodenticide.
[0029] The bioactive agent may be an immunogen, i.e., a material capable of mounting a specific immune response in an animal. Examples of immunogens include antigens and vaccines. For example, immunogens may include immunogenic peptides, proteins or recombinant proteins, including mixtures comprising immunogenic peptides and/or proteins and bacteria (e.g., bacterins); intact inactive, attenuated, and infectious viral particles; intact killed, attenuated, and infectious prokaryotes; intact killed, attenuated, and infectious protozoans including any life cycle stage thereof, and intact killed, attenuated, and infectious multicellular pathogens, recombinant subunit vaccines, and recombinant vectors to deliver and express genes encoding immunogenic proteins (e.g., DNA vaccines).
[0030] The one or more bioactive agents typically constitute at least 0.1% of the weight of the particles, excluding water, or at least 1%, or at least 5%. Typically, they constitute at most 40%, or at most 20%, or at most 10%.
Mucoadhesive Polymer
[0031] The mucoadhesive polymer is a polymer that specifically binds to mucosal tissues, and helps retain the bioactive agent in close proximity to the mucosa, thereby improving administration. Suitable examples include synthetic polymers such as poly(acrylic acid), hydroxypropyl methylcellulose and poly(methyl acrylate), carboxylic-functionalized polymers, sulfate-functionalized polymers, amine-functionalized polymers, and derivatives or modifications thereof, as well as naturally occurring polymers such as carrageenan, hyaluronic acid, chitosan, cationic guar and alginate. Derivatized or otherwise modified versions of naturally occurring polymers may also be used, and many such polymers are known in the art. Nonlimiting examples include propylene glycol alginate and pectins, carboxymethyl chitosan, carboxymethylchitin, methyl glycol chitosan, trimethyl chitosan and the like.
[0032] A preferred mucoadhesive polymer is chitosan and modified or derivatized chitosan, which can be obtained through the deacetylation of chitin, the major compound of exoskeletons in crustaceans. Chitosan [a-(1˜4)-2-amino-2-deoxy-β-D-glucan], a mucopolysaccharide closely related to cellulose, exhibits chemical properties that are determined by the molecular weight, degree of deacetylation, and viscosity. Chitosan can form microparticles and nanoparticles that can bind large amounts of antigens by chemical reaction with crosslinking agents such as phosphate ions, glutaraldehyde or sulfate ions.
[0033] Although chitosan is used in some preferred embodiments, other polymers may be used to achieve a similar mucoadhesive function. These include but are not limited to gelatin, alginate, dextran, hyaluronic acid, agar, and resistant starch.
[0034] The one or more mucoadhesive polymers typically constitute at least 1% of the weight of the particles, excluding water, or at least 10%, or at least 15%. Typically, they constitute at most 50%, or at most 30%, or at most 20%.
Oil
[0035] In typical traditional products, a significant amount of bioactive agent is lost to the aqueous environment by leaching out of the particle during its preparation and through the gastric passage, particularly small molecular size bioactive agents such as viruses, proteins, drugs, antibiotics, pesticides and the like. In the present invention, leaching of bioactive agent from the particle is largely eliminated by discrete particles, domains or phases containing the agent being dispersed in, or coated by, an oil. Any type of oil, including vegetable, animal or synthetic oils and fats in either liquid or solid form, or waxes, can be used for coating the bioactive agent. Vegetable origin oils used in the present invention include, without limitation, castor oil, coconut oil, coco butter, corn oil, cottonseed oil, olive oil, olive squalane, palm oil, peanut oil, rapeseed oil, safflower oil, sesame oil, soybean oil, sunflower oil, stearate, carnauba wax and mixtures thereof. Animal origin oils used in the present invention include, without limitation, fish oil, shark squalane, butterfat, beeswax, lanolin, lard and the like. In some cases the dispersing oil is a mixture of olive or shark squalanes with any other type of oil, fat or wax. Typically, the mass of oil is greater than the combined mass of bioactive agent and mucoadhesive polymer.
[0036] In a typical procedure, an aqueous solution containing the bioactive agent and mucoadhesive polymer is homogenized with oil at a ratio of one part solution to 1.1-5 parts oil by weight until a uniform emulsion is produced. To assist in the formation of a uniform and stable emulsion, a nonionic surfactant may be added. Suitable nonionic surfactants, without limitation, include ethoxylated aliphatic alcohol, polyoxyethylene surfactants and carboxylic esters, etc. Once a stable emulsion is formed, the aqueous droplets dispersed in the oil are solidified by a chemical or physical reaction of the mucoadhesive polymer. For example, gelatin and agar polymers are solidify by dropping the temperature or changing the pH of the emulsion; while chitosan is solidified by raising the pH of the emulsion to above 6.5 and/or by adding counterions such as sodium tripolyphosphate (TPP).
[0037] The one or more oils typically constitute at least 1.5% of the weight of the particles, excluding water, or at least 10%, or at least 20%. Typically, they constitute at most 40%, or at most 30%, or at most 25%.
Enteric Coating Polymer
[0038] Droplets of the oil dispersion, either containing or coated by the mucoadhesive polymer, are dispersed in a matrix of enteric coating polymer that provides gastric protection and intact post gastric release or delivery of the bioactive agent, i.e., release in the intestine.
[0039] Exemplary enteric coating polymers include polymers soluble in water at sufficiently high pH, but insoluble at low pH. Typically, they are soluble at a pH greater than 5.0, and insoluble at a pH less than 4.0. Suitable polymers are substantially soluble or digestible under the relatively mild pH conditions of an animal's intestine, where the bioactive material is to be released, but insoluble and indigestible in the stomach, where the external matrix of enteric coating polymer protects the sensitive bioactive agent from deterioration. In some cases, the enteric coating polymer is crosslinked, for example with divalent cations, to prevent dissolution or digestion in the stomach.
[0040] Suitable enteric coating polymers can be selected from any of a wide variety of hydrophilic polymers including, for example, polyacrylic acid, poly(meth)acrylates, carboxymethyl cellulose, methyl cellulose, cellulose acetate phthalate and water soluble, natural or synthetic polysaccharide gums. One exemplary synthetic enteric coating polymer is EUDRAGIT® FS30D (Evonik Industries). Sodium alginate and pectins are preferred water soluble gums, because of their mild crosslinking conditions.
[0041] Alginates provide a preferred hydrophilic carrier matrix for gastric sensitive bioactive agents, particularly due to their ease of use in forming solid gel compositions. Alginate solutions form solid gels when combined or mixed with divalent cations. Nonetheless, in some embodiments the alginate is not crosslinked, but remains indigestible and insoluble in a gastric environment and therefore protective of the particle contents while under the low pH conditions of an animal's stomach.
[0042] Alginates comprise varying proportions of 1,4-linked β-D-mannuronic acid (M), α-L-guluronic acid (G), and alternating (MG) blocks. The viscosity of alginate solutions is mostly determined by the molecular ratio of M/G blocks. Low viscosity alginates typically contain a minimum of 50% mannuronate units and their viscosity ranges from 20-200 mPa. Medium and high viscosity alginates contain a minimum of 50% of guluronic acid units and their viscosity is typically over >200 mPas.
[0043] In some embodiments the matrix forming polymer is alginate, pectin or a mixture thereof. Low viscosity grade alginates and low methoxy pectins are preferred. Typical low methoxy pectins have a methylation degree below 50%, and these are typically crosslinked with a divalent cation such as Ba, Ca, Mg, Sr or Zn.
[0044] he one or more enteric coating polymers typically constitute at least 10% of the weight of the particles, excluding water, or at least 20%, or at least 30%. Typically, they constitute at most 70%, or at most 50%, or at most 40%.
Optional Ingredients
[0045] In some embodiments the composition optionally includes nutrients, nutraceuticals, feed attractants and/or taste masking compounds, in addition to the primary bioactive agent. Penetration enhancers or adjuvants may also be included, to elicit a strong immune response and improve the antigen taken up by mucosal lymphocytes. One exemplary adjuvant is beta glucan.
Making the Compositions
[0046] A first general way of making the particles is as follows. An aqueous mixture comprising a dispersed bioactive agent and mucoadhesive polymer is homogenized with oil to produce an emulsion of the aqueous mixture in the oil. Typically, a ratio of 1 part aqueous mixture to 1.1-5 parts oil by weight is used in making the emulsion. The emulsion is then slurried in an aqueous solution comprising an enteric coating polymer, and the slurry is sprayed, dropped or injected into an aqueous solution containing a crosslinker for the enteric coating polymer, thereby forming the particles.
[0047] In a second general method, an aqueous mixture comprising a dispersed bioactive agent is homogenized with oil to produce an emulsion of the aqueous mixture in the oil. Typically, a ratio of 1 part aqueous mixture to 1.1-5 parts oil by weight is used in making the emulsion. Droplets of the emulsion are then dispersed in aqueous mucoadhesive polymer, which is crosslinked to form intermediate particles that may optionally be separated from the crosslinking solution. The isolated or non-isolated intermediate particles are then slurried in an aqueous solution comprising an enteric coating polymer. The particles are formed by spray drying, or by freeze drying and milling.
[0048] In one specific method of making the compositions, an oil containing dispersed particles of bioactive agent associated with the mucoadhesive polymer is slurried into a 5-15% solution of low viscosity grade sodium alginate, optionally including 1-3% of low methoxy pectins, and the slurry is injected, dropped or spray atomized into an aqueous solution of divalent cations such as calcium chloride. The size of the resulting matrix particles can be adjusted by the rate and method of delivery of the alginate dispersion into the calcium chloride solution. In another embodiment the slurry is dried without crosslinking the alginate, using any drying method known in the art, for example spray drying or vacuum drying. Typically the resultant particles range in size from about 20 μm to about 8 millimeters, more typically from about 50 μm to about 1000 μm.
[0049] In an alternative specific method, 0.5-2% of an insoluble source of divalent cations such as CaCO 3 is added to the slurry of bioactive agent-containing oil droplets in sodium alginate solution, followed by adding 0.5-1% of a weak organic acid such as glucono-delta-lactone (GDL) as an acidifier to slowly release the cations, such as calcium ions. The cations crosslink the alginate to form a solid cake gel, which can be chopped or crushed into small chunks or particles. Typically the resultant chunks or particles range in size from about 50 μm to about 10 millimeters, more typically from about 100 to about 5000 μm. The skilled practitioner will recognize that other natural or synthetic polymers, preferably anionic polymers, can be utilized using ionic interaction-based affinity, forming the basis of the present compositions.
Using the Compositions
[0050] The compositions of this invention can be stored in aqueous suspension or dried by any drying method known in the art, and stored in a dehydrated state for long periods of time without a significant loss of activity.
[0051] Compositions according to the invention can be administered orally as a component of drinking water, as a food additive, or as part of a vaccine formulation containing a pharmaceutically acceptable carrier and optional adjuvants. Alternatively, the present compositions can be included in other standard oral dosage forms. Those skilled in the art will appreciate that there is a wide variety of art-recognized food, feed, nutraceutical or pharmaceutical dosage forms and acceptable carriers, suitable for delivering the composition to the targeted animal.
[0052] Administration of the compositions in accordance with this invention can be effected in single or multiple dose protocols. In one embodiment, immunogenic compositions are administered in multiple dose protocols administered over a period of about 3 days to about 10 days or longer, and can be repeated periodically as the target species evidences loss of immunity.
[0053] For applications in drinking water for use in swine, poultry, cattle or aquatic animals, additional oil or inert polypropylene or polyester particles can be incorporated in the composition to increase buoyancy (i.e., decrease density) so that watering devices for delivery in fish culture tanks could be used to deliver the present compositions. Thus, the compositions can be administered to animals either as a component of their daily feed or as a component of their drinking water.
EXAMPLES
Example 1a
Preparation of the Composition of the Invention
[0054] An inventive composition was prepared as follows. Three grams of mucoadhesive polymer (Chitosan, FMC Biopolymers Inc.) was dissolved in 100 ml of 0.5N glacial acetic acid solution at 50° C. The pH of the solution was adjusted to 5.8 with sodium hydroxide and the solution allowed to cool down to room temperature. Tween 80 (0.2%, Sigma, St Louis, Mo.) and Antifoam (0.5%, Sigma, St Louis, Mo.) were added and the chitosan solution kept at 4° C. until use. A 30 ml solution containing 300 mg ovalbumin (“OVA”, a model vaccine) was added to the chitosan solution to produce a mixture. The resulting solution was added to 195 g olive oil containing 5% Span-80 (Sigma) and homogenized at 10,000 rpm for 30 min in an ice bath to form a water in oil emulsion. A 20 ml aqueous sodium tripolyphosphate (5%) and 0.5N NaOH was slowly added with mixing to the bioactive agent emulsion containing ovalbumin and crosslinked chitosan microparticles in a continuous oil phase. The particles were allowed to harden for at least 2 h but not removed from the oil phase.
[0055] The dispersion of particles in oil was stirred into 330 ml of a 9% aqueous solution of low viscosity grade sodium alginate (FMC Biopolymers Inc.) that also contained 66 g oligosaccharides (instant inulin, Cargill, Minneapolis, Minn.), 10 g lecithin and 3 g Tween-80. The resulting aqueous dispersion was injected into a cross-linking solution containing 5% CaCl 2 to form alginate matrix beads, each containing multiple oil droplets that in turn each contained microparticles of ovalbumin and crosslinked chitosan. The beads were freeze dried and milled below 150 μm sized particles to obtain a dry composition of the present invention.
Example 1b
[0056] An alternative method of forming compositions of the invention utilizes an emulsion of an aqueous bioactive solution in an oil. Ten ml of an aqueous solution containing 100 mg ovalbumin was combined with 15 g canola oil containing 5% Span-80 and homogenized to form a fine water in oil emulsion. The emulsion was mixed with a 100 ml of 3% aqueous chitosan solution, and the dispersion was injected into a cross-linking solution containing 5% tripolyphosphate solution (5% TPP). The particles were allowed to harden for at least 2 h. The resulting solid crosslinked chitosan particles contained embedded oil droplets, and each of these oil droplets in turn contained dispersed smaller than 10 μm droplets of the aqueous ovalbumin. The solid particles were isolated by filtration and were finely dispersed in 400 ml of an aqueous solution of 9% low viscosity grade alginate. The resulting aqueous dispersion was injected into a cross-linking solution containing 5% CaCl 2 to form alginate matrix beads. The beads were freeze dried and milled below 150 μm sized particles to obtain a dry composition of the present invention.
Example 2
Preparation of an Immunogenic Composition
[0057] Chitosan (3 g, FMC Biopolymer) was dissolved in 100 ml solution of 0.5N glacial acetic acid at 50° C. The pH of the solution was adjusted to 5.8 with sodium hydroxide and the solution was allowed to cool to room temperature. A 10 ml solution containing 100 mg ovalbumin (OVA) as a model vaccine was mixed with 50 mg of immune-stimulating agent (beta glucan, AHD International, Atlanta, Ga.) and added into the chitosan solution. The resulting mixture was emulsified in 150 g shark squalane oil (Jedwards International) containing 5% w/w Span-80 at 10,000 rpm for 30 minutes to form an emulsion of aqueous droplets of OVA, chitosan and beta glucan in a continuous oil phase. The emulsion was added with stirring to 400 ml of an aqueous solution of 9% low viscosity grade sodium alginate in 0.5N NaOH that also contained oligosaccharides (40 g, instant inulin). The resulting emulsion was injected into a 5% CaCl 2 solution to crosslink the alginate, resulting in an immunogenic composition of the current invention. The composition was freeze dried and milled to particles less than 250 μm in size.
Example 3
Preparation of a Composition for Treatment/Prevention of Parasitic Infection of Fish
[0058] A composition containing a protein antigen or parasiticidal compound for treatment of parasite infestation in fish is prepared. Ten mg of the bioactive agent is dissolved in 10 ml of 3% aqueous chitosan solution as described in Example 2 above, and emulsified in 15 g of oil mixture containing 75% olive oil, 20% squalane oil and 5% Span-80.
[0059] One ml of an aqueous 5% sodium tripolyphosphate, 0.5N NaOH solution is emulsified in one g olive oil and mixed into the bioactive agent emulsion, resulting in a dispersion in oil of particles containing the bioactive agent and crosslinked chitosan. The dispersion is allowed to stand for 2 h to harden the crosslinked chitosan. The resulting dispersion of particles in oil is added with stirring to a 20 ml solution containing 9% low viscosity grade sodium alginate, 1% low methoxypectin, 30% w/w instant inulin and 1% Tween-80. The resulting mixture is injected into a cross-linking solution containing 3% CaCl 2 to form beads of an alginate-pectin matrix containing embedded dispersed oil droplets each in turn containing microparticles of bioactive and crosslinked chitosan. The beads are freeze dried and milled to below 150 μm to obtain a dry composition of the present invention.
Example 4
Preparation of a Composition Containing a Pharmaceutical Drug
[0060] A composition containing a pharmaceutical drug (a glucocorticoid such as dexamethasone or methyl prednisolone) for treatment of colonic diseases is prepared. The drug is added to chitosan solution as described in Example 1 or 2 above, and emulsified in a mixture of 95% squalane oil and 5% Span-80. An alkali emulsion containing 5% sodium tripolyphosphate in 0.5N NaOH in squalane oil is prepared and slowly mixed (20% w/w) into the bioactive emulsion to crosslink the chitosan, and the mixture is allowed to stand for at least 2 h to harden the crosslinked particles. The oil dispersion of chitosan microparticles is mixed into a liquid containing the enteric coating polymer (30% w/w EUDRAGIT® FS30D, Evonik Industries) at a ratio of 1:3 emulsion/Eudragit liquid and spray-dried to form a dry particulate composition of the present invention.
Example 5
Encapsulation Efficiency of a Bioactive Agent in the Composition of the Current Invention
[0061] The effect of the additional oil dispersion and enteric coating polymer matrix in the composition of the current invention was evaluated using ovalbumin (OVA) to simulate a typical protein drug or vaccine. Three OVA (Sigma) containing compositions were prepared. Composition 1 consisted of OVA bound chitosan microparticles, prepared by dissolving 100 mg OVA in 10 ml of 3% chitosan solution and injecting the solution into 10% aqueous TPP to form crosslinked beads, followed by a 2 h hold to harden the beads and subsequent freeze drying and milling. Composition 2 was made by emulsifying a 10 ml aqueous solution containing 100 mg OVA in 15 g of squalane oil containing 3% Span-80, and mixing the resulting emulsion in 20 ml of 3% chitosan solution. The resulting slurry was then injected into a 10% TPP solution to form beads, followed by hardening, freeze drying and milling as above. Composition 3 consisted of OVA bound chitosan microparticles according to the invention, prepared as in Example 2.
[0062] The encapsulation efficiency of OVA in the three types of composition was determined as follows. Five hundred mg of each composition was dispersed in 10 ml RIPA buffer and incubated at room temperature for 30 min. The suspensions were vortexed for 5 min and then centrifuged at 3000 rpm for 15 min. The supernatant was assayed for OVA content using Western Blot analysis, as follows.
[0063] Western Blot: the compositions were lysed with RIPA buffer as described above, and a calculated amount equivalent to 12 μg of protein per sample was loaded on a 10% SDS-polyacrylamide gradient gel (SDS-PAGE, Bio-Rad, Hercules, Calif.). Proteins were transferred onto a PVDF membrane (Bio-Rad) and blocked for 1 h with 5% non-fat milk in PBS containing 0.5% Tween-20 (PBS-T). Blots were incubated with an appropriate primary antibody at 1:5000 dilutions for 1 h at room temperature. After washing with PBS-T (3×10 mL, 5 min. each), the membranes were incubated with an appropriate HRP-conjugated secondary antibody (EMD Millipore Corporation, Billerica, Mass., USA) at 1:5000 dilution for 1 h. After washing with PBS-T (3×10 mL, 5 min. each), chemiluminescent films were developed with an ECL substrate (Amsheram Biosciences). The encapsulation efficiency of OVA (% retention of the original amount of OVA) is presented in Table 1.
[0000] TABLE 1 Encapsulation Composition Efficiency (%) 1 70 2 95 3 95
The results demonstrate the protective effect of the oil dispersion in compositions 2 and 3 in preventing the leaching (loss) of the bioactive agent to a simple aqueous environment. However, significant differences between comparative Composition 2 and inventive Composition 3 were found when tested under gastric conditions, as described below in Example 7.
Example 6
Degradation of Unprotected Protein Antigen Activity in Simulated Gastric Juice
[0064] To evaluate the loss of activity of a protein antigen following a typical gastric exposure, non-encapsulated OVA (10 mg) was incubated in 10 ml simulated gastric fluid containing 0.08% pepsin at pH-2 for 2 h at 37° C. on a shaker. Medium was withdrawn at 15 min, 30 min, 60 min and 120 min incubation times, and the amount of residual OVA was analyzed using Western Blot analysis as described above. Table 2 shows the degradation of OVA over 2 h exposures in simulated gastric juice, indicated as % remaining activity relative to pre-exposure activity.
[0000] TABLE 2 Remaining Time (min) activity (%) 15 61 30 55 60 38 120 2
These results demonstrate that the activity of unprotected protein-based antigen or bioactive agent will be completely degraded in the animal digestive tract.
Example 7
Gastric Protection of a Bioactive Agent in the Composition of the Current Invention
[0065] To evaluate the remaining activity of a protein antigen after gastric exposure, three compositions were prepared as described in Example 5. Five hundred mg each of the three compositions were incubated in 10 ml simulated gastric fluid containing 0.08% pepsin at pH-2 for 2 h at 37° C. on a shaker. At the end of 2 h exposure, the gastric solutions were withdrawn and the remaining activity of the OVA in the compositions was measured as described in Example 5. Table 3 shows the remaining activity of OVA in each of the compositions after 2 h exposure to simulated gastric juice.
[0000] TABLE 3 Remaining Composition activity (%) 1 10 2 20 3 90
These results clearly demonstrate the superior gastric protective effect of inventive Composition 3 relative to prior art Compositions 1 and 2.
Example 8
The Effect of the Viscosity Grade of Alginate in the Composition on Gastric Protection
[0066] Three compositions containing 9% low grade viscosity alginate (50 cP), 6% medium grade viscosity alginate (300 cP) and 1% high grade viscosity alginate (800 cP) were prepared according to Example 2 above. The three compositions were exposed to simulated gastric juice as described in Example 7 and the remaining activity of the OVA in the compositions measured as described in Example 5. Table 4 shows the remaining activity of OVA in each of the compositions after 2 h exposure to simulated gastric juice.
[0000] TABLE 4 Alginate Remaining viscosity grade activity (%) High (800 cp) 25 Medium (300 cp) 40 Low (50 cp) 90
These results demonstrate that compositions containing lower viscosity grade alginate provide higher protection of a protein-based antigen or bioactive in the simulated animal digestive tract.
Example 9
Optimal Particle Size of the Inventive Composition
[0067] In this example the protecting effect of the particle size of a dried and milled inventive composition in a simulated gastric environment was assessed. An OVA composition was prepared as described in Example 5, followed by separating the dry powder into 2 particle sizes: small particles that went through a 50 μm screen, and large particles that were captured on the 50 μm screen but passed through a 100 μm screen. Table 5 shows the remaining activity of OVA in each particle size of the composition after 2 h exposure in simulated gastric juice.
[0000] TABLE 5 Remaining Particle size activity (%) 50-100 μm 90 <50 μm 40
These results show that optimal gastric protection is provided when the dry composition is milled to a particle size above 50 μm.
Example 10
Oral Administration of OVA Composition to Mice
[0068] Ovalbumin is orally administered to mice to test the efficacy of the inventive compositions in inducing an immune response.
[0069] Animals: Ten-twelve week old female BALB/C mice are used. Mice are fed ad libitum. Each experimental group is housed in a separate cage.
[0070] Ovalbumin composition: Ovalbumin (1 mg/g of ovalbumin, Sigma, St. Louis, Mo.,) is incorporated into the inventive composition as described in Example 5. Three groups of 4 mice each are inoculated as follows: 1) ovalbumin (OVA) in the composition, administered orally, 2) OVA solution, administered subcutaneously (SC), 3) antigen free composition administered orally. Mice are inoculated at 0 and 3 weeks. Each dose administers a total 100 mg of dry composition mixed with corn oil at a ratio of 1:2 w/w of dry composition/oil, coated onto feed pellets. At week 4 each mouse is euthanized and serum and spleen cells are harvested.
[0071] Immunological assays: Serum is assayed for IgG and IgA by ELISA. ELISA is performed using OVA absorbed to polystyrene plates. Samples are placed in wells in triplicate at a 1:25 dilution for serum. Goat anti-mouse antibody conjugated with horse radish peroxidase is used, followed by an orthophenylenediamine substrate (Sigma, St. Louis, Mo., U.S.A.). Optical density of each well is determined by placing the plate in a microtiter plate spectrophotometer and reading the plate at 490 nm. Spleen cells are tested for antibody secreting cells (ASC) specific for OVA, using techniques described previously.
[0072] The OVA specific IgG and IgA antibodies are quantified by determining the increase in optical density over time. OVA specific serum and IgA IgG and ASC secreting cells for each mouse inoculated with OVA are expected to be equally increased in those mice injected with OVA and orally fed the composition of the present invention. No OVA specific IgG or IgA antibodies are expected to be detected in mice fed antigen free composition. Thus, the composition is expected to be effective in inducing an immune response upon oral administration.
Example 11
Oral Administration of a Composition Containing Antigens to Chickens
[0073] Salmonella enteritidis is a major cause of disease in laying hens. Infection decreases production and increases mortality in flocks. Moreover, S. enteritidis can be passed through the egg to baby chicks, infecting subsequent generations or humans who consume infected eggs. Since infection begins by this bacteria attaching and invading the intestinal mucosa, and long term infection involves infection of intestinal lymphoid tissues, stimulation of mucosal immunity is imperative to control this disease.
[0074] To assess the efficacy of vaccinating chickens with the vaccine compositions of the present invention, the flagellin of Salmonella enteritidis, a key immunogen, is incorporated within the composition according to Example 2, except that the vaccine emulsion is mixed in the alkaline sodium alginate phase at a ratio of 1:2 w/w and the slurry is spray-dried. The dry composition is top-coated on feed and administered orally to chicks. Ten-week old chickens receive 3 oral doses at 2 week intervals of the composition loaded with either 300 μg of flagellin antigen of S. enteritidis or Bovine serum albumin. One week after the last oral dose of antigen, serum and intestinal fluid are collected and assayed for flagellin specific antibodies by ELISA. Results are expected to show that orally vaccinated birds have significantly increased flagellin specific antibodies in the serum.
Example 12
Oral Administration of a Composition Containing Antigens to Calves
[0075] The efficacy of orally administered ovalbumin containing composition prepared in accordance with the present invention to stimulate an immune response in the lungs of calves is demonstrated.
[0076] Ovalbumin is incorporated in the composition as described in Example 1a. For oral administration to calves, a composition containing a dose of 40 μg of ovalbumin per mg is administrated in the feed. Four calves are used per experimental group and each calf receives 5 mg of ovalbumin per dose for 5 consecutive days.
[0077] Two groups of calves are used to assess the efficacy of orally administered ovalbumin to induce a specific immune response. Group 1 is given 2 doses of ovalbumin in an incomplete Freund's adjuvant by subcutaneous (SC) injection 3 weeks apart. This group serves as the parenteral control, the method of vaccination routinely used for any vaccine. Group 2 receives 2 oral regimens of a composition containing ovalbumin 3 weeks apart. Serums are evaluated for isotypic antibody response to ovalbumin. Results are expected to show that a significant amount of OVA specific IgG and IgA is produced in the orally fed calves with OVA-containing composition. The expected very high level of serum IgA predicts high effectiveness in stimulating a systemic immune response in cattle.
Example 13
Oral Administration of a Composition Containing Vibrio Antigens to Fish
[0078] Vibrio alginolyticus is a serious bacterial infection in aquaculture, particularly severe in rainbow trout. It is now endemic in all trout-producing countries where it can cause severe economic losses. It is also becoming a more significant pathogen of farmed salmon, primarily in the freshwater growing phase, but it has been reported to cause losses in the sea as well. Vaccination can prevent V. alginolyticus from having a significant impact at any stage of the farming cycle of salmonids. A typical vaccination program involves a primary vaccination of fry of 2-5 grams and an oral booster vaccination 4-6 months after the primary vaccination. However, an ideal vaccination program would involve only one type of vaccination provided periodically to the fish in order to maintain an effective antibody titer in the fish serum throughout the entire culture period.
[0079] Experimental design: The efficacy of orally administered ERM vaccine containing composition prepared in accordance with the present invention to stimulate an immune response in trout serum is demonstrated.
[0080] Attenuated V. alginolyticus is incorporated within a composition as described in Example 1b. For oral administration to fish, a composition containing a dose of 2 μg of V. alginolyticus vaccine per mg is administrated in the feed. Twenty fish at an average size of 5 g are used per experimental group and each fish receives 1 dose of V. alginolyticus vaccine in feed ration for 5 consecutive days.
[0081] Three groups of fish are used to assess the efficacy of orally administered V. alginolyticus vaccine to induce an immune response relative to a standard vaccination by injection. Group 1 is vaccinated using a vaccination by injection protocol. This group serves as the parenteral control, the method of vaccination routinely used for any vaccine. Group 2 receives one oral regimen of a composition containing V. alginolyticus vaccine. Group 3 receives one oral regimen of vaccine free composition. Sera are evaluated for isotypic antibody response to V. alginolyticus 6 weeks post vaccination. Results are expected to show that a significant amount of V. alginolyticus specific IgA is produced in the orally fed fish with V. alginolyticus -containing composition. The immune response in serum of both orally and injected vaccinated fish is expected to be comparable. The expected very high level of serum IgA predicts high effectiveness in stimulating a systemic immune response in fish.
Example 14
Composition Containing a Rodenticide
[0082] Warfarin is the most common rodenticide used to control rat and mouse infestations. Rodents ingesting baits containing Warfarin exhibit obvious symptoms of poisoning in 15-30 minutes and become unconscious in 1-2 hours. However, because of its fast acting effect the rodent typically ingest a sublethal amount of Warfarin and recovery occurs within 8 hours. Encapsulating the Warfarin may delay onset of the symptoms, allowing for the consumption of a full lethal dose.
[0083] Experimental Methods: Ten-twelve week old female BALB/C mice are used. Mice are fed ad libitum. Each experimental group is housed in a separate cage.
[0084] Inventive Warfarin composition: Warfarin (400 mg/g of composition, Sigma, St. Louis, Mo.) is incorporated into a composition as described generally in Example 3. Three groups of 4 mice are each fed ad libitum as follows: 1) Inventive Warfarin composition, mixed in baits at 4% Warfarin activity, 2) Unencapsulated Warfarin, mixed in baits feed at 4% activity, 3) Bait containing a composition as in Example 3, containing no Warfarin or other bioactive. The feed intake and kill effect on the mice are monitored.
[0085] Results show that feed intake of groups 1 and 3 are similar while the feed intake in group 2 (unencapsulated Warfarin) is over 25% less. It is expected that all mice in group 1 are dead after 8 h from feeding while all group 2 mice remain alive after 8 h from feeding. | A process for selective transvinylation of a reactant carboxylic acid with a reactant vinyl ester to give a product vinyl ester and the corresponding acid of the reactant vinyl ester in the presence of one or more ruthenium catalysts, wherein a) the reactant vinyl ester, the reactant carboxylic acid and the ruthenium catalyst are supplied to a reactor, wherein b) the molar ratio of reactant vinyl ester to reactant carboxylic acid is 1:3 to 3:1, and c) the transvinylation reaction is conducted, d) on completion of the transvinylation reaction, the reactant vinyl ester and the corresponding acid are separated from the reaction mixture by distillation, e) the product vinyl ester is separated by distillation from the bottom product of the distillation, and f) the remaining reaction mixture is recycled into the reactor. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Application No. 2002-69168, filed Nov. 8, 2002, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a power supply apparatus, and more particularly to a power supply apparatus for a motor and a control method thereof having an inrush current protection circuit.
[0004] 2. Description of the Related Art
[0005] A three-phase motor has a coil with a triangular winding. A power supply apparatus for the three-phase motor, as shown in FIG. 5, supplies a three-phase voltage necessary to drive an AC motor 117 and comprises an AC power supply 101 to supply commercial AC voltage (AC 110 / 220 V), a diode rectifier part 103 to rectify the commercial AC voltage, an inrush current protection circuit 102 and 111 to block an inrush current on an initial supply of power, a DC capacitor 115 to smooth the rectified AC voltage from the diode rectifier part 103 , an over voltage protection circuit 112 and 114 to protect the DC capacitor 115 from an over voltage condition, and an inverter 116 to invert DC voltage to AC voltage having various kinds of frequency and then to output three-phase voltage. In the inverter 116 are provided a PWM (Pulse Width Modulation) part ( ) to generate a PWM signal and a plurality of transistors switched on/off according to a square wave signal of the PWM part. The power supply apparatus for the AC motor 117 further comprises a microprocessor ( ) to control an output of the inverter 116 by turning on/off the plurality of transistors according to a PWM control signal and to control an output frequency so as to control a rotation speed of the AC motor 117 .
[0006] However, the conventional inrush current protection circuit 102 and 111 of the conventional power supply apparatus for the AC motor 117 operates only when power is initially supplied to a system. That is, once the power is supplied and the DC capacitor 115 is charged, an operation of the conventional inrush current protection circuit 102 and 111 is not necessary to operate the conventional power supply apparatus. Also, the over voltage protection circuit 112 and 114 is operationally needed only in a case that the rectified AC voltage input to the DC capacitor 115 is stabilized (sufficiently charged) to control the motor in view of operation characteristics of the over voltage protection circuit 112 and 114 . That is, directly after the power is initially supplied, an operation of the over voltage protection circuit 112 and 114 is not needed. However, a resistor Rs adapted, to the conventional inrush current protection circuit 101 and 111 is used. The resistor Rs can be either a high resistance resistor or a thirmistor so as to block an initial over current condition. As a capacitance of the DC capacitor 115 is increased, a resistance of the resistor Rs is increased and accordingly, a size of a product is increased by an increase in a layout of the conventional inrush current protection circuit.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an aspect of the present invention to provide a power supply apparatus for a motor and a control method thereof to enable a number of parts and a cost of production to be decreased by reducing a layout size of a circuit thereof by using a resistor for inrush current protection and over voltage protection.
[0008] Additional aspects and/or 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.
[0009] The above and/or other aspects are achieved by providing a power supply apparatus for a motor comprising an AC power supply, a diode rectifier circuit to rectify power of the AC power supply and a DC capacitor to smooth the rectified AC power, a current limiting part provided between the AC power supply and the DC capacitor; a connection switching part to switch a connection state of the diode rectifier circuit and the current limiting part; a controller to control the connection switching part so that the diode rectifier circuit and the current limiting part are connected to each other either in parallel or in series.
[0010] The power supply apparatus for the motor may further comprise a detecting part to detect voltage applied between first and second end parts of the DC capacitor.
[0011] The current limiting part may include a resistor provided between the AC power supply and the DC capacitor and may be connected to the DC capacitor; the connection switching part may include a relay having a first contact point and a second contact point to allow the diode rectifier circuit and the resistor to be connected to each other, respectively, in parallel and in series; and the controller controls the relay to connect the diode rectifier circuit and the resistor in series in a case that power is supplied initially, and in parallel in a case that the voltage applied between the first and second end parts of the DC capacitor is detected to be more than a predetermined voltage value.
[0012] The power supply apparatus for the motor may further comprise an over voltage protection switching part connected to the resistor and provided in parallel with the diode rectifier circuit; and an over voltage protection diode having an anode connected to a contact point of the resistor and the over voltage protection switching part, and a cathode connected to the diode rectifier circuit.
[0013] The detecting part may comprise a comparator so as to detect the voltage applied between the first and second end parts of the DC capacitor.
[0014] The above and/or other aspects are achieved by providing a control method of a power supply apparatus for a motor comprising an AC power supply, a diode rectifier circuit to rectify power of the AC power supply, a DC capacitor to smooth the rectified AC power, a resistor connected to the DC capacitor and a two-contact relay to allow an end part of the diode rectifier circuit selectively connected to one of the first and second end parts of the resistor by turns, comprising connecting the diode rectifier circuit to the resistor in series so as to charge the DC capacitor, the AC power being supplied initially; detecting a voltage applied between the first and second end parts of the DC capacitor; and connecting the diode rectifier circuit to the resistor in parallel in a case that the detected voltage is more than a predetermined voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and/or other aspects and advantages of the present invention will become apparent and more readily appreciated from the following description of an embodiment, taken in conjunction with the accompanying drawings of which:
[0016] [0016]FIG. 1 is a view illustrating a circuit of a power supply apparatus for a motor according to an embodiment of the present invention;
[0017] [0017]FIGS. 2A to 2 D are views illustrating voltage and current waveforms at respective contact points of the power supply apparatus for the motor of FIG. 1, with power being initially supplied;
[0018] [0018]FIGS. 3A to 3 D are views illustrating voltage and current waveforms at respective contact points of the power supply apparatus for the motor of FIG. 1, with an over voltage condition occurring;
[0019] [0019]FIGS. 4A to 4 B are graphs illustrating voltage regions where a relay is on and a switching part is turned on; and
[0020] [0020]FIG. 5 is a view illustrating a circuit of a conventional power supply apparatus for a motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Reference Will now be made in detail to the embodiment of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiment is described below in order to explain the present invention by referring to the figures.
[0022] [0022]FIG. 1 is a view illustrating a circuit of a power supply apparatus for a motor according to an embodiment of the present invention. As shown in FIG. 1, the circuit of the power supply apparatus for the motor comprises a diode rectifier circuit 3 connected to an AC power supply 1 , a resistor 12 and an over voltage protection switching part 14 provided in parallel with the diode rectifier circuit 3 , a two-contact relay 11 sequentially connecting an end part of the diode rectifier circuit 3 to one of first and second end parts of the resistor 12 , an over voltage protection diode 13 having a cathode connected to the end part of the diode rectifier circuit 3 and an anode connected to a contact point of the resistor 12 and the over voltage protection switching part 14 , a DC capacitor 15 provided in parallel with the resistor 12 and the over voltage protection switching part 14 , an inverter 16 provided in parallel with the DC capacitor 15 , and a controller 20 to control the two-contact relay 11 . The circuit of the power supply apparatus for the motor further comprises a detecting part 19 to detect a voltage applied between first and second end parts of the DC capacitor 15 and to provide a signal corresponding to the detected voltage to the controller 20 . A comparator is used as the detecting part 19 .
[0023] The resistor 12 , the two-contact relay 11 and the over voltage protection diode 13 operate as an inrush current and over voltage protection circuit 10 .
[0024] An operation process of the circuit of the power supply apparatus for the motor will be described as follows. When power is initially supplied, the diode rectifier circuit 3 is connected to a first contact point 11 a provided to the first end part of the resistor 12 by the two-contact relay 11 and is operated as an inrush current protection circuit. Thus, the DC capacitor 15 is charged with a current of the diode rectifier circuit 3 through the resistor 12 connected to the two-contact relay 11 .
[0025] In a case that the charging of the DC capacitor 15 is completed and thus a voltage of the DC capacitor 15 is above a predetermined voltage, the controller 20 applies a control signal to the two-contact relay 11 and controls the diode rectifier circuit 3 to connect to a second contact point 11 b provided to the second end part of the resistor 12 . Accordingly, rectified input power is directly applied to the DC capacitor 15 . The resistor 12 connected to the two-contact relay 11 , the over voltage protection diode 13 and the over voltage protection switching part 14 are operated as an over voltage protection circuit. An operation principle of the over voltage protection circuit is described as follows. The controller 20 detects Vpn, voltage applied between the first and second end parts of the DC capacitor 15 by a comparator ( ), and if the Vpn is larger than a predetermined voltage, a current is generated corresponding to over voltage of the DC capacitor 15 . Thus,,energy related to the over voltage condition is transformed to thermal energy through the resistor 12 .
[0026] A control process of the controller 20 for inrush current and over voltage protection implemented by the power supply apparatus for the motor having a structure of FIG. 1 is as follows. As shown in FIG. 1, the power is initially supplied from the AC power supply 1 , and a control signal is applied to the two-contact relay 11 to connect the diode rectifier circuit 3 and the resistor 12 in series, and thus the DC capacitor 15 is slowly charged with the current inputted through the resistor 12 . After the DC capacitor 15 is completely charged, if the voltage of the DC capacitor 15 is more than a predetermined over voltage reference value, the control signal is provided to the two-contact relay 11 to connect the diode rectifier circuit 3 and the resistor 12 in parallel, so that the over voltage condition of the DC capacitor 15 is corrected by energy related to the over voltage condition being transformed to thermal energy through the resistor 12 .
[0027] As shown in FIGS. 2 A- 2 D and 3 A- 3 D, an AC input power is a sine wave in which positive and negative voltages are alternated (refer to FIG. 3A). The AC input power is rectified through the diode rectifier circuit 3 and then the rectified power is inputted through the resistor 12 . As the rectified power is inputted through the resistor 12 , the DC capacitor 15 is gradually charged and has a voltage curve gradually increasing. However, if the voltage of the DC capacitor 15 is more than a predetermined over voltage reference value, as shown in FIGS. 3 A- 3 D, the controller 20 actuates the two-contact relay 11 (refer to FIG. 3C) and makes the over voltage protection switching part 14 switch on/off (refer to FIG. 3D) so as to make the diode rectifier circuit 3 connect to the second contact point 11 b. Accordingly, the Vpn, the voltage applied to the DC capacitor 15 , is represented in a decreasing form (refer to FIG. 3B).
[0028] [0028]FIG. 4A and 4B are graphs illustrating voltage regions where a relay is on and a over voltage protection switching part is turned on. The controller 20 , if the voltage of the DC capacitor 15 is increased to be at a relay driving voltage V 1 , makes the two-contact relay 11 on, and if the voltage of the DC capacitor 15 is increased to be at an over voltage upper limit Vh 2 by energy provided from the AC motor 17 , turns on the over voltage protection switching part 14 , to, thereby consume energy through the resistor 12 which corresponds to the over voltage condition. Thus, if the voltage of the DC capacitor 15 is lower than an over voltage lower limit Vh 1 , the controller 20 turns off the over voltage protection switching part 14 . Whenever the voltage of the DC capacitor 15 enters the over voltage condition region between the voltage lower limit Vh 1 and the over voltage upper limit Vh 2 , the controller 20 turns on/off the over voltage protection switching part 14 , to thereby stabilize the voltage of the DC capacitor 15 .
[0029] A conventional inrush current protection circuit used only when power is initially supplied and an over voltage protection circuit used only when charged voltage of a DC capacitor is more than a predetermined voltage, are implemented to have respective resistors. However, according to the embodiment of the present invention, an inrush current protection circuit and an over voltage protection circuit using a single resistor are implemented and use the single resistor according to respective functions thereof, to thereby decrease a number of parts, a size of a product and a cost of production of the circuit.
[0030] As described above, according to the present invention, provided is a power supply apparatus for a motor and a control method thereof to enable a number of parts and cost of production to be decreased based on an improved layout of the circuit by using a single resistor for not only inrush current protection but also for over voltage protection.
[0031] Although an embodiment of the present invention has been shown and described, it will be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. | A power supply apparatus for a motor including an AC power supply, a diode rectifier circuit to rectify power of the AC power supply and a DC capacitor to smooth the rectified power, comprising a current limiting part provided between the AC power supply and the DC capacitor; a connection switching part to switch a connection state of the diode rectifier circuit and the current limiting part; a controller to control the connection switching part so that the diode rectifier circuit and the current limiting part are connected to each other one of in parallel and in series. Thus, an inrush current protection circuit and an over voltage protection circuit use a single resistor according to their respective functions. | 7 |
BACKGROUND OF THE INVENTION
This invention has to do with circuit arrangments for voice communication, typically from a local station via a radio link or the like to a central station, with provision for generating code tone signals over the same link.
The invention is concerned especially with improving the known type of compact communication unit which may typically be held conveniently in the hand with flexible cable connections to the local station of the radio link. Such a hand-held unit typically includes a small microphone which may normally operate as loud speaker to reproduce incoming audio signals. Operation of a manual switch connects the microphone to an amplifier for outgoing voice transmission. Additionally, a plurality of tone generating circuits having distinctive respective frequencies may be manually actuated to transmit code signals, as to alert the central station.
An important object of the present invention is to permit communication units of the described type to be made more compact and economical. In particular, it is desired to reduce the number of major elements that must be individually mounted on the circuit board of the unit and provided with suitable electrical connections.
The presently available units typically include at least two tone generators with outputs connected in parallel to give a distinctive sound for the code signaling phase of operation. Each tone generator comprises an individual amplifier which is caused to oscillate by positive feedback and is provided with suitable means for stabilizing the frequency of the resulting oscillation. Stabilized oscillators of that general type are available commercially in the form of a two-stage transistor amplifier with the stages coupled by frequency stabilizing means which may comprise a tuned electrical circuit or a mechanical device such as a tuning fork with piezoelectric coupling elements, or the like. For the sake of definiteness the invention will be described primarily as utilizing oscillating amplifiers each formed as an integrated circuit and with frequency stabilization by an external tuning fork coupled to the respective amplifier stages by piezoelectric transducers cemented to the two tines of the fork. With that illustrative arrangement, an integrated circuit and a tuning fork must be provided for each individual tone that is to be generated. Since purchasers usually specify capability for generating a definite number of tones, there is then little or no flexibility in the number of major elements required for the tone generating portion of the equipment.
Communication units of the described type are commonly controlled manually by two distinct switched of push-button type, with the control buttons well separated from each other on the unit to facilitate their separate operation. One switch is operated to enable voice transmission over the radio link. The tone code generating phase is enabled by operating the other switch, or by operating both switches together. With neither switch operated the unit is in idle condition, and the microphone is then typically connected between ground and an audio input terminal so that it can act as loudspeaker to reproduce any incoming communication from the radio link. The described control format requires at least two switches, each of which must have several distinct electrical poles to handle such functions as switching on the radio link if it is normally idle, energizing the microphone amplifier for voice transmission and the tone generating amplifiers for tone production, switching the microphone between its amplifier and the audio input line, and supplying the radio link with the proper output signals for the respective modes of operation. Thus, it is difficult or impossible to reduce significantly the space requirements for the switching facility.
SUMMARY OF THE INVENTION
The present invention provides appreciable saving of parts cost and of space on the circuit board of such instruments by dual use of one of the oscillator amplifiers both for tone generation during operation in signaling mode and for amplifying the microphone output during voice communication operation. Despite the very different performance characteristics required for those modes of operation, it has been found to be feasible to use a single amplifier for both functions without significant increase in the complexity of the switching system. By providing such dual amplifier utilization, the invention permits elimination from the system of an entire amplifier and its electrical connections.
BRIEF DESCRIPTION OF THE DRAWING
A full understanding of the invention, and of its further objects and advantages, will be had from the following description of an illustrative embodiment. The accompanying drawing, which is a part of that description, is a schematic diagram representing an illustrative form of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
In the drawing, two typical tone generating circuits are represented at 10 and at 30, respectively. Additional tone generators in any desired number may be provided, as indicated by the broken lines at 28.
Referring first to tone generator 10, a typical two-stage amplifier is represented at 12, with the input 13, the output 14 and the positive feedback circuit 17 including the resistance R2 and the capacitance C2 in series. The amplifier is selectively energized by applying power via the line 24 under control of the switch designated S2,4. The first amplifier stage comprises the transistor Q1, which is connected as a common-emitter inverting amplifier with voltage gain. Its output signal is taken across the collector resistance R11 and is supplied to the line 15. The second stage transistor Q2 receives its input signal from the line 16 and is connected as a non-inverting emitter follower with the emitter resistance R12.
The two stages are coupled with respect to alternating current signals via the conventional tuning fork stabilizer 20, which comprises the grounded fork proper 21 and the two piezoelectric transducer elements 22 and 23. Those elements are cemented to the respective tines of the fork, with one terminal contacting the fork and the other insulated from it by the dielectric crystal and at a potential which varies with flexure of the tines. Line 15 is connected to transducer 22, driving the fork in response to the output of the amplifier first stage. Transducer 23 responds to the resulting fork movement, producing on the line 16 an input signal for the amplifier second stage, which performs impedance matching between the tuning fork element and output line 14. Capacitor C4 improves the tuning.
The phase relations of the amplifier, its feedback circuit and the coupling action through tuning fork 20 are so arranged as to provide strong positive overall feedback. In the present circuit the tuning fork stabilizer is so arranged that a positive signal on one piezoelectric element produces a negative signal on the other. The resulting two inversions, one in the first amplifier stage and the other in the tuning fork stabilizer, then give overall positive feedback around the loop. That positive feedback with gain greater than unity causes the amplifier to operate in regenerative mode, producing oscillations at the natural frequency of the tuning fork.
The second tone generator 30 of the figure typically comprises the amplifier 32, which is shown only in block form and which is typically substantially identical with amplifier 12 of tone generator 10, just described. Generator 30 also includes the stabilizing tuning fork assembly 20a, which is typically substantially identical to fork assembly 20 except that the fork has a different natural frequency. When in its regenerative tone generating mode, generator 30 operates as already described for generator 10, producing on the output line 34 a tone signal having a frequency determined by tuning fork 20a.
In accordance with the present invention, one of the tone generators of the FIGURE, shown as generator 30, operates selectively as a tone generator, and has also the capability, in response to suitable control, to operate in the entirely different mode of providing a stable and substantially linear amplifier for processing signals received from the microphone M.
As illustratively shown, the system of the FIGURE includes two distinct switch banks S1 and S2, which are separately operable in response to any desired control means. The switch banks typically comprise respective multipole push-button switches, which are normally in the idle positions shown in the drawing, and are individually operable manually to shift all their poles or component switches simultaneously to the opposite positions. The individual component switches of each bank are designated by numerals following the designation S1 or S2.
The drawing assumes connection of the illustrated communication unit via a five-conductor flexible cable, not explicitly shown, to a local station, which may be connected to a central station via a radio link or the like. The cable includes a ground conductor connected to the terminal 43, a positive direct current power conductor connected to the terminal 40, and other conductors to be described. With both switch banks S1 and S2 in idle position, as shown in the drawing, tone generators 10 and 30 are both disabled by open position of switches S1,3 and S2,4. The open switch S1,1 lifts the ground from the terminal 42, typically acting through a control conductor to switch the radio link or its equivalent to receiving mode. The audio input terminal 41 then receives audio information supplied from the radio link via an audio cable conductor, and passes it via the idle switch S1,2 to the microphone M. With the other microphone terminal grounded via the switch S2,1, the microphone acts as a loudspeaker to reproduce such input audio.
Upon operation of switch bank S1, control terminal 42 is grounded via switch S1,1, typically shifting the radio link to sending mode. Closure of the switch S1,3 supplies power to amplifier 32 of tone generator 30. However, the normal tone generating mode of that generator is disabled by idle condition of switch bank S2, which lifts the ground from tuning fork 21a at switch S2,1 and connects the capacitance C7 via switch S2,3 between lines 15a and 16a, thereby bypassing the entire tuning fork assembly 20a for alternating current signals. The latter action effectively couples the two stages of amplifier 32 via capacitance C7. Since that coupling is non-inverting in its action, the overall feedback action via circuit 37 becomes negative, converting the amplifier to stable operating mode at a controlled gain. Operated position of switch S1,2 connects microphone M via the coupling capacitance C8 between ground and input line 33 of amplifier 32, rendering the amplifier responsive to any output signals from the microphone. Capacitance C8 is preferably selected to provide with the impedance of the microphone a time constant approximately equal to that of feedback circuit 37, producing essentially linear frequency response. The amplifier output on line 34 is coupled via the capacitance C5, the resistance R7 and the idle switch S2,2 to the output terminal 44 and thence to the output line of the cable. Thus, operation of S1 readies the system for voice transmission.
On the other hand, when switch banks S1 and S2 are both operated, the system is shifted to code generating mode. Operation of switch S2,1 isolates microphone M and grounds tuning fork 21a. Operation of S2,3 opens the shunt connection through C7 across the tuning fork assembly, restoring amplifier 32 to oscillating mode and producing its characteristic tone signal on output line 34. Operation of switch S2,4 supplies power to tone generator 10, which acts as already described to produce its characteristic tone on output line 14. The two tone signals are coupled via the respective capacitances and summing resistances C5, R5 and C6, R6 and are combined at the junction 46. Resistance R7 is typically small compared to R5, and can be either neglected or taken into account in selection of R5, as desired. The combined tone signal at junction 46 is preferably adjustably attenuated by the potentiometer P1 to equalize the tone code and voice signal levels, and is then supplied via the operated switch S2,2 to output terminal 44 and the radio link or its equivalent.
In normal operation of the described communication unit, audio information from the central station can be monitored via the microphone-speaker in idle condition of the system. If it is desired to transmit to the central station, both switch banks S1 and S2 are typically operated, transmitting the tone code characteristic of the two tone generators. Release of both switch banks then makes any response from the central office audible via the microphone. Finally, operation of S1 alone then provides for voice transmission. | Communication units for hand-held use, combining a microphone for voice communication with means for generating at least two code frequencies for signaling, are made more compact and economical by dual capability of a single amplifying circuit in oscillating mode for tone generation and in substantially linear mode for amplifying the microphone output. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a method for treating a semi-conductor wafer and in particular, but not exclusively, to what is known as planarisation.
It is common practice in the semi-conductor industry to lay down layers of insulating material between conducting layers in order to prevent short circuits. If a layer of insulating material is simply deposited in the normal way undulations begin to build up as the layers pass over the metallic conductors which they are designed to insulate. Various techniques have been developed to try to overcome this problem by filling the trenches or valleys between the conductors to a height above the top of the conductors so that after treatment a generally planar layer exists on the top of the wafer. One example of such a technique is to spin on layers of polyimide to smooth out the surfaces. However, in practice, narrow trenches tend to be incompletely filled whilst wide valleys are not fully levelled. As the 2-D dimensions of devices are reduced, these problems are accentuated.
SUMMARY OF THE INVENTION
One aspect the invention consists in a method of treating a semi-conductor wafer comprising, depositing a liquid short-chain polymer having the general formula Si x (OH) y or Si x H y (OH) z on the wafer to form a generally planar layer.
The reference to the polymer being liquid is simply intended to indicate that it is neither gaseous nor solidified at the moment of deposition.
Another aspect the invention consists in a method of treating a semi-conductor wafer in a chamber including, introducing into the chamber a silicon-containing gas or vapour and a compound, containing peroxide bonding, in vapour form, reacting the silicon-containing gas or vapour with the compound to form a short-chain polymers on the wafer to form a generally planar layer.
The silicon-containing gas or vapour may be inorganic and preferably is silane or a higher silane, which may be introduced into the chamber with an inert carrier gas, for example nitrogen. The compound may be, for example, hydrogen peroxide or ethandiol.
The method may further comprise removing water and/or OH from the layer. For example the layer may be exposed to a reduced pressure and/or exposed to a low power density plasma, which may heat the layer to 40° to 120° C.
The method may further comprise forming or depositing an under layer prior to the deposition of the polymer. This under layer may be silicon dioxide and may have a thickness of between 1000 and 3000 Å. It may for example be 2000 Å thick. The under layer may conveniently be deposited by plasma enhanced chemically vapour deposition. Either the under layer and/or the wafer may be pre-treated by, for example a plasma, to removing contaminants. In that case it may be pretreated with a plasma, for example using oxygen as a reactive gas.
Similarly the surface of the deposited polymer layer may be treated in a plasma using a reactive oxygen gas in order to enhance chain lengthening and cross-linking within the polymer. This gas could be, for example, oxygen, nitrogen or hydrogen peroxide vapour and other gases may be appropriate. The plasma has a heating effect which enhances crosslinking, but there may also be a radiation effect from the various gases. This chain linking may alternatively be catalysed by exposing the polymer layer to UV light, x-rays or ion bombardment. However, in many applications acceleration of chain linking may not be desirable; instead it may be desirable for the polymer molecule particles to settle before significant chain linking occurs.
The method may further comprise depositing or forming a capping layer on the surface of the deposited layer. This capping layer may be silicon dioxide. The capping layer is deposited after a proportion of the condensation reactions have occured and water has been removed from the layer.
The method may further comprise heating the polymer layer and this heating preferably takes place after capping. The polymer layer may be heated to between 180°-220° C. for between 50-70 minutes. For example it may be heated to 220° C. for 60 minutes. The layer may subsequently be allowed to cool to an ambient temperature and then reheated to 430°-470° C. for 30-50 minutes. For example the second heating may last 40 minutes at 450° C. Indeed this second heating may suffice and may be achieved using a furnace, heat lamps, a hotplate or plasma heating.
In one preferred arrangement the polymer layer may be heated to between 200°-450° C., prior to capping, in order that the cap can be deposited at elevated temperatures. Although the capping layer could be deposited in one or more steps e.g. a `cold` capping layer deposited at the temperature of the planarising layer followed by a hot capping layer; the polymer layer having first been heated to 200°-450° C. as described above.
The density of the hydrogen peroxide may be in the range of 1.20-1.35 gms/cc and a density of 1.25 gms/cc may be particularly preferred. The hydrogen peroxide is preferably at 50% concentration when introduced into the chamber.
The ambient temperature within the chamber may be within the range of 0°-80° C. during the deposition of the polymer layer, but the wafer platten is preferably at 0° C. or at the dew point of the polymer when in vapour form. Low pressure is also desirable but requires low temperatures (eg 400 mT, -10° C.).
In order to avoid heating the platen, the wafer is preferably lifted from the platen for each processing step which involves heating.
The method can be used to achieve planarisation or gap filling. In the latter case the ambient chamber temperature may conveniently be even higher. The invention also includes wafers treated by any of the methods set out above and semi-conductor devices including polymer layers formed by the method above.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be performed in various ways and a specific embodiment will now be described, by way of example, with reference to the following drawings, in which;
FIG. 1 is a schematic view of an apparatus for performing the treatment method;
FIGS. 2A and 2B are hugely magnified photographs of cross-sections of a wafer treated by the method; and
FIGS. 3A to 3E illustrate schematically the steps of the process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus for treating semi-conductor wafers is schematically illustrated at 10 in FIG. 1. It will be understood that only the features which are particularly required for the understanding of the invention are described and illustrated. The general construction of such apparatus is well known in the art.
Thus, the apparatus 10 includes a chamber 11 having a duplex shower head 12 and a wafer support 13. The shower head 12 is connected to RF source 14 to form one electrode, whilst the support 13 is earthed and forms another electrode. Alternatively the R.F. source 14 could be connected to the support 13 and the shower head 12 earthed. The shower head 12 is connected by respective pipes 15 and 16 to a source of SiH 4 in N 2 or other inert carrier and a source 16 of H 2 O 2 . The carrier gas is conveniently used for ease of operation of the equipment; it is believed that the process could be performed without it.
The source 16 comprises a reservoir 17 of H 2 O 2 , an outlet pipe 18, a pump 19 and a flash heater 20 for vaporising the H 2 O 2 .
In use the apparatus is arranged to deposit a short chain, inorganic polymer, which is initially a liquid, between the interconnects on a semi-conductor chip to produce planarisation either locally or globally, or for `gap filling`. The polymer is formed by introducing into the chamber the silane and the hydrogen peroxide in vapour form and reacting them within the chamber spontaneously. Once the resultant polymer is deposited on the wafer, it has been found that its viscosity is such that it fills both small and large geometries or gaps and is generally self levelling. It is believed that effectively there is a settlement process taking place as the polymerization takes place. The more settlement which occurs prior to full polymerization the less likelihood there is of cracking. Very small dimensioned gaps can be filled and because of the fill layer properties these gaps can even, in certain circumstances, be re-entrant.
As has been mentioned, if left, the chains within the polymer will slowly extend and cross link. In some circumstances it may be desirable to accelerate this process by plasma treatment. This treatment produces UV radiation and it is believed that it is this radiation which is responsible for increasing the speed of chain extension and cross linking. Other forms of radiation treatment may therefore be equally applicable. A variety of gases may be appropriate for use at this stage, for example any inert gas or hydrogen, nitrogen or oxygen containing gases.
For good quality films it is desirable to remove as much water and OH from the film at an early stage. This can be done by exposing the layer to a reduced pressure causing the layer to pump water out and the subsequently heating the layer to between say 40° C. and 120° C. A pump 22 is provided for reducing chamber pressure.
However in order to solidify fully the polymer layer, it has been found that it is generally necessary to subject the layer to more intense heat treatment. In many instances it is necessary or desirable first to deposit a capping layer over the polymer. It is believed that this assists in providing mechanical stability for the polymer layer during cross linking. It may also help to control the rate at which the layer looses water during heating and so have a controlling affect on shrinkage and cracking.
A suitable capping layer would be silicon dioxide.
The heat treatment stage after the capping involves removing excess water from the layer which is a by-product of the cross-linking reaction. The bake also removes SiOH bonds. The speed at which the water is removed may be important and several ways of removing water have been successful. One suitable sequence comprises baking the layer for 60 minutes at 200° C., cooling it to ambient temperature and then rebaking it for 40 minutes at 450° C. Microwave heating has also been successful. A simple bake at 450° C. will often also suffice, or the bakes may be replaced by the following steps:
1. 2000 Å `cold` cap deposited at between 20°-40° C.
2. Plasma heat treatment in N 2 0 which raises the temperature to 300°-400° C.
3. 4000-6000 Å `hot` cap is deposited.
Alternatively, in some cases, a single stage `hot cap` deposited at 300°-400° C. will suffice.
It has been found that the adhesion of the polymer layer to the underlying substrate material can be enhanced by depositing an under layer, for example of silicon dioxide. Typically this should be of the order of 2000 Å thickness and it may be laid down by plasma-enhanced chemical vapour deposition.
Examples of actual deposited layers are illustrated in the photographs of FIGS. 2A and 2B. It will be seen that the upper surface of the layers 21 are generally planar despite the huge magnification involved.
Although SiH 4 has proved to be particularly successful, it is believed that the method will be applicable with most silicon-containing gases or vapours. It has been found that to some extent a suitable polymer can be obtained with any concentration or density of H 2 O 2 , but a density range 1.20-1.35 gms/cc has been particularly successful. The most preferred H 2 O 2 density is 1.25 gms/cc. An H 2 O 2 concentration of 50% is very effective but it is believed that the preferred concentration may vary depending on whether the object is to achieve planarisation or gap filling. It is preferred that more H 2 O 2 is supplied than SiH 4 and it is particulary preferred that the H 2 O 2 :SiH 4 ratio is of the order of 3:1.
In the event that the wafer needs to be removed from the chamber between processing stages, it may be desirable to pre-treat the exposed surface, when the wafer is placed back in the chamber, in order to remove any organics or other contaminants from the exposed surface.
FIGS. 3A to E illustrate the preferred processing sequence schematically FIG. 3A shows formation of the underlayer 302 (adhesion enhancer) by PECVD at 300 Deg. C., with a probably chemistry of SiH 4 +2N 2 O→SiO 2 ↓ +2H 2 +2N 2 . FIG. 3B shows formation of the planarising layer 304 (planarises features), with reference numeral 306 denoting surface tension forces, by CVD at approx. 0 deg. C., with a probably chemistry of SiH 4 +3H 2 O 2 →Si(OH) 4 ↓ +2H 2 O+H 2 . FIG. 3C shows a treatment stage, i.e., a first post treatment (promotion of polymerisation and removal of water), by pumpout at approx. 0 deg. C., and pumpout at approx. 150 deg. C., with a probable chemistry of Si(OH) 4 →SiO 2 +2H 2 O↑. FIG. 3D shows formation of the capping layer 308 (provides mechanical stability during densification step) by PECVD at 300 deg. C., with a probably chemistry of SiH 4 +2N 2 O→SiO 2 ↓ +2H 2 +2N 2 . FIG. 3E shows a second treatment stage, i.e., a second post treatment (densification of film, where reference numeral 310 denotes shrinkage), by anneal at 450 deg. C. In FIG. 3A, an underlayer 301, which functions as an adhesion enhancer, is formed by PECVC at 300 Deg C. In FIG. 3B, a planarising layer 302 is formed by CVD at approximately 0 Deg. C. The resultant layer, exhibiting surface tension forces 303, provides planarising features. FIG. 3C shows a first post treatment stage for promotion of polymerisation and removal of water (H 2 O), as a result of a pumpout at approximately 0 Deg. C., and a pumpout at approximately 150 Deg. C. FIG. 3D shows formation of the capping layer 304 by PECVD at 300 Deg. C. The capping layer 304 provides mechanical stability during a next densification step. FIG. 3E show a second post treatment stage for achieving film densification (shrinkage) by annealing at 450 Deg. C. It may be advantageous to wash the chamber with H 2 O 2 between at least some of the processing stages.
As it is desirable to keep the platten or support 13 at around 0° C., the wafer may be lifted above the support 13 for each heating process so that the heat of the wafer is not significantly transmitted to the support 13. This can be achieved by arranging an intermediate position 23 for a wafer loading device 21. | A wafer processing method relates to treating a semi-conductor wafer and in particular, but not exclusively, to planarization. The method consists of depositing a liquid short-chain polymer formed from a silicon containing gas or vapor. Subsequently water and OH are removed and the layer is stabilised. | 8 |
[0001] This application claims the benefit of the priority of U.S. Provisional Application Ser. No. 60/553,587, filed Mar. 15, 2004 and entitled “TRAINING TREE TRANSDUCERS”, the disclosure of which is hereby incorporated by reference.
BACKGROUND
[0002] Many different applications are known for tree transducers. These have been used in calculus, other forms of higher mathematics. Tree transducers are used for decidability results in logic, for modeling mathematically the theories of syntax direction translations and program schemata, syntactic pattern recognition, logic programming, term rewriting and linguistics.
[0003] Within linguistics, automated language monitoring programs often use probabilistic finite state transducers that operate on strings of words. For example, speech recognition may transduce acoustic sequences to word sequences using left to right substitution. Tree based models based on probabilistic techniques have been used for machine translation, machine summarization, machine paraphrasing, natural language generation, parsing, language modeling, and others.
[0004] A special kind of tree transducer, often called an R transducer, operates with its roots at the bottom, with R standing for “root to frontier”. At each point within the operation, the transducer chooses a production to apply. That choice is based only on the current state and the current root symbol. The travel through the transducer continues until there are no more state annotated nodes.
[0005] The R transducer represents two pairs, T1 and T2, and the conditions under which some sequence of productions applied to T1 results in T2. This is similar to what is done by a finite state transducer.
[0006] For example, if a finite state transition from state q to state r eats symbol A and outputs symbol B, then this can be written as an R production of q(A x0)->B (r x0).
[0007] The R transducer may also copy whole trees, transform subtrees, delete subtrees, and other operations.
SUMMARY
[0008] The present application teaches a technique of training tree transducers from sample input/output pairs. A first embodiment trains the tree pairs, while a second embodiment trains the tree transducers based on tree/string pairs. Techniques are described that facilitate the computation, and simplify the information as part of the training process.
[0009] An embodiment is described which uses these techniques to train transducers for statistical based language processing: e.g. language recognition and/or language generation. However, it should be understood that this embodiment is merely exemplary, and the other applications for the training of the tree transducers are contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other aspects will now be described in detail with reference to the accompanying drawings, wherein:
[0011] FIG. 1 shows derivation trees and their simplifications;
[0012] FIG. 2A shows a flowchart;
[0013] FIG. 2B shows a speech engine that can execute the flowchart of FIG. 2A ;
[0014] FIG. 2C shows a flowchart of a second embodiment; and
[0015] FIGS. 3 and 4 show a model and parameter table.
DETAILED DESCRIPTION
[0016] The present application describes training of tree transducers. The embodiment describes training of tree transducers, e.g., probabilistic R transducers. These transducers may be used for any probabilistic purpose. In an embodiment, the trained transducers are used for linguistic operations, such as machine translation, paraphrasing, text compression and the like. Training data may be obtained in the form of tree pairs. Linguistic knowledge is automatically distilled from those tree pairs and transducer information.
[0017] TΣ represents the set of trees over the alphabet Σ. An alphabet is a finite set of symbols. Trees may also be written as strings over the set Σ.
[0018] A regular tree grammar or RTG allows compactly representing a potentially infinite set of trees. A weighted regular tree grammar is a set of values, where trees in the set have weights associated with them. The trees can be described as a quadruple G (Σ, N, S, P), where Σ is the alphabet, and N is the set of non-terminals, S is the starting (initial) terminal, and P is the set of weighted productions. The productions are written left to right. A weighted RTG can accept information from an infinite number of trees. More generally, the weighted RTG can be any list which includes information about the trees in a tree grammar, in a way that allows the weight to change rather than a new entry each time the same information is reobtained.
[0019] The RTG can take the following form:
TABLE I Σ = {S, NP, VP, PP, PREP, DET, N, V, run, the, of, sons, daughters} N = {qnp, qpp, qdet, qn, qprep} S = q P = {q → 1.0 S(qnp, VP(VB(run))), qnp → 0.6 NP(qdet, qn), qnp → 0.4 NP(qnp, qpp), qpp → 1.0 PP(qprep, np), qdet → 1.0 DET(the), qprep → 1.0 PREP(of), qn → 0.5 N(sons), qn → 0.5 N(daughters)}
[0020] The tree is parsed from left to right, so that the leftmost non-terminal is the next one to be expanded as the next item in the RTG. The left most derivations of G build a tree pre-order from left to right according to
LD ( G )≡{( t , (( p 1 , r 1 ), . . . , ( p n , r n ))ε D G |∀1≦ i<n:p i+1 ≮ lez p i }
[0021] The total weight of t in G is given by W G :T Σ →R, the sum of leftmost den derivations producing t:
W G ( t ) ≡ ∑ ( t , h ) ∈ LD ( G ) ∏ i = 1 n w i where
h = ( h 1 , … , h n ) and h i = ( p i , ( l i , r i , w i ) )
[0022] Therefore, for every weighted context free grammar, there is an equivalent weighted RTG that produces weighted derivation trees. Each weighted RTG is generated from exactly the recognizable tree language.
[0023] An extended transducer are is also used herein. According to this extended transducer xR, an input subtree matching pattern in state q is converted into its right hand side (“rhs”), and it's Q paths are replaced by their recursive transformations. The right hand side of these rules may have no states for further expansions (terminal rules) or may have states for further expansion. In notation form
⇒ x ≡ { ( ( a , h ) , ( b , h · ( i , ( q , pattern , rhs , w ) ) ) ) ❘
( q , pattern , rhs , w ) ∈ R ⋀
i ∈ paths a ⋀ q = label a ( i ) ⋀ pattern ( a ↓ ( i · ( 1 ) ) ) = 1 ⋀
b = a [ i ← rhs [ p ← q ′ ( a ↓ ( i · ( 1 ) · i ′ ) ) , ∀ p ∈ paths rhs : label rhs ( p ) = ( q ′ , i ′ ) ] ] }
where, b is derived from a by application of a
rule (queue, pattern)->rhs to an unprocessed input subtree ai which is in state q.
Its output is replaced by the output given by rhs. Its non-terminals are replaced by the instruction to transform descendent input subtrees.
[0026] The sources of a rule r=(q, l, rhs, w) ε R are the input-paths in the rhs:
sources( rhs )≡{ i l |∃p ε paths rhs ( Q× paths), q l εQ :label rhs ( p )=( q l , i l )}
[0027] The reflexive, transitive closure of x is written * x , and the derivations of X, written D(X), are the ways of transforming input tree I (with its root in the initial state) to an output tree O:
D ( X )≡{( I, O, h )ε T Σ ×T Δ ×(paths× P )*|( Q i ( I )( )) * x ( O, h )}
The leftmost derivations of X transform the tree-preorder from left to right (always applying a transformation rule to the state-labeled subtree furthest left in its string representation):
LD ( X )≡{( I, O , (( p 1 , r 1 ), . . . , ( p n ,r n ))ε D ( X )|∀1≦ i<n:p i+1 ≮ lez p i }
The total weight of (I, O) in X is; given by W x :T Σ ×T Δ →R, the sum of leftmost derivations transforming I to O:
W x ( I , O ) ≡ ∑ ( I , O , h ) ∈ LD ( X ) ∏ i = 1 n w i where
h = ( h 1 , … , h n ) and h i = ( p i , ( l i , r i , w i ) )
[0028] The tree transducers operate by starting at an initial state root and recursively applying output generating rules until no states remain, so that there is a complete derivation. In this way, the information (trees and transducer information) can be converted to a derivation forest, stored as a weighted RTG.
[0029] The overall operation is illustrated in the flow chart of FIG. 2A ; and FIG. 2B illustrates an exemplary hardware device which may execute that flowchart. For the application of language translation, a processing module 250 receives data from various sources 255 . The sources may be the input and output trees and transducer rules described herein. Specifically, this may be the translation memories, dictionaries, glossaries, Internet, and human-created translations. The processor 250 processes this information as described herein to produce translation parameters which are output as 260 . The translation parameters are used by language engine 265 in making translations based on input language 270 . In the disclosed embodiment, the speech engine is a language translator which translates from a first language to a second language. However, alternatively, the speech engine can be any engine that operates on strings of words such as a language recognition device in speech recognition device, a machine paraphraser, natural language generator, modeler, or the like.
[0030] The processor 250 and speech engine 265 may be any general purpose computer, and can be effected by a microprocessor, a digital signal processor, or any other processing device that is capable of executing the steps described herein.
[0031] The flowchart described herein can be instructions which are embodied on a machine-readable medium such as a disc or the like. Alternatively, the flowchart can be executed by dedicated hardware, or by any known or later discovered processing device.
[0032] The system obtains a plurality of input and output trees or strings, and transducer rules with parameters. The parameters may then be used for statistical machine translation. More generally, however, the parameters can be used for any tree transformation task.
[0033] At 210 , the input tree, output tree and tranducer rules are converted to a large set of individual derivation trees, “a derivation forest”.
[0034] The derivation forest effectively flattens the rules into trees of depth one. The root is labeled by the original rule. All the non-expanding A labeled nodes of the rule are deterministically listed in order. The weights of the derivation trees are the products of the weights of the rules in those derivation trees.
[0035] FIG. 1 illustrates an input tree 100 being converted to an output tree 110 and generating derivation trees 130 . FIG. 1 also shows the transducer rules 120 . All of these are inputs to the system, specifically the input and output tree are the data that is obtained from various language translation resources 255 , for example. The transducer rules are known. The object of the parsing carried out in FIG. 1 is to derive the derivation trees 130 automatically.
[0036] The input/output tree pairs are used to produce a probability estimate for each production in P, that maximizes the probability of the output trees given the input trees. The result is to find a local maximum. The present system uses simplifications to find this maximum.
[0037] The technique describes the use of memoization by creating the weighted RTG's. Memoization means that the possible derivations for a given produced combination are constant. This may prevent certain combinations from being computed more than once. In this way, the table, here the wRTG can store the answers for all past queries and return those instead of recomputing.
[0038] Note the way in which the derivation trees are converted to weighted RTG's. At the start, rule one will always be applied, so the first RTG represents a 1.0 probability of rule one being applied. The arguments of rule one are 1.12 and 2.11. If 1.12 is applied, rule 2 is always used, while 2.11 can be either rule 3 or rule 4, with the different weightings for the different rules being also shown.
[0039] At 230 , the weighted RTG is further processed to sum the weights of the derivation trees. This can use the “inside-outside” technique, (Lari, et al, “The estimation of stochastic context free grammars using the inside-outside algorithm, Computer Speech and Language, 4, pp 35-36). The inside-outside technique observes counts and determines each time a rule gets used. When a rule gets used, the probability of that rule is increased. More specifically, given a weighted RTG with parameters, the inside outside technique enables computing the sums of weights of the trees derived using each production. Inside weights are the sum of all weights that can be derived for a non-terminal or production. This is a recursive definition. The inside weights for a production are the sum of all the weights of the trees that can be derived from that production.
β G ( n ∈ N ) ≡ ∑ ( n , r , w ) ∈ P w · β G ( r )
β G ( r ∈ T Σ ( N ) ❘ ( n , r , w ) ∈ P } ≡ ∏ p ∈ paths r ( N ) β G ( label r ( p ) )
[0040] The outside weights for a non-terminal are the sum of weights of trees generated by the weighted RTG that have derivations containing it but exclude its inside weights, according to
α G ( n ∈ N ) ≡
{ 1 if n = S ∑ p , ( n ′ , r , w ) ∈ P : label r ( p ) = n w · α G ( n ′ ) ︷ uses of n in productions · ∏ p ′ ∈ paths r ( N ) - { p } β G ( label r ( p ′ ) ) ︸ sibling nonterminals otherwise .
[0041] Estimation maximization training is then carried out at 240 . This maximizes the expectation of decisions taken for all possible ways of generating the training corpus, according to expectation, and then maximization, as:
∀ p ∈ parameters : counts p ≡ E t ∈ training [ ∑ d ∈ derivations i ( # of times p used in d ) · weight parameters ( d ) ∑ d ∈ derivations i weight parameters ( d ) ]
[0042] 2. Maximizing by assigning the counts to the parameters and renormalizing
∀ p ∈ parameters : p ← counts p Z ( p )
[0043] Each iteration increases the likelihood until a local maximum is reached.
[0044] The step 230 can be written in pseudocode as:
For each ( i , o , w example ) ∈ T : // Estimate
i . Let D ≡ d i , o
ii . compute α D , β D using latest W // inside - outside weights
iii . For each prod = ( n , rhs , w ) ∈ P : label r hs ( ( ) ) ∈ R in
derivation wRTG D = ( R , N , S , P ) :
A . γ D ( prod ) ← α G ( n ) · w · β G ( rhs )
B . Let rule ≡ label rhs ( ( ) )
C . count rule ← count rule + w example · γ D ( prod ) β D ( S )
iv . L ← L + log β D ( S ) · w example
For each r = ( q , pattern , rhs , w ) ∈ R : // Maximize
i . w r ← count r Z ( counts , r )
δ ← L - lastL L
lastL ← L , itno ← itno + 1
By using the weighted RTG's, each estimation maximum iteration takes an amount of time that is linear to the size of the transducer. For example, this may compute the sum of all the counts for rules having the same state, to provide model weights for a joint probability distribution of the input output tree pairs. This joint normalization may avoid many different problems.
[0045] The above has described tree-to-tree transducers. An alternative embodiment describes tree to string transducers is shown in the flowchart of FIG. 2C . This transducer will be used when a tree is only available at the input side of the training corpus. Note that FIG. 2C is substantially identical to FIG. 2A other than the form of the input data.
[0046] The tree to string transduction is then parsed using an extended R transducer as in the first embodiment. This is used to form a weighted derivation tree grammar. The derivation trees are formed by converting the input tree and the string into a flattened string of information which may include trees and strings. 285 of FIG. 5 c simply refers to this as derivation information. The parsing of the tree to string transduction may be slightly different then the tree to tree transduction. Instead of derivation trees, there may be output string spans. A less constrained alignment may result.
[0047] This is followed in FIG. 2C by operations that are analogous to those in FIG. 2A : specifically, creation of the weighted RTG, the same as the weight summing of 230 and the expectation maximization of 240 .
EXAMPLE
[0048] An example is now described here in of how to cast a probabilistic language model as an R transducer.
[0049] Table 2 shows a bilingual English tree Japanese string training corpus.
TABLE 2 ENGLISH: (VB (NN hypocrisy) (VB is) (JJ (JJ abhorrent) (TO (TO to) (PRP them)))) JAPANESE: kare ha gizen ga daikirai da ENGLISH: (VB (PRP he) (VB has) (NN (JJ unusual) (NN ability)) (IN (IN in) (NN english))) JAPANESE: kare ha eigo ni zubanuke-ta sainou wo mot-te iru ENGLISH: (VB (PRP he) (VB was) (JJ (JJ ablaze) (IN (IN with) (NN anger)))) JAPANESE: kare ha mak-ka ni nat-te okot-te i-ta ENGLISH: (VB (PRP i) (VB abominate) (NN snakes)) JAPANESE: hebi ga daikirai da etc.
[0050] FIGS. 3 and 4 respectively show the generative model and its parameters. The parameter values that are shown are learned via expectation maximization techniques as described in Yamada and Knight 2001.
[0051] According to the model, an English tree becomes a Japanese string in four operations. FIG. 3 shows how the channel input is first reordered, that is its children are permeated probabilistically. If there are three children, then there are six possible permutations whose probabilities add up to one. The reordering is done depending only on the child label sequence.
[0052] In 320 , a decision is made at every node about inserting a Japanese function word. This is a three-way decision at each node, requiring determination of whether the word should be inserted to the left, to the right, or not inserted at all. This insertion technique at 320 depends on the labels of the node and the parent. At 330 , the English leaf words are translated probabilistically into Japanese, independent of context. At 340 , the internal nodes are removed, leaving only the Japanese string.
[0053] This model can effectively provide a formula for
P. (Japanese string|English tree)
in terms of individual parameters. The expectation maximization training described herein seeks to maximize the product of these conditional probabilities based on the entire tree-string corpus.
[0055] First, an xRs tree to string transducer is built that embodies the probabilities noted above. This is a four state transducer. For the main-start state, the function q, meaning translate this tree, has three productions:
q x→i x, r x q x→r x, i x q x→r x
State 5 means “produce a Japanese word out of thin air.” There is an i production for each Japanese word in the vocabulary.
i x→“de” i x→“kuruma” i x→“wa” . . .
[0063] State r means “reorder my children and then recurse”. For internal nodes, this includes a production for each parent/child sequence, and every permutation thereof:
r NN(x0:CD, x1:NN)→q x0, q x1 r NN(x0:CD, x1:NN)→q x1, q x0 . . .
[0067] The RHS then sends the child subtrees back to state q for recursive processing. For English leaf nodes, the process instead transitions to a different state t to prohibit any subsequent Japanese function word insertion:
r NN(x0:“car”)→t x0 r CC (x0:“and”)→t x0 . . .
[0071] State t means “translate this word”. There is a production for each pair of cooccuring in English and Japanese words.
t “car”→“kuruma” t “car”→*e* t “car”→*e* . . .
[0076] Each production in the XRS transducer has an associated weight, and corresponds to exactly 1 of the model parameters.
[0077] The transducer is unfaithful in one respect, specifically the insert function word decision is independent of context. It should depend on the node label and the parent label. This is addressed by fixing the q and r production. Start productions are used:
q x:VB→q.TOP.VB x q x:JJ→q.TOP.JJ x . . .
[0081] States are used, such as q.top.vb which states mean something like “translate this tree, whose route is vb”. Every parent-child payer in the corpus gets its own set of insert function word productions:
q.TOP.VB x →i x, r x q.TOP.VB x →r x, i x q.TOP.VB x →r x q.VB.NN x →i x, r x q.VB.NN x →r x, i x q.VB.NN x →r x . . .
[0089] Finally, the R productions need to send parent child information when they recurse to the q.parent.child states.
[0090] The productions stay the same. Productions for appraisal translations and others can also be added.
[0091] Although only a few embodiments have been disclosed in detail above, other modifications are possible, and this disclosure is intended to cover all such modifications, and most particularly, any modification which might be predictable to a person having ordinary skill in the art. For example, an alternative embodiment could use the same techniques for string to string training, based on tree based models or based only on string pair data. Another application is to generate likely input trees from output trees or vide versa. Also, and to reiterate the above, many other applications can be carried out with tree transducers, and the application of tree transducers to linguistic issues is merely exemplary.
[0092] Also, only those claims which use the words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims
[0093] All such modifications are intended to be encompassed within the following claims | Training using tree transducers is described. Given sample input/output pairs as training, and given a set of tree transducer rules, the information is combined to yield locally optimal weights for those rules. This combination is carried out by building a weighted derivation forest for each input/output pair and applying counting methods to those forests. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to tumour therapy. In one aspect, the present invention relates to conjugates of a toxin and a target-binding moiety, e.g. an antibody, which are useful in the treatment of cancer. In particular, the toxin is an amatoxin, and the target-binding moiety is preferably directed against tumour-associated antigens. In particular, the amatoxin is conjugated to the antibody by linker moieties. In particular the linker moieties are covalently bound to functional groups located in positions of the amatoxin proved as preferred positions for the attachment of linkers with respect to optimum antitumor activity. In a further aspect the invention relates to pharmaceutical compositions comprising such target-binding moiety toxin conjugates and to the use of such target-binding moiety toxin conjugates for the preparation of such pharmaceutical compositions. The target-binding moiety toxin conjugates and pharmaceutical compositions of the invention are useful for the treatment of cancer.
BACKGROUND OF THE INVENTION AND STATE OF THE ART
[0002] Antibody therapy has been established for the targeted treatment of patients with cancer, immunological and angiogenic disorders. The use of antibody-drug conjugates (ADC), i. e. immunoconjugates, for the local delivery of cytotoxic or cytostatic agents, i.e. drugs to kill or inhibit tumor cells in the treatment of cancer theoretically allows targeted delivery of the drug moiety to tumors, and intracellular accumulation therein, where systemic administration of these unconjugated drug agents may result in unacceptable levels of toxicity to normal cells as well as the tumor cells sought to be. Maximal efficacy with minimal toxicity is sought thereby. Efforts to design and refine ADC have focused on the selectivity of monoclonal antibodies (mAbs) as well as drug-linking and drug-releasing properties. Both polyclonal antibodies and monoclonal antibodies have been reported as useful in these strategies.
Amatoxins
[0003] Amatoxins are cyclic peptides composed of 8 amino acids. They can be isolated from Amanita phalloides mushrooms or prepared from the building blocks by synthesis. Amatoxins specifically inhibit the DNA-dependent RNA polymerase II of mammalian cells, and thereby also the transcription and protein biosynthesis of the affected cells. Inhibition of transcription in a cell causes stop of growth and proliferation. Though not covalently bound, the complex between amanitin and RNA-polymerase II is very tight (K D =3 nM). Dissociation of amanitin from the enzyme is a very slow process what makes recovery of an affected cell unlikely. When the inhibition of transcription lasts too long, the cell will undergo programmed cell death (apoptosis).
Conjugates of Amatoxins and Target-Binding Moieties
[0004] Earlier patent application EP 1 859 811 A1 (published Nov. 28, 2007) by the inventors describes conjugates, in which β-amanitin is coupled to albumin or to the monoclonal antibodies HEA125, OKT3, and PA-1. Furthermore, the inhibitory effect of these conjugates on the proliferation of breast cancer cells (MCF-7), Burkitt's lymphoma cells (Raji), and T-lymphoma cells (Jurkat) was studied.
Epithelial Cell Adhesion Molecule (EpCAM) Antigen
[0005] Epithelial cell adhesion molecule (EpCAM, CD326) is one of the best-studied target antigens on human tumors (Trzpis et al., 2007; Baeuerle and Gires, 2007). It represents a type I membrane glycoprotein of 314 amino acids with an apparent molecular weight of 40 kDa (Balzar et al., 1999). It is overexpressed in the majority of adenocarcinomas (Winter et al., 2003; Went et al., 2004). In particular, EpCAM expression is enhanced in node-positive breast cancer, epithelial ovarian cancer, cholangiocarcinoma, pancreatic adenocarcinoma and squamous cell head and neck cancer. Increased EpCAM expression is indicative for a poor prognosis in breast and gallbladder carcinomas (Gastl et al., 2000; Varga et al., 2004; Spizzo et al., 2002; Spizzo et al., 2004). Importantly, EpCAM is expressed by tumor initiating or cancer stem cells in mammary, colorectal and pancreatic carcinomas (Al-Hajj et al., 2003; Dalerba et al., 2007; Li et al., 2007).
[0006] EpCAM-specific monoclonal antibodies have been used as a diagnostic tool for the detection of rare circulating tumor cells in cancer patients (Allard et al., 2004; Nagrath et al., 2007). A couple of engineered anti-EpCAM antibodies are currently investigated in clinical studies.
HER2 Antigen
[0007] HER2 (Her2/neu; ErbB2), a receptor tyrosine kinase with an apparent molecular weight of 185 kDa is overexpressed in about 25-30% of human breast cancers and gastric cancers. This overexpression, which is often due to amplification of the receptor-encoding gene, generally represents a poor prognosis, often involving progressive disease in the years after the initial diagnosis is made.
[0008] Monoclonal antibody therapy has been established for the targeted treatment of patients with Her2/neu-positive cancers. HERCEPTIN® (trastuzumab) is a recombinant DNA-derived humanized monoclonal antibody that selectively binds with high affinity in a cell-based assay (Kd=5 nM) to the extracellular domain of the human epidermal growth factor receptor 2 protein, HER2 (ErbB2). Trastuzumab is an IgG1 kappa antibody that contains human framework regions with the complementarity-determining regions of a murine antibody (4D5) that binds to HER2. Trastuzumab binds to the HER2 antigen and thus inhibits the growth of cancerous cells. Because trastuzumab is a humanized antibody, it minimizes any HAMA response in patients. Trastuzumab has been shown, in both in vitro assays and in animals, to inhibit the proliferation of human tumor cells that overexpress HER2. Trastuzumab is a mediator of antibody-dependent cellular cytotoxicity, ADCC. HERCEPTIN® is clinically active in patients with ErbB2-overexpressing metastatic breast cancers that have received extensive prior anti-cancer therapy. Although HERCEPTIN® is a breakthrough in treating patients with ErbB2-overexpressing breast cancers that have received extensive prior anti-cancer therapy, the majority of the patients in this population fail to respond or respond only poorly to HERCEPTIN® treatment. Therefore, there is a significant clinical need for developing further HER2-directed cancer therapies for those patients with HER2-overexpressing tumors or other diseases associated with HER2 expression that do not respond, or respond poorly, to HERCEPTIN® treatment.
TECHNICAL PROBLEMS UNDERLYING THE PRESENT INVENTION
[0009] There was a need in the prior art for target-binding moiety toxin conjugates that exert their toxic effects to target cells or tissues at much lower concentration so that the conjugates may be administered at lower concentrations and harmful side effects to non-target cells are minimized. Furthermore, there was a need in the prior art for the treatment of other types of cancer, particularly those being therapy resistant, or poorly responding to actual tumour therapies.
[0010] The present invention fulfils these and other needs. For example, the inventors found out in the experiments underlying the present invention that very effective target-binding moiety toxin conjugates, in particular antibody amatoxin conjugates, can be constructed by choosing particular linkage points in the amatoxin part of the conjugate and by choosing particular linker compounds. Such target-binding moiety toxin conjugates are very effective in that they exert their toxic activity to the target cells at very low concentrations (IC 50 of about 5×10 −12 M) as well as by being highly specific for their target cells. Without wishing to be bound by a particular theory, these advantages might be explained in that the linkage between the target-binding moiety and the amatoxin or, if present, between the linker and the amatoxin is efficiently cleaved inside the target cell and to a much lesser degree outside the cell.
[0011] The above overview does not necessarily describe all problems solved by the present invention.
SUMMARY OF THE INVENTION
[0012] In a first aspect the present invention relates to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) at least one amatoxin; and (iii) optionally a linker L2; wherein the at least one amatoxin is connected to the target-binding moiety or, if present, to the linker L2 via the 6′ C-atom of amatoxin amino acid 4.
[0013] In a second aspect the present invention relates to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) at least one amatoxin; and (iii) optionally a linker L3; wherein the at least one amatoxin is connected to the target-binding moiety or, if present, to the linker L3 via the δ C-atom of amatoxin amino acid 3.
[0014] In a third aspect the present invention relates to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) at least one amatoxin; and (iii) optionally a linker L 1; wherein the at least one amatoxin is connected to the target-binding moiety or, if present, to the linker L1 via the γ C-atom of amatoxin amino acid 1.
[0015] In a fourth aspect the present invention relates to the target-binding moiety toxin conjugate according to the first, the second, or the third aspect for use in medicine.
[0016] In a fifth aspect the present invention relates to the target-binding moiety toxin conjugate according to the first, the second, the third or the fourth aspect for the treatment of cancer or of an autoimmune disease in a patient, wherein the cancer is preferably selected from the group consisting of pancreatic cancer, cholangiocarcinoma, breast cancer, colorectal cancer, lung cancer, prostate cancer, ovarian cancer, stomach cancer, kidney cancer, head and neck cancer, brain tumors, childhood neoplasms, soft tissue sarcomas, epithelial skin cancer, malignant melanoma, leukemia, and malignant lymphoma and wherein the autoimmune disease is preferably selected from the group consisting of Ankylosing Spondylitis, Chagas disease, Crohns Disease, Dermatomyositis, Diabetes mellitus type 1, Goodpasture's syndrome, Graves' disease, Guillain-Barré syndrome (GBS), Hashimoto's disease, Hidradenitis suppurativa, Idiopathic thrombocytopenic purpura, Lupus erythematosus, Mixed Connective Tissue Disease, Myasthenia gravis, Narcolepsy, Pemphigus vulgaris, Pernicious anaemia, Psoriasis, Psoriatic Arthritis, Polymyositis, Primary biliary cirrhosis, Relapsing polychondritis, Rheumatoid arthritis, Schizophrenia, Sjögren's syndrome, Temporal arteritis, Ulcerative Colitis, Vasculitis Wegener's granulomatosis, in particular Rheumatoid arthritis.
[0017] In a sixth aspect the present invention relates to a pharmaceutical composition comprising at least one type of target-binding moiety toxin conjugate according to the first, the second, and/or the third aspect and further comprising one or more pharmaceutically acceptable diluents, carriers, excipients, fillers, binders, lubricants, glidants, disintegrants, adsorbents; and/or preservatives.
[0018] This summary of the invention does not necessarily describe all features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows the structural formulae of different amatoxins. The numbers in bold type (1 to 8) designate the standard numbering of the eight amino acids forming the amatoxin. The standard designations of the atoms in amino acids 1, 3 and 4 are also shown (Greek letters α to γ, Greek letters α to δ, and numbers from 1′ to 7′, respectively).
[0020] FIG. 2 shows a comparison of the binding affinities of huHEA125-Ama and huHEA125 to target cells by a binding competition analysis. EpCAM-expressing Colo205 cells were incubated with a fixed amount of directly FITC-labeled mouse HEA125 antibody. Binding to target cells was analyzed by flow cytometry. Competition of binding with increasing amounts of huHEA125-Ama or huHEA125 revealed a very similar affinity towards the target antigen.
[0021] FIG. 3 shows the surface expression of EpCAM antigen on various carcinoma cell lines detected by indirect immunofluorescence: FIG. 3A Capan-1; FIG. 3B Colo205; FIG. 3C OZ; and FIG. 3D MCF-7. The grey-shaded histograms on the left side of each diagram show the results obtained with control antibody Xolair®; the histograms having a white area on the right side of each diagram show the results obtained with antibody huHEA125. The abbreviation FL1-H stands for “fluorescence 1 height” which means the intensity of fluorescence 1, i.e. the green channel for FITC.
[0022] FIG. 4 shows the binding of huHEA125-Amanitin and huHEA125-Phalloidin conjugates to MCF-7 breast cancer cells analyzed by flow cytometry. The abbreviation FL1-H stands for “fluorescence 1 height” which means the intensity of fluorescence 1, i.e. the green channel for FITC.
A: bold histogram, huHEA125-Amanitinl; shaded histogram, huHEA125; dotted histogram, Xolair (negative control); B: bold histogram, huHEA125-Amanitin4; shaded histogram, huHEA125; dotted histogram, Xolair (negative control); C: bold histogram, huHEA125-a-Phalloidin; shaded histogram, huHEA125; dotted histogram, Xolair (negative control).
[0026] FIG. 5 shows a comparison of the inhibition of MCF-7 cell proliferation caused by the conjugate huHEA125-Amanitin1, the non-binding control conjugate Xolair-Amanitin1, and free Amanitin.
[0027] FIG. 6 shows a comparison of the inhibition of MCF-7 cell proliferation caused by the conjugate huHEA125-Amanitin4, the conjugate alpha-phalloidin-huHEA125, and free Amanitin.
[0028] FIG. 7 shows a comparison of the inhibition of Capan-1 cell proliferation caused by conjugate huHEA125-Amanitin3, Amanitin-armed control antibody Xolair®, and free Amanitin.
[0029] FIG. 8 shows a comparison of the inhibition of Colo205 cell proliferation caused by conjugate huHEA125-Amanitin3, Amanitin-armed control antibody Xolair®, and free Amanitin.
[0030] FIG. 9 shows a comparison of the inhibition of MCF-7 cell proliferation caused by conjugate huHEA125-Amanitin3, Amanitin-armed control antibody Xolair®, and free Amanitin.
[0031] FIG. 10 shows a comparison of the inhibition of OZ cell proliferation caused by conjugate huHEA125-Amanitin3, Amanitin-armed control antibody Xolair®, and free Amanitin.
[0032] FIG. 11A to D show a comparison of the inhibition on cell proliferation exerted by various α-amanitin conjugates at different amanitin concentrations using the Her2/neu positive cell lines SKOV-3, SKBR-3 and NCI-N87 as well as the Her2/neu negative cell line MDA-MB231.
[0033] FIG. 12 shows the antitumor activity of various α-amanitin conjugates at two different concentrations (A: 30 μg/kg and B: 150 μg/kg body weight) in an in vivo SKOV-3 xenograft tumor model.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0034] Before the present invention is described in detail below, it is to be understood that this invention is not limited to the particular methodology, protocols and reagents described herein as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.
[0035] Preferably, the terms used herein are defined as described in “A multilingual glossary of biotechnological terms: (IUPAC Recommendations)”, Leuenberger, H. G. W, Nagel, B. and Kölbl, H. eds. (1995), Helvetica Chimica Acta, CH-4010 Basel, Switzerland).
[0036] Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integer or step.
[0037] Several documents are cited throughout the text of this specification. Each of the documents cited herein (including all patents, patent applications, scientific publications, manufacturer's specifications, instructions, GenBank Accession Number sequence submissions etc.), whether supra or infra, is hereby incorporated by reference in its entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
[0038] The term “target-binding moiety”, as used herein, refers to any molecule or part of a molecule that can specifically bind to a target molecule or target epitope. Preferred target-binding moieties in the context of the present application are (i) antibodies or antigen-binding fragments thereof; (ii) antibody-like proteins; and (iii) nucleic acid aptamers. “Target-binding moieties” suitable for use in the present invention typically have a molecular mass of at least 15 kDa, at least 20 kDa, at least 30 kDa or of at least 40 kDa or more.
[0039] As used herein, an “antibody toxin conjugate” refers to a target-binding moiety toxin conjugate in which the target-binding moiety is an antibody or antigen-binding fragment thereof according to above alternative (i).
[0040] As used herein, an “antibody-like protein toxin conjugate” refers to a target-binding moiety toxin conjugate in which the target-binding moiety is an antibody-like protein according to above alternative (ii).
[0041] As used herein, an “aptamer conjugate” refers to a target-binding moiety toxin conjugate in which the target-binding moiety is a nucleic acid aptamer according to above alternative (iii).
[0042] In the context of the present application the terms “target molecule” and “target epitope”, respectively, refers to an antigen and an epitope of an antigen, respectively, that is specifically bound by a target-binding moiety, preferably the target molecule is a tumour-associated antigen, in particular an antigen or an epitope which is present on the surface of one or more tumour cell types in an increased concentration and/or in a different steric configuration as compared to the surface of non-tumour cells or an antigen preferentially expressed on cells involved in autoimmune diseases, examples of such antigens are Immunoglobulin G Fc-part, Thyreotropin-receptor, Type IV Collagen, Proteinase 3, DNA Topoisomerase I, Placoglobin. Preferably, said antigen or epitope is present on the surface of one or more tumour cell types but not on the surface of non-tumour cells.
[0043] Preferably the term “tumour associated antigen” comprises all substances, which elicit an immune response against a tumour. Particular suitable substances are those which are enriched in a tumour cell in comparison to a healthy cell. These substances are preferably present within and/or are accessible on the outside of the tumour cell. If the tumour antigen is only present within a tumour cell, it will still be accessible for the immune system, since the antigen or fragments thereof will be presented by the MHC system at the surface of the cell. In a preferred aspect tumour antigen is almost exclusively present on and/or in the tumour cell and not in a healthy cell of the same cell type.
[0044] Suitable tumour antigens can be identified, for example, by analyzing the differential expression of proteins between tumour and healthy cells of the same cell type using a microarray-based approach (Russo et al., Oncogene. 2003, 22:6497-507), by PCR- or microarray-based screening for tumor specific mutated cellular genes (Heller, Annu. Rev.
[0045] Biomed. Eng. 2002, 4: 129-53) or by serological identification of antigens by recombinant expression cloning (SEREX; Tureci et al., Mol Med Today. 1997, 3:342-349). The skilled artisan is aware of a large number of substances which are preferentially or exclusively present on and/or in tumor cell, which include for example, oncogenes like, for example truncated epidermal growth factor, folate binding protein, melanoferrin, carcinoembryonic antigen, prostate-specific membrane antigen, HER2-neu and certain sugar chains like, for example, epithelial mucins.
[0046] It is preferred that tumour antigens are selected, which elicit a strong immune response, preferentially a MHC class I immune response. Antigens eliciting a strong immune response will induce at least 1%, preferably at least 5%, more preferably at least 10% and most preferably at least 15% IFN-γ-producing CD8 + T or CD4 + T cells isolated from mice previously immunized with the antigen, upon challenge with the antigen and/or will induce preferably at least 5%, and most preferably at least 15% of B-cells cells isolated from mice previously immunized with the antigen, upon challenge with the antigen to proliferate. Antigens fulfilling these criterions are candidates for use in therapeutic and/or prophylactic cancer vaccines.
[0047] In a particular preferred embodiment the tumour antigen is selected from the group consisting of T-cell or B-cell-defined cancer-associated antigens belonging to unique gene products of mutated or recombined cellular genes, in particular cyclin-dependent kinases (e.g. CDC2, CDK2, CDK4), p15 Ink4b , p53, AFP, β-catenin, caspase 8, p53, Bcr-abl fusion product, MUM-1 MUM-2, MUM-3, ELF2M, HSP70-2M, HST-2, KIAA0205, RAGE, myosin/m, 707-AP, CDC27/m, ETV6/AML, TEL/Amll, Dekcain, LDLR/FUT, Pml-RARa, TEL/AMLI; Cancer-testis (CT) antigens, in particular NY-ESO-1, members of the MAGE-family (MAGE-Al, MAGE-A2, MAGE-A3, MAGE-A4, MAGE-A6, MAGE-10, MAGE-12), BAGE, DAM-6, DAM-10, members of the GAGE-family (GAGE-1, GAGE-2, GAGE-3, GAGE-4, GAGE-5, GAGE-6, GAGE-7B, GAGE-8), NY-ESO-1, NA-88A, CAG-3, RCC-associated antigen G250; Tumour virus antigens, in particular human papilloma virus (HPV)-derived E6 or E7 oncoproteins, Epstein Barr virus EBNA2-6, LMP-1, LMP-2; overexpressed or tissue-specific differentiation antigens, in particular gp77, gp100, MART-1/Melan-A, p53, tyrosinase, tyrosinase-related protein (TRP-1 and TPR-2), PSA, PSM, MC1R; widely expressed antigens, in particular ART4, CAMEL, CEA, CypB, EpCAM, HER2/neu, hTERT, hTRT, ICE, Muc1, Muc2, PRAME RU1, RU2, SART-1, SART-2, SART-3, and WT1; and fragments and derivatives thereof. Particular preferred tumour antigens are antigens derived from HER-2 and EpCAM. In the context of this section the term fragment refers to C-terminally and/or N-terminally deleted proteins, which comprise at least one epitope which can be specifically bound by a target-binding moiety.
[0048] The term “antibody or antigen binding fragment thereof”, as used herein, refers to immunoglobulin molecules and immunologically active portions of immunoglobulin molecules, i.e. molecules that contain an antigen binding site that immunospecifically binds an antigen. Also comprised are immunoglobulin-like proteins that are selected through techniques including, for example, phage display to specifically bind to a target molecule, e.g. to the target protein EpCAM or Her2. The immunoglobulin molecules of the invention can be of any type (e.g., IgG, IgE, IgM, IgD, IgA and IgY), class (e.g., IgG1, IgG2, IgG3, IgG4, IgA1 and IgA2) or subclass of immunoglobulin molecule. “Antibodies and antigen-binding fragments thereof” suitable for use in the present invention include, but are not limited to, polyclonal, monoclonal, monovalent, bispecific, heteroconjugate, multispecific, human, humanized (in particular CDR-grafted), deimmunized, or chimeric antibodies, single chain antibodies (e.g. scFv), Fab fragments, F(ab′) 2 fragments, fragments produced by a Fab expression library, diabodies or tetrabodies (Holliger P. et al., 1993), nobodies, anti-idiotypic (anti-Id) antibodies (including, e.g., anti-Id antibodies to antibodies of the invention), and epitope-binding fragments of any of the above.
[0049] In some embodiments the antigen-binding fragments are human antigen-binding antibody fragments of the present invention and include, but are not limited to, Fab, Fab′ and F(ab′) 2 , Fd, single-chain Fvs (scFv), single-chain antibodies, disulfide-linked Fvs (dsFv) and fragments comprising either a VL or VH domain. Antigen-binding antibody fragments, including single-chain antibodies, may comprise the variable domain(s) alone or in combination with the entirety or a portion of the following: hinge region, CL, CH1, CH2, and CH3 domains. Also included in the invention are antigen-binding fragments also comprising any combination of variable domain(s) with a hinge region, CL, CH1, CH2, and CH3 domains.
[0050] Antibodies usable in the invention may be from any animal origin including birds and mammals. Preferably, the antibodies are from human, rodent (e.g. mouse, rat, guinea pig, or rabbit), chicken, pig, sheep, goat, camel, cow, horse, donkey, cat, or dog origin. It is particularly preferred that the antibodies are of human or murine origin. As used herein, “human antibodies” include antibodies having the amino acid sequence of a human immunoglobulin and include antibodies isolated from human immunoglobulin libraries or from animals transgenic for one or more human immunoglobulin and that do not express endogenous immunoglobulins, as described for example in U.S. Pat. No. 5,939,598 by Kucherlapati & Jakobovits.
[0051] The term “antibody-like protein” refers to a protein that has been engineered (e.g. by mutagenesis of loops) to specifically bind to a target molecule. Typically, such an antibody-like protein comprises at least one variable peptide loop attached at both ends to a protein scaffold. This double structural constraint greatly increases the binding affinity of the antibody-like protein to levels comparable to that of an antibody. The length of the variable peptide loop typically consists of 10 to 20 amino acids. The scaffold protein may be any protein having good solubility properties. Preferably, the scaffold protein is a small globular protein. Antibody-like proteins include without limitation affibodies, anticalins, designed ankyrin repeat proteins (for review see: Binz et al. 2005) and proteins with ubiquitine based scaffolds. Antibody-like proteins can be derived from large libraries of mutants, e.g. be panned from large phage display libraries and can be isolated in analogy to regular antibodies. Also, antibody-like binding proteins can be obtained by combinatorial mutagenesis of surface-exposed residues in globular proteins.
[0052] The term “nucleic acid aptamer” refers to a nucleic acid molecule that has been engineered through repeated rounds of in vitro selection or SELEX (systematic evolution of ligands by exponential enrichment) to bind to a target molecule (for a review see: Brody and Gold, 2000). The nucleic acid aptamer may be a DNA or RNA molecule. The aptamers may contain modifications, e.g. modified nucleotides such as 2′-fluorine-substituted pyrimidines.
[0053] The term “amatoxin” includes all cyclic peptides composed of 8 amino acids as isolated from the genus Amanita and described in ref. (Wieland, T. and Faulstich H., 1978); further all chemical derivatives thereof; further all semisynthetic analogs thereof; further all synthetic analogs thereof built from building blocks according to the master structure of the natural compounds (cyclic, 8 amino acids), further all synthetic or semisynthetic analogs containing non-hydroxylated amino acids instead of the hydroxylated amino acids, further all synthetic or semisynthetic analogs, in which the thioether sulfoxide moiety is replaced by a sulfide, sulfone, or by atoms different from sulfur, e.g. a carbon atom as in a carbaanalog of amanitin.
[0054] Functionally, amatoxins are defined as peptides or depsipeptides that inhibit mammalian RNA polymerase II. Preferred amatoxins are those with a functional group (e.g. a carboxylic group, an amino group, a hydroxy group, a thiol or a thiol-capturing group) that can be reacted with linker molecules or target-binding moieties as defined above. Amatoxins which are particularly suitable for the conjugates of the present invention are α-amanitin, β-amanitin, γ-amanitin, ε-amanitin, amanin, amaninamide, amanullin, and amanullinic acid as shown in FIG. 1 as well as salts, chemical derivatives, semisynthetic analogs, and synthetic analogs thereof. Particularly preferred amatoxins for use in the present invention are α-amanitin, β-amanitin, and amaninamide.
[0055] As used herein, a “chemical derivative” (or short: a “derivative”) of a compound refers to a species having a chemical structure that is similar to the compound, yet containing at least one chemical group not present in the compound and/or deficient of at least one chemical group that is present in the compound. The compound to which the derivative is compared is known as the “parent” compound. Typically, a “derivative” may be produced from the parent compound in one or more chemical reaction steps.
[0056] As used herein, an “analog” of a compound is structurally related but not identical to the compound and exhibits at least one activity of the compound. The compound to which the analog is compared is known as the “parent” compound. The afore-mentioned activities include, without limitation: binding activity to another compound; inhibitory activity, e.g. enzyme inhibitory activity; toxic effects; activating activity, e.g. enzyme-activating activity. It is not required that the analog exhibits such an activity to the same extent as the parent compound. A compound is regarded as an analog within the context of the present application, if it exhibits the relevant activity to a degree of at least 1% (more preferably at least 5%, more preferably at least 10%, more preferably at least 20%, more preferably at least 30%, more preferably at least 40%, and more preferably at least 50%) of the activity of the parent compound. Thus, an “analog of an amatoxin”, as it is used herein, refers to a compound that is structurally related to any one of α-amanitin, β-amanitin, γ-amanitin, ε-amanitin, amanin, amaninamide, amanullin, and amanullinic acid as shown in FIG. 1 and that exhibits at least 1% (more preferably at least 5%, more preferably at least 10%, more preferably at least 20%, more preferably at least 30%, more preferably at least 40%, and more preferably at least 50%) of the inhibitory activity against mammalian RNA polymerase II as compared to at least one of α-amanitin, β-amanitin, γ-amanitin, ε-amanitin, amanin, amaninamide, amanullin, and amanullinic acid. An “analog of an amatoxin” suitable for use in the present invention may even exhibit a greater inhibitory activity against mammalian RNA polymerase II than any one of α-amanitin, β-amanitin, γ-amanitin, ε-amanitin, amanin, amaninamide, amanullin, or amanullinic acid. The inhibitory activity might be measured by determining the concentration at which 50% inhibition occurs (IC 50 value). The inhibitory activity against mammalian RNA polymerase II can be determined indirectly by measuring the inhibitory activity on cell proliferation. A suitable assay for measuring inhibition of cell proliferation is described in Example 3.
[0057] A “semisynthetic analog” refers to an analog that has been obtained by chemical synthesis using compounds from natural sources (e.g. plant materials, bacterial cultures, or cell cultures) as starting material. Typically, a “semisynthetic analog” of the present invention has been synthesized starting from a compound isolated from a mushroom of the Amanita family. In contrast, a “synthetic analog” refers to an analog synthesized by so-called total synthesis from small (typically petrochemical) building blocks. Usually, this total synthesis is carried out without the aid of biological processes.
[0058] A “linker” in the context of the present application refers to a molecule that increases the distance between two components, e.g. to alleviate steric interference between the target-binding moiety and the amatoxin, which may otherwise decrease the ability of the amatoxin to interact with RNA polymerase II. The linker may serve another purpose as it may facilitate the release of the amatoxin specifically in the cell being targeted by the target binding moiety. It is preferred that the linker and preferably the bond between the linker and the amatoxin on one side and the bond between the linker and the antibody on the other side is stable under the physiological conditions outside the cell, e.g. the blood, while it can be cleaved inside the cell, in particular inside the target cell, e.g. cancer cell or immune cell. To provide this selective stability the linker may comprise functionalities that are preferably pH-sensitive to generate pH-sensitive linkers as described, e.g. in S. Fletcher, M. R. Jorgensens and A. D. Miller; Org. Lett. 2004, 6 (23), pp 4245-4248, or protease sensitive to generate protease sensitive linkers as described, e.g. in L. DA Ibsen, Blood 2003, 102, 1458-65 or Francisco J A, Cerreny C G, Meyer D L, Nat. Biotechnol 2003, 21, 778-84. Alternatively, the bond linking the linker to the target binding moiety may provide the selective stability. Preferably a linker has a length of at least 1, preferably of 1-20 atoms length (e.g. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 atoms) wherein one side of the linker has been reacted with the amatoxin and, the other side with a target-binding moiety. In the context of the present invention, a linker preferably is a C 1-20 -alkyl, C 1-20 -heteroalkyl, C 2-20 -alkenyl, C 2-20 -heteroalkenyl, C 2-20 -alkynyl, C 2-20 -heteroalkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, aralkyl, or a heteroaralkyl group, optionally substituted. The linker may contain one or more structural elements such as amide, ester, ether, thioether, disulfide, hydrocarbon moieties and the like. The linker may also contain combinations of two or more of these structural elements. Each one of these structural elements may be present in the linker more than once, e.g. twice, three times, four times, five times, or six times. In some embodiments the linker may comprise a disulfide bond. It is understood that the linker has to be attached either in a single step or in two or more subsequent steps to the amatoxin and the target binding moiety. To that end the linker to be will carry two groups, preferably at a proximal and distal end, which can (i) form a covalent bond to a group, preferably an activated group on an amatoxin or the target binding-peptide or (ii) which is or can be activated to form a covalent bond with a group on an amatoxin. Accordingly, if the linker is present, it is preferred that chemical groups are at the distal and proximal end of the linker, which are the result of such a coupling reaction, e.g. an ester, an ether, a urethane, a peptide bond etc. The presence of a “linker” is optional, i.e. the toxin may be directly linked to a residue of the target-binding moiety in some embodiments of the target-binding moiety toxin conjugate of the present invention. It is preferred that the linker is connected directly via a bond to the targeting moiety, preferably at its terminus. If the target-binding moiety comprises free amino, carboxy or sulfhydryl groups, e.g. in the form of Asp, Glu, Arg, Lys, Cys residues, which may be comprised in a polypeptide, then it is preferred that the linker is coupled to such a group.
[0059] As used herein, a first compound (e.g. an antibody) is considered to “specifically bind” to a second compound (e.g. an antigen, such as a target protein), if it has a dissociation constant K D to said second compound of 100 μM or less, preferably 50 μM or less, preferably 30 μM or less, preferably 20 μM or less, preferably 10 μM or less, preferably 5 μM or less, more preferably 1 μM or less, more preferably 900 nM or less, more preferably 800 nM or less, more preferably 700 nM or less, more preferably 600 nM or less, more preferably 500 nM or less, more preferably 400 nM or less, more preferably 300 nM or less, more preferably 200 nM or less, even more preferably 100 nM or less, even more preferably 90 nM or less, even more preferably 80 nM or less, even more preferably 70 nM or less, even more preferably 60 nM or less, even more preferably 50 nM or less, even more preferably 40 nM or less, even more preferably 30 nM or less, even more preferably 20 nM or less, and even more preferably 10 nM or less.
[0060] As used herein, a “patient” means any mammal or bird who may benefit from a treatment with the target-binding moiety toxin conjugates described herein. Preferably, a “patient” is selected from the group consisting of laboratory animals (e.g. mouse or rat), domestic animals (including e.g. guinea pig, rabbit, chicken, pig, sheep, goat, camel, cow, horse, donkey, cat, or dog), or primates including human beings. It is particularly preferred that the “patient” is a human being.
[0061] As used herein, “treat”, “treating” or “treatment” of a disease or disorder means accomplishing one or more of the following: (a) reducing the severity of the disorder; (b) limiting or preventing development of symptoms characteristic of the disorder(s) being treated; (c) inhibiting worsening of symptoms characteristic of the disorder(s) being treated; (d) limiting or preventing recurrence of the disorder(s) in patients that have previously had the disorder(s); and (e) limiting or preventing recurrence of symptoms in patients that were previously symptomatic for the disorder(s).
[0062] As used herein, “administering” includes in vivo administration, as well as administration directly to tissue ex vivo, such as vein grafts.
[0063] An “effective amount” is an amount of a therapeutic agent sufficient to achieve the intended purpose. The effective amount of a given therapeutic agent will vary with factors such as the nature of the agent, the route of administration, the size and species of the animal to receive the therapeutic agent, and the purpose of the administration. The effective amount in each individual case may be determined empirically by a skilled artisan according to established methods in the art.
[0064] “Pharmaceutically acceptable” means approved by a regulatory agency of the Federal or a state government or listed in the U.S. Pharmacopeia or other generally recognized pharmacopeia for use in animals, and more particularly in humans.
EMBODIMENTS OF THE INVENTION
[0065] The present invention will now be further described. In the following passages different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.
[0066] In a first aspect the present invention is directed to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) an amatoxin; and (iii) optionally a linker L2; wherein the amatoxin is connected to the target-binding moiety or, if present, to the linker L2 via the 6′ C-atom of amatoxin amino acid 4 (see FIG. 1 ). In preferred amatoxins usable in the first aspect said amino acid 4 is 2′-sulfur-substituted tryptophan or 2′-sulfur-substituted 6′ -hydroxy-tryptophan.
[0067] In a preferred embodiment of the first aspect the amatoxin is connected to the target-binding moiety or, if present, to the linker L2 via an oxygen atom bound to the 6′ C-atom of amatoxin amino acid 4. It is further preferred that the amatoxin is connected to the target-binding moiety or, if present, to the linker L2 via an ether linkage (i.e. amatoxin-O-L2 or amatoxin-O-target-binding moiety). In these embodiments, it is preferred that amino acid 4 is 6′-hydroxy-tryptophan.
[0068] In preferred embodiments of the first aspect the linker L2 is present and the conjugate has the following structure: amatoxin-6′C—O-L2-C(O)—NH-target-binding moiety.
[0069] In a second aspect the present invention is directed to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) an amatoxin; and (iii) optionally a linker L3; wherein the amatoxin is connected to the target-binding moiety or, if present, to the linker L3 via the 8 C-atom of amatoxin amino acid 3 (see FIG. 1 ). In preferred amatoxins usable in the second aspect said amino acid 3 is isoleucine, γ-hydroxy-isoleucine or γ,δ-dihydroxy-isoleucine.
[0070] In a preferred embodiment of the second aspect the amatoxin is connected to the target-binding moiety or, if present, to the linker L3 via an oxygen atom bound to the δ C-atom of amatoxin amino acid 3. It is further preferred that the amatoxin is connected to the target-binding moiety or, if present, to the linker L3 via an ester linkage preferably in the form of an amatoxin-O—C(O)-L3-target binding boiety or an amatoxin-O—C(O)-target-binding moiety, more preferably an amatoxin-δC—O—C(O)-L3-target-binding moiety or an amatoxin-δC—O—C(O)-target-binding moiety, i.e. an amatoxin-δCH 2 —O—C(O)-L3-target-binding moiety or an amatoxin-δCH 2 —O—C(O)-target-binding moiety; an ether linkage preferably in the form of an amatoxin-O-L3 or an amatoxin-O-target-binding moiety preferably an amatoxin-δC—O-L3-target binding moiety or an amatoxin-δC—O-target binding moiety, more preferably an amatoxin-δCH 2 —O-L3-target binding moiety or an amatoxin-δCH 2 —O-target binding moiety; or a urethane linkage preferably in the form of an amatoxin-O—C(O)—NH-L3 or amatoxin-O—C(O)—NH-target-binding moiety, preferably an amatoxin-δC—O—C(O)—NH-L3-target-binding moiety or an amatoxin-K—O—C(O)—NH-target-binding moiety, i.e. an amatoxin-δCH 2 —O—C(O)—NH-L3-target-binding moiety or an amatoxin-δCH 2 —O—C(O)—NH-target-binding moiety. In these embodiments, it is preferred that amino acid 3 is γ,δ-dihydroxy-isoleucine.
[0071] In preferred embodiments of the second aspect the linker L3 is present and the conjugate has one of the following structures: (i) amatoxin-δC—O—C(O)-L3-C(O)—NH-target-binding moiety; (ii) amatoxin-δC—O-L3-C(O)—NH-target-binding moiety; or (iii) amatoxin-δC—O—C(O)—NH-L3-C(O)—NH-target-binding moiety, i.e. (i) amatoxin-δCH 2 —O—C(O)-L3-C(O)—NH-target-binding moiety; (ii) amatoxin-δCH 2 —O-L3-C(O)—NH-target-binding moiety; or (iii) amatoxin-δCH 2 —O—C(O)—NH-L3-C(O)—NH-target-binding moiety.
[0072] In a third aspect the present invention is directed to a target-binding moiety toxin conjugate comprising: (i) a target-binding moiety; (ii) an amatoxin; and (iii) optionally a linker L1; wherein the amatoxin is connected to the target-binding moiety or, if present, to the linker L1 via the γ C-atom of amatoxin amino acid 1 (see FIG. 1 ). In preferred amatoxins usable in the third aspect said amino acid 1 is asparagine or aspartic acid.
[0073] In a preferred embodiment of the third aspect the amatoxin is connected to the target-binding moiety or, if present, to the linker LI via a nitrogen atom bound to the γ C-atom of amatoxin amino acid 1. It is further preferred that the amatoxin is connected to the target-binding moiety or, if present, to the linker L1 via an amide linkage (i.e. amatoxin-C(O)—NH-L1 or amatoxin-C(O)—NH-target-binding moiety; the C-atom in the aforementioned C(O)-moiety is the γ C-atom of amatoxin amino acid 1). In these embodiments, it is preferred that amino acid 1 is asparagine.
[0074] In preferred embodiments of the third aspect the linker L1 is present and the conjugate has the following structure: amatoxin-γC(O)—NH-L1-C(O)—NH-target-binding moiety. In this context it is preferred that the amide on the target-binding moiety side of the conjugate is the product of a reaction with a free amino group that was present in the target-binding moiety.
[0075] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety is connected to the amatoxin or, if present, to the linker L1, L2, or L3 via an amino group present in the target-binding moiety.
[0076] In preferred embodiments of the first, the second, or the third aspect the amatoxin is selected from α-amanitin, β-amanitin, γ-amanitin, ε-amanitin, amanin, amaninamide, amanullin, or amanullinic acid (all shown in FIG. 1 ), as well as salts, chemical derivatives, semisynthetic analogs, and synthetic analogs thereof. Particularly preferred amatoxins are α-amanitin, β-amanitin, and amaninamide, as well as salts, chemical derivatives, semisynthetic analogs, and synthetic analogs thereof.
[0077] The target binding moiety is in preferred embodiments a protein, in particular an antibody. Proteins and in particular antibodies will comprise several amino acids, which allow the coupling of amatoxins. Preferred amino acids have free amino, hydroxy, or carbonyl-groups, including Lys, Gln, Glu, Asp, Asn, Thr, and Ser. Accordingly, it is possible to couple more than one amatoxin molecules to one protein molecule. An increase of the number of amatoxins per molecule will also increase the toxicity. Accordingly, in a preferred embodiment the ratio of protein to amatoxin is between 1 protein molecule to between 1 and 15 amatoxin molecules, preferably 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15. For the purpose of the calculation of the ratio in case of dimmers like IgGs the dimmer is considered as one molecule. Similar ratios are preferred, if the target binding moiety is not a protein.
[0078] In preferred embodiments of the first, the second, or the third aspect the linker L1, L2, or L3 has above indicated meaning and preferred meanings. In further preferred embodiments of the first, the second, or the third aspect the linker L1, L2, or L3 comprises a disulfide bond. In preferred embodiments of the first, the second, or the third aspect the linker L1, L2, or L3 has a length of 1 to 20 atoms, e.g. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 atoms. The length of the linker is defined as the shortest connection—as measured by the number of atoms or bonds—between the toxin moiety and the target-binding moiety.
[0079] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety specifically binds to an epitope that is present on a tumour cell. It is particularly preferred that the target-binding moiety specifically binds to an epitope of T-cell- or B-Cell-defined cancer-associated antigen belonging to unique gene products of mutated or recombined cellular genes, in particular cyclin-dependent kinases (e.g. CDC2, CDK2, CDK4), p15 Ink4b , p53, AFP, β-catenin, caspase 8, p53, Bcr-abl fusion product, MUM-1 MUM-2, MUM-3, ELF2M, HSP70-2M, HST-2, KIAA0205, RAGE, myosin/m, 707-AP, CDC27/m, ETV6/AML, TEL/Amll, Dekcain, LDLR/FUT, Pml-RARa, TEL/AMLI; Cancer-testis (CT) antigens, in particular NY-ESO-1, members of the MAGE-family (MAGE-A1, MAGE-A2, MAGE-A3, MAGE-A4, MAGE-A6, MAGE-10, MAGE-12), BAGE, DAM-6, DAM-10, members of the GAGE-family (GAGE-1, GAGE-2, GAGE-3, GAGE-4, GAGE-5, GAGE-6, GAGE-7B, GAGE-8), NY-ESO-1, NA-88A, CAG-3, RCC-associated antigen G250; Tumour virus antigens, in particular human papilloma virus (HPV) -derived E6 or E7 oncoproteins, Epstein Barr virus EBNA2-6, LMP-1, LMP-2; overexpressed or tissue-specific differentiation antigens, in particular gp77, gp100, MART-1/Melan-A, p53, tyrosinase, tyrosinase-related protein (TRP-1 and TPR-2), PSA, PSM, MC1R; widely expressed antigens, in particular ART4, CAMEL, CEA, CypB, EpCAM, HER2/neu, hTERT, hTRT, ICE, Muc1, Muc2, PRAME RU1, RU2, SART-1, SART-2, SART-3, and WT1; and fragments and derivatives thereof. Particular preferred tumour antigens are antigens derived from the HER-2 and EpCAM proteins.
[0080] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety is selected from the group consisting of: (i) antibody or antigen-binding fragment thereof; (ii) antibody-like protein; and (iii) nucleic acid aptamer. In preferred embodiments the antibody or the antigen-binding fragment thereof is selected from a diabody, a tetrabody, a nanobody, a chimeric antibody, a deimmunized antibody, a humanized antibody or a human antibody. In preferred embodiments the antigen binding fragment is selected from the group consisting of Fab, F(ab′) 2 , Fd, Fv, single-chain Fv, and disulfide-linked Fvs (dsFv). In preferred embodiments the antibody or the antigen binding fragment thereof comprises (a) either the membrane-bound form of the heavy chain of huHEA125 (SEQ ID NO: 1) or the soluble form of the heavy chain of huHEA125 (SEQ ID NO: 2); and/or (b) the light chain of huHEA125 (SEQ ID NO: 11).
[0081] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety toxin conjugate comprises (i) an antibody or an antigen binding fragment thereof specifically binding to epithelial cell adhesion molecule (EpCAM), wherein the antibody or an antigen binding fragment thereof comprises: (a) the heavy chain of huHEA125, wherein the heavy chain is selected from the group consisting of: (a1) the membrane-bound form of the heavy chain according to SEQ ID NO: 1, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 26 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions; and (a2) the soluble form of the heavy chain according to SEQ ID NO: 2, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 27 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions; and (b) the light chain of huHEA125 according to SEQ ID NO: 11, wherein the variable domain of the light chain VL as shown in
[0082] SEQ ID NO: 12 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VL, and wherein the constant domain of the light chain CL as shown in SEQ ID NO: 28 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions; (ii) an amatoxin; and (iii) optionally a linker L1, L2, or L3.
[0083] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety toxin conjugate comprises: (a) the heavy chain of huHEA125, wherein the heavy chain is selected from the group consisting of: (a1) the membrane-bound form of the heavy chain according to SEQ ID NO: 1, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VH; and (a2) the soluble form of the heavy chain according to SEQ ID NO: 2, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VH; and (b) the light chain of huHEA125 according to SEQ ID NO: 11, wherein the variable domain of the light chain VL as shown in SEQ ID NO: 12 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid deletions and/or between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid additions positioned in the framework regions of VL.
[0084] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety toxin conjugate comprises: (a) the heavy chain of huHEA125, wherein the heavy chain is selected from the group consisting of: (al) the membrane-bound form of the heavy chain according to SEQ ID NO: 1, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 26 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions; and (a2) the soluble form of the heavy chain according to SEQ ID NO: 2, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 27 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions; and (b) the light chain of huHEA125 according to SEQ ID NO: 11, wherein the variable domain of the light chain VL as shown in SEQ ID NO: 12 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions positioned in the framework regions of VL, and wherein the constant domain of the light chain CL as shown in SEQ ID NO: 28 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges, amino acid deletions and/or amino acid additions.
[0085] In preferred embodiments of the first, the second, or the third aspect the target-binding moiety toxin conjugate comprises: (a) the heavy chain of huHEA125, wherein the heavy chain is selected from the group consisting of: (al) the membrane-bound form of the heavy chain according to SEQ ID NO: 1, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 26 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges; and (a2) the soluble form of the heavy chain according to SEQ ID NO: 2, wherein the variable domain of the heavy chain VH as shown in SEQ ID NO: 3 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges positioned in the framework regions of VH, and wherein the constant domain of the heavy chain as shown in SEQ ID NO: 27 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges; and (b) the light chain of huHEA125 according to SEQ ID NO: 11, wherein the variable domain of the light chain VL as shown in SEQ ID NO: 12 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges positioned in the framework regions of VL, and wherein the constant domain of the light chain CL as shown in SEQ ID NO: 28 comprises between 0 and 10 (e.g. 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) amino acid exchanges.
[0086] Within further preferred embodiments of the first, the second, or the third aspect the target-binding moiety comprises the heavy chain of huHEA125 (membrane-bound form, SEQ ID NO: 1) and/or the light chain of huHEA125 (SEQ ID NO: 11). In one embodiment of the first, the second, or the third aspect, the heavy chain of huHEA125 and/or the light chain of huHEA125 each comprise independently from each other up to 20 (e.g. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20) amino acid exchanges, deletions, or additions, wherein these amino acid exchanges, deletions, or additions may be positioned in the constant domains of the heavy chain and/or in the constant domain of the light chain and/or in the framework regions of the variable domain of the heavy chain and/or in the framework regions of the variable domain of the light chain. In a particularly preferred embodiment of the first, the second, or the third aspect, the antibody is a complete IgG antibody comprising two heavy chains of huHEA125 (SEQ ID NO: 1) and two light chains of huHEA125 (SEQ ID NO: 11), wherein one heavy chain is connected to one light chain via a disulfide linkage and wherein the heavy chains are connected to each other by one or two (preferably two) disulfide linkages.
[0087] Within further preferred embodiments of the first, the second, or the third aspect the target-binding moiety comprises the heavy chain of huHEA125 (soluble form, SEQ ID NO: 2) and/or the light chain of huHEA125 (SEQ ID NO: 11). In one embodiment of the first, the second, or the third aspect, the heavy chain of huHEA125 and/or the light chain of huHEA125 each comprise independently from each other up to 20 (e.g. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20) amino acid exchanges, deletions, or additions, wherein these amino acid exchanges, deletions, or additions may be positioned in the constant domains of the heavy chain and/or in the constant domain of the light chain and/or in the framework regions of the variable domain of the heavy chain and/or in the framework regions of the variable domain of the light chain. In a particularly preferred embodiment of the first, the second, or the third aspect, the antibody is a complete IgG antibody comprising two heavy chains of huHEA125 (SEQ ID NO: 2) and two light chains of huHEA125 (SEQ ID NO: 11), wherein one heavy chain is connected to one light chain via a disulfide linkage and wherein the heavy chains are connected to each other by one or two (preferably two) disulfide linkages.
[0088] In a fourth aspect the present invention is directed to the target-binding moiety toxin conjugate according to the first, the second, or the third aspect for use in medicine.
[0089] In a fifth aspect the present invention is directed to the target-binding moiety toxin conjugate according to the first, the second, the third or the fourth aspect for the treatment of cancer or an autoimmune disease in a patient, wherein the cancer is preferably selected from the group consisting of pancreatic cancer, cholangiocarcinoma, breast cancer, colorectal cancer, lung cancer, prostate cancer, ovarian cancer, stomach cancer, kidney cancer, head and neck cancer, brain tumors, childhood neoplasms, soft tissue sarcomas, epithelial skin cancer, malignant melanoma, leukemia, and malignant lymphoma and wherein the autoimmune disease is preferably selected from the group consisting of Ankylosing Spondylitis, Chagas disease, Crohns Disease, Dermatomyositis, Diabetes mellitus type 1, Goodpasture's syndrome, Graves' disease, Guillain-Barré syndrome (GBS), Hashimoto's disease, Hidradenitis suppurativa, Idiopathic thrombocytopenic purpura, Lupus erythematosus, Mixed Connective Tissue Disease, Myasthenia gravis, Narcolepsy, Pemphigus vulgaris, Pernicious anaemia, Psoriasis, Psoriatic Arthritis, Polymyositis, Primary biliary cirrhosis, Relapsing polychondritis, Rheumatoid arthritis, Schizophrenia, Sjögren's syndrome, Temporal arteritis, Ulcerative Colitis, and Vasculitis Wegener's granulomatosis, in particular Rheumatoid arthritis.
[0090] In a sixth aspect the present invention is directed to a pharmaceutical composition comprising at least one type of the target-binding moiety toxin conjugate according to the first, the second, or the third aspect and further comprising one or more pharmaceutically acceptable diluents, carriers, excipients, fillers, binders, lubricants, glidants, disintegrants, adsorbents; and/or preservatives. It is envisioned that the pharmaceutical composition may comprise two or more different target-binding moiety toxin conjugates. Preferably the target binding moieties bind to different targets. In particular in tumour therapy it has be recognized that it may be advantageous to administer two or more target-binding moieties directed against two different targets on the same tumour cell thereby increasing the likelihood that all tumour cells are killed by the administration of the therapeutic and decreasing the likelihood of development of resistance.
[0091] It is particularly preferred that the pharmaceutical composition of the seventh aspect or as prepared in the sixth aspect can be used in the form of systemically administered medicaments. These include parenterals, which comprise among others injectables and infusions. Injectables are formulated either in the form of ampoules or as so called ready-for-use injectables, e.g. ready-to-use syringes or single-use syringes and aside from this in puncturable flasks for multiple withdrawal. The administration of injectables can be in the form of subcutaneous (s.c.), intramuscular (i.m.), intravenous (i.v.) or intracutaneous (i.c.) application. In particular, it is possible to produce the respectively suitable injection formulations as a suspension of crystals, solutions, nanoparticular or a colloid dispersed systems like, e.g. hydrosols.
[0092] Injectable formulations can further be produced as concentrates, which can be dissolved or dispersed with aqueous isotonic diluents. The infusion can also be prepared in form of isotonic solutions, fatty emulsions, liposomal formulations and micro-emulsions. Similar to injectables, infusion formulations can also be prepared in the form of concentrates for dilution. Injectable formulations can also be applied in the form of permanent infusions both in in-patient and ambulant therapy, e.g. by way of mini-pumps.
[0093] It is possible to add to parenteral drug formulations, for example, albumin, plasma, expander, surface-active substances, organic diluents, pH-influencing substances, complexing substances or polymeric substances, in particular as substances to influence the adsorption of the target-binding moiety toxin conjugates of the invention to proteins or polymers or they can also be added with the aim to reduce the adsorption of the target-binding moiety toxin conjugates of the invention to materials like injection instruments or packaging-materials, for example, plastic or glass.
[0094] The target-binding moiety toxin conjugates of the invention can be bound to microcarriers or nanoparticles in parenterals like, for example, to finely dispersed particles based on poly(meth)acrylates, polylactates, polyglycolates, polyamino acids or polyether urethanes. Parenteral formulations can also be modified as depot preparations, e.g. based on the “multiple unit principle”, if the target-binding moiety toxin conjugates of the invention are introduced in finely dispersed, dispersed and suspended form, respectively, or as a suspension of crystals in the medicament or based on the “single unit principle” if the target-binding moiety toxin conjugate of the invention is enclosed in a formulation, e.g. in a tablet or a rod which is subsequently implanted. These implants or depot medicaments in single unit and multiple unit formulations often consist of so called biodegradable polymers like e.g. polyesters of lactic acid and glycolic acid, polyether urethanes, polyamino acids, poly(meth)acrylates or polysaccharides.
[0095] Adjuvants and carriers added during the production of the pharmaceutical compositions of the present invention formulated as parenterals are preferably aqua sterilisata (sterilized water), pH value influencing substances like, e.g. organic or inorganic acids or bases as well as salts thereof, buffering substances for adjusting pH values, substances for isotonization like e.g. sodium chloride, sodium hydrogen carbonate, glucose and fructose, tensides and surfactants, respectively, and emulsifiers like, e.g. partial esters of fatty acids of polyoxyethylene sorbitans (for example, Tween®) or, e.g. fatty acid esters of polyoxyethylenes (for example, Cremophor®), fatty oils like, e.g. peanut oil, soybean oil or castor oil, synthetic esters of fatty acids like, e.g. ethyl oleate, isopropyl myristate and neutral oil (for example, Miglyol®) as well as polymeric adjuvants like, e.g. gelatine, dextran, polyvinylpyrrolidone, additives which increase the solubility of organic solvents like, e.g. propylene glycol, ethanol, N,N-dimethylacetamide, propylene glycol or complex forming substances like, e.g. citrate and urea, preservatives like, e.g. benzoic acid hydroxypropyl ester and methyl ester, benzyl alcohol, antioxidants like e.g. sodium sulfite and stabilizers like e.g. EDTA.
[0096] When formulating the pharmaceutical compositions of the present invention as suspensions in a preferred embodiment thickening agents to prevent the setting of the target-binding moiety toxin conjugates of the invention or, tensides and polyelectrolytes to assure the resuspendability of sediments and/or complex forming agents like, for example, EDTA are added. It is also possible to achieve complexes of the active ingredient with various polymers. Examples of such polymers are polyethylene glycol, polystyrol, carboxymethyl cellulose, Pluronics® or polyethylene glycol sorbit fatty acid ester. The target-binding moiety toxin conjugates of the invention can also be incorporated in liquid formulations in the form of inclusion compounds e.g. with cyclodextrins. In particular embodiments dispersing agents can be added as further adjuvants. For the production of lyophilisates scaffolding agents like mannite, dextran, saccharose, human albumin, lactose, PVP or varieties of gelatine can be used.
[0097] In a further aspect the present invention is directed to a method of treating cancer, or an autoimmune disease, wherein the cancer is preferably selected from pancreatic cancer, cholangiocarcinoma, breast cancer, colorectal cancer, lung cancer, prostate cancer, ovarian cancer, stomach cancer, kidney cancer, head and neck cancer, brain tumors, childhood neoplasms, soft tissue sarcomas, epithelial skin cancer, malignant melanoma, leukemia, or malignant lymphoma and wherein the autoimmune disease is preferably selected from the group consisting of Ankylosing Spondylitis, Chagas disease, Crohns Disease, Dermatomyositis, Diabetes mellitus type 1, Goodpasture's syndrome, Graves' disease, Guillain-Barré syndrome (GBS), Hashimoto's disease, Hidradenitis suppurativa, Idiopathic thrombocytopenic purpura, Lupus erythematosus, Mixed Connective Tissue Disease, Myasthenia gravis, Narcolepsy, Pemphigus vulgaris, Pernicious anaemia, Psoriasis, Psoriatic Arthritis, Polymyositis, Primary biliary cirrhosis, Relapsing polychondritis, Rheumatoid arthritis, Schizophrenia, Sjögren's syndrome, Temporal arteritis, Ulcerative Colitis, and Vasculitis Wegener's granulomatosis, in a patient in need thereof, comprising administering to the patient an effective amount of a target-binding moiety toxin conjugate as defined in the first, the second, or the third aspect.
EXAMPLES
[0098] In the following, the invention is explained in more detail by non-limiting examples:
Example 1
Materials and Methods
[0099] 1.1 Chimeric Antibody huHEA125
[0100] Several years ago, the inventors have established a hybridoma cell line secreting the anti-EpCAM mouse monoclonal antibody HEA125 (Moldenhauer et al., 1987; Momburg et al., 1987). Using molecular biology techniques this hybridoma line was reconstructed to produce a chimeric version of the antibody consisting of the mouse variable domains hooked up to human kappa constant light chain and human IgG1 constant heavy chain. The resulting antibody huHEA125 binds to EpCAM-expressing cells with high affinity (K d =2.2×10 −9 M) and high specificity. The gene sequences and the amino acid sequences of huHEA125 immunoglobulin are shown below:
[0000] huHEA125 Heavy Chain
[0101] Peptide sequence heavy chain, membrane bound form (IGHV/IGHD/IGHJ/IGHG1; IGHG1 is underlined) (SEQ ID NO: 1):
[0000]
EVKLLESGGGLVQPGGSLKLSCAASGFDFSRFWMTWVRQAPGKGLEWIG
EINLDSSTINYTPSLKDKFIISRDNAKNTLFLQMSKVRSEDTALYYCSR
GISMDYWGQGTSVTVSS ASTKGPSVFPLAPSSKSTSGGTAALGCLVKDY
FPEPVTVSWNSGALTSGVHTFPAVLQSSGLYSLSSVVTVPSSSLGTQTY
ICNVNHKPSNTKVDKKVEPKSCDKTHTCPPCPAPELLGGPSVFLFPPKP
KDTLMISRTPEVTCVVVDVSHEDPEVKFNWYVDGVEVHNAKTKPREEQY
NSTYRVVSVLTVLHQDWLNGKEYKCKVSNKALPAPIEKTISKAKGQPRE
PQVYTLPPSRDELTKNQVSLTCLVKGFYPSDIAVEWESNGQPENNYKTT
PPVLDSDGSFFLYSKLTVDKSRWQQGNVFSCSVMHEALHNHYTQKSLSL
SPGLQLDETCAEAQDGELDGLWTTITIFISLFLLSVCYSAAVTLFKVKW
IFSSVVELKQTLVPEYKNMIGQAP
[0102] Peptide sequence heavy chain, secreted form (SEQ ID NO: 2):
[0000]
EVKLLESGGGLVQPGGSLKLSCAASGFDFSRFWMTWVRQAPGKGLEWIG
EINLDSSTINYTPSLKDKFIISRDNAKNTLFLQMSKVRSEDTALYYCSR
GISMDYWGQGTSVTVSSASTKGPSVFPLAPSSKSTSGGTAALGCLVKDY
FPEPVTVSWNSGALTSGVHTFPAVLQSSGLYSLSSVVTVPSSSLGTQTY
ICNVNHKPSNTKVDKKVEPKSCDKTHTCPPCPAPELLGGPSVFLFPPKP
KDTLMISRTPEVTCVVVDVSHEDPEVKFNWYVDGVEVHNAKTKPREEQY
NSTYRVVSVLTVLHQDWLNGKEYKCKVSNKALPAPIEKTISKAKGQPRE
PQVYTLPPSRDELTKNQVSLTCLVKGFYPSDIAVEWESNGQPENNYKTT
PPVLDSDGSFFLYSKLTVDKSRWQQGNVFSCSVMHEALHNHYTQKSLSL
SPGK
[0103] Peptide sequence (IGHV/IGHD/IGHJ=VH domain; the framework regions FR1, FR2, FR3 and FR4 are underlined) (SEQ ID NO: 3):
[0000]
EVKLLESGGGLVQPGGSLKLSCAAS GFDFSRFW MTWVRQAPGKGLEWIG
E INLDSSTI NYTPSLKDKFIISRDNAKNTLFLQMSKVRSEDTALYYC SR
GISMDY WGQGTSVTVSS
[0104] Nucleic acid sequence (annotated according to the IMGT-nomenclature, IGHV/IGHD/IGHJ; IGHD underlined; IGHJ doubly underlined):
[0000] FR1 (SEQ ID NO: 4): GAAGTGAAGCTTCTCGAGTCTGGAGGTGGCCTGGTGCAGCCTGGAGGAT CCCTGAAACTCTCCTGTGCAGCCTCA CDR1 (SEQ ID NO: 5): GGATTCGATTTTAGTAGATTCTGG FR2 (SEQ ID NO: 6): ATGACTTGGGTCCGGCAGGCTCCAGGGAAAGGGCTAGAATGGATTGGAG AA CDR2 (SEQ ID NO: 7): ATTAATCTAGATAGCAGTACGATA FR3 (SEQ ID NO: 8): AACTATACGCCATCTCTAAAGGATAAATTCATCATCTCCAGGGACAACG CCAAAAATACGCTGTTCCTGCAAATGAGCAAAGTGAGATCTGAGGACAC AGCCCTTTATTACTGT CDR3 (SEQ ID NO: 9): TCAAGA GGTATTT CTATGGACTAC FR4 (SEQ ID NO: 10): TGGGGTCAGGGAACCTCAGTCACCGTCTCCTCA
huHEA125 Light Chain
[0105] Peptide sequence light chain (IGKV/IGKJ/IGKC; IGKC is underlined) (SEQ ID NO: 11):
[0000]
DILLTQSPAILSVSPGERVSFSCRASQSIGISLHWYQQRPSDSPRLLIK
YASESISGIPSRFSGSGSGTDFTLSINSVESEDIADYYCQQSNIWPTTF
GAGTKLELK RTVAAPSVFIFPPSDEQLKSGTASVVCLLNNFYPREAKVQ
WKVDNALQSGNSQESVTEQDSKDSTYSLSSTLTLSKADYEKHKVYACEV
THQGLSSPVTKSFNRGEC
[0106] Peptide sequence (IGKV/IGKJ=VL domain; the framework regions FR1, FR2, FR3 and FR4 are underlined) (SEQ ID NO: 12):
[0000]
DILLTQSPAILSVSPGERVSFSCRAS QSIGIS LHWYQQRPSDSPRLLIK
YAS ESISGIPSRFSGSGSGTDFTLSINSVESEDIADYYC QQSNIWPTT F
GAGTKLELK
[0107] Nucleic acid sequence (annotated according to the IMGT-nomenclature, IGKV/IGKJ; IGKV is underlined; IGKJ is doubly underlined):
[0000]
FR1 (SEQ ID NO: 13):
GACATCTTGCTGACTCAGTCTCCAGCCATCCTGTCTGTGAGTCCAGGAG
AAAGAGTCAGTTTCTCCTGCAGGGCCAGT
CDR1 (SEQ ID NO: 14):
CAGAGCATTGGCATAAGT
FR2 (SEQ ID NO: 15):
TTACACTGGTATCAGCAAAGACCAAGTGATTCTCCAAGGCTTCTCATAA
AG
CDR2 (SEQ ID NO: 16):
TATGCTTCT
FR3 (SEQ ID NO: 17):
GAGTCAATCTCTGGGATCCCTTCCAGGTTTAGTGGCAGTGGATCAGGGA
CAGATTTTACTCTTAGCATCAACAGTGTGGAGTCTGAAGATATTGCAGA
TTATTACTGT
CDR3 (SEQ ID NO: 18:
CAACAAAGTAATATCTGG CCAAC CACG
FR4 (SEQ ID NO: 19):
TTCGGTGCTGGGACCAAGCTGGAGCTGAAA
1.2 Control Antibody Xolair®
[0108] The control antibody Xolair® (Omalizumab, human IgG1 antibody directed against human IgE immunoglobulin) was produced by Novartis, Germany.
1.3 Carcinoma Cell Lines
[0109] The following carcinoma cell lines were used for growth inhibition studies with huHEA125-amatoxin conjugates:
[0000]
:
Capan-1
pancreatic adenocarcinoma
MCF-7
human breast adenocarcinoma (derived from pleural effusion)
Colo205
colon cancer metastasis
OZ
cholangiocarcinoma
[0110] The following carcinoma cell lines were used for growth inhibition studies or mouse xenograft studies with HERCEPTIN-amatoxin conjugates:
[0000] SKOV-3 ovarian carcinoma SK-BR-3 breast adenocarcinoma NCI-N87 gastric carcinoma MDA-MB231 breast carcinoma
Cells were obtained from the American Type Culture Collection (Manassas, USA).
1.4 Synthesis of Amanitin Derivatives with Linker at Amino Acid 1
1 . 4 . 1 Synthesis of Di-t-butyloxycarbonyl-hexamethylenediamine
[0111] Thirty g of t-butyloxycarbonylazide was dissolved in 50 ml of 1.4-dioxan and added dropwise to 12 g of hexamethylenediamine dissolved in 60 ml of 1,4-dioxane at 0° C. After 20 h at RT diethylether was added and the precipitate isolated in a Buchner funnel. Recrystallized from methanol/water.
[0000] 1.4.2 Synthesis of t-Butyloxycarbonyl-hexamethylenediamine Hydrochloride
[0112] 12.9 g of di-t-butyloxycarbonyl-hexamethylenediamine was suspended in 100 ml of diethylether containing HCl (2N) and stirred magnetically for 3 h at RT. The precipitate formed was isolated and thoroughly washed with diethylether yielding a first fraction of the product. Addition of another 100 ml of diethylether containing HCl (2N) yields another fraction of the product, which is pure after several washings with diethylether. Yield ca. 3 g.
1.4.3 Synthesis of J3-Amanitin-(t-butyloxy-carbonyl)-hexamethylenediamide (I)
[0113]
[0114] 20 mg of dried β-amanitin (22 μmol) was dissolved in 0.3 ml of dried dimethylform-amide (DMF), and 0.005 ml of triethylamine was added. Under magnetic stirring, the reaction mixture was cooled to −18° C. (ice/NaCl) and after 10 min 0.164 ml of a mixture of 0.1 ml of chloroisobutylformate and 1.0 ml of DMF (110 μmol, 5 eq.) was added. The reaction was allowed to proceed for 20 min at −18° C. Fifty-five mg (220 μmol, 10 eq.) of t-butyloxy-carbonyl-hexamethylenediamine hydrochloride and 0.005 ml of triethylamine were dissolved in 0.3 ml of DMF, added to the reaction and stirred for 1 h at RT.
[0115] The reaction mixture was applied to 4 tlc silica plates (20×20 cm) and developed in chloroform/methanol/water (65:25:5). The product was identified in the u.v. light (R F =0.49), scraped off and extracted with methanol. Yield 11.5 mg. Recovery of β-amanitin by the same procedure was 7.5 mg.
1.4.4 Synthesis of β-Amanitin-hexamethylenediamide (II)
[0116]
[0117] 4.54 mg (4.05 μmol) β-Amanitin-(t-butyloxy-carbonyl)-hexamethylenediamide (I) was stirred at room temperature in 250 μl trifluoroacetic acid. After 2 minutes the excess TFA was evaporated at 20° C. and the remaining solid coevaporated 2 times with 1 ml acetonitrile and methanol. The crude amine was dissolved in 1000 μl dmso and prified on a LaPrep-HPLC: column: Kromasil 100-C18, 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at X=295 nm. Solvent A: 95% water: 5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water: 90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-20 25 min 0% A; 25-27 min 100% A; 27-35 min 100% A. The fractions with the same retention time were collected and the solvents evaporated.
[0118] 4.0 mg (70% yield) of a white foam. MS: 1019 M+H;
[0000] 1.4.5 Synthesis of β-Amanitin-hexamethylenediamido-suberoyl-HERCEPTIN and β-Amanitin-hexamethylenediamido-dithio[bis-propionate]-HERCEPTIN
[0119] 1.33 mg of β-amanitin-hexamethylendiamide (II) was dissolved in 144 μl molecular sieve dried DMF. 16.0 μl solution of DSS (disuccinimidyl suberate; 3.7 mg DSS/100 μl DMF) or 16.0 μl solution of DSP (dithiobis(succinimidyl) propionate; 3.4 mg DSP/100 μl DMF) and 3.7 μl triethylamine have been added respectively. Reaction was performed over night at RT. Reaction products have been precipitated by 2×30 ml dried diethylether and resolubilized in 133 μl dried DMF. 133 μl of each DMF solution was added to 2.25 ml HERCEPTIN solution (2 mg/ml in PBS). Reaction was performed over night at RT on a rotating shaker. Isolation of the antibody-conjugates β-amanitin-hexamethylenediamido-suberoyl-HERCEPTIN and β-amanitin-hexamethylenediamido-suberoyl-HERCEPTIN was performed by separation of macromolecular components on a G25-gelfiltration column.
1.4.6 Synthesis of β-Amanitin-hexamethylenediamido-suberoyl-Xolair
[0120] The β-amanitin conjugate with the control antibody Xolair (2 mg/ml) was prepared according to the huHEA125 conjugate. Ratio toxin:IgG was ca 1:1.
1.4.7 Synthesis of β-Amanitin-hexamethylenediamido-suberoyl-huHEA125
[0121] 10 mg of (I) (9.0 μmol) were treated with 0.2 ml of trifluoroacetic acid for 2 min at RT. The acid was removed in vacuo, and the residue dissolved in 0.2 ml of DMF. After the addition of 0.010 ml of triethylamine, 9.0 mg of disuccinimidylsuberate (DSS) (27 μmol) in 0.1 ml of DMF was added and reacted for 2.5 h at RT. The reaction product was precipitated with dietylether, centrifuged, and the pellet dissolved in 0.2 ml of DMF. Half of this solution was added to 8 mg of huHEA125 in 4 ml of PBS. The mixture was rotated slowly for 16 h at 5° C., and the toxin-antibody conjugate was separated from unreacted amanitin and N-hydroxy-succinimide on a Sephadex G25 column (100×2 cm) developed with PBS.
[0000] 1.4.8 Synthesis of β-Amanitin-N-hydroxysuccinimide ester (I)
[0122] 10 mg of dried β-amanitin (11 μmol) was dissolved in 0.1 ml of dry dimethylformamide (DMF). To this solution 8 mg of N-hydroxysuccinimide (70 μmol) in 0.02 ml of DMF was added, followed by 4 mg of dicyclohexylcarbodiimide (20 μmol) in 0.02 ml of DMF. The mixture was allowed to react for 16 h at RT, and the solution separated from crystallized dicyclohexylurea. β-Amanitin-N-hydroxysuccinimide ester was precipitated by the addition of 10 ml of diethylether, and the precipitate isolated by centrifugation. The pellet was macerated with another 10 ml of ether and centrifuged again. Purification was not necessary, because the following step allowed separation and recovery of unreacted β-amanitin.
[0000] 1.4.9 Synthesis of β-Amanitin-huHEA125 (huHEA125-Amanitin1)
[0123] The precipitate of (I) was dissolved in 0.2 ml of DMF, added to 4 ml of huHEA125 (2 mg/ml) in PBS and rotated slowly over night at 5° C. Applied to a Sephadex G25 column (100×2 cm) developed with PBS, the reaction product was separated from unreacted β-amanitin and N-hydroxysuccinimide. The toxin load was ca. 1 amanitin per IgG molecule.
[0000] 1.5 Synthesis of Amanitin huHEA Conjugate with Linker at Amino Acid 4
1.5.1 Synthesis of α-Amanitin-6′-(t-butyl-acetate) (I)
[0124] Twenty mg of α-amanitin (22 μmol) was dissolved in 0.4 ml of dry dimethylformamide (DMF), and 1.5 eq. (33 μmol) of 0.5M sodium ethylate were added under magnetic stirring. Immediately, 18 μl (5.5 eq., 120 μmol, 23.4 mg, d=1.3) of t-butyl bromoacetate (mwt. 195) was added and allowed to react for 10 min. The reaction mixture was applied to 2 silica tlc plates (20 cm×20 cm, Merck HF254) and developed in chloroform/methanol/water (65:25:4).The product (R F =0.41) was detected in u.v. light, scraped off and eluted with methanol. Yield: 55%.
[0000] 1.5.2 Synthesis of α-Amanitin-6′-acetyl-(t-butyloxycarbonyl)-ethylene diamide (II)
[0125] Five mg (5 μmol) of (I) were reacted with 0.2 ml of trifluoroacetic acid for 2 min, and the acid was removed in vacuo. The residue was dissolved in 0.2 ml DMF, and 0.005 ml of triethylamine was added. Under magnetic stirring, the solution was brought to −18° C. (ice/NaCl) and 3.4 mg (25 μmol, 5 eq.) of isobutylchloroformate was added. The reaction was allowed to proceed at −18° C. for 20 min., and 9.8 mg (50 μmol, 10 eq.) of t-butyloxycarbonyl-ethylenediamine hydrochloride dissolved in 0.1 ml DMF and 0.006 ml triethylamine were added. The reaction mixture was stirred for 1 h at RT. The product was precipitated with dry diethylether, and the residue developed on a silica tlc plate as described above. (R F =0.28). Yield: 85%.
[0000] 1.5.3 Synthesis of α-Amanitin-6′-acetylethylene-diamido-suberoyl-huHEA125 (huHEA125-Amanitin4)
[0126] Four mg (3.6 μmol) of (II) was dissolved in 0.2 ml of trifluoroacetic acid for 2 min and evaporated in vacuo. The residue was dissolved in 0.2 ml of dry DMF, 0.005 ml of triethylamine added, and reacted with 3 mg (8.2 μmol, 2.3 eq.) of disuccinimidyl suberate
[0127] (DSS) under magnetic stirring for 2.5 h at RT. The amanitin derivative was precipitated with dry diethylether, centrifuged, macerated with ether again, and centrifuged. Dissolved in 0.15 ml of DMF it was added to 5 ml of huHEA125 (2 mg/ml) in PBS and rotated slowly over night at 5° C. Developed on a Sephadex G25 column (100×2 cm) with PBS the antibody amanitin conjugate was separated from unreacted amanitin derivative and by-products. The ratio toxin:antibody was 3.0.
[0000] 1.6 Synthesis of Amanitin Herceptin Conjugates with Linker at Amino Acid 4
1 . 6 . 1 Synthesis of 6′O—(NH-boc-6-aminohexyl)-α-amanitin (1)
[0000]
[0128] Under argon 30.00 mg (32.6 μmol) of vacuum dried α-amanitin was dissolved in 1000 μl dry dimethyl sulfoxide (DMSO). 73.18 mg (261.2 μl, 6 eq.) NH-boc-aminohexylbromide (Fluka 89171) and 3.66 mg (32.6 μmol) potassium tert.-butylate was added. After 90 minutes at room temperature the reaction mixture was acidified to pH=4 with acetic acid and diluted with 40 ml diethylether. The solid was collected and taken up in 1000 μl methanol. The methanol solution was diluted with 1000 μl water. The solution was purified on a LaPrep-HPLC: column: Kromasil 100-C18, 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water: 5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water: 90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-30 min 100% A. The fractions with the same retention time were collected and the solvents evaporated.
[0129] 9.9 mg (27% yield) of a white powder. MS: 1118 M+H; 1140 M+Na +
[0000] 1.6.2 Synthesis of 6′-O-(-6-aminohexyl)-α-amanitin (2)
[0000]
[0130] 9.90 mg (8.85 μmol) 6′-(—NH-boc-6-aminohexyl-)-α-amanitin (compound (1)) was dissolved in 250 μl trifluoroacetic acid. The reaction mixture was stirred under argon at ambient temperature. After 2 minutes the acid was removed in vacuum at 20° C. and the residue dried. The crude α-amanitin ether was purified on a LaPrep-HPLC: column: Kromasil 100-C18, 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water: 5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water: 90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-25 min 50% A; 25-30 min 0% A; 30-35 min 0% A; 35-40min 100% A, 40-45 min 100% A. The fractions with the same retention time were collected and the solvents evaporated.
[0131] 9.10 mg (99% yield) of a white powder. MS: 1019 M+H+; 1041 M+Na+
[0000] 1.6.3 Synthesis of α-amanitin-Herceptin Conjugates (3) and (4)
[0132] 2.0 mg of compound (2) was dissolved in 113 μl molecular sieve dried DMF. 21.8 μl solution of DSS (disuccinimidyl suberate; 3.7 mg DSS/100 μl DMF) or 23.9 gl solution of DSP (dithiobis(succinimidyl) propionate; 3.7 mg DSP/100 μl DMF) and 5.7 μl triethylamine have been added respectively. Reaction was performed over night at RT. Reaction products have been precipitated by 2×30 ml dried diethylether and resolubilized in 200 μl dried DMF. 59 μl (DSS) or 173 μl (DSP) of the DMF solutions were added to 6.0 ml antibody solution (2 mg/ml in PBS). Reaction was performed over night at RT on a rotating shaker. Isolation of the antibody-conjugates (3) and (4) was performed by separation of macromolecular components on a G25-gelfiltration column.
[0000]
[0000] 1.7 Synthesis of Amanitin Herceptin Conjugates with Linker at Amino Acid 4
1.7.1 Synthesis of 6′-O-(5-O-t-butyl-carboxypentyl)-α-amanitin (5)
[0000]
[0133] Under argon 17.07 mg (18.6 μmol) of vacuum dried α-amanitin was dissolved in 1000 μl dry dimethyl sulfoxide (DMSO). 60.1 μl (18.6 μmol, 1 eq.) potassium-tert-butanolate as a 3.09 M solution in DMSO was added at once. After the addition of the base 38 μl (148.6 μmol) of 6-bromoheptanoic acid-tert-butylester was added. The reaction mixture was stirred for 8 hours. After 8, 11, 23, 34, 50 and 52 h additional amounts of potassium-tert-butanolate (60.1 μl) and 6-bromoheptanoic acid-tert-butylester (38 μl) was added. After 56 h the reaction mixture was quenched with 100 μl of a 0.3M solution of acetic acid in DMSO. The volatiles of the reaction mixture were removed at 40° C. and 8 mbar. The crude amanitin ether was purified on a LaPrep-HPLC: column: Kromasil 100-C 18 , 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water:5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water:90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-35 min 100% A. The fractions with the same retention time (20.2 min) were collected and the solvent evaporated.
[0134] 17.88 mg (53% yield) of a white powder. MS: 1089 M+H + ; 1111 M+Na +
[0000] 1.7.2 Synthesis of 6′-O-(carboxypentyl)-α-amanitin (6)
[0000]
[0135] 14.84 mg (13.64 mmol) 6′-(-carboxypentyl)-α-amanitin (compound (5)) was dissolved under argon in 250 μl trifluoro acetic acid (TFA). The reaction mixture was stirred for 2 minutes and evaporated to dryness at 20° C. The residue was co-evaporated 2 times with 1 ml methanol. The remaining solid was purified on a LaPrep-HPLC: column: Kromasil 100-C 18 , 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water: 5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water: 90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-40 min 0% A. The fractions with the same retention time were collected and evaporated.
[0136] 7.05 mg (50% yield) of a white powder. MS: 1033 M+H + ; 1056 M+Na +
[0000] 1.7.3 Synthesis of α-amanitin-Herceptin Conjugate (7)
[0137] 10.0 mg of compound (6) was dissolved in 100 μl molecular sieve dried DMF. 80.0 μl solution of N-hydroxysuccinimide (7.4 mg N—OH-Succ/80 μl DMF) and 80.0 μl solution of DCCi (N,N-dicyclohexylcarbodimide; 3.4 mg DCCi/80 μl DMF) was added. Reaction was performed over night at RT. Reaction product was precipitated by 2×30 ml dried diethylether and resolubilized in 800 μl dried DMF. 266 μl of the DMF solution was added to 5.0 ml antibody solution (6 mg/ml in PBS). Reaction was performed over night at RT on a rotating shaker. Isolation of the antibody-conjugate (7) was performed by separation of macromolecular components on a G25-gelfiltration column.
[0000]
[0000] 1.8 Synthesis of Amanitin huHEA Conjugate with Linker at Amino Acid 3
1.8.1 Synthesis of α-Amanitin-glutarate
[0138] 3.0 mg (3.3 μmol) of α-amanitin, dried in vacuo over P 4 O 10 was dissolved in 0.25 ml of dry pyridine and reacted with 0.9 mg (79 μmol) glutaric anhydride in 0.1 ml pyridine for 24 h at RT in the dark. The peptide was precipitated by addition of 7 ml of dry diethylether, centrifuged, and the solid washed a second time with diethylether and centrifuged.
[0139] By way of this reaction an α-amanitin derivative is obtained wherein R 1 =—OH (in FIG. 1 ) is replaced by R 1 =—O—C(O)—(CH 2 ) 3 —COOH.
[0000] 1.8.2 Synthesis of α-Amanitin-glutaric acid N-hydroxysuccinimidate
[0140] 3.4 mg of α-amanitin glutarate (3.3 μmol) was dissolved in 0.05 ml of dry dimethylformamide (DMF), and 2.4 mg (7 eq.) of N-hydroxy-succinimide dissolved in 0.01 ml of DMF were added. After the addition of 1.2 mg of dicyclohexylcarbodiimide in 0.01 ml of DMF the reaction was allowed to proceed for 16 h at RT. The solution was separated from the crystals formed, and the peptide precipitated by the addition of 4 ml of dry diethylether. After centrifugation, the pellet was washed with another 4 ml of ether and centrifuged. The solid was dissolved in 0.1 ml of dimethylformamide and immediately used for the reaction with the antibody solution.
[0000] 1.8.3 Synthesis of α-Amanitin-glutarate-huHEA125 (huHEA125-Amanitin3)
[0141] 0.1 ml of the solution of 3.0 mg of α-amanitin-glutaric acid N-hydroxysuccinimidate was added to 10 mg of hu-HEA125 antibody in 5 ml of PBS and reacted under slow rotation at 5° C. in the dark. After 16 h the solution was applied to a Sephadex G25 column (120×1.5 cm) equilibrated with PBS, and the protein fraction collected. Amanitin load was determined spectrophotometrically from the absorption difference at 310 nm of the protein solution against a blank containing the same concentration of the native antibody, using the molar extinction coefficient for amatoxins of 13.500 cm −1 M −1 . Ratio α-amanitin: IgG of this preparation was ca. 8.
[0000] 1.9 Synthesis of Amanitin Herceptin Conjugates with Linker at Amino Acid 3
1.9.1 Synthesis of δ-O—(NH-boc-6-aminohexylcarbamoyl)-α-amanitin (8)
[0000]
[0142] Under argon 13.43 mg (14.6 μmol) vacuum dried α-amanitin was dissolved in 1000 μl dry dimethyl formamide (DMF). 7.08 mg (29.2 μmol) NH-Boc-6-isocyanato aminohexane and 18.46 mg (29.2 μmol) di-Butyl dilaurylstannate was added and the reaction mixture stirred at ambient temperature. After 23 hours additional 13.43 mg (14.6 μmol) NH-Boc-6-isocyanatoaminohexane was added. After 52 hours the reaction mixture was hydrolyzed with 200 μl methanol and evaporated to dryness. The residue was dissolved in 1200 μl DMSO and purified on a LaPrep-HPLC:column: Kromasil 100-C 18 , 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water:5% methanol. Solvent B: 5% water:95% methanol. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-35 min 100%A. The fractions with the same retention time were collected and the solvents evaporated.
[0143] 9.06 mg (53% yield) of a white solid. MS: 1161 M+H + ; 1183 M
[0000] 1.9.2 Synthesis of δ-O-(6-aminohexylcarbamoyl)-α-amanitin (9)
[0000]
[0144] 9.06 mg (7.8 μmol) compound (8) was dissolved in 250 μl trifluoroacetic acid and stirred for 2 minutes at ambient temperature. The reaction mixture was evaporated to dryness and the residue koevaporated 2 times with 1.5 ml acetonitrile. The solid was purified on a LaPrep-HPLC: column: Kromasil 100-C18, 10 μm, 250×20 mm, with acetonitrile/water, flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water:5% acetonitrile. Solvent B: 5% water:95% acetonitrile. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-35 min 100% A. The fractions with the retention time between 12-17 min were collected and evaporated to a white solid.
[0145] 8.75 mg (95% yield). MS: 1061 M+H + ; 1083 M+Na +
[0000] 1.9.3 Synthesis of α-amanitin-Herceptin Conjugates
[0146] 2.0 mg of compound (9) was dissolved in 113 μl molecular sieve dried DMF. 21.8 μl solution of DSS (disuccinimidyl suberate; 3.7 mg DSS/100 μl DMF) or 23.9 μl solution of DSP (dithiobis(succinimidyl) propionate; 3.7 mg DSP/100 μl DMF) and 5.7 μl triethylamine was added respectively. The reaction was performed over night at RT. Reaction products were precipitated by 2×30 ml dried diethylether and resolubilized in 200 μl dried DMF. 122 μl (DSS) or 176 μl (DSP) of the DMF solutions were added to 6.0 ml of a solution of Her-2 specific Herceptin antibody (2 mg/ml in PBS). The reaction was performed over night at RT on a rotating shaker. The isolation of the antibody-conjugate (10) and (11), respectively, was performed by separation of macromolecular components on a G25-gelfiltration column.
[0000]
[0000] 1.10 Synthesis of Amanitin Herceptin Conjugates with Linker at Amino Acid 3
1 . 10 . 1 Synthesis of δ-O-(5-O-t-butyl-carboxypentylcarbamoyl)-α-amanitin (12)
[0000]
[0147] Under argon 30.76 mg (33.5 μmol) vacuum dried α-amanitin was dissolved in 1000 μl dry dimethyl formamide (DMF). 14.28 mg (13.83 μl, 66.9 μmol) isocyanatohexanoic acid-tert-butylester and 42.28 mg (40.26 μl, 66.9 μmol) dibutyll dilaurylstannate was added. After 23 hours stirring at room temperature additional isocyanato ester (13.83 μl) was added and the reaction mixture was quenched with methanol after 33 hours. The reaction mixture was evaporated to dryness and the remaining solid was dissolved in DMSO and purified on a LaPrep-HPLC: column: Kromasil 100-C 18 , 10 μm, 250×20 mm, with methanol/water (0.05% TFA), flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water:5% methanol 0.05% trifluoroacetic acid. Solvent B: 10% water:90% methanol 0.05% trifluoroacetic acid. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-35 min 100%A. The fractions with the same retention time were collected and the solvents evaporated.
[0148] 17.95 mg (47% yield) of a powder. MS: 1133 M+H + ; 1155 M+Na +
[0000] 1.10.2 Synthesis of δ-O-(carboxypentylcarbamoyl)-α-amanitin (13)
[0000]
[0149] 17.95 mg (15.9 μmol) tert-butylester (Compound (12)) was dissolved in 500 μl trifluoro acetic acid (TFA) and stirred for 2 minutes at ambient temperature. Excess trifluoro acetic aceid was removed in vacuum and the remaining solid was coevaporated two times with 1.5 ml acetonitrile. The free carboxylic derivative (13) was purified on a LaPrep-HPLC: column: Kromasil 100-C 18 , d=10 mm, 10 μm, 250×20 mm, with acetonitril/water, flow: 26 ml/min, detection at λ=295 nm. Solvent A: 95% water:5% acetonitrile. Solvent B: 5% water:95% acetonitrile. Gradient: 0-5 min 100% A; 5-20 min 0% A; 20-25 min 0% A; 25-27 min 100% A; 27-35 min 100%A. The fractions with the same retention time 12-17min were collected and the solvents evaporated.
[0150] 11.34 mg (66% yield) of a white slid. MS: 1076 M+H + ; 1098 M+Na +
[0000] 1.10.3 Synthesis of Synthesis of Herceptin-α-amanitin conjugate
[0151] 10.0 mg HDP compound (13) was dissolved in 100 μl molecular sieve dried DMF. 80.0 μl solution of N-hydroxysuccinimide (7.4 mg N—OH-Succ/80 μl DMF) and 80.0 μl solution of DCCi (N,N-dicyclohexylcarbodimide; 3.4 mg DCCi/80 μl DMF) were added. The reaction was performed over night at RT. The reaction product was precipitated by 2×30 ml dried diethylether and resolubilized in 800 μl dried DMF. 266 μl of the DMF solution was added to 5.0 ml antibody solution (6 mg/ml in PBS). Reaction was performed over night at RT on a rotating shaker. The isolation of the antibody-conjugate (14) was performed by separation of macromolecular components on a G25-gelfiltration column.
[0000]
[0000] 1.11 Synthesis of Amanitin Herceptin Conjugates with Linker at Amino Acid 3
1.11.1 Synthesis of α-Amanitin-glutarate
[0152] 3.0 mg (3.3 μmol) of α-amanitin, dried in vacuo over P 4 O 10 was dissolved in 0.25 ml of dry pyridine and reacted with 0.9 mg (79 μmol) glutaric anhydride in 0.1 ml pyridine for 24 h at RT in the dark. The peptide was precipitated by addition of 7 ml of dry diethylether, centrifuged, and the solid washed a second time with diethylether and centrifuged. By way of this reaction an α-amanitin derivative is obtained wherein R 1 =—OH (in FIG. 1 ) is replaced by R 1 =—O—C(O)—(CH 2 ) 3 —COOH.
1.11.2 Synthesis of α-Amanitin-glutaric Acid N-hydroxysuccinimidate
[0153] 3.4 mg of α-amanitin glutarate (3.3 μmol) was dissolved in 0.05 ml of dry dimethylformamide (DMF), and 2.4 mg (7 eq.) of N-hydroxy-succinimide dissolved in 0.01 ml of DMF were added. After the addition of 1.2 mg of dicyclohexylcarbodiimide in 0.01 ml of DMF the reaction was allowed to proceed for 16 h at RT. The solution was separated from the crystals formed, and the peptide precipitated by the addition of 4 ml of dry diethylether. After centrifugation, the pellet was washed with another 4 ml of ether and centrifuged. The solid was dissolved in 0.1 ml of dimethylformamide and immediately used for the reaction with the antibody solution.
1.11.3 Synthesis of α-Amanitin-glutarate-Herceptin (15)
[0154] 0.1 ml of the solution of 3.0 mg of α-amanitin-glutaric acid N-hydroxysuccinimidate was added to 10 mg of Herceptin antibody in 5 ml of PBS and reacted under slow rotation at 5° C. in the dark. After 16h the solution was applied to a Sephadex G25 column (120×1.5 cm) equilibrated with PBS, and the protein fraction collected. Amanitin load was determined spectrophotometrically from the absorption difference at 310 nm of the protein solution against a blank containing the same concentration of the native antibody, using the molar extinction coefficient for amatoxins of 13.500 cm −1 M −1 . Ratio α-amanitin: IgG of this preparation was about 4.
[0000]
1.12. Synthesis of Aminophalloidin (APHD)-suberoyl-huHEA 125
[0155] Aminophalloidin was prepared from mono-tosylphalloidin by reaction with methanolic ammonia. Conjugation of aminophalloidin with huHEA125 was performed in analogy to the reaction described in 1.5.3.
Example 2
Binding Studies
2.1 Binding Competition Analysis
[0156] Binding of conjugate huHEA125-amanitin3 vs. non-conjugated huHEA125 antibody was analyzed in a competition experiment by flow cytometry. The α-amanitin-huHEA125 conjugate was synthesized as described above in sections 1.6.1 to 1.6.3.
[0157] Colo205 target cells (colon cancer metastasis) were washed twice in FACS buffer (Dulbecco's PBS with 1% heat-inactivated fetal calf serum and 0.1% sodium azide) counted and adjusted to 2×10 7 cells per ml. Fifty μl of cell suspension was given to each well of a 96 well U-bottom microtiter plate to which 50 μl/well of FITC-labeled huHEA125 antibody was pipetted. Serial dilutions of amanitin-huHEA125 or huHEA125 ranging from 400 μg/ml to 10 ng/ml final dilution were added in triplicates in a volume of 50 μl/well and incubated for 1 h on ice. Subsequently, the plate was centrifuged (2 min at 2000 rpm) and the supernatant was removed from the cells. Cells were re-suspended in 150 μl of FACS buffer and centrifuged again. After two washing steps by centrifugation, cells were taken up in 100 μl/well of propidium iodide solution (1 μg/ml in FACS buffer) allowing discrimination of dead cells. Analysis was performed on a FACScan cytometer (Becton and Dickinson, Heidelberg, Germany) using CellQuest software.
[0158] As shown in FIG. 2 competition of binding to target cells with increasing amounts of huHEA125-amanitin conjugate or unmodified huHEA125 antibody revealed a comparable binding strength over the whole concentration range from 10 ng/ml to 400 μ/ml competing antibody or antibody conjugate. Therefore, the conjugation procedure did not significantly alter the affinity of huHEA125-amanitin to the target cells.
2.2 Surface Expression of EpCAM Antigen on Various Carcinoma Cell Lines Detected by Indirect Immunofluorescence
[0159] Cell lines Capan-1, Colo205, OZ, and MCF-7 were first incubated with either huHEA125 or Xolair®. After washing, binding of the primary antibody was visualized by FITC-labelled F(ab′) 2 goat anti-human IgG (H+L) as second step reagent. The results are shown in FIG. 3A (Capan-1), FIG. 3B (Colo205), FIG. 3C (OZ), and FIG. 3D (MCF-7). The grey-shaded histograms in the left side of each diagram show the results obtained with control antibody Xolair®; the histograms having a white area in the right side of each diagram show the results obtained with antibody huHEA125.
[0000] 2.3 Binding of huHEA125-amanitin and huHEA125-phalloidin Conjugates to MCF-7 Breast Cancer Cells
[0160] Binding of huHEA125-amanitin and huHEA125-phalloidin conjugates versus non-conjugated huHEA125 antibody was analyzed by flow cytometry. MCF-7 target cells were washed twice in FACS buffer (Dulbecco's PBS with 1% heat-inactivated fetal calf serum and 0.1% sodium azide) counted and adjusted to 2×10 7 cells per ml. Fifty μl of cell suspension was given to each well of a 96 well U-bottom microtiter plate. Immunotoxins huHEA125-amanitin1, huHEA125-amanitin4 and huHEA125-phalloidin as well as unconjugated huHEA125 antibody were added at a concentration of 1 μg/ml in a volume of 100 μl per well and incubated for 1 h on ice. The plate was centrifuged (2 min at 2000 rpm) and the supernatant was removed from the cells. Cells were re-suspended in 150 μl of FACS buffer and centrifuged again. Subsequently, 100 μl of FITC-labeled F(ab′) 2 goat anti-human IgG (H+L) secondary antibody was added per well and incubated again for 1 h on ice. After two washing steps by centrifugation, cells were taken up in 100 μl/well of propidium iodide solution (1 μg/ml in FACS buffer) allowing discrimination of dead cells. Analysis was performed on a FACScan cytometer (Becton and Dickinson, Heidelberg, Germany) using CellQuest software.
[0161] As shown in FIG. 4 the binding capacity of immunotoxins to target cells was only moderately reduced by the conjugation procedure. When compared with the non-modified huHEA125 antibody showing a mean fluorescence intensity (MFI) of 1094, conjugation with amanitin1 decreased binding to MFI 730, conjugation with amanitin4 resulted in a MFI of 905, whereas coupling to alpha-phalloidin reduced MFI to 604. These values were obtained with identical antibody amounts of conjugates.
Example 3
Specific Growth Inhibition of Carcinoma Cells by Immunoconjugates Composed of huHEA125 Antibody and Amanitin at Different Binding Sites
3.1 Proliferation Assay
[0162] Inhibition of cell growth by amanitin-IgG conjugates was determined by incorporation of [ 3 H]-thymidine. Serial dilutions of amanitin-huHEA125 and amanitin in complete medium (RPMI 1640 supplemented with 10% heat-inactivated FCS, 2 mM L-glutamine and 1 mM sodium pyruvate) ranging from 2×10 −5 M to 6×10 −13 M were prepared in triplicates in a volume of 100 μl in the wells of a 96 well flat-bottom tissue culture microtiter plate. In each well, cells were added in 50 μl at a density of 5×10 4 per ml in the experiments with huHEA125-Amanitin1 and huHEA125-Amanitin4 and at a density of 2×10 4 per ml in the experiments with huHEA125-Amanitin3. Plates were incubated in a humidified atmosphere at 37° C. and 5% CO 2 for 72 or 96 h. At 20 h before the end of the assay, 1 μCi of [ 3 H]-thymidine was added. Subsequently, plates were processed with a Tomtec cell harvester and the incorporated radioactivity was determined by liquid scintillation counting (Wallac Betaplate Liquid Scintillation Counter, PerkinElmer Life and Analytical Sciences) and given as cpm.
3.2 Comparison of Inhibition of Carcinoma Cell Proliferation Caused by Conjugates Using Different Linkage Sites in the Amanitin Moiety
[0163] Three examples of growth inhibition induced by different amanitin-IgG conjugates are depicted in FIGS. 5 , 6 , and 9 . In all three experiments MCF-7 cells were used. FIG. 5 shows a comparison of huHEA125-Amanitinl with the non-binding control Xolair-Amanitin1 and with free Amanitin. In the experiment outlined in FIG. 6 huHEA125-Amanitin4 was compared with an alpha-phalloidin huHEA125 conjugate and with free Amanitin. FIG. 9 shows a comparison of huHEA125-Amanitin3 with Amanitin-armed control antibody Xolair and with free Amanitin.
[0164] The IC 50 of conjugates huHEA125-amanitinl and huHEA125-amanitin4 were both approximately 5×10 −12 M ( FIGS. 5 and 6 ) and the IC 50 of conjugate huHEA125-amanitin3 was approximately 2×10 −12 M ( FIG. 9 ). In contrast, the phalloidin-huHEA125 preparation exhibited virtually no effect at least at the dose levels tested ( FIG. 6 ). In accordance with our previous findings, the IC 50 of Amanitin alone is in the range of 10 −7 M ( FIGS. 5 , 6 , and 9 ).
3.3 Comparison of Inhibition of Carcinoma Cell Proliferation for Different Carcinoma Cell Lines
[0165] Four examples of growth inhibition tested in four different carcinoma cell lines are depicted in FIGS. 7 , 8 , 9 , and 10 . In all four experiments, the conjugate huHEA125-Amanitin3 was used.
[0166] In case of the pancreatic carcinoma cell line Capan-1 the huHEA125-Amanitin3 immunotoxin induced growth arrest at amanitin concentrations of 1×10 −11 to 3×10 −10 M as depicted in FIG. 7 .
[0167] In case of the colon cancer cell line Colo205 the huHEA125-Amanitin3 immunotoxin induced growth arrest at amanitin concentrations of 1×10 −12 to 4×10 −11 M as depicted in FIG. 8 .
[0168] In case of the breast cancer cell line MCF-7 the huHEA125-Amanitin3 immunotoxin induced growth arrest at amanitin concentrations of 1×10 −12 to 1×10 −11 M as depicted in FIG. 9 .
[0169] In case of the cholangiocarcinoma cell line OZ the huHEA125-Amanitin3 immunotoxin induced growth arrest at amanitin concentrations of 1×10 −11 to 6×10 −10 M as depicted in FIG. 10 .
Example 4
Specific Growth Inhibition of Carcinoma Cells by Immunoconjugates Composed of Herceptin Antibody and Amanitin at Different Binding Sites and Using Different Linking Chemistry
[0170] Inhibition of cell growth by amanitin-Herceptin conjugates was determined by in vitro BrdU incorporation as described in Current Protocols in Immunology 1 (see chapter 7.10. Coligan, J. E. et al., eds.) John-Wiley & Sons, New York). Compounds (3), (4), (7), (10), (11), (14), non-conjugated Herceptin and α-amanitin as such were incubated for 72 h and 120 h, respectively, with three tumor cell lines expressing Her2/neu in high concentration, namely, SKOV-3, SK-BR-3 and NCI-N87 and one Her2/neu negative cell line MDA-MB231. Non conjugated Herceptin showed no cytotoxicity on any cell line while the various amanitin conjugates showed a marked toxicity on the Her2/neu positive cell lines with an EC 50 in the pico- to nanomolar range, no siginifcant toxicity was observed on the Her2/neu negative cell line. (See FIGS. 11A to 11D ). The indicated molar concentration is indicated on the basis of the entire amanitin comprised in the respective conjugate.
Example 5
In vivo Xenograft Tumor Model
[0171] A mouse tumor xenograft model, wherein 2.5×10 & SKOV-3 ovarial carcinoma cells are implated sub-cutaneously (s.c.) into SCID mice and allowed to grow for 10 days. After 10 days a single dose of 30 μg/kg body weight (see FIG. 12A ) or at 150 μg/kg body weight (see FIG. 12B ) of various α-amanitin-Herceptin conjugates (Compounds (15), (3), (4) , (10), (11), and (7)) and non-conjugated Herceptin (Control) were administered intravenously. A clear concentration dependent reduction of tumor growth was observed. Conjugates (7), (10) and (15) led to full tumor remission within the period of observation, i.e. 87 days from the initiation of the experiment.
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[0191] EpCam protein expression in human carcinomas. Hum. Pathol. 35 (1), 122-128, 2004 Wieland, T. and Faulstich H. Amatoxins, phallotoxins, phallolysin, and antamanide: the biologically active components of poisonous Amanita mushrooms. CRC Crit. Rev. Biochem. 5 (3), 185-260 (1978)
[0192] Winter M. J., Nagtegaal I. D., van Krieken J. H., Litvinov S. V. The epithelial cell adhesion molecule (Ep-CAM) as a morphoregulatory molecule is a tool in surgical pathology. Am. J. Pathol. 163 (6), 2139-2148 (2003)
Sequence Listing—Free Text Information
[0193] SEQ ID NO: 1: chimeric antibody huHEA125, heavy chain, membrane-bound form
[0194] SEQ ID NO: 2: chimeric antibody huHEA125, heavy chain, secreted form
[0195] SEQ ID NO: 3: chimeric antibody huHEA125, heavy chain, VH domain
[0196] SEQ ID NO: 4: chimeric antibody huHEA125, heavy chain, FR1 segment
[0197] SEQ ID NO: 5: chimeric antibody huHEA125, heavy chain, CDR1 segment
[0198] SEQ ID NO: 6: chimeric antibody huHEA125, heavy chain, FR2 segment
[0199] SEQ ID NO: 7: chimeric antibody huHEA125, heavy chain, CDR2 segment
[0200] SEQ ID NO: 8: chimeric antibody huHEA125, heavy chain, FR3 segment
[0201] SEQ ID NO: 9: chimeric antibody huHEA125, heavy chain, CDR3 segment
[0202] SEQ ID NO: 10: chimeric antibody huHEA125, heavy chain, FR4 segment
[0203] SEQ ID NO: 11: chimeric antibody huHEA125, light chain
[0204] SEQ ID NO: 12: chimeric antibody huHEA125, light chain, VL domain
[0205] SEQ ID NO: 13: chimeric antibody huHEA125, light chain, FR1 segment
[0206] SEQ ID NO: 14: chimeric antibody huHEA125, light chain, CDR1 segment
[0207] SEQ ID NO: 15: chimeric antibody huHEA125, light chain, FR2 segment
[0208] SEQ ID NO: 16: chimeric antibody huHEA125, light chain, CDR2 segment
[0209] SEQ ID NO: 17: chimeric antibody huHEA125, light chain, FR3 segment
[0210] SEQ ID NO: 18: chimeric antibody huHEA125, light chain, CDR3 segment
[0211] SEQ ID NO: 19: chimeric antibody huHEA125, light chain, FR4 segment
[0212] SEQ ID NO: 20: chimeric antibody huHEA125, heavy chain, CDR1 domain
[0213] SEQ ID NO: 21: chimeric antibody huHEA125, heavy chain, CDR2 domain
[0214] SEQ ID NO: 22: chimeric antibody huHEA125, heavy chain, CDR3 domain
[0215] SEQ ID NO: 23: chimeric antibody huHEA125, light chain, CDR1 domain
[0216] SEQ ID NO: 24: chimeric antibody huHEA125, light chain, CDR2 domain
[0217] SEQ ID NO: 25: chimeric antibody huHEA125, light chain, CDR3 domain
[0218] SEQ ID NO: 26: chimeric antibody huHEA125, heavy chain, constant domain, membrane bound form
[0219] SEQ ID NO: 27: chimeric antibody huHEA125, heavy chain, constant domain, secreted form
[0220] SEQ ID NO: 28: chimeric antibody huHEA125, light chain, constant domain | The invention relates to tumour therapy. In one aspect, the present invention relates to conjugates of a toxin and a target-binding moiety, e.g. an antibody, which are useful in the treatment of cancer. In particular, the toxin is an amatoxin, and the target-binding moiety is preferably directed against tumour-associated antigens. In particular, the amatoxin is conjugated to the antibody by linker moieties. In particular the linker moieties are covalently bound to functional groups located in positions of the amatoxin proved as preferred positions for the attachment of linkers with respect to optimum antitumor activity. In a further aspect the invention relates to pharmaceutical compositions comprising such target-binding moiety toxin conjugates and to the use of such target-binding moiety toxin conjugates for the preparation of such pharmaceutical compositions. The target-binding moiety toxin conjugates and pharmaceutical compositions of the invention are useful for the treatment of cancer. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to U.S. Patent Application No. 62/268,338 entitled “Pulsed-DC Dielectric Barrier Discharge Plasma Actuator and Circuit,” filed previously on Dec. 16, 2015, and U.S. Patent Application No. 62/273,957 entitled “Methods and Apparatus for Pulsed-DC Dielectric Barrier Discharge Plasma Actuator and Circuit,” filed previously on Dec. 31, 2015, the contents of which are incorporated herein by reference in their entirety.
GOVERNMENT LICENSE RIGHTS
This invention was made with government support under SBIR Contract NNX14CC12C awarded by NASA. The government has certain rights in the invention.
FIELD OF THE DISCLOSURE
The present description relates generally to a pulsed direct current powering system for a dielectric barrier discharge (DBD) plasma actuator for flow control.
BACKGROUND OF RELATED ART
Interest in dielectric barrier discharges (DBD) “plasma actuators” for flow control has seen a tremendous growth in the past 15 years in the U.S. and around the world. The reasons for this are likely based on their special features that include being fully electronic with no moving parts, having a fast response time for unsteady applications, having a very low mass which is especially important in applications with high g-loads, being able to apply the actuators onto surfaces without the addition of cavities or holes, having an efficient conversion of the input power without parasitic losses when properly optimized, and the easy ability to simulate their effect in numerical flow solvers.
The predominant DBD configuration used for flow control consist of two electrodes, one uncoated and exposed to the air and the other encapsulated by a dielectric material. For plasma actuator applications, the electrodes are generally arranged in a highly asymmetric geometry.
Referring to FIG. 1 , an example configuration for an alternative current (AC) set-up for a prior art AC plasma actuator 10 is shown in FIG. 1 . For the AC-DBD operation, the electrodes 102 and 104 are supplied with an AC voltage from the power source 112 that, at high enough levels, causes the air over the covered electrode to weakly ionize. This is typically less than 1 PPM weakly ionized gas. The ionized air appears blue, which is a characteristic of the composition of the air as ionized components of the air recombine and de-excite. The emission intensity is extremely low, requiring a darkened space to view by eye.
The ionized air, in the presence of the electric field produced by the geometry of electrodes 102 and 104 , results in a body force vector field that acts on the ambient (non-ionized, neutrally charged) air or other fluid. The body force can be used as a mechanism for active aerodynamic control. In determining the response of the ambient air, the body force appears as a term on the right-hand-side of the fluid momentum equation.
For a single dielectric barrier discharge (SDBD), during one-half of the AC cycle, electrons leave the metal electrode and move towards the dielectric where they accumulate locally. In the reverse half of the cycle, electrons are supplied by surface discharges on the dielectric and move toward the metal electrode. The time scale of the process depends on the gas composition, excitation frequency, and other parameters. In air and at atmospheric pressure, it occurs within a few tens of nanoseconds.
Although the generated plasma is composed of charged particles, it is net neutral because it is created by the ionization of neutral air and an equal number of negative electrons and positive ions exist in the plasma. The charged particles respond to the external electric field, and the electrons move to the positive electrode and the positive ions move to the negative electrode. This movement results in an imbalance of charges on the edges of the plasma that sets up an electric field in the plasma that is opposite to the externally applied electric field. The imbalance of charges on the edges of the plasma is due to the thermal motion of the charged particles in the plasma. The rearrangement of the charged particles continues until the net electric field in the plasma is neutralized.
Enloe et al. studied the space-time evolution of the ionized air light-emission over a surface mounted SDBD plasma actuator using a photo-multiplier tube (PMT) fitted with a double-slit aperture to focus on a narrow 2-D region of the plasma. (Enloe, L. et al., “Mechanisms and Responses of a Single-Dielectric Barrier Plasma Actuator: Plasma Morphology.” AIAA , Vol. 42, 2004, pp. 589-594.) The slit was parallel to the edge of the exposed electrode and could be moved to different locations over the other electrode that was covered by the dielectric.
FIG. 2 shows a sample time series of the results from Orlov. (Orlov, D. M., Modelling and Simulation of Single Dielectric Barrier Discharge Plasma Actuators , Ph.D. thesis, University of Notre Dame, 2006.) The top graph is a visualization of the of the PMT output that was acquired phase-locked with the AC input to the actuator. The lower portion of FIG. 2 shows the AC input supplied to the electrodes over the same time period. The light emission is taken as an indication of the plasma density, which is a good assumption based on the disparate time scales between the recombination time (order of 10 −8 sec) versus the discharge time scale (order of 10 −3 sec).
The explanation for the difference in the emission character in the two half-cycles shown in FIG. 2 is associated with the source of electrons. During the negative-going half cycle, the electrons originate from the bare electrode, which is essentially an infinite source that readily gives them up. In the positive-going half cycle, the electrons originate from the dielectric surface. These apparently do not come off as readily, or when they do, they come in the form of fewer, larger micro-discharges. This asymmetry has been modeled by Boeuf and Orlov and plays an important role in the efficiency of the momentum coupling to the neutrals. (Boeuf, J. et al. “Electrohydrodynamic force in dielectric barrier discharge plasma actuators.” J. Phys. D.: Appl. Phys ., Vol. 40, 2007, pp. 652-662; Orlov, D., Font, G., and Edelstein, D., “Characterization of Discharge Modes of Plasma Actuators.” AIAA J., Vol. 46, 2008, pp. 3142-3148.) It further suggests some optimization can come in the selection of the AC waveform to improve the performance of the plasma actuator.
Wall-mounted AC plasma actuators 10 with an asymmetric electrode design like that shown in FIG. 1 , induce a velocity field similar to that of a tangential wall jet. Enloe et al. correlated the reaction force (thrust) generated by the induced flow with the actuator AC amplitude. (Enloe, L., McLaughlin, T., VanDyken, Kachner, Jumper, E., Corke, T., Post, M., and Haddad, O., “Mechanisms and Responses of a Single-Dielectric Barrier Plasma Actuator: Geometric Effects.” AIAA, Vol. 42, 2004, pp. 595-604.) A similar experiment was performed by Thomas et al. to investigate parameters in the actuator design. (Thomas, F. et al., “Optimization of SDBD Plasma Actuators for Active Aerodynamic Flow Control,” AIAA J., Vol. 47-9, 2010, pp. 2169-2177.) At the lower voltages, the induced thrust of the AC plasma actuator 10 was found to be proportional to V 3:5 AC. This was first observed by Enloe et al. (“Geometric Effects.”) Thomas et al. verified consistency between the reaction force and the fluid momentum by integrating the velocity profiles downstream of the actuator. (“Optimization of SDBD Plasma Actuators”) Post found that the maximum induced velocity was proportional to V 3:5 AC, which is consistent with conserved momentum in the self-similar velocity profile region near the actuator. (Post, M. L., “Plasma actuators for separation control on stationary and unstationary airfoils” Ph.D. thesis, University of Notre Dame, 2004.) At the highest voltages, the thrust change with voltage still appears to follow a power law relation, although the exponent is smaller and not necessarily universally accepted. The voltage at which the power-law exponent changes is a function of the area of the covered electrode, with a smaller area causing the change to occur at lower voltages.
As indicated, the body force produced by AC-DBD plasma actuators occurs over a relatively short portion of the two-halves of the AC cycle. In addition, only the portion where the electrons leave the exposed electrode to be deposited onto the dielectric surface, contributes the significant amount of the net body force. This process of the AC body force generation is often referred to as “big push, little push.” It is known that at larger static pressures, with atmospheric pressure being considered part of that set, it is easier to ionize the air using AC. Ionizing the air makes it conductive and thereby responsive to the electric field.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a prior art AC plasma actuator.
FIG. 2 is a graph of the visually observed plasma output compared to the voltage of the prior art AC plasma actuator.
FIG. 3 is a schematic of an example pulsed DC plasma actuator in accordance with the teachings of the present disclosure.
FIG. 4 is an example assembled circuit for testing the pulsed DC plasma.
FIG. 5 is an example testing assembly for the pulsed DC plasma actuator.
FIG. 6 shows the example pulsed DC plasma actuator of FIG. 3 in operation generating plasma.
FIG. 7 is a graph of the voltage and current of the example pulsed DC plasma actuator of FIG. 3 over time.
FIG. 8 is a comparison of the force generation of different pulsed DC plasma actuator sizes.
FIG. 9 is a comparison of the force generation of the pulsed DC plasma actuator (2.5″) with the prior art AC design of FIG. 1 .
FIG. 10 is a comparison of the force generation of the example pulsed DC plasma actuator (5″) with the prior art AC design of FIG. 1 at various voltages.
FIG. 11 is a comparison of the force generation using different dielectric materials using different example pulsed DC plasma apparatus.
FIG. 12A is an example pressure testing set-up for an example pulsed DC plasma actuator.
FIG. 12B is an interior view of the example pressure testing set-up for the pulsed DC plasma actuator of FIG. 12A .
FIG. 13 is a comparison of the induced force of an example pulsed DC plasma actuator at various pressures and voltages.
FIG. 14 is a comparison of the slopes derived from the pressure data of FIG. 13 at various voltages.
FIG. 15 is a comparison of the slopes derived from the pressure data of FIG. 13 at various pressures.
FIG. 16 is a cross-sectional schematic of an example turbo-machine compressor application of pulsed DC plasma actuator.
FIG. 17 is a detailed view of the survey ring in the example turbo-machine compressor of FIG. 16 showing the placement of the pulsed DC plasma actuator in this example.
FIG. 18 is detailed illustration of an example survey ring and exploded view of the example survey ring.
FIG. 19 is a cross-section of the survey ring showing the construction of the example pulsed DC plasma actuator in place in the survey ring of FIG. 18 .
DETAILED DESCRIPTION
The following description of example methods and apparatus is not intended to limit the scope of the description to the precise form or forms detailed herein. Instead, the following description is intended to be illustrative so that others may follow its teachings.
Referring now to the figures, FIG. 1 shows an example prior art AC-DBD plasma actuator 10 including a pair of electrodes 102 and 104 , a dielectric 106 , and a power source 112 . The electrodes 102 and 104 are separated by dielectric 106 but both electrically connected to the power source 112 which is capable of producing an AC waveform. The electrodes 102 and 104 are supplied with an AC voltage from the power source 112 that causes the air over the covered electrode to ionize. The ionized air, in the presence of the electric field produced by the geometry of electrodes 102 and 104 , results in a body force vector field that acts on the ambient (non-ionized, neutrally charged) air or other fluid. The body force can be used as a mechanism for active aerodynamic control.
FIG. 2 shows a sample time series of the performance of the prior art AC-DBD plasma actuator 10 that is shown in FIG. 1 . The top graph is a visualization of the PMT output that was acquired phase-locked with the AC input to the actuator over approximately 600 microseconds. The lower portion of FIG. 2 shows the AC input supplied to the energized electrodes over the same time period as the upper graph portion.
An example pulsed DC plasma actuator 20 , disclosed herein, is illustrated as FIG. 3 . The example pulsed DC plasma actuator 20 includes a pair of electrodes 202 , 204 , dielectric 206 , a resistor 208 , a solid state switch 210 , and a DC voltage source 212 . The example micro-pulsed DC plasma actuator 20 is meant to be a hybrid approach that embodies at least some of the best aspects of AC and DC plasma actuators. As such, the example pulsed DC plasma actuator 20 arrangement disclosed herein is similar to most typical AC-DBD designs 10 , such as shown in FIG. 1 , with staggered electrodes 102 , 104 that are separated by a dielectric insulator 106 . However, for the example plasma actuator 20 , shown in FIG. 3 , instead of an AC voltage source 112 to drive the actuator, the pulsed-DC utilizes a power source, such as the DC voltage source 212 . The DC voltage source 212 is used because DC is better at producing a body force if the air is already ionized. It will be appreciated that this DC source into the device may be accomplished via any suitable power generation including for example, a power converter or a voltage rectifier from an AC source, like the AC power source 112 used in FIG. 1 .
As shown in the schematic for the pulsed-DC plasma actuator 20 in FIG. 3 , the DC voltage source 212 is electrically connected to both the exposed electrode 202 and the lower electrode 204 . Between the electrodes, the resistor 208 limits the current to the lower electrode 204 , which is also connected to a fast-acting solid-state switch 210 . The solid-state switch 210 , when closed, shorts the voltage to the lower electrode to the power supply ground from the DC voltage originally supplied. A periodic trigger signal consisting of a transistor-transistor logic (TTL) pulse is supplied to activate the solid-state switch 210 to deliver the micro-pulses to the electrodes 202 , 204 . This can be accomplished by an external controller or an internal signal generator. The pulse formed by the DC waveform produced by voltage source 212 and solid state switch 212 is a square wave with a floor of 0 V and a ceiling of the output voltage of voltage source 212 . In other examples, the pulse could be varied with frequency modulation to include different pulses lengths, and the DC waveform could also be constructed to regulate and control the voltage at either electrode 202 , 204 .
While the example pulsed DC plasma actuator 20 is shown extending from the surface in FIG. 3 , it will be appreciated that the pulsed DC plasma actuator 20 or any portion thereof may also be inserted into a recessed area of the surface so that it is flush with a surface when installed. This may be required for certain aerodynamic applications, such as wing or rotor placement. For instance, the exposed electrode 202 may be partially covered and the lower electrode 204 may be partially exposed. These electrodes can be composed of any suitable conductive material such as copper, etc. The dielectric insulator 206 , in this example, is ULTEM polyetherimide (PEI) tape, but it may also be made of any suitable electrically insulating material, for example, thin and flexible materials such as KAPTON polyamide tape or a thermoplastic film such as PEEK. It will be appreciated that the dielectric insulator 106 may also be a rigid material such as MACOR that is machineable and durable.
In this example, the fast-acting solid-state switch 210 consists of a stacked MOSFET design. The solid-state switch 210 used for the present results was a five device stack. It will be appreciated that the solid-state switch 210 could be any suitably fast switching device. A periodic trigger signal consisting of a TTL pulse was supplied to activate the MOSFET switch.
In the example pulsed DC plasma actuator 20 shown in FIG. 3 , the upper electrode 202 is exposed to the air or other fluid passing over the surface of the actuator. The lower electrode 204 is located under the dielectric layer 206 . When the pulsed DC plasma actuator 20 is energized, the solid-state switch 210 momentarily grounds the lower electrode 204 . The voltage supplied to the electrodes 202 , 204 may be static or variable. In the example, both are supplied with the output voltage of the power source 212 ; in other examples, the voltages may include an offset. If the exposed upper electrode 202 is an anode, electrons flow from conductive material into the dielectric via the ionized fluid. This provides greater force than a reversed arrangement where the exposed upper electrode 202 is a cathode. In the DC plasma actuator 20 , this provides superior efficiency by eliminating the reversing cycle of the prior AC plasma actuator 10 .
Referring still to FIG. 3 , the edges of the exposed upper electrode 202 and the covered lower electrode 204 are overlapped by a small amount in order to produce a more uniform plasma in the full spanwise direction of the surface. If no overlap is provided, the air gap between the electrodes 202 and 204 tends to break down at the applied voltage before the dielectric 206 . At atmospheric pressure, almost any available dielectric material has a dielectric strength and breakdown voltage superior to air, and therefore, air gaps typically are avoided in the design of the plasma actuator. If an air gap is present, the result is often a spanwise non-uniformity in the plasma, which tends to reduce the effectiveness of the plasma actuator.
As will be appreciated, the example pulsed DC plasma actuator 20 of FIG. 3 is a single dielectric barrier discharge (SDBD) plasma actuator. The example SDBD plasma actuator is stable at atmospheric pressure and any other pressure because it is self-limiting due to charge accumulation on the surface of the dielectric 206 . In other words, the behavior of the pulsed DC plasma actuator 20 is primarily determined by the buildup of charge on the covered, insulated lower electrode 204 . When the AC voltage source 212 applies an AC voltage, a plasma discharge appears on the surface of the dielectric 206 above the lower electrode 204 and directed momentum, defined by the body force vector f B , is coupled to the surrounding air. The body force vector f B may be tailored for a given application through the orientation and design of the geometry of the electrodes 202 and 204 . For example, the electrodes 202 and 204 may be designed to produce upstream or downstream oriented wall jets or streamwise vortices.
A picture of an example assembled circuit is shown in FIG. 4 which shows an inductive current sensor 402 and a high voltage probe 404 as part of a test setup for the actuator. The inductive current sensor 402 , in this example, is a Pearson Model 2100 seen as the thick ring in the background. The high voltage probe 404 is, in this example, a LeCroy Model PPE 20 kV. These two devices were used to record current and voltage time series supplied to the pulsed DC plasma actuator 20 . Analysis of these time series was used to correlate its effect on the thrust performance of the pulsed DC plasma actuator 20 . As the DC voltage source, this example used a high-voltage power source as DC voltage source 212 , in this example, a Glassman, Model PS/PH050R60-X18 (with a maximum voltage rating of 50 kV, and maximum current limit of 60 mA).
Referring to FIG. 5 , the thrust of the pulsed DC plasma actuator 20 can be measured by the test setup for the plasma actuator thrust measurements that is shown. The test setup includes a scale 502 , a truss 506 , and a waveform generator 508 . The thrust generated by the pulsed DC plasma actuator 20 was measured using the setup shown by mounting the pulsed DC plasma actuator 20 on an electronic force measuring scale 502 . The electronic force scale 502 was shielded from possible electronic noise by a covering of copper foil 504 . To further minimize electronic noise possibly generated by the plasma actuator operation, the actuator was suspended above the force measuring platen by a wooden truss 506 . The distance of the pulsed DC plasma actuator 20 from the electronic force scale was determined in separate experiments to be beyond that where any generated electronic noise by the actuator had any influence on the reading of scale 502 . The wire connections to the electrodes 202 , 204 were fine gauge coated copper wire. These run between the clips at the ends of the white leads to the electrodes 202 , 204 (made of copper in this setup) on the pulsed DC plasma actuator 20 .
As seen on the right side of FIG. 5 , the setup includes a variable frequency wave-form generator 508 , capable of frequency modulation in its output, and an oscilloscope 510 , in this example a 4-channel LaCroy digital oscilloscope (a WaveRunner model 6050A). The waveform generator 508 , sometimes referred to as a function generator, provides an input signal to a circuit 512 , shown as the white breadboard, that produces a narrow trigger pulse that was supplied to the stacked MOSFET circuit fast-acting solid-state switch 210 . The example repetitive pulse created by the energization of the power supply and triggered by the switch 210 is replicated every 1 millisecond. As mentioned above, in other embodiments the wave-form generator 508 could modulate the length of time between pulses to vary the length of time between pulses. A depiction of the plasma generated by the pulsed-DC operation is shown in FIG. 6 . There appears to be no discernible differences between the appearance of the plasma in the operation of the DC and AC plasma actuators.
Referring to FIG. 7 , the current and high-voltage time series to the pulsed DC plasma actuator 20 during operation were acquired and internally stored by the oscilloscope 510 . The oscilloscope 510 can sample at 50106 Samples/s. This monitoring rig had to be extensively modified from its stock configuration to achieve the granularity need to capture the example 0.1 millisecond pulses created by the pulsed DC plasma actuator 20 . The data was then transferred to a laptop computer where they were archived and post processed. An example of the simultaneously captured voltage and current time series data is shown in FIG. 7 .
FIG. 7 corresponds to a supply voltage, V ddH =7000 kV and an actuation frequency of 1000 Hz for a 2.5 in. long actuator. There are similar time series for every thrust measurement data point that will appear in subsequent figures. In FIG. 7 , the top plot shows two simultaneous voltage time traces. The trace with the sharp downward peaks is measured at the drain of the last power MOSFET in the chain output of the solid-state switch 212 . This is labeled V drain5 . It corresponds to the voltage time series that is supplied to the covered electrode of the pulsed DC plasma actuator 20 . The other voltage time trace labeled V ddH corresponds to the DC voltage that is supplied to the exposed electrode of the plasma actuator. The bottom plot in FIG. 7 corresponds to the time series of the current being supplied to the covered electrode of the pulsed DC plasma actuator 20 .
In further experiments, in order to reduce the current through the solid-state switch circuit, the actuator length was decreased by a factor of two, namely from 5 in. down to 2.5 in. The lower two pulsed-DC frequencies were also used to minimize current. The results are shown in FIG. 8 . A repeated set of thrust measurements for the 5 in. actuator is shown for comparison. The generated thrust for the 2.5 in. actuator was found to be approximately 3-times that of the 5 in. actuator. One would expect the thrust to scale by the length of the actuator therefore, this is an indication that the previous results were current limited. Therefore, accounting for the length of the actuator, the thrust-per-unit-length of the pulsed-DC plasma actuator 20 is approximately 6-times that of the AC plasma actuator.
Experiments were performed to document the induced thrust produced by a DBD plasma actuator mounted on a force measuring scale in the manner shown in FIG. 5 . For this, the pulsed DC plasma actuator 20 consisted of electrodes that were 2.5 in. in FIG. 9 and an electrode length of 5 in. in FIG. 10 . The dielectric layer consisted of two, 2 mil. thick layers of Kapton film. The actuator was operated either with an AC input in the manner shown in FIG. 1 , or with a pulsed-DC input as shown in FIG. 3 . The two approaches were categorized in terms of the amount of induced thrust produced by the two plasma actuator arrangements. The results are shown in FIGS. 9 and 10 . For the AC operation, the voltage scale is peak-to-peak voltage. For the pulsed-DC operation it is the DC voltage. During the experiments, the temperature and humidity in the lab were monitored. These were respectively 71F and 35% relative humidity.
The thrust of the AC plasma actuator 10 displays the characteristic power law relation namely, T˜V 3.5 . In contrast, the thrust generated by the pulsed DC plasma actuator is linear with the input DC voltage. Most notably, the thrust generated by the pulsed-DC plasma actuator operation is more than an order of magnitude larger than that produced by AC operation. In fact, the pulsed-DC thrust levels in FIG. 9 are larger than the largest thrust levels documented with AC plasma actuators, which occurred at 10-times higher voltages.
Referring to FIG. 11 , although a Kapton dielectric was used in the previous sample thrust measurements, it generally is not suitable for experiments that operate for long periods of time, since it is degraded by the ozone (O 3 ) generated by the plasma. Another dielectric material used is Ultem film, which is a PolyEtherImide (PEI) that is not affected by exposure to O 3 . It has a dielectric strength of approximately 3 kV/mil, which is verified in tests. The dielectric strength of Ultem film is approximately half that of the Kapton film, however this is not a critical issue with the lower voltages of the pulsed-DC operation. Experiments were performed to compare the thrust generated with the Ultem film dielectric against those with the Kapton film. The thickness of the Ultem film used in these experiments was 3 mil.
Continuing to referring to FIG. 11 , the thrust comparison between the Ultem and Kapton dielectric materials with the 2.5 in. long actuators is shown in the graph. Two pulsed-DC frequencies of 500 Hz and 1000 Hz are presented. In general, the thrust produced with the Ultem dielectric was less than that with the Kapton at the lower voltages. The change in the thrust with voltage was however higher with the Ultem, so that at the higher voltages, the thrust produced with the two different dielectric materials were comparable.
Referring to FIGS. 12A-12B , experiments were performed to examine the effect of static pressure on the thrust produced by the pulsed-DC plasma actuator. The experiments consisted of placing the thrust measuring setup shown in FIG. 5 and discussed above inside of a cylindrical pressure vessel 1202 . FIG. 12A shows a depiction of the exterior of the pressure vessel 1202 and its interior, with the pulsed DC plasma actuator 20 mounted on the electronic force measuring scale 502 . The pressure vessel 1202 was sealed to prevent air leakage when pressurized. The power to the pulsed DC plasma actuator 20 as well as a voltage proportional to the force exerted on the electronic scale 502 were transferred by high-pressure electronic connectors in the pressure vessel wall. A visual reading of the force scale display was also performed through the viewing window in the pressure vessel 1202 .
The air pressure inside the vessel 1202 , as shown in FIG. 12B , was set using an air compressor and monitored with a dial pressure gauge. The air was filtered with a 1 micron in-line filter. The pressure inside the vessel 1202 was changed slowly, in discrete steps. The temperature of the air inside the chamber was allowed to reach thermal equilibrium with the outside temperature in the laboratory before measurements were taken. This temperature was nominally 25 C. The air in the chamber was frequently purged. In addition, repeatability checks were performed that included purging and re-pressurizing the air in the vessel 1202 .
The results of the pressure tests of the pulsed DC plasma actuator 20 are shown in FIGS. 13 and 14 . FIG. 13 shows the change in the generated thrust as a function of the static pressure for different pulsed-DC voltages. At any voltage, the thrust generally decreases with increasing static pressure until it reaches a minimum at approximately 80 psig (6.44 bar), and then begins to increase. This behavior is similar to that found by Valeriotti and Corke for the AC powered plasma actuator, although the pressure of the minimum thrust in that case was at a lower static pressure of 14.7 psig (2 bar). (Valerioti, J. and Corke, T. C., “Pressure Dependence of Plasma Actuated Flow Control.” AIAA J ., Vol. 50, 2012, pp. 1490.)
The data in FIG. 13 was re-plotted in FIG. 14 to illustrate the change in the generated thrust as a function of the DC voltage for the different static pressures. This illustrates that at any of the static pressures, the thrust varies linearly with DC voltage. The slopes of the linear transfer function, dT=dV DC for each of the static pressures is shown in FIG. 15 . This mimics the pressure dependence of the thrust at any of the voltage levels that was shown in FIG. 12 . This is somewhat in contrast with the AC plasma actuator where the exponent of the power-law relation between the generated thrust and voltage increased with increasing pressure even in the portion up to 2 bar pressure where the thrust was decreasing. The exponent of the AC actuator eventually saturated for pressures above 6 bar.
Referring to FIG. 16 , another example of the pulsed-DC driven plasma actuator 20 , shown in FIG. 3 , is used in a turbo-machine compressor 1600 . The turbo-machine compressor 1600 includes a survey ring 1602 , a rotor 1604 , a gear box 1606 , and magnetic bearings 1608 . In this example, the pulsed DC plasma actuator 20 is combined with itself as seven additional arc segments of pulsed DC plasma actuator 20 will be added to cover the full azimuth of the survey ring 1602 . This 1.5-stage compressor is powered by a 298 kW (400 HP) variable RPM electric motor (not shown) that is connected to the rotor 1604 through a gear box 1606 that spins the rotor up to 15,000 RPM. With a 45 cm. (18 in.) diameter rotor 1604 , the tip Mach number at the highest RPM is 1.2. The rotor 1604 spins on magnetic bearings 1608 that provides static and dynamic tip gap control. A cut-away schematic of the flow path design is shown in FIG. 15 .
Referring now to FIGS. 17-19 , extensive experiments have been performed to investigate the effects of circumferential groove casing treatments for stall control. Ross developed a functional relationship between the surge margin extension due to a casing treatment. (Ross, M., Tip Clearance Flow Interaction with Circumferential Groove Casing Treatment in a Transonic Axial Compressor ., Ph.D. thesis, University of Notre Dame, 2013.) This considered a one dimensional control volume that involved a balance between axial momentum in the tip-leakage flow and the drag force produced by the casing grooves. This is embodied in the following relation:
Cd cv Q O πD ( x 0 −x zs )=η r K A c {tilde over (Q)}τC ax −F g (1)
in which F g is the drag force produced by the casing grooves, {tilde over (Q)} is the momentum flux of the tip-leakage flow per unit area, C d cv is the experimentally determined drag coefficient for the control volume, Q 0 is the approach flow momentum per unit area, x 0 is the virtual origin of the tip leakage jet, x zs is the axial location of the line of zero axial shear, π is the pressure ratio across the blade row, P t3 /P 1 ,τ is the tip gap dimension, D is the compressor annulus outer diameter, r is the blade count of the rotor, C ax is the rotor blade axial chord, and K Ac is the actual-to-approximate tip leakage jet axial momentum ratio.
Referring to FIG. 17 , the example of the pulsed DC plasma actuator 20 in the turbo-machine compressor 1600 is shown. In this example, we substituted the drag force produced by the casing grooves with the body force produced by the pulsed-DC plasma actuator. This is shown schematically in FIG. 17 . The schematic shows what is believed to be the optimum actuator location on survey ring 1602 , which is at the leading edge of the row of compressor blades 1702 . The choice of this location for the plasma actuator 20 is based on Vo et al. who suggested a criteria for stall inception in which reverse flow in the tip-gap region moves forward (upstream) of the blade row leading edge, designated as x blade le in FIG. 16 . (Vo, H., Tan, C., and Greitzer, E., “Criteria for Spike Initiated Rotating Stall.” J. Turbomachinery , Vol. 130, 2008, pp. 011023.) The actuator location is therefore intended to resist the upstream motion of the reverse flow front. This is believed to be the mechanism by which casing grooves suppress stall.
The upstream edge of the reverse flow on the casing wall that is caused by the tip leakage will be marked by a stagnation line where the wall shear stress is zero. Its location is denoted as x zs . Therefore Equation 1 can be rearranged to solve for x zs , namely
x
zs
C
ax
=
x
0
C
ax
-
η
r
π
K
A
c
Cd
cv
Q
~
Q
O
τ
D
+
1
π
F
p
Cd
cv
Q
O
D
(
2
)
where F p is the plasma actuator body force. Many of the quantities in Equation 2 such as {tilde over (Q)}, π, x 0 , K A c , and C d cv came from Ross for a smooth casing reference. At stall, x zs =0, therefore Equation 2 can be solved for Q 0 in terms of a known compressor geometry and other constant values known from previous experiments. Having Q 0 , allows the approach Mach number to be determined by which, assuming isentropic flow relations, the approach flow static pressure, P 1 , can be found. The total pressure downstream of the rotor, P t2 , is then found from P 1 (P t2 =P 1 ) where P t2 =P 1 the known pressure ratio across the compressor rotor. Thus, the total pressure rise across the rotor at stall, π s2 , is computed.
Again assuming isentropic flow, the approach static temperature, T 1 , is found based on the approach flow Mach number and total temperature. The approach flow density, ρ 1 is then found assuming an ideal gas relation. Having ρ 1 and Q 0 , the approach flow velocity can be found. Finally with the approach flow velocity, in flow cross-section area, and air density, ρ 1 , known, the mass flow at stall, {dot over (m)} s2 is determined.
Assuming the same design point performance, the stall margin extension (SME) is defined as the difference between the stall margin with the pulsed DC plasma actuator 20 (subscript 2) and that with the smooth casing without the actuator (subscript 1). This is given by Equation 3.
SME
=
π
d
m
.
d
(
m
.
s
1
π
s
1
-
m
.
s
2
π
s
2
)
(
3
)
A Matlab script was generated to solve Equations 2 and 3, as well as perform the other ancillary calculations needed in their solution. Based on actuator body force of 300 mN/m shown in FIG. 9 , a stall margin extension of 3.4% was obtained by the active intervention of one example of the pulsed DC plasma actuator 20 . This equation shows that the pulsed DC plasma actuator 20 can be used to dynamically suppress traveling stall cells.
Referring to FIGS. 18-19 , a schematic drawing of the pulsed DC plasma actuator 20 implementation for stall control is shown installed on the survey ring 1602 such as that shown in FIG. 16 . The pulsed DC plasma actuator 20 is located in a specially designed survey ring 1602 that becomes part of the outer casing of the turbo-machine compressor 1600 directly over the compressor rotor 1604 . In this example implementation, the actuator assembly covers only 41.6° arc segment of the ring. Of this, the plasma actuator length covers 31.8°.
As shown in FIG. 18 , ports 1802 are placed in the survey ring 1602 to accept pairs of pressure transducers 1804 on both azimuthal sides of the pulsed DC plasma actuator 20 . The purpose of these pressure transducers 1804 is to detect the passage of traveling stall cells that are known to form prior to a fully stalled condition. Fasteners 1806 are used to secure the pieces of survey ring 1602 together, which can be other mechanical fasteners, chemical adhesives, or neither.
Referring to FIG. 19 , the implementation of plasma actuator 20 into the design of the turbo-machine compressor 1600 involves machining an azimuthal cavity around the inside of the survey ring 1602 . The cavity will be filled by an electrically insulating ring that has an azimuthal recess to allow the insertion of a copper lower electrode 204 . The copper electrode, in this example, is split into in azimuthal segments, or may cover the complete circumference, depending on the scale and design of the pulsed DC plasma actuator 20 . The insulating ring 1902 with the inset copper covered electrode 204 in this example is covered by 2-4 mil thick Ultem tape. This total assembly is flush with the inside wall of the survey ring 1602 , which forms the casing wall over the rotor 1604 . The exposed electrode 202 will be attached to the surface of the Ultem tape. Again, the design allows for full flexibility in the location and orientation of the exposed electrode 202 in order to control the induced flow to the needs of the situation.
The materials in the example shown in FIGS. 18-19 were chosen based on their electrical and mechanical properties. The materials that are inset in the aluminum survey ring 1602 all have a coefficient of thermal expansion that is close to, but slightly larger than that of aluminum. Therefore, as the compressor 1600 heats up during operation, the aluminum survey ring 1602 will remain tight and not over-stress the survey ring. As mentioned above, the Ultem tape for the dielectric layer 206 has excellent electrical properties for the pulsed DC plasma actuator 20 . Ultem has been utilized in numerous plasma flow control experiments. The exposed electrode 202 extends approximately 1 mil (0.001 in) above the casing wall. The nominal tip-gap between rotor 1604 and survey ring 1602 in this example is 0.020 in.
In the example shown in FIGS. 16-19 , the velocity vector imparted on the fluid is used to control the lift of the of the compressor blades 1702 . The pulsed DC plasma actuator 20 can also be used dynamically to control the flow of the air flowing over the compressor blades 1702 . It will be appreciated that this use and its specific parameters pertain to just one example of the application of the pulsed DC plasma actuator 20 . Similarly, the dynamic flow control of the pulsed DC plasma actuator 20 can be used to improve heat conductivity in an air duct, reduce dynamic stall, or reduce turbulent fluid flows that cause noise in a helicopter rotor, airplane landing gear, or within an AC system. The pulsed DC plasma actuator 20 can be used to reduce drag on the surface by manipulating the fluid flow increasing range and efficiency of ground or air based vehicles. The drag reduction can also be used to prevent frictional heating of a hypersonic vehicle in flight. The force imparted by the pulsed DC plasma actuator 20 can be used to initiate convective airflows even in a sealed environment or provide a small amount of propulsion to a satellite at high orbit. The pulsed DC plasma actuator 20 can also be used to efficiently generate plasma for dynamic electromagnetic shielding. In addition to these uses of the pulsed DC plasma actuator 20 , one of ordinary skill in the art will be able to apply the induced flow created by the pulsed DC plasma actuator 20 for other uses and in other applications including plasma generation, control of separated flow, stall reduction, motionless airfoils, thrust generation, or a number of other uses. Further, it will be appreciated that the parameters of the example apparatus may be varied to suit the situation where the plasma actuator 20 is being used.
Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. | A plasma generating device intended to induce a flow in a fluid via plasma generation includes a dielectric separating two electrodes and a power supply. The first electrode is exposed to a fluid flow while the second electrode is positioned under the dielectric. The power supply is electrically coupled to a switch and the first and second electrodes. When the power supply is energized by repeated action of the switch, it causes a pulsed DC current between the electrodes which causes the fluid to ionize generating a plasma. The generation of the plasma induces a force with a velocity component in the fluid. | 7 |
[0001] This application is a continuation of U.S. Application Ser. No. 10/125,827 filed Apr. 18, 2002, now U.S. Pat. No. 6,931,768.
FIELD OF THE INVENTION
[0002] The devices and methods described below relate to skateboarding shoes and particularly to the design of the sole of skateboarding shoes.
BACKGROUND OF THE INVENTIONS
[0003] A skateboard is controlled primarily through the rider's feet. Greater control of a skateboard may be provided by appropriate footwear and allow the rider to perform more skateboard tricks, such as ollies, kickflips, and crooks, with a greater degree of mastery. Any shoe designed for use during skateboarding should be designed to appropriately transmit forces between the rider's foot and the skateboard. In other words, the shoe should be designed to account for the required force transfer used by a skateboard rider to control the skateboard. In addition, the shoe should be designed to provide the rider with a better grip of the skateboard. In particular, the shoe should provide a better grip in the ollie area of the shoe. The skateboard shoes described below provide a structure which provides an appropriate grip between the shoe and a skateboard and facilitates appropriate force transfer between the skateboard and a rider.
SUMMARY
[0004] The shoes described below provide for improved force transfer during skateboarding. The sole of the shoe comprises three pads where the shoe contacts a skateboard. The sole area corresponding to the outside front of the foot is made from a low durometer material that aids in gripping the skateboard. The sole area corresponding to the inside front of the foot (the ball of the foot) is made from a moderate durometer material that provides both gripping ability and durability. The sole area corresponding to the heel of the foot is made from a high durometer material to enhance direct force transfer and to provide high wear resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows the sole of a skateboarding shoe.
[0006] FIG. 2 shows the medial side of a skateboarding shoe.
[0007] FIG. 3 shows the lateral side of the skateboarding shoe shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0008] FIG. 1 shows the sole 1 of a skateboarding shoe. The sole comprises a lateral pad 2 , a toe pad 3 , a medial pad 4 , and a heel pad 5 . These pads are provided in materials having differing hardness in order to promote the forces applied by skateboarders to the skateboard during use.
[0009] The lateral pad 2 and toe pad 3 have a durometer value in the range of about 53 Shore A to about 57 Shore A. The lateral pad 2 and toe pad 3 may be made of many compounds of appropriate hardness, and a suitable compound comprises 29.5% standard Malaysian rubber, 35.4% butadiene rubber (polybutadiene rubber or high-cis polybutadiene rubber such as BR01™ or Taktene™), 3.9% butyl rubber, 25.5% silica (such as Zeosil™, or other dispersing agent), 4.9% plasticizer (such as paraffinic process oil (P Oil) or naphthenic process oil) and 0.8% coupling agent (such as Silane or any other chemical used to adjust the curing properties of the rubber). The pads may comprise different weights of the same materials, or may comprise similar materials, though the pads should have a relatively soft durometer value.
[0010] The lateral pad is disposed generally on the lateral side of the sole and the toe pad is disposed generally in the forefoot region of the sole. The two areas are referred to as the ollie area by skateboarders, because it is the area of the shoe to perform an ollie. The lateral pad may be integrally formed with the toe pad. As an integral whole, the lateral pad 2 and the toe pad 3 are located on the anterior portion of the lateral midfoot 6 , the lateral portion of the forefoot 7 , and the anterior portion of the forefoot 8 .
[0011] The lateral pad may also be treated or coated with substances to provide a moderate degree of tackiness. In one embodiment butyl rubber provides the required tackiness. The relative softness (and tackiness, if enhanced) of the lateral pad enhances the friction, or “grip,” between the pad and the shoe during all maneuvers in which the skateboarder attempts to apply lateral force to the board with a swiping or lateral movement of the foot across the board.
[0012] The medial pad 4 has a durometer value in the range of about 56 Shore A to about 60 Shore A. The medial pad may be made of many compounds of appropriate hardness, and a suitable compound comprises 19.3% standard Malaysian rubber, 38.5% butadiene rubber (polybutadiene rubber or high-cis polybutadiene rubber such as BR01™ or Taktene™), 9.6% nitrile butadiene rubber, 27.0% silica (such as Zeosil™, other dispersing agent), 4.8% plasticizer (such as paraffinic process oil (P Oil) or naphthenic process oil), and 0.8% coupling agent (such as Silane or any other chemical used to adjust the curing properties of the rubber). The pad may comprise different weights of the same materials, or may comprise similar materials, though the pad should have a relatively moderate durometer value as compared to the lateral pad and the heel pad. In the embodiment shown in FIG. 1 , the medial pad 4 is located in the area of the sole corresponding to the ball of the foot (the medial portion of the forefoot 9 ) and the anterior portion of the medial midfoot 10 .
[0013] The heel pad 5 has a durometer value in the range of about 60 Shore A to about 64 Shore A. The heel pad 5 may be made of many compounds of appropriate hardness, and a suitable compound comprises 19.1% standard Malaysian rubber, 38.2% butadiene rubber (polybutadiene rubber or high-cis polybutadiene rubber such as BR01™ or Taktene™), 9.5% nitrile butadiene rubber, 28.6% silica (such as Zeosil™, or other dispersing agent), 3.8% plasticizer (such as paraffinic process oil (P Oil) or naphthenic process oil) and 0.8% coupling agent (such as Silane or any other chemical used to adjust the curing properties of the rubber). The pad may comprise different weights of the same materials, or may comprise similar materials, though the pad should have a relatively hard durometer value.
[0014] The heel pad is located in the area of the sole corresponding to the heel 11 . However, the heel pad 5 can also extend somewhat into the midfoot region as shown in FIG. 1 (where the heel extends into the posterior portion of the lateral midfoot 12 ). The heel pad may also be referred to as the heel if provided in a discrete form. The relative hardness of the heel pad promotes efficient application of downward force on the skateboard during maneuvers in which the skateboarder must assert downward force.
[0015] With this construction of sole, the heel pad is harder than the medial pad, and the medial pad is harder than the lateral pad or toe pad. However, the toe pad and lateral pad typically have the same durometer value. The remaining portion of the outsole that is not covered by the pads 2 , 3 , 4 , and 5 , located in the arch area 13 (the area of the sole under the arch of foot when the shoe is worn), shank area 14 , and midfoot area 15 , may be made of any suitable material, such as phylon or molded ethyl vinyl acetate. The arch and midfoot region of the outsole may be integrally formed with the midsole of the shoe, and may be referred to as an exposed area of the midsole even though it functions as the outsole.
[0016] Each pad may have an embossed or raised tread pattern. In the embodiment shown in FIG. 1 the lateral pad 2 and toe pad 3 tread pattern comprises a series of contour lines 16 . The medial pad 4 and heel pad 5 tread patterns comprise a series of raised treads 17 . The particular shape of the treads illustrated in this drawing is a trademark of DC Shoes, Inc., though any other tread pattern may be used. Other trademarks 18 may be applied at various positions on the sole.
[0017] FIG. 2 shows the medial side of a skateboarding shoe 25 with the sole 1 attached to the shoe upper 26 . Disposed on the medial side of the shoe are a medial heel side pad 27 , a medial side pad 28 , and a toebox pad 29 . The medial heel side pad 27 comprises materials similar to those materials that comprise the heel pad 5 . The medial heel side pad has a durometer value in the range of about 60 Shore A to about 64 Shore A. The medial side pad 28 comprises materials similar to those that comprise the medial pad 4 . The medial side pad has a durometer value in the range of about 56 Shore A to about 60 Shore A. The toebox pad 29 comprises materials similar to those materials that comprise the lateral pad 2 and toe pad 3 . The toebox pad has a durometer value in the range of about 53 Shore A to about 57 Shore A. The medial heel side pad, medial side pad, and toebox pad allow the skateboard rider to use the toes and the inside edge of the foot to more effectively control the skateboard.
[0018] The medial heel side pad 27 and the medial pad 28 may cover a larger area and thus cover part of the upper 26 . Likewise, the toebox pad 29 may cover a larger portion of the toebox 30 . The toe pad 3 may be integrally formed with the toe box pad 29 , the medial pad 4 may be integrally formed with the medial side pad 28 , and the heel pad 5 may be integrally formed with the medial heel side pad 27 . Thus, the medial heel side pad 27 may form an upwardly extending extension of the heel pad 5 . Similarly, medial side pad 28 may form an upwardly extending extension of the medial pad 4 , and the toe box pad 29 may form an upwardly extending extension of the toe pad 3 .
[0019] FIG. 3 shows the lateral side of a skateboarding shoe 25 . Disposed on the lateral side of the shoe are a lateral heel side pad 32 , a lateral side pad 33 , and the toebox pad 29 . The lateral side heel pad 32 comprises materials similar to those materials that comprise the heel pad 5 . The lateral heel side pad has a durometer value in the range of about 60 Shore A to about 64 Shore A. The lateral side pad 33 comprises materials similar to those materials that comprise the lateral 2 pad and the toe pad 3 . The lateral side pad 33 has a durometer value in the range of about 53 Shore A to about 57 Shore A.
[0020] The lateral heel side pad 32 and the lateral side pad 33 may cover a larger area and thus cover more of the upper 26 . The toebox pad 29 may cover a larger portion of the toebox 30 . The lateral pad 2 , the lateral side pad 33 , and the toe box pad 29 may be integrally formed with each other. Likewise, the heel pad 5 and the lateral heel side pad 32 may be integrally formed with each other. Thus, the lateral heel side pad 32 may form an upwardly extending extension of the heel pad 5 . Likewise, lateral side pad 33 and the toebox pad 29 may form upwardly extending extensions of the lateral pad 2 or the toe pad 3 .
[0021] Together, the heel pad 5 , the medial heel side pad 27 , and lateral heel side pad 32 may form an integral heel pad. The integral heel pad may be disposed on the portions of the of the shoe corresponding to the medial side of the heel, the lateral side of the heel, the counter portion of the heel, and the portion of the sole corresponding to the plantar portion of the heel. Likewise, the lateral pad 2 , the toe pad 3 , the lateral side pad 33 , and toebox pad 29 may form an integral ollie pad. The integral ollie pad may be disposed on the portions of the shoe corresponding to the toe box, the lateral side of the shoe, and the portions of the sole corresponding to the plantar portion of the toes and the plantar portion of the lateral side of the foot.
[0022] In use, the shoes constructed as described will be worn by a skateboarder while skateboarding. For maneuvers which require application of downward force to the skateboard, the rider will apply force in the customary fashion, by stomping on the board with the heel or other parts of the foot, but such forces will be applied more efficiently than they would with typical athletic shoes. For maneuvers which require application of lateral forces on the skateboard, the rider will apply force in the lateral direction in the customary manner, by swiping the board with the outer or inner edge of the shoes, but the swiping force will be more efficiently transferred to the skateboard vis-à-vis the same action with typical athletic shoes. Thus, the rider will have more control over the skateboard and will be better able to perform tricks and maneuvers.
[0023] The skateboard shoe described above can be made with many modifications from the materials and specific construction shown in the illustrations. Many elastomers and plastics can be used in place of the materials mentioned, which are merely the currently preferred materials. The specific structure of the pads may be varied while providing substantial coverage of the corresponding areas with the desired hardness and interoperability with the rider and skateboard. The pads need not be discrete, and may be co-molded or integrally formed as a single piece with areas of differing hardness corresponding to the illustrated pads, and they may be co-molded or integrally formed with the midsole or other components of the shoe. Thus, while the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims. | A skateboard shoe having a sole with four sole pads; each sole pad having differing durometer values: a lateral pad and a toe pad comprised of a low durometer value (Shore A) material, a medial pad comprised of a moderate durometer value (Shore A) material, and a heel pad comprised of a hard durometer value (Shore A) material. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority to European Application EP 16180569.2 filed 21 Jul. 2016, the complete disclosure of which is expressly incorporated by reference herein in its entirety for all purposes.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of financial transactions made from a financial account. More particularly, the present disclosure relates to a method for initiating financial transactions to a designated entity and the subsequent processing of the financial transaction. Moreover, the disclosure relates to a computer program and a computer readable medium. The computer readable medium comprises computer-executable instructions, which, when executed by the respective devices being equipped with processors cause the devices to perform the method steps of the disclosure on the respective device interacting with the respective other device.
BACKGROUND
[0003] Electronic financial transactions have become more and more important in daily life. Many of these financial transactions are nowadays based on dedicated applications running on a terminal accessed by a user providing an interface interconnecting the merchant with a financial account of the user. The involved processes often do not require direct interaction with further means of payment, e.g. with a debit or credit card, as the respective information is stored in the application, e.g. as a softcard, or is accessible by the application. Examples for such financial transactions are, amongst others, cashless payment on a website or mobile payment and digital wallet services executed on a mobile device such as a smartphone. Especially the latter is suitable for substituting payments by cash and therefore render the requirement to carry cash for many people obsolete.
[0004] However, certain entities such as charitable organisations, especially those directly collecting small amounts of money, rely on people carrying cash. Especially when people are carrying small amounts of cash with them, they tend to donate small amounts e.g. to collecting boxes which are positioned close to a cash register or at the exit of a store or the like. Even though electronic financial transaction methods are suitable for transferring money, their use for handling such small amounts which are donated easily is often considered inefficient and inconvenient. As a consequence thereof, the evolvement of cashless living reduces the possibilities for charitable organisations to get donations.
[0005] Accordingly, in the light of the increasing importance of cashless living, there is a requirement to provide technical solutions to connect these kind of entities into electronic financial transaction procedures.
SUMMARY OF THE INVENTION
[0006] The present disclosure provides one or more solutions to the problems and disadvantages existing due to evolved payment and cash handling behaviour. Other technical advantages of the present disclosure will be readily apparent to one skilled in the art from the following description and claims.
[0007] The present disclosure is directed to a computer implemented method for collecting and processing electronic donations, i.e. financial transaction from a financial account of a user to a financial account of at least one destination entity, such as the financial account of a charitable organisation, initiated by the user at a user terminal, the method comprising:
providing an electronic donation application to be executed on the user terminal; presenting, via user selection of a recipient for the electronic donation, at least one destination entity as potential recipient for the electronic donation; receiving, via the electronic donation application, a user selection of a recipient for the electronic donation together with the amount of the financial transaction for the donation; transmitting, from the electronic donation application, a donation request to a donation processing server, the request including the amount of the financial transaction, the designated recipient for the financial transaction, user information and electronic account information; storing the donation request, by a collection application executed on the donation processing server; transmitting at least one financial transaction request from the donation processing server to a payment service provider for processing the financial transaction from the financial account of the user to a donation receiving entity, wherein the at least one financial transaction request is transmitted when the amount(s) specified in the donation request(s) stored by the collection application exceed a predefined threshold amount and/or after a predefined period of time has lapsed; receiving, at the donation processing server, a financial transaction confirmation receipt from the payment service provider, indicating that the financial transaction has been processed; transmitting, from the donation processing server, a donation confirmation to the selected destination entity, the donation confirmation containing at least the amount corresponding to the designated recipient and the user information.
[0016] The present disclosure includes multiple aspects for collecting and processing electronic donations from an electronic account of a user, initiated by the user on a user terminal via an electronic donation application executed on the user terminal. The user account may be linked to a credit card or a debit card issued by a card issuer. The electronic donation may be in form of an electronic financial transaction request requesting the transfer of money from the respective account to a destination entity. Non-limiting examples of electronic financial transactions are payments made on e-commerce, cashless payments at point-of-sales making use of a soft card installed on a user terminal, bank transfers initiated via a user interface executed on or accessible through a user terminal and to be processed from a user account or the like.
[0017] A user terminal may be any device connected to a network such as the internet and providing an interface to interact, directly or indirectly, with the donation processing server and to receive instructions from the user to initiate a payment, such as smartphones, personal computers, tablet computers configured to execute a respective application or capable to connect to a respective web-service over a network.
[0018] An electronic donation application may be a dedicated application for a user terminal and executed on the user terminal. Alternatively, the electronic donation application may be in the form of a plugin, an inFrame solution, an SDK or the like implemented on a website used for requesting and processing electronic financial transaction, e.g. a credit card payment interface. The electronic donation application may be implemented to be presented in the same window or frame of the website or the application or may be opened as a new window or frame. The electronic donation application may also provide a communication interface for the user to communicate with a donation processing server held by the card issuer for initiating, processing and authorizing electronic financial transactions. The electronic donation application may also communicate directly with the payment service provider (PSP) in order to request processing of the electronic financial transaction. Alternatively, the donation processing server may communicate directly with the PSP. The PSP may inform the user via the electronic donation application directly or via the donation processing server about the status of the electronic financial transaction.
[0019] The donation processing server may be any hardware and/or software, e.g. a virtual machine, used to receive, transmit and/or process the request for the financial transaction initiated by the user. Accordingly, the donation processing server communicates with the user via the electronic donation application executed on the terminal.
[0020] After the electronic donation application is provided to the user, either executed on the user terminal or accessible through the user terminal, a list of potential recipients is presented to the user for selection as destination entity for the electronic financial transaction. The list of potential recipients may be in form of a database located on the donation processing server or on a server on a donation receiving entity subsequently distributing donations to the final destination entities.
[0021] The user selects, via the electronic donation application, a recipient of the donation to be processed as an electronic financial transaction, as well as the amount for the electronic financial transaction. The amount for the electronic financial transaction may either be based on a user selection or may be determined based on other parameters selected by the user.
[0022] Both, the selected recipient and the amount or the kind of amount determination may be stored in an electronic configuration file created by the electronic donation application and as such may be used as preferences and/or suggestions for further donation requests. The electronic configuration file may be stored on the user terminal and/or on the donation processing server. The electronic configuration file may be accessed by the electronic donation application after identification and/or authentication of the user.
[0023] After the user has made the above selections or has confirmed the suggestions presented based on the information stored in the electronic configuration file, a donation request is transmitted from the electronic donation application to the donation processing server. The request may include the amount of the electronic financial transaction, the designated recipient for the donation, user information and information related to the electronic account to be used for the electronic financial transaction. The electronic donation application may request, prior to transmitting the donation request, confirmation and/or authentication of the user in order to authorize the request. Alternatively, the donation processing server, after receiving the donation request, may send a confirmation and/or authorization request to the electronic donation application to be presented to the user of the user terminal. In non-limiting examples, these requests may ask for a password or a PIN code or for biometric authentication of the user.
[0024] After the donation request is received by the donation processing server, it is stored by a collection application executed on the donation processing server. The collection application may store various donation requests for joint processing. The processing of the donation request(s) may be initiated based on certain predefined criteria, such as the amount(s) specified in the donation request(s) and stored in the collection application till a predefined threshold amount is exceeded and/or after a predefined period of time has lapsed. Accordingly, if the sum of the stored donation requests or the value of the only stored donation request exceeds the threshold amount, the requests proceed to processing. In addition, or alternatively, processing may be triggered after a predefined period of time has lapsed; according to this, stored donation requests may be processed e.g. once a month, independent from the amount. Alternatively, donation requests may be processed in a time independent manner if the collection of requests has exceeded the threshold amount.
[0025] Processing of the donation request includes transmitting financial transaction requests corresponding the donation requests from donation processing server to the respective entity in charge of processing the electronic financial transaction. If the electronic financial transaction is a bank transfer to be made from a bank account, the request is transmitted to the respective responsible bank. If the electronic financial transaction is to be made from a debit or a credit card, the request is send to the PSP for processing.
[0026] After processing of the financial transaction request at the respective responsible entity, a financial transaction confirmation receipt, indicating that the electronic financial transaction has been processed and has become effective, is received by the donation processing server. After the electronic financial transaction has been processed and confirmed, a donation confirmation may be sent to the selected destination entity, wherein the donation confirmation includes at least information regarding the amount and the corresponding user information. Alternatively, or in addition, a donation confirmation may be sent to the user via the electronic donation application executed on the user terminal for presentation to the user or it may be sent by different means for to the user, e.g. by email.
[0027] In another aspect of the present disclosure, the electronic donation application may be integrated in a payment processing application executed on or accessed by the user terminal from processing financial transactions from a user financial account over a network. According to this, the electronic donation application may be in form of a plugin, an inFrame solution, an SDK or the like implemented in the merchant's web site or in a dedicated application for a the user terminal, e.g. a credit card payment processing application for a mobile device such as a smart phone, used for processing and authorizing financial transactions initiated or requested by the user. A non-limiting example for a financial transaction to be processed from a user's financial account may relate to a purchase made by the user, which should be paid by the credit or debit card of the user associated a financial account of the user.
[0028] In yet another aspect of the present disclosure, the donation may be associated to a purchase made by the user. According to this, every time the user initiates a financial transaction such as a purchase which is to be paid by electronic payment, the electronic donation application suggests a donation. The suggestion may be based on information contained in the electronic configuration file. Alternatively or in addition, the donation request may be automatically initiated. When the donation is associated to a financial transaction initiated by the user, the amount of the purchase may by determined automatically. Automatic determination may be based on rounding of the amount or based on a fixed percentage of the amount of the financial transaction. The determination process may also include certain threshold levels used for rounding or associated to predefined percentage levels.
[0029] In yet another aspect of the disclosure, the financial transaction for the donation may be combined by the electronic donation application with the other financial transaction initiated by the user, e.g. with the financial transaction for the purchase resulting in a single combined financial transaction request. In this case single combined financial transaction request contains at least information related to the amounts of the donation and the financial transaction initiated by the user as well as information regarding the destination entities for the donation and the financial transaction initiated by the user. As such, two separated financial transaction are transmuted together to the donation processing server as a single transaction request for further processing of the respective payments.
[0030] In a further aspect of the disclosure, the donation processing server, having received the combined financial transaction request, splits the request into a financial request for the financial transaction initiated by the user, e.g. the purchase initiated by the user, and a financial donation request. The resulting financial transaction initiated by the user is processed normally, e.g. send to the PSP for payment, while the financial donation request is stored by the collection application on the donation processing server for further processing.
[0031] In another aspect of the disclosure, in case the destination entity the user would like to make a donation to is not included in the list presented by electronic donation application, the user may request inclusion of said destination entity. After the user has entered and submitted the respective information in an inclusion request to the donation processing server, the request may be processed directly by the donation processing server to include the requested destination entity into the request. Alternatively, a subsequent request may be sent to an intermediary subsequently distributing donations to the final destination entities. After the requested destination entity has been added, either by the intermediary subsequently distributing donations to the final destination entities or by the donation processing server, a confirmation message is presented to the user via the electronic donation application indicating the requested destination entity is now available for selection.
[0032] The present disclosure is also directed to a computer program product comprising program instructions for carrying out each of the method steps of the disclosure, when said product is executed on a computer.
[0033] Further, the present disclosure is directed to a computer readable medium storing program instructions, which, when executed by a processor of a computer cause the computer to perform each of the method steps of the disclosure.
[0034] One advantage that may be realized in the practice of some embodiments of the described methods is that financial transactions initiated and requested by a first user or owner of a joint account can be controlled, approved and authorized by a second user or owner of the joint account. Other technical advantages of the present disclosure will be readily apparent to one skilled in the art from the following description of preferred embodiments and the claims.
[0035] Various embodiments of the present application obtain only a subset of the advantages set forth. No single advantage is critical to the embodiments. Any claimed embodiment may be technically combined with any other claimed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The accompanying drawings illustrate exemplary embodiments of the disclosure and serve to explain, by way of example only, the principles of the disclosure.
[0037] FIG. 1 shows a flowchart of the user initiated single transaction electronic donation collection and processing method;
[0038] FIG. 2 shows a flowchart of the combined transaction electronic donation collection and processing method; and
[0039] FIG. 3 shows a block diagram showing the entities involved in the collection and processing method for electronic donation.
DETAILED DESCRIPTION
[0040] The present disclosure will now be described more fully hereinafter with reference to the accompanying figures, in which preferred embodiments are shown. The method, however, may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. It should be noted that these figures are intended to illustrate the general characteristics of the methods utilized in certain embodiments. However, the figures may not precisely reflect the precise structure or performance characteristic of any given embodiment. Moreover, in the figures similar reference numerals designate corresponding parts throughout the different views or embodiments.
[0041] FIG. 1 is a flowchart illustrating exemplarily the overall steps for collecting and processing electronic donation from an electronic account of a user. In step 101 an electronic donation application is provided and executed on a user terminal.
[0042] At step 102 the electronic donation application checks for an electronic configuration file associated to the user and/or the user terminal. If an electronic configuration file exists, a destination entity and a donation amount are presented 102 a to the user based on the information of the electronic configuration file. If no electronic configuration file exists, a list of possible destination entities and a selection interface for the donation amount is presented 102 b to the user. In the present case, the content of the list corresponds to destination entities included in the services of an intermediary subsequently distributing donations to destination entities elected to receive donations.
[0043] At step 103 the electronic donation application receives user input for the donation request, either in form of confirmation of a suggestion based on the electronic configuration file or on user selection. In addition, if no electronic configuration file exists, or upon user input, the electronic donation application prompts information regarding the financial account to be used.
[0044] At step 104 the electronic donation application transmits a donation request to a donation processing server, wherein the request includes at least information regarding the amount for the donation, the designated recipient for the donation, user information and electronic account information.
[0045] At step 105 , responsive to receiving the donation request at the donation processing server, a collection application being executed on the donation processing server stores the donation request.
[0046] At step 106 , the donation processing server checks whether a predefined condition for (joint) processing of stored donation requests, namely the sum of the donation request(s) exceeding predefined threshold and/or after a predefined period of time lapsed after receiving the donation request is met. If a predefined condition is met, the stored donation request(s) is/are processed (step 107 ) and the corresponding financial transaction requests are sent to the PSP that processes the transaction as any other transaction, for example authorisation, clearing and settlement steps. As a donation receiving entity is in charge of subsequently distributing donations to the final destination entities, all financial transactions are directed to the donation receiving entity's account. If none of the conditions are met, the donation processing server continues to collect donation requests until a condition is met.
[0047] At step 108 , the donation processing server receives a financial transaction confirmation receipt from the PSP, indicating that the financial transaction(s) is/are processed and has/have become effective. Subsequently, at step 109 , a donation confirmation is sent from the donation processing server to the donation receiving entity subsequently distributing the donations, wherein the donation confirmation includes at least the amount of the donation corresponding to the designated recipient and may also include the corresponding user information.
[0048] FIG. 2 is a flowchart illustrating exemplarily the overall steps for collecting and processing electronic donation from an electronic account of a user associated to another financial transaction initiated by the user, i.e. a purchase to be paid by electronic payment. In step 201 an electronic donation application integrated into a credit card payment processing application is executed on a user terminal.
[0049] At step 202 the electronic donation application checks for an electronic configuration file associated to the user and/or the user terminal. If an electronic configuration file exists, a destination entity and a donation amount are presented 202 a to the user based on the information of the electronic configuration file. If no electronic configuration file exists, a list of possible destination entities and a selection interface for the donation amount is presented 202 b to the user. In the present case, the content of the list corresponds to destination entities included in the services of a donation receiving entity subsequently distributing donations to destination entities elected to receive donations. As the donation is associated the purchase initiated by the user, further to fixed donation amounts, the amount may further be determined, either by rounding or percentage based, in relation the amount of the purchase made.
[0050] At step 203 the electronic donation application receives user input for the donation request, either in form of confirmation of a suggestion based on the electronic configuration file or on user selection. As the donation will be associated to the purchase, the same credit card will be used for the donation.
[0051] At step 204 the electronic donation application integrated into the payment processing application combines the individual requests, i.e. the donation request and the purchase request, into one single combined financial transaction request.
[0052] At step 205 the combined financial transaction request is transmitted to a donation processing server, wherein the request includes at least information regarding the amount for the donation, the designated recipient for the donation, amount of the purchase, recipient of the purchase amount, user information and credit card information.
[0053] At step 206 , responsive to receiving the combined financial transaction request at the donation processing server, the donation processing server splits the combined request into a donation request and a purchase request.
[0054] At step 207 the donation request is stored by a collation application being executed on the donation processing server and the purchase request is sent for processing of the payment to the PSP.
[0055] At step 208 , the donation processing server checks whether a predefined condition for (joint) processing of stored donation requests, namely the sum of the donation request(s) exceeding predefined threshold and/or after a predefined period of time lapsed after reception of the donation request. If a predefined condition is met, the stored donation request(s) is/are processed (step 209 ) and sent to the corresponding financial transaction requests are sent to the PSP. As a donation receiving entity is in charge of subsequently distributing donations to the final destination entities, all financial transactions are directed to the donation receiving entity's account. If none of the conditions are met, the donation processing server continues to collect donation requests until a condition is met.
[0056] At step 210 , the donation processing server receives a financial transaction confirmation receipt from the PSP, indicating that the financial transaction(s) is/are processed and has/have become effective. Subsequently, at step 211 , a donation confirmation is sent from the donation processing server to the donation receiving entity subsequently distributing the donations, wherein the donation confirmation includes at least the amount of the donation corresponding to the designated recipient and may also include the corresponding user information.
[0057] FIG. 3 is a block diagram showing the entities involved in the method for collecting and processing electronic donations from a user account. The user 300 having an electronic account 301 associated to a credit card 311 accesses a user terminal 302 executing are accessing a electronic donation application 303 . The user terminal 302 is connected to a network 304 and by this the electronic donation application 303 can communicate with a donation processing server 305 . The donation processing server 305 executes a collection application 306 and communicates with a PSP 307 and with a donation receiving entity 308 having an account 309 and in charge of subsequently distributing donations to the final destination entities 310 . The collection application 306 stores donation requests from at least one user and monitors for conditions to be met for bulk-processing of the stored donation requests. The conditions are either that the sum of the stored donation requests exceeds a predefined threshold of a predefined period of time having lapsed after receiving the donation request.
[0058] After at least one of the conditions is met, the donation requests are processed. For this reason, the requests are transmitted to the PSP 307 and according to the donation requests, money is transferred from the electronic account 301 of the user to the account 309 of the donation receiving entity 308 . After the financial transactions have been processed by the PSP 307 , a transaction confirmation receipt is transmitted from the PSP 307 to the donation processing server 305 . Subsequently, the donation processing server 305 transmits a donation confirmation to the donation receiving entity 308 , wherein the donation confirmation contains the information necessary for distributing the donations to the designated entities 310 , i.e. at least the amount corresponding each of the designated recipient 310 . In addition, user information corresponding thereto can be included to allow subsequent issuing of the donation receipt from the designated recipient 310 to the user 300 .
[0059] This description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. | A method for collecting and processing electronic donations from an electronic account of a user, initiated by the user at a user terminal, includes presenting, on an electronic donation application, potential recipients for the electronic donation; receiving a user selection of a recipient for the electronic donation together with the amount of the financial transaction for the donation; and transmitting a donation request including the amount of the financial transaction, the designated recipient for the financial transaction, user information and electronic account information to a donation processing server. Further steps include storing the donation request, by a collection application executed on the donation processing server for further processing when a predefined condition is met; and receiving, at the donation processing server, a financial transaction confirmation receipt from the payment service provider and transmitting, a donation confirmation to the recipient. | 6 |
TECHNICAL FIELD OF THE INVENTION
This invention pertains to an improved capacitive structure of a type comprising a group of capacitive layers, each of which includes a dielectric substrate and a metallized area on one surface of the dielectric substrate and which are arranged such that the metallized areas on alternate layers extend to opposite edges of the capacitive structure, and opposed masses of conductive material, each of which covers one such edge of the capacitive structure and provides electrical connections to the metallized areas extending to the same edge. A capacitive property is exhibited where the metallized areas overlie one another.
BACKGROUND OF THE INVENTION
Capacitive structures of the type noted above are exemplified in U.S. Pat. Nos. 4,462,062, 4,448,340 and U.S. Pat. No. 4,531,268. These patents disclose that such a capacitive structure may be advantageously made by winding, in overlying relation on a drum, two webs of polymeric film, each providing a dielectric substrate. Each web of such film has a metallized coating on its upper surface, except for a narrow, longitudinal, demetallized zones, which may be scribed by laser means, and which divides the metallized coating into a relatively wide metallized area extending to and along one edge and a relatively narrow metallized strip extending to and along the other edge. The webs, which are of equal width, are offset laterally such that, as the webs are slit into parallel ribbons of uniform width before being wound on the drum, alternate ones of the successive layers of the overlying ribbons have their edges offset laterally in relation to the remaining layers. The resultant structure, which is called a "rope" because it has a tendency to be somewhat limp, is compressed at an elevated temperature so as to form a more rigid structure, which is called a "stick". A conductive, metallic mass, which typically is constituted by successive layers, e.g. an inner layer of aluminum applied by a metal-spraying process, a middle layer of copper applied by a metal-spraying process, and an outer layer of eutectic tin and lead solder applied by a dipping process, covers each edge of the overlying ribbon so as to provide electrical contacts to and between the metallized areas extending to and along such edge. The stick is sawed into discrete capacitors. In each capacitor, the conductive, metallic masses serve as electrodes, and a capacitive property is exhibited where the relatively wide metallized areas of the successive layers overlie one another. For further background, reference may be had to U.S. Pat. No. 3,670,378 and U.S. Pat. No. 4,229,865, which disclose other examples of capacitive structures of the type noted above.
Although capacitive structures of the type noted above as known heretofore have performed well in many applications, cracking can occur in their manufacture and in subsequent operations, particularly in capacitive structures more than approximately 0.1 inch thick. Cracking can introduce unwanted variability in the capacitive properties of such structures. Usually, when cracking occurs, a microscopic or macroscopic separation occurs between two layers of such a capacitive structure. Usually, such separation occurs between two central layers of the capacitive structure, at one of its sawed ends or at both of its sawed ends, whereby an unwanted cavity is formed in which ionic contaminants or other conductive contaminants can accumulate, which can reduce the dielectric resistance of the capacitive structure. Furthermore, some layers of the capacitive structure may break along a breaking line tending to be generally perpendicular to such separation, whereby the capacitance of the capacitive structure is reduced in an uncontrolled manner. Although there is no intention to be herein bound to any particular theory, it is believed that cracking occurs because opposite edges of the respective layers of metallized polymeric film are locked into the conductive, metallic masses providing electrical contacts, when the capacitive structures are subjected to thermal excursions, as explained below.
Typically, the discrete capacitors are heated to approximately 215° C. for thermal normalization, then cooled. Cracking (when it occurs) is observed when the discrete capacitors cool. Typically, the inner layers of the metallic masses noted above are aluminum, which expands at a rate of approximately 25×10 -6 cm/cm/°C. Typically, the polymeric film is a polyester film, such as a poly(ethylene terephthalate) film, which expands at a rate of approximately 17×10 -6 cm/cm/°C. Aluminum has a thermal conductivity of approximately 2.37 watts/cm/°C. as compared to poly(ethylene terephthalate) film, which has a thermal conductivity of approximately 1.54 × 10 -3 watts/cm/°C. Thus, each of the electrical contacts has a higher thermal conductivity and expands at a greater rate, as compared to the layers of metallized polymeric film. Consequently, the electrical contacts tend to separate the layers of metallized polymeric film before such layers expand. Furthermore, as cooling occurs, the electrical contacts tend to contract while the layers of metallized polymeric film tend to remain expanded. The outer layers of metallized polymeric film tend to cool before the inner layers cool, whereby the outer layers tend to form a rigid structure, to which the inner layers tend to conform as the inner layers cool. Since the upper, outer layers of metallized polymeric film, and the lower, outer layers of metallized polymeric film tend to compete for adherence of the inner layers of metallized polymeric film, the inner layers of metallized polymeric film thus tend to separate from each other, so as to form a crack.
A polyester film, such as a poly(ethylene terephthalate) film, is partially crystalline and tends to continue to crystallize with each temperature excursion. As such film continues to crystallize, such film tends to shrink. Such shrinkage tends to progress from the outer layers toward the inner layers and to contribute to cracking as discussed above.
Cracks seem to be also attributable to thermal expansion of adsorbed gases at metallized surfaces of the layers of metallized polymeric film. When the discrete capacitors are manufactured, and again when the discrete capacitors are soldered to substrates, the discrete capacitors can experience temperature changes from about 300K to about 500K, whereby such gases expand by a factor of 1.66 at constant pressure. While the expanding gases tend to separate the respective layers, the outer layers tend to cool before the inner layers cool and to form rigid, expanded structures, to which the inner layers tend to remain attached. Finally, as the central layers cool, a crack tends to form, which is bounded by concave surfaces of the layer of metallized polymeric film on opposite sides.
Because the respective layers tend to be well laminated, i.e., well adhered from layer to layer, very high forces are required to separate such layers. Sometimes, a crack steps through several layers before continuing between two adjacent layers. Such a step-form crack, which requires polymeric film layers to be sheared, demonstrates that such high forces tending to cause cracking are exerted. Frequently, a crack runs the entire width of a discrete capacitor and is sufficiently wide to allow light to pass through the crack, as may be easily seen under low magnification, possibly without any magnification. Cracks as wide as approximately 0.003 inch have been observed in discrete capacitors having a nominal thickness of approximately 0.16 inch. Occasionally, small cracks occur in the outer layers of such a structure, perhaps due to other crack-producing mechanisms.
Accordingly, there has been a need, to which this invention is addressed, for an improved capacitive structure, in which unwanted variability due to cracking is minimized.
SUMMARY OF THE INVENTION
Accordingly, this invention provides a capacitive structure of the type noted above, in which thermal stresses tending to cause some of its capacitive layers to delaminate from one another tend to be substantially relieved before any of such layers delaminate from one another.
The capacitive structure provided by this invention comprises an upper substructure and a lower substructure. Each substructure comprises a plurality of capacitive layers laminated in stacked relation to one another. Each capacitive layer includes a dielectric substrate and a metallized area, which covers a major portion of one surface of the dielectric substrate of such capacitive layer, and which extends only to one of its first and second edges. The metallized areas on alternate ones of the capacitive layers in each substructure extend to opposite edges. The first edges of alternate ones of the capacitive layers in each substructure extend beyond the first edges of the remainder of the capacitive layers in such substructure so as to form indentations along the first edges of such substructure. The second edges of alternate ones of the capacitive layers in each substructure extend beyond the second edges of the remainder of the capacitive layers of such substructure so as to form indentations along the second edges of such substructure.
Moreover, at least one separating layer is sandwiched between the upper and lower substructures. Each such separating layer is made of a material bonding less aggressively to at least one of the upper and lower substructures than the upper and lower substructures would bond to each other if each such separating layer were omitted. Preferably, and particularly but not exclusively, if the adjoining layers (between which the separating layer is sandwiched) are made of dielectric, polyester film, such as dielectric, poly(ethylene terephthalate) film, whether or not either of the adjoining layers has a metallized area on its surface facing the separating layer, the separating layer contains polytetrafluoroethylene, which bonds negligibly (if at all) to such a film. The separating layer may be conveniently applied by spraying a colloidal suspension of polytetrafluoroethylene in a liquid carrier containing a suitable binder. A discrete layer containing polytetrafluoroethylene at least at its opposite surfaces, such as a film containing or consisting essentially of polytetrafluoroethylene, may be alternatively used as the separating layer.
In a less preferred embodiment, the separating layer is a discrete layer containing polytetrafluoroethylene at least at its opposite surfaces, such as a film containing or consisting essentially of polytetrafluoroethylene, as disposed between an underlying one of the capacitive layers of the upper substructure and an overlying one of the capacitive layers of the lower substructure. In the less preferred embodiment, one of the adjoining layers (between which the separating layer is sandwiched) can have a metallized area on its surface facing the separating layer.
In a more preferred embodiment, the upper substructure comprises an underlying layer of dielectric, polyester film, preferably dielectric, poly(ethylene terephthalate) film, and the lower substructure includes an overlying layer of similar film. Also, the separating layer is a discrete layer containing polytetrafluoroethylene, as mentioned above, and is sandwiched between the underlying layer of the upper substructure and the overlying layer of the lower substructure. The underlying layer of the upper substructure and the overlying layer of the lower substructure may be a single piece, such as a flattened tube of such film, in a suitable width when flattened, or a folded piece of such film, in a suitable width when folded.
It is contemplated that the separating layer may be merely sandwiched between the dielectric substrate of a capacitive layer of one such substructure and an intervening layer of dielectric material, such as an underlying layer or an overlying layer as noted above, the intervening layer being sandwiched between the separating layer and the capacitive layers of one of the substructures. The separating layer may be conveniently provided by a thin coat applied by spraying, as noted above, or otherwise, to one surface of the intervening layer. Preferably, if a metallized surface of one of the capacitive layers would be otherwise exposed to a crack along the separating layer, the intervening layer covers the metallized surface.
In a most preferred embodiment, which is a refinement of the more preferred embodiment described above as comprising an overlying layer and an underlying layer, the separating layer is provided by a thin coat applied by spraying, as mentioned above, or otherwise to one surface of the underlying layer of the upper substructure or to one surface of the overlying layer of the lower substructure. Even if other materials are used for an underlying layer of the upper substructure and for an overlying layer of the lower substructure, and even if another material is used for the separating layer, it is advantageous to provide the separating layer by a thin coat applied by spraying, as mentioned above, or otherwise to one surface of an underlying layer of the upper substructure or to one surface of an overlying layer of the lower substructure, rather than to provide a discrete layer as the separating layer.
Furthermore, the capacitive structure provided by this invention comprises a first mass of conductive material covering and extending into the indentations formed along the first edges of the capacitive layers of the upper and lower substructures, so as to provide electrical connections to and between the metallized areas extending to the first edges of the capacitive layers of the upper and lower substructures, and a second mass of conductive material covering and extending into the indentations formed along the second edges of the capacitive layers of the upper and lower substructures, so as to provide electrical connections to and between the metallized areas extending to the second edges of the capacitive layers of the upper and lower substructures. The masses of conductive material bond the capacitive layers of each substructure to one another and bond the upper and lower substructures to each other with the separating layer sandwiched between such substructures. Conductive, metallic masses, as discussed above, may be advantageously used for the masses of conductive material of the capacitive structure provided by this invention.
During and following thermal normalization, the capacitive structure provided by this invention tends to crack preferentially between the separating layer and the adjacent layer, or between the separating layer and the adjacent layers on opposite sides of the separating layer, but not to crack elsewhere. After thermal normalization of such a capacitive structure, the capacitive structure can be then impregnated with wax, which tends to fill any crack between the separating layer and either of the adjacent layers, so as to prevent any ionic contaminants or other conductive contaminants from entering the crack and bridging the conductive, metallic masses providing electrical contacts.
These and other objects, features, and advantages of this invention are evident from the following description of a preferred embodiment of this invention with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a greatly enlarged, cross-sectional view of a capacitive structure constituting prior art, portions of such structure being broken out for illustration purposes, and a crack being shown between two capacitive layers of such structure.
FIG. 2 is a similarly enlarged, cross-sectional view of a capacitive structure constituting a preferred embodiment of this invention, portions of such structure being broken out for illustration purposes, and a crack being shown along a separating layer of such structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before a detailed description is given of a capacitive structure constituting a preferred embodiment of this invention, it is useful to consider a capacitive structure exemplifying prior art, as shown in FIG. 1. As shown in FIG. 1, a capacitive structure 10 comprises a group of capacitive layers 12, each including a dielectric substrate with metallized areas covering the upper surface 14 of the dielectric substrate, except for a narrow, longitudinal, demetallized zones 14a dividing the metallized surface 14 into a relatively wide area 14b and a relatively narrow strip 14c. Alternate ones of the capacitive layers 12, which are of equal width, are offset laterally in relation to each other such that alternate ones of the capacitive layers 12 have their edges offset laterally in relation to the remaining layers. Thus indentations 20 are formed along the left edges of the capacitive layers 12, and indentations 22 are formed along the right edges of the capacitive layers 12. An upper cover 16 and a lower cover 18, each being a single, thicker plate of dielectric material, are provided respectively at the top and bottom surfaces of the group of capacitive layers 12. A conductive, metallic mass 24, which may be constituted by an inner layer of aluminum applied by a metal-spraying process, a middle layer of copper applied by a metal-spraying process, and an outer layer of eutectic tin and lead solder applied by a dipping process, covers the left edges of the capacitive layers 12 and covers the left edges of the upper cover 16 and the lower cover 18. The inner, middle, and outer layers of the mass 24 are not differentiated in FIG. 1. The mass 24 extends above the upper cover 16, so as to form an upper flange 26 bonding the upper cover 16 to the capacitive layers 12 at the left side of the capacitive structure 10. The mass 24 extends beneath the lower cover 18, so as to form a lower flange 28 bonding the lower cover 18 to the capacitive layers 12 at the left side of the capacitive structure 10. Similarly, a conductive, metallic mass 30 covers the right edges of the capacitive layers 12 as well as the right edges of the upper cover 16 and the lower cover 18. The mass 30 extends similarly above the upper cover 16, so as to form an upper flange 32, and below the lower cover 18, so as to form a lower flange 34. The upper flange 32 and the lower flange 34 bond the cover plates 16, 18, to the capacitive layers 12 at the right side of the capacitive structure 10. Each of the lower flanges 28, 34, also serves as a stand-off foot, which elevates the lower cover 18 in relation to a circuit board or other substrate (not shown) to which the capacitive structure 10 may be surface mounted.
As shown in FIG. 1, a crack 38 has formed between two of the capacitive layers 12, namely two inner layers of the capacitive structure 10. As shown, some of the capacitive layers 12 adjacent to the crack 36 have broken, so as to form breaks 38 along a breaking line tending to be generally perpendicular to the crack 36. The crack 36 and the breaks 38 have introduced unwanted variability into the capacitive property of the capacitive structure 10.
In FIG. 2, a capacitive structure 100 constituting a preferred embodiment of this invention comprises an upper substructure 102 and lower substructure 104, is divided by an imaginary plane 106. The upper substructure comprises a group of capacitive layers 112, each including a dielectric substrate with metallized areas covering the upper surface 114 of the dielectric substrate, except for a narrow, longitudinal, demetallized zone 114a dividing the metallized surface 114 into a relatively wide area 114b and a relatively narrow strip 114. Alternate ones of the capacitive layers 112, which are of equal width, are offset laterally in relation to each other such that alternate ones of the capacitive layers 112 have their edges offset laterally in relation to the remaining layers 112. Thus, indentations 116 are formed along the left edges of the capacitive layers 112, and indentations 118 are formed along the right edges of the capacitive layers 112. An upper cover 120, which is a single, thicker plate of dielectric material, is provided at the top surface of the group of capacitive layers 112. The lower substructure 104 comprises a group of capacitive layers 122, which are similar to the capacitive layers 112, each of the capacitive layers 122 including a dielectric substrate with metallized areas covering the upper surface 124 of the dielectric substrate, except for a narrow, longitudinal, demetallized zone 124a dividing the metallized surface 124 into a relatively wide area 124b in a relatively narrow strip 124c. Alternate ones of the capacitive layers 122, which are of equal width, are offset laterally in relation to each other such that alternate ones of the capacitive layers 122 have their edges offset laterally in relation to the remaining layers 122. Thus, indentations 126 are formed along the left edges of the capacitive layers 122, and indentations 128 are formed along the right edges of the capacitive layers 122. A lower cover 130, which is similar to the upper cover 120, is provided at the bottom surface of the capacitive layers 122.
The upper substructure 102 is provided with an underlying layer 132 of non-metallized, dielectric material. The lower substructure 104 is provided with an overlying layer 134 of non-metallized, dielectric material. The overlying layer 134 is similar to the underlying layer 132 of the upper substructure 102, except that the overlying layer 134 of the lower substructure 104 is provided with a thin coat 136, which serves as a separating layer between the upper substructure 102 and the lower substructure 104, and which is made of a material that bonds less aggressively to the overlying layer 134 than the overlying layer 134 and the underlying layer 132 would bond to each other if the thin coat 136 were omitted, preferably a material containing polytetrafluoroethylene. The thin coat 136 may be conveniently applied by spraying a colloidal suspension of polytetrafluoroethylene in a liquid carrier containing a suitable binder, a preferred spray being Crown™ 6065 Permanent TFE Coating, as available commercially from Crown Industrial Products, of Hebron, Ill. Various oils and resins may be alternatively used. Preferably, so as to facilitate handling and loading, the underlying layer 132 of the upper substructure 102 and the overlying layer 134 of the lower substructure 104 have thicknesses of approximately 1 mil each. Thicker films may be more easily handled but unnecessarily add thickness and cost to the capacitive structure 100.
Preferably, the dielectric substrates of the capacitive layers 112, 122, are poly(ethylene terephthalate) film, and each of the aforementioned layers 132, 134, also is poly(ethylene terephthalate) film. Poly(ethylene terephthalate) film is preferred because of its dielectric properties and because of its ability to bond to itself and to the metallized areas on the capacitive layers 112, 122. Other dielectric materials may be alternatively used.
Although the aforesaid layers 132, 134, are shown as separate pieces, it is contemplated by this invention that such layers may be alternatively provided by a single piece, such as flattened tube of such film, in a suitable width when flattened, or a folded piece of such film, in a suitable width when folded. In either instance, each layer provided by flattening or folding may have a thin coat like the thin coat 136.
Moreover, it is contemplated by this invention that, rather than the thin coat 136 applied by spraying, as mentioned above, or otherwise on the overlying layer 134 of the lower substructure 104, one or more discrete layers containing polytetrafluoroethylene, preferably a single such layer, such as a film containing or consisting essentially of polytetrafluoroethylene, may be alternatively used as a separating layer between the upper substructure 102 and the lower substructure 104, whereupon the aforesaid layers 132, 134, or one of such layers 132, 134, may be entirely omitted. A suitable film is Teflon™ film from E. I. DuPont de Nemours & Company of Wilmington, Del. If both of such layers 132, 134, are omitted, or if one of such layers 132, 134, is omitted, a thin coat like the thin coat 136 may be directly applied by spraying, as noted above, or otherwise to the capacitive layer 112 lowermost in the upper substructure 102 or to the capacitive layer 122 uppermost in the lower substructure 104. It is preferable, whether the separating layer is provided by a thin coat like the thin coat 136 or by a discrete layer, to retain the overlying layer 134 of the lower substructure 102, since such layer 134 covers the metallized surface 124 of the capacitive layer 122 uppermost in the lower substructure 102. Such surface 124 would be otherwise exposed to any contaminants in any crack along the separating layer. Furthermore, as mentioned above, various oils and resins are useful instead of polytetrafluoroethylene.
A conductive, metallic mass 140, which may be advantageously constituted by an inner layer of aluminum applied by a metal-spraying process, a middle layer of copper applied by a metal-spraying process, and an outer layer of eutectic tin and lead solder applied by a dipping process, covers the left edges of the capacitive layers 112, the underlying layer 132 of the upper substructure 102, the overlying layer 134 of the lower substructure 104, and the capacitive layers 122, as well as the upper cover 120 and the lower cover 130. The inner, middle, and outer layers of the mass 140 are not differentiated in FIG. 2. The mass 140 extends above the upper cover 120 so as to form an upper flange 142 bonding the upper cover 120 to the capacitive layers 112. The mass 140 extends beneath the lower cover 130 so as to form a lower flange 144 bonding the lower cover 130 to the capacitive layers 112. A conductive, metallic mass 150, which may be similarly constituted, covers the right edges of the capacitive layers 112, the underlying layer 132 of the upper substructure 102, the overlying layer 134 of the lower substructure 104, and the capacitive layers 122, as well as the upper cover 120 and the lower cover 130. The mass 150 extends above the upper cover 120 so as to form an upper flange 152, and below the lower cover 130, so as to form a lower flange 154. Each of the lower flanges 144, 154, also serves as a stand-off foot, which elevates the lower cover 130 in relation to a circuit board or other substrate (not shown) to which the capacitive structure 100 may be surface mounted.
During and following thermal normalization, the capacitive structure 100 tends to crack preferentially between the separating layer provided by the thin coat 136 and the underlying layer 132 of the upper substructure 102, and possibly between the separating layer defined by the thin coat 136 and the overlying layer 134 of the lower substructure 104, but not to crack elsewhere. After thermal normalization of the capacitive structure 100, the capacitive structure 100 is impregnated with wax, which tends to fill any crack between the separating layer defined by the thin coat 136 and either of the adjacent layers, such as the crack 160 shown in FIG. 2 between the thin coat 136 and the underlying layer 132 of the upper substructure 102, so as to prevent any ionic contaminants or other conductive contaminants from entering the crack and bridging the conductive, metallic masses 140, 150. A suitable wax is Bee Square Amber™ wax, as available commercially from Petrolite Co., of Tulsa, Okla.
Herein, directional terms including "upper", "lower", "left", "right", "overlying", "underlying", "uppermost", and "lowermost", are referred o a capacitive structure in a convenient orientation, as shown in the drawing, but are not intended to limit this invention to any particular orientation.
Various modifications may be made in the capacitive structure provided by this invention without departing from the scope and spirit of this invention. | A capacitive structure, in which thermal stresses tending to delaminate its capacitive layers tend to be substantially relieved before such layers delaminate. The capacitive structure is divided into an upper substructure and a lower substructure, each comprising a plurality of capacitive layers, a separating layer being sandwiched between such substructures. The upper substructure comprises an underlying layer of dielectric material. The lower substructure comprises an overlying layer of dielectric material. The separating layer is provided by spraying a colloidal suspension of polytetrafluoroethylene in a liquid carrier containing a suitable binder onto one surface of one of such overlying and underlying layers. The separating layer bonds less aggressively to at least one of the substructures than the substructures would bond to each other if the separating layer were omitted. | 7 |
This is a continuation of copending application(s) Ser. No. 07/991,313 filed on Dec. 16, 1992 now U.S. Pat. No. 5,407,310.
The present invention is directed to oil spill recovery systems which can be rapidly deployed to confine and collect oil and other liquids floating on the surface of a body of water for subsequent disposal by suitable recovery systems.
BACKGROUND OP THE INVENTION
In the recovery of oil spills, it is essential that recovery operations begin as soon as possible after the spill. For this purpose new U.S. Coast Guard regulations require that oil tankers have available adequate systems for recovering all oil which could be released in the event of a spill. Such systems must be rapidly deployable and capable of operating in a fool-proof and safe manner to capture the maximum amount of oil floating on the surface of the water in the vicinity of the oil spill.
One proposed system for recovering spilled oil is described in U.S. Pat. No. 3,788,079 issued Jan. 29, 1974 to Kirk and Reynolds. This '079 patent describes a system wherein a cover is deployed over an oil spill by spreading it horizontally over the spill. In this system weights attached to lines connected to the periphery of the cover which is the tremendous fire hazard potentially created when a large explosive charge is detonated in the vicinity of an oil spill. Another disadvantage is the difficulty of assuring that all of the explosively propelled weights are discharged outwardly at the same time with the same velocity to assure uniform deployment of the cover by the outwardly propelled weights.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to an improved deployment system for a cover which is used to entrap floating oil. In a preferred form of the invention, the cover is deployed by gas propelled rockets which use, as a motor force, high pressure gas confined by the rockets. Such a system has the advantage that no explosive flames are created to activate the system or to provide the propelling force. The rockets are independently propelled and can, themselves, act as weights necessary to draw the edges of the deployed cover below the surface of the water to entrap the covered oil slick. Other novel features of the invention are the systems for holding the cover, venting the cover and storing the cover during initial deployment of the support carrying the cover with automatic release of the storage means as a result of the firing of cover deployment rockets.
Additionally, the preferred form of the invention involves means for assuring that the cover deploying rockets are activated only when they are in proper position to fully deploy the cover.
DETAILED DESCRIPTION OF THE INVENTION
In order that the invention may be more fully understood, reference should be had to the following detailed description taken in connection with the following drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagramatic side view of an inflated raft showing the cover before deployment held in a pocket with the firing tubes mounted above an inflated tower.
FIG. 2 shows the raft immediately after firing of the rockets, showing the initial stages of deployment of the cover.
FIG. 3 shows the raft with the cover deployed, the anchor released and oil entrapped.
FIGS. 4A and 4B show side and top views, respectively, of the inflated raft with the inflatable platform.
FIG. 5 is a plan view showing the pockets for holding the cover, the pocket backing and the air vent for releasing air from under the deployed cover. (For clarity, the cover is not shown)
FIG. 6 is a schematic partial sectional view showing a portion of the inflatable support, the vent, the pocket backing and a portion of the deployed cover.
FIG. 7 is a side and top view of the rocket firing tube assembly.
FIG. 8 shows a schematic sectional view of the power supply, control and the various sensors used for determining the proper time of firing.
FIG. 9 is a diagramatic view showing the arrangement of the bridle attached to the gas cylinder for deploying the cover when the gas rocket is activated.
FIG. 10 is a diagramatic schematic, partially cut away, drawing showing the arrangement of the firing mechanism for rupturing the disk which activates the rocket.
FIG. 11 is a side view of the canister for holding the raft.
FIG. 12 is a schematic diagramatic partially sectional view of the deflated raft and cover packed in the canister for storage, ready for deployment.
FIG. 13 is a schematic diagramatic view of the initial stages of inflation of the raft with the outer shell of the storage canister being discarded.
FIG. 14 shows a schematic diagrammatic partial view of the inflated raft with the cover deployed prior to releasing the anchor.
Referring now to FIGS. 1, 2 and 3, there is shown a diagramatic side view of the present invention illustrating the raft, the cover and the firing mechanism for deploying the cover.
In FIG. 1, the raft 10 is generally shown as an inflatable tubular ring 11 having an inflatable tower 12 which has a plurality of legs which support an inflatable upper platform 13. The rocket firing tubes 14 are carried by the platform 13. Lines 22 connect each rocket to an outer peripheral portion of the deployable cover. In a preferred embodiment of the invention, there are eight gas rockets, each connected to one of eight spaced points around the periphery of the cover. Only one of the deploying lines 22 is illustrated, being schematically shown as leading to the cover which is contained in the pocket 16.
In FIG. 2, the device is shown immediately after firing of all of the rockets showing the cover 24 being pulled out of the pocket 16.
In FIG. 3, the cover has been fully deployed and has trapped a mass of oil 100 under the deployed cover. As shown in this FIG. 3, an anchor 30 has been released and is attached, by means of lines 32, to equally spaced points around the perimeter of the cover. The anchor thus tends to pull the periphery of edges of the cover together.
Referring now to FIG. 4, there are shown plan and side views of the inflatable support 10 illustrating the eight individual tubes 11, the legs 12 and the platform 13 without any of the other equipment.
In FIG. 5, there is a plan view showing the opened pockets 16, the vents 17, the pocket backing 16A, all of which secure the deployable cover (not shown). These pocket covers are held together by hook and loop tabs 16B (of the type sold by Velcro) which are released during the deployment of the cover.
In FIG. 6, there is a diagramatic sectional view showing a cylindrical tube 11 and a leg 12. The pocket backing is shown at 16A and the pocket, partially opened, is shown at 16. A portion of the cover 24 is shown as being fully deployed. As can be seen, the vent 17 is held above the water line by the cylindrical tube 11. Thus, when the cover has been fully deployed the air trapped under the cover can vent rapidly through the vent 17 so that the deployed device has a minimal protrusion above the water line.
Referring now to FIG. 7, there are shown schematic side and plan views of the firing system 14 illustrating a plurality of tubes 40 which are to hold the rockets, each tube having a firing mechanism 42 and a rocket triggering mechanism 44 mounted on the inner ends thereof. As noted from FIG. 7, these tubes all project upwardly at a slight upward angle, on the order of 12°, from a plate 46.
In FIG. 8, there is schematically shown a fire control mechanism which is carried by the plate 46 which preferably supports the firing tubes 40. This control system consists of an x-motion sensor 50, a y-motion sensor 52 and an accelerometer 56. The motions sensed by these devices are fed to a power supply and control system 54. All of these are standard, commercially available items, preferred embodiments of the devices being described later in the specification.
In FIG. 9, there is shown a schematic diagramatic sectional view of a gas cylinder 72 which serves as the gas rocket. This cylinder carries a washer 70 at its rear end, this washer being connected to a bridle 23 which in turn is connected to the deployment lines 22 for deploying the cover 24 (see FIG. 2).
Referring now to FIG. 10, there is illustrated a detail of the gas rocket preferably employed in the present invention. This shows the location of a burst disk 75 which is to be ruptured by a cutter 76 carried on the end of a firing mechanism 42 which is activated by an ignitor 44.
As soon as an oil spill is encountered, the inflatable support is deployed over the spill. Dispersal of the system can be accomplished by dropping it from the side of the ship 200 (see FIG. 3) or towing it away from the side of the ship before deployment of the cover. Equally it can be dispersed from another vessel or from an aircraft 300 (see FIG. 3).
Normally, the device will be confined in a canister 80 (See FIGS. 11 & 12) which is adapted to fall away from the inflatable device when the capacitor is in the water and the raft starts to inflate. The activation of the inflation system is accomplished by remote control and occurs when the canister is in proper position.
As seen most clearly in FIG. 12, the raft 10 is stored in deflated condition in the canister 80 with all of the sections thereof in position to be inflated. Inflation is accomplished by a gas control and battery system 64. The anchor 30 is shown in the base 82 of the canister. The two halves of the canister are held together by breakable straps 83 which are too weak to resist the expansion force created by the inflating raft.
Inflation of the raft effectively disengages the inflatable raft from the canister 80 and will prevent the support 10 from sinking. FIG. 13 shows the raft partially inflated and being ejected from the lower half 82 of the canister, this lower half not yet having sunk. The upper half 81 has been discarded and is sinking. The lower half 82 is arranged to sink when the raft is fully inflated.
Once the raft has been fully inflated and is in position over an oil spill, a remote control device checks the circuits in the control system to see that all circuits are functioning properly. At this point, the system for firing the gas propelled rockets is activated. This system is preferably additionally controlled by the x and y sensors which check for pitch and roll of the platform 46. In addition, the accelerometer is read to make sure that the firing takes place at the top of a wave rather than in the trough. As a result, when the platform 46 reaches the top of a wave and is level, the eight rockets will be discharged by activating the firing mechanism 44 and the puncturing mechanism 42 which propelles the cutter 76 through the burst disk 75. This releases the gas pressure which drives the rocket out of the tube 14, pulling the cords 22 and deploying the cover 24 in its extended pattern.
At this point the raft 10, anchor 30 and inflation cylinder 62 are in the general position shown in FIG. 14. The anchor is still retained by a yoke 61 which leads to a wire 65 supporting the anchor 30. On command a remote controlled cutter 60 severs wire 65 and releases the anchor. FIG. 14 also shows the remote controlled gas release system for the inflation cylinder 62. As seen from FIG. 14, the lower case 82 has now sunk so that the anchor is free to fall to the full depth allowed by anchor line 32. If the lower case 82 has too much buoyancy, a controlled leak may be included in case 82 to provide a timed sinking. Equally, a valve timed to the inflation of the raft may permit flooding of case 82.
At this point the anchor release mechanism 60 is activated by remote control and the anchor 30 is allowed to fall. The dropping of the anchor 30 pulls on the lines 32 and draws the edges of the cover 24 down through the oil slick deep into the water to form the shape generally shown in FIG. 3. This confines the oil in a central portion of the cover underneath the raft 10.
During the operation of the deployment of the cover 24 and its collection underneath the raft, air is rapidly released from under the cover through the vent 17 which, in the preferred embodiment, preferably completely surrounds the cylinder 11. Since the vent is held above the surface of the oil and the water by the cylinder 11, oil cannot escape through this vent. After the oil has been collected, it can be retrieved from under the cover by a suitable pumping means which can be inserted under the edge of the cover or can be pushed through an opening in a portion of the vent.
In a preferred embodiment of the invention, the cover 24 is preferably 1.14 ounce rip stop nylon coated on one side in orange so as to be clearly visible. The cylinder, including the legs 12 and platform 13 are made of 4.70 ounce neoprene with rip stop nylon covering. The platform 46 is preferably a 30 inch circular flattened aluminum sheet 1/8th inch thick. The firing tubes are 2.610 inch ID×11 5/8 inch long extruded aluminum tubes. The vent is preferably "texulene" 13 to 14 ounces, (a PVC Vinyl coated polyester 17×12 weave). The bridles are preferably Kevlar Aramid fibers 0.062 inch in diameter and the lines 22 are preferably 5/16 inch braided nylon. The x and y sensors are preferably normal sensors used in industry such as a Honeywell Microswitch No. 9SS. The accelerometer is a piezoelectric type available from Setra Electronics. The firing system 44, preferably is a Whittaker ordinance 4406 thruster and the penetrating mechanism 42 is a stainless steel tube with a sharp cutting edge 76 for penetrating the rupture disk 75. A similar system can be used for severing the anchor retaining wire 65. These Whittaker thrusters are completely contained and can be used in an explosive atmosphere without danger. The rupture disk is preferably an Ansel 4526 rupture disk and the cylinder is preferably filled to a pressure of 3000 psi. As a propellant compressed nitrogen is preferred. Such a filled cylinder weighs 4.6 lbs. | A system for deploying a cover over an oil spill, to collect the spilled oil, uses a plurality of gas propelled rockets are attached to lines arranged around the periphery of the cover. Outward projection of the rockets spreads the cover, the weight of the expended rockets then pulling the edges of the cover below the water surface to trap the covered oil. Attitude detectors are preferably employed for preventing firing of the rockets when the rocket platform is not generally level. | 4 |
This application claims priority to U.S. patent application Ser. No. 10/026,227 filed Dec. 21, 2001 now U.S. Pat. No. 7,082,142 entitled “System and Method for Delivering Content in a Unicast/Multicast Manner.”
BACKGROUND OF THE INVENTION
The present invention relates to content delivery, and more particularly to a system and method for enabling multicast synchronization of unicast information streams.
In conventional packet, frame or cell based systems there are typically two modes of communication: point-to-point (also known as Unicast) and point-to-multipoint (also known as Multicast). Generally, Unicast is communication between a single sender and a single receiver over a network as opposed to multi cast which is a communication between a single sender and multiple receivers.
Multicast is a receiver-based concept: receivers join a particular multicast session group and traffic is delivered to all members of that group by the network infrastructure. The sender or content provider does not need to maintain a list of specific receivers since only one copy of a multicast message will pass over any link in the network, and copies of the message will be made only where paths diverge at a router. Thus multicasting yields many performance improvements and conserves bandwidth end-to-end in the network.
Some examples of multicasting applications include the transmission of corporate messages to employees, communication of stock quotes to brokers, video and audio conferencing for remote meetings and telecommuting, and replicating databases and web site information. Multicasting efficiently supports these types of transmissions by enabling sources to send a single copy of a message to multiple recipients who explicitly want to receive the information. This is far more efficient than requiring the source to send an individual copy of a message to each requester such as is done in a unicasting manner, in which case the number of receivers is limited by the bandwidth available to the sender. It is also more efficient than broadcasting one copy of the message to all nodes (broadcast) on the network, since many nodes may not want the message, and because broadcasts are limited to a single subnet.
In spite of the various benefits affording by multicasting, unicasting has the unequalled benefit and flexibility of allowing users to select different types of content at their leisure and on their specific timeframes as opposed to being bound by the constraints of a multicast presentation. For example, typically, once a multicasting sessions begins, those who request to join the multicast sessions thereafter will only receive the multicasted content from the point on at which they joined as to opposed to having the content start from the beginning as in conventional unicasting.
Accordingly, it would be desirable to have a system and method which combines and integrates the various benefits and savings attributed to both unicasting and multicasting.
SUMMARY OF THE INVENTION
The present invention is a system and method for enabling multicasting of unicasted content thereby advantageously incorporating the flexibility of unicast delivery with the efficiency of multicast delivery. In one embodiment, the present invention is a method comprising receiving a plurality of requests for unicast transmission streams, providing the plurality of unicast transmission streams, synchronizing the plurality of unicast transmission streams and replacing the synchronized plurality of unicast transmission streams with a multicast stream.
In one embodiment, the present invention is a method comprising synchronizing a plurality of separate unicasts and converging the plurality of synchronized unicasts into a single multicast, wherein the unicasts have been converged at the same point within each unicast.
In another embodiment, the present invention is a method comprising delivering a plurality of point-to-point communications to a plurality of users, converting the plurality of point-to-point communications into a point-to-multipoint communication and delivering the point-to-multipoint communication to the plurality of users.
In yet another embodiment, the present invention is a method for multicasting initially unicasted information streams, the method comprising processing a plurality of unicast streams to converge the plurality of unicast streams and converting the plurality of converged unicast streams to a multicast stream, wherein the multicast stream replaces the plurality of unicast stream without interruption of the stream content.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary system configuration of the present invention.
FIG. 2 illustrates another exemplary system configuration of the present invention.
FIG. 3 illustrates an exemplary content delivery configuration of the present invention.
FIG. 4 illustrates an exemplary content delivery configuration of the present invention.
FIG. 5 illustrates an exemplary content delivery configuration of the present invention.
FIG. 6 illustrates an exemplary sender configuration of the present invention.
FIG. 7 illustrates another exemplary method of the present invention.
FIG. 8 illustrates yet another exemplary method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , an exemplary system 10 is shown including, as way of illustration, an exemplary unicast/multicast sender 20 in communication with a number of exemplary receivers 30 , 32 , 34 , 36 and 38 . For illustrative purposes, five receivers are shown but it is contemplated that any number of receivers is possible herein, even amounts greatly exceeding five receivers. Exemplary receivers 30 , 32 , 34 , 36 and 38 are adapted to receive multimedia content provided by unicast/multicast sender 20 . As used herein, the term multimedia or multimedia content includes, although is not solely limited to, recorded and live video and audio clips and files, image files, digital music clips and files, movies, recorded books, archived television and radio programs, interactive multimedia netcasting, such as interactive netcasting of video, text, graphics, animation, music videos, television shows, movie trailers, and other multimedia. Unicast/multicast sender 20 and exemplary receivers 30 , 32 , 34 , 36 and 38 are in communication via one or more networks, not shown, which preferably includes unicast and multicast compatible architecture including the appropriate servers and routers for facilitating unicast and multicast communications. In the present invention, one or more of the networks may be involved in the transmission and delivery of information between the senders and receivers such as a public shared IP network spanning many countries and covering thousands of IP sub-networks and other public and private Intranets. The receivers in the present invention may be any one or more of a variety of user devices/players which may include a personal computer, a Web enabled TV terminal/settop, a car audio player, a handheld media player such as an MP3 player or digital Walkman-type device, a PDA and any other device with the ability to receive and play any number of multimedia selections.
In the present invention, the transmission of information between senders and receivers is best performed by utilizing high bandwidth signals, such as signals containing digital representations of one or more movies, audio selections and related multimedia, between widely separated locations which is commonly done via special connections to high bandwidth transmission lines which are interconnected to form a point-to-point connection from a source or sender, such as a multimedia server to a receiver, such as a client personal terminal or device. Existing communication systems that provide such interconnection are now capable of supporting broadband data communication on both an inter-subscriber terminal basis (such as through an exchange) or on a client-server to subscriber terminal basis. In either case, both the subscriber terminal and the infrastructure equipment may contain a dedicated transmitter/receiver device, such as a modem. For example, current broadband access systems that provide interconnection may user use copper cabling (i.e. “twisted pair” technology), coaxial, fiber based cable or combinations thereof, and conventionally employ two transmitter/receiver devices, such as two broadband modems, one at each end of the connection.
Referring still to FIG. 1 , exemplary receivers 30 , 32 , 34 , 36 and 38 are adapted to communicate with sender 20 through their respective networks such as their respective access networks or Local Area Networks (LANs), as described earlier herein. One exemplary connection may involve a broadband line, a T1/T3 line, Frame Relay (FR), ATM, an X.25 connection and/or a wireless connection of some sort. In accordance with the present invention, receivers 30 , 32 , 34 , 36 and 38 will request a unicast information stream, such as information streams 40 , 42 , 44 , 46 and 48 which are then provided to each requesting party or receiver by sender 20 . During this initial phase or unicast phase 50 , each of the information streams are provided or broadcast to each of the receivers in a unicast manner, e.g. a separate information stream is provided to each separate receiver. In accordance with the present invention and as described in more detail later herein, the various unicast information streams are merged or converged during a merging/convergence phase 60 . Upon reaching a convergence point 70 , the information streams are thereby provided in a multicast manner within multicast phase 80 . Advantageously, once the information streams are merged and provided in a multicast manner, the network(s) performs the replication functions necessary so that each receiver can receive the requested information stream. It is contemplated that other receivers in addition to the ones shown may join the multicast in a conventional manner and receive the multicast stream.
Referring now to FIG. 2 , another exemplary system configuration 210 is shown. In this embodiment, an exemplary unicast/multicast sender 220 is in communication with a number of exemplary receivers 230 , 232 , 234 , 236 and 238 . Exemplary receivers 230 , 232 , 234 , 236 and 238 are adapted to communicate with sender 220 via unicast and multicast connections. In accordance with this embodiment of the present invention, receivers 230 , 232 , and 234 are receiving information via a multicasted information stream 240 . In conjunction therewith, receivers 236 and 238 are initially receiving unicasted information via unicasted streams 250 and 252 during a unicast phase 260 . During this initial phase or unicast phase 260 , each of the information streams are provided or broadcast to each of the receivers in a unicast manner, e.g. a separate information stream is provided to each separate receiver. In accordance with the present invention and as described in more detail later herein, the various unicast information streams are merged or converged during a merging/convergence phase 270 . Upon reaching a convergence point 280 , the previously unicasted information streams are thereby provided in a multicast manner within multicast phase 290 . In one embodiment, the unicast streams are merged into multicast stream 240 or alternatively, a separate multicast stream may be provided to receivers 236 and 238 . Advantageously, once the information streams are merged and provided in a multicast manner, the network(s) performs the replication functions necessary so that each receiver can receive the requested information stream.
Referring to FIGS. 3-5 , some exemplary content provisioning scenarious are shown which more fully illustrate the workings of the present invention. Referring to FIG. 3 , a multimedia complex or server 300 is provided which has the capability to deliver multiple streams of a multimedia event, such as a video, audio or other related event. For exemplary purposes, multimedia server 300 is shown delivering six streams of a single thirty minute long multimedia event, multicast streams A, B and C and unicast streams X, Y and Z. These six streams serve fifteen exemplary customers, C 1 -C 15 . In this example, each of customers C 1 -C 12 is viewing one of the three multicast streams A, B and C, while customer C 13 views unicast stream X, customer C 14 views unicast stream Y, and customer C 15 views unicast stream Z.
Referring still to FIG. 3 , it is assumed for exemplary purposes that stream A starts at a time of 3:10, stream B at 3:20, stream C at 3:30, stream X at 3:31, stream Y at 3:35 and stream Z at 3:39. For purposes of this exemplary embodiment, the multicast streams start at specific ten minute intervals while the unicast streams start at more random times. The times shown are merely provided for illustrative purposes only so that the teachings of the present invention can be more fully described. Referring now also to FIG. 4 , assuming that the current time is 3:39 and that at 3:40 the multicast event being streamed at A (shown in FIG. 3 and having started at 3:10) will end and then a new stream D will start from the beginning, i.e. thereby maintaining a constant of three multicast streams. As one possible application, this invention could slow Unicast stream Z by a factor of approximately 10% which would bring it into sync with stream D in less than 10 minutes. For example, every minute that transpires, stream unicast stream Z would be 1/10 th closer in synchronization with stream D. If the stream being provided is, for example, contains a digitized movie, then unicast stream Z and multicast stream D would be on approximately the same frame or scene with the digitized movie within the span of approximately ten minutes. In accordance with the present invention, once the streams are synchronized or have met a certain convergence point, then unicast stream Z could be discontinued and customer C 15 would be switched to watching multicast stream D, as shown in FIG. 5 .
In the present invention, any speed up or slow down in the speed of any content provided to a user, such as a multimedia presentation, is preferably be done with consideration of the user experience. While any change in speed is technically possible the best experience for the customer comes from a change that is not noticeable. Different material would have different tolerances to changes in speed of presentation. It is conceivable that a percentage change in speed in the range of approximately 1 to 10% may be applicable in many circumstances but theoretically, any change is speed is possible, so long as the user experience is not adversely affected.
In accordance with the present invention and as described with reference to FIGS. 1-5 , the entities requesting content from the multimedia server, such as any number of clients, customers or users are connected to a network and are capable of joining in and participating with a uni/multicast session on the network. It is contemplated that the clients, customers or user are connected to the network through an Internet connection having access to conventional netcasting routers thus enabling Unicast and Multicast IP communications between the clients, customers or users and the provider of the content, such as the multimedia server. The clients, customers or users may be connected to network or networks over a Plain Old Telephone Service (POTS) dial-up connection, an ISDN connection or an Asynchronous Digital Subscriber Loop (ADSL) connection, each to a Local Exchange Carrier (LEC) (not shown) and from there to an Internet Service Provider (ISP) (not shown), which in turn is connected to the IP network through an appropriate router. Alternatively, a client, customer or user can be connected to an ISP through a cable modem over cable facilities through a cable TV provider. Even further, the client, customer or user could be connected to a LAN and to a customer premises router to a UR over, for example, a Wide Area Network (WAN), T1 facilities, Frame Relay, ATM, or X.25. Of course other possible connections and combinations of connections are possible so long as transmission from a content service provider, such as a multimedia server, to the appropriate content requestor is enabled.
Referring to FIG. 6 , an exemplary configuration for a multimedia server or sender is shown. Exemplary sender 600 may include a unicast component 620 , a converger component 630 and a multicast delivery component 640 which function and provide in a number of manners, such as a content delivery mechanism and as a transition mechanism that enables those initially Unicast-connected clients on their respective Unicast IP networks to access the Multicasted content on the network. Such a transition may be enabled via converger component 630 which may calculate the necessary stream modifications necessary to synchronize the unicast stream(s) to the multicast stream(s). Sender 600 may also enable users to join a group on the network by providing information relating to what multicast sessions are in progress or scheduled on the network by receiving and sending data on those groups within a session. In the present invention, it is contemplated the sender 600 may handle a theoretically unlimited amount of users between users that have established initial unicast delivery sessions and those that are eventually merged or converged into multicast delivery sessions, subject to the constraints and limitations of the network(s) involved. In one embodiment of the present invention, unicast delivery component 620 , converger component 630 and multicast delivery component may be implemented as software running in conjunction with any number of general or specialized computer processors to implement the steps and methods described herein for delivering and synchronizing content delivery over a network. In one embodiment of the present invention the converger component could reside with the sender 600 or with the receiver 610 or as part of the network provided the ability to communicate with the unicast and multicast delivery components is maintained.
Referring now to FIG. 7 , an exemplary method for providing content in a both a unicasting and multicasting manner is shown. In one embodiment, a number of unicast requests are received, step 700 . The received unicast requests are fulfilled by providing the requested unicast content to the requestors or users via unicast streams, step 710 . The unicast streams are then synchronized or converged, step 720 . The converged streams are then provided in a multicast format to the initial requesters in a manner transparent to the users but more efficient and scalable in a network perspective, step 730 . It is contemplated that in step 720 , if there are multiple unicast streams, not all of the unicast streams may be able to be converged in a manner transparent to the user. In such a case, only those unicast streams that can be readily and transparently scaled up or scaled down to reach a suitable convergence point before converting the streams to a multicast format will be undertaken, such as described earlier herein with respect to FIGS. 3-5 .
Referring now to FIG. 8 , another embodiment of a method of the present invention is shown. In this embodiment, a number of content requests are received, step 800 . The requested content may then be provided by either delivering unicast streams and/or multicast streams to the requesters or users, step 810 . Once a number of streams are being delivered, one or more of the unicast streams are merged with one or more of the multicast streams, step 820 . The content is then delivered in both a unicast and multicast stream format, step 830 , provided that any unicast streams are necessary at all. It is contemplated and preferred that in step 830 , the number of unicast and multicast streams provided in step 830 will be less than the original amount of streams provided in step 810 given that one or more of the unicast streams will have been consolidated into a multicast format.
While the 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, 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 | The present invention is a system and method for enabling multicast synchronization of initially unicasted content. Multiple unicast streams are synchronized in order to convert the unicast streams into a multicast stream. Each unicast stream may be accelerated or slowed down in relation to a reference stream to a common point within each stream upon which the unicast streams are replaced by a multicast stream of the same content. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of Canadian Patent Application No. 2,359,125 filed Oct. 12, 2001.
TECHNICAL FIELD
This invention relates to through-fittings for sealing around cables, tubes, sensors or the like. The invention may be embodied in junction boxes which may be installed and used below grade (and may also be used in other applications). The invention has particular application to junction boxes for telephone lines, cable television lines, fiber optic data communication lines, electrical circuits, and the like.
BACKGROUND OF THE INVENTION
Underground junction boxes may remain buried for years. During that time they should protect their contents against the entry of ground water. It is known to completely fill underground junction boxes with a water-displacing medium such as grease. This is messy, however, both at the time the junction box is filled with grease and later if it becomes necessary to access any components or conductors inside the junction box.
There is a need for cost-effective, durable junction boxes suitable for use in below-grade applications. There is also a general need for through-fittings capable of sealing around a cable or the like at the point where the cable passes through a bulkhead.
SUMMARY OF THE INVENTION
This invention provides through-fittings which may be used to seal around cables or the like. The invention also provides junction boxes equipped with such through-fittings and methods for sealing around cables or the like.
Accordingly, one aspect of the invention provides a through-fitting for a cable or the like. The through-fitting comprises a stub having a bore; an annular seal within the bore; and a cap in threaded engagement with the stub. The cap is movable between a first position and a second position. A sleeve is disposed within the bore and has an inwardly-angled end surface. The sleeve is movable axially within the bore relative to the annular seal in response to motion of the cap. When the cap is in the first position, the seal is not substantially compressed. When the cap is in the second position, the end surface of the sleeve compresses the seal radially inwardly. In addition or in the alternative, the end surface of the sleeve may compress a portion of the seal radially outwardly. In some embodiments the sleeve is attached to the cap so that it moves axially as the cap is screwed onto the stub. In such embodiments the sleeve may be formed integrally with the cap, or affixed to the cap by an adhesive, snap fastening, threading, plastic welding, or other suitable fastening means.
In some embodiments of the invention the through-fitting comprises a chamber and a passageway communicating between the chamber and the bore. The chamber has a variable volume. When the cap is in the first position the chamber has a first volume and when the cap is in the second position the chamber has a second volume smaller than the first volume. In such embodiments a sealant such as grease, silicone grease, gel and other types of sealing materials well known in the art may be extruded from the chamber into the bore as the cap is tightened.
The through-fitting may comprise a burst member blocking the passage. The burst member may, for example, comprise a thin plastic member blocking an aperture in the sleeve.
Another aspect of the invention provides a method for sealing a through-fitting around a cable. The method comprises: passing a cable through the through-fitting; compressing a seal in the through-fitting against the cable; and, extruding a sealant around the cable within the through-fitting. Both compressing the seal and extruding the sealant are performed by threading a cap onto the through-fitting.
Further aspects of the invention and features of specific embodiments of the invention are described below.
BRIEF DESCRIPTION OF DRAWINGS
In drawings which illustrate non-limiting embodiments of the invention:
FIGS. 1A, 1 B 1 C are cross-sectional views through a through-fitting according to a currently preferred embodiment of the invention;
FIGS. 1D and 1E are respectively longitudinal and transverse cross-sections through a sleeve portion of the through-fitting of FIG. 1A;
FIG. 2 is an isometric view of a clip that may be used to prevent premature operation of the through-fitting of FIG. 1A;
FIG. 3A is an exploded view of a small sub-grade junction box according to one embodiment of the invention;
FIG. 3B is a section through the junction box of FIG. 3A;
FIGS. 4A and 4B are longitudinal cross-sectional views of a through-fitting according to an alternative embodiment of the invention in open and sealed configurations respectively;
FIG. 5 is a bottom perspective view of a junction box according to an alternative embodiment of the invention;
FIG. 6 is a cross-sectional view through a through-fitting according to another embodiment of the invention;
FIGS. 7A, 7 B, 7 C and 7 D are additional views of the through-fitting of FIG. 6;
FIG. 8 is a front perspective view of a terminal mounting plate which may be used in a junction box like that of FIG. 5;
FIG. 9 is a back perspective view of the plate of FIG. 8;
FIG. 10 is a top plan view of the plate of FIG. 8;
FIG. 11 shows the interior of the junction box of FIG. 5;
FIG. 11A is a partially cut away view of the box of FIG. 5;
FIG. 12 is a detailed view of a grounding connection to a cable;
FIG. 13 is a view of the box of FIG. 5 in an open configuration with a branch cable installed;
FIG. 14 is a partial sectional view through a portion of the box of FIG. 5 showing a seal and clasp;
FIG. 15 is a section through a hinge of the box of FIG. 5; and,
FIG. 16 is a section through a through-fitting according to an alternative embodiment of the invention.
DESCRIPTION
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
FIGS. 1A, 1 B and 1 C are a cross-sections through a through-fitting 10 according to a currently-preferred embodiment of the invention. FIG. 1A shows through-fitting 10 in a non-sealed state, as initially supplied. FIG. 1B shows through-fitting 10 in an intermediate state and FIG. 1C shows through-fitting 10 in a sealed state. Through-fitting 10 comprises a threaded stub 12 which projects from a base 14 . Base 14 could, for example, be a wall of a junction box. A bore 16 passes through stub 12 . A cable C may be inserted through bore 16 .
Stub 12 bears male threads 18 . A cap 20 bears female threads 22 which engage threads 18 . The outer end of stub 12 projects into an annular chamber 24 in cap 20 . In the illustrated embodiment, annular chamber 24 is defined between a concentrically arranged sleeve 36 which extends axially into bore 16 . Sleeve 36 is a reasonably close fit into the bore of stub 12 . Chamber 24 may be filled with a sealant such as a suitable grease. For example, chamber 24 may be filled with a suitable grade of grease, silicone grease, gel or other types of sealing materials well-known in the art. An elastomeric seal 28 is located in stub 12 . Seal 28 is preferably retained in bore 16 of stub 12 . This prevents seal 28 from being displaced if cable C is pulled outwardly during installation. In the illustrated embodiment, seal 28 has a circumferential groove which receives a flange 29 which projects into bore 16 .
Seal 28 has an inner lip seal 30 which seals around cable C and an outer seal 32 . In the illustrated embodiment, outer seal 32 comprises an annular groove 34 in seal 28 . Groove 34 divides the outer part of seal 28 into a first annular part 35 A and a second annular part 35 B. Sleeve 36 is located in bore 16 . Preferably sleeve 36 is formed integrally with cap 20 , such that sleeve 36 is joined to cap 20 at their respective outer ends. In alternative embodiments, cap 20 and sleeve 36 may be separate parts and sleeve 36 may simply abut against cap 20 at its outer end. Sleeve 36 extends inwardly inside bore 16 , such that an inner end 50 of sleeve 36 is located to enter annular groove 34 . As shown in FIGS. 1A and 1B, sleeve 36 has apertures, such as slots 37 .
Through-fitting 10 may be used by passing cable C through bore 16 , sleeve 36 , seal 28 and outer seal 31 . Cap 20 is then turned so that it screws onto stub 12 . As this occurs, sleeve 36 encounters annular groove 34 and wedges apart annular parts 35 A and 35 B of seal 28 . As they are wedged apart, annular part 35 A is pressed against a wall 13 of bore 16 and annular part 35 B is pressed against cable C. In preferred embodiments, the inner end of sleeve 36 and the outer end of seal 28 are sized and shaped so that one of annular parts 35 A and 35 B is fully displaced before the other. In the illustrated embodiment, the portion of the inner end of sleeve 36 that contacts annular part 35 B is more gradually tapered than the portion that contacts annular part 35 A. Annular part 35 A may be slightly longer than annular part 35 B. With this configuration, as cap 20 is tightened, part 35 A is fully pressed against wall 13 of bore 16 before part 35 B is fully pressed toward cable C. In the illustrated embodiment, annular part 35 B is thicker than annular part 35 A. Annular part 35 B may also comprise notches (not shown) which may be used to make annular part 35 B more pliable.
Preferably, seal 28 is forced tightly enough against cable C that seal 28 can serve as a strain relief.
As shown in FIGS. 1B and 1C, when cap 20 is tightened, the volume of chamber 24 is reduced. This forces grease out of chamber 24 into bore 16 . To facilitate this, a number of longitudinal grooves 38 may optionally be provided in bore 16 of stub 12 . Tightening cap 20 causes grease to be forced along grooves 38 (if present) and through slots 37 of sleeve 36 and discharged into bore 16 around cable C. Cap 20 , sleeve 36 and seal 28 are dimensioned so that the grease flows between seal 28 and cable C. Initially, inner seal 30 acts to help block the grease from traveling inwardly along cable C. However, as annular part 35 B is forced tightly against cable C, annular part 35 B prevents grease from traveling inwardly along cable C.
Chamber 24 preferably has a volume greater than or equal to the volume which remains in the bore of stub 12 after cable C has been placed through it. Thus, excess grease will be forced out along cable C in each direction. The volume of chamber 24 may be, for example, 120% or more of the volume of that part of the bore of stub 12 which is not expected to be occupied by cable C. The volume of chamber 24 may be significantly more than this.
The aperture 39 by way of which cable C passes through cap 20 may have a diameter similar to that of cable C. This helps to ensure that grease will not tend to flow out through aperture 39 . A seal 31 similar to seal 30 may also be provided in aperture 39 . A seal ring 33 may be secured or attached to cap 20 and may be sized and shaped to fit over a flange in seal 31 to strengthen the seal provided by seal 31 and to retain the position of seal 31 . Preferably seal 30 is more flexible than seal 31 so that when grease in bore 16 initially becomes pressurized, it may tend to escape through inner seal 30 instead of through seal 31 . However, once annular part 35 B is forced tightly against cable C, annular part 35 B prevents grease from traveling inwardly along cable C and escaping through inner seal 30 . Consequently, some excess grease may escape through seal 31 .
Through-fitting 10 preferably includes a mechanism for preventing cap 20 from being screwed down prematurely. This mechanism may take any of various forms. For example, the mechanism could comprise:
a tab 40 (See FIG. 1A) located to block cap 20 from being screwed down until tab 40 has been broken off or bent out of the way;
a clip 42 , as shown for example in FIG. 2, which clips around stub 12 below cap 20 and blocks cap 20 from being screwed down until clip 42 has been removed. Clip 42 has a grasping tab 43 and a pair of arms 44 A and 44 B which are dimensioned to snap into place around stub 12 when cap 20 is in the unscrewed position shown in FIG. 1A; and/or,
an adhesive sticker spanning cap 20 and some adjacent structure, such as stub 12 .
Optionally apertures 37 in sleeve 36 may be covered by rupture members 37 A (See FIGS. 1 D and 1 E). Rupture members 37 A may comprise very thin skins of plastic which rupture to permit passage of grease from chamber 24 when through-fitting 10 is closed around a cable C. Rupture members 37 A may help to hold grease in place in chamber 24 until it is desired to seal through-fitting 10 around a cable C.
Cap 20 may be pre-charged with grease when through-fitting 10 is put into service. Where this is done, service personnel do not need to insert grease into through-fitting 10 from a separate container of grease.
A through-fitting 10 may be used in many contexts. For example, a through-fitting 10 may be mounted to a flange and used as a bulkhead fitting. A through-fitting 10 may also be used to pass cables into a junction box. Stub 12 may be formed integrally with the junction box.
FIG. 3A shows a junction box 40 according to one embodiment of the invention. Box 40 comprises a base portion 42 which supports a number of through-fittings 10 . Base portion 42 is threaded to receive a cover portion 44 . An O-ring 46 seals the joint between cover portion 44 and base portion 42 .
FIG. 3B is a section through junction box 40 being used to protect splice connections between two cables C 1 and C 2 . In the illustrated embodiment, a web 48 projects from base 42 into junction box 40 between two through-fittings 10 . Web 48 keeps a splice S from being pulled too far toward base 42 .
FIG. 4A shows a through-fitting 110 according to an alternative embodiment of the invention. The parts of through-fitting 110 are identified by reference numerals which are incremented by 100 relative to corresponding parts of through-fitting 10 . Through-fitting 110 has a threaded stub 112 and a cap 120 which together define an annular chamber 124 . Chamber 124 may be filled with grease. The inner wall of chamber 124 is defined by a sleeve 136 which extends axially inside cap 120 . An annular elastomeric seal 128 is located within a bore 116 of stub 112 . Seal 128 may, in some cases, comprise a one-quarter inch long flat o-ring.
Through-fitting 110 differs from through-fitting 10 primarily in details of the design of seal 128 . The through-fitting 10 of FIGS. 1A, 1 B and 1 C is currently preferred because it is believed that seal 28 will, in general, provide a seal superior to the seal provided by seal 128 .
Seal 128 projects axially into bore 116 from a groove 129 . The inner end 136 A of sleeve 136 is beveled. As cap 120 is tightened, the inner end of sleeve 136 engages the outer end of seal 128 and compresses seal 128 radially inwardly around cable C. Seal 128 is thick enough to accommodate variations in the diameter of cable C. Typically cable C will not be exactly round but may instead be oval in shape. Cap 120 may hit a stop, or the end of threads 118 , or, in some other manner, be positively stopped at the point when it has been properly tightened and a proper seal has been made to cable C.
As cap 120 is screwed toward its closed position, which is shown in FIG. 4B, grease is extruded from chamber 124 , through grooves 138 and into bore 116 . The beveled end of sleeve 136 helps to pack the grease around cable C. Ridge 139 may help to minimize the amount of excess grease that escapes from along cable C to the outside end of through-fitting 110 . A chamber 166 may be provided to receive and hold any excess grease which is displaced along cable C toward the inside end of through-fitting 110 .
A plug 168 (shown in dashed outline in FIG. 4A) may be supplied to seal through-fittings 110 which are not in use. A junction box which includes through-fittings 10 or 110 may be shipped with plugs 168 in place in some or all through-fittings. When a cable is to be installed in such through-fittings, plug 168 may be removed and may be stored inside the junction box for possible reuse.
Plug 168 has a inner end 168 A which bears against seal 28 or 128 and an outer end 168 B which abuts against ridge 39 or 139 . Cap 20 or 120 is screwed on so that ridge 39 or 139 engages outer end 168 B and presses plug 168 into a position so that its inner end 168 A is compressing and is sealed against seal 28 or 128 . Plug 168 is long enough so that, even when it is installed as described above, chamber 24 or 124 remains open.
FIG. 5 shows a junction box 200 according to another embodiment of this invention. Junction box 200 may be used, for example, for joining telephone cables. Junction box 200 receives a telephone cable containing, for example, twenty-five pairs of conductors, each pair capable of serving one telephone line. Inside junction box 200 , connections are made to a number of other cables which each may carry a fewer number of pairs of conductors. For example, the box may be used to make connections to branch cables which each carry three pairs of conductors. Each of the branch cables could, for example, be connected to supply telephone lines to a house or business. Junction box 200 is sealed to prevent the entrance of moisture, either where the cables enter the box or around the door which permits access to the interior of the box.
Box 200 comprises a housing 212 which, in this embodiment, comprises a lid 214 and a base 213 . Lid 214 is hinged to base 213 at hinges 216 . A clasp 218 holds lid 214 in a closed position relative to base 213 . Projecting lugs 220 on lid 214 and base 213 permit use of additional fasteners 222 , such as screws, to hold box 210 closed and to serve as a backup in case latch 218 fails.
Base 213 accommodates through couplings for a main cable C 1 and a number of branch cables C 2 . In the illustrated embodiment, a through-fitting 230 for main cable C 1 is centrally disposed on a bottom of base 213 and is surrounded by through-fittings 240 for eight branch cables. Through-fittings 240 may, for example, comprise through-fittings of the types shown in FIG. 1A or 4 A. The number of through-fittings and their arrangement on junction box 200 may be varied. In the illustrated embodiment, through-fittings 240 are arranged around a circle centered generally on through-fitting 230 .
FIG. 6 is a cross-sectional view through a through-fitting 230 . FIGS. 7A, 7 B, 7 C and 7 D show other views of through-fitting 230 . Through-fitting 230 provides both strain relief for cable C 1 and seals against the entry of moisture at the point where cable C 1 enters box 200 . A through-fitting 230 may be used in other contexts such as points where cables, tubes, or the like, pass into boxes, through bulk heads or the like.
Through-fitting 230 comprises a seal 270 , which may comprise an o-ring. O-ring 270 is compressed against a flange 272 which surrounds an opening 274 through which cable C 1 enters box 200 . A compression member 276 bears a slanting annular face 278 . When compression member 276 is clamped against box 200 , face 278 compresses o-ring 270 inwardly against cable C 1 and also compresses o-ring 270 against surface 272 , thereby providing a seal around cable C 1 . In the illustrated embodiment, compression member 276 is clamped against box 200 by means of screws 285 which pass through holes 279 . In the illustrated embodiment, the screws are received in threaded bosses 280 on box 200 .
Through-fitting 230 includes a well 282 on the inside of o-ring 270 . Well 282 may be filled with grease to provide additional sealing around cable C 1 . Clamping members 284 cover off the top end of well 282 and additionally clamp against cable C 1 to provide strain relief. In the illustrated embodiment, clamping members 284 are each generally semi-circular and have a central channel 287 for receiving cable C 1 . Clamping members 284 are received in a pan-shaped depression 286 having a flat bottom 286 A and a sloping side wall 286 B. As shown in FIG. 7C, clamping members 284 are initially spaced apart from one enough to permit cable C 1 to be passed between them. Clamping members 284 are forced downwardly into depression 286 by, for example, screws 285 , clamps or the like. As this is done, the outer surfaces of clamping members 284 ride down sloped walls 286 B and are thereby forced against cable C 1 as shown in FIG. 7 B. Preferably, clamping members 284 are clamped down until they form a seal against surface 286 A which, as noted above, is preferably flat. Apertures 288 are provided for pumping grease into well 282 . Preferably there is more than one aperture to permit the grease being introduced to displace air within well 282 . This facilitates at least substantially completely filling well 282 around cable C 1 with grease.
Clamping members 284 preferably include projections, ribs or bumps which dig at least slightly into the sheathing of cable C 1 so as to provide strain relief.
Terminals 290 (see FIG. 11) are mounted on a plate 292 which fits inside box 200 . FIGS. 8, 9 , and 10 are respectively a front perspective view, back perspective view and top plan view of plate 292 . FIGS. 8 and 9 show plate 292 without terminals 290 .
FIG. 11 shows the interior of a box 200 according to one embodiment of the invention. In this embodiment, the conductors of cable C 1 enter box 200 and extend to terminals 290 which are positioned at spaced apart locations in a ring surrounding cable C 1 . Terminals 290 may be numbered for reference. The individual pairs of conductors C 1 -A exit from cable C 1 and are connected to terminals 290 on the underside of plate 292 .
As best seen in FIGS. 8 and 10, plate 292 preferably includes indicia including numbers or letters which identify individual sets of terminals 290 . Preferably plate 292 includes ridges, lines, grooves, or the like which visually segregate terminals 290 into groups. One group of terminals 290 may be associated with each through-fitting 240 . In the illustrated embodiment, terminals 290 are grouped together to provide three sets of two terminals 290 adjacent each ingress point where a cable C 2 can be received into box 200 .
Plate 292 preferably provides channels 294 by way of which cables C 1 -A can be routed to each group of terminals 290 . Channels 294 may, for example, be provided by indentations in the lower surface of plate 292 . FIG. 11A shows a partially cutaway view of a box 200 which illustrates how conductors C 1 -A can be carried through channels 294 beneath plate 292 to make electrical connections to the undersides of terminals 290 .
Plate 292 preferably makes a tight contact with base 213 of box 200 . This closes off the top of the grease cavities 166 of through-fittings 240 (see FIG. 6 ). Plate 292 includes an aperture 296 for each incoming cable C 2 (see FIGS. 8 and 9 ). Each aperture 296 is preferably a relatively tight fit to the expected cable C 2 so that there is not too much of a tendency for excess grease to be extruded from cavities 166 through aperture 296 around cable C 2 .
In many applications, properly grounding cables C 1 and C 2 is important. There is a desire for a robust grounding mechanism. The illustrated embodiment of the invention provides a grounding ring 298 (see FIGS. 11 and 12 ). Grounding ring 298 is connected to a ground conductor, which is typically a shield, of cable C 1 by a strap 298 A. Strap 298 A may be integral with grounding ring 298 . A number of grounding terminals 299 are provided on grounding ring 298 . Grounding terminals 299 are preferably located adjacent through-fittings 240 (see FIG. 6) to permit grounding of cables C 2 .
The precise manner in which grounding is achieved will depend upon the structure of cable C 1 . FIG. 12 illustrates a possible means of connection to the ground conductor of cable C 1 . This structure may be used where cable C 1 has a shield which surrounds the conductors of cable C 1 . This connection is known in the trade as a “bullet bond”. Curved metal conductors 300 and 301 which match the curvature of sheath S are placed inside and outside sheath S respectively. A bolt 302 is connected to conductor 300 . Bolt 302 passes through an aperture in shielding S and also passes through an aperture in strap 298 A. A nut 303 clamps conductor 300 tightly to shield S and also provides a good electrical contact with strap 298 A. The bullet bond may be installed by slitting sheath S and peeling back a portion of sheath S to permit the conductors to be moved away to allow the insertion of member 300 . In FIG. 12, the conductors and other portions of cable C 1 have been cut away to provide a view of member 300 .
FIG. 13 shows a box 200 according to the invention in which a cable C 2 has been installed. Cable C 2 protrudes through aperture 296 into the interior of box 200 . A section of the sheath of cable C 2 is stripped away to expose the shielding conductor which, in the illustrated embodiment, surrounds the conductors of cable C 2 . FIG. 6 shows grounding clamp 308 in side view. A ground clamp 308 is clamped onto cable C 2 to make electrical contact with the sheath of cable C 2 . The inward end of ground clamp 308 has a slot which receives one of ground terminals 299 . A nut (not shown) on the ground terminal 299 can then clamp the ground clamp 308 against grounding conductor 298 to provide a good ground connection for cable C 2 . Individual conductors C 2 -A from cable C 2 can be attached to selected ones of terminals 290 . Hooks 310 may be provided for neatly storing conductors out of the way.
Ridges 293 (see FIG. 8) on plate 292 prevent grounding clamp 308 from twisting to one side or the other after grounding clamp 308 is installed.
A junction box 200 as described above provides a convenient way for connections to be made from the conductors of cable C 1 to the conductors of individual cables C 2 . Furthermore, the box provides a convenient point at which tests may be made and signals may be sampled to located broken conductors or other defects which interfere with the operation of a system which includes conductors of cable C 1 and/or C 2 .
FIG. 14 shows a sealing o-ring 320 which assists in providing a seal between top 214 and base 213 of box 200 when box 200 is closed. O-ring 320 is received between the wall of base 213 and an interface 322 of top 214 . As shown in FIG. 14, o-ring 320 may be received between an interrupted flange 324 and a number of protrusions 326 . This construction permits base 213 to be injection-molded in a relatively straightforward manner while providing retaining means for o-ring 320 both above and below. Each location at which there is a projection 326 corresponds to a gap 324 A in flange 324 .
It can be appreciated that when top 214 is closed, interface 322 compresses o-ring 320 inwardly against base 213 . To assist in providing the best seal possible, lid 214 has a ramped surface 328 located inwardly from surface 322 . When top 214 is fully closed, ramped surface 328 wedges inside the upper edge of base 213 and urges it outwardly, thereby insuring that a seal will not be lost by excessive inward deflection of the edge of base 213 .
Hinges 216 should be configured so that they do not interfere with the fitting of top 214 onto base 213 . Hinges 216 preferably permit top 214 to float slightly so that it can find its own position in respect of base 213 . FIG. 15 is a sectional view through a portion of the interface between top 214 and base 213 which shows ramped surface 328 providing support to the top edge of base 213 when box 200 is closed. FIG. 15 also shows a cross-section through a hinge 216 which has a pin 330 which is free to float somewhat relative to top 214 .
The main portions of box 200 including top 214 and base 213 may be made from a suitable rigid material. The material is preferably flame-retardant. By way of example, these components may be injection-molded from a suitable plastic such as PVC, polycarbonate or the like.
There are various advantages to junction boxes 40 and 200 which are described above. One advantage is that they are quite compact, although the volume of either of these junction boxes may be made as large as required, within practical limits. Another advantage is that all cables come out of the same side of the box. This is beneficial because it facilitates pulling box 40 or 200 out of a vault or other underground enclosure through what can sometimes be a relatively small opening. It can be appreciated that the design of box 200 , in particular, permits organized wiring and also permits new cables C 2 to be readily added.
A suitable connector may be provided on the end of cable C 1 for joining cable C 1 to another cable or a piece of equipment.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example:
The number of conductors in cable C 1 and C 2 may vary.
Box 200 could be round, as illustrated, or some other shape, such as rectangular, square, octagonal, etc. To enable sealing of box 200 in the manner described above with an o-ring 320 , it is preferable that box 200 be either round or, at least, have rounded corners.
Through-fittings 40 may comprise another mechanism for automatically injecting grease from a chamber as they are tightened onto a cable or the like. For example, FIG. 16 shows a through-fitting 400 which has a cap 420 which bears against a piston 421 . Piston 421 is located in a cylinder 422 which is filled with an extrudable sealant such as grease. Screwing down cap 420 displaces piston 421 and thereby causes grease to be extruded from cylinder 422 into bore 416 through a passage 423 . A through-fitting of the type shown in FIG. 16 will typically include seals, cable strain reliefs and the like which are not shown in FIG. 16 .
The foregoing description mentions through-fittings and junction boxes which include various components and sub-assemblies. These various components and sub-assemblies do not all need to be used together. They may be used individually, or in combination with each other, or in combination with other elements not disclosed herein.
The invention is not limited to junction boxes for telephone lines.
The through-fittings described above, particularly through-fitting 10 may provide good enough sealing that, for some applications, grease is not necessary.
Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims. | A through-fitting for a box or bulk head contains a cavity which holds grease. When the through-fitting is tightened, grease from the cavity is automatically injected to seal the through-fitting. The through-fitting may be used in below-grade junction boxes. A junction box has various useful features. The junction box can be conveniently injection-molded. The junction box has application in fields including wired telephone connections. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority of a PCT Patent Application EP2009/050094 filed Jan. 7, 2009 with the European Patent Office, which in turn claims priority of a European Patent Application No. 08100427.7 filed Jan. 14, 2008, the content of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to an integrated circuit having one or more of multi-junction opto-electronic devices. More specifically, it relates a multi-junction opto-electronic device having a stack of wavelength selective absorption layers. It is also related to a manufacturing method for such multi-junction opto-electronic device.
BACKGROUND OF THE INVENTION
The usage of the photo-electric effect in solar cells to generate energy is one of the most promising approaches to satisfy the demand on energy in a “green” fashion. Since the existing world record for the efficiency of solar cells is about 38% but for very costly chip, an improvement is highly demanded especially to lower the manufacturing cost. And the area of research for solar cells is closed to the one concerning opto-electronic devices used for detecting light for the purpose of optical communication. The semiconductor in conventional solar cells performs two processes simultaneously to produce a photovoltaic effect; absorption of light, and the separation of electric charges (electrons and positively charged species called “holes”). Semiconductors absorb photons having higher energy than the bandgap by exciting an electron from the valence band to the conduction band, leaving behind a positively charged hole. If these excited state charge carriers can be separated before they spontaneously recombine, voltage and current can be derived that can provide power to a load. However, several energy loss mechanisms complicate and limit the energy production potential. First, light energy that is lower than the semiconductor bandgap simply passes through unutilized, which represents a significant loss. Second, when an electron is excited to the conduction band by a photon with energy greater than the bandgap, it will lose energy as heat (thermalization of photogenerated carriers) until the energy of the electron is reduced to the bandgap energy. This loss of energy is referred to as ‘overexcitation energy’. Finally, an electron in its excited state will spontaneously return to its ground state, and in doing so will release energy as heat or light. This is known as recombination of the photoexcited electron-hole pairs. Together, these losses limit silicon semiconductors to a maximum achievable efficiency of 33% or in specific cases up to 38%. Conventional single junction silicon solar cells today exhibit efficiencies between 11-18% as a result of light loss due to reflection from the front surface of the cell, shadowing by the electrical contacts, and ohmic losses at the semiconductor/electrode junctions.
The energy of photons decreases at higher wavelengths. The highest wavelength when the energy of photon is still big enough to produce free electrons is 1.15 μm when silicon material is used. Radiation with higher wavelength causes only heating up of solar cell and does not produce any electrical current. So even at lower wavelengths many photons do not produce any electron-hole pairs, yet they effect on increasing solar cell temperature.
The cost of silicon-based technologies lies largely in materials. Because silicon is a relatively poor absorber of light, the cells are quite thick (˜200-400 μm), and therefore use large amounts of high-quality silicon. The usage of thin-film solar cells may reduce the material cost possibly up to 1/80th of conventional solar cells. Since individual cells are made by cutting through silicon crystals or ingots, additional material losses (known as kerf losses) are associated with sawing. Batch processing to create interconnections, combined with high material and manufacturing facility costs, further add to the fixed costs. Given the low light absorption and high material costs associated with traditional solar technology, thin films emerged in the 1970s as a potential solution, using less silicon (amorphous silicon) or entirely new semiconductor materials, such as cadmium telluride (CdTe), copper indium gallium diselenide (CIGS), or cadmium sulfide (CdS), together with transparent conducting oxides. Higher efficiency triple junction cells comprising InGaP/InGaAs/Ge for space applications have achieved 28% efficiency. However, these new semiconductors require vacuum deposition, which makes manufacturing scale-up costly. Thus, despite the reduction in raw material costs, all of the thin film technologies remain complex and expensive. For this reason, the thin film solar cell technologies have taken at over twenty years to transition from the status of promising research (about 8% efficiency) to low volume manufacturing facilities.
Nowadays, optical technology is focusing on photonic integrated circuits on a chip. Optical IOs or optical chip-to-chip communication directly onto the chip is restricted today by the fact that the realization of optical detectors in complementary metal oxide semiconductor (CMOS) integrated circuits (IC) is very challenging. Several approaches are found in the literature to integrate optical detectors into commercial IC process. They range from on chip photo diodes implemented with PN (positive-negative) junction available in the process over deep trench memory cells used as detector to hybrid implementations where additional semiconductor layers e.g. Germanium is placed on top of the chip.
Silicon is a useable semiconductor only for very short wavelength detectors. A CMOS process or even better a BICMOS process offers a whole range of PN-junction which can be used as detectors. The depletion zones that are generated by PN-junctions are a prerequisite for the generation of solar current. The larger the depletion zone, the larger the sensitive area of a detector and the more charge-hole pairs will be generated by incident light. The usage of lightly doped silicon (the intrinsic area) causes a larger depletion area as for heavily doped silicon. This depletion zone can be further influenced by an externally applied voltage to the PC-contact or a pre-loading of the P- and N-contact. The PC-contact is also used to prevent a loading of the diffractive grating and thus avoids a reduction of the grating efficiency. This makes an optimization for a vertical standing wave possible. Degenerated grating efficiencies would cause moving maxima of intensity of the standing wave.
Generally, strained silicon techniques like “dual stress liner” or “embedded silicon germanium” are used to improve the switching characteristic of P-MOS and N-MOS transistors (p- or n-type metal oxide semiconductor transistor) by introducing tensile or compressive stress on the atomic structure. For opto-electronic devices the usage of strained silicon would reduce the bandgap by tensile strain that enlarges the atomic distance. This causes an increased sensitivity of the material for wavelengths that are not suitable for silicon detectors without a strain. This increases the absorption of the material. Strained Silicon is available for standard SOI technologies and hence no process modifications are required.
In U.S. Pat. No. 6,891,869 is described a device comprising a number of different wavelength selective active-layers arranged in a vertical stack, having band-alignment and work-function engineered lateral contacts to said active-layers, consisting of a contact-insulator and a conductor-insulator. Photons of different energies are selectively absorbed in or emitted by the active-layers. Contact means are arranged separately on the lateral sides of each layer or set of layers having the same parameters for extracting charge carriers generated in the photon-absorbing layers and/or injecting charge carriers into the photon-emitting layers. The required layers are comparably thick being not optimized for thin-film layers. And the device does not use any facility to concentrate energy of light and does not use any resonant structure.
In US2007/0041679 is described an integrated optical signal wavelength demultiplexing device which may simultaneously demultiplex and detect an optical signal. The integrated device features a waveguide structure to carry an optical signal, a photo-detector in close proximity to the waveguide structure, and a wavelength limiting grating structure integrated with the photo-detector. The grating structure is fabricated within the photo-detector and is used to transmit only a selected wavelength onto the photo-detector.
SUMMARY OF THE INVENTION
In view of the above, it is an object of the present invention to develop an opto-electronic device which is based on standard process used for the manufacturing of integrated circuits while optimizing its efficiency and lowering its cost.
This object is achieved in accordance with the invention by a multi-junction opto-electronic device comprising a stack of wavelength selective absorption layers. The absorption layers comprise each a first layer with a grating of a specific pitch defining the wavelength of the incident light to be absorbed within a subjacent second electrically active layer itself on a third electrically inactive layer. The second electrically active layer within the different absorption layers is in electrical connection with lateral contacts to extract the electrical charge carriers generated by the absorbed incident light within the active layer.
A first embodiment of the multi-junction opto-electronic device according to the invention is characterized in that the grating within the first layer of the absorption layers is defined by periodic stripes of specific width depending on the wavelength to be absorbed by the respective absorption layers. The period of the stripes alignment is defined by the pitch of the grating.
In an embodiment according to the invention, the active layer within the absorption layers is defined by regions doped at variable concentrations such that the region underneath the stripes correspond to a first region doped at a concentration at least an order of magnitude smaller that the concentration of the second regions in between the first regions. The stripes of the first layer are electrically isolated from the first region of the second electrically active layer usually by some glass-like material. The dopants for the first region can be of p- or n-kind whereas being the same for the whole active layer. And the dopants for the second region within the active layer are chosen to be alternately of p- and n-kind. Possibly but not necessarily, the gratings within the first layer of the different absorption layers are covered by an anti-reflective coating. And some electrically inactive filling material can be deposit within the first layer of the absorption layers for equalizing the first layer. This is usually done by covering the gratings possibly but not necessarily already covered itself by the anti-reflective coating.
In an alternative embodiment according to the invention, the absorption layers are covered by an electrically inactive distance layer of a specific width adapted for the generation of stationary waves in the perpendicular direction to the plane comprising the absorption layers. Those stationary waves are coming from a superposition of incident light waves possibly but not necessarily combined with reflected light waves.
In an advantageous alternative according to the invention, the multi-junction opto-electronic device is based on silicon technology such that the electrically inactive layers are made with some glass like material possibly but not necessarily silicon oxide (SiO 2 ). The stripes are then made with poly-silicon and the second electrically active layer is made of silicon accordingly doped. The anti-reflective coating can be made of SiNi. In some embodiment, the grating within the first layer of the absorption layer is made with some material causing tensile strain on the electrically active second layer adjacent to the grating.
In another alternative embodiment according to the invention, the grating is defined by periodic poly-stripes with a period (named a) equal to the pitch of the grating. The poly-stripes themselves are defined by a width varied periodically along their length with a second period (named b). Both period parameters (a and b) are optimized to maximize the absorption of both polarization S and P from the incident light. An advantageous proposed design is optimized for the usage of ultra-thin film solar cells using evanescent coupling into the electrically active silicon absorption layer. Each layer is designed to interact with a certain wavelength, comprising a grating filter that is optimized to provide evanescent coupling into the ultra thin (˜100 nm), electrically active layer, comprising depletion zones.
The invention further relates to an integrated circuit comprising one or more multi-junction opto-electronic devices as described above. The invention is also related to a manufacturing method for multi-junction opto-electronic device comprising the step to manufacture a wavelength selective absorption layer as above and then to stack several of such absorption layers with different pitch to absorb correspondingly different wavelengths of the incident light.
Advantageous developments of the invention are described in the claims, the following description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be understood and appreciated more fully in the below detailed description with the reference to the attached drawings in which:
FIG. 1 is a schematic cross-sectional view along the depth of a stack of wavelength selective absorption layers according to the invention;
FIG. 2 a shows absorption curves of different wavelength lights for gratings of different pitches and widths;
FIG. 2 b is a schematic top view of the two dimensional grating made out of poly-stripes;
FIGS. 3 a - 3 c is a schematic cross-sectional view of several stripes according to the invention;
FIG. 4 is a schematic cross-sectional view along the depth of, and perpendicular to, the stack of FIG. 1 ;
FIG. 5 a is a cross-sectional view of the stack of FIG. 1 ;
FIGS. 5 b , 5 c are top views of the stack of FIG. 1 ;
FIG. 6 a is a schematic top view of four stacks from FIG. 1 ; and
FIG. 6 b is a schematic top view of the four stacks from FIG. 6 a assembled according to the inventions.
Following is a list of reference numbers being used in the above drawings:
1 wavelength selective absorption layer;
2 3d-metal interconnection;
3 3 a; 3 b metal contact;
4 first layer;
5 grating;
6 anti-reflective coating;
7 second active layer;
8 depletion area;
9 third electrically inactive layer;
10 electrically inactive filling material;
11 electrically inactive distance layer;
12 single layer of 11 ;
13 second region highly doped in between the first region 8 ;
14 thin layer;
15 poly-stripes
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
On FIG. 1 is described a cross-sectional view of a stack of wavelength selective absorption layers 1 according to the invention. The cross-section is taken along the growth axis of the stack almost at its border to show at least partly the lateral electrical contacts. The lateral contacts are placed at the top of each wavelength selective absorption layers 1 and are made out of 3d-metal interconnections 2 electrically connected to metal contacts 3 a with an inverted trapezoid like shape such to extract electrical charge carriers generated by absorbed incident light.
Each wavelength selective absorption layers 1 is accordingly made out of a first layer 4 with a grating 5 whose pitch defines the wavelength of the incident light to be absorbed by that absorption layer 1 . Advantageously, the pitch from the gratings of the different absorption layers 1 stacked together as shown on FIG. 1 are chosen at different values such to cover in an optimized way the wavelength spectrum of interest of the incident light. The choice of the pitches is defined accordingly depending on the material used and the number of wavelength selective absorption layers 1 stacked together. On FIG. 2 a are shown different absorption curves for incident light and different pitches (named a and b for the possible embodiment based on a two dimensional diffractive grating made out of poly-stripes) as well as different widths of the two dimensional gratings (named a 1 , a 2 and b 1 as shown in FIG. 2 b ). The choice of the pitches and the widths is taken according to the incident wavelength to be absorbed. Generally, a second order diffractive grating is not a required preliminary, but matches the number of intensity maxima and the minimum feature size of the given process. By that, a maximum of depletion zones can be feed by intensity maxima. An optimized design has a maximum intensity at each depletion zone.
The gratings 5 on each wavelength selective absorption layer 1 as shown on FIG. 1 are covered by some anti-reflective coating 6 to avoid that to much incident light is reflected on the surface of the grating and do not contribute to the generation of electrical charge carriers. It could be conceivable to provide only the first or some of the first top gratings from the stack with such anti-reflective coating 6 since the incident light reflected from wavelength selective absorption layers deep in the stack would at least partly contribute to generation of electrical charge carriers within absorption layers laying above. Also some ground contacts 3 b protruding the anti-reflective coating 6 are electrically connected to the gratings to guarantee that no electrostatic phenomenon possibly due to incident radiation take place.
To equalize the top of each wavelength selective absorption layer is deposit above the grating 5 within the first layer 4 an electrically inactive filling material 10 . The grating 5 of each absorption layer 1 is itself subjacent to a second layer 7 being electrically active. This is strictly speaking the layer where incident light usually sun light for a solar cell is absorbed. Each grating 5 with their specific pitch acts on a respective wavelength of the spectrum of the incident light as a diffractive filter such that the light at the corresponding wavelength is concentrated within the second layer just underneath the border of the gratings. This regions correspond approximately to the limit of the depletion area 8 localized within the active second layer 7 under the grating 5 . Such depletion or first region is obtained by being doped at a concentration at least an order of magnitude smaller than the concentration of the second regions in between the first regions. The active layer 7 is possibly but not necessarily lay down on a third electrically inactive layer 9 . Just underneath the grating 5 and above the second active layer 7 is placed some electrically inactive layer 14 .
FIG. 1 shows that between the different wavelength selective absorption layers 1 can be placed some electrically inactive distance layer 11 of specific width. The different widths can be obtained by choosing a different number of layers building up that distance layer 11 depending on the stationary waves generated in the perpendicular direction to the plane comprising the absorption layers. Those stationary waves are coming from a superposition of incident light waves possibly combined with light waves reflected at some of the layers from the stack. The width of a single layer 12 of that distance layer 11 is given by the material and the manufacturing process used.
The stacking of the different wavelength selective absorption layers 1 can be obtained in different way using existing manufacturing processing. Usually, the distance layer will be made out of some glass like material i.e. made out of silicon oxide (SiO 2 ). Therefore, a tempering (heat processing) of the stack will achieve to glue all the absorption layers 1 to a stack.
Generally, the choice of the material for the gratings may depend on the cost factor and could possibly be based on silicon technology. In that case, all the electrically inactive layers i.e. the filling material 10 within the first layer 4 , the electrical isolation 14 , the third electrically inactive layer 9 and the electrically inactive distance layer 11 are made out of silicon oxide. The grating itself 5 can be made out of polysilicon (PC) while the anti-reflective coating 6 could be made out of SiNi (see FIG. 3 a ). But other material can be chosen within the scope of the present invention. The second active layer 7 is made out of silicon accordingly doped. Independently of the chosen dopants material, the first region corresponding to the depletion area 8 can be of p- or n-kind but is the same for the whole second active layer 7 as shown on FIG. 3 c . The dopants for the second region 13 in between the first region 8 are alternately of p- and n-kind. FIGS. 3 a and 3 b show a schematic cross-sectional view of the grating 5 with the second active layer 7 and the underneath third electrically inactive layer 9 . Directly under the grating 5 within the active layer 7 are the regions poorly doped or of p- or n-kind and corresponding to the depletion area 8 . In between are the heavily doped regions 13 alternately of p- or n-kind i.e. p+ or n+ (see FIG. 3 c ).
FIG. 3 b shows a detailed cross-sectional view of the grating 5 . The grating 5 with a pitch p consists of longitudinal stripes of width w and height hp while the top of the stripes is slightly smaller then the bottom being in close vicinity to the second active layer 7 so to build stripes with trapezoid like cross-sections due to manufacturing conditions. The stripes are electrically isolated from the second active layer 7 by some inactive thin layer 14 possibly made out of silicon oxide. The depletion area 8 within the second active layer 7 is defined by a depletion width d slightly bigger than the width w of the stripes 14 and by a channel height hs corresponding approximately to the thickness of the second active layer 7 . Not only the pitch p but possibly also the width w and the height hp of the grating may be optimized to diffract a maximum of incident light at some specific wavelength within the subjacent second active layer 7 . It is of advantage if the depletion area is as large as possible so to absorb a maximum of light generating accordingly a maximum of electrical charge carriers to be extracted by the electrical contacts.
On FIG. 4 is shown a cross-sectional view of the stack of wavelength selective absorption layers 1 of FIG. 1 across the length of the stripes building the grating 5 . The metal contacts within each wavelength selective absorption layers 1 are interconnected between them on both sides of the stack by the 3d-metal interconnections 2 . On FIG. 4 are clearly visible the different stripes 5 covered by the anti-reflective coating 6 . Subjacent to gratings are shown the second active layer 7 with the depletion area 8 spread below almost the entire length of the stripes. The second active layer 7 is laying down the third electrically inactive layer 9 while between the different wavelengths selective absorption layers 1 are placed the electrically inactive distance layer 11 possibly of different width.
On FIGS. 5 b and 5 c are shown a top view of the stack of wavelength selective absorption layer from FIG. 1 . The 3d-metal interconnections 2 are removed at the left side to be able to assembly a maximum of stacks on a single integrated circuit (see cross sectional view FIG. 5 a ). On the right side of the stack are shown the different metal contacts 3 with the beginning of the 3d-metal interconnections 2 . Also visible are the different parallel stripes building the grating 5 while the electrically inactive filling material 10 is removed to show in between the stripes the top of the second active layer 7 . The Si-based technology is chosen for the example shown on FIGS. 5 a to 5 c . FIG. 5 b is a one-dimensional grating example. And FIG. 5 c is a two-dimensional grating example according to the invention and as used for the absorption curves on FIGS. 2 a and 2 b.
FIGS. 6 a to 6 c show an alternative grating according to the invention made out of periodic poly-stripes 15 (two-dimensional gratins as shown on FIG. 5 c ). The average distance between the stripes is defined by parameter a and corresponds to the pitch of the grating. The poly-stripes 15 are also defined by a width which is varied along the length of the stripes periodically with a period b. The structure of poly-stripes is advantageously chosen when both the S and P polarizations of incident light shall be captured. Such poly-stripes 15 can be based on usual poly-silicon allowing using standard CMOS manufacturing process without implying process modifications. FIG. 6 a shows a top view of several stacks from FIG. 5 c with the poly-stripes 15 and the 3d-metal interconnection 2 to be assembled on an integrated circuit as shown on FIG. 6 b.
Advantageously, strained silicon instead of bulk silicon can be chosen for the second active layer 7 within each wavelength selective absorption layer 1 . The strained silicon layer provides greater mobility for the generated electrical carrier charges (electrons and holes). Photo-detectors build using such material provides high charge mobility and thus higher response and performance in comparison to a photo-detector device which uses bulk silicon for light absorption. The high charge mobility also translates into greater photo-current and higher responsivity of the photo-detector device. This is due to the fact that the tensile strain on the silicon reduces the band gap. Thus, light at still longer wavelengths can be absorbed by the second active layer 7 made out of strained silicon layer as can be absorbed by bulk silicon. Due to the number and location of the metal contacts and the interconnection of all the active regions after assembly, potential defects and bad processing of the metal interconnect causing a broken contact do not harm the design. One working contact per row (see FIG. 6 b ) would be sufficient to collect all generated charges by incident light within that row. | A multi-junction opto-electronic device including a stack of wavelength selective absorption layers is proposed. The absorption layers include each a first layer with a grating of a specific pitch defining the wavelength of the incident light to be absorbed within a subjacent second electrically active layer itself on a third electrically inactive layer. The second electrically active layer within the different absorption layers is in electrical connection with lateral contacts to extract the electrical charge carriers generated by the absorbed incident light within the active layer. The grating within the first layer of the absorption layers is defined by periodic stripes of specific width depending on the wavelength to be absorbed by the respective absorption layers. The period of the stripes alignment is defined by the pitch of the grating. Advantageously, ordinary silicon technology can be used. | 8 |
[0001] This application claims the benefit of U.S. Serial Nos. 60/217,965; 60/241,614; and 60/292,988.
FIELD OF THE INVENTION
[0002] The present invention is in the field of medicine, particularly in the treatment of Type II diabetes and obesity. More specifically, the present invention relates to β 3 adrenergic receptor agonists useful in the treatment of Type II diabetes and obesity.
BACKGROUND OF THE INVENTION
[0003] The current preferred treatment for Type II, non-insulin dependent diabetes as well as obesity is diet and exercise, with a view toward weight reduction and improved insulin sensitivity. Patient compliance, however, is usually poor. The problem is compounded by the fact that there are currently no approved medications that adequately treat either Type II diabetes or obesity.
[0004] One therapeutic opportunity that has recently been recognized involves the relationship between adrenergic receptor stimulation and anti-hyperglycemic effects. Compounds that act as β 3 receptor agonists have been shown to exhibit a marked effect on lipolysis, thermogenesis and serum glucose levels in animal models of Type II (non-insulin dependent) diabetes.
[0005] The β 3 receptor, which is found in several types of human tissue including human fat tissue, has roughly 50% homology to the β 1 and β 2 receptor subtypes yet is considerably less abundant. Stimulation of the β 1 and β 2 receptors can cause adverse effects such as tachycardia, arrhythmia, or tremors. An agonist that is selective for the β 3 receptor over the β 1 and β 2 receptors is, therefore, more desirable for treating Type II diabetes or obesity relative to a non-selective agonist.
[0006] However, recent studies have suggested the presence of an atypical beta receptor associated with atrial tachycardia in rats ( Br. J. of Pharmacol., 118:2085-2098, 1996). In other words, compounds that are not agonists of the β 1 and β 2 receptors can still modulate tachycardia through activation of a yet to be discovered β 4 or through some other unknown pathway.
[0007] A large number of publications have appeared in recent years reporting success in discovery of agents that stimulate the β 3 receptor. Despite these recent developments, there remains a need to develop a selective β 3 receptor agonist which has minimal agonist activity against the β 1 and β 2 receptors.
SUMMARY OF INVENTION
[0008] The present invention relates to a compound of formula I:
[0009] wherein:
[0010] A 1 , A 2 and A 3 are carbon or nitrogen provided that only one of A 1 , A 2 and A 3 can be nitrogen;
[0011] Het is an optionally substituted, optionally benzofused 5 or 6 membered heterocyclic ring;
[0012] R 1 , R 1a and R 1b are independently H, halo, hydroxy, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 1 -C 4 haloalkyl, or SO 2 (C 1 -C 6 alkyl);
[0013] R 2 is H or C 1 -C 6 alkyl;
[0014] R 3 is H or C 1 -C 6 alkyl;
[0015] R 4 is H or C 1 -C 6 alkyl;
[0016] or R 3 and R 4 combine with the carbon to which both are attached to form a C 3 -C 6 cyclic ring;
[0017] or R 4 and X 1 combine with the carbon to which both are attached to form a C 3 -C 8 cyclic ring;
[0018] or R 4 combine the carbon to which both are attached, and the phenyl group to which X 1 is attached to form:
[0019] wherein:
[0020] n and m are independently 0, 1, 2, or 3 provided that the sum of n+m is≦4 and that R 3 is H;
[0021] X is OCH 2 , SCH 2 or a bond;
[0022] X 1 is a bond or a C 1 -C 5 divalent hydrocarbon moiety;
[0023] x 2 is O, S, NH, NHSO 2 , SO 2 NH, CH 2 or a bond; and
[0024] X 3 is optionally substituted phenyl or an optionally substituted 5 or 6 membered heterocyclic ring; or a pharmaceutical salt thereof.
[0025] The present invention also relates to processes for preparing, as well as novel pharmaceutical formulations containing, a compound of formula I. In another embodiment, the pharmaceutical formulations of the present invention may be adapted for use in treating Type II diabetes and obesity and for agonizing the β 3 receptor.
[0026] The present invention also relates to methods for treating Type II diabetes and obesity, as well as a method for agonizing the β 3 receptor employing a compound of formula I.
[0027] In addition, the present invention relates to a compound of formula I for use in treating Type II diabetes and obesity as well as a compound of formula I for use in agonizing the β 3 receptor. The present invention is further related to the use of a compound of formula I for the manufacture of a medicament for treating Type II diabetes and obesity as a well as for agonizing the β 3 receptor.
[0028] The present invention is also related to a compound of formula II:
[0029] which is useful as an intermediate to prepare a compound of formula I.
DETAILED DESCRIPTION
[0030] For the purposes of the present invention, as disclosed and claimed herein, the following terms are defined below.
[0031] The term “halo” represents fluoro, chloro, bromo, or iodo.
[0032] The terms “C 1 -C 6 alkyl” and “C 1 -C 4 alkyl” represent a straight, branched or cyclic hydrocarbon moiety having from one to six and one to four carbon atoms, respectively. C 1 -C 4 alkyl groups include methyl, ethyl, n-propyl, isopropyl, cyclopropyl, n-butyl, isobutyl, secbutyl, t-butyl and cyclobutyl. A “C 1 -C 4 haloalkyl” group is a C 1 -C 4 alkyl moiety substituted with up to six halo atoms, preferably one to three halo atoms. An example of a haloalkyl group is trifluoromethyl. A “C 1 -C 6 alkoxy” group is a C 1 -C 6 alkyl moiety connected through an oxy linkage.
[0033] The term “divalent hydrocarbon moiety” refers to a straight or branched chain of carbon atoms that may optionally have one or more points of unsaturation. Thus, a hydrocarbon diradical according to the present invention includes alkylene, alkenylene and alkylidene moieties. Examples include but are not intended to be limited to methylene, ethylene, propylene, butylene, —CH(CH 3 )CH 2 ——CH(C 2 H 5 )CH 2 —, —CH(CH 3 )CH(CH 3 )—, —CH 2 C(CH 3 ) 2 —, —CH 2 CH(CH 3 )CH 2 —, —C(CH 3 ) 2 CH 2 —, —CH═CHCH 2 —, —CH═CH—, —C═CCH 2 —, and the like.
[0034] The term “optionally substituted” as used herein means an optional substitution of one to three, preferably one or two groups independently selected from oxo, nitro, cyano, phenyl, benzyl, halo, C 1 -C 6 alkyl, C 1 -C 4 haloalkyl, COR 5 , NR 6 R 6 , NR 6 COR 5 , NR 6 SO 2 R 7 , OR 6 , OCOR 5 , OSO 2 R 7 , SR 6 , SOR 7 , SO 2 R 7 or SO 2 NR 6 R 6 ; wherein
[0035] R 5 is H, C 1 -C 6 alkyl, phenyl, benzyl, C 1 -C 4 haloalkyl, NR 6a R 6a or OR 6a ;
[0036] R 6 and R 6a are independently H, C 1 -C 6 alkyl or phenyl; or when two R 6 or R 6a groups are attached to the same nitrogen atom, said R 6 or R 6a groups, together with the nitrogen to which they are attached, may combine to form a piperidine, pyrrolidine, hexamethyleneimine or morpholine ring; and
[0037] R 7 is C 1 -C 6 alkyl or phenyl.
[0038] The term “heterocyclic ring” represents a stable, saturated, partially unsaturated, fully unsaturated or aromatic ring, said ring having from one to four heteroatoms that are independently selected from the group consisting of sulfur, oxygen, and nitrogen. The heterocycle may be attached at any point which affords a stable structure. Representative heterocyclic rings include 1,3-dioxolane, 4,5-dihydro-1H-imidazole, 4,5-dihydrooxazole, furan, imidazole, imidazolidine, isothiazole, isoxazole, morpholine, oxadiazole, oxazole, oxazolidinedione, oxazolidone, piperazine, piperidine, pyrazine, pyrazole, pyrazoline, pyridazine, pyridine, pyrimidine, pyrrole, pyrrolidine, tetrazole, thiadiazole, thiazole, thiophene and triazole. Representative “benzofused” heterocyclic rings include benzoxazole, benzimidazole, benzofuran, benzothiophene, benzothiazole, azaindole, and indole. Further specific examples of benzofused and non-benzofused heterocycles are described below in the Preparations and Examples sections.
[0039] 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.
[0040] The term “patient” includes human and non-human animals such as companion animals (dogs and cats and the like) 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 preferred patient of treatment is a human.
[0041] The terms “treating” and “treat”, as used herein, include their generally accepted meanings, i.e., preventing, prohibiting, restraining, alleviating, ameliorating, slowing, stopping, or reversing the progression or severity of a pathological condition, or sequela thereof, described herein.
[0042] The terms “preventing”, “prevention of”, “prophylaxis”, “prophylactic” and “prevent” are used herein interchangeably and refer to reducing the likelihood that the recipient of a compound of formula I will incur or develop any of the pathological conditions, or sequela thereof, described herein.
[0043] As used herein, the term “effective amount” means an amount of a compound of formula I that is capable of treating conditions, or detrimental effects thereof, described herein or that is capable of agonizing the β 3 receptor.
[0044] The term “selective β 3 receptor agonist” means a compound that displays preferential agonism of the β 3 receptor over agonism of the β 1 or β 2 receptor. Thus, β 3 selective compounds behave as agonists for the β 3 receptor at lower concentrations than that required for similar agonism at the β 1 and β 2 receptors. A β 3 selective compound also includes compounds that behave as agonists for the β 3 receptor and as antagonists for the β 1 and β 2 receptors.
[0045] The term “pharmaceutical” when used herein as an adjective means substantially non-deleterious to the recipient patient.
[0046] The term “formulation”, as in pharmaceutical formulation, is intended to encompass a product comprising the active ingredient(s) (compound of formula I), and the inert ingredient(s) that make up the carrier, as well as any product which results, directly or indirectly, from combination, complexation or aggregation of any two or more of the ingredients, or from dissociation of one or more of the ingredients, or from other types of reactions or interactions of one or more of the ingredients. Accordingly, the pharmaceutical formulations of the present invention encompass any composition made by admixing a compound of the present invention and a pharmaceutical carrier.
[0047] The term “unit dosage form” refers to 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.
[0048] Because certain compounds of the invention contain an acidic moiety (e.g., carboxy), the compound of formula I may exist as a pharmaceutical base addition salt thereof. Such salts include those derived from inorganic bases such as ammonium and alkali and alkaline earth metal hydroxides, carbonates, bicarbonates, and the like, as well as salts derived from basic organic amines such as aliphatic and aromatic amines, aliphatic diamines, hydroxy alkamines, and the like.
[0049] Because certain compounds of the invention contain a basic moiety (e.g., amino), the compound of formula I can also exist as a pharmaceutical acid addition salt. Such salts include the salicylate, sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, decanoate, caprylate, acrylate, formate, isobutyrate, heptanoate, propiolate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, 2-butyne-1,4 dioate, 3-hexyne-2, 5-dioate, benzoate, chlorobenzoate, hydroxybenzoate, methoxybenzoate, phthalate, xylenesulfonate, phenylacetate, phenylpropionate, phenylbutyrate, citrate, lactate, hippurate, β-hydroxybutyrate, glycolate, maleate, tartrate, methanesulfonate, propanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, mandelate and like salts. Preferred acid addition salts include the hemifumarate, benzoate, salicylate, R-mandelate, hydrochloride and glycolate salts.
[0050] It is recognized that various stereoisomeric forms of a compound of formula I exist. The compounds may be prepared as racemates and can be conveniently used as such. Therefore, the racemates, individual enantiomers, diastereomers, or mixtures thereof form part of the present invention. Unless otherwise specified, whenever a compound is described or referenced in this specification all the racemates, individual enantiomers, diastereomers, or mixtures thereof are included in said reference or description.
[0051] It is also recognized that various tautomeric forms of a compound of formula I may exist, and all tautomeric forms are part of the present invention. Unless otherwise specified, whenever a compound is described or referenced in this specification all tautomeric forms, or mixtures thereof, are included in said reference or description.
[0052] Preferred Compounds of the Invention
[0053] Certain compounds of the invention are particularly interesting and are preferred. The following listing sets out several groups of preferred compounds. It will be understood that each of the listings may be combined with other listings to create additional groups of preferred compounds.
[0054] a) A 1 , A 2 and A 3 are carbon;
[0055] b) Het is at the ortho-position relative to X;
[0056] c) Het is optionally substituted one to three times independently with halo, hydroxy, oxo, cyano, nitro, phenyl, benzyl, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, COR 8 , CO 2 R 8 , CONR 8 R 8 , NR 8 R 8 , NHCO(C 1 -C 4 alkyl), NHCO(phenyl), NHCO(benzyl), SR 8 , SO(C 1 -C 4 alkyl), SO 2 (C 1 -C 4 alkyl), SO 2 (NR 8 R 8 ), OCO(C 1 -C 4 alkyl), OCO 2 R 8 or OCONR 8 R 8 where R 8 is independently at each occurrence H or C 1 -C 4 alkyl;
[0057] d) Het is an optionally substituted 5-membered, non-benzofused ring containing one or two heteroatoms that are independently selected from the group consisting of sulfur, oxygen, and nitrogen;
[0058] e) Het is selected from furan; isothiazole; isoxazole; oxazole; and thiophene; wherein said Het moieties are optionally substituted once with fluorine, methyl, cyano, SO 2 NH 2 or COCH 3 ;
[0059] f) Het is selected from thien-2-yl; thien-3-yl; thiazol-2-yl; isoxazol-3-yl; isoxazol-5-yl; and isothiazol-5-yl;
[0060] g) Het is thien-2-yl optionally substituted once with fluorine, methyl, cyano, SO 2 NH 2 or COCH 3 ;
[0061] h) Het is thien-2-yl;
[0062] i) R 1 , R 1a and R 1b are independently H, halo, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkyl, or SO 2 (C 1 -C 4 alkyl);
[0063] j) R 1 is H, methyl, ethyl, CF 3 , chloro or fluoro;
[0064] k) R 1 is H, methyl, chloro or fluoro;
[0065] l) R 1 is H or fluoro;
[0066] m) R 1 is H;
[0067] n) R 1a is H, methyl, ethyl, CF 3 , chloro or fluoro;
[0068] o) R 1a is H, methyl, chloro or fluoro;
[0069] p) R 1a is H;
[0070] q) R 1b is H, methyl, ethyl, CF 3 , chloro or fluoro;
[0071] r) R 1b is H, methyl, chloro or fluoro;
[0072] s) R 1b is H;
[0073] t) R 2 is H or C 1 -C 4 alkyl;
[0074] u) R 2 is H;
[0075] v) R 3 and R 4 are independently H or C 1 -C 4 alkyl;
[0076] w) R 3 is H or methyl;
[0077] x) R 4 is H or methyl;
[0078] y) R 3 and R 4 are both methyl;
[0079] z) R 8 is independently at each occurrence H or C 1 -C 4 alkyl;
[0080] aa) X is OCH 2 ;
[0081] bb) X 1 is a bond, methylene or ethylene;
[0082] cc) X 1 is methylene;
[0083] dd) X 2 is at the para-position relative to X 1 ;
[0084] ee) X 2 is a bond or O;
[0085] ff) X 2 is O or CH 2 ;
[0086] gg) X 2 is O;
[0087] hh) X 3 is optionally substituted one to three times independently with halo, hydroxy, oxo, cyano, nitro, phenyl, benzyl, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, COR 8 , CO 2 R 8 , CONR 8 R 8 , NR 8 R 8 , NHCO(C 1 -C 4 alkyl), NHCO(phenyl), NHCO(benzyl), SR 8 , SO(C 1 -C 4 alkyl), SO 2 (C 1 -C 4 alkyl), SO 2 (NR 8 R 8 ), OCO(C 1 -C 4 alkyl), OCO 2 R 8 or OCONR 8 R 8 ;
[0088] ii) X 3 is phenyl, pyridyl, thienyl or furanyl wherein said X 3 moieties are substituted one to three times with fluoro, chloro, cyano, hydroxy, methyl, ethyl, trifluoromethyl, methoxy, ethoxy, amino, CO 2 CH 3 , CO 2 CH 2 CH 3 , CONR 8 R 8 , SCH 3 , SCH 2 CH 3 , SOCH 3 , SOCH 2 CH 3 , SO 2 CH 3 or SO 2 CH 2 CH 3 ;
[0089] jj) X 3 is phenyl, pyridyl, thienyl or furanyl wherein said X 3 moieties are substituted one to three times with fluoro, cyano, hydroxy, methyl, ethyl, methoxy, ethoxy, amino, CO 2 CH 3 , CO 2 CH 2 CH 3 , CONH 2 , SCH 3 , SCH 2 CH 3 , SOCH 3 , SOCH 2 CH 3 , SO 2 CH 3 or SO 2 CH 2 CH 3 ;
[0090] kk) X 3 is phenyl, pyridyl, thienyl or furanyl wherein said X 3 moieties are substituted one to three times with fluoro, amino, CO 2 CH 3 , CO 2 CH 2 CH 3 , cyano, CONH 2 , SO 2 CH 3 or SO 2 CH 2 CH 3 ;
[0091] ll) X 3 is phenyl, pyridyl or pyridazinyl wherein said X 3 moieties are substituted once or twice with chloro, cyano, CONH 2 or SO 2 CH 3 ;
[0092] mm) X 3 is phenyl, pyridyl, thienyl or furanyl wherein said X 3 moieties are substituted once with cyano or CONH 2 ;
[0093] nn) X 3 is phenyl or pyridyl wherein said X 3 moieties are substituted once with cyano or CONH 2 ;
[0094] oo) X 3 is pyridyl substituted once with cyano or CONH 2 ;
[0095] pp) X 3 is 5-cyano or 5-carboxamido-pyrid-2-yl;
[0096] qq) X 3 is 4-cyano or 4-carboxamido-phenyl;
[0097] rr) X 3 is 3-cyano or 3-carboxamido-pyrid-2-yl;
[0098] ss) X 3 is 2-cyano or 2-carboxamido-phenyl;
[0099] tt) the compound of formula I is an acid addition salt;
[0100] uu) the compound of formula I is the hydrochloride salt;
[0101] vv) the compound of formula I is the glycolate salt;
[0102] ww) the compound of formula I is the hemi-fumarate salt.
[0103] Synthesis
[0104] The compound of formula I may be prepared as described in the following Schemes and Examples.
[0105] The reaction of Scheme 1 may be carried out under conditions appreciated in the art for the amination of epoxides. For example, the epoxide of formula II may be combined with an amine of formula III in a lower alcohol, dimethylformamide, dimethylsulfoxide, or acetone, preferably ethanol, isopropanol, n-butanol or t-butanal, at room temperature to the reflux temperature of the reaction mixture, preferably between 40° C.-90° C. The reaction may also be carried out under conditions generally described in Atkins, et al., Tet. Let., 27:2451, 1986. These conditions include mixing the reagents in the presence of trimethylsilyl acetamide in a polar aprotic solvent such as acetonitrile, dimethylformamide, acetone, dimethylsulfoxide, dioxane, diethylene glycol dimethyl ether, tetrahydrofuran, or other polar aprotic solvents in which the reagents are soluble.
[0106] The compound of formula I may also be prepared via a Suzuki coupling as shown in Scheme 2.
[0107] A compound of formula IV may be reacted with a compound of formula III as described above in Scheme 1. The compound of formula V (an aryl halide) may then be reacted with a heteroaryl boronic acid, an aryl boronic ester, or an aryl boronic cyclic ester, preferably an aryl boronic acid, under conditions appreciated in the art for the coupling of aromatic halides with aryl boronic acids and their derivatives. This coupling is known in the art generally as a Suzuki coupling. The skilled artisan will recognize that an aryl triflate may also be employed in the present Suzuki coupling as an alternative to employing an aryl halide.
[0108] The epoxide starting materials employed in Schemes 1 and 2 may be prepared by techniques recognized and appreciated by one skilled in the art. See, e.g., U.S. Pat. No. 4,663,334; European Patent Application 171209; Korn, et al., J. Pharm. Sci., 69(9):1010-13, 1980 and references cited below in the Preparations section for representative and/or analogous procedures for preparing the epoxides of formula II and IV. To illustrate, epoxides of formula II, where X is OCH 2 or SCH 2 , may be prepared according to the procedure detailed in Scheme 3 wherein R 9 is OH or SH and X′ is OCH 2 or SCH 2 .
[0109] Equimolar amounts of a compound of formula VI and (2S)-(+)-glycidyl 3-nitrobenzenesulfonate may be dissolved in an inert solvent such as acetone and treated with a slight excess of a weak base, such as potassium carbonate. The suspension may then be heated at reflux for 16-20 hours with stirring to provide a compound of formula II(a). Compounds of formula IV, where X is OCH 2 or SCH 2 , may be prepared in an analogous fashion.
[0110] The amino starting materials employed in Schemes 1 and 2 (formula III compound) may also be prepared by techniques recognized and appreciated by one skilled in the art. For example, an amine of formula III, where X 2 is , may be prepared according to the procedure detailed in Scheme 4.
[0111] A compound of formula IX may be prepared by reacting an arylalkyl alcohol of formula VII with excess (5 mol/equivalent) formula VIII compound by methods well known in the art (see, e.g., Sh. Prikl. Kin., 45:1573-77, 1972). The reaction may also be carried out by mixing the reagents in an aprotic solvent, preferably diglyme, and adding potassium t-butoxide (0.5 mol/equivalent). The reaction is typically heated at reflux until water present in the reaction mixture is removed (generally 2-8 hours). A compound of formula X may then be prepared by hydrogenation of the corresponding compound of formula IX over a precious metal catalyst. The hydrogenation can be affected at between 20 and 60 psi of hydrogen (preferably 50 psi), and with a variety of solvents (preferably methanol/acetic acid), temperatures (preferably 50° C.), and catalysts (preferably 5% palladium on carbon wetted with ethanol denatured with toluene) well known in the art.
[0112] A skilled artisan will appreciate that a compound of formula X could be coupled with a wide variety of halides to yield the claimed ethers. The coupling can be carried out according to procedures well known in the art and is preferably performed by mixing the starting materials in N,N-dimethylacetamide and toluene in the presence of potassium carbonate. The reaction is typically then heated to reflux for 5 to 24 hours to effect the reaction and to remove water present in the reaction mixture.
[0113] Compounds of formula VI, VII and VIII are either commercially available, known in the art, or can be prepared by methods known in the art or described herein.
[0114] The following Preparations, Examples and Formulations are provided so that the invention might be more fully understood. They should not be construed as limiting the invention in any way.
Preparations
[0115] Epoxides of Formula II and IV
[0116] Epoxides 1-21, 23-54 and 56-74 are prepared for use as described in Scheme 1. Epoxides 22 and 55 are prepared for use as described in Scheme 2. These epoxides are pictured in Tables 1 and 2 below.
TABLE 1 Het =
[0117] [0117] TABLE 2 Y =
Epoxide 1
[0118] A mixture of 2-(1-methylpyrazol-5-yl)phenol (4. mmol, 810 mg), (2S)-glycidyl 3-nitrobenzenesulfonate (5.58 mmol, 1.45 g), potassium carbonate (5.58 mmol, 771 mg) and acetone (40 ml) are refluxed for 16 hours, cooled to room temperature and the solids removed via filtration. The filtrate is concentrated and the crude product purified on silica gel (40% ethyl acetate/hexane) to give 956 mg of the title epoxide.
Epoxide 2
[0119] Methyl hydrazine (23.2 mmol, 1.23 ml) is added to a solution of 2-(3-hydroxy-2-propen-1-on-1yl)phenol ( J. Am. Chem. Soc., 72:3396, 1950), 15.4 mmol, 2.54 g) in methanol (7 ml) and the mixture is heated at 100° C. for one hour. After cooling, the reaction mixture is diluted with water (100 ml) and stirred for one hour. The precipitate is collected via filtration and purified on silica gel (30% ethyl acetate/hexane) to give 811 mg of 2-(1-methylpyrazol-3-yl)phenol.
[0120] A mixture of 2-(1-methylpyrazol-3-yl)phenol (4.59 mmol, 800 mg), (2S)-glycidyl 3-nitrobenzenesulfonate (5.51 mmol, 1.42 g), potassium t-butoxide (5.51 mmol, 515 mg) and tetrahydrofuran (30 ml) are refluxed for 16 hours, cooled to room temperature and poured into saturated aqueous ammonium chloride. The aqueous layer is extracted with ethyl acetate (3×) and the extracts washed with brine, dried over magnesium sulfate, and concentrated in vacuo. The crude product is purified on silica gel (40% ethyl acetate/hexane) to give 785 mg of the title epoxide.
Epoxide 6
[0121] A mixture of 2-(pyrazol-5-yl)phenol (Catalan, et al., J. Am. Chem. Soc., 114(13):5039-48, 1992, 10 mmol, 1. g), triethylamine (40.0 mmol, 5.6 ml), and acetonitrile (55 ml) is cooled in an ice bath under N 2 and treated dropwise with chlorotrimethylsilane (12.0 mmol, 1.52 ml). After the addition is complete, the cold bath is removed and the reaction mixture stirred at ambient temperature for 1 hour. The reaction mixture is then treated with trityl chloride (10.0 mmol, 2.78 g) and stirred at ambient temperature overnight, followed by refluxing for 1 hour. The reaction mixture is concentrated, treated with saturated aqueous sodium bicarbonate, and extracted with ethyl acetate (3×50 ml). The extracts are dried over magnesium sulfate and concentrated to a viscous oil. The oil is crystallized from 20% ethyl acetate/hexane to give 1.72 g of N-trityl-2-(pyrazol-5-yl)phenol.
[0122] A solution of this intermediate phenol (4.27 mmol, 1.72 g) is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate (4.27 mmol, 1.11 g) substantially as decribed for epoxide 2 except that the present reaction is refluxed for 48 hours and the crude product is purified via crystallization from ethyl acetate to give 860 mg of the title epoxide.
Epoxide 7
[0123] Phenylhydrazine (476 mmol, 51.5 g) and 2-hydroxyacetophenone (476 mmol, 64.8 g) are stirred under reflux in dry ethanol (280 ml) for 6 hours. After cooling, the crystals are filtered off, washed with cold ethanol and dried under vacuum at 50° C. to yield 73 g (68%) of the hydrazone, which is then mixed with nickel chloride (7 g) and heated under a nitrogen atmosphere to 240° C. for 3 hours. After cooling, the mixture is suspended in dichloromethan (800 ml), salt is removed by filtration and the filtrate is concentrated. The resulting crystals are filtered off, washed with dichloromethane (50 ml) and dried in vacuo at 40° C. to give 16.1 g of 2-(2-indolyl)phenol (24%). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 8
[0124] 2-Hydroxyacetophenone (220 mmol, 30 g) is stirred in a mixture of dimethylformamide-dimethyl acetal for 5 hours at 70° C., cooled and recrystallised from diethylether. The intermediate is dissolved in dry ethanol (200 ml) and formamidine acetate (0.61 mmol, 63.5 g) is added. A solution of sodium (0.61 mol, 14 g) in ethanol (450 ml) is added in several portions and the mixture is refluxed for 18 hours and evaporated. Recrystallisation from diisopropylether yielded 3.6 g (10%) of 2-(pyrimidin-4-yl)phenol as a solid. This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 19
[0125] A mixture of 4-chloro-2-hydroxybenzoic acid hydrazide (Chemical Abstracts, 93:7808, 475 mg, 2.55 mmol) and triethylorthoformate (3.6 ml) is heated at 130° C. for 3.5 hours. After cooling, a precipitate formed and is collected by filtration. The filter cake is recrystallized from methanol to give 173 mg (35%) of 5-chloro-2-(1,3,4-oxadiazol-2-yl)phenol. This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield 170 mg (69%) of the titl epoxide.
Epoxide 20
[0126] A mixture of methyl 3-hydroxybenzoate (5.48 g, 36.0 mmol) and 1,2-diaminoethane monotosylate (9.85 g, 42.4 mmol) is heated at 210° C. for 7 hours. After cooling, the mixture is stirred with aqueous 2N sodium hydroxide and extracted with ethyl acetate. The precipitate which formed and is present in the aqueous layer is collected by filtration and dried in vacuo to give 1.3 g (22%) of 2-(3-hydroxyphenyl)imidazoline.
[0127] To a solution of 2-(3-hydroxyphenyl)imidazoline (0.895 g, 5.52 mmol) in tetrahydrofuran (11 ml) is added water (11 ml), potassium carbonate (1.5 g, 10.8 mmol), then di-t-butyl-dicarbonate (1.2 g, 5.5 mmol). The resulting mixture is stirred over night before additional di-t-butyl-dicarbonate (120 mg) is added and the stirring is continued for several hours. The mixture is diluted with water and extracted with ethyl acetate. The organic layer is washed with brine, dried over sodium sulfate, and concentrated under reduced pressure. The residue is purified via chromatography on silica gel with dichloromethane/ethanol (gradient up to 20:1) to give 615 mg of t-butyl (2-(3-hydroxyphenyl)imidazolin-1-yl)carboxylate (42%). This Boc-protected product (610 mg, 2.33 mmol) is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield 720 mg (97%) of the title epoxide.
Epoxide 22
[0128] A mixture of 2-iodophenol (5.00 g, 22.7 mmol), (2S)-glycidyl 3-nitrobenzenesulfonate (5.89 g, 22.7 mmol) and potassium carbonate (3.44 g, 24.9 mmol) in methylethylketone (150 ml) is refluxed for 18 hours. After cooling, the salts are removed by filtration. The filter cake is rinsed thoroughly with dichloromethane and the collected filtrates are evaporated. The residue is purified via flash chromatography on silica gel using a hexane-hexane/ethyl acetate gradient (100 to 90:10).
Epoxide 23
[0129] Sodium (1.21 g, 52.6 mmol) is added to 200 ml methanol to prepare a solution of sodium methoxide. After addition of guanidine hydrochloride (12.41 g, 129.9 mmol) and 3-(dimethylamino)-1-(2-hydroxyphenyl)-2-propen-1-one (5.0 g, 26.15 mmol; J. Heterocyclic Chem., 14:345, 1977) the mixture is heated at reflux over night. The reaction solvent is removed under reduced pressure, and the residue treated with water. The resulting precipitate is collected by filtration and dried in vacuo to give 4.25 g of 2-amino-4-(2-hydroxyphenyl)pyrimidine (87%). This pyrimidine precursor is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give 2.05 g of the title epoxide (37.5%).
Epoxide 24
[0130] A mixture of 3-hydroxyacetophenone (20.0 g, 146.9 mmol) and N,N-dimethylformamide dimethyl acetal (26.26 g, 220.4 mmol) is heated over night at 100° C. The excess of the acetal is removed under reduced pressure and 3-(dimethylamino)-1-(3-hydroxyphenyl)-2-propen-1-one (10.3. g, 37%) is obtained after chromatography on silica gel with dichloromethane/ethanol 9:1. This intermediate enone is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give 5.02 g of the title epoxide (78%).
Epoxide 25
[0131] A solution of 3-(dimethylamino)-1-(3-hydroxyphenyl)-2-propen-1-one (2.2 g, 11.5 mmol) and hydroxylamine hydrochloride (1.17 g, 16.8 mmol) in 45 ml dioxane/water 1:1 is heated for 2 hours at 60° C. The reaction is poured into ice-water and the precipitate is collected by filtration, washed with water, and dried in vacuo to give 1.4 g of 3-(5-isoxazolyl)phenol (75.5%). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give 1.33 g of the title epoxide (70%).
Epoxide 26
[0132] 2-Amino-4-(3-hydroxyphenyl)pyrimidine, prepared substantially as described for 2-amino-4-(2-hydroxyphenyl)pyrimidine, is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give the title epoxide.
Epoxide 30
[0133] To dioxane (113 ml) is added 2-methoxy-5-fluorophenylboronic acid (4.25 g, 24.9 mmol), 2-bromothiophene (3.65 g, 22.7 mmol, 0.9 eq.) and potassium carbonate (2M, 37 ml). Palladium (0) tetrakistriphenylphoshine (0.03 eq.) is then added and th resulting mixture is heated to 85° C. for 3 hours. The reaction is cooled to room temperature and poured into et l acetate and water. The aqueous layer is extracted twice with ethyl acetate. The organic layers are combined, and dried over sodium sulfate, concentrated to a brown oil and the resulting residue is flash chromatographed in 20% toluene/hexanes to afford 11.5 g of 2-(thien-2-yl)-4-fluoroanisole (90%).
[0134] The protected product from above (11.0 g, 52.8 mmol) is demethylated with 110 grams of pyridine hydrochloride neat at 200 degrees for 3 hours. The reaction is poured into ice/water and ethyl acetate is added. The layers are separated and the organic layer is washed with water, dried over sodium sulfate and concentrated to a brown solid. This is then flash chromatographed with 1:3 ethyl acetate/hexanes to afford 7.82 g of 2-(thien-2-yl)-4-fluorophenol (77% yield). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 31
[0135] Epoxide 31 is prepared from 2-methoxy-6-flourophenylboronic acid and 2-bromothiophene by a procedure substantially similar to that described for Epoxide 30.
Epoxide 33
[0136] A mixture of 2-methoxybenzaldehyde (10.0 g, 73.4 mmol), tosylmethylisocyanide (14.34 g, 73.4 mmol) and potassium carbonate (10.14 g, 73.4 mmol) in 220 ml methanol is heated at reflux for 6 hours. The solvent is removed under reduced pressure and the residue poured into ice-water (800 ml). The precipitate is collected by filtration, washed with water, and dried in vacuo to give 9.05 g of 5 (2-methoxyphenyl)oxazole (70%).
[0137] Boron tribromide (1M in dichloromethane, 36 ml) is added slowly to a cold solution (0° C.) of the above oxazole (3.0 g, 17.1 mmol) in dichloromethane (215 ml). After stirring over night at room temperature, ice-water (50 ml) is added carefully. The aqueous layer is extracted with dichloromethane (50 ml), and the combined organic layers are dried over sodium sulfate and concentrated under reduced pressure. The precipitate which formed after addition of dichloromethane (70 ml) is collected by filtration, heated with dichloromethane (15 ml), and filtered again to give 3.16 g of 2-(5-oxazolyl)phenol. This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give 400 mg of the title epoxide (9.5%).
Epoxide 34
[0138] 2-Methoxyphenylboronic acid (2 eq.) and pyrazole (1 eq.) are coupled with copper(II) acetate catalysis as described in Tetrahedron Lett. 39:2941-44, 1998 and the product is demethylated by treatment with boron tribromide in dichloromethane (see, for example, Synth. Commun. 27(20):3581-90, 1997) to yield 2-(pyrazol-1-yl)phenol. This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give the title epoxide.
Epoxide 35
[0139] 2-(Imidazolidin-2-on-1-yl)anisole ( Ger. Offen. 1977, DE 2528079) is demethylated with boron tribromide and the resulting 2-(imidazolidin-2-on-1-yl)phenol is reacte with (2S)-glycidyl 3-nitrobenzenesulfonate substantially s described for Epoxide 1 to yield the title epoxide.
Epoxide 36
[0140] 2-(Imidazol-1-yl)anisole (L. M. Sitkina, A. M. Simonov, Khim. Geterotsikl. Soedin 1966, 143) is demethylated with boron tribromide and the resulting 2-(imidazol-1-yl)phenol is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to give the title epoxide.
Epoxide 37
[0141] 3-(Dimethylamino)-1-(4-hydroxyphenyl)-2-propen-1-one is prepared from 4-hydroxyacetophenone substantially in the same manner as that described for 3-(dimethylamino)-1-(3-hydroxyphenyl)-2-propen-1-one (Epoxide 24). 4-(5-Isoxazolyl)phenol is prepared from 3-(dimethylamino)-1-(4-hydroxyphenyl)-2-propen-1-one substantially in the same manner as that described for 3-(5-isoxazolyl)phenol (Epoxide 25). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 45
[0142] 2-(3-Formyl-1-pyrrolyl)phenol (3 g, 16 mmol) and triethylamine (17.6 mmol) are added to a suspension of hydroxylamine hydrochloride (1.22 g, 17.6 mmol) in acetic anhydride (7.7 ml) and the mixture is allowed to stir overnight at ambient temperature. The mixture is refluxed for 5 hours, concentrated, dissolved in 50 ml ethanol and stirred for 10 min with 50 ml 2 M aqueous sodium hydroxi e. After neutralisation with aqueous hydrochloric acid, and extraction with ethylacetate, the organic layer is dried and concentrated. The residue is purified by chromatography (toluene/ethanol 9:1) to yield 2-(3-cyano-1-pyrrolyl)phenol (2.4 g, 92%). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 47
[0143] To 2-(3-formyl-1-pyrrolyl)phenol (2.9 g, 15.5 mmol) in 50 ml dry tetrahydrofuran are added sodium cyanoborohydride (1.94 g, 31 mmol) and boron trifluoride diethyletherate (5.7 ml, 47 mmol). The resulting solution is stirred for 3 hours at ambient temperature. Saturated sodium bicarbonate (100 ml) is added and the resulting mixture is stirred for 1 hour before extraction with t-butylmethylether. The organic layer is dried and concentrated and the residue is purified by chromatography (toluene/ethanol 9:1) to yield 2-(3-methyl-1-pyrrolyl)phenol (300 mg, 11%). This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 48
[0144] 2-Bromo-5-fluoro-phenol (0.87 ml, 7.9 mmol) and 2-thiopheneboronic acid (2.02 g, 15.8 mmol) are dissolved in 100 ml dioxane. The resulting solution is flushed with argon before tetrakis(triphenylphosphine)palladium (456 mg, 0.395 mmol) and 2 ml of aqueous 2M sodium carbonate solution (20 mmol) are added. After flushing again with argon the mixture is refluxed for 15 hours at 100° C. The solution is allowed to cool to room temperature and the mixture is filtered. The filtrate is evaporated and the residue is taken up in dichloromethane and extracted with water. The organic layer is dried with sodium sulfate then concentrated. The residue is purified by chromatography (CH 2 Cl 2 /EtOH gradient 100:0 to 98:2) to yield 1.13 g of 2-(thien-2-yl)-5-fluorophenol (74%).
[0145] 2-(Thien-2-yl)-5-fluorophenol and (2S)-glycidyl 3-nitrobenzenesulfonate are reacted as described for the preparation of Epoxide 1 to give the title epoxide.
Epoxides 49-51
[0146] 2-Bromo-5-fluorophenol is coupled with thiophene-3-boronic acid; 2-bromo-4,5-difluorophenol is coupled with thiophene-2-boronic acid; and 2-bromo-4,5-difluorophenol is coupled with thiophene-3-boronic acid in Suzuki reactions substantially as described for Epoxide 48, to yield 2-(thien-3-yl)-5-fluorophenol; 2-(thien-2-yl)-4,5-difluorophenol; and 2-(thien-3-yl)-4,5-difluorophenol, respectively. These phenolic products are reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxides.
Epoxides 52 and 61
[0147] To a solution of 6-fluorochroman-4-one (21.0 g, 126 mmol) in acetic acid (105 ml) is added bromine (6.5 ml, 126 mmol) at such a rate as to not raise the temperature above 25° C. After the addition is complete, the reaction is allowed to stir for 2 hours before pouring into 1 liter of ice. The resulting mixture is stirred over night. The precipitate which formed is filtered and placed in drying oven to produce 21 g of 3-bromo-6-fluorochroman-4-one.
[0148] The product from (14 g, 57 mmol) above is dissolved in triethylamine (100 ml) and is stirred at ref ux for 2 hours. The reaction is cooled and concentrated, ta en up in chloroform, washed with 2N aqueous hydrochloric acid and water. The organic layer is dried over sodium sulfate and concentrated. The product residue is crytallized from hot ethyl acetate.
[0149] The product from above (6-fluorochromen-4-one (5.25 g, 32.0 mmol) and hydroxylamine hydrochloride (4.65 g, 67.2 mmol) are dissolved in ethanol (180 ml) and the resulting mixture is heated to reflux. The reaction is allowed to stir for 18 hours before cooling and concentrating. The residue is is taken up in toluene and filtered to give 690 mg of 4-fluoro-2-(isoxazol-5-yl)phenol and from the filtrate 594 mg of 4-fluoro-2-(isoxazol-3-yl)phenol. These phenolic products are separately reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxides.
Epoxide 53
[0150] 2-Fluoro-6-(thien-3-yl)anisole is prepared from 2-fluoro-6-iodoanisole (1.35 g, 5.36 mmol) by Suzuki coupling with thiophene-3-boronic acid according to the general procedure described in Representative Procedure 4(b) below; yield: 1.05 g (94%).
[0151] 2-Fluoro-6-(thien-3-yl)phenol is obtained from the anisole (1.0 g, 4.8 mmol) with an excess of boron tribromide in dichloromethane by stirring over night. The crude phenol (1.1 g) is used for the next step without further purification.
[0152] Sodium hydride (0.18 g, 4.5 mmol, 60% in oil) is washed several times with hexane under argon and added to a solution of 2-fluoro-6-(thien-3-yl)phenol (0.44 g, 2.26 mmol) and (2S)-glycidyl 3-nitrobenzenesulfonate (0.587 g 2.26 mmol) in dry tetrahydrofuran (20 ml). After stirri at room temperature over night, the mixture is quenched w h ice-cold water, diluted with brine, and extracted with eth l acetate. The organic layer is dried over sodium sulfate, concentrated under reduced pressure, to give 65 mg (11%) of the title epoxide after chromatography (silica gel, dichloromethane).
Epoxide 54
[0153] A mixture of 2-bromo-1-(2-benzyloxyphenyl)ethanone (10.0 g, 32.77 mmol; prepared according to a procedure from J. Med. Chem., 35:3045, 1992) and sodium formate (4.46 g, 65.6 mmol) in dry DMF (100 ml) is stirred at room temperature over night. The mixture is poured into water (400 ml) and extracted with dichloromethane (2×100 ml). The combined extracts are dried over sodium sulfate and concentrated under reduced pressure.
[0154] The residue is dissolved in acetic acid (100 ml), treated with ammonium acetate (12.62 g, 163.7 mmol), and the mixture is heated for 3 hours. After cooling, the mixture is diluted with water (400 ml) and extracted with dichloromethane (2×100 ml). The combined organic layers are washed with saturated aqueous sodium bicarbonate solution (2×100 ml), dried over sodium sulfate, and concentrated in vacuo. 4-(2-Benzyloxyphenyl)oxazole (1.99 g, 24%) is obtained after chromatography (silica gel, dichloromethane).
[0155] To a solution of the oxazole from above (1.99 g, 7.92 mmol) in dichloromethane (20 ml) is added 10% palladium on carbon (1.99 g). The mixture is put under an atmosphere of hydrogen, stirred at room temperature over night, then filtered through Celite. The solvent is removed under reduced pressure to leave 2-(oxazol-4-yl)phenol (1.15 g, 90%), which is used for the next step without further purification.
[0156] The title epoxide (1.05 g, 72%) is prepared from the above phenol (1.08 g, 6.7 mmol) and (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1.
Epoxide 55
[0157] To a solution of 2-fluoro-6-iodoanisole (Justus Liebigs, Ann. Chem., 746:134, 1971; 4.31 g, 17.1 mmol) in dichloromethane (35 ml) is added a 1M solution of boron tribromide in dichloromethane (18.2 ml). The mixture is kept under argon and stirred for 4 hours at room temperature. The mixture is poured into a saturated aqueous sodium bicarbonate solution and-the aqueous layer is extracted with ethyl acetate. The combined organic layers are dried over sodium sulfate and concentrated under reduced pressure to give 2-fluoro-6-iodophenol (4.2 g).
[0158] The title epoxide (4.44 g, 86%) is prepared from the above phenol and (2S)-glycidyl 3-nitrobenzenesulfonate substantiallly as described for Epoxide 1 except using butanone as solvent.
Epoxides 56-60
[0159] Epoxides 56, 57, 58, 59 and 60 are prepared from 2-methoxy-5-fluorophenylboronic acid and 3-bromothiophene; 2-methoxy-6-fluorophenylboronic acid and 5-chloro-2-bromothiophene; 2-methoxyphenylboronic acid and 2-bromo-5-fluorothiophene; (3-methoxypyrid-2-yl)boronic acid and 2-bromothiophene; and 2-methoxy-6-fluorophenyl and 3-bromothiophene, respectively, by a procedure substantially similar to that described for Epoxide 30.
Epoxide 62
[0160] A slurry of 2-cyano phenol (25 g, 209.87 mmol), triethylamine hydrochloride (43.3 g, 314.81 mmol), and sodium azide (20.5 g, 314.81 mmol) in toluene (200 mL) is heated to the reflux temperature of the mixture and then the mixture is allowed to stir at reflux for 15 hours. The mixture is cooled and washed with water (200 mL). The aqueous layer is washed with ether (100 mL), made acidic with concentrated HCl, and the resulting solid is collected by filtration. The solid is washed twice with water (200 mL) and dried under vacuum at 100° C. for 15 hours to give 33.05 g of 2-(tetrazol-3-yl)phenol (97%).
[0161] 2-(Tetrazol-3-yl)phenol (32.8 g, 202.3 mmol) is dissolved in dimethylformamide (100 mL) and water (25 mL) and cooled in ice. Sodium hydroxide (8.49 g, 212.3 mmol) in water (20 mL) is added and the solution is warmed to ambient temperature. After thirty minutes, iodomethane (31.58 g, 222.5 mmol) is added neat. The solution is stirred for 15 hours then diluted with ethyl acetate (300 mL) and water (500 mL). The aqueous layer is washed three times with ethyl acetate (300 mL) and the organic layers are combined, washed three times with water (1 L), once with brine (1.2 L), dried over magnesium sulfate, filtered and concentrated in vacuo. The solid is purified by flash column chromatography (80% hexane:20% ethyl acetate gradient to 50% hexane:50% ethyl acetate as an eluent) to give 23.5 g of 2-(1-methyltetrazol-3-yl)phenol (66%).
[0162] 2-(1-Methyltetrazol-3-yl)phenol (0.25 g, 1.54 mmol), (2S)-glycidyl 3-nitrobenzenesulfonate (0.42 g, 1.62 mmol), and potassium carbonate (0.45 g, 3.23 mmol) is dissolved in methyl ethyl ketone (2 mL), the mixture is heated to the reflux temperature of the mixture, and then is allowed to stir at reflux for 15 hours. The slurry is cooled, filtered and concentrated in vacuo. The solid is purified by flash column chromatography (80% hexane:20% ethyl acetate gradient to 50% hexane:50% ethyl acetate as an eluent) to give 270 mg (75%) of the title epoxide. FDMS m/e=233 (M + +1).
Epoxide 63
[0163] The title epoxide is prepared from 2-hydroxybenzaldehyde and glyoxal by the method described in Eur. J. Med. Chem., 33:181-187, 1998. This phenolic product is reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1, however, the title epoxide is used without purification as described therein.
Epoxide 64
[0164] 2-Thienyl-1-methoxybenzene (10 g, 53 mmol) is cooled to −78° C. in dry tetrahydrofuran (265 ml) under nitrogen while stirring. n-Butyl lithium in hexanes (1.6M, 37 ml, 59 mmol, 1.1 eq.) is added slowly and the resulting mixture is stirred cold for an hour. Chloromethyl formate (4.1 ml, 53 mmol, 1.0 equivalent) is added and the reaction is stirred cold for another hour. The mixture is allowed to warm to room temperature before quenching with saturated bicarbonate solution and ethyl acetate. The layers are separated and the organic phase is washed with brine, dried over sodium sulfate and concentrated. The residue is purified via flash chromatography in 5% ethyl acetate/hexanes to afford 7.9 g of 2-(5-methoxycarbonylthien-2-yl)-1-methoxybenzene (61%).
[0165] 2-(5-Methoxycarbonylthien-2-yl)-1-methoxybenze is demethylated with boron tribromide to give 1-(5-methoxycarbonylthien-2-yl)phenol. This phenolic product i reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxide.
Epoxide 65
[0166] A solution of 5-bromothiophene-2-carbonitrile (1.25 g, 6.65 mmol) in 50 ml of dioxane is degassed with argon, tetrakis-(triphenylphosphine)-palladium(0) (768 mg, 0.665 mmol) is added and the mixture is stirred for 5 minutes. 2-Methoxybenzene boronic acid (2.02 g, 13.3 mmol) and aqueous 2 N sodium carbonate (13.3 ml) are successively added and the mixture is stirred for 16 hours at 85° C. Extractive work-up (2×50 ml dichloromethane and 2×30 ml water). The organic phase is dried over sodium sulfate, filtrated and evaporated. The residue (4.05 g) is purified via flash column on silica (eluent: 100% hexane>hexane/ethyl acetate 96:4 gradient to give 1.37 g of 2-(5-cyanothien-2-yl)anisole (96%). M+=215.
[0167] An intimate mixture of 2-(5-cyanothien-2-yl)anisole (1.2 g, 5.9 mmol) and pyridinium hydrochloride (13.7 g, 119 mmol) is heated for 1 hour to 210° C. under argon. The mixture was cooled to ambient temperature and a 1:1 mixture of water and ethyl acetate is added to break and dissolve the solid cake formed during the reaction. The slurry is then transferred to a separation funnel and dichloromethane is added until the organic phase had a higher density than the water phase (organic phase=lower phase). The organic phase contains the desired product and is separated. The remaining aqueous phase is additionally extracted twice with dichloromethane and the collected organic phases are dried over sodium sulfate and evaporated. The residue is purified via flash column on silica (eluen 100% hexane>hexane/ethyl acetate 8:2 gradient) to give 973 mg of 2-(5-cyanothien-2-yl)phenol (87%). M+=201.
[0168] To a solution of 2-(5-cyanothien-2-yl)phenol (970 mg, 4.819 mmol) in 20 ml of dry 2-butanone is added (2S)-glycidyl 3-nitrobenzenesulfonate (1.25 g, 4.82 mmol) and potassium carbonate (732 mg, 5.30 mmol) successively. After stirring for 48 hours at 75° C., the mixture is diluted with ethyl acetate and extracted with 2N aqueous sodium hydroxide (2×30 ml) and water (1×30 ml). (M+=257).
Epoxides 66-70
[0169] Epoxides 66-70 are prepared by a procedure substantially similar to that described for Epoxide 65. The starting halogeno thiophenes used to prepare Epoxides 65-70 are known from the literature, see e.g., J. Mater. Chem., 5(4), 653-61, 1995; J. Chem. Soc. , Perkin Trans. 2, 5:625-30, 1982; Chem. Scr., 5(5), 217-26, 1974; Bull. Soc. Chim. Fr., 11:4115-20, 1967; Bull. Soc. Chim. Fr., 11:4121-6, 1967; Bull. Inst. Chem. Res., 52(3):561-5, 1974; J. Med. Chem., 43(16):3168-3185, 2000; Bioorg. Med. Chem. Lett., 10(5):415-418, 2000; and JP 08311060.
Epoxide 73
[0170] A 25 ml 1-propanol solution of 2-methoxyphenyl boronic acid (1.2 g, 7.5 mmol) and 5-bromothien-2-ylsulfonamide (1.2 g, 5 mmol) is stirred under N 2 at room temperature. Palladium(II) acetate (56 mg, 0.25 mmol), triphenylphosphine (200 mg, 0.75 mmol), 2M aqueous Na 2 CO 3 (3 ml, 6 mmol), and 7 ml H 2 O are added and the resulting mixture is refluxed (˜88° C.) for 1 hour. The reaction is cooled, diluted with ethyl acetate, washed with brine, and the brine back extracted with ethyl acetate. The extract are combined, washed with aqueous NaHCO 3 , brine, dried (Na 2 SO 4 ), filtered, and the filtrate is concentrated. The residue is purified by chromatography (SiO 2 , ethyl acetate/hexane gradient) to give 943 mg (70%) of 5-(2-methoxyphenyl)thiophene-2-sulfonamide.
[0171] A 70 ml CH 2 Cl 2 suspension of 5-(2-methoxyphenyl)thiophene-2-sulfonamide (1.0 g, 3.7 mmol) is stirred under N 2 at −75° C. as boron tribromide (1.1 ml, 12 mmol) is syringed into the reaction mixture. The amber solution is stirred for 30 minutes at −75° C., then at 0° C. for 2-3 hours. The reaction is quenched with ice, extracted with CH 2 Cl 2 . The extracts are washed with brine, dried (Na 2 SO 4 ), filtered, and the filtrate is concentrated. The residue is purified by chromatography (SiO 2 , ethyl acetate/hexane gradient) to give 720 mg of 5-(2-hydroxyphenyl)thiophene-2-sulfonamide (76%).
[0172] 5-(2-Hydroxyphenyl)thiophene-2-sulfonic acid amide (1.8 g, 7.1 mmol), K 2 CO 3 (1.1 g, 8.5 mmol), and (2S)-glycidyl 3-nitrobenzenesulfonate (2.1 g, 7.8 mmol) are reacted as described for the preparation of Epoxide 1 to give 1.5 g of the title epoxide (70%).
Epoxide 74
[0173] (2-Methoxyphenyl)acetaldehyde is prepared by oxidation of 2-(2-methoxyphenyl)ethanol according to the procedure disclosed in J. Org. Chem., 49:1720, 1999. A mixture of (2-methoxyphenyl)acetaldehyde (3.8 g, 25.3 mmol) and dimethylformamide dimethyl acetal (4.52 g, 37.9 mmol) is stirred at room temperature for 1 hour. Excess of the acetal is removed under reduced pressure to leave 4.68 g of 3-dimethylamino-2-(2-methoxyphenyl)propenal (90%).
[0174] A solution of 3-dimethylamino-2-(2-methoxyphenyl)propenal (4.68 g, 22.8 mmol) and hydrazine hydrate (6.7 ml) in ethanol (100 ml) is heated at reflux or 30 minutes. The solvent is removed in vacuo and the residue is chromatographed (silica gel, dichloromethane/ethanol 95:5) to give 2.69 g of 4-(2-methoxyphenyl)pyrazole (68%).
[0175] To a solution of 4-(2-methoxyphenyl)pyrazole (300 mg, 1.72 mmol) in dichloromethane (13 ml) is added a 1M solution of boron tribromide (3.8 ml) in dichloromethane. The mixture is stirred at room temperature over night then concentrated under reduced pressure. The residue is chromatographed (silica gel, dichloromethane/ethanol 9:1) to give 270 mg of 2-(pyrazol-4-yl)phenol (98%).
[0176] 2-(Pyrazol-4-yl)phenol and (2S)-glycidyl 3-nitrobenzenesulfonate are reacted as described for the preparation of Epoxide 1 to give 180 mg of the title epoxide (50%).
Epoxides 3-5, 9-18, 21, 27-29, 32, 38-41, 43, 46, 71 and 72
[0177] 2-(Thien-2-yl)phenol ( J. Heterocycl. Chem., 22(6):1667-9, 1985); 2-(thiazol-2-yl)phenol (Arnold, et al., WO 94/22846); 2-(5-isoxazolyl)phenol; 2-(pyrrolidin-2-on-1-yl)phenol (Tetrahedron, 26(17):4207-4212, 1970); 2-morpholinophenol; 2-piperidinophenol; 1-(2-hydroxyphenyl)piperazine; 2-(2-hydroxyphenyl)benzoxazole; 2-(2-hydroxyphenyl)benzothiazole; 2-(4,4-dimethyl-2-oxazolin-2-yl)phenol ( Bioorg. Med. Chem. Lett., 6(18):2173-76, 1996); 2-(1-pyrrolidino)phenol; 2-(pyrrol-1-yl)phenol ( J. Het. Chem., 8:283-287, 1971); 2-(1,3,4-oxadiazol-2-yl)phenol (WO 94/22846); 2-(isoxazol-3-yl)phenol ( J. Het. Chem., 8:283-287, 1971); 2-(isothiazol-5-yl)phenol ( J. Chem. Res. ( S ), 349, 1988; J. Chem. Res. (S), 163, 1992); 2-(1,3,4-thiadiazol-2-yl)phenol (WO 94/22846); 2-(1,2,3-thiadiazol-4-yl)phenol; 2-(oxazol-2-yl)phenol (WO 94/22846); 4-(2-hydroxyphenyl)-2(5H)-furanone (Ger. Offen. DE2829414); 4-4-fluoro-2-hydroxyphenyl)-2(5H) -furanone (Ger. Offen. DE2829414); 2-(furan-3-yl)phenol (Ger. Offen. DE2914166); 2-thiazol-4-yl-phenol (WO 94/22846); 2-(thiazol-4-yl)phenol (WO 94/22846); 2-(4,5-dimethylimidazol-2-yl)phenol ( Eur. J. Med. Chem., 33:181-187, 1998, using 4,5-dimethylimidazole instead of imidazole); 2-(3-formylpyrrol-1-yl)phenol ( J. Het. Chem., 283-287, 1971 using 2,5-dimethoxy-3-formyl-tetrahydrofuran instead of 2,5-dimethoxy-tetrahydrofuran); 2-(3-methylisoxazol-5-yl)phenol ( J. Org. Chem., 49:4419, 1984); and 2-(4-methylisoxazol-5-yl)phenol ( Pol. J. Chem., 56:501, 1982) are reacted with (2S)-glycidyl 3-nitrobenzenesulfonate substantially as described for Epoxide 1 to yield the title epoxides.
[0178] Amines of Formula III
[0179] Amines 1-49 are prepared for use as described in Schemes 1 and 2. These amines are pictured in Tables 3-5 below.
TABLE 3 X 3 =
[0180] [0180] TABLE 4 X 3 =
[0181] [0181] TABLE 5 X 3 =
[0182] Amines 1 and 10 may be prepared according to procedures detailed in U.S. Ser. No. 09/068,192, the teachings of which are herein incorporated by reference. Amines 11, 26 and 33 may be prepared by a procedure substantially similar to that described for Amine 1. Amines 2, 3, 8, and 9 may be prepared according to procedures detailed in U.S. Pat. No. 5,977,154, the teachings of which are herein incorporated by reference. Amines 27, 29 and 40 may be prepared by a procedure substantially similar to that described for Amine 9.
Amine 4
[0183] 4-(2-Amino-2-methylpropyl)phenol (50.8 g, 225 mmol), 2-chloro-3-cyanopyridine (30.8 g, 222 mmol), potassium carbonate (77.7 g, 562 mmol, powdered), N,N-dimethylacetamide (609 ml), and isooctane (122 ml) are combined and heated to reflux. The water formed during the reaction is removed azeotropically via a Dean-Stark trap. After about 1-2 hours the reaction is complete. The slurry is cooled to 30° C. and filtered. The filter cake is washed with N,N-dimethylacetamide (250 ml) and the combined organic fractions are concentrated by rotary evaporation at 80° C. The resulting dark green oil is dissolved in dichloromethane (580 ml), and washed with water (160 ml). The phases are separated and the organic phase washed with water (250 ml). Water (1 L) is added to the organic phase and the pH adjusted to 1 with 12N aqueous hydrochloric acid (about 25 ml). The phases are separated and the acidic aqueous layer is washed with dichloromethane (250 ml). Dichloromethane (1 L) is added to the acidic aqueous phase and the pH is adjusted to 12-13 with 5N aqueous sodium hydroxide. The phases are separated and the organic phase is dried over sodium sulfate. After filtration the solution is concentrated to give 53 g of the title amine (88%).
Amine 6
[0184] 4-(2-Amino-2-methylpropyl)phenol (55.18 g, 244.9 mmol) is added to 5.05N KOH (97.2 mmol). The mixture is warmed to 50° C. to give a homogeneous yellow solution. Chlorobenzene (1104 ml) and N,N-dimethylacetamide (10.7 g, 122 mmol) is added and the mixture is heated to reflux (about 100° C.). The water is removed azeotropically via a Dean-Stark trap. At about 125° C. a solid began to form. When the pot temperature reached 132° C. the water has been removed and the reaction mixture is a thick but stirable slurry (mechanical stirring required). The Dean-Stark trap is removed and an additional 100 ml of chlorobenzene is removed and discarded. Dry chlorobenzene (50 ml) is added to the slurry, followed by ethyl 2-chloronicotinate (50.0 g, 269 mmol) in chlorobenzene (50 ml). The slurry is heated at reflux until the reaction is complete (about 24 hours). After cooling to room temperature, water (385 ml) and 1N NaOH (25 ml, 0.1 equiv) is added to the mixture and the phases are separated. The organic phase is washed with water (285 ml) and the solution is concentrated to a net weight of 700 g (89%).
Amine 7
[0185] 4-(2-Amino-2-methylpropyl)phenol (3.00 g, 18.2 mmol), methyl 6-chloronicotinate (3.27 g, 19.1 mmol), powdered potasssium carbonate (3.76 g, 27.2 mmol, 300 mesh), N,N-dimethylacetamide (60 ml), and toluene (15 ml) are combined and heated to reflux. The water formed during the reaction is removed azeotropically via a Dean-Stark trap. After about 2 hours, the internal temperature reached 154° C. and the reaction is complete. The slurry is cooled to 30° C. and filtered. The filter cake is washed with N,N-dimethylacetamide and the combined organic fractions concentrated by rotary evaporation at 75° C. The resulting oil is dissolved in ethyl acetate (50 ml), and washed with water (30 ml). The phases are separated and the aqueous phase is extracted with ethyl acetate (20 ml) after some saturated aqueous sodium chloride solution (10 ml) is added to facilitate phase separation. The combined organic fractions are washed with water (2×30 ml) and saturated aqueous sodium chloride (30 ml) and then dried over sodium sulfate. After filtration the solution is concentrated to give 4.60 g (80%) of the title amine.
Amine 12
[0186] 2-Cyano-3-chloropyridine (Bremner, et al., Syn. Comm., 27:1535, 1997; Kaneda, et al., Chem. Pharm. Bull., 33:565, 1985) is coupled to 4-(2-amino-2-methylpropyl)phenol to prepare the title amine by a procedure substantially similar to that described above for Amine 4.
Amine 24
[0187] Potassium tert-butoxide (58.6 ml, 58.6 mmol, 1M in tetrahydrofuran) is added to a solution of 3,4-dichlorothiophenol (10.0 g, 55.8 mmol) in tetrahydrofuran (300 ml) at 0° C. and the solution stirred for 30 minutes. Methyl iodide (8.32 g, 58.6 mmol) is added dropwise and the resulting slurry is stirred for 16 hours. The solvents are removed in vacuo and the residue is dissolved in 150 ml each of methyl-t-butyl ether and 1M NaHSO 4 . The phases are separated and the organic layer is washed with 150 ml each of water and saturated aqueous sodium chloride. The organic layer is dried over sodium sulfate, filtered and concentrated in vacuo to give 9.67 g of 3,4-dichlorophenyl methylsulfide (90%).
[0188] The sulfide from above is converted to the corresponding sulfone as described below for Amine 38. The 3,4 dichloromethyl sulfone is coupled to 4-(2-amino-2-methylpropyl)phenol to prepare the title amine by a procedure substantially similar to that described above for Amine 4.
Amine 31
[0189] To a 1 gallon autoclave is added 2,5-dichloropyridine (123 g, 830 mmol), palladium II acetate (5.6 g, 24.9 mmol), 1,3-bis(diphenylphosphine)propane (20.5 g, 49.8 mmol), 1,1,1,3,3,3,-hexamethyldisilazane (700 ml), acetonitrile (1180 ml) and dimethylformamide (295 ml). The autoclave is pressurized to 70 psi with carbon monoxide and heated to 80° C. for 16 hours. The reaction mixture is filtered and washed with acetonitrile. The mixture is concentrated in vacuo to 590 g and 1L of water is added. The resulting slurry is cooled to 0° C. and filtered to give 102.6 g (79%) of 2-carboxamido-5-chloropyridine which is used without further purification.
[0190] 2-Carboxamido-5-chloropyridine is coupled to 4-(2-amino-2-methylpropyl)phenol to prepare the title Amine by a procedure substantially similar to that described above for Amine 4.
Amine 36
[0191] Oxalyl chloride (18.1 ml, 207 mmol) is added slowly to dimethylformamide cooled to −25° C. The resulting mixture is cooled to −45° C. and 2-carboxamido-5-chloropyridine (25 g, 160 mmol) is added portionwise. The reaction stirred for 30 minutes and pyridine (14.2 ml, 176 mmol) is added. The reaction stirred for 5 hours, 20 minutes and is poured into 1.5 L of water and 1 L of ethyl acetate is added. The phases are separated and the aqueous layer is extracted with 100 ml of ethyl acetate. The combined organics are washed with water (850 ml and 350 ml), saturated aqueous sodium chloride (100 ml), dried over sodium sulfate, filtered and concentrated in vacuo to give 19.95 g (92%) of 2-cyano-5-chloropyridine which is used without further purification.
[0192] 2-Cyano-5-chloropyridine is coupled to 4-(2-amino-2-methylpropyl)phenol to prepare the title amine by a procedure substantially similar to that described above for Amine 4.
Amine 38
[0193] To a solution of n-butyl lithium (0.544 mol) in tetrahydrofuran (700 ml) at −78° C. is added a solution of 3,4-difluorobromobenzene (100 g, 0.518 mol) in 200 ml of tetrahydrofuran. After 10 minutes, a solution of dimethyl disulfide in 100 ml of tetrahydrofuran is added and the resulting reaction mixture is warmed to ambient temperature over 60 minutes. The reaction is concentrated in vacuo and the resulting oil is partitioned between 750 ml methyl-t-butyl ether and 300 ml water. The phases are separated and the organic layer is washed with 300 ml of saturated aqueous sodium chloride, dried over magnesium sulfate, filtered, and concentrated in vacuo. The resulting oil is purified by vacuum distillation to provide 43.08 g of 3,4-difluorophenyl methylsulfide.
[0194] Metachloroperbenzoic acid (60.4 mmol) is added portionwise to a solution of the sulfide (43 g, 26.8 mmol) in 1L of dichloromethane at 0° C. After 15 minutes, the reaction mixture is warmed to ambient temperature and stirred for 1.25 hours. The solids are removed by filtration and the resulting solution washed with 750 ml of 1M sodium bisulfite, 2L sodium bicarbonate, 1L water, and 750 ml saturated aqueous sodium chloride. The organic layer is dried over magnesium sulfate, filtered and concentrated in vacuo to give 45.17 g (88%) of the title amine.
Amine 41
[0195] The acetic acid salt of 4-(2-amino-2-methylpropyl)phenol (15 g, 66.5 mmol) is dissolved in 90 ml of hot water. 5N aqueous sodium hydroxide (13.98 ml, 0.0699 mol) is added and the resulting mixture is allowed to stir for one hour upon which a precipitate formed. The reaction is then placed in the refrigerator to allow more precipitation. The precipitate is filtered to afford 6.91 g of 4-(2-amino-2-methylpropyl)phenol free base.
[0196] 4-(2-Amino-2-methylpropyl)phenol free base (6.91 g, 41.8 mmol) is dissolved in 100 ml of anhydrous tetrahydrofuran and the solution is purged with nitrogen. Di-t-butyl-dicarbonate (10.56 ml, 46 mmol) is added and the resulting solution is allowed to stir overnight. The reaction is concentrated, the residue dissolved in ethyl acetate, and then washed with water. The organic layer is dried over sodium sulfate, filtered and concentrated to a clear oil. The oil is taken up in anhydrous tetrahydrofuran and diisopropylethylamine (7.94 ml, 46 mmol) is added followed by trifluoromethanesulfonic anhydride (7.67 ml, 45 mmol). The reaction is allowed to stir for 3 hours, quenched with water, extracted with ethyl acetate, dried over sodium sulfate and concentrated to a clear solid.
[0197] A portion of the above solid (2.7 g, 6.8 mmol) is mixed with 3-cyanophenyl boronic acid (1.0 g, 6.8 mmol), aqueous potassium carbonate (2M, 7.1 ml, 14.3 mmol), lithium chloride (288 mg, 6.8 mmol) and 60 ml of tetrahydrofuran. The reaction is fitted with a condenser and purged with nitrogen before palladium(0) tetrakistriphenylphoshine is added (37.9 mg, 0.34 mmol). The reaction flask is covered with aluminum foil and the solution is brought to reflux. After 16 hours, the reaction is poured into a separatory funnel. Ethyl acetate (100 ml) is added and the organic layer is washed with water, 1N aqueous HCl, water, 1N aqueous sodium hydroxide and again with water. The organic layer is dried over sodium sulfate and concentrated to a brown solid. The crude product is purified on a silica flash column eluting with 20% ethyl acetate/80% hexanes to give 900 mg of the amine protected title amine.
[0198] The protected amine from above (1.025 g, 2.9 mmol) is placed in a flask and stirred with trifluoroacetic acid (neat). After 10 minutes, the solution is concentrated and taken up in 10 ml of methanol. This solution is then placed on a 10 g SCX column and washed with methanol (2×10 ml). The product is eluted with methanolic ammonia (2M) to give 735 mg of the title amine.
Amine 43
[0199] Carbonyldiimidazole (43.0 g, 265 mmol) is added in one portion to a solution of 2-chloro-5-carboxythiophene (39.2 g, 241 mmol) in 400 ml of tetrahydrofuran. The resulting mixture is allowed to stir for 60 minutes before aqueous ammonium hydroxide (28%, 125 ml) is added in one portion. After stirring for 90 minutes, the mixture is concentrated in vacuo and the residue is dissolved in ethyl acetate (750 ml). This organic solution is washed with aqueous sodium hydroxide (1N, 100 ml) and then four times with aqueous hydrochloric acid (1N, 100 ml). The organic layer is dried over sodium sulfate, filtered, and concentrated in vacuo, and dried overnight at 40° C. in vacuo to give 22.6 g of 2-chloro-5-carboxamidothiophene.
[0200] Oxalyl chloride (8.9 ml, 102 mmol) is added dropwise to a cold solution (−40° C.) of 2-chloro-5-carboxamidothiophene (15 g, 92.8 mmol) in dimethylformamide (150 ml). After the addition is complete, the reaction is allowed to stir for 2 hours before it is diluted with ethyl acetate (500 ml). The resulting mixture is washed four times with water (25 ml), dried over sodium sulfate, and concentrated in vacuo to give 12.3 g of 2-chloro-5-cyanothiophene.
[0201] 2-Chloro-5-cyanothiophene (3.8 g, 26.6 mmol) and 4-(2-amino-2-methylpropyl)phenol (4.0 g, 17.8 mmol) are dissolved in dimethylsulfoxide (15 ml). Sodium hydride (60% dispersion in oil, 1.5 g) is added in portions over 2 hours. The first addition (about half of the total) is done at room temperature. The reaction is heated to 50° C. and the remaining sodium hydride is added in portions. After the additions are complete, the reaction mixture is heated to 90° C. and is allowed to stir for 44 hours. After allowing the reaction mixture to cool, it is diluted with dichloromethane (45 ml) and water (90 ml). The layers are separated and the organic layer is washed with water (15 ml). Water (77 ml) is added to the organic layer and the pH of the aqueous phase is adjusted to 1 with concentrated hydrochloric acid (1.9 ml). The aqueous layer is washed with dichloromethane (14 ml) and then the pH is adjusted to 13 with aqueous sodium hydroxide (5N, 14 ml). The aqueous layer is extracted three times with dichloromethane (90 ml, 2×45 ml). The extracts are combined, dried over sodium sulfate, and concentrated in vacuo to give 3.5 g of the title amine.
Amine 48
[0202] 2-Methyl-hydroxy-phenol (15.0 g, 0.12 mol), 2-nitro propane (60.8 ml, 676 mmol)., potassium t-butoxide (6.77 g, 60 mmol) and diglyme (150 ml) are mixed together in a reaction vessel and said vessel is fitted with a Dean-Stark water trap. The reaction is heated to 134° C. until water and solvent began to collect in the trap. The reaction is slowly heated to 149° C. and then is allowed to cool back down to 130° C. at which point the reaction is stirred for 3 hours. Reaction is cooled to room temperature and water (20 ml) is added. After concentrating to about half the volume, water (100 ml) is added and the mixture is extracted with ethyl acetate (2×100 ml). The organic layer is then washed with 1N aqueous hydrochloric acid and water, dried over sodium sulfate and concentrated to a brown oil. A mixture of ethyl acetate and hexanes, (300 ml, 1:4 ethyl acetate/hexanes) is added and product is triturated.
[0203] The product from above (7.0 g) is taken up in methanol and acetic acid and 5% palladium on carbon is added. Hydrogen gas is injected into the reaction vessel up to 50 p.s.i. The mixture is then heated to 50° C. and shaken for 16 hours. The catalyst is filtered and the reaction is concentrated. Ethyl acetate (400 ml) is added and product is filtered to give 7.55 g of 2-(2-amino-2-methylpropyl)phenol acetic acid salt. 2-(2-Amino-2-methylpropyl)phenol acetic acid salt is converted to its free base form, the free base is reacted with di-t-butyl-dicarbonate, and the protected amine is reacted with 4-cyanophenyl boronic acid to prepare the title amine substantially as described above for Amine 41.
Amines 5, 13-23, 25, 28, 30, 32, 34, 35, 37, 39, 42, 44-47 and 49
[0204] Amines 5, 13-23, 25, 28, 30, 32, 34, 35, 37 and 39 are prepared by procedures substantially similar to that described for Amine 4. Amines 42 and 47 are prepared by procedures substantially similar to that described for Amine 41. Amines 44-46 are prepared by procedures substantially similar to that described for Amine 43. Amine 49 is prepared by procedures substantially similar to that described for Amine 48.
[0205] Aryl Halides of Formula V
[0206] Aryl halides 1-14 are prepared for use as described in Scheme 2. These aryl halides are pictured below in Tables 6 and 7.
TABLE 6 X 3 =
[0207] [0207] TABLE 7 X 3 =
[0208] Representative Procedure 1: Preparation of Aryl Halides
[0209] (2S)-1-(2-iodophenyloxy)-2,3-epoxypropane (Epoxide 22, 8 mmol) or (2S)-1-(2-iodo-6-fluorophenyloxy)-2,3-epoxypropane (Epoxide 55) is reacted with an equimolar amount of an amine of formula III (Amines 2-5, 9, 10, 12, 31, 36 or 40) in 100 ml of refluxing dry ethanol overnight. After evaporation of the solvent the residue is purified via flash chromatography on silica gel using a dichloromethane-dichloromethane/ethanolic ammonia gradient (100 to 95:5).
[0210] Boronic Acids
[0211] The following boronic acids or cyclic esters are obtained from commercial sources for use as described in Scheme 2.
TABLE 8
EXAMPLES
[0212] Representative Procedure 2: Amination of Epoxide
[0213] A vial is charged with a solution of single amine of formula III (0.2M in ethanol or t-butanol, 90 micromolar) and a solution of a single epoxide of formula II (0.2M in dimethylsulfoxide, 80 micromolar). The vial is sealed and heated to 80° C. for 24-48 hours. The solution is cooled to room temperature, diluted with methanol, and passed over a cation exchange column, eluting the basic material with 1N methanolic ammonia.
[0214] Representative Procedure 3: Amination of Epoxide
[0215] A stirred mixture of an epoxide of formula II (1 equivalent) and an amine of formula III (1-2 equivalents) in ethanol, methanol, n-butanol or t-butanol is heated at 70-80° C. for 2-72 hours. The solvent is evaporated to dryness to give a crude oil that is optionally diluted with methanol or ethanol and passed over a cation exchange column (eluting the free base product with 1N methanolic ammonia) before further purification.
[0216] The final products prepared via Representative Procedure 2 or 3 may be further purified by flash or radial chromatography. Typical chromatography conditions include: a) using a variable mixture of 25:5:1 chloroform/methanol/ammonium hydroxide and 9:1 chloroform/methanol; b) a variable mixture of 90:10:1 CH 2 Cl 2 /ethanolic NH 3 gradient; c) dichloromethane/6-12% methanol, 0.15-0.35M ammonia in dichloromethane gradient; d) methylene chloride with a step gradient to 2-8% methanol; e) chloroform/2.0M ammonia in methanol, from 0-10% to 6-20% gradient elution or f) isocratic 6-8% 2M ammonia in methanol: 92-94% dichloromethane.
[0217] Alternatively, the final products may be purified on C18 bonded silica gel using either mass guided or UV guided reverse phase liquid chromatography (acetonitrile/water with 0.01% hydrochloric acid or 0.1% trifluoroacetic acid). When purification of a compound of the present invention results in production of a free base, the free base thus prepared may be salified, e.g., by dissolution of the free base in CH 2 Cl 2 or diethylether, adding 1M ethanolic HCl or a solution of HCl in diethylether, and evaporating the volatiles, or as described in more detail below.
[0218] For example, a hydrochloride salt may be prepared by dissolving the free base in dichloromethane, diethylether, or a mixture of ethyl acetate and methanol and adding 1M ethanolic HCl, a solution of HCl in diethylether, or 0.5M ammonium chloride. The resulting mixture is allowed to stir for a short time, e.g., for five minutes, before evaporating the volatiles and optionally triturating in diethyl ether to give the hydrochloride salt.
[0219] The oxalate salts may be prepared by dissolving the free base in a small amount of ethyl acetate, optionally adding methanol for solubitity. The resulting solution is treated with 1 equivalent of a 0.5M solution of oxalic acid in ethyl acetate. The reaction mixture is either concentrated in vacuo or centrifuged, separated, and the solids are dried, to give the oxalate salt.
[0220] To prepare a succinate salt, the free base may be dissolved in a small amount of ethyl acetate or methanol and then treated with 1 equivalent of succinic acid in methanol. The resulting slurry is dissolved in the minimum amount of methanol then concentrated in vacuo to give the succinate salt.
[0221] For products synthesized from Epoxide 6, the c de products are treated with 1N HCl/dioxane for 2 hours at room temperature and concentrated before purifying on C18 bonde silica gel as described above to give a compound of the formula:
[0222] For products synthesized from Epoxide 20, the title compounds are prepared by removal of the Boc-protecting group from the imidazoline ring by stirring a solution of the crude protected product in dichloromethane/2N HCl 10:1.
[0223] For products synthesized from Epoxide 24, the intermediate N,N-dimethyl s are treated with hydrazine hydrate in ethanol to give a compound of the formula:
[0224] The table below sets out representative combinations of Amines and Epoxides that are reacted as described above in Representative Procedure 2 or 3. Preparation of desired product is confirmed via mass spectral analysis (MSA). Emax±Standard Error Mean (SEM) data, discussed in the “Demonstration of Function” section below, is also included for said compounds where available. The Emax values represent the average of at least 3 runs except as otherwise indicated.
TABLE 9 E.g. Epoxide Amine MSA Isolated Form Emax (%) ± SEM 1 3 1 475.2 Trifluoro Acetate 58.1 ± 2.6 2 5 1 460.2 Trifluoro Acetate 43.6 ± 9.7 3 1 2 498.3 Free Base <10 4 2 4 498.3 Free Base 55.0 ± 1.3 5 3 2 500.3 Free Base 66.1 ± 4.8 6 4 2 501.3 Free Base 58.7 ± 1.8 7 5 2 485.0 Free Base 48.8 ± 2.5 8 6 2 484.1 Free Base 33.7 ± n = 1 9 7 2 533.4 Free Base 23.7 ± 10.0 10 8 2 496.6 Free Base 35.1 ± 0.9 11 9 2 501.4 Free Base 18.0 ± 6.5 12 21 2 485.2 Hydrochloride 64.8 ± 6.3 13 33 2 485.3 Hydrochloride 54.8 ± 1.7 14 1 3 516.3 Free Base 16.9 ± n = 1 15 2 5 516.3 Free Base 70.9 ± 3.0 16 3 3 518.3 Free Base 67.6 ± 4.7 17 4 3 519.3 Free Base 62.9 ± 2.2 18 5 3 503.0 Free Base 49.1 ± 2.9 19 6 3 502.1 Free Base 31.3 ± n = 1 20 7 3 551.5 Free Base 30.4 ± 2.5 21 7 5 551.4 Free Base 48.0 ± 2.0 22 9 3 519.3 Free Base 22.0 ± 5.3 23 10 3 521.4 Di-Hydrochloride 29.9 ± 3.2 24 11 3 519.5 Di-Hydrochloride 17.3 ± 3.2 25 12 3 520.4 Tri-Hydrochloride 13.7 ± 3.5 26 13 3 553.3 Free Base 41.4 ± 6.6 27 14 3 569.3 Free Base 20.8 ± 8.5 28 15 3 533.3 Free Base 83.4 ± 7.2 29 17 3 501.3 Hydrochloride 48.4 ± 5.9 30 18 3 504.5 Free Base 51.7 ± 2.7 31 19 3 538.3 Free Base 12.1 ± n = 1 32 21 3 503.3 Hydrochloride 54.2 ± 5.0 33 23 3 529.3 Free Base 26.2 ± 4.3 34 24 3 502.4 Free Base <10 35 25 3 503.3 Free Base 28.9 ± n = 1 36 37 3 503.3 Free Base 17.5 ± n = 1 37 5 3 489.2 Trifluoro Acetate 41.5 ± 0.5 38 26 3 529.3 Free Base 20.5 ± n = 1 39 27 3 519.2 Oxalate 67.1 ± 0.7 40 27 3 500.3 Trifluoro Acetate 79.5 ± 6.7 41 38 3 518.3 Hydrochloride 33.5 ± 4.2 42 28 3 520.2 Oxalate 43.3 ± 2.7 43 40 3 502.4 Hydrochloride 61.9 ± 2.5 44 29 3 520.2 Oxalate 22.1 ± 3.3 45 32 3 503.3 Free Base 66.5 ± 3.9 46 33 3 503.3 Hydrochloride 64.7 ± 1.3 47 34 3 502.4 Hydrochloride 35.5 ± 5.5 48 1 4 498.3 Free Base 14.4 ± n = 1 49 2 2 498.3 Free Base 59.1 ± n = 1 50 3 4 500.3 Free Base 78.9 ± 2.5 51 3 4 499.9 Hydrochloride 74.1 ± 3.3 52 4 4 501.3 Free Base 70.1 ± 3.3 53 5 4 485.0 Free Base 74.5 ± 12.5 54 5 4 484.9 Hydrochloride 66.8 ± 6.8 55 6 4 484.1 Free Base 37.5 ± n = 1 56 7 4 533.3 Free Base 30.1 ± 2.1 57 8 4 496.4 Free Base 41.8 ± 5.6 58 9 4 501.3 Free Base 21.0 ± 3.4 59 20 3 504.3 Free Base <10 60 21 4 485.2 Hydrochloride 70.8 ± 3.1 61 23 4 511.4 Free Base 32.8 ± 4.3 62 37 4 485.3 Trifluoro Acetate 24.7 ± 5.2 63 30 4 518.2 Oxalate 52.6 ± 2.5 64 31 4 518.2 Trifluoro Acetate 30.5 ± 6.8 65 33 4 485.3 Hydrochloride 55.9 ± 5.8 66 1 5 516.3 Free Base 26.6 ± n = 1 67 2 3 516.3 Free Base 77.4 ± n = 1 68 3 5 518.3 Free Base 83.7 ± 3.0 69 3 5 517.9 Hydrochloride 80.7 ± 4.4 70 4 5 519.3 Free Base 73.8 ± 6.0 71 4 5 518.9 Hydrochloride 65.6 ± 1.3 72 5 5 503.0 Free Base 67.6 ± 7.1 73 5 5 502.9 Hydrochloride 69.5 ± 0.1 74 6 5 502.1 Free Base 36.8 ± n = 1 75 8 3 514.5 Free Base 40.3 ± 3.7 76 8 5 514.3 Free Base 48.8 ± 5.5 77 9 5 519.3 Free Base 22.4 ± 4.6 78 10 5 521.4 Di-Hydrochloride 30.3 ± 5.1 79 11 5 519.3 Di-Hydrochloride 21.3 ± 3.3 80 12 5 520.4 Tri-Hydrochloride 12.3 ± 0.2 81 13 5 553.3 Free Base 60.4 ± 5.1 82 14 5 569.2 Free Base 45.9 ± 10.7 83 15 5 533.3 Hydrochloride 83.5 ± 4.4 84 16 5 505.3 Free Base 72.1 ± 6.2 85 17 5 501.2 Hydrochloride 69.2 ± 12.1 86 18 5 504.3 Free Base 64.6 ± 3.3 87 19 5 538.1 Free Base 14.2 ± n = 1 88 20 5 504.3 Free Base <10 89 21 5 503.3 Hydrochloride 71.8 ± 2.5 90 23 5 529.5 Free Base 31.5 ± 2.8 91 26 5 529.3 Free Base 24.9 ± 9.3 92 24 5 502.4 Free Base 14.4 ± n = 1 93 25 5 503.3 Free Base <10 94 37 5 503.3 Free Base <10 95 39 5 536.3 Hydrochloride 13.9 ± 0.1 96 27 5 519.2 Oxalate 78.1 ± 6.6 97 28 5 520.2 Oxalate 52.4 ± 0.8 98 29 5 520.2 Oxalate 39.2 ± 4.0 99 30 5 536.2 Oxalate 59.1 ± 0.6 100 31 5 536.2 Trifluoro Acetate 31.4 ± 5.0 101 33 5 503.3 Hydrochloride 67.4 ± 4.0 102 34 5 502.4 Hydrochloride 46.1 ± 4.5 103 35 5 520.5 Free Base 21.1 ± 0.1 104 36 5 502.4 Hydrochloride 36.0 ± 5.0 105 1 6 545.4 Free Base <10 106 2 6 545.3 Free Base 53.2 ± 2.4 107 3 6 547.3 Free Base 84.3 ± 5.3 108 3 6 547.2 Trifluoro Acetate 87.1 ± 11.9 109 4 6 548.3 Free Base 61.4 ± 4.4 110 5 6 532.0 Free Base 60.3 ± 3.9 111 6 6 531.1 Free Base 23.6 ± n = 1 112 5 6 532.2 Trifluoro Acetate 56.9 ± 8.6 113 1 7 531.3 Free Base 20.7 ± n = 1 114 2 7 531.3 Free Base 56.6 ± n = 1 115 3 7 533.3 Free Base 61.9 ± 7.0 116 4 7 534.3 Free Base 58.2 ± 7.2 117 5 7 518.0 Free Base 32.2 ± 6.5 118 6 7 517.1 Free Base 29.5 ± n = 1 119 3 8 499.2 Trifluoro Acetate 55.2 ± 3.6 120 4 8 500.2 Trifluoro Acetate 35.8 ± 4.6 121 5 8 484.3 Trifluoro Acetate 38.9 ± 7.1 122 27 8 505.3 Trifluoro Acetate 61.9 ± 5.3 123 3 9 516.2 Trifluoro Acetate 73.6 ± 8.2 124 4 9 518.2 Trifluoro Acetate 46.7 ± 3.6 125 5 9 502.2 Trifluoro Acetate 40.3 ± 7.9 126 27 9 518.2 Trifluoro Acetate 62.2 ± 1.3 127 1 10 550.3 Free Base <10 128 2 10 550.3 Free Base 40.6 ± n = 1 129 3 10 552.2 Trifluoro Acetate 53.2 ± 4.8 130 4 10 553.3 Free Base 49.5 ± 3.4 131 4 10 552.9 Trifluoro Acetate 43.5 ± 1.4 132 5 10 537.0 Free Base 34.6 ± 7.8 133 6 10 536.1 Free Base 21.4 ± n = 1 134 21 10 537.4 Hydrochloride 47.7 ± 6.5 135 5 10 537.2 Trifluoro Acetate 35.2 ± 4.3 136 39 10 570.2 Hydrochloride <10 137 1 11 564.3 Free Base <10 138 2 11 564.3 Free Base 41.7 ± n = 1 139 3 11 566.3 Free Base 62.2 ± 7.4 140 4 11 567.3 Free Base 48.9 ± 2.5 141 5 11 551.0 Free Base 48.3 ± 9.9 142 6 11 550.1 Free Base 20.2 ± n = 1 143 3 12 500.2 Trifluoro Acetate 67.2 ± 4.8 144 4 12 501.2 Trifluoro Acetate 55.9 ± 1.1 145 4 36 501.2 Trifluoro Acetate 44.6 ± 6.2 146 5 12 484.2 Trifluoro Acetate 58.7 ± 2.9 147 27 12 501.2 Trifluoro Acetate 58.9 ± 3.6 148 30 12 536.2 Trifluoro Acetate 51.6 ± 9.7 149 31 12 518.2 Trifluoro Acetate 26.9 ± 4.0 150 3 13 476.2 Trifluoro Acetate 69.8 ± 6.0 151 4 13 477.2 Trifluoro Acetate 73.1 ± 3.8 152 5 13 461.2 Trifluoro Acetate 45.3 ± 4.2 153 3 14 476.2 Trifluoro Acetate 66.8 ± 5.5 154 4 14 477.3 Trifluoro Acetate 61.1 ± 7.7 155 5 14 461.2 Trifluoro Acetate 46.6 ± 4.2 156 3 15 577.1 Trifluoro Acetate 84.9 ± 0.2 157 4 15 578.1 Trifluoro Acetate 73.3 ± 6.6 158 5 15 562.1 Trifluoro Acetate 73.0 ± 3.0 159 3 16 577.2 Trifluoro Acetate 76.9 ± 7.4 160 5 16 562.2 Trifluoro Acetate 56.3 ± 1.4 161 3 17 533.2 Trifluoro Acetate 52.5 ± 4.7 162 4 17 428.2 Trifluoro Acetate 36.2 ± 2.6 163 5 17 518.2 Trifluoro Acetate 44.6 ± 4.3 164 3 18 551.2 Trifluoro Acetate 67.3 ± 3.5 165 4 18 552.2 Trifluoro Acetate 49.7 ± 3.9 166 5 18 536.2 Trifluoro Acetate 58.3 ± 9.5 167 3 19 509.2 Trifluoro Acetate 57.3 ± 3.5 168 4 19 510.2 Trifluoro Acetate 56.1 ± 4.5 169 5 19 494.2 Trifluoro Acetate 43.3 ± 6.8 170 3 20 576.2 Trifluoro Acetate 55.0 ± 4.8 171 4 20 * Trifluoro Acetate 47.9 ± 6.5 172 5 20 561.2 Trifluoro Acetate 40.4 ± 8.8 173 3 21 543.2 Trifluoro Acetate 87.9 ± 4.5 174 5 21 528.2 Trifluoro Acetate 59.3 ± 3.2 175 3 22 509.2 Trifluoro Acetate 67.4 ± 3.9 176 4 22 510.2 Trifluoro Acetate 57.0 ± 7.6 177 5 22 494.2 Trifluoro Acetate 46.0 ± 1.7 178 3 23 509.2 Trifluoro Acetate 64.4 ± 5.2 179 4 23 510.2 Trifluoro Acetate 62.2 ± 8.6 180 5 23 494.2 Trifluoro Acetate 52.4 ± 6.9 181 3 24 586.2 Trifluoro Acetate 66.2 ± 1.6 182 4 24 587.1 Trifluoro Acetate 57.6 ± 7.1 183 5 24 571.2 Trifluoro Acetate 53.7 ± 4.3 184 3 25 564.2 Trifluoro Acetate 64.1 ± 3.2 185 4 25 565.2 Trifluoro Acetate 45.1 ± 2.6 186 5 25 549.2 Trifluoro Acetate 41.1 ± 8.2 187 3 26 517.2 Trifluoro Acetate 45.1 ± 1.5 188 4 26 518.2 Trifluoro Acetate 38.3 ± 5.7 189 5 26 502.2 Trifluoro Acetate 35.1 ± 5.2 190 3 27 535.2 Trifluoro Acetate 54.5 ± 3.3 191 4 27 536.2 Trifluoro Acetate 49.5 ± 1.5 192 5 27 520.2 Trifluoro Acetate 40.3 ± 6.9 193 3 28 543.2 Trifluoro Acetate 73.5 ± 3.2 194 4 28 544.2 Trifluoro Acetate 56.6 ± 4.2 195 5 28 528.2 Trifluoro Acetate 48.1 ± 3.8 196 3 29 518.2 Trifluoro Acetate 74.4 ± 3.3 197 4 29 519.2 Trifluoro Acetate 67.7 ± 2.7 198 5 29 503.2 Trifluoro Acetate 48.1 ± 6.5 199 27 29 519.3 Trifluoro Acetate 83.0 ± 4.0 200 30 29 518.2 Trifluoro Acetate 59.5 ± 3.7 201 31 29 517.2 Trifluoro Acetate 26.8 ± 4.2 202 3 30 475.2 Trifluoro Acetate 59.1 ± 6.0 203 4 30 476.2 Trifluoro Acetate 57.8 ± 3.1 204 3 37 580.2 Trifluoro Acetate 67.6 ± 4.0 205 3 31 518.2 Trifluoro Acetate 70.3 ± 0.3 206 4 31 519.2 Trifluoro Acetate 64.2 ± 8.1 207 27 31 519.2 Trifluoro Acetate 70.5 ± 4.9 208 3 32 510.2 Trifluoro Acetate 92.4 ± 7.3 209 4 32 511.2 Trifluoro Acetate 88.3 ± 8.0 210 5 32 * Trifluoro Acetate 89.1 ± 2.7 211 27 32 511.2 Trifluoro Acetate 88.5 ± 9.3 212 5 33 484.7 Trifluoro Acetate 68.9 ± 3.1 213 27 33 500.2 Trifluoro Acetate 63.0 ± 3.2 214 30 33 517.2 Trifluoro Acetate 42.4 ± 9.4 215 31 33 535.2 Trifluoro Acetate 28.1 ± 4.5 216 3 34 533.2 Trifluoro Acetate 85.4 ± 4.9 217 5 34 518.2 Trifluoro Acetate 76.2 ± 8.3 218 3 35 551.2 Trifluoro Acetate 76.5 ± 1.7 219 5 35 536.2 Trifluoro Acetate 50.4 ± 6.3 220 3 36 500.3 Trifluoro Acetate 56.0 ± 2.9 221 5 36 484.2 Trifluoro Acetate 40.8 ± 8.3 222 4 37 581.2 Trifluoro Acetate 59.0 ± 10.0 223 3 38 570.2 Trifluoro Acetate 63.7 ± 3.1 224 4 38 571.2 Trifluoro Acetate 37.0 ± 0.3 225 3 39 571.2 Trifluoro Acetate 59.5 ± 4.3 226 4 39 572.2 Trifluoro Acetate 37.8 ± 9.2 227 30 40 535.2 Trifluoro Acetate 51.3 ± 10.8 228 31 40 535.2 Trifluoro Acetate 28.9 ± 3.4 229 5 41 468.2 Oxalate 34.7 ± 4.3 230 5 42 468.2 Oxalate 30.8 ± 6.0 231 3 43 505.2 Trifluoro Acetate 65.9 ± 4.2 232 5 43 490.2 Trifluoro Acetate 37.4 ± 2.8 233 3 44 523.2 Trifluoro Acetate 71.0 ± 4.7 234 5 44 508.2 Trifluoro Acetate 44.0 ± 4.4 235 3 45 * Trifluoro Acetate 60.5 ± 5.6 236 5 45 474.2 Trifluoro Acetate 36.8 ± 1.6 237 3 46 507.2 Trifluoro Acetate 57.7 ± 1.1 238 5 46 492.2 Trifluoro Acetate 47.6 ± 2.4 239 41 4 501.2 Hydrochloride 49.8 ± 4.5 240 41 5 519.2 Hydrochloride 65.7 ± 3.8 241 41 12 501.2 Hydrochloride 47.0 ± 2.5 242 41 29 519.2 Hydrochloride 55.9 ± 4.0 243 41 33 500.2 Hydrochloride 47.9 ± 3.5 244 41 40 518.2 Hydrochloride 66.6 ± 5.7 245 41 34 534.2 Hydrochloride 56.1 ± 2.9 246 41 35 552.2 Hydrochloride 52.1 ± 2.4 247 41 2 501.2 Hydrochloride 45.4 ± 3.4 248 41 3 519.2 Hydrochloride 47.5 ± 4.8 249 41 10 553.2 Hydrochloride 35.9 ± 2.9 250 41 38 571.2 Hydrochloride 31.6 ± 3.1 251 41 39 572.2 Hydrochloride 33.4 ± 5.7 252 41 27 536.2 Hydrochloride 38.4 ± 3.8 253 41 18 552.2 Hydrochloride 37.6 ± 2.7 254 41 16 578.2 Hydrochloride 50.5 ± 0.8 255 41 22 510.2 Hydrochloride 41.4 ± 3.9 256 41 14 477.3 Hydrochloride 50.6 ± 1.8 257 41 13 477.2 Hydrochloride 49.9 ± 3.4 258 41 43 506.2 Hydrochloride 48.4 ± 5.6 259 41 44 524.2 Hydrochloride 54.1 ± 3.9 260 41 45 490.2 Hydrochloride 38.2 ± 2.0 261 41 46 508.2 Hydrochloride 52.3 ± 6.6 262 43 5 530.2 Dihydrochloride 63.6 ± 4.3 263 17 4 486.6 Hydrochloride 64.3 ± 9.6 264 17 2 486.6 Hydrochloride 39.4 ± 10.1 265 17 10 535.7 Hydrochloride 42.7 ± 9.4 266 17 31 501.6 Hydrochloride 36.7 ± 6.8 267 17 36 486.6 Hydrochloride 37.1 ± 2.5 268 17 12 483.6 Hydrochloride 54.6 ± 8.2 269 17 9 500.6 Hydrochloride 41.3 ± 4.2 270 17 40 500.6 Hydrochloride 56.4 ± 8.3 271 45 5 526.6 Hydrochloride 39.0 ± 0.6 272 45 3 526.6 Hydrochloride 35.7 ± 2.8 273 46 5 529.6 Free Base 40.3 ± 0.5 274 46 3 529.6 Free Base 38.8 ± 1.4 275 47 5 514.6 Hydrochloride 47.0 ± 1.4 276 47 3 514.6 Hydrochloride 53.8 ± 2.0 277 48 3 536.6 Hydrochloride 42.3 ± 11.1 278 48 5 536.6 Hydrochloride 27.5 ± 2.7 279 49 3 536.6 Hydrochloride 17.0 ± 2.7 280 49 5 536.6 Hydrochloride 38.4 ± 5.1 281 50 3 554.6 Hydrochloride 15.6 ± 0.1 282 50 5 554.6 Hydrochloride 17.4 ± 2.1 283 51 3 554.6 Hydrochloride <10 284 51 5 554.6 Hydrochloride 10.8 ± 0.3 285 3 2 500.2 Oxalate 24.6 ± 3.8 286 3 33 499.1 Trifluoroacetate 72.1 ± 4.5 287 5 30 * Trifluoroacetate 39.9 ± 4.9 288 5 37 * Trifluoroacetate 52.9 ± 7.4 289 5 47 468.2 Oxalate 37.4 ± 7.2 290 5 48 468.2 Hydrochloride 22.7 ± 1.7 291 5 49 468.2 Hydrochloride 18.4 ± n = 1 292 52 4 503.3 Trifluoroacetate 43.5 ± 9.8 293 52 5 521.3 Trifluoroacetate 50.1 ± 5.6 294 52 12 503.3 Trifluoroacetate 43.9 ± 4.4 295 52 33 502.3 Trifluoroacetate 39.7 ± 8.7 296 52 40 520.2 Trifluoroacetate 47.9 ± 4.4 297 21 12 485.3 Hydrochloride 74.5 ± 6.7 298 21 31 503.4 Hydrochloride 54.5 ± 0.8 299 21 9 502.4 Hydrochloride 45.9 ± 3.9 300 21 36 485.3 Hydrochloride 52.2 ± 5.9 301 21 40 502.4 Hydrochloride 69.2 ± 1.2 302 39 3 536.3 Hydrochloride 12.8 ± n = 1 303 40 5 502.4 Hydrochloride 67.9 ± 6.1 304 40 10 536.3 Hydrochloride 44.8 ± 4.9 305 40 2 484.3 Hydrochloride 68.8 ± 6.5 306 40 4 484.4 Hydrochloride 82.4 ± 4.0 307 40 12 484.3 Hydrochloride 74.4 ± 1.8 308 32 5 503.3 Hydrochloride 71.2 ± 5.8 309 54 3 503.3 Hydrochloride 67.1 ± 1.2 310 54 5 503.3 Hydrochloride 72.7 ± 3.4 311 54 2 485.2 Trifluoroacetate 51.5 ± 1.7 312 54 4 485.4 Trifluoroacetate 59.8 ± 3.1 313 53 5 535.9 Trifluoroacetate 29.3 ± 4.1 314 60 12 518.3 Trifluoroacetate 42.0 ± 2.0 315 60 29 535.9 Trifluoroacetate 39.9 ± 2.5 316 60 40 535.3 Trifluoroacetate 58.8 ± 3.1 317 56 40 535.2 Trifluoroacetate 56.4 ± 5.0 318 56 33 517.2 Trifluoroacetate 41.8 ± 3.8 319 56 12 518.2 Trifluoroacetate 49.9 ± 3.9 320 56 5 536.2 Trifluoroacetate 51.4 ± 2.1 321 56 4 518.2 Trifluoroacetate 42.5 ± 2.3 322 57 4 552.1 Trifluoroacetate 27.6 ± 3.9 323 57 5 570.1 Trifluoroacetate 33.8 ± 3.8 324 57 12 570.2 Trifluoroacetate 38.5 ± 6.7 325 57 33 569.2 Trifluoroacetate 31.6 ± 7.8 326 57 40 569.2 Trifluoroacetate 30.4 ± 2.1 327 4 46 508.2 Trifluoroacetate 56.7 ± 2.1 328 4 43 506.1 Trifluoroacetate 57.4 ± 6.5 329 4 44 524.2 Trifluoroacetate 60.2 ± 3.0 330 4 45 490.2 Trifluoroacetate 55.9 ± 2.8 331 58 4 518.2 Hydrochloride 72.9 ± 2.0 332 58 5 537.2 Hydrochloride 80.6 ± 2.4 333 58 12 518.2 Hydrochloride 72.4 ± 3.0 334 58 33 517.0 Hydrochloride 77.8 ± 3.0 335 59 4 501.2 Hydrochloride 66.5 ± 1.8 336 59 5 519.2 Hydrochloride 68.8 ± 2.4 337 59 12 501.2 Hydrochloride 52.8 ± 3.7 338 59 33 500.2 Hydrochloride 65.5 ± 3.9 339 63 5 502.3 Hydrochloride 40.5 ± 1.2 340 43 3 530.3 Di-Hydrochloride 28.1 ± 2.3 341 63 3 502.3 Free Base 46.2 ± 6.3 342 3 34 533.2 Hydrochloride Not Tested 343 5 34 518.2 Hydrochloride Not Tested 344 27 5 519.2 Hydrochloride Not Tested 345 64 5 576.1 Oxalate 72.1 ± 4.2 346 64 29 576.1 Oxalate 57.3 ± 6.3 347 65 5 543.3 Hydrochloride 84.8 ± 3.4 348 66 5 532.3 Trifluoro Acetate 72.6 ± 5.5 349 67 5 543.3 Trifluoro Acetate 57.4 ± 3.3 350 68 5 532.3 Trifluoro Acetate 45.8 ± 1.9 351 69 5 543.3 Trifluoro Acetate 64.3 ± 1.3 352 70 5 532.0 Trifluoro Acetate 68.5 ± 2.5 353 73 5 597.3 Hydrochloride 96.5 ± 9.7 354 74 5 502.4 Hydrochloride 73.5 ± 2.5 355 32 31 503.3 Trifluoroacetate 66.6 ± 3.3 356 54 9 502.4 Trifluoroacetate 65.2 ± 1.9 357 54 31 503.2 Trifluoroacetate 65.4 ± 2.6 358 54 40 502.1 Trifluoroacetate 68.4 ± 1.5 359 72 3 517.6 Trifluoroacetate 31.2 ± 4.4 360 72 5 517.3 Trifluoroacetate 49.9 ± 3.5 361 32 9 502.4 Trifluoroacetate 70.1 ± 2.2 362 54 12 485.3 Trifluoroacetate 56.2 ± 2.9 363 54 36 485.3 Trifluoroacetate 50.1 ± 4.9 364 32 36 485.0 Trifluoroacetate 69.2 ± 2.5 365 32 40 502.0 Trifluoroacetate 80.2 ± 5.6 366 71 3 517.2 Trifluoroacetate 47.9 ± 3.5 367 71 5 517.2 Trifluoroacetate 69.5 ± 4.6 368 71 2 499.3 Trifluoroacetate 48.4 ± 2.5 369 71 4 499.4 Trifluoroacetate 59.3 ± 3.1
[0225] Representative Procedure 4: Suzuki Coupling
[0226] Procedure 4(a)
[0227] A compound of formula V (6.4 mmol) is dissolved in 50 ml of dry dioxane and thoroughly flushed with argon. Palladium(0) tetrakis(triphenylphosphine) (750 mg, 0.64 mmol) is added under argon and stirred at ambient temperature until the mixture becomes homogenous. The clear solution is divided into aliquots of 2 ml, and each testing tube is charged with 2 equivalents of an aryl boronic acid of formula IV and 500 μl of 2M aqueous sodium carbonate under argon. The testing tubes are sealed and heated in a microwave oven (MLS ETHOS 1600) for 35 minutes and 100° C. at 1000 W. After complete conversion the samples are diluted with 2 ml of water and extracted with 3 ml of dichloromethane. Extraction is repeated with 2 ml of dichloromethane. The organic solutions are collected and dried over sodium sulfate. The organic filtrate is treated with pre-treated Amberlyst 15 (3 to 4 g each). (Prior to use Amberlyst 15 is prewashed with dichloromethane, ethanol then dichloromethane until the filtrate is colorless). The suspensions are shaken for 30 minutes on an orbital shaker and filtered. The Amberlyst is repeatedly rinsed with dichloromethane/ethanol 1:1 (4×3 ml) and then repeatedly treated with dichloromethane/ethanolic ammonia 1:1. Finally the resin is treated with ethanolic ammonia overnight. The alkaline filtrates are collected and evaporated.
[0228] Procedure 4(b)
[0229] A mixture of an aryl halide of formula V (1.2 mmol), a boronic acid of formula IV (2.4 mmol), palladium(0) tetrakis(triphenylphosphine) (0.06 mmol), and 2M aqueous sodium carbonate (1.5 ml) in dioxane (20 ml) is heated over night at 100° C. in a sealed tube. The mixture is poured into water and extracted two times with ethyl acetate. The combined organic layers are washed with brine, dried over sodium sulfate, and concentrated under reduced pressure.
[0230] The final products prepared via Suzuki coupling may be purified by normal phase chromatography (silica gel, dichloromethane/ethanolic ammonia) providing the free bases or by reverse phase chromatography (acetonitrile/0.1% trifluoroacetic acid or 0.01% HCl in water) providing the trifluoro acetate or hydrochloride salts. The final products existing as salts may also be prepared in a separate salification step by dissolution of the free base in ethanol or dichloromethane and treatment of the solution with acid, e.g., 1N ethanolic HCl. Removal of all volatiles under reduced pressure, affords the desired salt.
[0231] The table below sets out representative combinations of aryl halides and boronic acids that are reacted as described above. Preparation of desired product is confirmed via mass spectral analysis (MSA). Emax±Standard Error Mean (SEM) data, discussed in the “Demonstration of Function” section below, is also included for said compounds where available. The Emax values represent the average of at least 3 runs except as otherwise indicated.
TABLE 10 Aryl Boronic E.g. Halide Acid MSA Salt Form Emax (%) ± SEM 370 2 1 552.3 Free Base 40.3 ± 2.8 371 3 1 534.2 Free Base 38.9 ± 3.9 372 4 1 552.3 Free Base 56.3 ± 4.8 373 1 2 495.7 Free Base 29.0 ± 6.8 374 2 2 513.5 Free Base 49.3 ± 0.3 375 3 2 495.8 Free Base 35.1 ± 7.3 376 4 2 513.5 Free Base 48.2 ± 6.7 377 5 2 547.2 Di-Hydrochloride 33.0 ± 4.2 378 1 3 500.5 Free Base 60.2 ± 3.2 379 2 3 518.5 Free Base 37.7 ± 1.6 380 3 3 500.3 Free Base 57.4 ± 4.1 381 4 3 518.3 Trifluoro Acetate 58.5 ± 6.9 382 5 3 552.3 Hydrochloride 32.3 ± 1.9 383 5 10 552.1 Hydrochloride 52.1 ± 5.4 384 1 4 550.6 Free Base 45.4 ± 5.6 385 2 4 568.3 Free Base 43.1 ± 4.3 386 3 4 550.7 Free Base 46.9 ± 6.7 387 4 4 568.2 Trifluoro Acetate 78.7 ± 14.9 388 1 5 495.8 Free Base <10 389 2 5 513.5 Free Base 20.3 ± 2.0 390 3 5 495.8 Free Base 14.4 ± 1.7 391 4 5 513.5 Free Base 22.5 ± 1.5 392 5 5 547.4 Di-Hydrochloride 17.6 ± 0.4 393 5 6 586.0 Hydrochloride 50.0 ± 3.6 394 5 7 594.3 Hydrochloride 76.9 ± 5.0 395 5 8 536.3 Hydrochloride 46.6 ± 5.9 396 5 9 566.1 Hydrochloride 50.5 ± 1.9 397 6 10 518.4 Hydrochloride 29.9 ± 4.4 398 6 3 518.4 Hydrochloride 22.1 ± 1.7 399 7 10 536.3 Hydrochloride 37.3 ± 3.7 400 7 3 536.3 Hydrochloride 26.0 ± 3.5 401 8 10 518.4 Hydrochloride 46.3 ± 6.8 402 8 3 518.4 Trifluoroacetate 31.1 ± 3.3 403 9 10 536.3 Hydrochloride 57.9 ± 11.2 404 9 3 536.3 Hydrochloride 40.4 ± 7.8 405 1 9 514.3 Hydrochloride 64.4 ± 7.1 406 1 6 534.0 Trifluoroacetate 55.8 ± 7.1 407 1 7 542.2 Hydrochloride 79.7 ± 7.6 408 1 8 484.3 Hydrochloride 74.0 ± 6.5 409 2 9 532.2 Hydrochloride 71.3 ± 3.9 410 2 6 552.3 Hydrochloride 76.0 ± 5.0 411 2 7 560.3 Trifluoroacetate 78.2 ± 9.9 412 2 8 502.4 Hydrochloride 74.4 ± 7.0 413 3 9 514.3 Hydrochloride 66.9 ± 9.2 414 3 6 534.3 Trifluoroacetate 65.7 ± 11.4 415 3 7 542.3 Trifluoroacetate 80.6 ± 5.7 416 3 8 484.3 Hydrochloride 68.9 ± 6.7 417 4 9 532.2 Hydrochloride 79.3 ± 2.4 418 4 6 552.4 Hydrochloride 74.4 ± 6.5 419 4 7 560.2 Trifluoroacetate 87.5 ± 1.8 420 4 8 502.4 Hydrochloride 78.9 ± 2.3 421 10 3 517.3 Hydrochloride 53.4 ± 6.9 422 10 9 531.3 Hydrochloride 60.1 ± 8.2 423 10 6 551.4 Hydrochloride 63.1 ± 4.7 424 10 7 559.1 Hydrochloride 71.2 ± 7.9 425 10 8 501.3 Hydrochloride 67.1 ± 3.0 426 11 3 517.3 Hydrochloride 61.0 ± 7.1 427 11 9 531.3 Hydrochloride 72.4 ± 6.9 428 11 6 551.3 Hydrochloride 75.5 ± 6.9 429 11 7 559.3 Trifluoroacetate 84.7 ± 12.3 430 11 8 501.3 Hydrochloride 77.4 ± 9.0 431 12 3 500.3 Hydrochloride 50.3 ± 7.8 432 12 9 514.3 Hydrochloride 60.7 ± 8.4 433 12 6 534.2 Hydrochloride 56.5 ± 11.0 434 12 7 542.3 Trifluoroacetate 73.1 ± 5.1 435 12 8 484.3 Hydrochloride 61.4 ± 6.1 436 13 3 518.4 Hydrochloride 57.5 ± 12.0 437 13 9 532.2 Hydrochloride 72.0 ± 10.5 438 13 6 552.3 Hydrochloride 64.3 ± 12.4 439 13 7 560.1 Trifluoroacetate 75.0 ± 9.6 440 13 8 502.4 Hydrochloride 73.4 ± 4.4 441 14 3 500.3 Hydrochloride 64.2 ± 7.0 442 14 9 514.3 Hydrochloride 61.5 ± 3.0 443 14 6 534.2 Hydrochloride 56.1 ± 11.2 444 14 7 542.3 Trifluoroacetate 83.8 ± 11.4 445 14 8 484.3 Hydrochloride 74.5 ± 14.1 446 4 3 518.5 Hydrochloride 64.0 ± 6.0
Example 447
[0232] [0232]
[0233] A solution of Amine 4 (300 mg, 1.130 mmol) and trimethylsilyl acetamide (TMSA) (210 mg, 1.614 mmol) is dissolved in acetonitrile (1.5 mL) and stirred for 30 minutes. To this solution is added Epoxide 62 (250 mg, 1.076 mmol) in acetonitrile (3 mL) and ytterbium triflate (13 mg, 0.215 mmol). The solution is heated at 80° C. for 24 hours and concentrated in vacuo. The resulting solid is purified by flash column chromatography (99% dichloromethane:1% methanol gradient to (95% dichloromethane:5% methanol as eluent) to give 135 mg of the title compound (25%). FDMS m/e=500 (M + +1). Emax (±SEM)=74.5 (4.0).
Example 448
[0234] [0234]
[0235] The compound of Example 346 is hydrolized with 1.0 equivalent of lithium hydroxide (1M), in tetrahydrofuran at room temperature overnight, and then concentrated to a crude residue which is purified via HPLC as the trifluoroacetic acid salt as described above in Representative Procedure 2 and 3. MS 562.2. Emax (±SEM)=79.9 (5.5).
Example 449
[0236] [0236]
[0237] The title compound is prepared from the compound of Example 345 as described in Example 448. MS 562.2. Emax (±SEM)=74.2 (2.2).
Example 450
[0238] [0238]
[0239] The compound of Example 345 in dimethylformamide is treated with 1.0 equivalent of sodium ethoxide and 4.0 equivalents of formamide. The mixture is heated to 100° C. for 4 hours, cooled to room temperature then concentrated. The residue is purified via HPLC as the trifluoroacetic acid salt as described above in Representative Procedure 2 and 3. MS 561.2. Emax (±SEM)=67.4 (2.1).
Example 451
[0240] [0240]
[0241] The compound of Example 50 (250 mg) and 0.5 molar equivalents (29 mg) of fumaric acid are suspended in 5 mL of ethanol denatured with toluene and the mixture is heated mildly to effect dissolution. After approximately five minutes, the solution begins to precipitate. The temperature of the crystal slurry is maintained at the crystallization temperature (56-57° C.) for about one hour. The heat source is then turned off and the slurry is allowed to cool with stirring overnight. Ethanol denatured with toluene (2 mL) is added and the solids are isolated by vacuum filtration. The filter cake is washed with ethanol denatured with toluene (5 mL) and air dried to give 230 mg of the title compound. mp=147-149° C. (measured by differential scanning calorimetry (DSC) with a scan rate of 10° C./minute).
Example 452
[0242] [0242]
[0243] The compound of Example 50 (57.7 mg) is dissolved in 2.5 mL of absolute ethanol and the solution is stirred at room temperature. To the stirred solution is added benzoic acid (1 equivalent, 14.1 mg) dissolved in 200 microliters of methanol. The resulting mixture is stirred at room temperature for 3.5 to 4 hours. Precipitation occurrs in approximately 30-60 minutes. The precipitate is isolated by vacuum filtration and the filter cake is collected and air-dried overnight. mp=148-150° C. (measured by DSC with a scan rate of 5° C./minute).
Example 453
[0244] [0244]
[0245] The compound of Example 50 (200 mg) is dissolved in 1 mL of acetone and the solution is stirred at room temperature. To the stirred solution is added R-mandelic acid (1 equivalent, 61 mg) in acetone (1 ml). The resulting, mixture is stirred at room temperature and the precipitate is isolated by vacuum filtration. The filter cake is collected and air dried overnight. mp=138-140 ° C. (measured by DSC with a scan rate of 5° C./minute).
Example 454
[0246] [0246]
[0247] The compound of Example 50 (106 mg) is dissolved in 1 mL of ethyl acetate and the solution is stirred at room temperature. To the stirred solution is added salicylic acid (1 equivalent, 29 mg) in 150 microliters of methanol. The resulting mixture is stirred at room temperature and then heated up to 50° C. Hexane is added to the mixture as an antisolvent at elevated temperature until cloud point (approxiamtely 1 ml ethyl acetate:l ml of hexane). The slurry is allowed to slowly cool to room temperature. The precipitate is isolated by vacuum filtration and the filter cake is collected and air dried overnight. mp=124° C. (peak max) (measured by DSC with a scan rate of 5° C./minute).
[0248] Demonstration of Function
[0249] The genes encoding the human β 1 -adrenergic receptor (Frielle et al., Proc. Natl. Acad. Sci., 84:7920-7924, 1987), the human β 2 -adrenergic receptor (Kobika et al., Proc. Natl. Acad. Sci., 84:46-50, 1987, Emorine et al., Proc. Natl. Acad. Sci., 84:6995-6999, 1987) and the human β3 adrenergic receptor (Granneman et al., Molecular Pharmacology, 44(2):264-70, 1993) are individually subcloned into a phd expression vector (Grinnell et al., Bio/Technology, 5:1189-1192, 1987) and transfected into the DXB-11 Chinese hamster ovary (CHO) cell line by calcium phosphate precipitation methodology. The stably transfected cells are grown to 95% confluency in 95% Dulbecco's modified Eagles Medium (DMEM), 5% fetal bovine serum and 0.01% proline. Media is removed and the cells are washed with phosphate buffered (pH 7.4) saline (without magnesium and calcium). Cells are then lifted using an enzyme free cell dissociation solution (Specialty Media, Lavallette, N.J.) and pelleted by centrifugation.
[0250] Cells from each of the above cell lines are resuspended and added (20,000/well) to a 96-well plate. Cells are incubated at 37° C. with representative compounds of the invention for 20 minutes in buffer (Hank's balanced salt solution, 10 mM HEPES, 0.1% BSA, 1 mM L-ascorbic acid, 0.2% dimethyl sulfoxide, 1 mM 3-isobutyl-1-methylxanthine, pH 7.4). After halting the incubation with quench buffer (50 mM Na Acetate, 0.25% Triton X-100, pH 5.8), the c-AMP level is quantified by scintillation proximity assay (SPA) using a modification of the commercially available c-AMP kit (Amersham, Arlington Heights, Ill.) with rabbit anti-cAMP antibody (ICN Biomedicals, Aurora, Ohio) for the kit.
[0251] Sigmoidal dose response curves, from the whole cell receptor coupled c-AMP assay are fit to a four parameter logistic equation using non linear regression: y=(a−d)/(1+(Dose/c) b )+d where a and d are responses at zero and maximal dose, b is the slope factor and c is the EC 50 as previously described (DeLean et al., Am. J. Physiol., 235, E97-E102, 1978). EC 50 is assessed as the concentration producing 50% of the maximum response to each agonist.
[0252] Isoproterenol is accepted in the art as a non-selective β 3 agonist and is widely used as a comparator-in evaluating the activity of compounds. See Trends in Pharm. Sci., 15:3, 1994. The % intrinsic activity (E max ) of representative compounds of the invention is assessed relative to isoproterenol by the compound's maximal response divided by the isoproterenol maximal response times 100.
[0253] In vitro Rat Atrial Tachycardia
[0254] Male rats (250-350 g) (Harlan Sprague Dawley, Indianapolis, Ind., USA) are killed by cervical dislocation. Hearts are removed and the left and right atria are dissected and mounted with thread in tissue baths containing 10 mls of modified Krebs' solution. Initial resting tension is 1.5-2.0 g at the outset of the experiment ( Naunyn - Schmied Arch. Pharmacol., 320:145, 1982). Tissues are allowed to equilibrate approximately 30 minutes with vigorous oxygenation before exposure to a compound of the invention.
[0255] To evaluate the ability of test compounds to increase heart rate, representative compounds of the present invention are added cumulatively once the atrial rate reached a steady state from the previous addition. Compound addition is continued until no further increase in atrial rate occurred or until a concentration of 10 −4 M is reached. The increase in beats per minute (bpm) is measured for each concentration of test compound by means of a BioPac System ( Br. J. of Pharmacol., 126:1018-1024, 1999).
[0256] Utilities
[0257] As agonists of the β 3 receptor, a compound of the present invention is useful in treating conditions in human and non-human animals in which the β 3 receptor has been demonstrated to play a role. The diseases, disorders or conditions for which compounds of the present invention are useful in treating or preventing include, but are not limited to, (1) diabetes mellitus, (2) hyperglycemia, (3) obesity, (4) hyperlipidemia, (5) hypertriglyceridemia, (6) hypercholesterolemia, (7) atherosclerosis of coronary, cerebrovascular and peripheral arteries, (8) gastrointestinal disorders including peptid ulcer, esophagitis, gastritis and duodenitis, (including that induced by H. pylori ),. intestinal ulcerations (including inflammatory bowel disease, ulcerative colitis, Crohn's disease and proctitis) and gastrointestinal ulcerations, (9) neurogenic inflammation of airways, including cough, asthma, (10) depression, (11) prostate diseases such as benign prostate hyperplasia, (12) irritable bowel syndrome and other disorders needing decreased gut motility, (13) diabetic retinopathy, (14) neuropathic bladder dysfunction, (15) elevated intraocular pressure and glaucoma and (16) non-specific diarrhea dumping syndrome.
[0258] In treating non-human, non-companion animals, the compounds of the present invention are useful for increasing weight gain and/or improving the feed utilization efficiency and/or increasing lean body mass and/or decreasing birth mortality rate and increasing post/natal survival rate.
[0259] Formulation
[0260] The compound of formula I is preferably formulated in a unit dosage form prior to administration. Therefore, yet another embodiment of the present invention is a pharmaceutical formulation comprising a compound of formula I and a pharmaceutical carrier.
[0261] The present pharmaceutical formulations are prepared by known procedures using well-known and readily available ingredients. In making the formulations of the present invention, the active ingredient (formula I compound) will usually be mixed with a carrier, or diluted by a carrier, or enclosed within a carrier which may be in the form of a capsule, sachet, paper or other container. When the carrier serves as a diluent, it may be a solid, semisolid or liquid material which acts as a vehicle, excipient or medium for the active ingredient. Thus, the compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosol (as a solid or in a liquid medium), soft and hard gelatin capsules, suppositories, sterile injectable solutions and sterile packaged powders.
[0262] Some examples of suitable carriers, excipients, and diluents include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, water syrup, methyl cellulose, methyl and propylhydroxybenzoates, talc, magnesium stearate and mineral oil. The formulations can additionally include lubricating agents, wetting agents, emulsifying and suspending agents, preserving agents, sweetening agents or flavoring agents. The compositions of the invention may be formulated so as to provide quick, sustained or delayed release of the active ingredient after administration to the patient.
Formulation Examples
Formulation 1
Tablets
[0263] [0263] Ingredient Quantity (mg/tablet) Active Ingredient 5-500 Cellulose, microcrystalline 200-650 Silicon dioxide, fumed 10-650 Stearate acid 5-15
[0264] The components are blended and compressed to form tablets.
Formulation 2
Suspensions
[0265] [0265] Ingredient Quantity (mg/5 ml) Active Ingredient 5-500 mg Sodium carboxymethyl cellulose 50 mg Syrup 1.25 mg Benzoic acid solution 0.10 ml Flavor q.v. Color q.v. Purified water to 5 ml
[0266] The medicament is passed through a No. 45 mesh U.S. sieve and mixed with the sodium carboxymethyl cellulose and syrup to form a smooth paste. The benzoic acid solution, flavor, and color are diluted with some of the water and added, with stirring. Sufficient water is then added to produce the required volume.
Formulation 3
Intravenous Solution
[0267] [0267] Ingredient Quantity Active Ingredient 25 mg Isotonic saline 1,000 ml
[0268] The solution of the above ingredients is intravenously administered to a patient at a rate of about 1 ml per minute.
[0269] Dose
[0270] The specific dose administered is determined by the particular circumstances surrounding each situation. These circumstances include, the route of administration, the prior medical history of the recipient, the pathological condition or symptom being treated, the severity of the condition/symptom being treated, and the age and sex of the recipient. However, it will be understood that the therapeutic dosage administered will be determined by the physician in the light of the relevant circumstances.
[0271] Generally, an effective minimum daily dose of a compound of formula I is about 5, 10, 15, or 20 mg. Typically, an effective maximum dose is about 500, 100, 60, 50, or 40 mg. Most typically, the dose ranges between 15 mg and 60 mg. The exact dose may be determined, in accordance with the standard practice in the medical arts of “dose titrating” the recipient; that is, initially administering a low dose of the compound, and gradually increasing the does until the desired therapeutic effect is observed.
[0272] Route of Administration
[0273] The compounds can be administered by a variety of routes including the oral, rectal, transdermal, subcutaneous, topical, intravenous, intramuscular or intranasal routes.
[0274] Combination Therapy
[0275] A compound of formula I may be used in combination with other drugs that are used in the treatment/prevention/suppression or amelioration of the diseases or conditions for which compounds of formula I are useful. Such other drug(s) may be administered, by a route and in an amount commonly used therefor, contemporaneously or sequentially with a compound of formula I. When a compound of formula I is used contemporaneously with one or more other drugs, a pharmaceutical unit dosage form containing such other drugs in addition to the compound of formula I is preferred. Accordingly, the pharmaceutical compositions of the present invention include those that also contain one or more other active ingredients, in addition to a compound of formula I. Examples of other active ingredients that may be combined with a compound of formula I, either administered separately or in the same pharmaceutical compositions, include, but are not limited to:
[0276] (a) insulin sensitizers including (i) PPARγ agonists such as the glitazones (e.g. troglitazone, pioglitazone, englitazone, MCC-555, BRL49653 and the like), and compounds disclosed in WO97/27857, 97/28115, 97/28137 and 97/27847; (ii) biguanides such as metformin and phenformin;
[0277] (b) insulin or insulin mimetics;
[0278] (c) sulfonylureas such as tolbutamide and glipizide;
[0279] (d) alpha-glucosidase inhibitors (such as acarbose);
[0280] (e) cholesterol lowering agents such as
[0281] i. HMG-CoA reductase inhibitors (lovastatin, simvastatin and pravastatin, fluvastatin, atorvastatin, and other statins),
[0282] ii. sequestrants (cholestyramine, colestipol and a dialkylaminoalkyl derivatives of a cross-linked dextran),
[0283] iii. nicotinyl alcohol nicotinic acid or a salt thereof,
[0284] iv. proliferator-activator receptor a agonists such as fenofibric acid derivatives (gemfibrozil, clofibrat, fenofibrate and benzafibrate),
[0285] v.inhibitors of cholesterol absorption for example beta-sitosterol and (acyl CoA:cholesterol acyltransferase) inhibitors for example melinamide,
[0286] vi. probucol,
[0287] vii. vitamin E, and
[0288] viii. thyromimetics;
[0289] (f) PPARδ agonists such as those disclosed in WO97/28149;
[0290] (g) antiobesity compounds such as fenfluramine, dexfenfluramine, phentermine, sibutramine, orlistat, and other β 3 adrenergic receptor agonists;
[0291] (h) feeding behavior modifying agents such as neuropeptide Y antagonists (e.g. neuropeptide Y5) such as those disclosed in WO 97/19682, WO 97/20820, WO 97/20821, WO 97/20822 and WO 97/20823;
[0292] (i) PPARα agonists such as described in WO 97/36579 by Glaxo;
[0293] (j) PPARγ antagonists as described in WO97/10813; and
[0294] (k) serotonin reuptake inhibitors such as fluoxetine and sertraline. | The present invention relates to a β 3 adrenergic receptor agonist of formula I:
or a pharmaceutical salt thereof; which is capable of increasing lipolysis and energy expenditure in cells and, therefore, is useful for treating Type II diabetes and/or obesity. The compound can also be used to lower triglyceride levels and cholesterol levels or raise high density lipoprotein levels or to decrease gut motility. In addition, the compound can be used to reduced neurogenic inflammation or as an antidepressant agent. Compositions and methods for the use of the compounds in the treatment of diabetes and obesity and for lowering triglyceride levels and cholesterol levels or raising high density lipoprotein levels or for decreasing gut motility are also disclosed. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a self-propelled construction machine, in particular a road milling machine, recycler, stabiliser, finisher or roller, comprising a machine frame, on which a working unit is arranged, and comprising a drive unit for driving the working unit.
[0003] 2. Description of the Prior Art
[0004] In road construction, self-propelled construction machines of different designs are used, including the known road milling machines, recyclers, stabilisers, finishers or rollers. Existing layers of the road surfacing can be removed using the known road milling machines and existing surfaces can be prepared using the recyclers. The stabilisers are used to stabilise soils that do not have sufficient load-bearing capacity, for example for road construction. The finishers are used to build roads, a distinction being drawn between asphalt finishers for laying asphalt and slip form finishers for laying concrete. Rollers are used to compress a wide range of materials in road construction, groundwork, agriculture and landfill construction. Construction machines of this type have a working unit for carrying out the work required for the building operations, which working unit may for example be a working roller, and in particular a milling roller equipped with milling tools in the case of road milling machines, stabilisers and recyclers. The working roller is driven by a drive unit which has at least one internal combustion engine. The fuel for the internal combustion engine, in particular a diesel engine, is provided in a fuel tank, in particular a diesel fuel tank.
[0005] Furthermore, it is known that construction machines comprise a water tank for storing service water. This service water is used for example in the known road milling machines in order to ensure that, during the milling process, the milling tools are cooled and thus the service life is increased, or is used in the known rollers in order to remove dirt from the roller lining and thus prevent the work result from being negatively impacted. Along with fuel and water, additional operating materials are also required for the operation of the construction machine. Therefore, in addition to the fuel tank and water tank, the known construction machines also have one or more operating material tanks arranged on the machine frame.
[0006] US 2008 260 461 A1 discloses a self-propelled construction machine comprising a drive unit having two internal combustion engines for the milling roller.
[0007] A general problem of construction machines is the limited space available for accommodating all the machine components. The construction machine should have as compact a design as possible in order to be able to keep a sufficiently wide lane open for moving traffic, to be able to be used even in confined spaces and to allow the construction machine to be transported without special permits.
[0008] A particular problem of construction machines comprising internal combustion engines is the ever stricter exhaust emission regulations. New exhaust emission regulations make it compulsory for exhaust gases to be treated further by means of additional technology. One known technique for post-treatment of exhaust gases is selective catalytic reduction (SCR). When using construction machines in different countries, the problem still arises of having to comply with various emissions guidelines. The engine technology and exhaust gas treatment technology required to comply with stricter emissions guidelines place high demands on fuel quality, for example low sulphur content, but this cannot be guaranteed in all countries. If fuel of sufficient quality is not available in individual countries, a construction machine having an exhaust gas treatment system cannot be used. It is therefore necessary to produce various designs of construction machines for different countries, the engine technology and exhaust gas technology of which machines are adapted to the respective general conditions. However, producing different configurations increases production complexity, the overall result of which is higher production costs, in particular in the case of small-batch production.
[0009] Exhaust gas treatment systems require additives, in particular a urea solution which has to be provided in an additional operating material tank. In one configuration of the construction machine having an exhaust gas treatment system, it is necessary to provide a urea solution, although this is not the case in a configuration without an exhaust gas treatment system. Equipping the construction machine with an exhaust gas treatment system means that changes have to be made to the chassis of the construction machine in order to attach the operating material tank. Otherwise, accommodating an additional tank increases the dimensions of the construction machine.
[0010] A sealed double-chamber tank for a motor vehicle is known from DE 10 2011 100 476 A1. The double-chamber tank has a single tank shell which is divided into two chambers. One chamber may hold diesel fuel and the other chamber may hold urea. DE 10 2011 100 476 A1 only describes the double-chamber tank in detail, and not the motor vehicle in which the double-chamber tank is installed. When the double-chamber tank is installed in the motor vehicle, the tank forms a separate component which is supported by the vehicle frame. DE 10 2009 000 094 A1 proposes integrating a tank for receiving a reducing agent in a fuel tank or washing water tank of a motor vehicle; however DE 10 2009 000 094 A1 also does not describe the motor vehicle comprising the fuel tank and the washing water tank in detail.
SUMMARY OF THE INVENTION
[0011] An object of the invention is to solve the problem of cost-effective production of self-propelled construction machines in different machine configurations for the respective countries while taking into account the limited space available. The object of the invention is in particular to provide additional operating materials in self-propelled construction machines with the limited space available without the need for major changes to the construction machine.
[0012] In one embodiment of a construction machine, in particular a road milling machine, recycler, stabiliser or roller, the additive, in particular the urea solution for operating the exhaust gas treatment system, is provided in an operating material tank integrated in the fuel tank. An alternative embodiment provides the integration of the fuel tank in a water tank of the construction machine, which the known construction machines generally have. When integrating the operating material tank in the fuel tank, however, the construction machine does not need to have a water tank.
[0013] Furthermore, the construction machine may be distinguished in that at least the fuel tank is formed from parts of the machine frame when the operating material tank is integrated in the fuel tank; however, when the operating material tank is integrated in the water tank, at least the water tank is formed from parts of the machine frame.
[0014] The integration of the operating material tank in a tank formed from the machine frame is advantageous since the structural complexity and the complexity of assembling various machine configurations can be kept as low as possible, and it is possible to standardise the parts used and to thus optimise the manufacturing costs. Furthermore, the complexity of subsequently upgrading or retrofitting the machine is reduced, since additional components can be integrated in the machine frame without further adaptations. The integration of the operating material tank in the fuel tank or water tank does not necessitate any changes to the machine frame, and therefore different production lines for construction machines having or not having exhaust gas treatment systems are not necessary.
[0015] Integrating the operating material tank in the fuel tank or water tank allows a standard machine frame to be used for the different machine configurations without major upgrading work. The decision regarding the machine configuration does not have to be taken until the final assembly stage, the operating material tank being built into the fuel tank or water tank in one case or the fuel tank or water tank being used without the operating material tank in the other case. Since the fuel tank or water tank is formed from parts of the machine frame, additional attachments are not required for each instance of equipping the machine.
[0016] When the operating material tank is integrated in the fuel tank or water tank, the dimensions of the construction machine can also remain unchanged, since the operating material tank does not take up any extra space on the machine frame. It has been found that the filling volume of the fuel tank or water tank is indeed reduced by arranging the operating material tank in the fuel tank or water tank. However, since the required amount of additive is relatively low by comparison with the amount of fuel or water, the dimensions of the fuel tank or water tank can remain unchanged in practice. Therefore, the structural modifications to the construction machine in order to retrofit an exhaust gas treatment system are minor. The operating material tank preferably has a filling volume that is at most 20%, in particular from 5 to 15%, of the filling volume of the fuel tank, when the operating material tank is integrated in the fuel tank. When the operating material tank is integrated in the water tank, the filling volume of the operating material tank is up to 20%, preferably from 2 to 7%, of the water tank.
[0017] The fuel tank has a filling volume that is generally between 200 and 1500 l. If the construction machine is a heavy milling machine, the filling volume of the fuel tank is between 1000 and 1500 l, whereas the filling volume is between 200 and 1000 l if the construction machine is a small milling machine. In the case of stabilisers, the filling volume of the fuel tank is between 800 and 1500 l, for example. The filling volume of the water tank is, depending on the machine type and the machine size, generally between 300 and 5000 l. Milling machines have a larger water tank, and heavy milling machines have a water tank having a filling volume of between 1500 and 5000 l, for example. In the case of small milling machines, the filling volume is between 500 and 1500 l, whereas stabilisers have a smaller (up to 500 l) water tank, or do not have a water tank.
[0018] In road milling machines, for example, the fuel tank is generally arranged in the central region of the machine frame. Owing to the static load in this region, the fuel tank is an integral component of the machine frame, for which reason replacement of the fuel tank is not possible. In the fuel tank, the operating material tank can be installed in a simple manner without major upgrading work, so that different machine configurations can be mounted without additional complexity during manufacturing.
[0019] A preferred embodiment of the invention provides for the operating material tank to be formed as an exchangeable unit which is designed such that the tank can be inserted into an opening in the fuel tank or water tank, the opening in the fuel tank or water tank being closed by the operating material tank. If the intention is to not equip the construction machine with an exhaust gas treatment system, the opening in the fuel tank or water tank simply has to be closed by a cover. In a construction machine having or not having an exhaust gas treatment system, the opening in the fuel tank or water tank for inserting the operating material tank can also be used for access for finishing, maintenance or servicing operations.
[0020] In a particularly preferred embodiment, the operating material tank has a trough part and a cover part, the cover part extending laterally beyond the trough part. If the operating material tank in inserted into the opening in the fuel tank or water tank, the operating material tank having the cover part, which extends laterally beyond the trough part, rests on the fuel tank or water tank, it being possible for the cover part of the operating material tank to be sealed with respect to the fuel tank or water tank in a simple manner.
[0021] The operating material tank has a closable tank opening which is preferably arranged on the cover part so as to be able to fill up the operating material tank from the side on which the tank is easily accessible.
[0022] The cover part of the operating material tank preferably has a peripheral rim to create a collection trough for additive that overflows during refilling. This prevents urea solution from entering the fuel tank or water tank and/or reaching components of the construction machine that are at risk of corrosion. In order to drain the urea solution, the cover part has an outflow opening having an outflow conduit, by means of which the solution can be guided to the ground without coming into contact with parts of the construction machine. For example, the outflow conduit can lead into or next to the milling roller housing.
[0023] The operating material tank can include different materials. Preferably, the operating material tank is a metal tank, in particular an aluminium tank, the inside of which is provided with an anti-corrosion coating, in particular a polyethylene coating.
[0024] The operating material tank can have a separate operating material removal unit for each internal combustion engine of the drive unit, which removal unit is preferably inserted into an operating material removal opening in the tank, so that the removal unit can be mounted and demounted in a simple manner. The simple mounting and demounting of the removal unit as a separate component in particular simplifies the equipping or retrofitting of an existing construction machine with the exhaust gas treatment system and the associated operating material tank. In addition to a suction conduit extending towards a low point of the operating material tank, the operating material removal unit can also contain additional components, such as a heating system, a temperature measurement device, sensors, or one or more filters.
[0025] In the known construction machines, in which the machine frame is carried by front and rear running gears, the fuel tank having the operating material tank is preferably arranged on the machine frame between the front and rear running gears. A preferred embodiment provides for the arrangement of the fuel and operating material tank between the front and rear running gears, the fuel tank preferably being located below the control platform. This is advantageous in that the operating material tank can be easily accessed from the control platform.
[0026] A further particularly preferred embodiment provides that the fuel and operating material tank is covered by at least one tread plate which is arranged above the fuel tank. The tread plate has a preferably closable access opening which is arranged above the tank opening in the operating material tank. A further advantage of the tread plates is the vibration isolation of the machine operator's platform from the machine frame.
[0027] In a self-propelled road milling machine, in order to make optimum use of the available space and/or for reasons of optimum weight distribution, the drive unit for the working unit is arranged on the machine frame preferably behind the fuel tank with reference to the working direction of the construction machine and the water tank is preferably arranged in front of the fuel tank with reference to the working direction of the construction machine. In a self-propelled stabiliser, in order to make optimum use of the available space and/or for reasons of optimum weight distribution, the drive unit for the working unit is arranged on the machine frame preferably in front of the fuel tank with reference to the working direction of the construction machine, the fuel tank preferably being arranged in the rear region of the machine frame. The water tank is arranged on the machine frame preferably in front of the working unit with reference to the working direction of the construction machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In the following, embodiments of the invention will be described in more detail with reference to the drawings, in which:
[0029] FIG. 1 is a simplified side view of a road milling machine as an example of a construction machine,
[0030] FIG. 2 shows the part of the machine frame of the construction machine of FIG. 1 below the control platform, the access opening in the fuel tank being closed by a cover,
[0031] FIG. 3 is a simplified schematic view of the part of the machine frame of the construction machine of FIG. 1 below the control platform with the operating material tank integrated in the fuel tank,
[0032] FIG. 4 is a simplified side view of a stabiliser as an example of a construction machine,
[0033] FIG. 5 is a plan view of the stabiliser, it being possible to see the operating material tank integrated in the fuel tank,
[0034] FIG. 6 shows a part of the machine frame of the stabiliser, an operating material tank not being provided, and
[0035] FIG. 7 shows a part of the machine frame of an alternative embodiment of the construction machine according to the invention comprising a fuel tank integrated in the water tank.
DETAILED DESCRIPTION
[0036] As an example of a construction machine, FIG. 1 shows a front-loader road milling machine which has a machine frame 1 , to which front and rear running gears 3 , 4 , in particular crawler track running gears, are attached via lifting columns 2 , so that the machine frame 1 is adjustable in height relative to the ground 5 . The running gears 3 , 4 may also be wheels. The control platform 6 is arranged between the front and back part 1 A, 1 B, with reference to the working direction A, of the machine frame 1 . A working unit 7 is located on the machine frame 1 below the control platform 6 and comprises a milling roller 9 arranged in a milling roller housing 8 . The milled material is conveyed away by a conveying device 10 , which is only shown in part in FIG. 1 .
[0037] A water tank 11 for holding water for cooling the milling tools of the milling roller 9 is arranged on the front part 1 A of the machine frame 1 in front of the control platform 6 , while a drive unit 12 for driving the milling roller 9 is arranged on the back part 1 B of the machine frame 1 behind the control platform 6 . The drive unit 12 comprises at least one internal combustion engine (not shown), in particular a diesel engine, having an exhaust gas treatment system (not shown in FIG. 1 ). The fuel, in particular diesel fuel, is provided in a fuel tank 13 ( FIGS. 2 and 3 ) which can have a filling volume of from approximately 1000 to 1500 l. The diesel tank is arranged on the machine frame 1 below the control platform 6 and above the working unit 7 between the front and back part 1 A, 1 B, with reference to the working direction, of the machine frame 1 . The water tank 11 may have a filling volume that is up to 5000 l.
[0038] FIG. 2 is a simplified schematic view of a section through the part of the machine frame 1 below the control platform 6 . The fuel tank 13 has a bottom part 14 , side parts 15 and a cover part 16 , the parts of the fuel tank being formed from parts of the machine frame 1 . The fuel tank 13 is thus an integral component of the machine frame 1 of the construction machine. The fuel tank 13 can be filled with fuel via a lateral tank connection piece (not shown).
[0039] The cover part 16 of the fuel tank 13 has an access opening 17 which has a substantially rectangular shape of sufficient size to allow finishing, maintenance or servicing operations to be carried out on the inside of the fuel tank. Such access openings are known in the prior art and are referred to as manholes and the closure thereof as manhole covers, because, depending on requirements, they are dimensioned such as to allow a person to climb into the tank. If the dimensions are smaller, they are referred to as handholes and handhole covers. In a road milling machine that has a drive unit 12 having an internal combustion engine without an exhaust gas treatment system, the access opening 17 is tightly sealed by a cover 18 which is screwed to the cover part 16 of the fuel tank 13 with a seal 19 being placed therebetween ( FIG. 2 ).
[0040] FIG. 3 shows the construction machine equipped with an operating material tank 20 for holding an additive. The operating material tank 20 is filled with a urea solution which is provided for operating an exhaust gas treatment system 21 (only shown indicatively). Said tank forms a modular unit which is inserted with an exact fit into the fuel tank 13 when the cover 18 ( FIG. 2 ) is removed. The operating material tank 20 is a metal tank, in particular an aluminium tank, the inside of which is coated with a polyethylene coating 22 to protect against corrosion. The filling volume of the operating material tank 20 is for example from 5 to 20%, in particular up to 15%, for example approximately 10%, of the filling volume of the fuel tank 13 .
[0041] The operating material tank 20 has a trough part 23 having a bottom part 24 which includes two bottom plates 25 , 26 extending obliquely with respect to one another, so that the tank 20 has a low point 27 . The trough part 23 is sealed by a cover part 28 which extends outwards beyond the side parts 29 of the trough part 23 , so that the cover part 28 of the operating material tank 20 rests on the cover part 16 of the fuel tank 13 . The cover part 28 of the operating material tank 20 is screwed to the cover part 16 of the fuel tank 13 with a seal 30 being placed therebetween, so that the fuel tank is tightly sealed. The operating material tank 20 has a tank opening 32 which is sealed by a tank cover 31 and is provided on the cover part 28 . The cover part 28 of the operating material tank 20 has a peripheral rim 33 , so that the cover part is formed as a collection trough in order to collect operating material that overflows during refuelling. An outflow opening 34 having an outflow conduit 35 leading towards the ground is provided on the cover part 28 and can terminate in the milling roller housing 8 , which is open downwards.
[0042] To remove the additive, an operating material removal unit 36 is provided which is inserted into an operating material removal opening 37 in the cover part 28 of the operating material tank 20 . The operating material removal unit 36 has a suction conduit 38 which extends as far as the low point 27 of the tank 20 . A conduit 39 is connected to the removal unit 36 and leads to a suction pump 40 . An operating material conduit 41 leads from the suction pump 40 to the exhaust gas treatment system 21 of the internal combustion engine (not shown) of the drive unit 12 . To supply a second internal combustion engine of the drive unit 12 , a second removal unit can also be provided in addition to the first operating material removal unit 36 .
[0043] Tread plates 42 are arranged on the control platform 6 above the fuel and operating material tank 13 , 20 at a distance from the cover parts 16 , 28 . An access opening 43 , which is sealed by a pivotable cap 44 , is located above the tank opening 32 in the operating material tank 20 in one of the tread plates 42 .
[0044] FIGS. 2 and 3 show that equipping the construction machine with an additional operating material tank 20 does not necessitate any major structural modifications, the dimensions of the machine not being increased either.
[0045] As another example of a construction machine, FIGS. 4 and 5 are side and plan views, respectively, of a stabiliser equipped with a fuel and operating material tank 13 , 20 , the operating material tank 20 being formed in the same way as the tank of the embodiment in FIGS. 1 to 3 . The corresponding parts are provided with the same reference numerals. The stabiliser has front and rear running gears 3 and 4 which are carried by a machine frame 1 . The control platform 6 is located in front of the front running gear 3 with reference to the working direction, the working unit 7 and the drive unit 12 being arranged behind the control platform 6 and between the running gears 2 , 3 . The fuel tank 13 is located in the rear region of the machine frame 1 , the tank again being formed from parts of the machine frame 1 . The operating material tank 20 is inserted into an access opening 17 (shown by dashed lines) in the cover part 16 of the fuel tank 13 and rests together with the cover part 28 on the cover part 16 of the fuel tank 13 , so that the access opening 17 is tightly sealed.
[0046] FIG. 6 shows the back part of the machine frame 1 , an operating material tank not being installed in the fuel tank 13 . For this machine configuration, the access opening 17 of the fuel tank 13 is tightly sealed by a cover 18 , structural modifications to the machine frame not being necessary.
[0047] An alternative embodiment is shown in FIG. 7 , in which the operating material tank is not integrated in the fuel tank but in the water tank. The corresponding parts are provided with the same reference numerals. The parts of the water tank 11 are formed from parts of the machine frame 1 in this embodiment too, so that the water tank 11 is thus also an integral component of the machine frame 1 . In this embodiment, however, the fuel tank 13 does not have to be formed from parts of the machine frame 1 . FIG. 7 is a section through the parts of the machine frame 1 that form the water tank 1 . Like the fuel tank 13 , the water tank 11 comprises a bottom part 11 A, side parts 11 B and a cover part 11 C. There is an opening 11 D in the cover part 11 C, into which the operating material tank 20 is inserted. The operating material tank 20 inserted into the water tank 11 is, in the present embodiment, identical in construction to the operating material tank that is inserted into the fuel tank 13 ( FIG. 3 ). | A self-propelled construction machine, comprises a machine frame, on which a working unit is arranged, and comprises a drive unit for driving the working unit. An additive, in particular a urea solution for operating an exhaust gas treatment system, is provided in an operating material tank which is integrated in the fuel tank or water tank of the construction machine. The integration of the operating material tank in the fuel tank or water tank does not necessitate any modifications to the machine frame. The dimensions of the construction machine can also remain unchanged, since the fuel tank does not take up any extra space on the machine frame if the dimensions of the fuel tank or water tank are maintained. | 8 |
FIELD OF THE INVENTION
This invention relates to the disperse dyeing of synthetic hydrophobic fibers such as polyesters, for instance polyethylene terephthalate, and polyamides, for instance DuPont Company's Qiana® nylon.
BACKGROUND OF THE INVENTION
The disperse dyeing of hydrophobic synthetic fibers is normally done by the immersion of the material to be dyed into an aqueous dye bath which contains the dyestuff and various additives and auxiliaries. In this procedure it is important to obtain a reproducible exhaustion of dye from the bath to the material and to obtain a uniform distribution of the dye on the material. This can be done by dyeing at temperatures in excess of 100° C., typically 125° to 135° C. for polyesters and 110° to 115° C. for Qiana® type polyamides. Naturally such dyeing must be done in pressurized equipment. Alternatively the dyeing can be done at or near the boil, i.e. about 100° C., if large amounts of suitable additives called "carriers," e.g. 10% o.w.g., are added to the dye bath. These additives both accelerate the exhaustion or adsorption by the material of the dye from the bath and at the maximum dyeing temperature promote the uniform distribution of the dye, or levelness. The acceleration feature is necessary in this process because at temperatures near the boil the exhaustion of the dye would be inadequate under acceptable commerical conditions without such acceleration. A process of low or "at the boil" temperature dyeing using aromatic alkyl ethers such as anisol and phenetol as the carrier or "dyestuff adjuvant" is disclosed in French Pat. No. 1,159,581.
For economic reasons the high temperature dyeing procedure has come to be preferred and is largely the method of choice in the United States. However, levelness was found to be a recurrent problem. Attempts were made to solve this problem by the addition of small amounts of traditional carriers, e.g. 1-3% o.w.g. While these additives did promote dye migration which is important to achieving levelness they had an undesirable side effect in this process; they prematurely fixed the dye during the heat-up phase resulting in unlevelness. To avoid this effect it was necessary to either slow down the rate of heating the bath to dyeing tempertures or to spend excessively long times at elevated temperatures to allow the necessary migration of unevenly fixed dye. Thus the acceleration feature of these carriers which was important in the "at the boil" dyeing procedure was an undesirable property in the pressurized higher temperature dyeing procedure.
An additive which would promote dye migration without accelerating the exhaustion of the dye onto the material being dyed would be of interest as a levelling agent.
SUMMARY OF THE INVENTION
It has been discovered that suitable levelling agents for high temperature dyeing of hydrophobic synthetic fiber materials can be prepared by incorporating diaryl ethers of the following formula as the active ingredient: ##STR1## wherein R 1 and R 2 represent lower alkyl, preferably CH 3 , C 2 H 5 , C 3 H 7 or C 4 H 9 , n represents an integer between 1 and 3 and m represents an integer between 0 and 3.
The active ingredient may be combined with a suitable anionic, cationic or nonionic emulsifier and a diluent such as water or an organic solvent. The levelling agent is preferably used in amounts between 1 and 10 wt. % based on the weight of material being dyed more preferably 1 to 6 wt. % and most preferably 1 to 3 wt. %. The agent is normally added to the dye bath before the goods are immersed and the bath temperature raised to suitable levels for the material being treated, e.g. 125° to 135° C. for polyester. However, the agent may also be used to level already dyed goods by treating them in an aqueous bath containing the levelling agent at elevated temperatures, preferably using 3 to 10 wt. %, based on the weight of material being treated, of levelling agent and using a temperature of at least about 130° C.
DETAILED DESCRIPTION OF THE INVENTION
The active ingredient may be one of or a mixture of compounds within the formula. Typical active ingredients include:
1. o-tolyl phenyl-ether,
2. p-tolyl phenyl-ether,
3. mixtures of 1 and 2
4. o,o-ditolylether
5. o,p-ditolylether
6. mixtures of 4 and 5
7. xylyl-o-tolyl ether
8. di-xylylether
9. phenyl-xylyl ether
10. phenyl 2,3,5-trimethyl phenyl ether
11. o-tolyl-2,3,5-trimethyl phenyl ether
12. xylyl-2,3,5-trimethyl phenyl ether
Those active ingredients wherein both aromatic rings are substituted by methyl groups are preferred and ditolyl ether is particularly preferred. Especially preferred active ingredients are those ditolyl ethers which have at least one of the following minimum isomer contents:
6% 2,2' dimethyl diphenyl ether
29% 2,3' dimethyl diphenyl ether
25% 3,3' dimethyl diphenyl ether
22% 3,4' dimethyl diphenyl ether
12% 2,4' dimethyl diphenyl ether
5% 4,4' dimethyl diphenyl ether
The most preferred active ingredient is that containing all of the above minimums and about 1 mol % of oxiditolyl compounds.
Suitable emulsifiers can be of anionic, nonionic or cationic nature. Typical examples of anionic emulsifiers are sodium dodecylsulfate and dioctyl sodium sulfo succinate.
Typical examples of suitable nonionic emulsifiers are condensation products of ethylene oxide with octyl or nonylphenols or with castor oil.
Typical cationic emulsifiers are quaternary compounds such as stearamido propyl dimethyl hydroxy ethyl ammonium chloride and amides obtained from acids of tallow condensed with ethylene oxide.
It is of advantage if the emulsifier is chosen in such a way that stable emulsions are formed after the addition of water, that the emulsifier does not foam substantially and that it has no adverse effect on the dispersion stability of the disperse dyes in conjunction with which the levelling agent is being used.
Typical examples of suitable organic solvents for use as a diluent are perchloroethylene, trichloroethane, chloro fluorohydrocarbons or alkylbenzenes from C 8 H 10 to C 11 H 16 . These may be added to reduce the need for pre- or post-scouring the textile materials in process, to reduce the accumulation of trimers during the dyeing of polyester, or to reduce staining of the equipment by the dyes in use.
A preferred levelling agent comprises about 15 to 90 parts of active ingredient, about 5 to 20 parts of emulsifier, about 0 to 80 parts of water and about 0 to 70 parts of an organic solvent. Fluorinated or chlorinated hydrocarbons are preferred solvents and polyethers are preferred emulsifiers. A particular preferred solvent is perchloroethylene which is preferably used in equal weight amount with the active ingredient. A particularly preferred emulsifier is a mixture of the ethoxylation product of castor oil with 25 moles of ethylene oxide and the ethoxylation product of dinonyl phenol with 4 moles of ethylene oxide. An especially preferred levelling agent comprises 42.5 wt. % ditolyl ether, 42.5 wt. % perchloroethylene, 11.25 wt. % ethoxylated castor oil (25 moles ethylene oxide) and 3.75 wt. % ethoxylated dinonyl phenol (4 moles ethylene oxide).
The disperse dyestuffs which may be used with the levelling agent of the present invention are those typically used for the dying of hydrophobic synthetic fibers, particularly polyesters and polyamides. Included among these dyestuffs are those described in "Colour Index," Vol. 1, pages 1655 to 1742, 2nd Edition (1956).
The levelling agent may be used with any of the typical hydrophobic synthetic fiber materials including fabrics which are mixtures of synthetic and natural fibers such as cotton and polyester. The use of the levelling agent has been found to be particularly effective in disperse dyeing polyesters and polyamides. The polyesters include polyethylene terephthalate and polycyclohexane-dimethylene terephthalate and the polyamides include the Qiana® nylons.
The suitable dyeing conditions are those known in the art for disperse dyeing. The dye bath normally contains a dispersing agent for the dye, such as condensed naphthalene sulphonic acid sodium salt a sequestering agent such as sodium salt of ethylenediamine tetra acetic acid to complex any metal ions present, and a pH control agent such as acetic acid to keep the bath on the acidic side. The bath is normally heated from somewhat below boiling to a suitable dyeing temperature after the material to be dyed is immersed. Typical temperatures include about 125° to 135° C. for polyesters and about 110° to about 115° C. for polyamides.
The invention is further illustrated but not intended to be limited by the following examples in which "o.w.g." stands for "on weight of goods" and refers to the weight % of a given additive based on the weight of goods being dyed. The ditolyl ether referred to in these examples is one having all the isomer minimums specified hereinabove including 1 mol % of oxitolyl compounds.
EXAMPLES
EXAMPLE 1
A dyeing of 2% o.w.g. of CI Disperse Blue 139 is prepared on a texturized polyester doubleknit fabric by dyeing in a bath containing, aside from the dye, 1% o.w.g. of a naphthalene sulfonic acid product as dispersing agent and acetic acid to obtain a pH of 4.5, for 60 minutes at 130° C. After rinsing and drying of the blue dyeing, a portion of the dyeing is treated together with an identical weight portion of undyed fabric in dye baths containing 3% and 6% o.w.g. of a levelling agent consisting of 42.5 wt. % of ditolyl ether, 42.5 wt. % of perchloroethylene, 11.25 wt. % of ethoxylated castor oil (with 25 moles of ethylene oxide) and 3.75 wt. % of ethoxylated dinonyl phenol (with 4 moles of ethylene oxide) and acetic acid to obtain a pH of 4.5 in a typical laboratory high temperature dyeing apparatus for 30 minutes at 130° C. After removal of the two fabric pieces, the dye remaining in the dyebath is exhausted onto a fresh piece of polyester fabric.
Examination of the fabric pieces reveals approximately 27% of the dye on the originally undyed fabric and a very small amount (less than 5%) to have been left in the bath with the 3% applied product, the comparable figures for the 6% applied product dyeings being 38% and less than 5%. If the identical test is run without the product of the invention being present, the amount of dye transferred is 12% and the amount of dye left in the bath less than 5%. If the identical test is run with a 6% o.w.g. of a product formulated on the basis of biphenyl, a common carrier active ingredient, the following values are obtained: dye transferred: 24%, dye left in bath 11%.
EXAMPLE 2
One pound packages of texturized polyester yarn are dyed on a laboratory high temperature package dyeing apparatus with 2% o.w.g. of CI Disperse Blue 81 under conditions which are typical for today's high speed production: liquor flow 50 l/kg/min.; rate of temperature rise--4° C./minute, liquor flow direction inside-out. After the maximum dyeing temperature of 130° C. is reached, dyeing is continued for 15 minutes at this temperature. If the dyeing is executed in the presence of 3% o.w.g. of the levelling agent of Example 1, a dyeing that is level (i.e. contains a uniform dye concentration) from inside to outside of the package is obtained. If the dyeing is executed in the presence of 3% of a product based on a common carrier active ingredient with strong accelerating properties such as o-dichlorobenzene, a substantially unlevel dyeing is obtained with differences from inside to the middle of the package of 12% in dye concentration.
EXAMPLE 3
A dyeing of 2% o.w.g. of a CI Disperse Red 159 is prepared on Qiana® modified nylon fabric in a bath containing 1% o.w.g. of a naphthalene sulfonic acid product as dispersing agent, 0.5% o.w.g. ethylene diamine tetra acetic acid sodium salt, and acetic acid to pH 4.5, for 60 minutes at 112° C. After rinsing and drying of the red dyeing a portion of the dyeing is treated together with an identical weight portion of undyed Qiana® fabric in a dyebath containing 4% o.w.g. of the levelling agent of Example 1 and acetic acid to obtain a pH of 4.5 in a laboratory high temperature dyeing apparatus for 30 minutes at 112° C. A similar dye transfer test is also executed for 30 minutes at 126° C. in the absence of any transferring agent, even though this temperature is too high for practical application because of the danger of fiber degradation, as well as 112° C. without agent. Examination of the fabric pieces reveals that 16% of the dye has been transferred to the originally undyed fabric from the originally dyed fabric in the test at 112° C. without agent, in the test at 112° C. with 4% agent, 29% has been transferred; and in the test at 126° C. without agent 27% has been transferred. Thus the presence of the product of the invention in the dyebath substantially increases the rate of transfer of the dye at the maximum dyeing temperature from areas of high dye concentration to areas of low dye concentration, increasing the chances for obtaining a level dyeing.
EXAMPLE 4
Dyeings of 4% o.w.g. of CI Disperse Red 159 and dyeings of 4% o.w.g. of CI Disperse Red 60 were prepared on a texturized polyester doubleknit fabric using a dye bath containing 2% o.w.g. of a naphthalene sulphonic acid derivative dispersing agent, 0.5% o.w.g. of ethylene diamine tetra acetic acid sodium salt as sequestering agent and sufficient acetic acid to achieve a bath pH of 4.5. Dyeings as described were prepared in the presence and absence of 4% o.w.g. of the levelling agent of Example 1 and in the presence of 4% of a commercial carrier based on phenolic ester. Dyeings were prepared in a laboratory type high temperature dyeing apparatus with temperature control. They were started at approximately 80° C. and the temperature was raised at 4° C. per minute to 120° C. The dyeings were then interrupted by cooling rapidly below 90° C. and the dye remaining in the dye bath was exhausted on to an undyed piece of texturized polyester doubleknit fabric at 130° C. By comparing the depth of the original dyeings it is evident that the original dyeings made in the presence of the carrier are substantially deeper than those made in the presence of the levelling agent of Example 1 and much deeper than those made without carrier or levelling agent. Thus the levelling agent from Example 1 has a much reduced accelerating effect compared to the carrier. This is confirmed by comparing the corresponding exhaust dyeings. The exhaust dyeings made without carrier are the lightest while those based on the dyeings using the levelling agent of Example 1 are substantially deeper and those made in the absence of the carrier or levelling agent are the deepest.
Although the invention has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The present invention involves an improved levelling agent and a method of using it in the disperse dyeing of hydrophobic synthetic fiber materials such as polyesters and polyamides. The levelling agent enhances dye migration without substantially accelerating the exhaustion of dye onto the fabric being dyed. It is based on diaryl ethers such as ditolyl ether mixed with emulsifiers and optionally a diluent which is water or an organic solvent.
It also involves a process for improving the levelness of already dyed materials by subjecting them to temperatures above the boiling point of water in the presence of diaryl ether based levelling agents. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of International Application No. PCT/CN2012/078613, filed on Jul. 13, 2012, which claims priority to Chinese Application No. 201110390466.3, filed Nov. 30, 2011, and Chinese Application No. 201110458356.6, filed Dec. 31, 2011. The entire disclosures of each of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure relates to a communication field, and more particularly, to an information processing method, apparatus, and related server.
2. Description of the Prior Art
Network has been a part of human's life. People gather information from the network and share useful information on the network with other network users.
People can post information on virtual social networking space (e.g. twitter or QQ space which is developed by the applicant) and show themselves in many ways. For example, they can write a diary there, upload their pictures, listen to music, and share their feeling. The afore-mentioned information can be called as UGC (user generated content). User can have friends in the virtual social networking space so that they can read the UGC from their friends on the virtual social networking space. Furthermore, the friends of user A can directly read the content he has posted in the personal center, and other users can read the content through the space address of user A. Besides for reading the information, friends or other users can copy, forward, share, or spread the UGC posted by the user to make the UGC spread more broadly.
However, some users post illegal UGC, which does not comply with China internet regulations. For example, these UGC may be Falun Dafa, porn, earthquake rumors, or any other information influencing the society. Assume that the user posting illegal UGC as user A, and a friend of user A is user B. It means that user B can read all of the UGC posted by user A, which includes afore-mentioned illegal UGC. Furthermore, user B can forward these illegal UGC such that more users will read the illegal UGC, also.
In order to prevent illegal UGC from being spread over the network, corresponding solutions have been introduced. Specifically, when the user of the virtual social networking space read an illegal UGC in his own space, he can report it to the back end such that an examiner can delete the illegal UGC according to the reporting condition of the UGC.
In the aforementioned information managing process, the applicants find that the related art has following problems: the server only processes illegal UGC without dealing with those who posted illegal UGC. It means that those who posted illegal UGC are able to continuously post illegal UGC and thus the illegal UGC problem still remains.
SUMMARY OF THE INVENTION
It is therefore one of the primary objectives of the claimed invention to provide an information processing method, apparatus, and server, to solve the above-mentioned problem of illegal UGC.
According to an exemplary embodiment of the claimed invention, an information processing method is disclosed. The information processing method comprises: receiving network information; determining a level of a network object corresponding to the network information according to the network information; and performing a control process on the network object according to the level of the network object corresponding to the network information.
According to another exemplary embodiment of the claimed invention, an information processing device is disclosed. The information processing device comprises: a receiving module, for receiving network information; an information processing module, for determining a level of a network object corresponding to the network information according to the network information, and performing a control process according to the level of the network object.
According to another exemplary embodiment of the claimed invention, a computer readable medium is disclosed. The computer readable medium stores an instruction set, wherein when the instruction set is executed, a machine reading the computer readable medium is capable of executing aforementioned information processing method.
According to another exemplary embodiment of the claimed invention, an information processing device is disclosed. The information processing device comprises: a storage device, for storing instructions; a processor, coupled to the storage device, the processor executes the instructions stored inside the storage device to receive network information, determine a level of a network object corresponding to the network information according to the network information; and perform a control process on the network object according to the level of the network object corresponding to the network information.
According to another exemplary embodiment of the claimed invention, a server, is disclosed. The server comprises the aforementioned information apparatus claimed in claims.
In contrast to the related art, the present disclosure has following advantages.
Through the embodiments of the present disclosure, the present disclosure can send the file to be scanned to a plurality of engines to scan, and integrate the scanning information returned by the engines, determine the scanning result of the file, and give a feedback. Therefore, the present disclosure virus killing procedure can support multi-engine killing, integrate the scanning information of the engines according to actual strategies, efficiently utilize advantages of different engines, support all kinds of virus-killing requirements, and raise the accuracy of virus killing and system safety.
These and other objectives of the claimed invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of an information processing method according to a first embodiment of the present disclosure.
FIG. 2 is a flow chart of an information processing method according to a second embodiment of the present disclosure.
FIG. 3 is a flow chart of an information processing method according to a third embodiment of the present disclosure.
FIG. 4 is a flow chart of an information processing method according to a fourth embodiment of the present disclosure.
FIG. 5 is a diagram of an information processing device according to a first embodiment of the present disclosure.
FIG. 6 is a diagram of an information processing device according to a second embodiment of the present disclosure.
FIG. 7 is a diagram of an information processing device according to a third embodiment of the present disclosure.
FIG. 8 is a diagram of an information processing device according to a fourth embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Please refer to FIG. 1 , which is a flow chart of an information processing method according to a first embodiment of the present disclosure. As shown in FIG. 1 , an information processing method is disclosed. The information processing method can be a computer process, stored inside a computer readable medium (such as an optical disk). The information processing method comprises following steps:
Step 101 : receive network information.
In this embodiment, the network information can be reporting information reported by a reporting user. The reporting information comprises information of a reported user and a reported content. The network information can be the UGC posted by a user, and the UGC can comprise a corresponding signature word. That is, this step can be to receive the reporting information from a reporting user or to receive the UGC posted by a user and obtain a signature word from the UGC.
Step 102 : determine a level of the network object corresponding to the network information according to the network information.
After the network information is received, the present disclosure determines the level of the network object corresponding to the network information according to the network information. Upon the condition that the network information is reporting information and the network object corresponding to the network information is a reported user, in this step, the present disclosure determines the level of the reported user corresponding to the reporting information according to the information and determines whether the reported user is a malicious user, a genuine user, or a user to be determined. Upon the condition that the network information is the UGC posted by the user and the network object corresponding to the network information is the UGC, in this step, the present disclosure determines the level of the signature word contained inside the UGC according to a relationship between signature words and levels, where the relationship is predetermined according to the UGC and predetermined scores.
Step 103 : perform a control process on the network object according to the level of the network object corresponding to the network information.
After the level of the network object corresponding to the network information is received, the present disclosure performs a control process on the network object according to the level. Specifically, upon the condition that the network information is the reporting information, in this step, the present disclosure performs a control process on the reported user according to the level of the reported user corresponding to the reporting information. Upon the condition that the reported user is a malicious user, the present disclosure prohibits the reported user from logging in. Upon the condition that the reported user is not a malicious user, the present disclosure determines whether the reported user is a genuine user or a user to be determined. Upon the condition that the reported user is a genuine user, the present disclosure transfers the information posted or forwarded by the reported user to a first designated address. Upon the condition that the reported user is a user to be determined, the present disclosure transfers the information posted by the reported user according to the reporting number of the information posted by the reported user. Upon the condition that the network information is the UGC, in this step, the present disclosure performs a corresponding operation on the UGC according to a predetermined relationship between levels of the signature words of the UGC and operations.
In this embodiment, the present disclosure provides an information processing method, which receives the network information, determines the level of the network object corresponding to the network information according to the network information, and performs a control process on the network object according to the level of the network object corresponding to the network information. Therefore, the present disclosure can prevent the illegal UGC from being continuously spread on the network and thus solve the aforementioned problem.
In addition, the present disclosure provides an information processing method. As shown in FIG. 2 , the information processing method can be a computer process, stored inside a computer readable medium (such as an optical disk), and the information processing method comprises following steps:
Step 201 : Receive reporting information having information of a reported user and a reported content.
In order to prevent some users from posting or forwarding illegal information, when a user reads inappropriate information, the user can report the user who posted or forwarded illegal information.
Specifically, the server receives the reporting information of the user. The reporting information contains the information of the reported user, the reported content. Please note, the information of the reported user can be information for identifying the identity of the reported user.
Step 202 : Determine whether the reported user is a malicious user according to the reported content. Upon the condition that the user is a malicious user, perform step 203 , otherwise, perform step 204 .
In this step, the present disclosure determines whether the reported user is a malicious user. The reported content can comprise illegal information posted or forwarded by the reported user.
The malicious user is a user who has been reported to post more illegal information and/or forward more illegal information.
Specifically, upon the condition that the reported user is a malicious user, step 203 is then performed. Upon the condition that the reported user is not a malicious user, step 204 is then performed.
Step 203 : Prohibit the reported user from logging in.
In order to prohibit the malicious user from posting or forwarding illegal information, the server prohibit the malicious user from logging in such that the malicious user is no longer post or forward any information. The flow is ended.
Step 204 : Determine whether the reported user is a genuine user. Upon the condition that the reported user is a genuine user, then perform step 205 . Otherwise, perform step 206 .
It does not mean that the non-malicious user never post or forward illegal information.
Therefore, in order to control the illegal information more efficiently, the server not only has to control the malicious user, but has to further determine whether a non-malicious user is a genuine user or a user to be determined and perform different operations on different kinds of users.
Upon the reported user is a genuine user, the step 205 is performed. Upon the reported user is a user to be determined, the step 206 is performed.
Step 205 : Transfer information posted or forwarded by the reported user to a first designated address.
In general, information posted or forwarded by a genuine user contains very low illegal information. Therefore, the user transfers the information posted or forward by a genuine user to the first designated address.
In an embodiment of the present disclosure, the first designated address can comprise the space addresses of friends of the genuine user, related website addresses, and etc.
The present disclosure transfer the information posted or forwarded by the genuine user to a friend's space address such that the genuine user can easily read the information in the personal space. In this embodiment, the information posted or forwarded by the genuine user is displayed in the friend space such that friends of the genuine user can read the information. Furthermore, the information posted or forwarded by the genuine user is transferred to related websites such that more network users can read the information. This ensures the information posted or forwarded by the genuine user to be shared. The flow is ended.
Step 206 : Transfer the information posted by the reported user according to a reporting number of the reported user.
Upon the condition that the reported user is a user to be determined, even the reported user is neither a malicious user nor a genuine user, the present disclosure transfers the information posted by the reported user according to a reporting number of the reported user. Please note, the information posted by a user to be determined may comprise illegal information or approved information, where the approved information represents information which has never been reported yet.
Specifically, when the present disclosure transfers the information of a user to be determined, the server can only transfer the approved information to the second designated address without transferring the illegal information to the second designated address.
In this embodiment, the present disclosure provides an information processing method. The information processing method comprises: receiving reporting information which comprises information of the reported user and a reported content; determining whether the reported user is a malicious user according to the reported content; upon the condition that the reported user is a malicious user, prohibiting the reported user from logging in; upon the condition that the reported user is not a malicious user, determining whether the reported user is a genuine user or a user to be determined; upon the condition that the reported user is a genuine user, transferring information posted or forwarded by the reported user to a first designated address; and upon the condition that the reported user is a user to be determined, transferring information posted by the reported user according to a reporting number of the information posted by the reported user. Because the present disclosure prohibits the malicious user from logging in, this prevents the malicious users from continuously posting or forwarding illegal information and allows non-malicious users continuously to post or forward not-illegal information. Different kinds of users can execute differential experiences and thus control and eliminate the malicious users and illegal information.
In another embodiment, the present disclosure provides another information processing method. As shown in FIG. 3 , the information processing method can be a computer process stored inside a computer readable medium such as optical disk. The information processing method comprises following steps:
Step 301 : Receive reporting information. The reporting information comprises information of a reported user and a reported content.
In order to prevent from certain users from posting or forwarding illegal information and prevent illegal information from spreading in the network, when the users read illegal information, the users can report those who post or forward illegal information. The server real-time receives the reporting information from the users, where the reporting information carries the information of the reported user and the reported content.
Step 302 : Obtain a reporting number of the reported user.
After a user reads illegal information, the user can report to the server. The reporting number of the reported user may influence the identity of the reported user when the server identifies the reported user. That is, the reported user may be identified as a malicious user, a genuine user, or a user to be determined. The genuine user represents a user who will not ruin the network. The user to be determined represents a user who causes less damage to the network. The malicious user represents a user who ruins the network enormously. That the reporting number of the reported user is more means that the damage on the network caused by the reported user is more. In this embodiment, the reporting number of the reported user includes a reporting number of illegal information posted by the reported user and a reporting number of illegal information forwarded by the reported user.
Moreover, whether a user is a malicious user, a genuine user, or a user to be determined is real time determined according to real time received reporting information.
In this embodiment, as shown in FIG. 3 , the present disclosure classifies the reported user into different levels (the above-mentioned malicious user, genuine user, and a user to be determined).
Specifically, the server obtains the reporting number of the reported user according to the reporting information.
Step 303 : Determine whether the reported user is a malicious user according to the reporting information. Upon the condition that the reported user is a malicious user, perform step 311 . Otherwise, perform step 304 .
The present disclosure determines whether the reported user is a malicious user according to the reporting information. The malicious user is reported that he posts/forwards more illegal information.
Specifically, upon the condition that the reporting number of the reported user is greater than a third predetermined threshold, the reporting number of the information posted by the reported user is greater than a fourth predetermined threshold, and the reporting number of the information forwarded by the reported user is greater than a fifth predetermined threshold, the reported user is determined as a malicious user.
The third, fourth, fifth predetermined thresholds can be set according to actual demands. For example, the third predetermined threshold can be 200, the fourth predetermined threshold can be 110, and the fifth predetermined threshold can be 90.
Upon the condition that the reported user is a malicious user, step 311 is performed. Otherwise, step 304 is performed.
Step 304 : Determine whether the reported user is a genuine user. Upon the condition that the reported user is a genuine user, perform step 305 . Otherwise, perform step 306 .
In this step, the present disclosure determines whether the reported user is a genuine user according to the reporting number of the reported user. Upon the condition that the reported user is a genuine user, step 305 is performed. Otherwise, step 306 is performed. Upon the condition that the reporting number of the reported user is not greater than the third predetermined threshold, the reported user is not determined as a malicious user. However, a non-malicious user does not mean that he never posts or forwards illegal information.
If a non-malicious user is allowed to post or forward illegal information, illegal information cannot be controlled.
Therefore, in order to efficiently control the illegal information, the server not only controls the malicious user, but determine whether a non-malicious user is a genuine user or a user to be determined and further processes different operations on different kinds of users.
Specifically, upon the condition that the reporting number of the reported user is less than a second predetermined threshold and the reporting number of the information posted by the reported user is 0, the reported user is determined as a genuine user. Upon the condition that the reporting number of the reported user is greater than the second predetermined threshold but less than the third predetermined threshold, the reported user is determined as a user to be determined. Please note, the third predetermined threshold is greater than the second predetermined threshold.
In this embodiment, the second predetermined threshold can be set according to actual demands. For example, in order to make the reporting information more persuasive and to prevent users from reporting maliciously, the second predetermined threshold can be set as 30.
Upon the condition that the user is a genuine user, the step 305 is performed. Upon the condition that the user is a user to be determined, step 306 is performed.
Step 305 : Transfer the information posted or forwarded by the reported user to a first designated address.
The reporting number of a genuine user is less than the second predetermined threshold. It means that the information posted or forwarded by the genuine user contains very little illegal information. Therefore, the server transfers all information posted or forwarded by the genuine user to the first designated address.
In one embodiment, the first designated address can comprise space addresses of friends of the genuine user, related network addresses, etc.
The present disclosure transfer the information posted or forwarded by the genuine user to a friend's space address such that the genuine user can easily read the information in the personal space. Furthermore, the information posted or forwarded by the genuine user is transferred to related websites such that more network users can read the information. This ensures the information posted or forwarded by the genuine user to be shared. The flow is ended.
Step 306 : Calculate the reporting number of the information posted by the reported user and determine whether the reporting number of the information posted by the reported user is 0. Upon the condition that the reporting number is 0, perform step 310 . Otherwise, perform step 307 .
Upon the condition that the reported user is neither a malicious user nor a genuine user, the reported user is a user to be determined Information posted by a user to be determined may contain illegal information or approved information, where the approved information is information which has never been reported. In this step, upon the condition that the reported user is a user to be determined, the present disclosure calculates the reporting number of information posted by the reported user and determines the reporting number of the information posted by the reported user is 0. Upon the condition that the reporting number is 0, step 310 is performed to transfer the information posted by the reported user to a second designated address. Otherwise, step 307 is performed to do a further determination.
The server only transfers approved information to the second designated address without transferring illegal information to the second designated address.
In one embodiment, the second designated address can comprise space addresses of friends of the reported user.
“Friends” can read the approved information posted by the reported user in their own personal space. Only when the friends visit the space of the reported user, the friends can read all information posted by the reported user. The aforementioned “all” information can comprise approved information and illegal information posted by the reported user.
From the above, it can be seen that the present disclosure perform different operations on different kinds of information (illegal information and approved information). This ensures the approved information to be shared and also prevents illegal information from spreading.
The reported content can comprise illegal information posted and forwarded by the reported user. The present disclosure obtains the reporting number of the information posted by the reported user according to the reported content.
The reporting number reflects the number that the reported user posts illegal information. Or, it can represent that the reported user posts less illegal information but the illegal information is reported frequently.
Step 307 : Determine whether the reporting number of the information posted by the reported user is greater than a first predetermined threshold. If the reporting number is greater than 0, perform step 309 . Otherwise, perform step 308 .
Upon the condition that the reporting number of the information posted by the reported user is not 0, the present disclosure further determines whether the reporting number of the information posted by the reported user is greater than the first predetermined threshold. Upon the condition that, the reporting number is greater than 0 but less than the first predetermined threshold, the step 308 is performed. Upon the condition that the reporting number is greater than the first predetermined threshold, the step 309 is performed.
In this embodiment, the first predetermined threshold is an integer greater than 0, and it can be set according to actual demands. For example, if the reported user has posted 100 pieces of information, the first predetermined threshold can be set as 10.
Step 308 : Transfer the information of the reported user to the second designated address, where the information has never been reported.
Upon the condition that the reporting number of the information posted by the reported user is greater than 0 but less than the first predetermined threshold, it represents that the reported user only posts few illegal information and possibly has forwarded illegal information.
The server only transfer approved information posted by the reported user to the second designated address without transferring illegal information to the second designated address. The flow is ended.
Step 309 : Not transfer the information posted by the reported user to the second designated address.
Upon the condition that the reporting number of the information posted by the reported user is greater than 0 and the predetermined threshold, it represent that the reported user has post more illegal information and possibly forwarded illegal information.
The server does not transfer any information posted by the reported user to the second designated address. In this way, only when friends visit the space of the reported user, the friends can read the information posted by the reported user. The flow is ended.
The present disclosure limits the transfer of illegal information through refusing to transfer illegal information to the second designated address.
Step 310 : Transfer information posted by the reported user to the second designated address.
The reporting number of the user to be determined is not 0. The reporting number can comprise the reporting number of the information posted by the reported user and the reporting number of the information forwarded by the reported user.
After the reported user is identified as a user to be determined, different operations are performed on the user to be determined according to the reporting content.
Specifically, the present disclosure determines whether the reporting number of the information posted by the reported user is 0. Upon the condition that the reporting number is 0, it represents that the reporting number that the reported user forwards illegal information is not 0.
Upon the condition that the reported user never posts illegal information but has forwarded illegal information, the server transfers the information posted by the reported user to the second designated address. The flow is ended.
Step 311 : Prohibit the reported user from logging in.
In order to prohibit the malicious user from posting illegal information, the server prohibits the malicious user from logging in. This ensures that the malicious user not to post or forward any information.
Table 1 is a level table of reported users of this embodiment of the present disclosure. A genuine user can be classified as high active user and normal active user. A user to be determined can be classified as new user, silent user, user without posting and/or forwarding illegal information, user having little reported information, user having more reported information. A malicious user is a bad user who has posted more illegal information and forwarded more illegal information.
TABLE 1
level table of reported users
Level
Name of Level
Rank
Remarks
A
Genuine user
A1
High active user
A1
Normal active user
B
User to be determined
B2
New user
B2
Silent user
C1
User without posting and/or
forwarding illegal information
C2
User having little reported
information
C3
User having more reported
information
C
Malicious user
D
Bad user having posted more
illegal information and
forwarded more illegal
information
In this embodiment, the present disclosure receives the reporting information comprising information of the reported user and a reported content; determines whether the reported user is a malicious user; upon the condition that the reported user is a malicious user, prohibits the reported user from logging in; upon the condition that the reported user is not a malicious user, transferring information posted or forwarded by the reported user to the first designated address; upon the condition that the reported user is a user to be determined, transfer the information posted by the reported user according to the information posted by the reported user. Because the present disclosure prohibits the malicious user from logging in to prevent the malicious user from posting illegal information and allows the non-malicious user to continuously post or forward non-illegal information, different kinds of users can execute different experience. This controls and eliminates the malicious users and illegal information.
Please refer to FIG. 4 , which is a flow chart of an information processing method according to another embodiment of the present disclosure. It comprises following steps:
Step 401 : Classify signature words according to predetermined scores to generate a relationship between levels and signature words, and predetermines a relationship between levels of the signature words and operations.
In this embodiment, Falun Dafa promotion and other political contents which ruin the societies are classified as first-order signature word, porn is classified as second-order signature word, and commercials are classified as third-order signature word.
Furthermore, the operation corresponding to the first-order signature word is to prohibit the UGC containing the first-order signature word. The second-order and third-order signature words are allowed to be posted, but they have to be collected into the human checking database to be examined by humans. The signature words contained inside the UGC posted by the user are classified and scored according to an ordinary processing result and a man-made deleting rate. In addition, the present disclosure provides different operations and hints according to different levels and scores. For example, they may be a permission of friends to read-only, a permission of a user to read-only, a permission of anyone to read-only without forwarding or sharing, and no permission of posting, alone or in a combination, to control the transmission range.
Step 402 : Receive the UGC sent by the user and obtain the signature word from the UGC.
In this embodiment, a signature word database is set up inside a back end, where different signature words have different scores. The back end scans the entire UGC sent by the user and simultaneously calculates the score of each signature word. For example, if the UGC contains “indoor service” and the signature word database also contains “indoor service”, “indoor service” is the signature word obtained from the UGC.
Step 403 : Determine the level of the signature word in the UGC sent by the user according to a relationship between the levels and signature words where the relationship is generated according to predetermined scores to signature words.
Step 404 : Perform a corresponding operation on the UGC sent by the user according to a relationship between the levels of the signature word in the UGC and operations.
Upon the condition that the signature word inside the UGC is the first-order signature word, the present disclosure does not allow the user to post it, and recommends user has to delete the signature word first and then post the UGC.
Upon the condition that the signature word inside the UGC is the second-order signature word or third-order signature word, etc. The present disclosure allows the user to post it, but the UGC should be recorded into the human checking database to be examined by humans. The signature words contained inside the UGC posted by the user are classified and scored according to an ordinary processing result and a man-made deleting rate. In addition, the present disclosure provides different operations and hints according to different levels and scores. For example, they may be a permission of friends to read-only, a permission of a user to read-only, a permission of anyone to read-only without forwarding or sharing, and no permission of posting, alone or in a combination, to control the transmission range. In order to raise the hit rate, the signature word back end has clear data including the hitting condition and man-made deletion condition to real time operate.
FIG. 5 is a diagram of an information processing device according to a first embodiment of the present disclosure. As shown in FIG. 5 , the information processing device can be used to execute the above-mentioned steps of the first embodiment, and further illustration is thus omitted here. The information processing device comprises a receiving module 51 and an information processing module 52 . The receiving module 51 is used to receive network information. The information processing module 52 is used to determine a level of a network object corresponding to the network information according to the network information, and performing a control process according to the level of the network object.
FIG. 6 is a diagram of an information processing device according to a second embodiment of the present disclosure. As shown in FIG. 6 , the information processing device can be used to execute the above-mentioned steps of the second embodiment, and further illustration is thus omitted here. In this embodiment, the network information is reporting information, and the network object corresponding to the network information is a reported user. In this embodiment, the information processing device is based on the information processing device shown in FIG. 5 . The receiving module 51 is used to receive the reporting information, where the reporting information comprises information of the reported user and a reported content. The information processing module 52 comprises a determining unit 521 , a judging unit 522 , a first transferring unit 523 , a second transferring unit 524 , and a prohibition unit 525 .
The determining unit 521 is used to determine whether the reported user is a malicious user according to the reported content.
The judging unit 522 is used for determining whether the reported user is a genuine user or a user to be determined upon the condition that the reported user is not a malicious user
The first transferring unit 523 is used for transferring information posted or forwarded by the reported user to a first designated address upon the condition that the reported user is a genuine user.
The second transferring unit 524 is used for transferring information posted by the reported user according to a reporting number of the information posted by the reported user upon the condition that the reported user is a user to be determined.
The prohibition unit 525 is used for prohibiting the reported user from logging in upon the condition that the reported user is a malicious user.
In this embodiment, the information processing device real time receives the reporting information, where the reporting information comprises information of the reported user and a reported content; determines whether the reported user is a malicious user according to the reported content; upon the condition that the reported user is a malicious user, prohibiting the reported user from logging in; upon the condition that the reported user is not a malicious user, determining whether the reported user is a genuine user or a user to be determined; upon the condition that the reported user is a genuine user, transferring information posted or forwarded by the reported user to a first designated address; and upon the condition that the reported user is a user to be determined, transferring information posted by the reported user according to a reporting number of the information posted by the reported user. Because the present disclosure prohibits the malicious user from logging in, this prevents the malicious users from continuously posting or forwarding illegal information and allows non-malicious users continuously to post or forward not-illegal information. Different kinds of users can execute differential experiences and thus control and eliminate the malicious users and illegal information.
In addition, the present disclosure further provides another information processing device. As shown in FIG. 7 , the information processing device can execute the above-mentioned steps of the third embodiment, and further illustration is omitted here. The information processing device is based on the information processing device shown in FIG. 6 . The determining unit 521 comprises an obtaining sub-unit 5211 and a first determining sub-unit 5212 .
The determining unit 522 comprises a second determining sub-unit 5221 and a third determining 5222 .
The second transferring unit 524 comprises a calculating sub-unit 5241 , a first transferring sub-unit 5242 , a second transferring sub-unit 5243 , and a third transferring sub-unit 5244 .
The receiving module 51 is used to receive the reporting information, where the reporting information comprises information of the reported user and a reported content.
In order to prevent some users from spreading illegal information and stop the transmission of the illegal information, when a user read the illegal information on the network, the user can report those who posted or forwarded illegal information. The receiving module 51 receives the reporting information sent by the user, where the reporting information carries information of a reported user and a reported content.
The determining unit 521 is used for determining whether the reported user is a malicious user.
The determining unit 521 determines whether the reported user is a malicious user according to the reported content. The malicious user is a user who is reported to post more illegal information and is reported to forward more illegal information.
Specifically, the obtaining sub-unit 5211 is used for obtaining the reporting number of the reported user.
The first determining sub-unit 5212 is used for determining that the reported user is a malicious user upon the condition that the reporting number of the reported user is greater than a third predetermined threshold, the reporting number of the information posted by the reported user is greater than a fourth predetermined threshold, and a reporting number of the information forward by the reported user is greater than a fifth predetermined threshold.
The judging unit 522 is used for determining whether the reported user is a genuine user or a user to be determined upon the condition that the reported user is not a malicious user.
A reported user whose reporting number is not greater than the third predetermined threshold is not determined as a malicious user. But a non-malicious user may have posted or forward illegal information.
If the non-malicious user continuously posts or forwards illegal information, the illegal information cannot be controlled.
Therefore, in order to control the illegal information, the server not only performs a corresponding control on the malicious user, but determines whether the reported user is a genuine user or a user to be determined to perform different operations on different kinds of users.
Specifically, the second determining sub-unit 5221 is used for determining that the reported user is a genuine user upon the condition that the reporting number of the reported user is less than a second predetermined threshold and the reporting number of the information posted by the reported user is 0.
The third determining sub-unit is used for determining that the reported user is a user to be determined upon the condition that the reporting number of the reported user is greater than the second predetermined threshold but less than the third predetermined threshold. The third predetermined threshold is greater than the second predetermined threshold.
The first transferring unit 523 is used for transferring the information posted by the reported user to the first designated address upon the condition that the reported user is a genuine user.
The reporting number of a genuine user is less than the second predetermined value. It means that the information posted by the genuine user contains very few illegal information. Therefore, the first transferring unit 523 transfer all the information posted by the genuine user to the first designated address.
The second transferring unit 524 is used for transferring the information posted by the reported user according to the information posted by the reported user upon the condition that the reported user is a user to be determined. That is, the second transferring unit 524 decides whether to transfer the information to the second designated address.
Information posted by a user to be determined may contain illegal information and approved information. The approved information is information which has not never been reported.
The second transferring unit 524 transfers the approved information to the second designated address without transferring the illegal information to the second designated address.
Specifically, the calculating sub-unit 5241 is used for calculating the reporting number of the information posted by the reported user.
The first transferring sub-unit 5242 is used for transferring the information posted or forwarded by the reported user to a second designated address upon the condition that the reporting number of the information posted by the reported user is 0.
The second transferring sub-unit 5243 is used for transferring the information posted or forwarded by the reported user but never been reported to the second designated address upon the condition that the reporting number of the information posted by the reported user is greater than 0 and less than a first predetermined threshold.
The third transferring sub-unit 5244 is used for not transferring the information posted or forwarded by the reported user to the second designated address upon the condition that the reporting number of the information posted by the reported user is greater than the first predetermined threshold.
The first predetermined threshold is an integer greater than 0.
The prohibition unit 525 is used for prohibiting the reported user from logging in upon the condition that the reported user is a malicious user
In order to prohibit the malicious user from continuously posting illegal information, the prohibition unit 525 prohibits the malicious user from logging in such that the malicious user is no longer able to post or forward any information.
In this embodiment, the information processing device real time receives the reporting information, where the reporting information comprises information of the reported user and a reported content; determines whether the reported user is a malicious user according to the reported content; upon the condition that the reported user is a malicious user, prohibits the reported user from logging in to prevent the malicious user from continuously posting illegal information. Because the present disclosure prohibits the malicious user from logging in, this prevents the malicious users from continuously posting or forwarding illegal information and allows non-malicious users continuously to post or forward not-illegal information. Different kinds of users can execute differential experiences and thus control and eliminate the malicious users and illegal information.
FIG. 8 is a diagram of an information processing device according to a fourth embodiment of the present disclosure. As shown in FIG. 8 , the present disclosure provides an information processing device capable of executing the above-mentioned steps of the fourth embodiment, and further illustration is omitted here. In this embodiment, the network information is the UGC sent by the user, and the network object corresponding to the network information is the UGC. In this embodiment, the information processing device is based on the information processing device shown in FIG. 5 . The receiving module 51 is used for receiving the UGC sent by the user and obtaining a signature word from the UGC. Specifically, a signature word database is set up inside a back end, where different signature words have different scores. The back end scans the entire UGC sent by the user and simultaneously calculates the score of each signature word. For example, if the UGC contains “indoor service” and the signature word database also contains “indoor service”, “indoor service” is the signature word obtained from the UGC.
The information processing module 52 comprises a level determining unit 526 and an operating unit 527 .
The level determining unit is used for determining the level of the signature word according to a predetermined relationship between signature words and levels, wherein the predetermined relationship is formed according to predetermined scores to signature words.
The operating unit 527 is used for performing a corresponding operation on the UGC according to the level of the signature word and a predetermined relationship between the levels and operations. Upon the condition that the level of the signature word inside the UGC is not corresponding to the first-order signature word, it is allowed to be posted, but has to be collected into the human checking database to be examined by humans. The signature words contained inside the UGC posted by the user are classified and scored according to an ordinary processing result and a man-made deleting rate. In addition, the present disclosure provides different operations and hints according to different levels and scores. For example, they may be a permission of friends to read-only, a permission of a user to read-only, a permission of anyone to read-only without forwarding or sharing, and no permission of posting, alone or in a combination, to control the transmission range.
The information processing device can further comprise a setting module 53 for predetermining the corresponding relationship between the levels of signature words and operations according to the scores to the signature words, and predetermining the relationship between levels of the signature words and the operations.
In this embodiment, upon the condition that the level of the signature word inside the UGC is not corresponding to the first-order signature word, it is allowed to be posted, but has to be collected into the human checking database to be examined by humans. The signature words contained inside the UGC posted by the user are classified and scored according to an ordinary processing result and a man-made deleting rate. In addition, the present disclosure provides different operations and hints according to different levels and scores. Therefore, the present disclosure improves the user experience. Furthermore, in the related art, although the second-order or third-order signature words are allowed to be posted, there is a high possibility to be deleted by the back end. Or, in the related art, the examination process takes a lot of time, and influence the user experience. The present disclosure can solve the above-mentioned problems.
Moreover, the present disclosure further provides an information processing device, which can comprise a storage device and a processor. The storage device is used for storing instructions. The processor is coupled to the storage device, and is used to execute the instructions stored inside the storage device to receive network information, determine a level of a network object corresponding to the network information according to the network information, and perform a control process on the network object according to the level of the network object corresponding to the network information.
The present disclosure further provides a server, which comprises any one of an information processing device shown in FIG. 5-FIG . 8 .
From the above, one having ordinary skills in the art can clearly understand that the present disclosure can be implemented with software and needed common hardware. Surely, the present disclosure can be implemented with only hardware. But in many conditions, implemented with software and needed common hardware would be better. Under such an understanding, the present disclosure can be produced as a software product, which is stored inside a readable medium (such as a floppy disk, hard disk, or optical disk). The software product comprises several instructions such that a computer (such as a personal computer, server, or network equipment) can execute the instruction to perform the above-mentioned information processing methods.
Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | Embodiments of the present invention provide an information processing method, device, and server, relating to the technical field of communications, and solving the problem that a user continuously releasing illegal information in the network. The method comprises: receiving network information; determining, according to the network information, a rating result of a network object corresponding to the network information; controlling the network object according to the rating result of the network object corresponding to the network information. Embodiments of the present invention further provide an information processing device and server. The present invention is applied to the network information management. | 7 |
TECHNICAL FIELD
[0001] The invention relates to the field of chemical synthesis, and more particularly to a synthesis method of 3-methylamino-1,2-propanediol.
BACKGROUND OF THE INVENTION
[0002] The contrast media used in radiological examination of medical technology include hyperosmolar ionic and hypo-osmolar nonionic contrast media, wherein hyperosmolar ionic contrast medium has the disadvantages of leading to increased intravascular fluid, angiectasis, rising pulmonary venous pressure, vascular endothelial injury and large neurotoxicity, and rendering toxic and side effects in use, whereas nonionic contrast medium, applicable for blood vessel, nervous system, contrast enhanced CT scanning and the like, has the advantages of relatively low osmosis, low viscosity, and low toxicity, etc., alleviating toxic and side effects greatly. Among others, iopromide is a novel hypo-osmolar nonionic contrast medium, which has lower osmosis than ordinary ionic contrast medium, similar osmotic pressure to that of blood plasma, modest viscosity favorable for injection and less toxicity than ionic contrast medium, and may be used in myelography, more safely.
[0003] 3-methylamino-1,2-propanediol is an important material for producing iopromide as a hypo-osmolar nonionic contrast medium, and its content has a direct influence on the quality, the content of impurities, as well as the clinical effect of the final product iopromide, particularly on the occurrence of adverse reaction, etc.. If the content of impurities in 3-methylamino-1,2-propanediol is high, the synthesized iopromide in use will result in the following reactions: mild nausea, emesis, dizziness, acute emesis, chilly feeling, generalized urticaria, facial or laryngeal edema, bronchospasm, dyspnea-stethalgia, celialgia, headache or limb convulsion, etc.. In severe cases, prostration, unconsciousness, pneumonedema, heart arrest or ventricular fibrillation, acute arrhythmia or myocardial infarct, or even death may be incurred. In view of the aforementioned reasons, Schering Co. of Germany has been extremely critical of the quality of 3-methylamino-1,2-propanediol since 1985 when iopromide was officially put into market, and only a few countries can produce the product satisfying its quality demand.
[0004] The processes for preparing 3-methylamino-1,2-propanediol may be categorized on the basis of starting material into epichlorohydrin process, glycerin chlorohydrin process, glycide process and glyceraldehyde process, wherein the aminating agent includes aqueous monomethylamine solution or gaseous monomethylamine used directly; it may be categorized on the basis of operational pressure into low pressure process, high pressure process, etc.; it may be categorized on the basis of production process into batch process and continuous process. Both epichlorohydrin and glycerin chlorohydrin processes take the route involving glycerin chlorohydrin, and they only differ in cost. Glycide and glyceraldehyde processes have high production cost, poor economic benefit and low purity of product. Therefore, glycerin chlorohydrin process is the most commonly used production process at present, wherein glycerin chlorohydrin and aqueous monomethylamine solution, as the starting materials at a feeding ratio of 1:2.9-3.9 by weight, are subjected to amination reaction under a pressure of 0.3-0.4 MPa, and then an aliphatic alcohol such as methanol or ethanol is used as a solvent to dilute the viscous solution to filter out monomethylamine chloride, followed by purification by means of distillation to obtain the product 3-methylamino-1,2-propanediol. The existing production of 3-methylamino- 1,2-propanediol mainly has the following disadvantages: (1) excessive feeding ratio of monomethylamine to glycerin chlorohydrin, bringing difficulty for recovery of monomethylamine, and increasing energy consumption; (2) low purity of the product and high content of impurities; (3) low conversion of glycerin chlorohydrin; (4) the requirement of using an aliphatic alcohol such as methanol or ethanol, as a solvent, to dilute the viscous solution and to filter out monomethylamine chloride, which adds operational steps; and (5) long production cycle.
SUMMARY OF THE INVENTION
[0005] The technical problem to be solved by the present invention is to provide a method for synthesizing 3-methylamino-1,2-propanediol, which can enhance the purity of 3-methylamino-1,2-propanediol in the product, reduce the content of impurities, and enable the product meet the demand for high quality of synthesized iopromide.
[0006] The technical solution according to the present invention for solving the aforementioned technical problem is provided as follows.
[0007] A synthesis method of 3-methylamino-1, 2-propanediol includes the following steps:
[0008] (1) amination reaction: adding glycerin chlorohydrin, aqueous monomethylamine solution and an amination catalyst, namely NaOH solution and NaHCO 3 , into a reactor, stirring to mix the material sufficiently, and allowing the amination reaction to proceed in two temperature stages;
[0009] (2) treatment of amination solution: removing monomethylamine and water from the amination solution after the amination reaction is completed, filtering out solid resultant, and feeding filtrate into a still;
[0010] (3) purification by distillation: heating the material in the still, and distilling under reduced pressure to obtain the product 3-methylamino-1,2-propanediol, wherein the vacuum for distillation under reduced pressure is equal to or greater than 0.099 MPa and the temperature is 130-160° C.
[0011] The weight ratio of the glycerin chlorohydrin, the aqueous monomethylamine solution, the NaHCO 3 and the NaOH solution is 1:1.97-2.3:0.38-0.48:0.33-0.41, wherein the weight percentage of the NaOH solution is 40 wt %, and the weight percentage of the aqueous monomethylamine solution is 40 wt %.
[0012] The amination reaction in two temperature stages is carried out at 40-50° C. for 60-80 minutes, and then the material is heated to 55-65° C. to allow the reaction to continue for 100-150 minutes, wherein the reaction pressure is equal to or less than 0.15 MPa.
[0013] The temperature of the material rises in 10±2 minutes.
[0014] After the amination reaction is completed, the monomethylamine gas in the reactor is recovered first of all; and then the amination solution is fed into the still for recovery of the unreacted monomethylamine in the liquid phase by distillation, wherein the recovery of monomethylamine by distillation is carried out first under atmospheric pressure and then under vacuum when the temperature of the material in the still is 110-120° C.
[0015] After recovery of the monomethylamine by distillation and removal of moisture, the temperature of the material in the still is decreased to 50-70° C., and the solid resultant is filtered out. The solid sodium chloride filtered out is collected for collective disposal.
[0016] Before purification by distillation in the step (3), distillation is carried out to recover front cut fraction, wherein the recovery of the front cut fraction by distillation is carried out under vacuum at the gas-phase temperature of 60-100° C. Before recovery of the front cut fraction, condensed liquid is recovered when the gas-phase temperature is lower than 60° C. to prepare 40 % NaOH solution. The recovered front cut fraction is made full use by combining with next batch of distilland. The main components of the front cut fraction are unreacted glycerin chlorohydrin from the starting material, a small amount of product 3-methylamino-1,2-propanediol and a small amount of hydroxyl compounds. When the gas-phase temperature exceeds 100° C. and tends to rise further, the material in the still is cooled to 80-90° C., and distillation under reduced pressure is set off.
[0017] Vacuum scraper film evaporation is used as the distillation method for distilling the material in the still under reduced pressure in step (3), wherein the vacuum scraper film evaporation is the distillation under vacuum by distributing the liquid material under high-speed rotation into uniform film to evaporate quickly.
[0018] By taking the aforementioned technical solution, the following beneficial effects are achieved according to the invention:
[0019] 1. Because of the introduction of NaOH solution and NaHCO 3 in the amination reaction as aminating catalysts in the present invention, the reaction is catalyzed and the conversion of glycerin chlorohydrin is thus increased. It may be analyzed specifically as follows.
[0020] (1) The reaction system is made stronger alkaline, facilitating rapid substitution of CH 3 NH— group for —Cl group in glycerin chlorohydrin molecule, so that the amination reaction time is reduced.
[0021] (2) Relatively higher concentration of CH 3 NH 2 is ensured in the reaction system, which facilitates accelerating the reaction and reducing the reaction time. In the case that NaOH and NaHCO 3 are not added as the catalysts, HCl resulting from removal of Cl from glycerin chlorohydrin reacts with CH 3 NH 2 in the system to form CH 3 NH 3 Cl. This inevitably consumes considerable amount of CH 3 NH 2 , which reduces the content of CH 3 NH 2 in the system. Whereas after NaOH and NaHCO 3 are added, the resulted HCl reacts with NaOH and NaHCO 3 to form NaCl. Even if CH 3 NH 3 Cl is formed in the system, NaOH and NaHCO 3 will further react with CH 3 NH 3 Cl to form NaCl and CH 3 NH 2 due to the relatively strong alkalinity of the reaction system. Thus, relatively high concentration of CH 3 NH 2 is maintained in the system.
[0022] (3) The feeding ratio of monomethylamine to glycerin chlorohydrin may be reduced without affecting reaction rate and product quality.
[0023] (4) Conversion of glycerin chlorohydrin is increased.
[0024] (5) The pressure of amination reaction is reduced. Specifically, the operational pressure is lowered from 0.3-0.4 MPa in prior art to less than 0.15 MPa. Therefore, the production is safer, and the requirements for facility material, wall thickness, fasteners, processing and the like are decreased significantly.
[0025] 2. Since HCl produced in the amination reaction is mostly converted to NaCl rather than CH 3 NH 3 Cl in the system, in contrast to prior art, the operational steps including the step of using aliphatic alcohol as required to dissolve and dilute the material in order to filter out CH 3 NH 3 Cl due to the viscous state of the material in the later stage of removing monomethylamine and water, the step of evaporating the aliphatic alcohol, and the like are left out. By appropriate adjustment of the production process, the salt may be filtered out while it is still hot once the amination solution is deaminated and dewatered to a certain extent. Thus, the production operation is made easier. Not only the unit operating cycle is shortened, but also the production cost and energy consumption are relatively reduced.
[0026] 3. Since the product 3-methylamino-1,2-propanediol is distilled by way of vacuum scraper film according to the invention, the heating time for separation and purification of the product is reduced greatly, and thus the components of the product hardly decompose. Therefore, the product quality is improved significantly, and the content of 3-methylamino-1,2-propanediol in the product is increased to above 99.5% (GC). The product thus produced is a liquid that is totally colorless and transparent. Furthermore, compared with prior art, the energy consumption of the production is reduced remarkably. Specifically, power consumption is reduced by 20%, and coal consumption is reduced by 30%.
[0027] 4. Monomethylamine, condensed water and front cut fraction distilled out from the amination solution according to the invention are all recycled, which avoids volatilization and waste of the production starting material. Therefore, the availability of the starting material is increased. The production is achieved in a hermetic and clean environment, and the operational conditions for the production are improved notably.
[0028] 5. The product synthesized according to the invention, a liquid appearing colorless and transparent, has increased purity of above 99.5% (GC) and decreased impurities. Therefore, this product exactly meets the quality demand for synthesis of iopromide as a hypo-osmolar nonionic contrast medium.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] The invention will be further illustrated with reference to the following specific embodiments.
Embodiment 1
[0030] 1. Amination Reaction: 100 kg NaHCO 3 , 510 kg aqueous monomethylamine solution with a concentration of 40 wt %, 250 kg glycerin chlorohydrin and 90 kg 40 wt % NaOH solution were added to a 1000 L reactor sequentially, and then stirred for one hour. The reactants were heated to allow the reaction to proceed at 42° C. for 80 minutes. Then the temperature was increased to 60° C. in 10 minutes, and the reaction was allowed to proceed at 60° C. for 120 minutes. The reaction pressure was 0.12 MPa.
[0031] 2. Treatment of Amination Solution: The purge value of the reactor was switched on to discharge gaseous monomethylamine in the reactor to a kettle for absorbing monomethylamine until there was no pressure in the reactor, and then the amination solution was transferred to a 1000 L still for recovery of monomethylamine by distillation. The material in the still was heated. When the gas-phase temperature reached 101° C., a jet vacuum pump was started to evacuate the still. Heating was continued until the temperature of the material in the reactor reached 115° C. Then heating was stopped and evacuation was continued. After recovery of monomethylamine was completed, the temperature of the material was decreased to 60° C., and the material in the still was pressed into a filter press using compressed air to filter out the solid material. The solid material that was filtered out was collected for collective disposal, and the filtrate was fed into a 500 L still.
[0032] 3. Purification by Distillation: The jet vacuum pump was started, and the filtrate in the still was heated. The condensed liquid recovered before the gas-phase temperature reached 60° C. was used to prepare 40 wt % NaOH solution, and the liquid condensed between 60° C. and 100° C. was recovered as front cut fraction which was added to next batch of distilland for full use. When the gas-phase temperature exceeded 100° C. and tended to rise further, the still was cooled to 80° C. A vacuum group was turned on to keep the vacuum in the scraper film evaporator above 0.099 MPa. When the temperature was 140° C. , the discharge valve at the bottom of the still was switched on to feed the scraper film evaporator at a feed rate of 0.1 m 3 /h. Qualified product 3-methylamino-1,2-propanediol was distilled out.
[0033] Table 1 shows the quality index of 3-methylamino-1,2-propanediol synthesized according to the aforementioned method.
[0000]
TABLE 1
No.
Test Index
Analysis Method
Test Results
1
Appearance
Eye inspection
Colorless
and
transparent
liquid
2
Purity (GC) (%)
Gas chromatography
99.56
3
Cut fraction content before the
Gas chromatography
0.12
principal peak (GC) (%)
4
Cut fraction content after the
Gas chromatography
0.32
principal peak (GC) (%)
5
Moisture content (wt %)
Karl Fisher method
0.93
Embodiment 2
[0034] 1. Amination reaction: 210 kg NaHCO 3 , 1050 kg aqueous monomethylamine solution with a concentration of 40 wt %, 500 kg glycerin chlorohydrin and 183 g 40 wt % NaOH solution were added to a 2000 L reactor sequentially, and then stirred for 1.5 hours. The reactants were heated to allow the reaction to proceed at 45° C. for 70 minutes. Then the temperature was raised to 65° C. in 10 minutes, and the reaction was allowed to proceed at 65° C. for 100 minutes. The reaction pressure was 0.15 MPa.
[0035] 2. Treatment of Amination Solution: The purge value of the reactor was switched on to discharge gaseous monomethylamine in the reactor to a kettle for absorbing monomethylamine until there was no pressure in the reactor, and then the amination solution was transferred to a 2000 L still for recovery of monomethylamine by distillation. The material in the still was heated. When the gas-phase temperature reached 101° C., a jet vacuum pump was started to evacuate the still. Heating was continued until the temperature of the material in the reactor reached 120° C. Then heating was stopped and evacuation was continued. After recovery of monomethylamine was completed, the temperature of the material in the still was decreased to 70° C., and the material was pressed into a filter press using compressed air to filter out the solid material. The solid material that was filtered out was collected for collective disposal, and the filtrate was fed into a 500 L still.
[0036] 3. Purification by Distillation: The jet vacuum pump was started, and the filtrate in the still was heated. The condensed liquid recovered before the gas-phase temperature reached 60° C. was used to prepare 40 wt % NaOH solution, and the liquid condensed between 60° C. and 100° C. was recovered as front cut fraction which was added to next batch of distilland for full use. When the gas-phase temperature exceeded 100° C. and tended to rise further, the still was cooled to 80° C. A vacuum group was turned on to keep the vacuum in the scraper film evaporator above 0.099 MPa. When the temperature was 145° C., the discharge valve at the bottom of the still was switched on to feed the scraper film evaporator at a feed rate of 0.15 m 3 /h. Qualified product 3-methylamino-1,2-propanediol was distilled out.
[0037] Table 2 shows the quality index of 3-methylamino-1,2-propanediol synthesized according to the aforementioned method.
[0000]
TABLE 2
No.
Test Index
Analysis Method
Test Results
1
Appearance
Eye inspection
Colorless
and
transparent
liquid
2
Purity (GC) (%)
Gas chromatography
99.61
3
Cut fraction content before the
Gas chromatography
0.14
principal peak (GC) (%)
4
Cut fraction content after the
Gas chromatography
0.25
principal peak (GC) (%)
5
Moisture content (wt %)
Karl Fisher method
1.07
Embodiment 3
[0038] 1. Amination reaction: 200 kg NaHCO 3 , 1000 kg aqueous monomethylamine solution with a concentration of 40 wt %, 475 kg glycerin chlorohydrin and 175 g 40 wt % NaOH solution were added to a 2000 L reactor sequentially, and then stirred for 1.5 hours. The reactants were heated to allow the reaction to proceed at 50° C. for 60 minutes. Then the temperature was raised to 65° C. in 10 minutes, and the reaction was allowed to proceed at 65° C. for 100 minutes. The reaction pressure was 0.15 MPa.
[0039] 2. Treatment of Amination Solution: The purge value of the reactor was switched on to discharge gaseous monomethylamine in the reactor to a kettle for absorbing monomethylamine until there was no pressure in the reactor, and then the amination solution was transferred to a 2000 L still for recovery of monomethylamine by distillation. The material in the still was heated. When the gas-phase temperature reached 101° C., a jet vacuum pump was started to evacuate the still. Heating was continued until the temperature of the material in the reactor reached 115° C. Then heating was stopped and evacuation was continued. After recovery of monomethylamine was completed, the temperature of the material was decreased to 80° C., and the material in the still was pressed into a filter press using compressed air to filter out the solid material. The solid material that was filtered out was collected for collective disposal, and the filtrate was fed into a 1000 L still.
[0040] 3. Purification by Distillation: The jet vacuum pump was started, and the filtrate in the still was heated. The condensed liquid recovered before the gas-phase temperature reached 60° C. was used to prepare 40 wt % NaOH solution, and the liquid condensed between 60° C. and 100° C. was recovered as front cut fraction which was added to next batch of distilland for full use. When the gas-phase temperature exceeded 100° C. and tended to rise further, the still was cooled to 80° C. A vacuum group was turned on to keep the vacuum in the scraper film evaporator above 0.099 MPa. When the temperature was 150° C., the discharge valve at the bottom of the still was switched on to feed the scraper film evaporator at a feed rate of 0.15 m 3 /h. Qualified product 3-methylamino-1,2-propanediol was distilled out.
[0041] Table 3 shows the quality index of 3-methylamino-1,2-propanediol synthesized according to the aforementioned method.
[0000]
TABLE 3
No.
Test Index
Analysis Method
Test Results
1
Appearance
Eye inspection
Colorless
and
transparent
liquid
2
Purity (GC) (%)
Gas chromatography
99.65
3
Cut fraction content before the
Gas chromatography
0.09
principal peak (GC) (%)
4
Cut fraction content after the
Gas chromatography
0.26
principal peak (GC) (%)
5
Moisture content (wt %)
Karl Fisher method
0.84
INDUSTRIAL PRACTICABILITY
[0042] 1. Because of the introduction of NaOH solution and NaHCO 3 in the amination reaction according to the invention as aminating catalysts, (1) the reaction system is made stronger alkaline, facilitating rapid substitution of CH 3 NH— group for —Cl group in glycerin chlorohydrin molecule, so that the amination reaction time is reduced; (2) relatively higher concentration of CH 3 NH 2 is ensured in the reaction system, which facilitates accelerating the reaction and reducing the reaction time; (3) the feeding ratio of monomethylamine to glycerin chlorohydrin may be reduced without affecting reaction rate and product quality; (4) conversion of glycerin chlorohydrin is increased; and (5) the pressure of amination reaction is reduced, wherein the operational pressure is decreased from 0.3-0.4 MPa in prior art to less than 0.15 MPa, so that the production is safer, and the requirements for facility material, wall thickness, fasteners, processing and the like are lowered substantially.
[0043] 2. Since HCl produced in the amination reaction is mostly converted to NaCl rather than CH 3 NH 3 Cl in the system, in contrast to prior art, the operational steps including the step of using aliphatic alcohol as required to dissolve and dilute the material in order to filter out CH 3 NH 3 Cl due to the viscous state of the material in the later stage of removing monomethylamine and water, the step of evaporating the aliphatic alcohol, and the like are left out. By appropriate adjustment of the production process, the salt may be filtered out while it is still hot once the amination solution is deaminated and dewatered to a certain extent. Thus, the production operation is made easier. Not only the unit operating cycle is shortened, but also the production cost and energy consumption are reduced.
[0044] 3. Since the product 3-methylamino-1,2-propanediol is distilled by way of the vacuum scraper film according to the invention, the heating time for separation and purification of the product is reduced greatly, and thus the components of the product hardly decompose. Thus, the product quality is improved significantly, and the content of 3-methylamino-1,2-propanediol in the product is increased to above 99.5% (GC). The product thus produced is a liquid that is totally colorless and transparent. Furthermore, compared with prior art, the energy consumption of the production is reduced remarkably. Specifically, power consumption is reduced by 20%, and coal consumption is reduced by 30%.
[0045] 4. Condensed water, monomethylamine and front cut fraction distilled out from the amination solution according to the invention are all recycled, which avoids volatilization and waste of the production starting material. Therefore, the availability of the starting material is increased. The production is achieved in a hermetic and clean environment, and the operational conditions for the production are improved notably.
[0046] 5. The product synthesized according to the invention, a liquid appearing colorless and transparent, has increased purity of above 99.5% (GC) and decreased impurities. Therefore, this product exactly meets the quality demand for synthesis of iopromide as a hypo-osmolar nonionic contrast medium. | A synthesis method of 3-methylamino-1,2-propanediol is disclosed in the invention, and it includes the following steps: (1) adding glycerin chlorohydrin, aqueous monomethylamine solution and an amination catalyst, namely NaOH solution and NaHCO 3 , into a reactor, mixing the material sufficiently, and allowing amination reaction to proceed in two temperature stages; (2) removing monomethylamine and water from the amination solution after the amination reaction is completed, filtering out the solid resultant, and feeding the filtrate into a still; (3) distilling under reduced pressure to obtain 3-methylamino-1,2-propanediol, wherein the vacuum for distillation under reduced pressure is equal to or greater than 0.099 MPa and the temperature is 130-160° C. The product synthesized according to the invention, a liquid appearing colorless and transparent, has increased purity of over 99.5% (GC) and decreased impurities. Therefore, when this product is used for synthesis of iopromide as a hypo-osmolar nonionic contrast medium, it exactly meets the quality demand. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cationic starch and a cationic starch paste or slurry for papermaking which has a high nitrogen content and yet has a low cation equivalent value. The present invention relates also to a process for producing the same.
Major terms and abbreviations used in this specification are defined below.
(1) Cation equivalent value (meq): Expressed in terms of values measured by the colloidal titration of starch paste solution with PVSK (potassium polyvinylsulfate).
(2) Viscosity: Expressed in terms of values measured on a 1 wt % sample at 50° C. with a Brookfield viscometer, unless otherwise mentioned.
(3) Nitrogen content: Expressed in terms of percentage (%) values measured on a sample of cationic starch by the semimicro Kjeldahl method.
(4) DS value: Expressed in terms of an average of the number of substituted hydroxyl groups per glucose residue. It represents the degree of esterification and etherification of a derivative.
2. Description of the Prior Art
The recent trend in the papermaking industry is toward the use of increasing amounts and varieties of cationic chemicals for stable papermaking machine operation under the condition that more DIP (deinked pulp) and waste paper pulp are used than before. The consequence is an overall increase of cation equivalent value in the papermaking system containing as much general-purpose cationic starch as before. This in turn raises the zeta potential in the system, making it difficult to maintain it in the optimum range of -5 mV to ±0 mV in the wet end of paper making system. Therefore, although Cationic starch is essential for dry strength, it is necessary to limit cationic starch in its dosage amount and its degree of cationization. Such limitation, however, decreases the effect of cationic starch on flocculation or bonding of pulp fiber or fine fiber which is proportional to the amount and the degree of cationization.
The degree of cationization is proportional to nitrogen content in cationic starch, because cationic starch is produced by replacing the hydroxyl group in starch with a quaternary ammonium salt and/or a tertiary amino group. Thus, there has been a demand for a cationic starch and a cationic starch paste solution thereof for papermaking which has a high nitrogen content (which relates to the degree of cationization and the amount of cationic starch) and yet has a relatively low cation equivalent value.
It is common practice to use cationic starch powder in the papermaking process by adding it in the form of a starch paste or slurry to the machine chest, mixing chest, or fan pump for uniform dispersion into the paper stock. Uniform dispersion is desirable for improved paper strength and improved size yield.
Unfortunately, these requirements are not met by conventional cationic starch which has a high solution viscosity because it doe snot undergo acid treatment or oxidation (to lower the viscosity) in its manufacturing process. Conversely, lowering the viscosity also reduces the molecular weight of cationic starch, which adversely affects the performance of cationic starch. This is another reason why there has been a demand for a cationic starch and starch paste solution thereof for papermaking that has the above-mentioned dual characteristic properties.
SUMMARY OF THE INVENTION
The present invention is directed to a new cationic starch and cationic starch paste or slurry and a process for the production thereof, where the cationic starch and starch paste have a high nitrogen content and yet a low cation equivalent value, and also have a high molecular weight and yet a low solution viscosity.
The first aspect of the present invention resides in a cationic starch and starch paste solution thereof formed by substitution with a quaternary ammonium salt and/or tertiary amino group, characterized in that its nitrogen content (X) due to said quaternary ammonium salt and/or tertiary amino group is related to its cation equivalent value (Y) as defined below.
Y<about 0.7X-about 0.08
(in the case of natural terrestrial stem starch)
Y<about 0.3X-about 0.5
(in the case of natural subterranean stem starch having ester-type substituents)
Y<about 0.4X+about 0.02
(in the case of natural subterranean stem starch having no ester-type substituents)
The second aspect of the present invention resides in a process for producing the cationic starch defined above. The process comprises cationizing esterified natural starch, cationizing etherified natural starch, or carrying out the cationization by reactions in a plurality of steps or in one step. According to the present invention, the paste or slurry of cationic starch preferably contains less than 5.5% salt per starch in paste solution. It is produced either by adding a salt component to the reaction slurry before, during, or after the esterification or etherification and/or cationization, and drying the starch without its washing or with its incomplete washing such that salt remains in the starch, or by adding a salt component to the cationic starch before or after its gelatinization.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features which are characteristic of the present invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages, will be best Understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a graph showing the relation between the nitrogen content (X) and the cation equivalent value (Y) of the size solution of the cationic starch according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, constituent percentages are based on weight, unless otherwise specified.
The present invention covers cationic starch and a cationic starch paste or slurry formed by substitution with a quaternary ammonium salt and/or a tertiary amino group, characterized in that its nitrogen content (X) due to said quaternary ammonium salt and/or tertiary amino group is preferably related to its cation equivalent value (Y) as defined below.
Y<0.70097X-0.07978
(in the case of natural terrestrial stem starch)
Y<0.32936X-0.00495
(in the case of natural subterranean stem starch having ester-type substituents)
Y<0.40942X+0.02211
(in the case of natural subterranean stem starch having no ester-type substituents)
The expression of relations given above, and illustrated in FIG. 1, signifies that the relation between the nitrogen content and the cation equivalent value in the cationic starch of the present invention is represented by the straight lines and the area under the straight lines.
The starch used in the present invention is any of natural terrestrial stem starch (which includes corn starch, waxy corn starch, and wheat starch), natural subterranean stem starch having ester-type substituents (in the unprocessed state) (which includes potato starch), and natural subterranean stem starch having no ester-type substituents (which includes tapioca starch and sweet potato starch). It may be slightly modified by esterification, etherification, oxidation, acid treatment, or dextrination. Such modified starch may be used individually or in combination with one another or in combination with plain starch.
The cationic starch in the present invention should contain 0.15-0.60% nitrogen based upon the starch component, preferably 0.15-0.50% nitrogen. The nitrogen content is an indirect measure of the degree of cationization. With a nitrogen content less than 0.15% of the starch component, the cationic starch does not have sufficient plus charge for cohesive force to form flocks in paper stock. If the nitrogen content is higher than 0.15% and the cation equivalent value (Y) is larger than that specified by the expression of relation between the nitrogen content and the cation equivalent value (Y), then the cationic starch will excessively form flock in paper stock when used in an amount more than prescribed. With a nitrogen content in excess of 0.60% of the starch component, the cationic starch does not provide sufficient interfiber bonding force (which leads to insufficient paper strength) when used in an amount just enough not to disturb the formation of paper.
The viscosity of the paste or slurry of cationic starch should preferably be lower than 200 cP (measured on a sample of 1% concentration at 50° C.). In the case of natural terrestrial stem starch and natural subterranean stem starch having no ester-type substituents, it should preferably be lower than 100 cP. In the case of natural subterranean stem starch having ester-type substituents, it should preferably be lower than 150 cP. A paste of cationic starch with an excessively high viscosity presents difficulties in uniform dispersion into paper stock.
For the above-mentioned expression of relations to be satisfied according to the present invention, it is necessary that the content of salt component be less than 5.5% of the starch component, preferably less than 5.1% more preferably less than 4.1%. The function of the salt component is to relatively lower the cation equivalent value and viscosity of the paste of cationic starch. A salt component content in excess of 5.5% of the starch component in the paste solution retards the disintegration and dispersion of starch micells at the time of gelatinization.
The salt component is mainly an alkali metal or alkaline earth metal salt of an inorganic or organic acid. Examples include salts of inorganic acids such as sulfuric acid, nitric acid, phosphoric acid, hydrochloric acid, and carbonic acid; and salts of organic acids such as formic acid, acetic acid, butanoic acid, octanoic acid, stearic acid, (and other aliphatic saturated and unsaturated carboxylic acids), and benzoic acid (and other aromatic carboxylic acids). Preferred examples include salts of sulfuric acid, phosphoric acid, and carbonic acid, and salts of aliphatic saturated or unsaturated carboxylic acid having 2-7 carbons. These salts may be used in combination with one another.
There are two ways of adding the salt component to the paste or slurry solution of cationic starch. According to one embodiment, the salt component is added to the reaction slurry before, during, or after the esterification or etherification and/or cationization, and drying the starch without its washing or with its incomplete washing such that salt remains in the starch. According to another embodiment, the salt component is added to the cationic starch before or after its gelatinization. In the first embodiment, it is desirable to add a salt of an inorganic or organic acid in an amount more than 5% based on the weight of anhydrous starch, because the washing step usually follows the esterification, etherification, or cationization (except the one which is carried out last). An amount more than 5% per starch is necessary for uniform reaction without starch swelling. Any fraction in excess of 5% per starch will be removed in the washing step, and the content of salt in the cationic starch eventually decreases to 5.5% per starch or less.
The above-mentioned expression of relation may be satisfied if the cationic starch is produced by cationizing esterified natural starch, cationizing etherified natural starch, or carrying out the cationization by reactions in a plurality of steps.
The esterification may be accomplished in the usual way with one or more esterifying agents listed below. The degree of esterification should be DS 0.00005-0.05, preferably DS 0.000075-0.030. The step of esterification may be omitted if commercial low-substituted esterified starch is used. Suitable esterifying agents include:
(i) Acid halide or acid anhydride of saturated or unsaturated carboxylic acids (having 2-18 carbons) or aromatic carboxylic acids. Examples of saturated or unsaturated carboxylic acids include acetic acid propionic acid, octanoic acid, stearic acid, and oleic acid. Examples of aromatic carboxylic acids include benzoic acid. Of these examples, acetic acid and propionic acid are preferable.
(ii) Vinyl ester monomer with a C2-18 ester component. Examples include vinyl esters of aliphatic saturated and unsaturated carboxylic acids (such as vinyl acetate, vinyl propionate, vinyl butanoate, and vinyl acrylate), and vinyl esters of aromatic carboxylic acids (such as vinyl benzoate, and vinyl p-methylbenzoate). Of these examples, vinyl acetate monomer and vinyl propionate monomer are preferable. They may be used in combination with one another.
(iii) Derivatives of sulfonic acid, sulfinic acid, and phosphoric acid which have a C1-18 saturated or unsaturated hydrocarbon group or an aromatic hydrocarbon group.
The saturated or unsaturated hydrocarbon group includes methyl, propyl, octenyl, stearyl, and oleyl. The aromatic hydrocarbon group includes benzyl and toluyl.
(iv) Phosphates, which include alkali metal salts and alkaline earth metal salts of orthophosphoric acid, metaphosphoric acid, tripolyphosphoric acid, hexametaphosphoric acid, and phosphorous acid. Of these examples, alkali metal salts and alkaline earth metal salts of orthophosphoric acid, tripolyphosphoric acid, and phosphorous acid are preferable.
(v) Others, such as nitrated or nitrochlorinated aromatic or aliphatic compounds, and sulfuric acid.
The etherification may be accomplished in the usual way with one or more etherifying agents (mono or diepoxides) listed below. The degree of etherification should be DS 0.00005-0.05, preferably DS 0.000075-0.030. Suitable etherifying agents include: Mono or diepoxides including ethylene oxide, propylene oxide, 1,6-hexanediol diglycidyl ether, 1,5-pentanediol diglycidyl ether, p-diethoxybenzene, and 1,5-dipropoxynaphthalene, which have 2-18 carbons. Of these examples, ethylene oxide, propylene oxide, 1,4-buthanediol glycidyl ether, and 1,6-hexanediol glycidyl ether, which have 2-7 carbons, are preferably, with the first three being more desirable.
As mentioned above, the cationization may be accomplished in one step or in a plurality of steps.
(i) The cationization may be accomplished by the aid of any cationizing agent, such as a quaternary ammonium salt and a tertiary amine compound, alone or in combination.
Any commercial quaternary ammonium salt of chlorohydrin type or glycidyl type is of practical use from the standpoint of economy and easy operation. It is represented by the structural formula: ##STR1## (where R 1 , R 2 , and R 3 each denotes an alkyl group; and R4 denotes a substituent including a chlorohydrin or glycidyl group.)
A typical example of a quaternary ammonium salt is N,N-dimethyl-1-chloro-2-hydroxypropylammonium chloride.
The tertiary amine compound is represented by the formula below: ##STR2## (where R 1 , R 2 , and R 3 each denotes an alkyl group.) A typical example thereof is β-chloroethyldiethylamine hydrochloride.
(ii) In the case where the cationization is carried out in plural steps, the cationizing agent should be divided into two or more portions, which are fed sequentially at intervals longer than four hours.
There are no restrictions on the mode of the above-mentioned esterification, etherification, and cationization. They may be carried out by the wet process (in an aqueous slurry), the dry process (which employs a disc dryer or fluidized bed roaster), or the on-site reaction in a paper mill (which involves gelatinization).
The cationic starch and cationic starch slurry of the present invention produce the following effects as demonstrated by the examples and comparative examples given later.
The cationic starch has a cation equivalent value which remains low even though the content of nitrogen therein (or the degree of cationization) is increased. The result is that it is possible to use a cationic starch of high nitrogen content without excessive increase of zeta potential in the papermaking system. This facilitates control of the papermaking system, allowing the amount of starch to be varied over a broad range according to the desired paper strength.
Because of its low viscosity despite of its high molecular weight, the cationic starch is readily and uniformly dispersed into paper stock without adverse effect on paper strength. This leads to a high yield of the cationic starch in paper.
EXAMPLES
The invention will be described with reference to the following Examples and Comparative Examples, in which the cationizing agent was N,N-dimethyl-1-chloro-2-hydroxypropylammonium chloride. Examples 1 to 7 demonstrate the case in which subterranean stem starch having no ester-type substituents was esterified and then cationized.
Example 1
A 2-liter flask was charged with 500 g of tapioca starch and 750 of tap water. To the resulting starch slurry was added with stirring 4% NaOH solution to adjust it to pH 10.0. The starch was esterified with acetic anhydride (0.5% of starch). To the esterified starch were added 58 g of cationizing agent and 25 g of sodium sulfate (which prevents swelling). The slurry was adjusted to pH 11.5-12.0 with 4% NaOH solution and underwent reaction for 16 hours.
Example 2
The same procedure as in Example 1 was repeated except that the esterifying agent was replaced by propionic acid chloride.
Example 3
The same procedure as in Example 1 was repeated except that the esterifying agent was replaced by vinyl acetate.
Example 4
The same procedure as in Example 1 was repeated except that the esterifying agent was replaced by sodium p-toluenesulfonate.
Example 5
The same procedure as in Example 1 was repeated except that the esterifying agent was replaced by octanoic anhydride.
Example 6
The same procedure as Example 1 was repeated except that the esterifying agent was replaced by acrylic acid chloride.
Example 7
The same procedure as Example 1 was repeated except that the esterifying agent was replaced by vinyl octanoate.
Examples 8 and 9 demonstrate the case in which the slurry of cationic starch was incorporated with an alkali metal salt of an inorganic acid.
Example 8
The cationic starch obtained in Example 1 was incorporated with sodium sulfate (3.0% of starch).
Example 9
The cationic starch obtained in Example 3 was incorporated with sodium sulfate (3.0% of starch).
Examples 10 to 12 demonstrate the case in which the starch was natural terrestrial stem starch.
Example 10
The same procedure as in Example 9 was repeated except that the natural starch was corn starch.
Example 11
The same procedure as in Example 9 was repeated except that the natural starch was waxy corn starch.
Example 12
The same procedure as in Example 9 was repeated except that the natural starch was wheat starch.
Example 13
This example demonstrates the case in which subterranean stem starch having ester-type substituents was esterified and then cationized and the slurry of cationic starch was incorporated with an alkali metal salt of an inorganic acid. The same procedure as in Example 9 was repeated except that the natural starch was potato starch.
Example 14
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was esterified and then cationized with an increased amount of cationizing agent. The same procedure as in Example 9 was repeated except that the amount of cationizing agent was increased to 32 g.
Example 15
This and next examples demonstrate the case in which subterranean stem starch having no ester-type substituents was cationized in a single step and the slurry of cationic starch was incorporated with an alkali metal salt of an inorganic acid.
A 2-liter flask was charged with 500 g of tapioca starch and 750 of tap water. To the resulting starch slurry were added 58 g of cationizing agent and 25 g of sodium sulfate (which prevents swelling). To the slurry was further added with stirring 4% NaOH solution to adjust it to ph 11.5-12.0. The slurry underwent reaction for 16 hours. After dehydration, washing, and drying, the cationic starch was incorporated with sodium sulfate (3.0% of anhydrous starch).
Example 16
The same procedure as in Example 15 was repeated except that sodium sulfate was replaced by sodium chloride (3.0% of starch).
Example 17
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was etherified and then cationized.
A 2-liter flask was charged with 500 g of tapioca starch and 750 of tap water. To the resulting starch slurry was added with stirring 4% NaOH solution to adjust it to ph 11.5-12.0. The starch was etherified with 5.4 g of propylene oxide by reaction under a nitrogen stream for 16 hours. Then the starch was cationized with 58 g of cationizing agent by reaction for 16 hours.
Example 18
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was cationized in several reaction steps.
A 2-liter flask was charged with 500 g of tapioca starch and 750 of tap water. To the resulting starch slurry was added with stirring 4% NaOH solution to adjust it to ph 11.5-12.0. The starch was cationized with the cationizing agent which was added in portions of 19 g, 19g, and 20 g, at intervals of 4 hours. After the addition, reaction was continued for 12 hours.
Example 19
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was esterified and then cationized, with an alkali metal salt of an inorganic acid added to the starch slurry prior to cationization.
The starch slurry obtained in Example 1 was incorporated with sodium sulfate (3.0% of starch), and then the starch was gelatinized.
Example 20
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was esterified and then cationized, with an alkali metal salt of an inorganic acid added to the starch solution prior to cationization.
The starch slurry obtained in Example 1 was gelatinized and then sodium sulfate was added to the starch solution.
Example 21
This example demonstrates the case in which subterranean stem starch having no ester-type substituents was esterified and then cationized, with an alkali metal salt of an inorganic acid added prior to cationization.
The procedure in Example 1 was modified such that 20 g of sodium sulfate was previously added to the cationizing reaction solution, and the cationized product was dried without purification.
Comparative Example 1 (Conventional practice for natural subterranean stem starch having ester-type substituents)
A 2-liter flask was charged with 500 g of potato starch and 750 of tap water. To the resulting starch slurry was added 25 g of sodium sulfate (which prevents swelling). To the starch slurry was further added with stirring 4% NaOH solution to adjust it to ph 11.5-12.0. To the starch was added 58 g of cationizing agent. After dehydration, washing, and drying, there was obtained conventional cationic starch.
Comparative Example 2 (Conventional practice for natural subterranean stem starch having ester-type substituents)
The same procedure as in Comparative Example 1 was repeated except that the natural starch was replaced by corn starch.
Comparative Example 3 (Conventional practice for natural subterranean stem starch having ester-type substituents)
The same procedure as in Comparative Example 1 was repeated except that the natural starch was replaced by tapioca starch.
Evaluation Tests (Methods and Results)
A. The samples of cationic starch and size solution thereof obtained in the foregoing examples and comparative examples were tested in the following manner.
1. Nitrogen content: measured by the semimicro Kjeldahl method.
2. Viscosity of starch solution: measured with a Brookfield viscometer at 50° C. on a sample which had been gelatinized by heating (with stirring) at 90° C. for 20 minutes in a steam bath.
3. Cation equivalent value: determined by colloidal titration of the starch solution with PVSK, the end point being indicated by color change from blue to red.
The test results are shown in Table 1 and plotted in FIG. 1. It is noted that the samples in Examples 1-21 have the characteristic properties which satisfy the expression of relation given in claim 1, but this is not true for the samples in the Comparative Examples.
B. The samples of cationic starch and size solution thereof obtained in the foregoing examples and comparative examples were used for alkali papermaking under the following conditions.
Pulp: LBKP/NBKP--70/30
Filler: calcium bicarbonate (20% of pulp)
Sizing agent: AKD
CSF: 300 mL
The resulting paper samples were tested in the following manner.
1. Zeta potential: measured with a steaming potentiometer.
2. Breaking length: measured according to JIS P-8113.
3. Yield of cationic starch: calculated by dividing the content of starch in paper sample by the amount of starch added to paper stock.
The test results are shown in Table 2. It is apparent that the samples obtained in Examples 1-21 have a zeta potential in an adequate range, but this is not true for the samples obtained in the Comparative Examples. It is also apparent that the samples in Examples 1-21 are superior to those in the Comparative Examples in breaking length and yield of cationic starch.
TABLE 1______________________________________Sample Viscosity of Nitrogen Cation EquivalentNo. Starch Solution Content (X %) Value (Ymeq)______________________________________ 1 250 0.36 0.12 2 200 0.35 0.11 3 195 0.36 0.12 4 210 0.36 0.10 5 220 0.36 0.11 6 180 0.36 0.13 7 200 0.36 0.10 8 57 0.35 0.09 9 48 0.36 0.0910 40 0.37 0.0711 45 0.37 0.0812 46 0.37 0.0913 105 0.38 0.0714 28 0.20 0.0415 51 0.36 0.0816 230 0.36 0.1117 60 0.36 0.0718 165 0.36 0.1019 88 0.36 0.0820 95 0.36 0.0721 78 0.36 0.07(1) 285 0.38 0.12(2) 185 0.35 0.17(3) 290 0.41 0.20______________________________________ Comparative samples are indicated by parenthesized numbers.
TABLE 2______________________________________Sample Yield of Cationic Zeta-Potential BreakingNo. Starch (%) (mV) Length (kgf)______________________________________ 1 85 -1.27 5.80 9 90 -1.09 5.9410 88 -1.00 5.7713 94 -1.15 5.8617 89 -0.98 5.9019 80 -1.10 5.7820 86 -1.18 5.91(1) 64 -0.55 4.95(2) 71 -0.29 3.91(3) 68 -0.15 4.10______________________________________ Comparative samples are indicated by parenthesized numbers.
It will be appreciated by those skilled in the art that various modifications and changes can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be covered by the appended claims. | Disclosed herein is a new cationic starch and cationic starch paste or slurry. The starch paste or slurry has a low cation equivalent value despite its high nitrogen content and also has a low solution viscosity despite its high molecular weight. The cationic starch and cationic starch paste or slurry is formed by substitution with a one or both of quaternary ammonium salt or a tertiary amino group, characterized in that its nitrogen content (X) due to the quaternary ammonium salt and/or tertiary amino group is related to its cation equivalent value (Y) as defined below:
Y<0.70097X-0.07978
(in the case of natural terrestrial stem starch)
Y<0.32936X-0.00495
(in the case of natural subterranean stem starch having ester-type substituents)
Y<0.40942X+0.02211
(in the case of natural subterranean stem starch having no ester-type substituents) | 2 |
RELATED APPLICATIONS
[0001] The present invention claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 61/888,342, filed on 8 Oct. 2013.
BACKGROUND OF THE INVENTION
[0002] Many doors, such as classroom doors, are keyed from only one side. Currently, to lock a typical in swinging classroom door, an adult inside the classroom must have the correct key for each classroom door. In addition, the person locking the door must be outside the room to lock the door. Thus, the person locking the door must step outside of the room and into the hallway to lock the door. During typical operation, this arrangement is problem free. However, in times of distress, for example during an emergency lock-down, the extra step of walking out of the classroom and into the hallway to lock the door from the outside may place the individual in a compromised position. Moreover, this standard locking procedure does not provide a controlled room environment when the door must be quickly locked to secure occupants inside the room during an emergency lock-down situation. Further, it is not practical to keep doors in a constantly locked position. Doors locked at all times may present other security issues. For example, if doors are in a constant lock position any children, staff members, educators, or others with authorized access to the room would first need to knock on the door to gain access. This interrupts learning.
[0003] Certain solutions have been designed to remedy this situation. For example, a magnetic strip may be placed over the door strike plate and latch hole. Since the strip covers the latch hole, when the magnetic strip is in place, the door may remain in the locked position and yet freely swing open or closed. To lock the door, the magnetic strip must be removed by a staff member, student, or other approved person to thereby allow the lock to engage the latch hole. While this approach allows the door to be in a constant lock position while also providing access to the room, removal of the magnetic strip again requires opening the door and stepping into the hallway or opening the door during a dangerous lock-down situation, thereby putting the user at risk.
[0004] Another product designed to keep locked doors swinging freely includes the use of a thin metal bar that may be moved between locked and unlocked position. When the bar is in a first position it prevents the locked door from closing all the way. When the bar is flipped to a second position the door is allowed to lock. Installation of the metal bar onto a door frame requires a specific amount of space between the door and door frame. Further, depending on installation height, staff and students may need chairs or stools in order to reach the metal bar to move it when required. Moreover, the product is not particularly effective for use with outward swing doors. If this product is used with an outward swing door, the user must step into the hallway, flip the bar, and then step back into the classroom, thereby creating a potential risk to both the user and the room occupants during a lock down situation.
[0005] Yet another product created to lock a door in the event of an emergency is a peg and hole arrangement. A peg drops into a hole in the floor when rapid locking is required. This solution is not optimal for several reasons. First, the user must drill holes into the floor to accommodate the pegs. Second, the user must provide a way for security or administration to gain access to the room after the emergency or threat has passed. Since the door is locked by a peg from the inside, an exterior key will not allow entrance from the hallway. This may present a problem due to various laws regarding the locking of classroom doors. For example, and typically, school room doors may not be locked from the inside unless the door has a push button lock that disengages with a turn on the knob from the inside. Further, occupants are not allowed to be locked in a classroom without an accessible exit. Although children may be able to disengage the interior peg after the emergency has passed, they may not reliably do so.
[0006] Therefore, a solution is needed to enable a door, such as a classroom door, to be freely opened while the door is locked, but also permit quick and facile locking in the event of an emergency lock-down.
SUMMARY OF THE INVENTION
[0007] The present invention provides a solution to the aforementioned problems and shortcomings by providing a safety device for use with exteriorly locked doors. The device may be adapted for use on both outward swing and inward swing doors. A safety device according to the present invention provides a temporary barrier between the latch and the strike plate hole while the door is in a locked condition to thereby prevent the locked door latch from engaging the strike plate hole. The present device is adapted to attach to a door frame and to provide a temporary barrier over the latch hole. While the device is in place, the door may be in the locked position at all times, while simultaneously permitting ingress and egress to the room. In the event of an emergency lock-down, room occupants may push the door closed, remove the safety device from the strike plate, and thereby allow the locked latch to engage the latch hole. These steps may be taken while the occupants remain in the room and without need to exit the room into the hallway. At the same time, students or other room occupants may transition to their required safe locations within the room. The present invention enables rooms such as classrooms to be controlled in a relatively short time while keeping the user out of the hallway or door frame.
[0008] A safety device according to the present invention may preferably include a strike plate cover, a frame portion, a pull portion, and at least one magnet member. The strike plate cover is preferably sized and dimensioned to cover a strike plate of a lock set, and particularly cover the latch hole. The strike plate cover includes a first planar surface, a second planar surface, a first side edge, and second side edge. One of the side edges preferably includes a frame portion extending generally perpendicularly from the plane of the strike plate cover. The frame portion preferably includes a first frame surface and an oppositely disposed second frame surface. At least one of the frame surfaces includes at least one magnet member affixed thereto. The safety device further includes a pull portion. The pull portion extends from one of the frame surfaces, preferably the frame surface opposite the at least one magnet member. Optionally, the device may include a lanyard. When used, one of the ends of the lanyard is affixed to the pull portion, while the opposite end is adapted to be affixed to a door frame. When the safety device is pulled from the strike plate, the lanyard remains affixed to the door frame and thereby allows the device to dangle from the frame to prevent loss. The device may further and optionally include a protrusion on at least one planar surface of the strike plate cover. The protrusion provides additional friction to assist in securing the device to a strike plate while the door is closed.
[0009] Another embodiment safety device according to the present invention, and specifically for use with outwardly swinging doors, preferably includes a strike plate cover, an elongated frame portion, a pull portion, and at least one magnet member. Again, the strike plate cover is preferably sized and dimensioned to cover a strike plate of a lock set, and particularly to cover the latch hole. The strike plate cover includes a first planar surface, a second planar surface, a first side edge, and second side edge. One of the side edges includes a connector portion extending generally perpendicularly from the plane of the strike plate cover. An elongated frame portion extends from the connector portion and in a plane parallel to that of the strike plate cover. The frame portion further preferably includes a first frame surface and an oppositely disposed second frame surface. At least one of the frame surfaces includes at least one magnet member affixed thereto. The safety device further includes a pull portion. The pull portion extends from one of the frame surfaces. As in the previous embodiment, the device may optionally include a lanyard to prevent loss when the safety device is removed from the strike plate. The device may also be provided with an adjustment block for use during installation and stability, as will be discussed.
[0010] Another embodiment of a safety device according to the present invention, and specifically for use with doors having a crash bar type latch system, may preferably include a strike plate cover, a frame portion, a pull portion, and at least one magnet member. The strike plate cover may further be provided with a hooked end for engagement with the roller member of a crash bar latch system. The strike plate cover is preferably sized and dimensioned to cover a latching mechanism of a crash bar system, with the hooked end particularly engaging the roller member to prevent latching. The strike plate cover includes a first planar surface, a second planar surface, a first side edge, and second side edge. One of the edges includes an angled connector portion extending from the plane of the strike plate cover. A frame portion extends from the connector portion. The frame portion further preferably includes a first frame surface and an oppositely disposed second frame surface. At least one of the frame surfaces includes at least one magnet member affixed thereto. In this embodiment, the pull portion is integrated with the frame portion, as the user simply grasps the frame portion to slide the device away from the latch system to thereby engage the lock. As in previous embodiments, the device may optionally include a lanyard to prevent loss when the device is removed from the strike plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front perspective view of a safety device according to the present invention.
[0012] FIG. 2 is a back perspective view of the safety device illustrated in FIG. 1 .
[0013] FIG. 3 is a perspective side view of the safety device illustrated in FIGS. 1 and 2 .
[0014] FIG. 4 is a front plan view of the device illustrated in FIGS. 1-3 .
[0015] FIG. 5 is a rear plan view of the device illustrated in FIGS. 1-4 .
[0016] FIG. 6 is a left side view of the device illustrated in FIGS. 1-5 .
[0017] FIG. 7 is a right side view of the device illustrated in FIGS. 1-6 .
[0018] FIG. 8 is a top view of the device illustrated in FIGS. 1-7 .
[0019] FIG. 9 is a bottom view of the device illustrated in FIGS. 1-8 .
[0020] FIG. 10 is a view of a stamping of the device illustrated in FIGS. 1-9 in flat form to be bent to into the shape illustrated in FIGS. 1-9 .
[0021] FIG. 11 is a perspective front view of another embodiment of a safety device according to the present invention.
[0022] FIG. 12 is a back perspective view of the device illustrated in FIG. 11 .
[0023] FIG. 13 is a front plan view of the device illustrated in FIGS. 11 and 12 .
[0024] FIG. 14 is a rear plan view of the device illustrated in FIGS. 11-13 .
[0025] FIG. 15 is a left side view of the device illustrated in FIGS. 11-14 .
[0026] FIG. 16 is a right side view of the device illustrated in FIGS. 11-15 .
[0027] FIG. 17 is a top view of the device illustrated in FIGS. 11-16 .
[0028] FIG. 18 is a bottom view of the device illustrated in FIGS. 11-17 .
[0029] FIG. 19 is a back perspective view, similar to that of FIG. 12 , but showing an optional adjustment bar.
[0030] FIG. 20 is a front perspective view of the device illustrated in FIG. 19 and showing use of the adjustment bar.
[0031] FIG. 21 is a rear perspective view of the device, similar to that of FIG. 12 , but showing an alternative magnet placement.
[0032] FIG. 22 is a perspective front view of another embodiment of a safety device according to the present invention.
[0033] FIG. 23 is a front plan view of the device illustrated in FIG. 22 .
[0034] FIG. 24 is a bottom view of the device illustrated in FIGS. 22-23 .
[0035] FIG. 25 is a rear plan view of the device illustrated in FIGS. 22-24 .
[0036] FIG. 26 is a top view of the device illustrated in FIGS. 22-25 .
[0037] FIG. 27 is a left side view of the device illustrated in FIGS. 22-26 .
[0038] FIG. 28 is a right side view of the device illustrated in FIGS. 22-27 .
[0039] FIG. 29 is a view of the device illustrated in FIGS. 1-10 in place on a door frame and strike plate during use.
[0040] FIG. 30 is a fragmentary view similar to that of FIG. 29 but showing the door in the open position.
[0041] FIG. 31A is a fragmentary view similar to that of FIG. 30 but showing the door in the closed position and prior to device removal.
[0042] FIG. 31B is a cross sectional view of the device illustrated in FIGS. 1-10 in place with lock components positioned as in FIG. 31A , and taken along lines 31 B- 31 B thereof.
[0043] FIG. 32A is a fragmentary view similar to that of FIG. 31A and showing the door in the closed position during device removal.
[0044] FIG. 32B is a cross sectional view of the device with lock components positioned as in FIG. 32A during device removal, and taken along lines 32 B- 32 B thereof.
[0045] FIG. 33 is a fragmentary view, similar to that of FIGS. 31A and 32A but showing the device removed and hanging from a lanyard.
[0046] FIG. 34A is a view of the device illustrated in FIGS. 11-18 in place on a door frame and strike plate during use on an outward swing door.
[0047] FIG. 34B is a cross sectional view of the device in place with lock components positioned as shown in FIG. 34A and taken along lines 34 B- 34 B thereof.
[0048] FIG. 35 is a fragmentary enlarged view of the device illustrated in FIGS. 34A , 34 B but with the door in the open position.
[0049] FIG. 36 is a fragmentary view, similar to that of FIG. 34A , but showing the device during disengagement.
[0050] FIG. 37A is a view of the device illustrated in FIGS. 22-28 in place during use on a door frame and door having a crash bar latch system.
[0051] FIG. 37B is a cross sectional view of the device in place and with latching mechanism positioned as in FIG. 37A , and taken along lines 37 B- 37 B thereof.
[0052] FIG. 38 is a view similar to that of FIG. 37A , but showing the device during disengagement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0054] With attention to FIGS. 1-10 , an embodiment of a safety device 10 according to the present invention may be seen. As shown, the device 10 preferably includes a strike plate cover 12 , a frame portion 14 , a pull portion 16 , and at least one magnet member 18 . The strike plate cover 12 is preferably sized and dimensioned to cover a strike plate 20 (see FIGS. 31B-33 ) of a lock set, and particularly to cover the latch hole 22 (see FIG. 31B ). The strike plate cover 12 preferably includes a first planar surface 24 , a second planar surface 26 , a first side edge 28 , and second side edge 30 . One of the side edges 28 , 30 preferably includes a frame portion 14 extending generally perpendicularly from a plane of the strike plate cover 12 . The frame portion 14 preferably includes a first frame surface 32 and an oppositely disposed second frame surface 34 . At least one of the frame surfaces 32 , 34 includes at least one magnet member 18 affixed thereto. The magnet member 18 may be affixed by any fastening means that is satisfactory to affix the magnet 18 to the device 10 and resist removal during use, such as the rivet 36 shown. Moreover, a magnet member 18 for use with the present invention is preferably of a type being strong enough to affix the device 10 to a magnetically attractive ferrous material.
[0055] With further attention to FIGS. 1-10 and 31 A- 33 , the safety device 10 may be seen to include a pull portion 16 . The pull portion 16 extends generally perpendicularly from one of the frame surfaces 32 , 34 , preferably the frame surface 32 , 34 opposite the magnet member 18 , seen as frame surface 32 in these views. The pull portion 16 may optionally include a flanged end 38 for ease in gripping when the device 10 is removed, as will be discussed. Optionally, the device 10 may also include a lanyard 40 having a first end 42 and a second end 44 . In use, one the ends 42 , 44 of the lanyard 40 is affixed to the pull portion 16 , while the opposite end 42 , 44 is adapted to be affixed to a door frame 46 . An end 42 , 44 of the lanyard 40 may be affixed to the pull portion 16 by any suitable fastener, such as the rivet 36 shown, while the opposite end 42 , 44 is attached to a door frame 46 in the same manner as by a rivet 36 , screw, or other acceptable fastener (not seen in these views). When the safety device 10 is pulled from the strike plate 20 , the lanyard 40 remains affixed to the door frame 46 to thereby allow the device 10 to dangle from the frame 46 and prevent loss of the device 10 . The device 10 may be made of any suitably rigid and wear resistant material, such as a metal. When formed of metal, the device 10 may be formed from a metal stamping such as that shown in FIG. 10 and bent to the preferred configuration.
[0056] The device 10 may further and optionally include a protrusion 48 on at least one planar surface 24 , 26 of the strike plate cover 12 . The protrusion 48 provides additional friction to assist in securing the device 10 to a strike plate 20 while the door 50 is closed.
[0057] With specific attention now to FIGS. 29-33 , use of the device 10 may be seen. As shown, the device 10 may be normally installed on a door frame 46 , with the strike plate cover 12 placed adjacent and over the strike plate 20 and latch hole 22 of a door 50 . The door frame 46 is of a magnetically attractive ferrous material such that the magnet member 18 on the frame portion 14 is attracted to and holds the device 10 against the door frame 46 . When the device 10 is installed as is shown in FIGS. 29-31B , the door 50 may be in a constant locked position, with the strike plate cover 12 preventing the latch 52 from engaging in the latch hole 22 and locking the door 50 . In this manner, the device 10 may remain in place and the door 50 will open freely despite it being in a locked position. When quick locking of the door 50 is desired, as for example, during an emergency lockdown, an authorized user may simply grasp the pull portion 16 , as is seen in FIGS. 32A , 32 B, and move the device 10 in the direction of arrow A. With the device 10 and its strike plate cover 12 removed, the latch 52 is able to engage the latch hole 22 , and the door 50 is locked. As is seen in FIG. 33 , the device 10 , when provided with a lanyard 40 , dangles from the door frame 46 .
[0058] With attention now to FIGS. 11-21 and 34 A- 36 , another embodiment of a safety device 100 , 100 A, 100 B according to the present invention may be seen. The device 100 , 100 A, 100 B illustrated in these Figures is for use with outwardly swinging doors 50 . As shown, and similar to the previously described device 10 , the device 100 , 100 A, 100 B shown in these views preferably includes a strike plate cover 12 , an elongated frame portion 14 A, a pull portion 16 , and at least one magnet member 18 . The strike plate cover 12 is preferably sized and dimensioned to cover a strike plate 20 (see FIGS. 34B and 35 ) of a lock set, and particularly to cover the latch hole 22 (see FIG. 34B ). The strike plate cover 12 preferably includes a first planar surface 24 , a second planar surface 26 , a first side edge 28 , and second side edge 30 . One of the side edges 28 , 30 preferably includes a connector portion 54 extending generally perpendicularly from a plane of the strike plate cover 12 . An elongated frame portion 14 A extends generally perpendicularly from the connector portion 54 and in a plane parallel to that of the strike plate cover 12 . The frame portion 14 A further preferably includes a first frame surface 32 and an oppositely disposed second frame surface 34 . At least one of the frame surfaces 32 , 34 (seen as surface 34 in these views) includes at least one magnet member 18 affixed thereto. The magnet member 18 may be affixed by any fastening means that is satisfactory to affix the magnet 18 to the device 100 , 100 A, 100 B and resist removal during use, such as the rivet 36 shown, although other fastening means may be envisioned without departing from the invention. Moreover, a magnet member 18 for use with the present invention is preferably of a type being strong enough to affix the device 100 , 100 A, 100 B to a magnetically attractive ferrous material, such as a door frame 46 .
[0059] With further attention to FIGS. 11-21 and 34 A- 36 , the safety device 100 , 100 A, 100 B may be seen to include a pull portion 16 . The pull portion 16 extends generally perpendicularly from one of the frame surfaces 32 , 34 , preferably the frame surface 32 , 34 adjacent the magnet member 18 , seen as surface 34 in these views. As in the previous embodiment, the device 100 , 100 A, 100 B may optionally include a lanyard 40 having a first end 42 and a second end 44 . In use, one of the ends 42 , 44 of the lanyard 40 is affixed to the frame portion 14 A, while the opposite end 42 , 44 is adapted to be affixed to a door frame 46 . An end 42 , 44 of the lanyard 40 may be affixed to the frame portion 14 A by any suitable fastener, such as the rivet 36 shown, while the opposite end 42 , 44 is attached to a door frame 46 in the same manner as by a rivet 36 , screw, or other acceptable fastener. When the safety device 100 , 100 A, 100 B is removed from the strike plate 20 when not in use, the lanyard 40 remains affixed to the door frame 46 to thereby allow the device 100 , 100 A, 100 B to dangle from the frame 46 to prevent loss of the device 100 , 100 A, 100 B.
[0060] With attention now to FIGS. 19 and 20 , the device 100 A may be provided with at least one adjustment block 56 for use during installation and stability. As is shown, the frame portion 14 A may include a plurality of adjustment slots 58 . The adjustment slots 58 are arranged to slidingly accept screws 60 or other fasteners for the adjustment block 56 . In use, the adjustment block 56 may be moved along the slots 58 in the direction of arrow B (see FIG. 20 ) to thereby locate the block 56 adjacent a door frame 46 . Once the block 56 is snug against a door frame 46 , and the device 100 A is located properly against the strike plate 20 , the screws 60 may be tightened to prevent further movement.
[0061] FIG. 21 illustrates an alternative magnet member 18 arrangement, wherein a single magnet 18 may be used. It is to be understood that any number or configuration of magnet members 18 may be used without departing from the invention.
[0062] With specific attention now to FIGS. 34A-36 , use of the device 100 , 100 A, 100 B may be seen. As shown, the device 100 , 100 A, 100 B may be normally installed on a door frame 46 , of an outward swing door 50 with the strike plate cover 12 placed adjacent and over the strike plate 20 and latch hole 22 of a door 50 . The door frame 46 is of a magnetically attractive ferrous material such that the magnet member 18 on the frame portion 14 A is attracted to and holds the device 100 , 100 A, 100 B against the door frame 46 . When the device 100 , 100 A, 100 B is installed as is shown in FIGS. 34A-35 , the door 50 may be in a constant locked position, with the strike plate cover 12 preventing the latch 52 from engaging in the latch hole 22 and locking the door 50 . In this manner, the device 100 , 100 A, 100 B may remain in place and the door 50 will open freely despite it being in a locked position. When quick locking of the door 50 is desired as for example, during an emergency lockdown, an authorized user may simply grasp the pull portion 16 as is seen in FIG. 36 , and move the device 100 , 100 A, 100 B in the direction of arrow C. With the device 100 , 100 A, 100 B and its strike plate cover 12 removed, the latch 52 is able to engage the latch hole 22 and the door 50 is locked. When the device 100 , 100 A, 100 B is optionally provided with a lanyard 40 , the device 100 , 100 A, 100 B will dangle from the door frame 46 when not in use, as is shown in FIG. 33 .
[0063] FIGS. 22-28 and 37 A- 38 illustrate another embodiment of a safety device 200 according to the present invention, and specifically for use with doors 50 having a crash bar type latch system. As in the previously described embodiments, the device 200 illustrated in these views may preferably include a strike plate cover 12 A, a frame portion 14 , a pull portion 16 , and at least one magnet member 18 . As seen, the strike plate cover 12 A may further be provided with a hooked end 62 for engagement with a roller member 64 of a crash bar latch system (see FIG. 37B ). The strike plate cover 12 A is preferably sized and dimensioned to cover a catch mechanism 66 of a crash bar system, with the hooked end 62 particularly engaging the roller member 64 to prevent latching. The strike plate cover 12 A preferably includes a first planar surface 24 , a second planar surface 26 , a first side edge 28 , and second side edge 30 . One of the edges 28 , 30 terminates in an angled connector portion 54 A extending from the plane of the strike plate cover 12 A. A frame portion 14 extends from the connector portion 54 A. The frame portion 14 further preferably includes a first frame surface 32 and an oppositely disposed second frame surface 34 . At least one of the frame surfaces 32 , 34 includes at least one magnet member 18 affixed thereto. As in the previous embodiments, the magnet member 18 may be affixed by any fastening means that is satisfactory to affix the magnet 18 to the device 200 and resist removal during use, such as the rivet 36 shown. Moreover, a magnet member 18 for use with the present invention is preferably of a type being strong enough to affix the device 200 to a magnetically attractive ferrous material.
[0064] As may be further seen in the views of FIGS. 22-28 , and 37 A- 38 , the pull portion 16 discussed with regard to the previous embodiments is integrated with the frame portion 14 . With specific reference to FIG. 38 , the user simply grasps the frame portion 14 and slides the device 200 in the direction of arrow D, away from the latch system, to thereby allow the catch 66 to engage with the roller member 64 . As in the previous embodiments, the device 200 may optionally include a lanyard 40 having a first end 42 and a second end 44 . When used, one the ends 42 , 44 of the lanyard 40 is affixed to the frame portion 14 , while the opposite end 42 , 44 is adapted to be affixed to a door frame 46 . An end 42 , 44 of the lanyard 40 may be affixed to the frame portion 14 by any suitable fastener, such as the rivet 36 shown, while the opposite end 42 , 44 is attached to a door frame 46 in the same manner as by a rivet 36 , screw, or other acceptable fastener. When the safety device 200 is removed from the strike plate 20 , the lanyard 40 remains affixed to the door frame 46 to thereby allow the device 200 to dangle from the frame.
[0065] FIGS. 37A-38 illustrate use of the device 200 . As shown, the device 200 may be normally installed on a door frame 46 , of an outward swing door 50 having a crash bar locking system. When installed, the strike plate cover 12 is placed adjacent to and over the roller member 64 and catch 66 of a door 50 having a crash bar locking system. The door frame 46 is of a magnetically attractive ferrous material such that the magnet member 18 on the frame portion 14 is attracted to and holds the device 200 against the door frame 46 . When the device 200 is installed as shown in FIGS. 37A-38 , the door 50 may be in a constant locked position, with the strike plate cover 12 preventing the catch 66 from engaging the roller member 64 and locking the door 50 . In this manner, the device 200 may remain in place and the door 50 will open freely despite it being in a locked position. When quick locking of the door 50 is desired, as for example during an emergency lockdown, an authorized user may simply grasp the frame portion 14 as is seen in FIG. 38 , and move the device 200 in the direction of arrow D. With the device 200 and its strike plate cover 12 removed, the catch 66 is able to engage the roller member 64 and the door 50 is locked. As in the previous embodiments, if the device 200 is provided with a lanyard 40 , it will dangle from the door frame 46 when not in use.
[0066] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, 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. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. | A safety device for use with exteriorly locked doors. The safety device provides a temporary barrier between the latch and the strike plate hole to allow ingress and egress through the door while the door is in a constant locked position. The device includes a strike plate cover, a frame portion, a pull portion, and at least one magnet member. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of Provisional Application Ser. No. 60/987,954 filed on Nov. 14, 2007, entitled FLUID METERING AND PUMPING DEVICE and whose entire disclosure is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates generally to devices for regulating the flow of liquids, and more particularly, to flow dividers for dividing a stream of liquid, such as liquid fuel, into two or more smaller streams of liquid and to pumps for pumping a single flow of liquid to one or more locations in substantially accurate flow rates.
[0004] 2. Description of Related Art
[0005] When working with liquids, it is often desirable to divide a single stream of liquid into several smaller, equal streams of liquid or several substantially accurate streams of liquid. This is typically done using a fluid metering device such as liquid flow divider, an equal-flow pump, or an equal-flow liquid motor.
[0006] A typical prior art liquid flow divider is taught in U.S. Pat. No. 4,531,535 to Kiernan (hereinafter also referred to as “Kiernan”). As shown in FIG. 4 of Kiernan, such liquid flow dividers typically include multiple dividing units of two intermeshed spur gears. The various dividing units are typically linked together by a drive train that may include a drive line, drive shafts, or a sun gear. As a result of this linkage, all of the gears within the various dividing units rotate at substantially the same speed.
[0007] Within each individual dividing unit, a liquid inlet port is positioned on one side of the intermeshing portion of the pair of spur gears, and a liquid discharge port is positioned on the other side of the intermeshing portion of the pair of spur gears. A housing is provided that conforms to the exterior portions of the spur gears that are not in communication with the liquid inlet port or the liquid discharge port. All of the various dividing units' liquid inlet ports are in communication with a single, pressurized liquid source.
[0008] In operation, pressurized liquid from the pressurized liquid source first enters each dividing unit's liquid inlet port. The pressurized liquid then causes the gears in each dividing unit to rotate in opposite directions so that each gear's teeth carry liquid from the liquid inlet port, around the exterior portion of the gear, and into the liquid discharge port. Because all of the dividing gears within the liquid flow divider are preferably the same size and shape, and because the gears are linked together by a central drive train so that all of the gears rotate at the same rate, the flow rate of liquid around each of the flow divider's various gears is identical to the flow rate of liquid around each of the flow divider's other gears. Since each dividing unit includes two gears that convey liquid from the dividing unit's liquid inlet port to the dividing unit's liquid discharge port, liquid flows through each dividing unit at a rate that is equal to two times the rate at which the liquid flows around a single gear.
[0009] Accordingly, prior art liquid flow dividers are typically designed to include one dividing unit for each equal discharge stream that the flow divider is to produce. For example, if the flow divider is to produce ten equal discharge streams of liquid, the flow divider will include ten separate dividing units. As noted above, these dividing units are linked together by a drive train, such as a drive line or a central sun gear.
[0010] U.S. Pat. No. 6,857,441 B2 to Flavelle shows away to simplify the drive train in such a flow divider. However, such prior art liquid flow dividers, including the flow dividers described above, have significant disadvantages. First, because the drive trains within these flow dividers are typically less robust than the other components within the flow dividers, the drive trains often break or otherwise malfunction. Secondly, a tolerance stack-up between the mating parts can result in excessive running clearances between the gear outer diameter (OD) and the case bore interior diameter (ID) which, in turn, results in excessive fluid slip between the inlet and discharge side of the gears and produces inaccuracies in the liquid flow streams.
[0011] Accordingly, there is a need for improved liquid flow dividers, pumps and other fluid metering devices with parts having tolerances that can be more easily manufactured but still result in very close clearances between the gear OD and the case bore ID to reduce the fluid slip through the clearances which greatly improves the accuracy of the liquid flow stream or streams.
[0012] A prior art approach to reducing the clearances between the gears and the housing in a pump is shown in U.S. Pat. No. 4,127,365 to Martinet al. (hereinafter also referred to as “Martin”). In Martin, a moveable suction shoe surrounds the meshing point of the gears, and the shoe also covers the suction port, where liquid enters the pump. The higher pressure at the pump's outlet bears on the full outside surface area of the shoe, and pushes it firmly against the ends of the gears and against the tips of the gear teeth. This greatly reduces slip in the pump, but causes a problem that the difference between suction pressure and discharge pressure increases because an increasingly large load has to be borne by the tips of the gear teeth as the shoe is pressed harder and harder against the gears. In practice, this effect limits the suction shoe concept to pumps that only operate at low differential pressures. Also, the suction shoe cannot be used in a flow divider as described above because, unlike a pump, either the inlet or outlet port of a flow divider may be at a higher pressure than the other port.
[0013] In Martin, the lower pressure must at all times remain on the inside of the shoe. If the pressure inside the shoe becomes greater than the pressure outside the shoe, then the internal pressure will push the shoe away from the gears until the pump ceases moving any fluid. So, there is also a need for a way to balance the forces on the shoe, and to be able to control the forces whatever the pressure change at the pump or flow divider's port may be. All references cited herein are incorporated herein by reference in their entireties.
BRIEF SUMMARY OF THE INVENTION
[0014] The exemplary embodiments include a fluid metering or pumping device including first and second gears, a housing and a floating shoe. The second gear is disposed adjacent the first gear and intermeshes with the first gear. The housing surrounds the gears and seals them from outside liquid contact. Preferably, the housing is not in close contact with the gears, but still forms a chamber around the gears that is in liquid communication with a port that may be used to allow liquid either into or out of the pumps or fluid metering device. The floating shoe partially extends into the port of the pump, forming a first chamber defined by the port opening, the part of the shoe extending into the port, and the interior walls of the housing. Preferably, the floating shoe is not connected to the chamber surrounding the gears, but is in contact with both gears. The floating shoe forms a second chamber also defined by the outer surface of the gears between the contact point between the gears and the second chamber, and the gear mesh point. This second chamber is in liquid communication with the port that the shoe partially extends into, with the cross sectional areas of the second chamber formed by the gears and shoe, and the part of the shoe extending into the port being equal. In other words, the liquid pressure applied to the outward facing surface of the part of the floating shoe extending into the port is balanced with (e.g., equal to with a minimal force to maintain contact between the shoe and the gears) the liquid pressure applied to the inward facing surface of the shoe in the second chamber. By balanced, it is understood that some minimal force is preferred between the shoe and the gears to keep the gears in contact with the shoe even when the remaining pressures applied to the outward facing surface of the shoe extending into the port and to the inward facing surface of the shoe are equal. This minimal force may be applied by an additional force applied inward onto the shoe or outward against the gears. Alternative approaches for providing this minimal contact force include adjusting the surfaces of the shoe to acquire a slightly greater inward pressure than outward pressure, or a compression spring.
[0015] Additional gears may be arranged adjacent the first two gears with at least one of the additional gears intermeshed with one of the first two gears and also intermeshed with each other to form a line or circle of intermeshed gears. In this scenario, each pair of gears contacts a separate floating shoe and forms multiple pumps or fluid metering devices.
[0016] According to another exemplary embodiment, the floating shoe described above is divided into two members. The first member includes a part of the shoe that contacts the gears, and the second member includes a part of the shoe which extends into one of the liquid ports of the device. Both members are free to move towards or away from each other depending on the force exerted on them by the liquid in the two ports of the device. In this exemplary embodiment, which is configured with cross sectional areas of the inside facing walls of the shoe contacting the gears, with the outward facing wall of the part of the shoe extending into one port, and with the manner that the two pieces of the shoe fit together, a small centering force always presses the part of the shoe in contact with the gears towards the gears, regardless of which port contains a higher liquid pressure.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0017] The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements, and wherein:
[0018] FIG. 1 is a cross sectional side view of an exemplary embodiment of the invention perpendicular to a gears' axis of rotation;
[0019] FIG. 2 is a cross sectional side view of the embodiment of FIG. 1 parallel to the gears' axis of rotation;
[0020] FIG. 3 is a cross sectional side view of a two piece shoe in accordance with the preferred embodiments of the invention;
[0021] FIG. 4 is a cross sectional side view of a two piece shoe in accordance with the preferred embodiments of the invention;
[0022] FIG. 5 is a cross sectional side view of a multi-section pump or flow divider in accordance with the preferred embodiments of the invention; and
[0023] FIG. 6 is a cross sectional side view of a multi-section pump or flow divider with a central gear in accordance with the preferred embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention provides a fluid metering device, such as a liquid flow divider or pump, that has tolerances that are more easily manufactured and have no tolerance stack-up between the gear OD and the pressure loaded shoe ID that will increase the fluid slip between the gear OD and the pressure loaded shoe ID. While not being limited to a particular theory, each gear in the metering or pumping unit intermeshes with adjacent gears, which eliminates the need for a separate drive train between the elements of multi-element units that are typically less robust than the other components in the unit. More particularly, a preferred liquid metering device includes two or more gears located adjacent to each other that intermesh with the adjacent gears.
[0025] FIGS. 1 and 2 depict an exemplary fluid metering device 10 shown in cross-section perpendicular and parallel, respectively, to a gear's axis of rotation as will be described in greater detail below. As can best be seen in FIG. 1 , the fluid metering device 10 includes a first gear 12 , a second gear 14 , a housing 16 and a floating shoe 18 . The second gear 14 is disposed adjacent the first gear 12 and intermeshes with the first gear. The housing 16 surrounds the gears and seals them from outside liquid contact exterior of the housing, except through the first and second port as will be discussed in greater detail below. Preferably, the housing 16 is not in close or touching contact with the gears 12 , 14 , but still forms a first chamber 20 around the gears that is in liquid communication with a first port 22 that may be used to allow liquid either into or out of the fluid metering device 10 .
[0026] The floating shoe 18 partially extends into the first port 22 of the housing 16 . Preferably, the floating shoe 18 is not connected to the first chamber 20 surrounding the gears 12 , 14 , but is in contact with both gears. The floating shoe defines a second chamber 24 in liquid communication with the first port 22 that the shoe 18 partially extends into via a central bore 38 of the shoe. This second chamber 24 is around the gear mesh point and around one side of the gears. That is, the floating shoe 18 in contact with the pair of gears (e.g., the first and second gears 12 , 14 ) contacts the tips 26 of the gear teeth 28 , and also covers the outer edge 30 of the gears to beyond their point of intermeshing, thus forming the second chamber 24 as a sealed cavity in the space between the pair of gears and the floating shoe. This second chamber 24 is connected, through the inside of the shoe 18 , to the first port 22 of the device 10 , with a first section 32 of the shoe extending out of the chamber 20 surrounding the gears 12 , 14 and into the first port.
[0027] While not being limited to a particular theory, the area of the outward facing or exterior wall of the first section 32 of the floating shoe 18 that extends into the first port 22 is preferably equal the cross-sectional surface area of the second chamber, including the interior wall of a second part 34 of the floating shoe 18 aligned with the tips 26 of the gear teeth 28 that is exposed to the pressure in the chamber 20 having the two gears 12 , 14 and the interior surface space of the shoe. This preferred structural arrangement results in no net force on the shoe 18 from changing pressures at either the first port 22 or a second port 36 of the fluid metering device 10 as shown, for example, in FIGS. 1 and 2 .
[0028] It is noted that, as discussed above for the preferred embodiments, a minimal pressure should be maintained between the floating shoe 18 and the gears 12 , 14 to ensure continuous contact between the shoe and the gears. This minimal pressure may be maintained by, for example, added pressure on the exterior wall of the first section 32 of the floating shoe 18 , or pressure within the first chamber 20 applied to the exterior facing wall of the shoe within the first chamber. Pressure may be added to the exterior wall of the first section 32 by added fluid pressure or mechanical pressure; such as a compression spring applied in a compressed state between the exterior wall of the first section 32 and a cover 56 over the first port 22 (see FIG. 5 ). It is more appropriate to add mechanical pressure in very high pressure situations to offset any hysteresis in the device. The net effect is a balancing of the shoe in the device 10 and in contact with the gears regardless of changing pressures at either the first port 22 or a second port 36 .
[0029] Sometimes it is desirable to have a controllable net force on the shoe, regardless of which port has the higher pressure. In this case, a two-piece shoe 40 as shown, for example, in the fluid metering device 10 of FIGS. 3 and 4 , can be used. The two-piece shoe 40 is similar to the floating shoe 18 , and includes a first member 42 and a second member 44 cooperatively engageable and sharing a central bore 46 providing fluid communication between the first port 22 and the second chamber 24 . If the pressure is higher in the first port 22 that the two-piece shoe 40 extends into, the two members 42 , 44 are pushed together—as can best be seen in FIG. 3 —and the resultant force on the floating two-piece shoe 40 is a small force proportional to the difference in pressure between the first port 22 and the second port 36 .
[0030] Still referring to FIGS. 3 and 4 , the differences in area inside the chamber 20 between the gears 12 , 14 and the floating two-piece shoe 40 , and the area of the two-piece shoe exposed to the pressure in the port 22 can be biased to keep a small centering force that holds the two-piece shoe firmly against the gears. If the pressure in the port 22 is less than the pressure in the chamber 20 applied to the two-piece shoe 40 , the two parts of the two-piece shoe separate slightly. That is, the first member 42 of the shoe 40 may move toward the port 22 up to there the retaining ring 35 abuts the wall of the housing 16 adjacent the ring, yet the second member 44 remains in contact with the gears due to the pressure in the first chamber 20 applied toward the gears. Here, the differences in area inside and outside the two-piece shoe provide a small controllable centering force to hold the two-piece shoe against the gears, even with a reversal of the pressure difference. That is, the second member 44 is urged into contact with the gears regardless of which port contains a higher liquid pressure.
[0031] It is understood that additional gears may be arranged adjacent the first two gears 12 , 14 with at least one of the additional gears intermeshed with its adjacent one of the first two gears and also intermeshed with other additional gears to form a plurality of pairs of intermeshed gears. In this scenario each pair of gears contacts a separate floating shoe and forms multiple pumps or fluid flow dividers. In other words, when the fluid metering device includes multiple pumps or flow dividers, the gears may be arranged in a line, as can be seen for example in FIG. 5 .
[0032] FIG. 5 depicts a fluid metering device 50 with a plurality of gears forming adjacent alternate pairs of gears. For example, gear 12 interconnects with gear 14 to form one pair of gears, and gear 12 also interconnects with a gear 52 to form an adjacent alternate pair of gears. Each pair of adjacent alternate gears shares a respective floating shoe 40 , with each floating shoe having first and second members 42 , 44 as discussed above, and with successive floating shoes located on alternate sides of the line of gears. Each floating shoe 40 is confined within the housing 54 by a grommet or cover 56 including an aperture 58 preferably aligned with the central bore 46 of the shoe. The cover 56 is a fastener attached to the housing 54 by any approach readily understood by a skilled artisan (e.g., friction, adhesion, force, threaded engagement) and may similarly partially cover the first ports 22 shown in the other figures. While FIG. 5 shows gears arranged in a line, it is understood that the plurality of gears can be arranged in other forms while remaining within the scope of the invention. For example, the gears could be arranged in a curve, circle, polygon or some combination thereof while forming adjacent pairs of gears in contact with respective floating shoes.
[0033] FIG. 6 depicts yet another exemplary embodiment, where the fluid metering device 60 is configured as a series of gears 62 arranged around a central gear 64 and all intermeshing with the central gear. In this example, the fluid metering device 60 includes a plurality of floating shoes 66 , with each floating shoe again connected to a pair of gears (e.g., the central gear 64 and one of the gears 62 ). Each floating shoe 66 includes a central bore 68 providing fluid communication between the first port 22 and the second chamber 24 , as is consistent with the floating shoes 18 , 40 discussed above. While not being limited to a particular theory, in this embodiment, each gear 62 shares its matched floating shoe 66 with the central gear 64 . While the central gear 64 is shown significantly larger than each gear 62 , the relative proportions of the gears is not critical to the scope of the invention. It is understood that the relative proportions of the gears is influenced by several factors, including but not limited to the number and size of the floating shoes 66 , the alignment of the first ports 22 and floating shoes within the housing 70 , and the size of the paired gear (e.g., the central gear 64 for each of the series of gears 62 , and the respective gear 62 for the central gear 64 ).
[0034] As can best be seen in FIG. 2 , each floating shoe 18 , 40 and 66 preferably connects to side plates 15 as would readily be understood by a skilled artisan. The side plates 15 extend from the floating shoe 18 , 40 , 66 about opposite sides of the gears 12 , 14 , 62 , 64 to keep the gears laterally in place, that is, to prevent the gears from sliding off their intermeshed engagement with adjacent gears. It is also noted that each floating shoe also includes an elastic o-ring 25 and a retaining ring 35 . The elastic o-ring 25 provides a liquid seal between the floating shoe and its respective housing 16 , 54 , 70 . The retaining ring 35 keeps the floating shoe in a preferred orientation extending into the first port 22 preventing its extension further into the first port beyond the abutment of the retaining ring and the inner wall of the housing.
[0035] It is understood that the fluid metering and pumping device described and shown are exemplary indications of preferred embodiments of the invention, and are given by way of illustration only. Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, the gears may have teeth arranged preferably in a 1:1 ratio with matching teeth from adjacent gears, or may have some other intermeshed relationship, such as a 2:1 or 1:2 ratio with teeth from adjacent gears as long as the gears maintain their rotational communicative relationship. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only, and not for purposes of limitation. Without further elaboration, the foregoing will so fully illustrate the invention that others may, by applying current or future knowledge; readily adapt the same for use under various conditions of service. | A fluid metering/pumping device preferably includes a series of intermeshing gears. The fluid metering/pumping device includes an inlet port or area adjacent the intermeshing portion of each pair of gears within the series adjacent the point at which the pair of gears diverge. The device further includes a pressure loaded floating shoe adjacent the intermeshing portion of each pair of gears within the series adjacent the point at which the pair of gears converge. The device further includes a piston subjected to discharge pressure at each discharge port which conveys hydraulic pressure to each floating shoe. The device is configured to convey liquid from a main inlet stream of liquid, through the inlet ports or areas, and out of one or more discharge ports at substantially equal rates. | 5 |
This application is a continuation-in-part application of U.S. patent application Ser. No. 028,246, entitled "METHOD AND APPARATUS FOR ION ETCHING AND DEPOSITION," to McNeil, et al., filed on Mar. 20, 1987, U.S. Pat. No. 4758304, the teachings of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to maskless ion deposition and etching and more particularly to maskless ion deposition and etching existing surface topographies of objects of predetermined topographies using single and multiple ion beam sources in accordance with an algorithm using image restoration.
BACKGROUND OF THE INVENTION
Precision optical, semiconductor, and microelectronic components, and the like, having physical coating and surface height aberrations smaller than one wavelength of the incident radiation, are of strategic importance to the operation of many optical systems. Such components are very expensive because of the enormous investment of time and sophisticated equipment required to fabricate and figure their optical coatings and surfaces. Conventional methods of fabricating and figuring optical surfaces involve grinding surfaces into optics using abrasives. Although modern optic grinders have better abrasives, tools and even equipment under computer control, the physical process is essentially the same as it has been for hundreds of years.
Ion etching, also known as ion sputtering and ion milling, has been tried as an alternative process to abrasion. Ion sputtering is a physical process in which an ion is caused to impinge upon a surface of an object with sufficient energy to cause atoms or molecules of the object to be liberated from its surface.
Sputtering has become a popular processing technique in the semiconductor industry. However, sputtering has not found use in modifying optical surfaces because efforts to use sputtering for optic surfacing were severely limited by the ion current from the ion sources available at the time. One type of ion source used in such attempts is known as a Cockraft-Walton accelerator. U.S. Pat. No. 3,548,189 to Meinel, et al., and No. 3,699,334 to Cohen, et al., illustrate such ion sources in their disclosed devices. The Cockraft-Walton as well as other ion accelerators used in such attempts are only capable of driving a maximum beam current of a few hundred microamperes and produce quite high ion energies, often a fraction of an MeV. Limitations result from the fundamental design of such ion sources. For example, such sources contain only a single aperture for ion extraction. The ion current extractable from a single aperture is proportional to the voltage applied to the aperture which in turn determines the ion energy. The use of a single aperture as in the prior art thus mandates that high voltage be applied to the ion extraction aperture which results in high energy ions in order to obtain an ion current on the order of a hundred microamperes. Due to such limitations ion beam etching has been essentially unworkable.
In the early 1970's the Kaufman ion source as disclosed in the publication, "Technology of Ion Beam Sources Used in Sputtering", Journal of Vacuum Science and Technology, Vol. 15, pp. 272-276, March/April 1978 by H. F. Kaufman, et al., was developed. The Kaufman ion source is capable of producing beam currents of a large fraction of an ampere, at energies within the 300-1500 eV range. The beam is sufficiently controllable, stable and repeatable, to be satisfactory for use in surface modification devices. A Kaufman ion source having a grid structure in accordance with the invention can produce minimum current levels of at least about 200 times and optimally about 800 to 1500 times the current level of the Cockraft-Walton and other devices used previously in ion etching. Such Kaufman ion source beam current is on the order of 30 to 400 mA versus a Cockraft-Walton device beam current of less than 0.3 mA. Additionally, the use of RF driven or ECR plasma ion sources employing dual-grid extraction (a key element in Kaufman ion sources) allows the use of all of the Kaufman ion sources benefits while obtaining greater simplicity, stability, and higher reliability in operation.
The ions used in the 3,548,189 device are of substantially the same energy and a uniform current density is necessary. Only narrow ion beam sources are used and, since there is no mechanism for the integrated use of deposition sources, selective deposition in combination with selective removal is not possible. Such devices are limited to the figuring of small diameter elements because beam deflection is used as the steering mechanism, the ion source not being translatable, i.e., movable. For large diameter optics, such as those having diameters on the order of one-half meter or more, the distance from the deflection plates to the surface would have to be typically greater than the diameter of the surface. Beam current losses due to residual gas in the chamber would be great and make the process very inefficient. Too, beam dwell pattern computation is not considered in such prior art devices and methods using image processing and systems theory for optimized material removal are not applied.
In devices such as that shown in U.S. Pat. No. 3,699,334, ion beam impingement control is limited to electrostatic and magnetic deflection of the beam and to rotation of the object to be etched. In practicing the invention, the ion source or sources themselves are moved. The ion sources used in the prior art are either constructed as an integral part of the vacuum system containing the object to be etched or they are external to the vacuum system and connected thereto by a tube which is evacuated with the vacuum system. No such prior art systems utilize translatable ion sources. Too, the ion beam is necessarily maintained continuously in such prior art devices in part because of the high voltages involved in extracting 20 kV to 100 kV ions. Dwell computations are based on a two-step method in which the symmetrical errors need first be reduced to zero. Then isolated symmetrical errors are removed. In practicing the invention all errors, symmetrical and non-symmetrical, are removed in one step. Arbitrarily shaped components are difficult to figure with such prior art devices. In addition, the beam energies of the prior art devices, 20 to 100 kV, are known to damage many materials. The apparatus of the invention operates at a maximum energy of about two kV. The prior art beam taught by the '334 patent only focuses the ion beam to a diameter between one and five millimeters whereas that of the invention focuses the ion beam within a two to five centimeter and larger range to enable the correction of a wide range of sizes of surface aberrations far more efficiently than with prior art devices. The ion source used in accordance with the invention provides electrons to avoid the electric charge effects requiring a separate source of electrons in prior art devices.
A further method for figuring surfaces is by the addition of material using selective deposition.
As seen in FIG. 1, a prior art selective deposition method required a fixed mask having, for example, large numbers of small holes with variable spacing and/or different sizes. The FIG. 1 mask can be used for non-symmetrical surfaces. Some prior art applications may even require a "dished out" mask so that the mask strays within a short distance of the surface at all points.
The prior art rotating mask of FIG. 2 is suited primarily to rotationally symmetric surfaces although tilting the surface with respect to the mask can generate some aspherics. The surface produced by using this mask often shows a small spike immediately under the center of the mask. Additionally, this mask must take into account the spreading of the evaporant beam from the plane of the mask to the plane of the optic surface.
Using the prior art masks of FIGS. 1 and 2, one places what amounts to a stencil in front of the presumably uniform, (often approximated by planetary rotation) deposition source, in much the same way as one spray-paints a stencil onto a surface. The various mathematical techniques used to determine the mask shape must take into account the spreading of the evaporant stream on its way to the surface.
Major problems with the masked selective deposition methods of the prior art are that the mask material may become a contaminant in the deposited film and the mask may be difficult to fabricate. The rotating mask additionally produces a surface spike at the center of the masked area and has very critical alignment requirements.
In practicing the invention, selective surface deposition is performed using single or plural deposition sources which can be characterized for deposition profile. The profile can be used in accordance with a material deposition algorithm to deposit any surface, asymmetric aspheric included, without using a physical mask. This reduces film contamination, simplifies the equipment, increases reliability, and decreases the amount of time required to figure a surface by selective deposition.
Although very small features, much less than the diameter of the beam, cannot be deposited without a mask, surfaces much larger than the diameter of the beam can be easily deposited in accordance with the invention.
Even in those cases where a mask must be used, the ability to raster the deposition source across the mask in accordance with the invention provides the capability to produce very uniform exposures which is especially important when working on large surfaces.
Thus, it can be seen that the prior art devices and methods cannot figure large surfaces and cannot use both removal and deposition to figure a surface. Such devices are limited to low current, high energy, narrow beam ion sources and the control of beam current spatial distribution is difficult. Large and non-symmetric surfaces cannot be etched or deposited upon by such devices and methods.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a method using maskless deposition for changing the existing topography of the surface of an object to a predetermined topography. The method comprises the steps of comparing the existing topography of the surface to the predetermined topography, and using an algorithm comprising large restoration, using maskless deposition, including ion assisted deposition, selectively adding material to the surface of the object to cause the surface to reach the predetermined topography. The predetermined topography may be symmetric or non-symmetric. A plurality of deposition sources, such as sputter, evaporation, laser, IBS, and other sources with or without an ion assist, can be used. The invention also comprises a method using ion etching for changing the existing topography of the surface of an object to a predetermined topography. The method comprises the steps of comparing the existing topography of the surface to the predetermined topography, and using an algorithm comprising image restoration, and using a plurality of ion sources, selectively etching material from the surface of the object to cause the surface to reach the predetermined topography. The invention additionally comprises a method for tuning the thickness of a coating on an optical object to provide the object with substantially consistent light transmission or reflectivity over a relatively broad optical spectrum. The method comprises the steps of providing an object having a coating to be tuned, and using an algorithm comprising image restoration, etching the surface of the coating with an ion beam to selectively remove material therefrom, thereby causing the coating to reach the predetermined thickness. A single or a plurality of ion sources can be used. Deposition, including ion-assisted deposition, as well as ion etching can be used to tune the coating thickness. The coating is preferably tunable to a thickness of less than about 25 Angstroms and most preferably to a thickness of less than about 12 Angstroms.
One object of the present invention is, using one or more ion sources, to selectively etch the surfaces and coatings of objects.
Another object of the invention is to selectively use deposition to figure the surface of an object.
Yet another object of the present invention is to use selective deposition to figure the surface of an object to a thickness accuracy of within 25 Angstroms.
Still another object of the invention is to produce predetermined symmetric and non-symmetric surfaces.
Another object of the invention is to use both etching and deposition to produce surfaces having predetermined topographies.
One advantage of the present invention is that in accordance therewith, both transmissive and reflective objects can be economically produced.
Another advantage of the present invention is that in accordance therewith, a high current, low energy, broad ion beam can be used to etch a desired surface configuration on an object.
Yet another advantage of the invention is that surface extrapolations can be used to avoid edge effects.
Still another advantage is that high surface curvature and complex surfaces can be figured.
Yet another advantage of the invention is that an object may have its surface figured, then evaluated for acceptability, and have subsequent operations such as thin film coating performed thereon without the object being removed from a vacuum system.
Still another advantage is that delicate and lightweight objects can be figured because there is no weight loading on the object in practicing the invention as in conventional grinding or milling methods.
Other objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawing, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention 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 into and form a part of the specification, illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 shows a prior art stationary deposition mask;
FIG. 2 shows a prior art rotating deposition mask;
FIG. 3 illustrates a system for performing the method of the invention;
FIGS. 4A-D show beam profiles and spatial frequency components for two ion beams.
FIG. 5 illustrates a coating on an object to be ion beam etched in accordance with the invention; and
FIGS. 6A-C graphically show coating transmission consistency across a relatively broad optical spectrum for different coating thicknesses in the FIG. 5 object.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 3, which illustrates a system suitable for carrying out the method of the invention. As seen therein, an object 10 having a surface 12, beam source 14, an ion source grid 16, and an interferometer or other surface determining or monitoring instrument 18 such as a phase measuring interferometer or heterodyne interferometer are positioned within a vacuum chamber (not shown). A computer 20 is operatively connected to an apparatus 22 for controlling the position of object 10. Beam source 14 and ion source grid 16 are also under the control of computer 20 as is monitoring instrument 18. Ion source 14 is preferably a Kaufman ion source such as disclosed in a publication, Fundamentals of Ion-Source Operation by Harold R. Kaufman, Library of Congress Catalog Card Number 84-71750, although other sources may be used, including electron cyclotron resonance (ECR) and microwave plasma ion sources. Kaufman sources are well known and produce high current, low energy broad ion beams containing nearly monoenergetic ions so that ion beam sputtering therewith is essentially a linear process. The removal profile of the beam from source 14 is essentially the same regardless of where on the surface 12 of object 10 beam 24 is directed. Thus, sputtering yield remains constant. Beam source 14 and/or object 10 is translatable so that in operation the beam 24 remains normal, or at another selected angle, to surface 12 or to a reference plane or surface. The beam profile 24 does not change appreciably and its current energy distribution remains substantially constant during operation. Beam source 14 may additionally comprise a sputter magnetron or other device for ion assisted or other deposition.
In accordance with the invention, an algorithm compares a desired predetermined surface topography with the existing surface topography of surface 12 on object 10 and utilizing image restoration, controls beam 24 to provide deposition, such as ion assisted deposition, upon or to ion etch surface 12 to produce the predetermined surface topography. The predetermined topography may be symmetric or non-symmetric and ion assisted deposition may be also used to figure surface. The surface to be etched can be that of a coating.
By using several ion beam removal profiles, it is possible to cover the entire spatial frequency range as shown in FIGS. 4A-4D. Here, the nulls in the spatial frequency components of the broad beam can be chosen to fall on non-null components of a narrower beam. The use of both beams then covers the whole spatial frequency range of interest. The broad beams usually run higher current than the narrower beams. Higher beam current translates directly to faster material removal. The tradeoff is then to use the broadest available profiles as much as possible before using the narrower beams, provided that the spatial frequency range of the object figure error is properly covered.
The different beam profiles can be obtained by using different ion sources, varying the grid operation, masking fixed beam profiles, or altering the operating environment. If multiple ion sources are used, all sources can be operating simultaneously on different parts of the optic. This reduces the elapsed time for figuring while still obtaining the correct figure. The order of application of the different removal profiles is not significant because the material removal is linear and invariant with respect to space, ion dose, and time.
In many cases, the ion beam dwell time array exhibits regions in which little time is spent by the ion source, while other regions have a much larger time spent on them. The use of a single fixed array of ion sources achieves some speed-up in elapsed time, particularly if each source is on for about the same amount of time as the whole array moves across the optic (for uniform removal or deposition). The entire array should remain fixed for the dwell time specified by the largest element in the dwell time array corresponding to the position of each source in the array. In this case, it is better to have several completely separate arrays of sources, some of which dwell on the regions requiring the most material removal (a smaller total area), with the other arrays working on larger total areas where smaller dwell times are required. Practicing the invention thereby makes optimum use of the available ion current to get the shortest elapsed figuring time.
In practicing the invention, ion etching and ion depositing beam figuring is controlled using deconvolution for nearly flat optics, and matrix computations for optical and other elements having large surface slopes and high curvatures. The model for figuring computation begins with the superposition integral, ##EQU1## where h(x,α,y,β) is the impulse response or point-spread function for the system model. In this case, the impulse is located at point (α,β). The function f(x,y) is the original surface profile or existing topography of the optic or other element, and the function d(x,y) is the desired surface profile or predetermined surface topography. The function t(α,β) is the time that the ion beam dwells on the element at point (α,β). The function h(x,α,y,β) is the material removal profile for the ion beam.
The material removal profile described as h(x,α,y,β) is spatially variant. The shape of the removal profile can change depending on where the ion beam is pointed. If the removal profile is found not to change with position, then the removal profile is said to be position invariant or spatially invariant. The removal function may also have additional parameters related to dynamically changing the mechanical and electromagnetic configuration of the ion source.
For surfaces containing no large slop changes, the removal or deposition profile is spatially invariant for the ion sources used in practicing the invention. Surfaces having significant curvature will induce spatially variant removal or deposition profiles.
Figuring can also be performed by depositing material using a single deposition source or a plurality of deposition sources. In this case, the removal function is replaced with an addition function which satisfies the same constraints as the removal function. Those skilled in the art will understand that the calculations of the control parameters using additive techniques, e.g., ion deposition, are the same as the calculations of the control parameters for material removal, e.g., ion etching.
All of the functions but t(α,β) are known or measurable. To perform surface figuring, the function t(α,β) must be calculated. Because surface figuring in accordance with the preferred embodiment of the invention is under digital control, metrology and instrumentation, the integrals of equation 1 are replaced with summations and the domain is discrete. For the spatially invariant case, the superposition summation reduces to the definition of the discrete convolution. ##EQU2## Equation 2 can be solved using matrix techniques. However, using orthogonal transforms is easier and provides insight into the success or failure of the figuring operation.
An orthogonal transform such as the Fourier, Hadamard, Hartley, Cosine, and the like, has the property of diagonalizing a circulant (one dimensional) or block-circulant (two dimensional) matrix. This means that the solution to equation 2 in terms of t(α,β) can be obtained using algebraic techniques, provided that the removal or addition profile is spatially invariant. This procedure is described hereinbelow.
Let be an orthogonal transform. Taking the transform of both sides of equation 2 gives
F(u,v)-D(u,v)=T(u,v)H(u,v). (3)
where F is the transform of f(x,y)(F(u,v)= {f(x,y)}), D is the transform of D(x,y), the coordinates (u,v) are the conjugate coordinates to the spatial coordinates (x,y), etc. Equation 3 can be rearranged to form ##EQU3## where γ is a multi-variate function used to control the division when H(u,v) approaches zero or when F-D becomes noisy. When γ=1, equation 4 is called an inverse filter. When γ is a function of the signal-to-noise ratio at the transform coordinate (u,v), equation 4 is a Least Squares or Wiener filter. The function γ can be optimized to produce a time dwell array t(x,y)= -1 {F(u,v)} which has optimal or special properties when applied as the time dwell array for an ion beam figuring operation.
Filters constructed using equation 4 are called restoration, deblurring or deconvolution filters and are used extensively in image processing and system controls.
Once all of the functions in equation 2 are known, the residuals arising from the ion figuring process can be calculated by forming
E(u,v)=F(u,v)-D(u,v)-T(u,v)H(u,v) (5)
for different conditions applied with γ. E(u,v) is the error between the desired surface and what can actually be achieved with a well characterized ion figuring process. In accordance with the invention, by looking at e(x,y)= -1 {E(u,v)}, one can evaluate the prospects for a successful figuring operation before any work is actually done. This step provides for the rejection of those optical or other elements which have surfaces that are economically or otherwise unsuitable for ion beam figuring by removal or deposition.
For the case where the ion beam removal or deposition function is spatially variant, the time dwell array, calculated using matrix methods, is represented by
r=Ht (6)
where r is a vector formed by stacking the rows of f(x,y)-d(x,y), t is formed by stacking the rows of t(x,y), and H is formed by stacking partitions formed by stacking the rows of the point-spread function h(x,α,y,β) for each (α,β). The matrix H is the spatially varying point-spread function (PSF) matrix. The time array is recovered by forming
t=H.sup.-1 r (7)
where H -1 is the inverse of the matrix H. When the point-spread function is spatially invariant, H can be diagonalized by an orthogonal transform as described previously.
The matrix H is somewhat ill-conditioned, meaning that small amounts of noise or error present in the matrix coefficients will have a large effect on the coefficients in the inverse matrix. To help alleviate this problem, the inverse matrix can be calculated using Singular Value Decomposition (SVD) or Q-R or other decompositions where unstable vectors are removed from the inverse calculation. This produces an approximation to the solution, but one that has higher tolerance to noise. Iterative constrained conjugate gradient optimization can also be used to perform the calculation for the inverse PSF matrix.
The use of the constraints or vector removal corresponds to the use of γ≠1 in equation 4. An estimate of the residuals after figuring with a well characterized ion beam figuring process can be found by forming
e=r-H.sup.-1 t (8)
where H -1 is the calculated inverse point-spread matrix. The error vector can then be unstacked to form an error image which can be inspected for figurability just as in the spatially invariant case.
Edge effects are produced with conventional figuring techniques due to the inherent properties of polishing tools. For efficient material removal, a tool should be fairly stiff. As the tool moves so that part of it extends beyond the edge of the element being figured, pressure increases on the part of the surface in contact with the tool and the removal profile distorts. Surface material within the radius of the tool is improperly figured, thereby causing an edge effect. Although many attempts have been made to solve this problem in conventional grinding or milling, the effect remains. Similar problems exist in all types of surface contact tools and devices for material removal.
In ion beam figuring, removal and deposition profiles do not depend on mechanical supports and the ion beam profile remains the same whether or not an object to be figured is in place. Thus, optics and other elements having essentially no edge effects can be produced. Because the beam dwell array value at a given point depends on the condition of the surface in a region around that point, the size of the region being about the same size as the spatial extent of the removal or addition function, the dwell array value depends in part on a condition which does not exist, since it is off the edge of the object. In practicing the invention, the image of the object provided by the metrology is treated as a small piece of an infinite surface. Using this model, the measured surface map of the object is imagined to be an apertured rendition of the surface map of a much larger object extending far beyond the field of view of the metrological instrumentation. Data is constructed to fill in those parts of the surface map which would correspond to those parts of the larger object obscured by the aperture. Hence the image restoration or matrix solutions see a modified object with no abrupt edge and compute the correct dwell array for the original object. The constructed data must have the same properties in terms of surface structure as the original object because there should be a match of the real data with the nonphysical data at the edge of the physical object.
Construction of data beyond the edge of the physical object is achieved with Band Limited Surface Extrapolation (BLSE) using orthogonal transforms. Original data is filtered to provide a smoothed result with some data outside the original data. The original data is then re-inserted into the resultant image. These steps are repeated a number of iterations to build up data outside the original data area, limited in frequency content by the filter which provides the band limits.
The building up of the off-edge data can be very slow. The rate of construction of data is partially determined by the band limit filter. Since ideal filters introduce "ringing" artifacts into the image, variable order filters, such as Butterworth, Chebyshev, or other more advanced filters, can be used to improve the rate of convergence to an acceptable quality. In practicing the invention, the cutoff frequency of the filter is varied during the progressive iterations, typically proceeding from higher bandwidths to lower bandwidths, with the final iterations being performed using the transform of the ion beam removal or deposition function as the filter. The ion beam removal or deposition function is the optimal filter because it eliminates any frequencies not present in the ion beam itself, alleviating restoration difficulties in equation 4.
To further speed the convergence, the filters are set during early iterations to amplify, in some cases nonlinearly, some of the frequencies in the pass band. This builds up the nonphysical data areas more quickly than when conventional normalized filters are used.
Additional gains in edge smoothness are obtained in some cases by offsetting the object surface with respect to its reference plane. This costs additional figuring time during which the centroid of the ion beam is mostly off of the surface of the object being figured. However, this produces higher quality edge figure.
The invention is applicable to the production of large optical or other surfaces due to its inherent scalability. As the size of a work piece is increased, ion beam current can be increased by using larger ion sources or by using a plurality of smaller ion sources which can be run simultaneously. The use of a plurality of sources reduces the time needed to figure a particular surface and distributes the thermal load across the surface of the element during fighting to thereby reduce thermally induced distortion. The plurality of sources may all be of the same size or more likely, of different selected sizes to minimize object figuring time. The use of several size ion sources also provides figuring over large spatial frequency bands which results in a better final surface figure as previously discussed with reference to FIGS. 4A-4D. Spatial ion beam current density can be dynamically tuned using single or plural sources in practicing the invention to provide an optimal final surface figure.
Because weight loading due to gravity and forces applied in conventional figuring techniques and mechanical distortion caused by polishing tool weight are eliminated, very light weight and flexible optical and other elements can be figured using the invention.
As an example of the tuning of a coating, the following situation can be considered. The FIG. 5 structure 100 comprises a base object 102, a coating 104 of 0.5λ SiO 2 , a coating 106 of 0.25λ Al 2 O 3 , and a top coating 108 of 0.25λ SiO 2 , where λ is the wavelength of light. The coatings 104, 106 and 108 comprise an anti-reflecting coating for the visible wavelengths. This design is for 632 nm (HeNe laser red). If the individual film layers are too thick by 1/20th of a wavelength (λ), the transmission spectrum is distorted significantly from that desired.
In accordance with the invention, etching can be accomplished using the algorithm to correct the layer thicknesses. For example, if the layers are corrected to ±1/100th of a wavelength, the transmission spectrum is very much improved. Other techniques, including interferometry, can be used to monitor the layer thickness. For example, "Sensitive Techniques for Measuring Apparent Optical Figure Error Caused by Coating Nonuniformity" (H. E. Bennett and D. K. Burge, Proc. Boulder Damage Symposium 1981, Laser Induced Damage in Optical Materials: 1981, NBS Special Pub. 638, pp. 421) shows that monitoring the optical phase by ellipsometry is a very sensitive technique.
The transmission spectra for the ideal, incorrect, and algorithm corrected film stacks were computed using a thin films design and analysis program. The transmission spectrum for the ideal case (perfect layer thickness) is shown in FIG. 6A, the spectrum corresponding to the case where the layers are too thick is shown in FIG. 6B and the corrected stack (layers individually monitored and corrected) has the transmission spectrum shown in FIG. 6C.
Tables A, B, and C show the layer thicknesses for the FIGS. 6A, 6B, and 6C examples.
The thickness of the layers are preferably monitored after deposition by spectrophotometric techniques, although in some cases, interferometry may be adequate. If spectrophotometry is used, the measurement is spatially resolved to obtain the thickness at all points on the surface, as prescribed by the IBF control algorithm.
TABLE A______________________________________Layer Material Index Waves Microns thk______________________________________104 SiO.sub.2 1.4500 0.50000 0.21793106 Al.sub.2 O.sub.3 1.6500 0.25000 0.09576108 SiO.sub.2 1.4500 0.25000 0.10897______________________________________Light Polarization Reflectance % Transmission %______________________________________s-pol 0.7476 99.2523p-pol 0.7476 99.2523both 0.7476 99.2523______________________________________
TABLE B______________________________________Layer Material Index Waves Microns thk______________________________________104 SiO.sub.2 1.4500 0.55000 0.23972106 Al.sub.2 O.sub.3 1.6500 0.30000 0.11491108 SiO.sub.2 1.4500 0.30000 0.13076______________________________________Light Polarization Reflectance % Transmission %______________________________________s-pol 1.5927 98.4072p-pol 1.5927 98.4072both 1.5927 98.4072______________________________________
TABLE C______________________________________Layer Material Index Waves Microns thk______________________________________104 SiO.sub.2 1.4500 0.51000 0.22229106 Al.sub.2 O.sub.3 1.6500 0.24000 0.09193108 SiO.sub.2 1.4500 0.26000 0.11332______________________________________Light Polarization Reflectance % Transmission %______________________________________s-pol 0.7542 99.2458p-pol 0.7542 99.2458both 0.7542 99.2458______________________________________
Various grid structures, such as those described in U.S. patent application Ser. No. 028,246, of which this is a continuation-in-part, can be used to practice the method of the invention, which is particularly suitable for figuring the surfaces of large optics and other elements.
In practicing the invention, after a surface is figured, it may be coated with an additional material. Thus, the invention can be used to manufacture a mirror by etching or depositing material to figure a surface and then coating the surface by ion assisted or other deposition with a reflective coating. Similarly, a nonreflective or other coatings may be added to an object figured in accordance with the invention. The method of the invention is particularly useful to coat objects which are damaged when heated, since many conventional coating techniques require the substrate be heated to between 150° and 300° C. Ion assisted deposition of coatings may be carried out using a magnetron or other such device.
Although the invention has been described with reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. | The disclosure relates to maskless deposition and etching and more particularly to maskless deposition and etching of the surface of objects using single and multiple ion sources. | 7 |
OTHER APPLICATIONS
This application is a continuation-in-part of my earlier filed copending application Ser. No. 455,475 filed Jan. 4, 1983.
FIELD OF INVENTION
This invention relates to shades for solar greenhouses and the like and more particularly to improved structural members suitable for providing guidance for shading and like types of members.
Commercial systems are available for providing selective shading for solar greenhouses and the like. In one known arrangement, a shade is transferred from one motor driven roller towards a second motor driven roller by straps which are fastened to the leading edge of the shade, these straps being attached to one of the rollers and being wound upon the same to draw the shade from the other roller upon which the shade is coiled and normally stored. In addition, the leading edge of the shade is provided in the form of a rigid member, the edges of which are guided in a channel provided in a guiding member which has no structural function and is intended solely for the purpose of being a shade guide.
An inspection of the available system reveals that the leading rigid element of the aforegoing system extends laterally beyond the lateral edges of the shade so that the lateral edges of the shade are spaced from the guide and thus provide means for an inadvertent passage of solar radiation or the like between the guides and the shade edges. It is also to be noted that the guides have no structural function to be formed as has been noted hereinabove, and that the guides are generally mounted inwardly of the solar greenhouse structure in such a manner as to be readily receptive of inadvertent damaging forces or the like. Moreover, it will be noted that the shade is inconveniently positioned with its lateral edges subject to damage and deterioration.
Also commercially available are shades having lateral edges into which are incorporated wires or cables or the like which give to these lateral edges a conformation which is bulbous in nature. These bulbous lateral edges are accommodated in guiding tracks which heretofore have been exclusively rectilinear and solely vertically disposed. These shades have not been incorporated into solar greenhouses or other such complex structures for purposes of providing selective shielding or shading.
Also commercially available are rollers within which are provided internal motors of generally cylindrical conformation. These motors are utilized for selectively driving the rollers for taking up straps attached to shades or for rewinding shades and the like. Insofar as I am aware, these motor driven rollers have not been utilized in conjunction with the structural members of solar greenhouses or the like in the manner which will be described in greater detail hereinbelow.
SUMMARY OF INVENTION
It is a general object of the invention to provide improved systems and structural members to enable the selective shading and shielding of solar greenhouses and the like.
It is a further object of the invention to provide improved structural elements suitable for use in solar greenhouses and the like in order to provide for ready installation and operation of shading systems and so forth.
Yet another object of the invention is to provide for improved insulating and shading systems for solarium type greenhouses and the like utilizing integral built-in tracks to carry shading fabric so that the fabric may be readily held taut between two such tracks without sag and incorporating guide members which are easily installed and which provide an anti-sag feature.
Yet another object of the invention is to provide an insulating and shading system wherein integral built-in track channels are made accessible at the top and bottom of the tracking system by improved designing of the structural members into which the integral tracks are incorporated.
To achieve the above and other objects of the invention, there is provided an apparatus comprising spaced parallel bars defining parallel channel tracks with facing mouths. A shade extends laterally through the mouths and includes bulbous peripheries accommodated and retained in these tracks. The bars include ends at which the shade selectively enters and exits the tracks. A roller arrangement is operatively associated with the ends to take up and play out the shade. For structural purposes, the roller arrangement is displaced from the bars and, in accordance with the invention, there is provided a guide arrangement to guide a change in direction of the shade as the shade enters or exits the tracks in order to adapt the shade to the relative positions of the roller arrangement and the ends of the bars.
In accordance with a further aspect of the invention, the guide arrangement is provided with open guide tracks for receiving the bulbous peripheries and these guide tracks are of arcuate configuration whereby to change direction of the bulbous peripheries and thereby the direction of the shade. In addition to the aforesaid, the guide tracks on the different bars have proximal lateral guide walls which slope apart in the direction of the ends of the bars whereby to effect a stretching of the shade.
The aforesaid guide tracks may be provided with distal lateral guide walls which slope together in the direction of the ends of the bars and such that the guide tracks are of generally funnel shape.
In accordance with a feature of the invention, the guide tracks are of arcuate cross-section and this cross-section will preferably have a radius which increases in a direction away from the ends of the bars.
In accordance with another feature of the invention, the guide arrangement will include tubular extensions in continuation of the guide tracks, the tubular extensions being accommodated in the channel tracks at the ends of the bars and coupling the guide arrangement to the bars.
In accordance with other aspects of the invention, the bars each include a wall extending between the channel tracks with the guide arrangement including further extensions which with the corresponding tubular extensions straddle the aforementioned wall. The wall may be provided with a threaded opening and the further extensions mentioned hereinabove will be provided with an opening aligned with the threaded opening, the apparatus further including a locking member extending through the openings and engaging in the threaded opening. Still further, the ends of the bars will preferably be sloped relative to the channel tracks and the guide arrangement will include flanges sloped relative to the tubular extensions and in correspondence with the sloped ends.
The aforementioned guide arrangements may be included in single monolithic guide structures. One such guide structure may include a body defining two funnel shaped and generally arcuate guide tracks having generally parallel axes and there may furthermore be provided two parallel tubular extensions on the aforesaid body defining bores aligned in continuation of the guide tracks. These bores will preferably by generally tangentially related to the guide tracks.
In the aforesaid construction, each of the tubular extensions will preferably be provided with a lateral slot extending longitudinally therealong and through which the shade may extend with its periphery being accommodated at least partly in the corresponding tubular extension.
Another feature relates to the provision of a flat extension on the aforesaid body spaced from but parallel with the tubular extensions. Still further, there may be provided a flange on the aforesaid body in sloped relationship to the tubular extensions.
Other feature include that the guide tracks are at least about one-quarter of a circle in extent with the guide tracks being of varying arcuate cross-section which increases in a direction away from the corresponding tubular extensions.
Still another feature of the invention relates to the guide tracks having outer walls which slope at about 10°-45° relative to the associated axes.
The above and other objects, features and advantages of the invention will be found in the detailed description which follows hereinafter, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWING
In the drawing:
FIG. 1 is an interior perspective view of a portion of a lean-to type solar greenhouse provided with a shading arrangement to accordance with a preferred embodiment of the invention;
FIG. 2 is a partly diagrammatic and perspective view of a broken-away protion of the bottom sill construction embodied in the structure of FIG. 1 in correspondence with line A--A in FIG. 1;
FIG. 3 is a view of the ridge structure of FIG. 1 in correspondence with line B--B therein, the view being on enlarged scale and being partially diagrammatic in nature;
FIG. 4 is a partially diagrammatic view corresponding to section line B--B of FIG. 1;
FIG. 5 is a sectional view corresponding to line C--C in FIG. 1 but further illustrating a glazing and muntin connected thereto;
FIG. 6 is a top view of a guide constituting an element of the invention utilized in connection with the aforegoing structure;
FIG. 7 is a side view of the guide of FIG. 6 illustrating its cooperation with a glazing bar shown partially broken-away and in sections;
FIG. 8 is a bottom view of the guide of FIG. 8 illustrating its cooperation with a glazing bar as in FIG. 7; and
FIG. 9 is a diagrammatic view illustrating the operation of the guide means in cooperation with the other structures of the invention.
DETAILED DESCRIPTION
In FIG. 1 is illustrated a portion of a lean-to type solar greenhouse of the kind generally shown in the 1982 Theme Catalog entitled Four Seasons Passive Solar Greenhouse and Sun Space published and distributed by Four Seasons Solar Corp. of Farmingdale, N.Y. The illustrated portion of the Solar Greenhouse in FIG. 1 includes a gable end 10 and a front portion 12 having a curved-eave portion 14 and an upper sloped portion 16. Further illustrated are base sills 18 and 20 which may, for example, be mounted on a base wall or flat slab or deck (not shown) with appropriate fasteners. The method of mounting the base sill on the supporting ground is not a feature of the present invention and requires no further description in this text. The gable end 10 includes a plurality of parallel vertical glazing bars such as indicated at 22, 24, and 26. The bar 26 is in abutting relationship against the side of a dwelling or some other such similar construction. The front portion 12 includes a plurality of vertical glazing bars 28, 30, 32, 34 and 36. The glazing bar 36 furthermore provides a connection with gable end 10.
To conform with the shape of the glazing, which it is the purpose of the glazing bars to support, the glazing bar 28 has a curved section 38 and a sloped section 40. It terminates in an end portion 42. Glazing bars 28, 30, 32, 34 and 36 have similar curved and sloped portions.
Glazing panes as comprised by the gable end 10 are indicated in various forms at 44, 46, 48, 50, 52, 54 and 56. Portions of the glazing are concealed by shade fabric as indicated at 58, 60 and 62. The dwellings or other structure against which the solar greenhouse is mounted is not shown as its construction is not essential to an understanding of the present invention.
The glazing included in the front portion 12 includes glazing panes 70, 72, 74 and 76. The remaining glazing in FIG. 1 is concealed by shade fabric or shades 80, 82, 84 and 86. The number of shades and panels in FIG. 1 is illustrative only as a greater or lesser number of panels and glazing panes may be employed in accordance with the invention which is not limited thereby.
At the upper end of the solar greenhouse construction, is located a ridge structure 90. It engages the end portion of the glazing bars at the upper extremities thereof such as indicated at 42 to support and accommodate the same. The ridge structure 90 abuts at the back wall 92 against the dwelling other similar structure associated therewith as does the vertical glazing bar 26 of the gable end 10.
Also appearing in FIG. 1 is a representative sequence of rollers 94, 96, 98 and 100. These rollers in the illustrated embodiment are source rollers of shade fabric which store and supply the rolled up shade fabric upon demand. Further illustrated in FIG. 1 is a guide roll arrangement 102 which guides the shades or shade fabric in a change of direction so that the edges of these shades or fabrics may be engaged in track channels provided in the vertical glazing bars as will be described in greater detail hereinbelow. It is to be noted in the diagrammatic illustration of source rollers 94, 96, 98 and 100 that interior motors 110, 112, 114 and 116 are shown. These motors are contained and concealed within the rollers and operate to drive the same. Rollers with internal motors to drive the same are commercially available. They may be obtained from Somfy Systems, Inc. of Edison, N.J. The motors are of a asynchronous capacitor start and run, single phase type rated at 120 V. and 60 Hz. They are thermally protected totally enclosed brushless type motors equipped with permanently lubricated bearings requiring no maintenance and being relatively easy to wire. They include solenoid activated disc brakes which automatically stop and hold a load in any position without slippage whenever current to the motor is interrupted. The locking action assures safety and reliability of operation of the motorized system. The system can be provided with a limit switch to set the exact length of travel in both up and down directions automatically. A planetary type gear system is employed to lower motor speed and improve torque. Other details of the motor system can be found in U.S. Pat. No. 3,718,215.
The upper motorized rollers cooperate with corresponding motorized rollers concealed in the base sill 18. In the illustration, one motorized system is exposed by the cutaway such as, for example, seen at 120. The arrangement is such that, when the rollers in the sill 18 are operated to draw shade fabric downwardly, the motorized roller systems indicated at 94, 96, 98 and 100 permit the withdrawing of shades therefrom. The electrical system and operation is reversed when the shades 80, 82, 84 and 86 are to be drawn upwardly. In this case, the motorized systems indicated at 94, 96, 98 and 100 are actuated and the concealed systems in the base sill 18 release the material for being rolled back upon the upper rollers to expose greater, and greater amounts of the glazing as the operation continues. Also illustrated in FIG. 1, in diagrammatic form, is a photoelectric sensor 126. This photoelectric sensor is coupled in an electric circuit (not shown) connected with the aforementioned motors in order to drive the same in one or the other rotary directions as may be required. The photoelectric sensor 126 is representative only of any device capable of sensing an ambient condition such as solar radiation, temperature, wind and the like for purposes of automating the operation of the rollers. It will be noted, however, that, while the motorized roller systems are employed in accordance with the preferred embodiment of the invention, it is also possible that the shades be operated manually and also in connection with spring-loaded rollers as is the case in connection with domestic shades as are commonly and commercially available. In fact, a manually operated shade arrangement is indicated in association with end 10. Thus, there are no upper rollers associated with shades 58, 60 and 62, these being drawn from concealed rollers in base sill 20 by a manual operation of grasping rigid leading edge members indicated by way of example at 130, 132 and 134.
Also exposed in the illustration of FIG. 1 in diagrammatic form is a blower 140. The purpose of this blower (as will be illustrated and described in greater detail hereinbelow) is to evacuate air from between the shade and the associated glazing and to expel this air into the ambient atmosphere via an appropriate vent in order to reduce the temperature which prevails between the shades and the glazing thereby to reduce the possibility of damage to the glazing.
FIG. 2 illustrates on an enlarged scale a broken-away portion of the structure illustrated in FIG. 1 with conditions somewhat altered to show a more lowered condition of the shades. For purposes of orientation, it will be seen in FIG. 2 that there are illustrated base sill 18, vertical glazing bar 30 and shades 80 and 82. The base sill 18 includes an inner wall 150 and a first outer wall 152. The outer wall 152 supports a sloped upper wall 154 from which extends a vertical wall 156. The walls 154 and 156 cooperate to define a moisture drain 158. A bottom wall 160 extends between and connects the inner wall 150 with the outer wall 152. Drainage channels 162 and 164 are provided in horizontal disposition within the internal chamber 166 which is cooperatively defined by walls 150, 152, 154 and 160. Within the chamber 166 is accommodated the motorized roller system including the internal motor 170 and the encircling roller 172.
Each of the shades illustrated includes a bulbous lateral edge portion for purposes of being accommodated in and guided by track channels to be referred to hereinbelow.
Illustrative bulbous lateral edge portions or peripheries are indicated at 176 and 178 in FIG. 2. These constructions are commercially available and are generally of the type including wires extending through the bulbous peripheries and axially extending out of the same. Two such wires or cables are indicated at 180 and 182 in FIG. 2. They extend through and are guided by track channels 184 and 186 as will be described in greater detail hereinbelow. It is to be noted that, by reason of break-away portion 188, it is possible to see that these cables are attached to and wound onto roller 172 such as indicated 190 and 192. A winding up of these cables on the roller 172 causes the shades 80 and 82 to be drawn down towards the base sill 18 thereby to effect a greater degree of shading. This means that solar radiation passing through the glazing which is permeable thereto may be intercepted by the shades thereby to effect a greater or lesser degree of shielding as desired and as may be manually or automatically controlled. It will also be noted in FIG. 2 that the shades 80 and 82 are provided with rigid lead members 196 and 198. These members, at their extreme downward movement, come into abutting or substantially abutting relationship with cap elements 200 and 202 which are intended to cover drains such as indicated at 158 and to conceal the internal construction of the base sill 18 from viewing or from the damaging impact of dropped articles or the like. The caps 200 and 202 also constitute safety features inasmuch as they resist the penetration of probing fingers and the like which might otherwise be damaged by engagement with moving parts within the base sill 18 under inadvertent circumstances.
The cap members 200 and 202 extend generally from the vertical wall 156 to the upper lip 204 of the front wall 150. This is satisfactory in the case where the cables, such as indicated 180 and 182, extend through the glazing bar to the internal roller 172 which in this case acts take-up roller. In these circumstances, there is no need for the lead members 196 and 198 to move into the internal chamber 166 nor is there any need for the shade 80 or 82 to do likewise. In the event that it is desired to alter the construction so that the shade 80 and 82 can be directly taken-up on the roller 172 in addition to the cables 180 and 182 which they trail, the construction can be readily modified to provide a slot through which the shade 80 and 82 may pass. Thus, for example, the cap member 200 is provided with a notch 210 providing a break-away section 212 to expose a slot or passage 214 illustrative of a passageway through which the shades may enter the internal chamber 166 for engagement and being taken-up upon an associated roller. Thus, the invention includes the options whereby it is exclusively the cables which are taken-up on the lowermost roller or rollers or whereby the shades themselves are taken-up upon such roller or rollers.
FIG. 2 furthermore illustrates a second outer wall 220. This outer wall includes a protrusion 222 in facing relationship with a protrusion 224 on the outer wall 152. These two protrusions are provided with facing grooves 226 and 228 which have reentrant angles therein so that a thermal break member 230 having the form of a Maltese cross may be entrapped therein to prevent the flow of heat from the wall 152 to the wall 220.
The glazing is illustratively shown in the form of a double paned glass or plastic structure, the spaced panes being indicated at 240 and 242 with a spacing 244 therebetween To maintain this spacing, there is provided a spacer 246. The pane 242 restsagainst the vertical wall 156 and the glazing as a whole is entrapped between the walls 156 and 220 by means of a gasket 250 of a theremally insulative type. The upper walls of protrusions 222 and 224 define a platform at 252 and 254 upon which rests a pad 256 upon which rest the glazing and the spacer 246.
Further reference to the construction of the vertical glazing bar 30 will be made hereinbelow since the construction of this bar and other like bars in the structure constitute a significant feature of the invention, especially as regards the provision of the track channels 184 and 186. Before this discussion is undertaken, however, reference will next be made to FIGS. 3 and 4 which illustrate, in greater detail and/or diagrammatically, some of the features of the ridge structure 90 appearing in FIG. 1. For purposes of orientation, attention is drawn in FIGS. 3 and 4 to vertical glazing bar 30, shades 80 and 82, motorized roller system 94, guide roll 102 and blower system 140 which have been mentioned hereinabove. A guide 121 is shown in a diagrammatic form in FIG. 3 and its details will be later explained.
From what has been stated above, it will not be obvious that the glazing bars constitute supporting members or structures for the glazing. These supporting members are accommodated in and rest against the ridge structure 90. They provide track channels for receiving and guiding the respective shades. The ridge member 90 is structurally and functionally related therewith in a manner next to be described below.
Ridge structure 90 includes a rear wall 300 consisting of upper and lower parts 302 and 304. The upper and lower parts are connected through the intermediary of a thermal break member 306 which is made of insulative material accommodated in appropriate receptacles 308 and 310 respectively provided on the upper and lower parts 302 and 304. The ridge structure 90 also include upper wall 312 and lower wall 314. Moreover, it includes a front wall indicated at 316. Cooperatively, these walls define an internal chamber 318 within which is accommodated the blower 140.
The front wall 316 is provided with a vent indicated generally at 320. Associated with this vent is a removable shutter 322 which may be employed, for example, during cold weather seasons to shut off the escape of air from within the solar greenhouse. The front wall 316 has an auxiliary portion 324 connected thereto through the intermediary of a thermal break member 326. This auxiliary member 324 supports a receptacle 328 which is a glazing receptacle to accommodate and support appropriate glazing panels at the upper extremity of the front portion of the glazing of the solar greenhouse. An exemplary panel is diagrammatically illustrated at 330. It may consist of spaced panes 332 and 334 separated, for example, by a spacer 336. The panel 330 is held in place by a gasket shown at 338. A screen for preventing the influx of insects and the like is indicated at 340. It is associated with the vent 320. A second vent is indicated at 342. Cooperating therewith is a gravity operated flap 344 which likewise prevents the influx of foreign matter. The strength of the flow of air passing outwardly through the vent 342 is sufficient to open the flap 344 to the extent required.
FIG. 4 specifically illustrates the flow of air. Flow through the vent 320 is indicated by arrows 350 and 352. Flow of air through vent 342 is indicated by arrow 354. The circuitous route is indicated by dotted line path 356. It will now be noted that the utilization of the glazing bar with its track channels 184 and 186 and the function of supporting the associated glazing defines a space between the shades and glazing. This space is indicated in FIG. 4 at S. This spacing S is a minimum of about 11/2 inches. It is intended to assist in limiting the temperature which air entrapped between the glazing and shade may reach. This function is further accomplished by the utilization of the blower 140 which displaces or withdraws air from between the glazing and the shades and propels this air along the route 356 through the vent 320 and expels this air into ambient atmosphere through the vent 342. The the ridge structure and its blower cooperate with the glazing bar and the shades in both a structurally supportative and temperature controlling manner.
It will now be noted that the end portion 360 at the upper extremity of the glazing bar 30 has an extremity indicated at 362 which is angularly related both to the longitudinal axis of bar 30 and to the rear wall 304 of the ridge structure 90. This is intended to provide a space 364 within which to accommodate at least a partial intrusion of the guide roll 102. Thus the guide roll 102 may be conveniently positioned to guide the shade 80 from the roller system 94 into the associated track channels.
Similarly, the bottom extremity of the glazing bar 30 as indicated at 366 in FIG. 2 is angularly related to the walls between which it extends. The purpose of this angular construction is different from that at the upper extremity. It is intended to provide an appropriate relationship with the drain 158 thereby to permit a proper resting of the bottom extremity of bar 130 on the upper wall 154 and to permit an ease in installing the glazing bar 30 when the structure is being assembled.
An examination of FIG. 5, which is in part, a section of glazing bar 30, will next be undertaken in conjunction with an understanding of FIGS. 2, 3, and 4. In FIG. 5 appears the track channels 184 and 186. By reference to the other figures, it will be understood that these channels extend longitudinally through the glazing bar which is itself an extended member. Associated with the channel 184 is a mouth 400. Associated with the track channel 180 is a mouth 402. These mouths are of relatively restricted dimensions. They form and constitute slots extending longitudinally along the glazing bar 30. The track channels 184 and 186 are in a preferred embodiment of the invention preferably of circular conformation. An example diameter of these track channels is indicated at D. The width of the associated mouths 400 and 402 is indicated by way of example at W. The arrangement is such, that the width W is preferably no more than 50% of the dimension D. This, in effect, forms a reentrant angle indicated, by way of example, at A. The purpose of this is to form a track channel in which the bulbous periphery of the associated lateral edges of the corresponding shades are entrapped. This entrapment coupled with appropriate spacing of pairs of associated glazing bars enables the shades to be held in taut condition thereby avoiding sagging and the like. It also enables the bulbous portions to be vigorously guided along appropriate paths even as these paths turn through an angle associated with the curve eave portions of the overall construction. Thus the use of associated guide rolls or the like in the vicinity of the curved eave portions is avoided.
It will be noted that the glazing bar includes two side walls 404 and 406. These side walls extend between and connect inner wall 408 and outer wall 410. The arrangement of the wall is such that the glazing bar is in its preferred form quadrilateral in cross-section thereby defining four corners indicated in the drawing at 412, 414, 416 and 418. The track channels 184 and 186 are generally located at the corners 416 and 418. They are furthermore formed by interior walls indicated at 420, 422, 424 and 426. The walls 420 and 424, which partly define channels 184 and 186, have surface 428 and 430 which are flat. They also have surfaces 432 and 434 which conform to the shape of the channels. On the other hand, wall 422 has surfaces 436 and 438 both of which conform to the shape of the associated channel. Wall 428 likewise has surfaces 440 and 442 which conform to the shape of the associated channel 186.
In the wall 408 is provided a screw threaded groove 450. By means of this groove, attachments of various types may be provided by fastening members threadably engaged therein to provide for the connection or hanging of various types of auxiliary members or elements on the interior of the solar greenhouse. A corresponding grooved slot 452 is provided in wall 410. This provides for the utilization of fastening member 454 to sandwich glazing panes, for example, 456 and 458 against the supporting structure by means of a muntin 460 or clamping member which is entrapped by the head 462 to sandwich the glazing against the sealing members 464 and 466 accommodated in sealing receptacles 468 and 470 mounted on the outer wall 410 and constituting an integral part thereof. It will be furthermore noted that the wall 410 is provided with drainage grooves 472 and 474. The provision of these sealing receptacles and drainage has been heretofore available, but never in association with track channels and never for the partial purpose for extablishing a rigid spacing therebetween so as to provide a well defined spacing between a glazing and a associated shade arrangement as in accordance with the present invention.
Reference to FIG. 2 will show the orientation of screw threaded grooves 450 and 452 as well as seals 464 and 466 accommodated in their respective receptacles. The illustration will also show the orientation of drainage grooves 472 and 474. Not heretofore mentioned with respect to FIG. 2 is the chamber 480 defined between outer walls 152 and 220. This provides an accommodation for the upper extremity of flashing 482 the purpose of which is to provide a weather seal as between the bottom of the base sill 18 and the exterior supporting ground or other such construction.
Reference of FIG. 3 will likewise show the orientation of screw threaded grooves 450 and 452 as well as of sealing members 464 and 466 as well as drainage grooves 472 and 474.
From what has been stated above, it will be readily understood that the support arrangement of the invention, when utilized in connection with glazing or the like includes a plurality of spaced parallel glazing bars, each provided with two of the afore-described track channels. These track channels are arranged in cooperating pairs and in parallel and are such that respective shades extend between these channels with the bulbous peripheries of the shades being entrapped in slidable engagement therein.
The guide arrangement provided in accordance with the invention will provide a plurality of guides intended to cooperate with the aforementioned glazing bars and track channels in a manner which will become hereinafter apparent. One guide is provided as a cap for each of the aforesaid glazing bars. Each cap is intended to cooperate with the bulbous peripheries of two adjacent shades. Furthermore, each guide is intended to engage in and mate with the cooperating glazing bar and to provide for appropriate orientation therewith, as well as for a change of direction of the bulbous peripheries of the respective shades as they exit from or enter into the track channel provided in the glazing bars.
The details of such guide 121 is illustrated in detail in FIGS. 6-8 wherein it is seen that the guide is formed of a body 500 having lateral edges 502 and 504 in which is provided a square opening 506. Mounted on the body 500 are a pair of tubular extensions 508 and 510. These tubular extensions are provided with lateral longitudinally extending slits or slots 512 and 514. They are arranged to be in a substantially common plane and to correspond with the mouths in the corresponding track channels of glazing bar 30. Thus, the bulbous peripheries of the two corresponding shades may be accommodated in the internal circular bores 516 and 518 of tubular extensions 508 and 510 whereas the planar portion of the corresponding shades may extend through the slots 512 and 514. To augment the function of these slots, the body 500 is furthermore provided with laterally extending slots 520 and 522, the mouths 524 and 526 of which are flared to accommodate minor distortions of the shades as they pass into the tubular extensions with the bulbous peripheries thereon.
The bores 516 and 518 and tubular extensions 508 and 510 are provided with parallel axes of symmetry indicated at 530 and 532. Extending orthogonally therethrough are two axes 534 and 536 which constitute axes or planes of symmetry for two funnel shaped tracks 538 and 540. These funnel shaped tracks are tracks which are extensions of the bores 516 and 518. They are at least one-quarter of a circle in extent and in the illustrated embodiment are substantially of an extent of about one half of a circle. The purpose of these guide tracks 538 and 540 is to guide the change of direction of the bulbous peripheries of the associated shades as they pass into or out of the bores 516 and 518. For this purpose, the tracks 538 and 540 are substantially tangential to the tubular extensions 508 and 510 and the bores 516 and 518 thereof.
The tracks 538 and 540 have respective outer walls 542 and 544, as well as respective inner walls 546 and 548. These walls slope symmetrically at an angle 550 relative to axis 534 or 536 which is preferably comprised within the range of 10°-45°. The most functional of these walls are the walls 542 and 544 which walls are proximal to the corresponding walls on the next continguous guides (not shown) included in the guide arrangement and intended to function with respect to the same shades as are engaged in the illustrated guide 121. As will be explained in greater detail hereinbelow, the outer or proximal walls 542 and 544 are intended to guide the bulbous peripheries into the bores 516 and 518, while at the same time exerting a stretching force on the corresponding shades. This stretching force constitutes an anti-sag feature provided in accordance with the present invention.
The guide tracks 538 and 540 have radii 543 and 545 which in the preferred embodiment are about 0.420 and 0.500 inches respectively.
The guide tracks 538 and 540 are also of a gradually varying radius. The radius of the tubular extentions is indicated by way of example at 560. The radius adjacent the end of the guide track, which is distal with respect to the corresponding tubular extension, is indicated at 562. By way of example, the radius 560, in a preferred embodiment of the invention, is 0.1375 inches, while the radius 562 is 1.250 inches. The radius 560 is equal to one half of the diameter of the bores 516 and 518.
The upper end of glazing bar 30 is indicated at 570. This end is sloped relative to the longitudinal axis of the glazing bar and is equally sloped relative to the axis 530. To nest against the end 570 the guide of the invention is provided with a sloped flange 572. The end 570 and the flange 572 slope at an angle 574 relative to the axis 530, this angle may be, for example, in the order of magnitude of 60° and is preferably within the range of 45°-75°.
Nesting against the face 580 of glazing bar 30 is a flat or planar extension 582 which extends from the body 500. Extension 582 has a face 584 which is flat and in face-to-face engagement with the face 580. The face 584 is spaced from the corresponding tubular extensions by a distance indicated at 586. This distance is adequate to permit the tubular extensions and the flat extension 582 to straddle the wall 588 of the glazing bar thereby to clamp the guide in position with the flange 572 resting in nesting relationship against the end 570. Furthermore, the body is provided with a sloped section 590 which also rests against the sloped end 570.
Extension 582 is provided with an opening 592. The wall 588 of glazing rod 30 is provided with a portion 596 in which is provided a threaded opening 598. The opening 592 and the opening 598 are provided in aligned relationship to accommodate a bolt or locking member 600 by means of which the guide may be locked in position atop the associated glazing bar.
From the description given above, it will be seen that the guides 121, the details of which are illustrated in FIGS. 6-8, provides for a change in direction of the shade and its bulbous peripheries. Such a change in direction is illustrated in general manner in FIGS. 3 and 4. The guide is preferably a monolithic structure fabricated of a suitable plastic or of metal. The cooperation of a plurality of these guides is diagrammatically illustrated in FIG. 9 wherein, for purposes of orientation, some primed reference numerals are employed to enable considering the following explanation in view of structure which has been previously described. Thus, for example, in FIG. 9 appear shades 80' and 82' as well as guides 121', 121" and 121'". Furthermore shown are take-up rollers 121' and uppermost take-up roller 94'. It will be noted, of course, that while one roller 94' is illustrated in FIG. 9, that a series of such rollers corresponding to the respective shades might be readily employed in substitution therefor. Futhermore shown in FIG. 9 are glazing bars 30' provided with track channels or channel tracks 184' and 186'.
The curved guide tracks are generally radially offset relative to the associated roller 94'. Proximal walls of the tracks are indicated at 542' and 542". Distal walls are indicated by way of example at 546' and 546". Thus, it will be seen that the proximal walls are cooperating walls of two adjacent guides whereas the distal walls 546' and 546" are arranged in this pair of guides.
From the illustration in FIG. 9 it will furthermore be noted that the bulbous peripheries BP' and BP" are engaged in the channel tracks 184' and 186" relative to shade 82' whereas the bulbous peripheries of shade 80', which are indicated at BP'" and BP"", are respectively accommodated in channel tracks 186' and 184".
When, for example, the shade 82' is engaged on roller 94', its width may be, for example, as shown at W'. Thereafter, its bulbous peripheries BP' and BP" pass along proximal walls 542' and 542" whereby the bulbous peripheries are fanned out for subsequent accommodation in the tubular extensions 508 or 510 and thereafter in track channels 184' and 186". This will cause an increase in width of the shade from that indicated at W' to the width indicated at W". This constitutes the leading feature of the anti-sag characteristic of the novel structure of the guide arrangement of the invention, which also simultaneously performs the function of providing a change in direction, as has been referred to hereinabove as being shown in FIGS. 3 and 4. The cap or guard provided in accordance with the invention, is also well oriented with respect to the associated glazing bar. The tubular extensions operating in conjunction with the flat extension 582 provide a bracketing device which traverses one of the walls of the associated glazing bar to hold the guide firmly in position. This characteristic feature is further enhanced by the provision of the flange 572 and the sloped wall 590. The smooth continuation or transition of the bulbous peripheries from within the glazing bar to the take-up roller and vice versa is well provided for by the insertion of the tubular extensions 508 and 510 into the associated channel tracks of the glazing bar 30. An anchoring of the guide device is afforded by the utilization of locking device 600 which passes through opening 592 in extension 582 to be received and accommodated in threaded opening 598. The lateral extension of the shades into the guide device is well provided for by openings 524 and 526 as well as by the lateral slots 512 and 514 provided in the tubular extensions.
There will now be obvious to those skilled in the art many modifications and variations of the structures set forth hereinabove. These modifications and variations will not depart from the scope of the invention, if defined by the following claims. | A structural arrangement which is particularly useful in connection with solar greenhouses is provided. Therein is provided a structural member in the form of a hollow bar of elongated form provided with longitudinally extending and parallel track channels having relatively narrow longitudinally extended slot mouths. A shade with a bulbous periphery is engaged in each of the track channels and a guide member is provided which changes the direction of movement of the shade as it exits from the ends of the corresponding track channels. The guide includes tubular extensions which extend into the track channels. The guide furthermore includes arcuate guide channels which are funnel shaped and operate in extension of the tubular extensions. A member operates in conjunction with the tubular extensions to a wall of the afore-mentioned bars for the mounting of the guide. | 4 |
RELATED APPLICATIONS
This application is a National Phase Application of PCT/FR2012/050427, filed on Mar. 1, 2012, which in turn claims the benefit of priority from French Patent Application No. 11 51745 filed on Mar. 3, 2011, the entirety of which are incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to a method of preparing inorganic and/or organic surfaces comprising organized micro- or nanostructures, to the micro- or nanostructured surfaces obtained by application of this method, and to the various applications of these structured surfaces, notably in the area of photonics, catalysis, magnetic storage or biosensors.
2. Description of Related Art
Methods of preparing nanostructured surfaces, i.e. more generally surfaces comprising organic or inorganic nanostructures, are the object of constant research, as these surfaces have varied applications depending on the nature and morphology of they nanostructures.
Surfaces covered with organized metallic nanostructures find applications in emerging fields such as nanophotonics, or as a substrate for surface-enhanced Raman spectroscopy (SERS). One of the properties of these surfaces is to increase the Raman signal obtained by several orders of magnitude, hence their interest in the analytical and bio-analytical industry for biosensors. In fact, when metallic structures are sufficiently close together, their surface plasmons can then be coupled, generating electromagnetic “hot spots” responsible for the signal enhancement effect. The distance between these structures is therefore a crucial parameter requiring fine control.
Arrays of polymer nanostructures are designed essentially for biotechnology applications, the nanostructures serving as anchoring points for biomolecules such as oligonucleotides for DNA chips, or proteins, notably enzymes, for biosensors. One of the difficulties is that these nanostructures must be separated by a matrix, on which the biomolecules that are to be anchored specifically on the nanostructures cannot become attached. When the polymer used for fabricating the nanostructures is an electrically conducting polymer, such as a polypyrrole for example, the arrays can then have applications as micro-/nano-electrodes.
Nanostructured surfaces can basically be prepared according to two broad types of techniques: “sequential” techniques and “parallel” or “masking” techniques.
According to the “sequential” technique, the nanostructures are deposited on the surface of a substrate point-by-point by scanning the surface with sophisticated apparatus of the microscope tip type (electron or atomic force or tunnel-effect) or with an ion or electron beam. These techniques are expensive, time-consuming and require considerable know-how. Conversely, the sizes obtained are small, of the order of a few nanometers.
According to the “parallel” technique, deposition is carried out on a surface that has been masked beforehand. The masks most widely used are of porous alumina as the size of the pores and their spacing can be controlled during manufacture. Nevertheless, this method is still time-consuming as it requires two steps for synthesis of the mask, as well as several steps for deposition of the metal, for example by electron beam evaporation, vacuum evaporation or else electrolytically, then a step of removal of the mask to obtain the anticipated array of nanodots. Moreover, this method has risks of notable chemical contamination.
An alternative to using these porous masks is to use colloidal lithography. For example, notably in the article of Bayati M. et al., Langmuir, 2010, 26(5), 3549-3554, a method has already been proposed for fabricating surfaces comprising metal (gold, platinum, copper) nanorings, consisting of covering the surface of a substrate, on which deposition is to be effected, with a dispersion of polystyrene beads, which will self-organize in a monolayer on the surface of said substrate, then, after evaporation of the solvent (water), covering the substrate with a solution of a metal precursor (metal salt) so that the precursor infiltrates, by capillarity, the spaces left free between the polystyrene beads. After reduction of the metal salt to cause fixation of the metal on the surface, the substrate is rinsed, then the polystyrene beads constituting the mask are removed by treatment with chloroform. A metal deposit is thus obtained that is either in the form of nanodots if the time of impregnation with the solution of metal salt was long, or in the form of nanorings if the time of impregnation with the solution of metal salt was short. However, this method is time-consuming in application and does not allow the morphology and size of the deposits obtained to be modulated with high precision.
The use of masks consisting of an array of colloidal particles has also been envisaged for preparing nanostructured surfaces with an array of polymer dots. Thus, Valsevia et al. (Adv. Func. Mat., 2006, 16, 1242-1246) propose for example a method of surface nanostructuring consisting of depositing a layer of polymer (polyacrylic acid: PAA) by the technique of plasma-enhanced deposition on a substrate, then depositing, by spin-coating on said layer of polymer, a layer of colloidal spheres in the form of a compact hexagonal array. The method then comprises a step during which these spheres are abraded under plasma in order to reduce their size, then an additional step makes it possible to deposit another polymer (polyethylene glycol: PEG) on these spheres and on the layer of PAA that has been made accessible by abrasion of the colloidal spheres. Finally, the spheres are removed, revealing PAA dots organized in a hexagonal array in a matrix of PEG According to this method, the size of the PAA dots is controlled by the size of the spheres and the abrasion time, parameters which also allow control of the distance between the dots. This method is therefore complex and requires multiple steps, as well as expensive equipment.
Currently, no method exists that allows nanostructured surfaces with controlled morphology, thickness and roughness to be obtained simply, in an easily modulated manner, inexpensively and in a minimum of steps.
Objects and Summary
The inventors therefore set themselves the goal of developing a method for producing such surfaces.
The present invention therefore relates to a method of preparing a nanostructured surface with inorganic and/or organic organized nanostructures, said method employing colloidal particles and an electrochemical cell comprising a positive electrode and a negative electrode, said electrodes being plane-parallel relative to one another, with conducting faces opposite each other, and separated from one another by an insulating spacer having at least two openings and delimiting a free volume (V) between the two electrodes, said method being characterized in that it comprises the following steps:
i) preparing a dispersion of electrically charged, monodispersed hydrophilic colloidal particles (particles P 1 ) in an aqueous phase, said particles P 1 having a size greater than or equal to about 0.5 μm;
ii) preparing a dispersion of electrically charged colloidal particles (particles P 2 ) in an aqueous phase, said particles P 2 having a size less than that of the particles P 1 , being of the same electric charge as the particles P 1 , and optionally containing at least one electrochemical species;
iii) introducing the dispersion of particles P 1 into the free volume (V) through one of the openings in the spacer;
iv) causing the particles P 1 to migrate toward the surface of the electrode of charge opposite to that of the particles P 1 (working electrode), by applying a sinusoidal electric field perpendicularly to said electrodes,
v) applying a sinusoidal electric field of decreasing frequencies at constant potential, to cause aggregation of the particles P 1 on the surface of the working electrode;
vi) gradually increasing the frequency until a crystal lattice is obtained consisting of a monolayer of particles P 1 on the surface of the working electrode;
vii) immobilizing the particles P 1 in the form of said crystal lattice, by superimposing, on the sinusoidal electric field, a continuous electric field of sign opposite to the charge of the particles P 1 , then extinguishing the sinusoidal electric field while maintaining the continuous electric field for a sufficient time to cause adhesion of the particles P 1 on the surface of the working electrode;
viii) introducing the dispersion of particles P 2 into the free volume V of the electrochemical cell, and applying a continuous electric field for a sufficient time to cause migration and fixation of the particles P 2 on the free surface of the working electrode on which the organized array of particles P 1 has formed, and when the particles P 2 contain an electrochemical species, oxidation or reduction of said electrochemical species on the surface of the working electrode;
ix) removing the particles P 1 from the surface of the electrode to obtain a surface that is nanostructured with the particles P 2 or with the oxidized or reduced electrochemical species supplied by the particles P 2 .
Moreover, the method of preparing these surfaces offers the following advantages:
it is rapid, simple and inexpensive to apply, since it only requires a small amount of raw material (particles), and does not require any heavy or high-tech equipment, a simple voltage generator sufficing; it does not require special qualification, as the techniques used are simple to apply; it allows nanostructuring on large areas, i.e. areas of several cm 2 ; it is easy to modulate: variation of the electrical parameters at the voltage generator, of the concentration of colloidal particles P 1 and/or P 2 and of the duration of application of the electric fields makes it possible to obtain varied surface nanostructuring (varied morphology: holes, rings, and varied organization: hexagonal arrays, whether or not compact; triplets of particles P 1 isolated from one another, said triplets being arranged in rods (spheres of particles P 1 fused together three by three along a longitudinal axis) and/or in triangles); it is polyvalent, in that it allows nanostructured surfaces to be obtained by deposition of metal or by deposition of polymer, and can notably be in the form of nanoholes or nanorings; it is not harmful to the environment, nor is it dangerous since it only uses weak electric fields and no organic solvent; the risks of contamination by the surroundings are minimized since all the steps take place in a “closed” environment fin the cell).
According to a preferred embodiment of the invention, the particles P 1 are selected from spherical particles with average diameter between about 0.5 μm and 5 μm.
The particles P 1 are preferably polymer spheres surface-functionalized with anionic groups such as for example sulfate, carboxylate or phosphate groups or with cationic groups such as for example ammonium groups.
According to a preferred embodiment of the method according to the invention, the particles P 1 are polystyrene spheres surface-functionalized with sulfate groups.
The quantity of particles P 1 in the dispersion preferably varies from about 0.1 to 0.6 wt %, or, for particles having a density of 1, from about 3×10 8 to 5.75×10 9 particles/mL. This quantity of particles is sufficient to cover an area of 2 cm 2 . This quantity can be adjusted as a function of the crystal lattice of particles P 1 that we wish to produce on the working electrode. The quantity of particles P 1 in the dispersion must allow, as a maximum, a monolayer of particles to be deposited on the surface. With this limit, the larger the quantity of particles P 1 in the dispersion, the more the surface will be covered uniformly and the denser will be the crystal lattice formed at the end of step v) for a given surface area,
The particles P 2 can constitute the deposit or can serve as carrier for an electrochemical species that will constitute the deposit after reaction on the electrode.
Thus, according to a first embodiment of the method according to the invention, the particles P 2 constitute the deposit and are selected from filled polymers having at least one organic function having affinity for the working electrode, the metal particles surface-functionalized with at least one organic function having affinity for the working electrode and the carbon nanotubes surface-functionalized with at least one organic function having affinity for the working electrode.
In the sense of the present invention, “organic function having affinity for the electrode” means any function permitting fixation of the particles P 2 on the surface of the working electrode. These functions are in particular selected from groups having at least one thiol function and the nitrogen-containing functions such as amino groups, for example hexamethyldiamine or diamine octane, and cyclic groups in which the nitrogen atom or atoms form an integral part of the ring such as the 1,4,8,11-tetraazacyclotetradecane group (also known by the trade name Cyclam®) or a thionine salt such as thionine acetate.
As particles P 2 constituting the deposit, we may mention in particular particles of poly(styrene, divinylbenzene) surface-functionalized with nitrogen-containing groups such as 1,4,8,11-tetraazacyclotetradecane, particles of polystyrene surface-functionalized with molecules of hexamethyldiamine, gold particles surface-functionalized with thiol-polyethylene glycol-amine or with dithiol-octane or with diamine-octane and carbon nanotubes surface-functionalized with thionine acetate.
According to a second embodiment of the method according to the invention, the particles P 2 do not constitute the deposit but serve as carrier for an electrochemical species that will constitute the deposit after reaction on the electrode. According to this variant, the particles P 2 are then preferably selected from lamellar vesicles based on at least one surfactant and containing said electrochemical species.
“Lamellar vesicles based on at least one surfactant” means, in the sense of the present invention, vesicles comprising at least one wall in the form of a bilayer containing at least one surfactant. There is abundant literature devoted to lamellar vesicles, often called unilamellar, paucilamellar or multilamellar vesicles depending on whether they comprise one, a limited number or a large number of bilayers of surfactant, respectively. Liposomes and niosomes are examples of surfactant-based lamellar vesicles.
According to a preferred embodiment of the invention, the particles P 2 consist of multilamellar vesicles with an onion-like structure, i.e. of vesicles of roughly spherical shape consisting of a succession of concentric bilayers.
The charge carried by the particles P 2 will of course determine which electrode will be used as the working electrode. Thus, during application of the continuous electric field, the vesicles bearing a positive charge will migrate to the surface of the working electrode performing the function of cathode, and conversely, the vesicles bearing a negative charge will migrate to the surface of the working electrode performing the function of anode.
The electrochemical species contained in these vesicles is preferably selected from metal ions and redox monomers. As metal ion, we may mention in particular cupric ions, lead, nickel, cadmium, cobalt, ferric, zinc ions etc. As redox monomer, we may mention in particular pyrrole, aniline and thiophene.
Such vesicles are described for example in international application WO 00/08237.
The size of the lamellar vesicles used according to the invention can vary over a wide range provided that they nevertheless have a diameter less than that of the particles P 1 . According to a preferred embodiment of the invention, the lamellar vesicles have a size between 0.1 μm and 1.5 μm.
The quantity of particles P 2 in the dispersion preferably varies from 1 to 60 wt %, and even more preferably from 5 to 50 wt %, This quantity can be adjusted in relation to the thickness and morphology of the deposit that we wish to obtain on the surface of the electrode. Thus, when the quantity of particles P 2 is large, of the order of 50 wt % in the water, rings are obtained that form around the particles P 1 . The thickness of the deposit between the rings and the ring height both increase with the time of application of the continuous electric field and therefore with the quantity of particles P 2 attracted. When the quantity of particles P 2 is small, of the order of 5 wt % in the water, the deposit comprises holes that have formed under the particles P 1 . The diameter of these holes, like that of the rings, depends notably on the diameter of the particles P 1 .
The dispersions P 1 and P 2 can easily be introduced into the free volume of the electrochemical cell, for example by means of a syringe.
The frequency of the sinusoidal electric field applied during step iv) preferably varies from 8 to 4 kHz.
According to a particular embodiment, the electric field applied, during step iv) between the two electrodes preferably varies from 100 to 150 V/cm and the crystal lattice of particles P 1 is then a hexagonal array.
According to another particular embodiment, the electric field applied during step iv) between the two electrodes varies from 200 V/cm to 250 V/cm and the crystal lattice of particles P 1 is then an array in the form of chains consisting on average of 3 particles P 1 .
The duration of step iv) generally varies from about 15 to 90 min. For a given frequency of electric field, this duration is selected as a function of the particle size. The smaller the particles, the longer said duration.
According to a preferred embodiment of the invention, the frequency of the electric field during step v) gradually decreases from 5 to 0.4 kHz, in successive stages with a duration varying independently from about 20 to 2 min.
Still according to a preferred embodiment of the invention, the frequency of the electric field during step vi) gradually increases from 0.4 to 1.6 kHz, in successive stages with a duration varying independently from about 20 to 2 mm.
The crystal lattice of particles P 1 obtained on the surface of the working electrode at the end of step vi) can be in the form of a compact hexagonal array, a noncompact hexagonal array or in the form of an array consisting of an assemblage of particles P 1 , generally of triplets of particles P 1 isolated from one another, said triplets being arranged in rods (spheres of particles P 1 fused together three by three along a longitudinal axis) and/or in triangles. It should be noted that at the end of step v), the particles P 1 are already organized in the form of a crystal lattice but the distance between particles is as small as possible (in contact, most often). It is the gradual increase in frequency during step vi) that will then make it possible to move the particles apart until the expected array is obtained.
During step vii), the continuous electric field is preferably applied with a potential difference varying from 40 to 100 V/cm.
The duration of step vii) preferably varies from 0.1 to 5 s.
During step viii), the continuous electric field is preferably applied with a potential difference varying from 80 to 120 V/cm.
The duration of step viii) preferably varies from 5 to 30 min.
The particles P 1 can easily be removed, for example by rinsing with water or by means of an organic solvent such as tetrahydrofuran (THF) or by applying and then detaching an adhesive tape on the surface of the working electrode. Of course, during removal of the particles P 1 , a person skilled in the art will take care that the technique used does not also lead to removal of the particles P 2 or of the oxidized or reduced electrochemical species that was supplied by the particles P 2 .
The nanostructured surfaces obtained by the method defined above are ready to be used directly after step ix) of removal of the particles P 1 .
Thermal treatments intended to induce fusion of particles P 2 to obtain a continuous matrix can be carried out when the particles P 2 are of a polymeric nature for example.
It is also possible to proceed to an additional step of functionalization of the nanostructured surface, for example with biomolecules of interest such as proteins or nucleic acids (oligonucleotides, DNA).
Thus, according to a particular embodiment of the invention, the method according to the invention further comprises, after step viii) of fixation of the particles P 2 , an additional step of functionalization of the particles P 2 with a biomolecule of interest. Said additional functionalization step can in particular be carried out either just after step viii) of fixation of the particles P 2 and before step ix) of removal of the particles P 1 , or after step ix) of removal of the particles P 1 .
According to a first embodiment of this variant, the particles P 2 possess metal ions on the surface, notably when the particles P 2 are surface-functionalized with nitrogen-containing groups such as 1,4,8,11-tetraazacyclotetradecane which have the property of complexing the divalent metal ions such as nickel or zinc and can then be functionalized with biomolecules bearing a histidine group. In this case, the step of additional functionalization of the particles P 2 with a biomolecule can be carried out by simply contacting the surface bearing the particles P 2 with a solution of the biomolecule in a buffer. The duration of contacting (incubation) is in this case about 1 hour. After incubation of the solution of biomolecule, the surface is then rinsed, for example with a buffer solution.
According to a second embodiment of this variant, the particles P 2 are particles previously surface-functionalized with a streptavidin or biotin group or with an antibody. In this case, the particles P 2 can serve for specifically binding the proteins respectively bearing biotin or avidin ligands or the antigen corresponding to the antibody.
Finally, according to a third embodiment of this variant, the particles P 2 bear positive surface charges. In this case, they can be functionalized with DNA or oligonucleotides by electrostatic affinity.
As an example, these biomolecules of interest can be selected from all proteins bearing a histidine label, a streptavidin ligand or a biotin ligand, antigens, molecules of nucleic acids such as oligonucleotides and DNA.
The nanostructured surface obtained according to the method described above constitutes another object of the invention. It is characterized in that it is in the form of a surface functionalized with an organized array of particles P 2 or with the reduced or oxidized electrochemical species transported initially by the particles P 2 .
More particularly, such surfaces can be in the firm of insulating surfaces comprising an organized array of electrically conducting holes, said holes having a diameter from 300 nm to 1.5 μm and being spaced apart by from 1 to 4 μm (center-to-center distance between holes). They can also be in the form of a film of the reduced or oxidized electrochemical species, said film having holes, metal rings or shells with a diameter varying from 300 nm to 1.5 μm, spaced apart by from 1 to 4 μm (center-to-center distance between holes). When the surface is in the form of an organized array of metal rings, their height varies from 25 to 160 nm.
According to a particular embodiment of the invention, the surface is functionalized with one or more biomolecules of interest, as defined above.
The nanostructured surfaces can have various applications depending on the nature of the particles P 2 used or the nature of the electrochemical species transported by the particles P 2 .
Thus, according to a first embodiment, the invention also relates to the use of a surface obtained by the method according to the invention using, as particles P 2 , filled polymers having at least one organic function having affinity for the working electrode, for molecular detection in biotechnology (in the pharmaceutical industry for example). These surfaces can also be used as masks for other deposits in the holes left empty by the particles P 1 .
According to another embodiment, the invention relates to the use of a surface obtained by the method according to the invention using, as particles P 2 , lamellar vesicles transporting metal ions, and the deposit made on the surface of the working electrode is then of a metallic nature (metal nanorings for example), and the surfaces obtained can be used in photonics, in catalysis, in magnetic storage, as super-hydrophobic transparent surfaces, for the manufacture of biosensors, for optical detection, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows various experiments of nanostructuring of surfaces presented in the examples carried out in an electrochemical cell, in accordance with one embodiment;
FIG. 2 is a photograph obtained by phase-contrast optical microscopy of the surface of the electrode according to Example 1, in accordance with one embodiment;
FIG. 3 is an images obtained by atomic force microscopy (AFM) of the surface of the electrodes nanostructured in Example 1, in accordance with one embodiment;
FIG. 4 are images obtained by AFM of the surface of the electrode of Example 1, in accordance with one embodiment;
FIG. 5 is a 3D representation of the image of a hole observed by AFM from Example 1. in accordance with one embodiment;
FIG. 6 shows the images obtained by AFM of the surface of the electrode of Example 1 in accordance with one embodiment;
FIG. 7 are voltammograms obtained with a solution of ferricyanide of Example 1, in accordance with one embodiment;
FIG. 8 is a 3D representation of the images obtained by atomic force microscopy of the metal rings from Example 3, in accordance with one embodiment;
FIG. 9 is a photograph taken by scanning electron microscopy (SEM) of the surface of the nanostructured electrode of cell C 2 of Example 3, in accordance with one embodiment;
FIG. 10 is a photograph taken by scanning electron microscopy (SEM) of the surface of the nanostructured electrode of cell C 4 of Example 3, in accordance with one embodiment; and
FIG. 11 is a plot of the value of the contact angle (in °) as a function of the time of attraction of the particles P 2 (in seconds) from Example 3, in accordance with one embodiment.
DETAILED DESCRIPTION
Surfaces nanostructured with copper can also find application for limiting the formation of biofilms (antibacterial effect of copper).
The present invention is illustrated by the following practical examples, but it is not limited to these.
EXAMPLES
The various experiments of nanostructuring of surfaces presented in the examples given hereunder were carried out in an electrochemical cell ( 1 ) as shown schematically in the accompanying FIG. 1 , consisting of two plane-parallel electrodes ( 2 a , 2 b ) (glass plates coated with a film of ITO (indium-tin oxide) with a thickness of the order of about a hundred angströms), having the following dimensions 25 mm×50 mm and a thickness of 0.5 mm. These two electrodes ( 2 a , 2 b ) rest on one another, with conducting faces opposite each other, and are spaced apart by a distance of 250 μm by an insulating seal ( 3 ) of square or circular shape made of polytetrafluoroethylene (PTFE), having two openings (not shown) for introducing the dispersions of colloidal particles P 1 and P 2 into the volume ( 4 ) delimited by the insulating seal ( 3 ) once in position between the two electrodes ( 2 a , 2 b ). The two electrodes ( 2 a , 2 b ) are connected by conducting wires ( 5 ), such as copper wires, to the positive and negative terminals of a voltage generator ( 6 ).
Example 1
Preparation of a Surface Nanostructured by a Polymer Matrix Having Holes According to the Method According to the Invention
In this example, surfaces were prepared that were nanostructured by a polymer matrix having electrically conducting holes having a diameter of about 1.1 μm, 630 nm and 445 nm, thus creating an array of micro- or nano-electrodes.
1) First Step: Preparation of a Reverse Mask of Colloidal Particles P 1
50 μl of an aqueous dispersion of particles P 1 - a at 0.1 wt %, consisting of polystyrene beads with a diameter of 2 μm, surface-functionalized with sulfate groups, sold under the trade name Polybeads® (and already functionalized) by the company Polysciences Inc., was introduced into the cavity of an electrochemical cell using a micropipette.
This dispersion was left to sediment for 20 minutes in a sinusoidal electric field (frequency: 5 kHz, 120 V/cm). The sequence shown in Table I below was then applied for organizing the particles P 1 and immobilizing them on the positive electrode in a noncompact hexagonal array:
TABLE I
Frequency
AC potential
DC potential
Time
(kHz)
difference (V)
difference (V)
20
min
5
3
—
2
min
4
3
—
2
min
3
3
—
2
min
2
3
—
2
min
1.8
3
—
2
min
1.6
3
—
2
min
1.4
3
—
2
min
1.2
3
—
2
min
1
3
—
2
min
0.9
3
—
2
min
0.8
3
—
2
min
0.9
3
—
2
min
1
3
—
2
min
1.2
3
—
1
s
1.2
3
1
20
min
—
—
2.3
A hexagonal array of colloidal particles P 1 - a was obtained having a characteristic spacing of 4.0 μm from center to center.
The experiment was then continued by lowering the frequency to 400 Hz while maintaining the potential difference at 3 V.
The accompanying FIG. 2 is a photograph obtained by phase-contrast optical microscopy (magnification ×630) of the surface of the electrode having the hexagonal array of colloidal particles P 1 - a , the center-to-center distance of which is fixed by the frequency of the sinusoidal electric field. In FIG. 2 a ) the particles are organized as a compact hexagonal array (in the case when the experiment was to continued as far as a final frequency=400 Hz), and in FIG. 2 b ) they are organized as a noncompact hexagonal array (final frequency=1200 Hz, Table 1).
A similar experiment was carried out using polystyrene beads P 1 - b and P 1 - c with diameter of 3 μm and of 1 μm respectively, surface-functionalized with amine groups, sold under the trade name Polybeads® (and already functionalized) by the is company Polysciences Inc.
The electrical sequences applied for organizing the beads P 1 - b and P 1 - c are given below in Tables II and III respectively:
TABLE II
Frequency
AC potential
DC potential
Time
(kHz)
difference (V)
difference (V)
20
min
5
3
—
2
min
2.5
3
—
2
min
2
3
—
2
min
1.8
3
—
2
min
1.6
3
—
2
min
1.4
3
—
2
min
1.2
3
—
2
min
1
3
—
2
min
0.8
3
—
2
min
0.6
3
—
10
min
0.6
5
—
1
s
0.6
5
1
5
min
—
—
2.3
90
min
5
3.5
—
10
min
2.5
3.5
—
10
min
1.5
3.5
—
10
min
1
3.5
—
10
min
0.8
3.5
—
2
min
0.8
4.5
—
2
min
0.8
5.5
—
2
min
0.8
6.5
—
2
min
0.8
7.5
—
1
s
0.8
5.5
2
10
min
—
—
2.3
2) Second Step: Fixation of the Colloidal Particles P 2
An aqueous dispersion was prepared at 3 wt % of colloidal particles P 2 consisting of nanospheres (diameter 18 nm) of poly(styrene, divinylbenzene) surface-functionalized with an ion-complexing ligand, Cyclam® (1,4,8,11-tetraazacyclotetiadecane) according to the protocol described in C. Larpent et al., Comptes-rendue de Chimie, 2003, 6, 1275-1283. These particles have a content of cupric ions between 0.2 and 0.3 mmol/g of particles. In this dispersion, the cupric ions were complexed by the ligand Cyclam® fixed on the surface of the nanospheres.
Commercial polystyrene beads (Polybeads) of various sizes 50 nm, 100 nm and 200 nm (in the form of aqueous dispersions at 2.6 wt % of polystyrene beads) were also used as colloidal particles P 2 . 10 μL of these dispersions were diluted in 1 mL of a solution of hexamethylenediamine (0.1 mol/L) with stirring for 16 hours.
For each dispersion prepared, 50 μl of dispersion was then injected into the cavity of the electrochemical cell using a micropipette. A continuous electric field of −92 V/cm was then applied between the two electrodes for 30 min, in order to induce migration of the particles P 2 toward the electrode having the hexagonal array of particles P 1 - a (or P 1 - b or P 1 - c ) and fixation thereof on said electrode, between the particles P 1 - a (or P 1 - b or P 1 - c ).
3) Third Step: Removal of the Particles P 1
After extinction of the field, the cell was opened, washed with distilled water and with ethanol, and then dried. The particles P 1 - a (or P 1 - b or P 1 - c ) were then removed from the surface of the electrode using adhesive tape, which was applied on the electrode, leaving an array of microholes of variable diameter, in a polymer matrix consisting of the particles P 2 .
Images obtained by atomic force microscopy (AFM) of the surface of the electrodes nanostructured in this way are shown in the accompanying FIG. 3 : holes obtained in the matrix of particles P 2 from the mask produced using respectively a) particles P 1 - b : holes of about 1.1 μm in diameter, b) particles P 1 - a : holes of about 630 nm in diameter, and c) particles P 1 - c : holes of about 445 nm in diameter. The scale is identical for these 3 images.
The accompanying FIG. 4 shows the images obtained by AFM of the surface of the electrode obtained using particles P 1 - a with diameter of 2 μm, then particles P 2 , at different magnifications: scale a): 30 μm; b): 10 μm and c) 3 μm.
The accompanying FIG. 5 is a 3D representation of the image of a hole observed by AFM.
The accompanying FIG. 6 shows the images obtained by AFM of the surface of the electrode obtained using particles P 1 - a with diameter of 2 μm, then commercial polystyrene particles P 2 with a size of 200 nm ( FIG. 6 a ) and 100 nm ( FIG. 6 b ).
These surfaces comprising holes in a matrix consisting of colloidal particles can be heated in order to fuse the particles. A thermal treatment at 175° C. for 35 minutes was carried out for the 200-nm particles P 2 . The accompanying FIG. 6 c is a 3D representation of the image obtained by AFM of the surface of the heat-treated electrode.
4) Behavior in Arrays of Microelectrodes
We started with the structured surface based on beads P 1 - a . After fixation of the nanospheres P 2 (diameter 18 nm) and removal of the particles P 1 - a , the surface was heat-treated according to the following protocol: temperature rise from room temperature to 220° C. then a plateau at 220° C. for 35 minutes and temperature drop to room temperature in 1 hour. The aim of this thermal treatment was to fuse the nanospheres together in order to make the polymer matrix completely insulating. The surface therefore consists of conducting holes left free by removal of the particles P 1 - a . This heat-treated surface served as the working electrode in a setup with 3 electrodes with Ag/AgCl as reference electrode and a counter-electrode consisting of a platinum grid. The voltammograms obtained with a solution of ferricyanide (K 3 Fe(CN) 6 ) at 2 mM and of potassium nitrate (KNO 3 ) at 1M are given in the accompanying FIG. 7 , in which the current density J in A/mm 2 is a function of the potential E in volts before thermal treatment ( FIG. 7 a ) and after thermal treatment ( FIG. 7 b ). The scanning rate was 5 mV/s. The voltammogram obtained after thermal treatment has the sigmoidal form characteristic of the electrochemical behavior of an array of micro-electrodes.
Example 2
Preparation of a Nanostructured Surface with a Functional Polymer Matrix According to a Method that is not Part of the Invention
In this example, a surface was used that was covered with unorganized particles P 2 (particles functionalized with Cyclam® groups). In other words the step of fixation of the particles P 1 as described above in example 1 was not carried out. The aim of this example was to show that the particles P 2 can be post-functionalized with a biomolecule.
These surfaces were then functionalized with a protein, GFP (acronym of Green Fluorescent Protein), labeled beforehand with a 6-histidine group.
The slide covered with the particles P 2 was first treated with an aqueous solution of metal ions at 0.1 mol/L, for example in this case a solution of NiCl 2 . For this, the slide was placed in a vertical position in a tube containing 25 mL of the solution of Ni 2+ ions. It was left there for about 1 h, then the slide was rinsed 3 times with ultrapure water and twice with HEPES buffer (pH=7) containing imidazole (20 mM). A protein solution at 0.1 mg/ml of this same buffer solution was prepared and was centrifuged at 20800 g for 5 min at 4° C. in order to remove the protein aggregates. This solution was then deposited with a micropipette on the slide to cover the zone for deposition of particles P 2 . After incubation for 1 h, the slide was rinsed 5 times with the buffer solution described above.
A surface functionalized with GFP was obtained.
Example 3
Preparation of a Nanostructured Surface with a Metallic Matrix and Demonstration of its Super-Hydrophobic Character
A surface nanostructured with copper rings was prepared in this example.
1) First Step: Preparation of a Reverse Mask of Colloidal Particles P 1
50 μl of an aqueous dispersion of particles P 1 at 0.1 wt %, consisting of polystyrene beads with a diameter of 2 μm sold under the trade name Polybeads® by the company Polysciences, Inc. and already functionalized with sulfate groups, was introduced into the cavity of an electrochemical cell C 1 using a micropipette.
This dispersion was left to sediment for 20 minutes in a sinusoidal electric field (frequency: 5 kHz, 120 V/cm). A sequence similar to that shown in Table I of example 1 above was then applied for organizing the particles P 1 and immobilizing them on the positive electrode in a hexagonal array. The time for immobilizing the particles P 1 (last line of the table) was fixed at 5 mm or 20 minutes depending on the experiment.
2) Second Step: Fixation of the Colloidal Particles P 2
A dispersion of particles P 2 at 500 mg/ml consisting of multilamellar vesicles containing cupric ions was prepared by simple equal-weight mixing of an aqueous solution of cupric sulfate (0.68 M) and a surfactant of the tallow oil ethoxy late type sold under the trade name Genamin T020® by the company Clariant, and having the particular feature that it self-organizes in the form of multilamellar vesicles in the presence of an aqueous phase.
50 μl of this dispersion was introduced into the cavity of the electrochemical cell, then a continuous electric field of ˜92 V/cm was applied for 20 min, in order to attract the vesicles of surfactant containing the cupric ions, which will be reduced on the electrode. The particles P 1 thus underwent 20 minutes of immobilization.
The same experiment was repeated in two other electrochemical cells (C 2 and C 3 ), using exactly the same dispersions of particles P 1 and of particles P 2 , but applying the following parameters:
electrochemical cell C 2 : 20 minutes of immobilization of the particles P 1 and 5 minutes of attraction of the particles P 2 ; electrochemical cell C 3 : 5 minutes of immobilization of the particles P 1 and 20 minutes of attraction of the particles P 2 ; electrochemical cell C 4 : 5 minutes of immobilization of the particles P 1 and 130 minutes of attraction of the particles P 2 .
3) Third Step: Removal of the Particles P 1 and P 2
Extinction of the field causes detachment of the vesicles P 2 (empty of copper) from the electrode. The cells were then opened, washed with water and with ethanol to remove the vesicles P 2 and any trace of organic matter, and then dried.
The particles P 1 were then removed from the surface of the electrodes in each of the cells C 1 to C 3 using adhesive tape, which was applied on the electrode, leaving an array of copper micro-rings. For cell C 4 , the slide was immersed in a solution of pure tetrahydrofuran for 20 min, and then rinsed with THF. It was again immersed for 20 min in the solution of THF and then rinsed with THF and with ethanol before being dried.
FIG. 8 is a 3D representation of the images obtained by atomic force microscopy of the metal rings formed on the surface of each of the electrodes: a) electrochemical cell C 1 , b) electrochemical cell C 2 ; c) electrochemical cell C 3 .
It can be seen in this diagram that the morphology of the copper rings can be modulated as a function of the duration of application of the electric fields during migration and fixation of the particles P 1 and P 2 .
The accompanying FIG. 9 is a photograph taken by scanning electron microscopy (SEM), magnification ×3500, of the surface of the nanostructured electrode of cell C 2 .
The accompanying FIG. 10 is a photograph taken by scanning electron microscopy (SEM), magnification ×5000, of the surface of the nanostructured electrode of cell C 4 . In this case organized “shells” of copper are obtained.
4 Demonstration of the Super-Hydrophobic Character of the Organized Copper Surfaces
The static contact angle of the surfaces formed for different times of reduction and for one and the same time of immobilization of 5 min was measured, in particular on the surfaces obtained from C 3 corresponding to the 20 min point and C 4 corresponding to 130 min. Measurement consists of depositing a drop of ultrapure water using a syringe on the surface whose contact angle we wish to measure. A photograph of the drop is taken at grazing incidence. After digitization of the contour of the drop, the angle made by the tangent to the drop at the solid-liquid-gas triple point and the solid surface is calculated. This angle is called the contact angle (θ). This contact angle is controlled by the time of application of the field permitting reduction of the copper.
FIG. 11 plots the value of the contact angle (in °) as a function of the time of attraction of the particles P 2 (in seconds). A photograph showing the wetting of the structured surface for 8000 seconds by a drop of water is also shown.
Its maximum value is 160° for the surfaces tested, obtained according to the method of the invention, without any hydrophobization. For comparison, the highest value found in the literature for copper surfaces deposited under a continuous electric field is 138° (X Liu et al., Thin Solid Films, 2010, 518, 3731-3734).
Accordingly, these results demonstrate the super-hydrophobic character of the surfaces produced by the method according to the invention. | A method of preparing inorganic and/or organic surfaces includes organized micro- or nanostructures using colloidal particles in an electric field, to the micro- or nanostructured surfaces obtained by application of this method, as well as to the various applications of these structured surfaces, notably in the field of photonics, catalysis, magnetic storage or biosensors. | 2 |
TECHNICAL FIELD
This invention pertains to combustors for gas turbine engines, and pertains more particularly to an improved hybrid combustor incorporating the ceramic can combustors and a metallic annular combustor.
1. Background of the Invention
Gas turbine engine efficiency increases with increased temperature. To this end, it has been proposed to utilize ceramic components within gas turbine engines, particularly at the highest temperature locations therein, to increase gas turbine engine maximum temperatures. Utilization of ceramics, such as ceramic matrix composites, in the combustor of the gas turbine engine is therefore highly desirable.
However, ceramic material such as ceramic matrix composites are sensitive to the temperature difference through the thickness of the material. The temperature difference between the hot interior and the cooler exterior generate thermal stresses resulting in cracking of the ceramic matrix. This limits the allowable wall thickness of the design making it difficult to produce a conventional annular ceramic combustor configuration of a reasonably large diameter which needs larger wall thickness to withstand the buckling pressures associated with the larger diameters. Ceramic designs are thus limited by small diameter, low pressure drop, low heat loading, or a reduced combination of such factors, which ultimately limit the combustor performance.
2. Summary of the Invention
Accordingly, it is an important object of the present invention to provide an improved combustor for a gas turbine engine which utilizes ceramic materials in a geometric configuration which avoids the problems normally associated with such use of ceramics. More particularly, it is an important object of the present invention to provide a hybrid combustor having a plurality of can-type ceramic combustors disposed in a circular array, along with a conventional metallic annular combustor construction. summary, the present invention contemplates a plurality of ceramic can combustors each having a cylindrical ceramic wall, wherein primary, fuel-rich combustion occurs, along with a single annular, metallic combustor which receives the exhaust of the fuel-rich burn from all of the can combustors, along with pressurized air flow from the combustor inlet. Fuel-lean combustion continues to occur in the annular metallic combustor as a continuation of the fuel-rich combustion process in each of the can combustors. In this manner the ceramic cylindrical walls of the can combustors can be made of relatively small diameter to minimize thermal stresses and buckling forces thereon.
These and other objects and advantages of the present invention are specifically set forth in or will become apparent from the following detailed description of a preferred embodiment of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, perspective representation of a hybrid combustion constructed in accordance with the principles of the present invention;
FIG. 2 is a cross-sectional plan view of the hybrid combustor of the present invention; and
FIG. 3 is a front elevational view of a portion of the combustor of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, a gas turbine engine combustor 10 generally includes a plurality of can combustors 12 disposed in a circular array about the central axis 14 of an associated annular combustor 16 . As best depicted in FIG. 2, the gas turbine engine combustor 10 includes an annular outer casing 18 having a pressurized air inlet 20 , an exhaust 22 , and a fuel supply duct 24 leading to a fuel nozzle 26 associated with each of the can combustors 12 . Each fuel nozzle 26 in conventional fashion receives air for primary combustion from the pressurized air inlet as illustrated by arrows 28 , and may include a primary swirler 30 (FIG. 1) so as to deliver a finely mixed mixture of fuel and air into the primary combustion zone within each of the can combustors 12 .
Each can combustor 12 includes a cylindrical outer metal liner 32 and a continuous cylindrical inner ceramic wall 34 . For fuel-rich can combustors, the ceramic wall 34 is preferably non-perforated. Preferably the ceramic wall 34 is made of a ceramic matrix composite material. If desired, metal supports 36 may extend radially inwardly from the outer metal wall liner 32 to position the ceramic wall 34 centrally therewithin without inducing thermal stresses on the ceramic wall 34 . Defined between outer metal liner 32 and inner ceramic wall 34 is a ring-shaped, annular air space 40 extending axially along the can 12 . At the inlet end, the outer metal liner 32 extends radially inwardly to the fuel nozzle 26 . A floating metal grommet 42 effectively seals between and intersecures the outer metal liner 12 with the fuel nozzle 26 . As best depicted in FIG. 3, the inlet end of the outer liner 32 includes a plurality of inlet air passages 44 disposed in a full circular array for allowing pressurized air from the inlet 20 to enter the annular air space 40 for axial flow therealong on the exterior side of the ceramic wall 34 .
Annular metal combustor 16 conventionally includes inner and outer metal walls 44 , 46 disposed in an annular configuration normally surrounding the turbine section of the gas turbine engine. As desired, the metal walls 44 , 46 may have small openings 48 therein for film or effusion cooling of the metal walls 44 , 46 .
The inlet end of annular combustor 16 includes a plurality of relatively large openings 49 each of which receives the corresponding exhaust end of the associated can combustor 12 . Outer metal liner 32 of each can combustor is rigidly secured to the annular combustor walls 44 , 46 such as by a plurality of welded brackets 50 . Accordingly, each of the can combustors 12 is rigidly secured to the annular combustor 16 through associated metal liner 32 . The annular air passage 40 of each can combustor 12 opens into the inlet of the annular combustor 16 , as depicted by arrows 52 , to inject pressurized air received from inlet 20 directly in to the annular combustor 16 to support secondary combustion therein as described in greater detail below. In conventional fashion, the outlet end of the annular combustor 16 is appropriately secured to the combustor casing 18 for delivery of hot combustion products through the exhaust 22 .
In operation, pressurized air inlet flow from the compressor section of the gas turbine engine is delivered through air inlet 20 inside the annular outer combustor casing 18 in a generally axial direction. Fuel is delivered through each fuel nozzle 26 to mix with air for primary combustion to be delivered in to the interior of each can combustor 12 . Primary combustion occurs inside the ceramic wall 34 of each can combustor 12 . Preferably this is a fuel-rich burn combustion process inside each ceramic can combustor 12 . If transition to fuel-lean combustion is desired in the can combustors 12 , openings along the length of wall 34 may be included instead of the nonperforated configuration shown.
To minimize thermal stress across the ceramic wall 34 , its thickness is minimized. Minimization of the thickness of ceramic wall 34 reduces the temperature differential thereacross and therefore minimizes the thermal stresses imposed thereon. Additionally, the annular air passage 40 through which pressurized air flow is delivered provides cooling to the ceramic can 34 and the outer liner 32 to maintain material temperatures of both components within acceptable ranges. It is because of the necessity to minimize the thickness of the ceramic wall 34 that makes it unacceptable for use as a relatively large annular combustor, since the necessary thinness of the wall would subject it to buckling.
The combustion process inside each can combustor 12 continues throughout the axial length thereof and through the openings 49 into the annular combustor 16 . That is, the flame front created in the primary combustion zone within each can combustor 12 extends through the associated opening 49 and into the interior of the annular combustor 16 .
Significant pressurized air flow is injected into the annular combustor 16 through the annular air passage 40 as depicted by arrows 52 in FIG. 2 . The combustion process initiated in each of the can combustors continues within the annular combustor 16 with secondary, fuel-lean combustion occurring therewithin. Because the annular combustor is a continuous, circular configuration, the combustion process therewithin expands circumferentially into a continuous, ring-like combustion front. In this manner, the present invention provides all of the attendant advantages associated with conventional annular combustors, and in particular the elimination of thermal patterning therein. As noted, fuel-lean secondary combustion continues within the annular combustor 16 until the combustion process is completed therewithin. The exhaust products from the combustor 10 are delivered through exhaust 22 to drive the turbine section of the gas turbine engine.
Various alterations and modifications to the foregoing detailed description of a preferred embodiment of the invention will be apparent to those skilled in the art. Accordingly, the foregoing should be considered exemplary in nature and not as limiting to the scope and spirit of the invention as set forth in the appended claims. | A hybrid combustor for a gas turbine engine includes a plurality of circularly arrayed ceramic can combustors whose outlets communicate with the inlet of an annular, metal combustor. The combustion process is continuous through the plurality of can combustors and into the single annular combustor. Preferably only fuel-rich combustion occurs within each of the can combustors, and fuel-lean combustion continues within the single annular combustor. | 5 |
FIELD OF THE INVENTION
[0001] The present invention comprises a clamp arrangement and in particular such an arrangement for use as a hand tool.
BACKGROUND TO THE INVENTION
[0002] A variety of clamp arrangements are known which purport to provide provision of an ability to clamp securely and tightly over a wide range of clamping widths. Some have the ability to permit initial coarse adjustment of the jaws to an approximate target separation distance and enable subsequent tightening of the jaws about the item(s) to be clamped.
SUMMARY OF THE INVENTION
[0003] According to a first aspect the present invention provides a clamp arrangement comprising:
[0004] a first jaw and a second jaw mounted to be movable with respect to one another between a clamping configuration and a release configuration;
[0005] a catch mechanism comprising a movable detent operable to engage with a locking element in a plurality of different positions dependent upon the degree of separation of the jaws;
[0006] a tightening means operable to tighten the jaws by providing a tightening force acting via the catch mechanism.
[0007] It is preferred that one or both of the first and second jaws are pivotably movable. The arrangement may comprise an effectively fixed jaw and a movable jaw pivotally mounted with respect to the effectively fixed jaw.
[0008] Beneficially resilient biassing arrangement is provided to bias the jaws together. This preferably comprises a resilient biassing arrangement which acts to inhibit opening of the jaws beyond a predetermined extent, and acts to close the jaws if opened beyond the predetermined extent. A spring or elastically extendible tether may be provided for this purpose.
[0009] It is preferred that the arrangement includes a biassing arrangement to bias the detent into engagement with the locking element. The detent biassing arrangement may comprise a spring such as a leaf spring.
[0010] The detent is preferably manually actuatable to act against a biassing force to be moved, selectively, out of engagement with the locking element. The biassing force tends to urge the detent back into contact with the locking element.
[0011] The locking element preferably includes a plurality of spaced engagement formations, the detent engaging with different engagement formations dependent upon the degree of separation of the jaws. These engagement formations are beneficially in the form of teeth or serrations, preferably extending in a series along an edge (beneficially an arcing edge) of the locking element.
[0012] Preferably, the detent is pivotably movable into and out of engagement with the locking element. The detent is preferably mounted to one of the jaws.
[0013] Advantageously, the tightening arrangement acts to pivot the locking element to transmit a closing force via the detent to tighten the jaws. In an embodiment which may be preferred for certain uses, the tightening arrangement may comprise a screw threaded shaft, the locking element being matingly connected to the screw threaded shaft via a threaded bore connector. In certain embodiments, the tightening mechanism comprises an elongate handle which is rotated to effect tightening and release. In other embodiments tightening may be effected by a cam and follower arrangement or an expanding/contracting linkage (such as a scissors linkage).
[0014] In certain embodiments, it is preferred that one or both of the jaws have pivotable grip elements mounted to the end of the respective jaws. This may enable secure gripping during clamping of differently shaped items.
[0015] According to a second aspect, the present invention provides a clamp arrangement comprising:
[0016] a first jaw;
[0017] a second jaw pivotably mounted with respect to the first jaw;
[0018] a first closure system providing a first closing bias to close the jaws; and
[0019] a second closure system providing a second closing bias to close the jaws.
[0020] The first closure system preferably acts to locate the jaws to a relatively loosely clamped position and the second closure system acts to clamp the jaws more tightly from the relatively loosely clamped position.
[0021] Beneficially, this may for example comprise a resilient biassing arrangement which acts to inhibit opening of the jaws beyond a predetermined extent, and acts to close the jaws if opened beyond the predetermined extent. A spring or elastically extendible tether may be provided for this purpose. the first closure system comprises a resilient biassing element between the jaws.
[0022] It is preferred that the second closure system comprises a manually actuatable tightening mechanism.
[0023] Desirably, in this aspect of the invention the arrangement includes a catch mechanism comprising a movable detent operable to engage with a locking element in a plurality of different positions dependent upon the degree of separation of the jaws; and a tightening arrangement operable to tighten the jaws by providing a tightening force acting via the catch mechanism.
[0024] Preferred features of the second aspect of the invention may correspond to preferred features of the first defined aspect of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The invention will now be further described in specific embodiments, by way of example only, and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a schematic view of a clamp arrangement in accordance with the invention;
[0027] FIG. 2 is a schematic view of an alternative configuration of a clamp in accordance with the invention;
[0028] FIG. 3 is a schematic view of a further alternative clamp arrangement configuration in accordance with the invention;
[0029] FIG. 4 is a schematic view of a further alternative configuration, and;
[0030] FIG. 5 is a schematic view of a yet further embodiment in accordance with the invention;
[0031] FIG. 6 is a schematic view of a further alternative embodiment in accordance with the invention;
[0032] FIG. 7 is a schematic view of a yet further alternative embodiment in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring to the drawings, and initially primarily to FIG. 1 , there is shown a clamp arrangement comprising a first, effectively fixed, jaw ( 1 ), and a second pivotal jaw ( 9 ). Jaw ( 9 ) is mounted pivotally with respect to the fixed jaw ( 1 ) by means of pivot pin ( 15 ). The jaws open to separate respective pivotally mounted clamp anvils ( 7 ). Extending between the jaws ( 1 ) and ( 9 ) is a resilient spring tether ( 8 ) providing a first closure means for the arrangement. The spring tether ( 8 ) acts to close the jaws ( 1 ) ( 9 ) when they are pulled apart from a closed configuration as shown in FIG. 1 .
[0034] A handle ( 6 ) is connected to fixed jaw ( 1 ) by means of a screw threaded shaft ( 5 ) and a pivot connection ( 2 ). A locking plate ( 4 ) is mounted to threaded shaft ( 5 ) by means of a correspondingly threaded bore ( 3 ). Rotation of the threaded handle ( 6 ) about its longitudinal axis causes corresponding rotation of the threaded shaft ( 5 ), which enables the shaft of locking plate ( 4 ) to move longitudinally up along the threaded shaft ( 5 ) depending upon the direction of rotation. The end of locking plate ( 4 ) distal from the threaded bore ( 3 ) is provided with an arc-form serrated tooth edge ( 12 ). Locking plate ( 4 ) is mounted to be pivotable about pivot pin ( 15 ).
[0035] A detent lever ( 14 ) is mounted via a pivot ( 13 ) to the pivotable jaw ( 9 ). The proximal end of detent lever ( 14 ) is arranged to be gripped by the fingers of a user and extends downwardly and outwardly from the jaw ( 9 ). The distal end of detent lever ( 14 ) is provided with an engagement formation ( 16 ) which has corresponding teeth arranged to engage with the serrated tooth edge ( 12 ) of the locking plate ( 4 ). A leaf spring ( 10 ) is arranged to normally bias the distal end of detent lever ( 14 ) into meshed engagement with the serrated tooth arc-form edge of locking plate ( 4 ). A stop pin ( 11 ) is provided to limit the outward pivotal movement of the distal end of detent lever ( 14 ).
[0036] The engagement formation ( 16 ) of the lever ( 14 ) and serrated tooth edge ( 12 ) provide the catch mechanism of the invention. Other realisations of suitable catch mechanism are envisaged such as for example disengageable clutch or brake arrangements.
[0037] In use, in order to open the jaws of the clamp, the user grips the handle ( 6 ) and pulls the proximal end of lever ( 14 ) towards the handle ( 6 ) by means of the fingers. This causes the detent lever ( 14 ) to pivot about pivot pin ( 13 ) and the distal teeth ( 16 ) to disengage from engagement with the serrated tooth arc-form edge of the locking plate ( 4 ). The distal end ( 16 ) of lever ( 14 ) engages the stop pin ( 11 ) and thereafter drawing the proximal end of lever ( 14 ) toward the handle ( 6 ) causes continued opening of the jaws of the clamp arrangement.
[0038] Having been opened, the jaw can then be closed upon the items to be clamped. This is done by releasing the grip between handle ( 6 ) and detent lever ( 14 ) allowing the jaws to close under the influence of the resilient spring tether ( 8 ). The clamp anvils ( 7 ) abut the item to be clamped and the teeth ( 16 ) at the distal end of detent lever ( 14 ) re-engage with the serrated tooth arc-form edge of the locking plate ( 4 ) at a position along the arc-from edge dependent upon the size of the item being clamped. For larger items clamped, the position of engagement will be toward the lower point of the serrated arc-form edge. For smaller items the position of engagement will be toward the upper point of the serrated arc-form edge (approximating the clamp closed position as shown in FIG. 1 ). The detent leaf spring ( 10 ) biases the distal end of the detent lever ( 14 ).
[0039] This closure system provides a first closure action by means, effectively, of a quick release of the clamp, the engagement (clamping) force being provided via the resilient spring tether ( 8 ). This only provides a relatively weak clamping force. The maximum tightening force is provided by means of actuating the handle ( 6 ) by rotating it about its axis in a tightening direction, causing rotation of the screw threaded shaft ( 5 ) and movement in a downward direction (arrow A in FIG. 1 ) of the threaded bore ( 3 ) of the locking plate ( 4 ). This causes pivoting of the locking plate about pivot pin ( 15 ) and the arc-from serrated tooth edge of the locking plate ( 4 ) to pivot upwardly as shown by arrow B in FIG. 1 . This provides a force acting on the distal end ( 16 ) of detent lever ( 14 ) in an upward direction and therefore, via the pivot connection ( 13 ), the jaw ( 9 ) to be pivoted upwardly about pivot pin ( 15 ) enhancing and increasing the jaw closing force. Effectively therefore, the closing force is transmitted from the turning of the handle ( 6 ) via the locking plate ( 4 ) to the detent lever ( 14 ) and onto the jaw ( 9 ) in order to close the jaw.
[0040] Referring now to FIG. 2 , there is shown an alternative embodiment in which both jaws ( 101 and 109 ) are pivotable about respective pivots ( 115 ) and in this instance the second, tightening force is applied via handle ( 106 ) by means of a cam formation ( 105 ) which, when lever ( 106 ) is pivoted about a pivot pin ( 104 ) to a maximum extent urges, via cam follower ( 103 ), the jaw ( 101 ) to pivot, in closing fashion, about pivot pin ( 115 ).
[0041] A further alternative or embodiment is shown in FIG. 3 in which the jaw ( 201 ) is caused to pivot about pivot pin ( 215 ) by means of the lever actuation of handle ( 206 ) (in the direction shown by the arrow in FIG. 3 ). Such operation of the handle ( 206 ) causes a toggle linkage mechanism ( 205 ) to open and close the jaws. In the embodiment shown, movement of the lever ( 206 ) about pivot ( 204 ) in the direction of the arrow causes the jaws to close.
[0042] In both embodiments of FIG. 2 , closing forces applied by the handle by means of pivoting of the locking plate ( 124 , 224 ) to the detent lever (not shown and unto the respective other jaw ( 109 , 209 )). Additionally, in a similar fashion to the embodiment of FIG. 1 , the embodiments of FIGS. 2 and 3 could replace separate pivots ( 115 , 215 ) for each jaw with an effectively fixed jaw and a single pivoted jaw about a single pivot point as shown in FIG. 1 .
[0043] FIGS. 4 and 5 show alternative means of connecting the detent lever ( 14 ) to the arc-form serrated tooth edge ( 12 ) of the locking plate 4 . In both embodiments a separate pawl lever ( 20 ) is provided, pivoted about a respective pivot pin ( 21 ).
[0044] In the embodiment shown in FIG. 4 , the distal end of lever ( 14 ) engages in a slot formation of the pawl ( 20 ) such that actuation of the lever ( 14 ) by pulling towards the handle ( 12 ) causes the pawl ( 20 ) to pivot out of engagement with the serrated teeth ( 12 ).
[0045] The embodiment of FIG. 5 operates in a similar manner, however in this instance the lever ( 14 ) operates the pawl ( 20 ) via a spring ( 22 ) (or other compressible element) to prevent the detent lever releasing the jaws when the clamp is applying maximum pressure.
[0046] In the embodiment of FIG. 6 a pawl lever ( 320 ) is pivoted on a pivot ( 330 ) which is fixed with respect to jaw ( 301 ). When the jaws ( 301 , 309 ) are pulled apart as the clamp opens, the pawl teeth of lever ( 320 ) tend to disengage with the serrated tooth arc form edge ( 312 ) as the pivot post ( 320 ) moves away from the jaw ( 309 ). The trigger lever ( 314 ) is biassed by leaf spring ( 310 ) into engagement with the pawl lever tending to normally urge the pawl lever ( 320 ) into engagement with the serrated tooth arc form edge ( 312 ). The leaf spring also acts directly on the distal end of the pawl lever ( 320 ). The point of contact between the anvil ( 350 ) of the pawl lever ( 320 ) and the trigger lever is at a cam surface and arranged such that there is little or no turning moment generated about the pivot point ( 313 ) of the trigger lever ( 314 ). As a result the pawl lever ( 320 ) cannot cause the trigger lever ( 314 ) to rotate. In effect the trigger lever ( 314 ) locks the jaw ( 301 ) to the serrated tooth arc form edge ( 312 ) until the trigger lever ( 314 ) is moved to draw the jaw ( 301 ) away from the jaw ( 309 ).
[0047] In the embodiment of FIG. 7 the arrangement is generally similar to the arrangement of FIG. 1 but the fixed jaw ( 401 ) is mounted to be slideable along an elongate arm ( 450 ). The position of the jaw ( 401 ) on the arm ( 450 ) may be adjustable secured with a locking screw or other fixing, in certain embodiments. Jaw ( 409 ) pivots about pivot ( 415 ) in response to clamp opening actuation of the trigger lever ( 414 ). The handle ( 416 ) is rotated to apply the jaw tightening force via the catch mechanism about the item (or items) to be clamped.
[0048] The invention as described provides a robust clamp arrangement in which a first closure means (resilient spring tether ( 8 )) can be used for initial closing of the jaws in a quick, secure fashion about an item to be clamped. Subsequently, maximum clamping force may be applied via the tightening arrangement (rotatable handle ( 6 ) or other actuator handle), providing a second closure system to tighten the jaws to a maximum degree. | A clamp has a first jaw and a second jaw mounted to be movable with respect to one another between a clamping configuration and a release configuration. A catch mechanism has a movable detent operable to engage with a locking element in a plurality of different positions dependent upon the degree of separation of the jaws. A tightening mechanism is manually operable to tighten the jaws by providing a tightening force acting via the catch mechanism. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a safety door fastening, of the type for limiting the angle of opening of a door and comprising on the one hand a rigid retaining member defining a longitudinal space and being pivotably attached to a vertical pin located on the door frame and on the other hand a catch member, mounted to the door, comprising an arm having a terminal member adapted to slide in the longitudinal space of the retaining member and hold it.
2. Description of the Prior Art
Hitherto known door fastenings for limiting the angle of opening of a door are only operative if, each time that the door is to be opened to attend to a caller, the retaining member mounted to the door frame is applied to the door, something which, either for forgetfulness or excess trust, is frequently not done, whereby the protection sought by having the safety fastening is not obtained.
Moreover, the hitherto known door fastenings of the type described are not made to be operated from the outside.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a door fastening of the type described hereinbefore which will automatically, without having to be consciously applied by the user, be maintained in the operative safety position, thereby limiting the angle of opening of the door, and to provide means allowing the aforesaid means to be momentarily overridden from the outside of the door so that the user may cross through the door from the outside, without excluding the fact that such automatic means may be released from the inside to allow the door to be crossed from the inside, the fastening returning, in all cases automatically to its safety position when the door is reclosed.
The problem is solved according to the invention by a safety fastening characterised fundamentally in that the arm of the catch member is adapted for pivoting around a horizontal axis by operation of a lock means operable from the outside of the door, the retaining means having resilient means biasing it against the inner face of the door when the door is in the closed position thereof and said retaining member also having means which, in the closed position of the door, allows the arm of the catch member to be pivoted until its terminal member is disengaged from the longitudinal space of the retaining member.
The invention is also characterised in that the catch member also has a stop member limiting the pivoting movement of the arm in a downwards direction.
A further feature of the invention is that the catch member arm is fixedly attached to the cylinder of a lock means, said cylinder constituting the pivot shaft of the arm.
BRIEF DESCRIPTION OF THE DRAWING
Other objects and features of the invention will be disclosed in detail in the following description, with reference to the illustrative drawings in which:
FIG. 1 is a perspective view of a slightly open door retained by a fastening of the invention.
FIG. 2 is a front elevation view showing the closed door position of the fastening of FIG. 1.
FIG. 3 is a view similar to FIG. 2, showing the position in which the arm, operated from the outside by way of a key, is disengaged from the retaining member, with a view to crossing through the door from the outside.
FIG. 4 is a plan view of the fastening in the closed door position of FIG. 2.
FIGS. 5 and 6 are views similar to FIGS. 2 and 4, of a further embodiment of the safety fastening provided with an automatic means for holding the retaining member in the open position.
FIG. 7 is a perspective view of the embodiment of FIGS. 5 and 6, showing the retaining member held in the open, inoperative position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The safety fastening of the present invention comprises essentially a retaining member 1 pivotably mounted around a vertical pin 2 supported by a base plate 3 mounted to the door frame 4 of a door 5 and a catch member 6, mounted to the door 5, having an arm 7 fixedly attached to the cylinder 8 of a lock 9 mounted in said door 5.
According to the embodiment illustrated in FIGS. 1 to 4, said retaining member 1 is formed by an elongated loop which, delimiting a longitudinal space, is constituted by two arms 10 and 11 which are parallel over portion of their length and connected at one end to a lug 12 having the vertical pin 2 therethrough, said pin being supported by two lugs 13 of the base plate 3, whereas said plate is attached to the frame 4 by screws 14.
Arms 10 and 11 of the retaining member 1 form, adjacent their inner end curved portions 10a and 11a, respectively, the former of which is also projected forwardly out of the vertical plane in the opposide side thereof to the door in an extent sufficient to allow the catch member arm to pivot about its axis.
The space between the two curved portions forms a zone A through which the terminal member 15 of the arm 7 may be disengaged from the retaining member by pivoting the latter.
At least one of the arms of the loop is associated with the pin 2 by way of a coil spring 16 biasing the retaining member 1 against the inner face of the door 5 in the closed position of the latter. At their free or outer end, the arms 10 and 11 of said loop meet to form a terminal member 17 for manual holding.
The catch member 6 has the arm 7 mounted between a base plate 18 and a cover plate 19, said base plate being held by screws 20 to the door 5. At the free end of the arm 7 there is formed the said terminal member 15 extending outwardly therefrom generally at rightangles and terminated in the form of a button, for insertion between the parallel portions of arms 10 and 11 of the retaining member 1, and slidable along both without being able to be freed therefrom except at the front face of zone A or through the curved portion 10a. A stop pin 22 prevents the arm 7 from pivoting downwardly.
FIGS. 5 to 7 illustrate a further embodiment of the fastening, wherein the retaining member 1 is an elongate flat member 23 having a longitudinal slot or space 24, member 23 being likewise pivotably mounted at a pin 2 and having at the end of the slot 24 adjacent said pin 22 a stamped portion 25 having a curved vertical section extending outwardly in the opposite side thereof to the door. Said stamped portion 25 forms the zone A through which the terminal member 15 may be disengaged from the retaining member by pivoting the latter.
The terminal member 15 of the arm 7 of the catch member also has an external edge 26 curved to match the curve of the stamped portion 25.
On the other hand, means may be fitted to allow the retaining member 1 to be held in the open position thereof. Said means comprises a lever 27 capable of a limited pivoting movement around a pin 28 mounted in lugs 29 of the plate 3, and a spring 30 biasing it away from the frame 4, said lever 27 having a tooth 31 which, in the open position of the retaining member 1, automatically retains it in said position, with said tooth 31 engaging the edge of a cut away portion 32 of the retaining member, wherethrough said lever passes through said retaining member. Also the door 5 or the support plate 18 is provided with an extension 33 which, on the door being closed engages the free end of the lever 27, pivoting of which is limited by the edge of the cut away portion 32, so that in all cases the free end of the lever lies within the field of action of the extension 33.
The fastening operates as follows: in any position, the spring 16 biases the retaining member 1 against the inner face of the door, with the catch member 6 intercalated therein.
If it is desired to open the door from the inside to go out, the retaining member 1 is withdrawn by hand, pivoting it against the spring 16, whereby the door may be freely moved, since the terminal member 15 of the catch member 6 is disengaged through the zone A of the retaining member.
On the other hand, if it is wished to open the door from the inside in response to a call, the door handle is operated and the safety fastening immediately comes in to operation so that the arm 7, in the horizontal position, moves in the retaining member 1 until it reaches the end of the longitudinal space, whereby the opening angle is restricted and there is no way of increasing it, except by reclosing the door. In the said restricted opening position, the door 5 is partially open just sufficiently for the persons on either side of the door to be able to see each other and converse and even to hand over certain small objects.
In the case of opening the door from the outside, the lock 9 must be operated by the key 21, whereby the arm 7 pivots and is disengaged from the retaining member 1 and, in the embodiment of FIGS. 1-4, the arm 7 must be retained in this position and any other lock of the door must be operated to open the door, whereas in the embodiment of FIGS. 5 to 7, once the arm 7 is out of the zone A, it is retained in this position by resting on the edge 34 of the retaining member, as shown in the dotted line in FIG. 5.
In the embodiment of FIGS. 1 to 4, when the door 5 has been freely opened, the retaining member 1 returns on its own to the closed position, requiring it to be reopened by hand to be able to close the door. The said retaining member 1 automatic holding means, illustrated in FIGS. 5 to 7, mean that when the door 5 is opened, the retaining member 1 rotates until the edge of its cut-away portion 32 is engaged by the tooth 31 of the lever 27, whilst when the door is thereafter closed, the extension 33 on the door 5 or on the support plate pushes the lever 27 against its biasing spring 30, whereby the retaining member 1 is freed and is biased once again against the inner surface of the door. | A safety door fastening is disclosed, comprising a rigid retaining member pivotably attached to the door frame and a catch member attached to the door and having a terminal member adapted for sliding in a longitudinal space in the retaining member, to retain the latter and limit the angle of opening of the door, the retaining member having resilient means biasing it against the inner face of the door. It is possible to operate the catch member from the outside to disengage it from the retaining member. | 4 |
BACKGROUND
The core refractive index profile of a graded-index multimode preform and the fiber made thereof is characterized mainly by three parameters. These parameters are core diameter, maximum refractive index difference between the core and the cladding, and the profile of the refractive index of the core. A graded-index profile is generated by depositing a certain number of core layers. In order to optimise the graded-index profile, it is helpful to enhance the number of single layers to minimize the refractive index structures in the radial direction. By enhancing the number of core layers, the productivity of the deposition process is decreased. Conventionally the core layers are produced by a vapour deposition process, e.g. modified chemical vapour deposition (MCVD), plasma inside/outside vapour deposition (PIVD/POVD) or outside vapour deposition (OVD).
The MCVD process uses a layer specific precursor composition to achieve a desired refractive index profile. The gases in the composition react within a hot zone to dope glass and deposit it on the inner surface of a tube. At the start of the process, a burner is located at the inlet part of the tube. There are different chemical reaction and deposition conditions at the tube opening than in the middle or at the end of the tube. The opening region has changing core diameter and refractive index profile and is called the preform taper. The preform taper is a section of the tube where the gas composition enters the tube and this section is characterized by non-uniform and non-constant optical and geometrical properties. Depending on the process parameters used, the taper can typically have a length of 20 to 40 cm including the geometric and the profile taper. Within the profile taper, the refractive index profile can be described in first approximation by the profile exponent (also referred to as the alpha value). In general, the preform and fiber parameters of the taper region are so different and uncontrolled, that it is often not possible to use the fibers obtained from this preform region.
Glass soot is generated inside of the tube by an outer heat source in the MCVD process. This soot is deposited along the inner tube wall. Due to certain reaction, transport and deposition mechanisms using a homogenous gas phase reaction, a particular deposition course is generated along the tube. This soot deposition course is called a deposition function after the soot has been consolidated to transparent glass layers. The local changing single layer thickness and single layer refractive index at the inlet part of the deposition tube results in a need to reduce the preform taper.
Information relevant to attempts to address the problems described above can be found in the references described below.
German patent DE 60000283 T2 discloses a method for making a preform having a defined refractive index profile using a controlled reactive gas composition in a chemical vapor deposition (CVD) process. In addition to the composition (concentration of dopands), the velocity of the gas is aligned to reduce deviations in the refractive index profile. The criteria for optimisation is the deviation of the measured refractive index profile from the predetermined refractive index profile. The correction of the measured refractive index profile is carried out by adjusting the composition of the reactive gases as a function of time during the deposition process. To increase the accuracy of the profile measurements and the quality of corrections, the preform measurement is carried out at certain axial tube positions and angles. Additional preforms can be used to calculate a mean deviation.
The method described in DE 60000283 T2 yields unsatisfying results because the correlation of local and temporal profile deviations and the composition of the reactive gases is not acceptably precise. The mass flow controller typically used in dosing units bears only discrete adjusting possibilities and often has a time delay of some seconds. This is typically considered to be quite slow. In addition, there are effects on concentration mixing starting in the origin of the precursors, typically an evaporator, over the pipework up to the deposition area. By these mixing effects, mostly dopand diffusion, turbulent gas flow in the pipework, the modification of the gas composition is not sharp and the resulting profile correction is locally imprecise.
Another method for a correction of the refractive index profile based on preform as well as fiber profile measurements is described in U.S. published application U.S. 2011/0044596 A1. The given index profile is defined on the preform or based on the profile of the fiber. In this method, deviations of the refractive index profile are converted into changes of gas compositions and used in the CVD-process. The reaction time in the hot zone can be influenced by the velocity of the gases. Since the conversion of refractive index deviations to changes in the volume of the reacting gases can only be approximated, it is necessary to run several iteration cycles to obtain the desired refractive index profile.
In United Kingdom patent GB 2118165 A, a method to reduce the geometrical taper of preforms is described. A smaller geometrical taper is essential for good fiber quality but is not sufficient. A non-linear course of the support speed along the tube length is disclosed, which is optimised in an iterative manner.
Another known method for the profile correction of preforms built up by single layers in an inside/outside deposition process includes the variation of the gas flows of the precursor halides to reduce systematic deviations of single layer thickness and/or concentration. It has been shown that by controlling the gas flows, only locally indistinct layer thickness and refractive index changes can be employed. This is based on the time delay of the mass flow controllers, the mixing effects in the pipework from the evaporator to the reaction zone and turbulent gas flows through the reaction tube system. It is generally difficult to achieve locally precise changes in refractive index or layer thickness.
There remains a need for improved methods for the manufacture of graded-index multimode preforms particularly to reduce the front preform taper range
SUMMARY
The present inventions are directed to methods for making graded-index multimode preforms using inside deposition. One method for the making of a preform for a gradient-index multimode fiber uses a novel inside deposition process. The inside deposition process begins with a refractive index profile correction method that is carried out iteratively. First, a target refractive index profile for the preform is determined. A number of layers are deposited using inside deposition with fixed volume flows for the reacting gases and with fixed burner speeds for all deposited layers. The deposited tube is then collapsed and the resulting refractive index profile is measured. The measured profile is compared to a target profile and correction values are calculated. The correction values are converted into corrected burner speeds. The inside deposition is then performed with another tube. The inside deposition is performed with fixed volume flows for the reacting gases and corrected burner speeds for each individual deposited layer.
It is an object of this invention to describe a method for the production of a graded-index multimode preform, where a profile correction can be carried out precisely and reliably with minimized investment in labor and devices.
In a first embodiment, in a first step, a target refractive index profile for the preform to be produced is provided. In a second step, an inside deposition process is carried out with fixed volume flows of the reacting gases and a fixed burner speed along the tube length for all layers to be deposited. The tube is then collapsed and the actual refractive index profile is measured. A comparison of the target and actual refractive index profile is carried out and a correction values for the index profile are obtained. These correction values are converted into changes to the speed of the burner from layer number to layer number for different tube length positions. The burner speed values are the parameters varied. In a consecutive step, the inside deposition is repeated with the fixed gas volume flows and the corrected burner speeds. This process is repeated iteratively.
A benefit of the methods described herein is a correction the refractive index profile of the optical fiber. This is accomplished by varying the speed of the burner while keeping the gas flow volumes constant. In contrast to conventional art where the deviations are corrected by gas flow changes, which cannot be controlled precisely, in the methods disclosed herein, the correction is carried out by changing the speed of the burner, which can be controlled more precisely. Furthermore, it has been shown that there is an explicit and simple formula for the correlation between burner speed and the refractive index profile. Application of these methods employing this correlation reduces the number of trial runs based on experience and individual know-how.
In a preferred embodiment of the correction method, the measurement of the refractive index is carried out along the length of the collapsed preform. A deviation between the target refractive index and the measured refractive index in the taper range is calculated for each axial position of the preform. Furthermore a control of the quality of the refractive index over the complete length of the preform is possible.
In an alternative embodiment, the change in the burner speed results in a varying thickness of the single layers, but the sum of the thicknesses of the single layers is kept constant. In this method, an adjustment of the profile exponent of the graded refractive index profile is achieved.
In another embodiment, a deposition function depending on the sum of gas flows is used by calculating the correction function for the burner speed, whereas the maximum thickness of the deposition function is used to calculate the thickness of every single layer locally dependent. The deposition function describes the deposition rate in the hot zone of the burner by implementing the flowing reaction gases, the axial burner temperature profile and the burner speed.
It is particularly preferred to use the method described above for corrections of refractive index profiles which show a radial dependence dn/dr<0, i.e., a continuously decreasing refractive index when the radius increases.
The present inventions together with the above and other advantages may be understood from the following detailed description of the embodiments of the inventions illustrated in the drawings, wherein:
DRAWINGS
FIG. 1 shows a graded refractive index profile with a profile exponent of α 0 =2.07 of a fiber according to one embodiment;
FIG. 2 shows a graded refractive index profile with a profile exponent of α 0 =2.09 of a fiber according to an alternative embodiment;
FIG. 3 shows a course of a normalized single layer area for a target profile exponent of α 0 =2.07 and a measured profile index of α 0 =2.09 according to a further alternative embodiment; and
FIG. 4 shows an illustrative deposition function according to principles of the inventions.
DESCRIPTION
The refractive index profile correction methods according to these inventions aim at reducing the geometrical taper as well as the profile taper. By a specific course of the burner speed in the taper region, which is commonly equal for all core layers, it is possible to reduce the geometrical taper only. This taper is the sum of the tapers of all single layers and can be improved by adjusting the burner speed for all single core layers in the same manner at each taper position.
To reduce the profile taper in the production of graded-index multimode preforms and fibers too, the consistency of the burner speed in all core layers at one axial position has to be considered. It is otherwise supposed, that every single layer is produced with a unique burner speed course.
The present methods for making profile corrections are not limited to corrections in the taper region but can be used in all profile deviations along a substrate tube in the axial as well as the radial direction. To ensure uniqueness within the profile correction, it is desirable to have a refractive index profile dn/dr<0. It is therefore assumed, that the core refractive index within the preform is monotonically decreasing with increasing core radius.
The correction methods according to the inventions achieve a profile correction by varying the thickness of the core layer in radial direction or over the numbers of the core layers. Furthermore, there is a possibility of reducing or even eliminating small profile deviations along the length of the preform. A change in layer thickness is a result of the variation of the burner speed. This change can be realized in a short time period, even within a fraction of a second. So it is possible to optimise the refractive index profile even if the deviations and/or inhomogeneities are situated in very close proximity.
The methods are described based on an example of a graded-index profile. At the beginning of a correction run, there are constant single layer areas at every core layer in the radial and the axial directions.
Under these conditions, the normalized radial position of the single layers can be described based on the assumption of constant single layer areas as:
r k /a=√ ( k/k max )
where r k /a is the relative radius position of the deposited k th core layer within the preform, k is the running number of the core layer, k max is the maximum number of core layers, and a is the core radius within the preform.
The refractive index profile of a graded-index multimode fiber is commonly described by the following profile function:
Δn k =Δn max *[1−( r k /a ) α ]
where Δn k is the refractive index of the k th layer at the relative radial position r k /a, a is the core radius of the preform, Δn max is the maximum refractive index difference between the core center and the cladding of the preform, and α is the profile exponent.
As an example, the profile exponent of an ideal refractive index profile with a constant layer thickness is α 0 =2.07. Such a refractive index profile is shown in the diagram in FIG. 1 . The diagram points out the refractive index difference Δn k of the k th core layer with respect to the normalized radius r k /a. Under these conditions, the k th core layer with a radius r k yields a refractive index difference Δn k with the course shown in FIG. 1 .
If the profile exponent α changes, e.g. from α 0 =2.07 to α 1 =2.09, the refractive index difference Δn k of the k th layer results in a new radial position r′ k . FIG. 2 shows the refractive index profile which has been altered accordingly. The refractive index difference Δn k of the k th layer with respect to the normalized radius r k /a with a profile exponent α 1 =2.09 is depicted.
The calculation of the new normalized core radius r′ k /a of the k th core layer is carried out according to:
r′ k /a =exp[ln(1−Δ n k /Δn max )/α 1 ]
The resulting change in the single layer area is shown in FIG. 3 . The diagram shows the course of the normalized single layer areas for a profile exponent correction with a target α 0 =2.07 and a measured value of α 1 =2.09, where the numbering of the core layers starts from the center of the core. It is shown that the profile correction is to be carried out in such a way that core layers which are situated closer to the center of the core should be built thicker and outer core layers should be built thinner. As boundary conditions for the correction, it is practical for the change in the single layers thicknesses to be carried out in a way that the sum of the single layer thicknesses and the core radius of the preform are not affected and that only the profile parameter α is corrected.
In a next step of the correction method, the calculated correction values for the core layer areas and therefore the layer radii r k are converted into corrected values for the burner speed. The burner speed therefore constitutes the variable parameter for the correction method.
The core layer area of the k th core layer F k is proportional to the radius r k of the k th core layer and their individual thickness d k . If it is assumed that the cross-section area of each deposited core layer can be described as a circular ring. The core layer area F k and the change in the core layer area is correlated to the burner speed during the deposition process by the following relationship:
Δ V B,k =−V B,k *ΔF k /F k
where ΔV B,k is the correction value of the burner speed of the k th core layer, V B,k is the burner speed of the k th core layer, ΔF k is the correction value of the k th core layer area, and F k is the k th layer area. From the given formula, it can be seen that a positive correction ΔF k of the core layer area results in a negative correction ΔV B,k of the burner speed. The core layer area increases with a reduced burner speed and decreases with an increased burner speed.
The correction method is carried out by producing a first preform and measuring the refractive index profile in a second step. This actual refractive index profile is compared with the target profile and the correction values for single radii r k or single layer thickness d k are calculated. These values can be converted to corrected values ΔF k and further to corrected values for the burner speed ΔV B,k . These corrected burner speed values ΔV B,k are transferred to a control unit for the burner speed, and then can be used as the burner speed values for the next preform production. Usually this second preform has a minimized profile exponent deviation, which is within specified tolerances.
A refinement of the correction methods can be achieved by including the deposition function f in the correction. An exemplary deposition function is shown in FIG. 4 . The local position of the burner is labelled by x 0 . The zone which is heated by the burner contains an interval which is labelled B in the diagram. In the given example the burner moves from the right side to the left and the reacting gases flow through the inside of the tube from the right side to the left as well. The deposition function f bears an asymmetric shape. This asymmetry is mainly based on the direction of the reacting gas volume flow and the direction of movement of the burner. A displacement of the burner to the left and the deposition function is displaced accordingly. Furthermore the direction in which deposition can take place is predetermined by the direction of the reacting gas volume flow. The particles to be deposited cannot move against the gas flow direction, but do always move with the gas flow.
With a correction to the k th core layer area, the deposition region downstream of the burner region is broadened locally, while the delivered reaction gas as well as the glass material are deposited in different regions with varying deposition efficiency. The deposition function accounts for this local deposition rate. Due to the local broadening of the deposition function an effective core layer area change results with respect to the overall gas flow through the tube with a maximum approximately 5 to 15 cm downstream of the burner position. This local broadening of the deposition function downstream of the burner position is specific for inside-deposition processes and modifies the profile correction. The deposition function f k (x,t) for the k th core layer accounts for the deposition profile in proximity to a position x in the preform and further to the temporal displacement of the burner. Therefore, it is correlated to the position and time.
The asymmetry of f k (x,t) takes into account the increased deposition rates downstream.
The method for changing the radial profile shape is not limited to profile changes which can be described by a profile exponent change. In contrast a wide variety of profile shape with dn/dr<0 can be corrected by controlled changes to the single layer thickness.
It is to be understood that the above-identified embodiments are simply illustrative of the principles of the inventions. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the inventions and fall within the spirit and scope thereof. | Methods for making a preform for a graded-index multimode fiber by using an inside deposition process are disclosed. The methods are characterized by an iterative refractive index profile correction with the following steps: determining a target refractive index profile for the preform to be produced, carrying out an inside deposition process with fixed volume flows for the reacting gases inside a tube and a given burner speed for all deposited layers, collapsing the tube and measuring the actual refractive index profile, comparing the target profile with the actual profile and calculating a correction value of index differences, converting this correction value in corrected burner speeds as varying process parameter, carrying out a inside deposition process with fixed gas flows and corrected burner speeds for all layers to be deposited. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Submission Under 35 U.S.C. 371 for U.S. National Stage Patent Application of, and claims priority to, International Application Number PCT/CN2011/081712 entitled THICK CLEANING COMPOSITION, filed Nov. 3, 2011, which is related to and claims priority from Chinese Patent Number 201010553162.X, filed Nov. 22, 2010, the entirety of all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a thick cleaning composition, in particular to a thick liquid crystal cleaning composition for cleaning skin, eyes, teeth and hair in the field of personal care products.
BACKGROUND OF THE INVENTION
Cleaning compositions for decontaminating and cleaning skin, eyes, teeth and hair generally contain various surfactants for the purpose of cleaning and decontamination. In order to further improve foaming and cleaning effects of a cleaning composition, more than one surfactant is often added. A certain amount of a solvent, especially water or a mixed solvent of water and polyols, is also often used in a cleaning composition to dissolve surfactants and active ingredients, thus allowing easier use of the product. Although it is not essential to selectively add beautifying and cleaning adjuvants, more than one beautifying and cleaning adjuvants are also added so as to achieve the usability of a cleaning composition in the field of personal care products.
Cleaning and decontamination alone are not enough for a cleaning composition, and consumers wish to buy a cleaning composition with thick appearance. Consumers think that a thick cleaning composition is a product with fine performance and higher active matter content, and therefore believe that it is safe and cost-effective. Meanwhile, a thick cleaning composition can be packaged in a hose or a similar packaging container such that the cleaning composition will not flow out like water when the hose cap is opened. A thick cleaning composition is beneficial to reducing packaging cost for manufacturers, while convenient to use and carry for consumers.
Most of the traditional thick cleaning compositions currently available on the market are those compositions with high-content fatty acid soap as a major component, such as “a stable foaming cream” with fatty acid soap as a major component described in EP1166747 filed by Oreal. But thick cleaning compositions with fatty acid soap as a major component have a higher pH value (usually the pH value is 9-11), which will cause skin allergy, redness and swelling, and hair damage to some consumers. From the perspective of safety, cleaning compositions with fatty acid soap as a major component have no substantial progress over bar soap with regard to use safety of consumers.
In the art, to produce a thick cleaning composition with a pH value in a neutral or weakly acidic range, various associating thickening components are commonly used in its formula to achieve the purpose of product thickening. Associating thickening components are mainly associating polymers, which are usually polymers with hydrophilic groups and hydrophobic groups formed by grafting a small number of hydrophobic groups such as alkyl chains and alkyl oxyethyl chains to water-soluble polymers. Hydrophobic groups in surfactants and hydrophobic groups in associating polymers associate with each other in the presence of the surfactants due to mutual association of the hydrophobic groups, and then the surfactants form micelles (like strings of small water droplets on a cobweb) on or near chains of the associating polymers, thus increasing the viscosity of the cleaning composition due to this association. Such associating polymers, such as a hydrophilic amphoteric polymer described in WO00/39176 filed by Bfgoodrich Co., are used as components in personal care products to achieve the purpose of thickening and rheology modification.
Cleaning compositions using associating polymer components have very obvious disadvantages as follows: thick cleaning compositions will often be adhered to skin and hair surfaces during use such that they are difficult to be spread out, and the cleaning compositions will have large viscosity change due to the influence of temperature change, thus they look like fruit jelly in winter but are as thin as water in summer. In particular, the cleaning compositions are not easy to be spread out when used in winter, thus affecting foaming speed and foaming effect thereof. For cleaning compositions, foaming speed and foaming effect belong to another important factor for consumers to evaluate product quality. Accordingly, consumers are not satisfied with and can not accept the cleaning compositions using associating thickening components.
SUMMARY OF THE INVENTION
Through extensive and in-depth study, the inventors have surprisingly found that surfactant lyotropic liquid crystal phase is induced to be formed when long-chain fatty acyl acidic amino acid esters and fatty compounds are used together. Since stable liquid crystal phase is formed in a cleaning composition, the amount of surfactants to be used can be reduced, and the cleaning composition is advantageously characterized by high consistency, good thixotropy, rapid foaming and good foam quality. The inventors complete the invention on the above basis.
Composition
The inventor provides a thick cleaning composition, comprising the following components (a), (b), (c) and (d) based on weight percentage:
a component (a): one or more long-chain fatty acyl acidic amino acid esters, which accounts for 0.01%-30% of the cleaning composition based on weight percentage;
a component (b): one or more fatty compounds selected from fatty acids, fatty alcohols, fatty alcohol ethers or polyol fatty acid esters, which accounts for 0.1%-50% of the cleaning composition based on weight percentage;
a component (c): one or more surfactants, which accounts for 1%-80% of the cleaning composition based on weight percentage; and
a component (d): a solvent composed of one or more substances selected from water, lower alcohols, polyols and polyol ethers, which accounts for 10%-90% of the cleaning composition based on weight percentage.
Although claims of the invention particularly indicate and clearly claim the protection scope of “a thick cleaning composition” of the invention, it is to be believed that the invention will be better understood in light of the following description.
The thick cleaning composition provided by the invention is a surfactant lyotropic liquid crystal composition which at least comprises a lamellar phase liquid crystal or (and) a hexagonal phase liquid crystal or (and) a cubic phase liquid crystal.
The thick (or highly viscous) rheological morphology and performance of all surfactant solutions are very dependent on the microstructures of the surfactant solutions, i.e. the type and size of the micelles formed by self-aggregation of the surfactants in the solutions as well as the type of the liquid crystal phase formed. It is well known that the viscosity of a surfactant solution increases linearly with the increase of the surfactant concentration, and spherical micelles and rod-shaped micelles are successively formed. Since the movement of longer micelles is limited, a solution of rod-shaped micelles is more thick.
Liquid crystal phase with long-range order and short-range disorder, such as a lamellar phase liquid crystal, a hexagonal phase liquid crystal and a cubic phase liquid crystal, can be formed by further increasing the concentration of a surfactant in a solution. Description of a “liquid crystal phase” is familiar to those skilled in the art. A “lyotropic liquid crystal” (LCC) is usually a binary or multi-component system formed by a certain concentration of a surfactant in a solvent, which is characterized by both liquid flowability and solid anisotropy. A lamellar phase liquid crystal is a lamellarly arranged structure formed by lamellar micelles of a surfactant as well as a solvent or water. A hexagonal phase liquid crystal is a hexagonal structure formed by rod-shaped micelles arranged in parallel with each other. A cubic liquid crystal is a face-centered cubic or body-centered cubic or simple cubic structure formed by cubically-packed spherical or rod-shaped micelles in a solution. Especially, the hexagonal liquid crystal and the cubic liquid crystal both have much greater viscosity than the surfactant aggregates in the solution in a micellar state.
According to some literature, the formation of a lyotropic liquid crystal from a surfactant is completely determined by the high concentration of the surfactant in a solution and strongly affected by temperature. Brownian motion of the surfactant aggregates is quickened due to temperature rise or temperature change, thus damaging stability of the liquid crystal phase. Generally, for the lyotropic liquid crystal of a surfactant, the liquid crystal phase structure can only be kept stable within a narrow temperature range.
Through extensive and in-depth study, the inventors have surprisingly found that the use of long-chain fatty acyl acidic amino acid esters and fatty compounds together can advantageously induce a surfactant solution to form a stable liquid crystal phase within a wider temperature range and can reduce the amount of the surfactant to be used. Thixotropy and foam quality of the cleaning composition are also improved due to the stable existence of the liquid crystal phase.
There are many methods for identifying the liquid crystal phase of a surfactant solution. For example, an optical polarizing microscope can be used to observe the characteristic optical texture of the liquid crystal. Differential scanning calorimetry can be used to determine the temperature range for the existence of the liquid crystal and the phase-transition temperature by judging whether phase transition occurs. Small angle X-ray scattering can be used to accurately determine the structure of the liquid crystal phase, wherein the structural characteristics of the liquid crystal determine that each liquid crystal has its own characteristic interplanar spacing ratio, and thus the calculation results of Bragg Equation can be used to judge the existence and type of a liquid crystal. 2 H-NMR (nuclear magnetic resonance) can be used to judge the type of a liquid crystal based on the splitting amplitudes of pairs of split peaks resulting from quadrupole splitting of the quadrupole moment of 2 H nucleus in non-homogeneous environment. Freeze fracture electron microscopy can be used to observe the fracture surface of the liquid crystal through an electron microscope so as to determine the structure type of the liquid crystal, wherein the fracture surface is reproduced by platinum-carbon metal deposition.
At present, it is generally accepted that small angle X-ray scattering is the most effective and direct method for determining the existence of a liquid crystal phase and the type of the liquid crystal.
In the thick cleaning composition provided by the invention, the component (a), one or more long-chain fatty acyl acidic amino acid esters, has the following structural characteristics in the structure thereof:
I) an amino acid moiety is derived from acidic amino acids with the number of amino groups less than that of carboxyl groups, i.e. acidic amino acids with 3-8 carbon atoms that have 1 amino group and 2 carboxyl groups in an amino acid structure, including D-type, L-type and DL-type optical isomers thereof.
Specific examples of these acidic amino acids include: aminomalonic acid, aspartic acid, glutamic acid, α-aminoadipic acid, β-aminoadipic acid, α-aminopimelic acid, β-aminopimelic acid, γ-aminopimelic acid, α-aminosuberic acid, β-aminosuberic acid, γ-aminosuberic acid, α-amino-α-methylsuccinic acid, γ-methylglutamic acid, γ-methyleneglutamic acid, etc.
II) a long-chain fatty acyl moiety is linear or branched, saturated or unsaturated fatty acid-derived acyl with 8-22 carbon atoms.
Specific examples of the fatty acid-derived acyl include: acyl of linear saturated fatty acids such as octanoic acid, nonanoic acid, decanoic acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecylic acid, palmitic acid, heptadecanoic acid, steric acid, nonadecanoic acid, arachidic acid, heneicosioc acid and docosanoic acid, branched saturated fatty acids such as butyl-5-methylpentanoic acid, 2-isobutyl-5-methylpentanoic acid, dimethyloctanoic acid, dimethylnonanoic acid, 2-butyl-5-methylhexanoic acid, methylhendecoic acid, dimethyldecanoic acid, 2-ethyl-3-methylnonanoic acid, 2,2-dimethyl-4-ethyloctanoic acid, methyldodecanic acid, 2-propyl-3-methylnonanoic acid, methyltridecanoic acid, dimethyldodecanic acid, 2-butyl-3-methylnonanoic acid, methyltetradecanoic acid, ethyltridecanoic acid, propyldodecanic acid, butylundecanoic acid, pentyldecanoic acid, hexylnonanoic acid, 2-(3-methylbutyl)-3-methylnonanoic acid, 2-(2-methylbutyl)-3-methylnonanoic acid, butylethylnonanoic acid, methylpentadecylic acid, ethyltetradecanoic acid, propyltridecanoic acid, butyldodecanic acid, pentylundecanoic acid, hexyldecanoic acid, heptylnonanoic acid, dimethyltetradecanoic acid, butylpentylheptanoic acid, trimethyltridecanoic acid, methylhexadecanoic acid, ethylpentadecylic acid, propyltetradecanoic acid, butyltridecanoic acid, pentyldodecanic acid, hexylundecanoic acid, heptyldecanoic acid, methylheptylnonanoic acid, dipentylheptanoic acid, methylheptadecanoic acid, ethylhexadecanoic acid, propylpentadecylic acid, butyltetradecanoic acid, pentyltridecanoic acid, hexyldodecanic acid, heptylundecanoic acid, octyldecanoic acid, dimethylhexadecanoic acid, methyloctylnonanoic acid, methyloctadecanoic acid, ethylheptadecanoic acid, dimethylheptadecanoic acid, methyloctyldecanoic acid, methylnonadecanoic acid, dimethyloctadecanoic acid, butylheptylnonanoic acid, methylarachidic acid, dimethylnonadecanoic acid, nonyllauric acid, dimethylarachidic acid and hexylhexadecanoic acid, linear monoenoic acids such as octenoic acid, nonenoic acid, caproleic acid, undecylenic acid, lauroleic acid, tridecylenic acid, myristoleic acid, pentadecylenic acid, hexadecenoic acid, heptadecenoic acid, octadecenoic acid, oleic acid and nonadecyenoic acid, branched monoenoic acids such as methylheptenoic acid, methylnonenoic acid, methylundecylenic acid dimethylcaproleic acid, methyldodecenoic acid, methyltridecylenic acid, dimethyldodecenoic acid, dimethyltridecylenic acid, methyloctadecenoic acid, dimethylheptadecenoic acid and ethyloctadecenoic acid, and polyenoic acids such as linoleic acid, linolelaidic acid, linolenic acid, 9,12,15-octadecatrienoic acid, 10,12,14-octadecatrienoic acid, parinaric acid and arachidonic acid; the fatty acid-derived acyl can also include acyl of natural fatty acids such as coconut oil fatty acid, palm oil fatty acid, palm kernel oil fatty acid, corn oil fatty acid, peanut oil fatty acid, cottonseed oil fatty acid, linseed oil fatty acid, sunflower seed oil fatty acid, soybean oil fatty acid, sesame oil fatty acid, castor seed oil fatty acid, olive oil fatty acid, tea-seed oil fatty acid, tallow fatty acid, hydrogenated tallow fatty acid, lard fatty acid and fish oil fatty acid, as well as acyl of a mixture of the above various fatty acids; and the fatty acid-derived acyl is preferably acyl derived from linear fatty acids with 12-22 carbon atoms, such as caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid and docosanoic acid.
) an ester group moiety is monoester, diester or a mixture thereof formed by 2 carboxyl groups of amino acid and saturated or unsaturated, linear or branched fatty alcohols with 8-28 carbon atoms or (and) fatty alcohol ethers thereof with polyoxyalkylene having addition mole number of 1-30.
Specific examples of these linear or branched fatty alcohols forming esters include: fatty alcohols such as octyl alcohol, 2-ethylhexanol, sec-octyl alcohol, isooctyl alcohol, nonanol, sec-nonanol, decanol, iso-decanol, sec-decanol, undecanol, sec-undecanol, 2-methyldecanol, lauryl alcohol, sec-dodecyl alcohol, tridecanol, isotridecanol, myristyl alcohol, sec-tetradecyl alcohol, pentadecyl alcohol, sec-pentadecyl alcohol, cetyl alcohol, palmityl alcohol, sec-hexadecanol, heptadecanol, sec-heptadecanol, stearyl alcohol, isostearyl alcohol, sec-octadecanol, oleyl alcohol, eicosanol, docosyl alcohol, tetracosanol, hexacosanol, octacosanol, 2-butylhexanol, 2-butyldecanol, 2-hexyloctyl alcohol, 2-hexyldecanol, 2-hexyldodecyl alcohol, 2-octyldecanol, 2-octyldodecyl alcohol, 2-octyltetradecyl alcohol, 2-decyldodecyl alcohol, 2-decyltetradecyl alcohol, 2-decylhexadecanol, 2-dodecyltetradecyl alcohol and 2-dodecylhexadecanol, as well as a mixture thereof.
Preferably, the acidic amino acid moiety in the structures of the long-chain fatty acyl acidic amino acid esters is derived from aspartic acid and glutamic acid.
Preferably, the long-chain fatty acyl acidic amino acid esters have acyl of linear saturated fatty acids with 12-18 carbon atoms in the structures thereof.
Preferably, the long-chain fatty acyl acidic amino acid esters have monoester, diester or a mixture thereof formed by linear or branched saturated fatty alcohols with 12-22 carbon atoms in the structures thereof.
The long-chain fatty acyl acidic amino acid esters are selected from one or more of the following esters: N-lauroyl L-aspartic acid cetyl ester, N-lauroyl L-aspartic acid stearyl ester, N-lauroyl L-aspartic acid docosyl ester, N-lauroyl L-glutamic acid cetyl ester, N-lauroyl L-glutamic acid stearyl ester, N-lauroyl L-glutamic acid docosyl ester, N-lauroyl L-glutamic acid isododecyl ester, N-lauroyl L-glutamic acid isotridecyl ester, N-lauroyl L-glutamic acid hexyldecyl ester, N-lauroyl L-glutamic acid isostearyl ester, N-lauroyl L-glutamic acid octyldodecyl ester, N-lauroyl L-aspartic acid isododecyl ester, N-lauroyl L-aspartic acid isotridecyl ester, N-lauroyl L-aspartic acid hexyldecyl ester, N-lauroyl L-aspartic acid isostearyl ester, N-lauroyl L-aspartic acid octyldodecyl ester, N-myristoyl L-aspartic acid cetyl ester, N-myristoyl L-aspartic acid stearyl ester, N-myristoyl L-aspartic acid docosyl ester, N-myristoyl L-glutamic acid cetyl ester, N-myristoyl L-glutamic acid stearyl ester, N-myristoyl L-glutamic acid docosyl ester, N-myristoyl L-glutamic acid isododecyl ester, N-myristoyl L-glutamic acid isotridecyl ester, N-myristoyl L-glutamic acid hexyldecyl ester, N-myristoyl L-glutamic acid isostearyl ester, N-myristoyl L-glutamic acid octyldodecyl ester, N-myristoyl L-aspartic acid isododecyl ester, N-myristoyl L-aspartic acid isotridecyl ester, N-myristoyl L-aspartic acid hexyldecyl ester, N-myristoyl L-aspartic acid isostearyl ester, N-myristoyl L-aspartic acid octyldodecyl ester, N-palmitoyl L-aspartic acid isododecyl ester, N-palmitoyl L-aspartic acid isotridecyl ester, N-palmitoyl L-aspartic acid hexyldecyl ester, N-palmitoyl L-aspartic acid isostearyl ester, N-palmitoyl L-aspartic acid octyldodecyl ester, N-palmitoyl L-aspartic acid cetyl ester, N-palmitoyl L-aspartic acid stearyl ester, N-palmitoyl L-aspartic acid docosyl ester, N-palmitoyl L-glutamic acid cetyl ester, N-palmitoyl L-glutamic acid stearyl ester, N-palmitoyl L-glutamic acid docosyl ester, N-palmitoyl L-glutamic acid isododecyl ester, N-palmitoyl L-glutamic acid isotridecyl ester, N-palmitoyl L-glutamic acid hexyldecyl ester, N-palmitoyl L-glutamic acid isostearyl ester, N-palmitoyl glutamic acid L-octyldodecyl ester, N-stearoyl L-aspartic acid cetyl ester, N-stearoyl L-aspartic acid stearyl ester, N-stearoyl L-aspartic acid docosyl ester, N-stearoyl L-glutamic acid cetyl ester, N-stearoyl L-glutamic acid stearyl ester, N-stearoyl L-glutamic acid docosyl ester, N-stearoyl L-glutamic acid isododecyl ester, N-stearoyl L-glutamic acid isotridecyl ester, N-stearoyl L-glutamic acid hexyldecyl ester, N-stearoyl L-glutamic acid isostearyl ester, N-stearoyl L-glutamic acid octyldodecyl ester, N-stearoyl aspartic acid isododecyl ester, N-stearoyl aspartic acid isotridecyl ester, N-stearoyl aspartic acid hexyldecyl ester, N-stearoyl aspartic acid isostearyl ester and N-stearoyl aspartic acid octyldodecyl ester.
Preferably, the long-chain fatty acyl acidic amino acid esters are selected from one or more than one of the following esters: N-lauroyl L-aspartic acid cetyl ester, N-lauroyl L-aspartic acid stearyl ester, N-lauroyl L-aspartic acid docosyl ester, N-lauroyl L-glutamic acid cetyl ester, N-lauroyl L-glutamic acid stearyl ester, N-lauroyl L-glutamic acid docosyl ester, N-lauroyl glutamic acid isotridecyl ester, N-lauroyl L-glutamic acid isostearyl ester, N-lauroyl L-aspartic acid isotridecyl ester, N-lauroyl L-aspartic acid isostearyl ester, N-myristoyl L-aspartic acid cetyl ester, N-myristoyl L-aspartic acid stearyl ester, N-myristoyl L-aspartic acid docosyl ester, N-myristoyl L-glutamic acid cetyl ester, N-myristoyl L-glutamic acid stearyl ester, N-myristoyl L-glutamic acid docosyl ester, N-myristoyl glutamic acid isotridecyl ester, N-myristoyl L-glutamic acid isostearyl ester, N-myristoyl glutamic acid octyldodecyl ester, N-myristoyl L-aspartic acid isotridecyl ester, N-myristoyl L-aspartic acid isostearyl ester, N-palmitoyl L-aspartic acid isotridecyl ester, N-palmitoyl L-aspartic acid isostearyl ester, N-palmitoyl L-aspartic acid cetyl ester, N-palmitoyl L-aspartic acid stearyl ester, N-palmitoyl L-aspartic acid docosyl ester, N-palmitoyl L-glutamic acid cetyl ester, N-palmitoyl L-glutamic acid stearyl ester, N-palmitoyl L-glutamic acid docosyl ester, N-palmitoyl L-glutamic acid isotridecyl ester, N-palmitoyl L-glutamic acid hexyldecyl ester, N-palmitoyl L-glutamic acid isostearyl ester, N-stearoyl L-aspartic acid cetyl ester, N-stearoyl L-aspartic acid stearyl ester, N-stearoyl L-aspartic acid docosyl ester, N-stearoyl L-glutamic acid cetyl ester, N-stearoyl L-glutamic acid stearyl ester, N-stearoyl L-glutamic acid docosyl ester, N-stearoyl L-glutamic acid isotridecyl ester, N-stearoyl L-glutamic acid isostearyl ester, N-stearoyl L-aspartic acid isotridecyl ester and N-stearoyl aspartic acid isostearyl ester.
More preferably, the long-chain fatty acyl acidic amino acid esters are selected from one or more of the following esters: N-lauroyl L-aspartic acid docosyl ester, N-lauroyl L-glutamic acid cetyl ester, N-lauroyl glutamic acid isotridecyl ester, N-lauroyl L-glutamic acid isostearyl ester, N-lauroyl L-aspartic acid isotridecyl ester, N-lauroyl L-aspartic acid isostearyl ester, N-myristoyl L-aspartic acid stearyl ester, N-myristoyl L-glutamic acid cetyl ester, N-myristoyl glutamic acid isotridecyl ester, N-myristoyl L-glutamic acid isostearyl ester, N-myristoyl L-aspartic acid isotridecyl ester, N-myristoyl L-aspartic acid isostearyl ester, N-palmitoyl L-aspartic acid isotridecyl ester, N-palmitoyl L-aspartic acid isostearyl ester, N-palmitoyl L-glutamic acid stearyl ester, N-palmitoyl L-glutamic acid isotridecyl ester, N-palmitoyl L-glutamic acid hexyldecyl ester, N-palmitoyl L-glutamic acid isostearyl ester, N-stearoyl L-aspartic acid cetyl ester, N-stearoyl L-aspartic acid stearyl ester, N-stearoyl L-glutamic acid stearyl ester, N-stearoyl L-glutamic acid docosyl ester, N-stearoyl L-glutamic acid isotridecyl ester and N-stearoyl L-glutamic acid isostearyl ester.
In the invention, the component (a), the long-chain fatty acyl acidic amino acid ester(s), preferably accounts for 0.1-20% of the cleaning composition based on weight percentage, more preferably 0.2-10% and most preferably 0.5-3%.
In the thick cleaning composition provided by the invention, the component (b): one or more fatty compounds selected from fatty acids, fatty alcohols, fatty alcohol ethers or polyol fatty acid esters.
The fatty acids are linear or branched, saturated or unsaturated fatty acids with 8-22 carbon atoms.
These fatty acids are selected from one or more of the following acids: saturated fatty acids such as octanoic acid, nonanoic acid, decanoic acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecylic acid palmitic acid, heptadecanoic acid, steric acid, nonadecanoic acid, arachidic acid, heneicosioc acid, docosanoic acid, isostearic acid, 2-butyl-5-methylpentanoic acid, 2-isobutyl-5-methylpentanoic acid, dimethyloctanoic acid, dimethylnonanoic acid, 2-butyl-5-methylhexanoic acid, methylhendecoic acid, dimethyldecanoic acid, 2-ethyl-3-methylnonanoic acid, 2,2-dimethyl-4-ethyloctanoic acid, methyldodecanoic acid, 2-propyl-3-methylnonanoic acid, methyltridecanoic acid, dimethyldodecanic acid, 2-butyl-3-methylnonanoic acid, methyltetradecanoic acid, ethyltridecanoic acid, propyldodecanoic acid, butylundecanoic acid, pentyldecanoic acid, hexylnonanoic acid, 2-(3-methylbutyl)-3-methylnonanoic acid, 2-(2-methylbutyl)-3-methylnonanoic acid, butylethylnonanoic acid, methylpentadecylic acid, ethyltetradecanoic acid, propyltridecanoic acid, butyldodecanic acid, pentylundecanoic acid, hexyldecanoic acid, heptylnonanoic acid, dimethyltetradecanoic acid, butylpentylheptanoic acid, trimethyltridecanoic acid, methylhexadecanoic acid, ethylpentadecylic acid, propyltetradecanoic acid, butyltridecanoic acid, pentyldodecanoic acid, hexylundecanoic acid, heptyldecanoic acid, methylheptylnonanoic acid, dipentylheptanoic acid, methylheptadecanoic acid, ethylhexadecanoic acid, propylpentadecylic acid, butyltetradecanoic acid, pentyltridecanoic acid, hexyldodecanoic acid, heptylundecanoic acid, octyldecanoic acid, dimethylhexadecanoic acid, methyloctylnonanoic acid, methyloctadecanoic acid, ethylheptadecanoic acid, dimethylheptadecanoic acid, methyloctyldecanoic acid, methylnonadecanoic acid, dimethyloctadecanoic acid, butylheptylnonanoic acid, methylarachidic acid, dimethylnonadecanoic acid, nonyllauric acid, dimethylarachidic acid and hexylhexadecanoic acid, unsaturated fatty acids such as octenoic acid, nonenoic acid, caproleic acid, undecylenic acid, lauroleic acid, tridecylenic acid, myristoleic acid, pentadecylenic acid, hexadecenoic acid, heptadecenoic acid, octadecenoic acid, oleic acid, nonadecenoic acid, methylheptenoic acid, methylnonenoic acid, methylundecylenic acid, dimethylcaproleic acid, methyldodecenoic acid, methyltridecylenic acid, dimethyldodecenoic acid, dimethyltridecylenic acid, methyloctadecenoic acid, dimethylheptadecenoic acid, ethyloctadecenoic acid, linoleic acid, linolelaidic acid, linolenic acid, 9,12,15-octadecatrienoic acid, 10,12,14-octadecatrienoic acid, parinaric acid and arachidonic acid; and mixed fatty acids derived from natural grease: coconut oil fatty acid, palm oil fatty acid, palm kernel oil fatty acid, corn oil fatty acid, peanut oil fatty acid, cottonseed oil fatty acid, linseed oil fatty acid, sunflower seed oil fatty acid, soybean oil fatty acid, sesame oil fatty acid, castor seed oil fatty acid, olive oil fatty acid, tea-seed oil fatty acid, tallow fatty acid, hydrogenated tallow fatty acid, lard fatty acid, fish oil fatty acid, etc.
Preferably, the fatty acids are linear or branched saturated fatty acids with 12-22 carbon atoms.
The fatty alcohols or (and) the fatty alcohol ethers are linear or branched, saturated or unsaturated fatty alcohols with 8-28 carbon atoms, or (and) fatty alcohol ethers thereof with polyoxyalkylene having addition mole number of 1-30.
The fatty alcohols or (and) the fatty alcohol ethers are selected from one or more of the following: fatty alcohols such as octyl alcohol, 2-ethylhexanol, sec-octyl alcohol, isooctyl alcohol, nonanol, sec-nonanol, 1-decanol, isodecanol, sec-decanol, undecanol, sec-undecanol, 2-methyldecanol, lauryl alcohol, sec-dodecyl alcohol, 1-tridecanol, isotridecanol, myristyl alcohol, sec-tetradecyl alcohol, pentadecyl alcohol, sec-pentadecyl alcohol, cetyl alcohol, palmityl alcohol, sec-hexadecanol, heptadecanol, sec-heptadecanol, stearyl alcohol, isostearyl alcohol, sec-octadecanol, oleyl alcohol, docosyl alcohol, eicosanol, tetracosanol, hexacosanol, octacosanol, 2-butylhexanol, 2-butyldecanol, 2-hexyloctyl alcohol, 2-hexyldecanol, 2-hexyldodecyl alcohol, 2-octyldecanol, 2-octyldodecyl alcohol, 2-octyltetradecyl alcohol, 2-decyldodecyl alcohol, 2-decyltetradecyl alcohol, 2-decylhexadecanol, 2-dodecyltetradecyl alcohol and 2-dodecylhexadecanol; and the fatty alcohol ethers are fatty alcohol ethers of the above fatty alcohols with polyoxyalkylene having addition mole number of 1-30. Preferably, the fatty alcohols or (and) the fatty alcohol ethers are linear or branched saturated fatty alcohols with 12-22 carbon atoms, or (and) fatty alcohol ethers thereof with polyoxyalkylene having addition mole of number 1-7.
The polyol fatty acid esters are polyol fatty acid esters formed by polyols having 2-6 hydroxyl groups and linear or branched, saturated or unsaturated fatty acids having 8-22 carbon atoms.
The polyol fatty acid esters are selected from one or more of the following: glyceryl monostearate, glyceryl dilaurate, ethylene glycol monolaurate, ethylene glycol monostearate, ethylene glycol dilaurate, ethylene glycol distearate, propylene glycol monolaurate, butylene glycol monopalmitate, diglycol dilaurate, diglyceryl dilaurate, trilaurin, glyceryl monopalmitate, tripalmitin, glyceryl tristearate, caprylic-capric triglyceride, diglyceryl monolaurate, diglyceryl distearate, pentaerythritol monolaurate, pentaerythritol tetrapalmitate, pentaerythrityl tetrastearate, pentaerythritol tetraisostearate, methyl gluoside laurate, sorbitol anhydride dioleate, etc.
Preferably, the polyol fatty acid esters are polyol fatty acid esters formed by polyols having 2-6 hydroxyl groups and linear saturated fatty acids having 12-18 carbon atoms.
In the invention, the fatty compounds are preferably selected from one or more of the following: lauric acid, myristic acid, palmitic acid, stearic acid, isostearic acid, docosanoic acid, lauryl alcohol, isotridecanol, docosyl alcohol, glyceryl stearate, trilaurin and pentaerythritol tetrastearate.
In the invention, the component (b), the fatty compound(s), preferably accounts for 0.1%-35% of the cleaning composition based on weight percentage, more preferably 0.5-20%.
In the thick cleaning composition provided by the invention, the component c), the surfactant(s), is selected from anionic surfactants, zwitterionic surfactants, nonionic surfactants and cationic surfactants or a mixture thereof.
Among the surfactants, the anionic surfactants are selected from one or more of the following: carboxylate, alkyl polyoxyethylene ether carboxylate, alkyl sulfate, alkyl polyoxyethylene ether sulfate, alkylamide ether sulfate, alkylaryl polyether sulfate, alkyl sulfonate, alkyl polyoxyethylene ether sulfonate, alkylamide sulfonate, alkylaryl sulfonate, α-alkene sulfonate, petroleum sulfonate, alkyl phosphate salt, alkyl polyoxyethylene ether phosphate salt, acyl isethionate salt, fatty acyl amino acid salt, fatty acyl taurine salt, sulfosuccinate salt, acyl lactate, etc.;
Alkyl or acyl of all the above compounds can be selected from alkyl or acyl containing 8-30 carbon atoms, and aryl can be selected from phenyl or benzyl. The average addition mole number of polyoxyethylene is 2-50 mol. The above salts include alkali metal salts such as potassium salts and sodium salts; alkaline earth metal salts such as magnesium salts; ammonium salts; organic amine salts; alkanolamine salts such as diethanolamine salts, triethanolamine salts and diisopropanolamine salts; or basic amino acid salts such as lysine salts and arginine salts;
The zwitterionic surfactants are selected from one or more of the following: alkyl betaine; alkylamide betaine; sulphobetaine; sulfite and sulfate betaine; phosphinate and phosphonate betaine; phosphite and phosphate betaine; imidazoline amphoteric surfactants: amphoteric acetate and amphoteric propionate; amino acid type amphoteric surfactants: long-chain alkyl amino acid salt, N-alkyl polyamine ethyl glycinate, alkyl polyamine polyamino acid salt, etc.;
The nonionic surfactants are selected from one or more of the following: fatty glyceride polyoxyethylene ether; alkyl phenol polyoxyethylene ether; fatty acid polyoxyethylene ester; alkanolamide; polyoxyethylene alkanolamide; polyoxyethylene sorbitan fatty acid ester; polyoxyethylene fatty acid xylitol ester, alkyl glycoside, etc.; and
The cationic surfactants are selected from one or more of the following: long-chain alkyl trimethyl ammonium halide; long-chain alkyl dimethyl benzyl ammonium halide; long-chain amide alkyl dimethyl benzyl ammonium halide; di(long-chain amide alkyl)dibenzyl ammonium halide; imidazoline quaternary ammonium salt; alkyl pyridinium salt, etc.
Preferably, the surfactants are anionic surfactants.
In the invention, the component (c), the surfactant(s), preferably accounts for 5-50% of the cleaning composition based on weight percentage, more preferably 10-40%, and most preferably 15-25%.
In the thick cleaning composition provided by the invention, the component d) is selected from water, lower alcohol, polyol and polyol ether; and the component d) is selected from one or more of the following: pure water, distilled water, deionized water, mineral water, ethanol, propanol, isopropanol, ethylene glycol, polyethylene glycol with different molecular weight, diethylene glycol, propylene glycol, polypropylene glycol with different molecular weight, dipropylene glycol, glycerol, polyglycerol, maltitol, sorbierite, etc.
In the invention, the solvent preferably accounts for 35-80% of the cleaning composition based on weight percentage, more preferably 55-80%.
During preparation of the cleaning composition, various traditional beautifying or cleaning adjuvants can be added without affecting stability according to the end use.
The thick cleaning composition provided by the invention can also comprise one or more beautifying and cleaning adjuvants for skin, eyes, teeth and hair, i.e. rheology modifiers, humectants, polymers, superfatting agents, saccharides, powders, siloxane, pearlescing agents, pH regulators, opacifiers, special ingredients of cosmetics and therapeutic cosmetics, preservatives, chelating agents, antimicrobial agents, antioxidants, dye or essence.
Various traditional beautifying and cleaning adjuvants are only auxiliary materials of the invention, but for further understanding and describing the examples, these additives are exemplified as follows:
The rheology modifiers: hydrophobically modified associating polymers, hydrophobically modified non-ionic polyols, cellulose derivatives, etc. The rheology modifiers which are used in a small amount for the purpose of thickening are especially beneficial for further realizing the object of the invention. For example, the rheology modifiers include PEG-120 methyl glucoside dioleate, PEG-150 pentaerythritol tetrastearate, PEG-75 dioleate and PEG-150 distearate.
The humectants: sodium chondroitin sulfate, sodium hyaluronate, sodium adenosine phosphate, sodium lactate, pyrrolidone carboxylate, etc.;
The polymers: polyvinylpyrrolidone, etc.;
The superfatting agents: animal and vegetable fat derivatives, fatty acid esters, etc.;
The saccharides: maltose, glucose, fructose, etc.;
The powders: modified or unmodified silicon dioxide, bentonite, diatomite, modified starch, lauroyl lysine, etc.;
The siloxane: dimethyl siloxane, etc.;
The pearlescing agents: ethylene glycol monostearate, ethylene glycol distearate, etc.;
The pH regulators: citric acid, fruit acid, potassium hydroxide, sodium hydroxide, triethanolamine, etc.;
Special ingredients of cosmetics and therapeutic cosmetics: vitamins, various plant extracts, etc.;
The opacifiers: styrene/acrylate copolymers, etc.;
The preservatives: phenoxyethyl alcohol, methyl p-hydroxybenzoate, etc.;
The chelating agents: disodiumedetate, etc.;
The antimicrobial agents: zinc pyrithione, chloroxylenol, etc.; and
The antioxidants: butylated hydroxytoluene, etc.
Detailed notes of these traditional beautifying or cleaning adjuvants can be seen in Cosmetics, Science and Technology by Sagarin, etc. The variety and number of various traditional beautifying or cleaning adjuvants that can be used in the cleaning composition are too numerous to be exemplified one by one, and all the adjuvants can be added so long as they would not affect the stability of the cleaning composition.
The functions and functional mechanism of various components of the cleaning composition of the invention are as follows:
Surfactants and solvents play the role of cleaning and decontamination in the cleaning composition.
The function of the long-chain fatty acyl acidic amino acid esters and the fatty compounds in the cleaning composition is to induce “micelles” formed by the surfactants and the solvents to transform towards the required “liquid crystal phase” (stable liquid crystal phase can not be formed by using the fatty compounds alone), thus the cleaning composition becomes a “toothpaste-like” thick cleaning composition with “good rheological property”.
The above “good rheological property” means that fluid has thick apparent viscosity and good thixotropy, wherein thixotropy refers to easy daubing and quick foaming during use of the cleaning composition.
The above term “toothpaste-like” means that viscosity is more than 10,000 cps (centipoise).
Preparation Method
The production process of the invention is a method commonly used by those skilled in the art, which is briefly described as follows: in a container equipped with stirring paddles (the stirring paddles can be anchor-type, frame-type, spiral push-type, etc.) as well as a jacket or metal coil heating and cooling system, a solvent (usually a mixed solvent of water, polyols, etc.) is first added, heating is started, the container is slowly heated to about 60° C., then other various components are sequentially added (except volatile components, preservatives and essence), the container is slowly heated to about 80° C. during stirring, and stirring is started and the temperature is kept at about 80° C. for 3 hours. After full stirring is confirmed and relevant indexes are met, a cooling system is started for cooling to about 40° C., and then volatile components, preservatives and essence are added and fully mixed before the body is discharged.
The component b), the fatty compounds, can also be pre-added to any one of the surfactants, solvents, beautifying and cleaning adjuvants, and stirred and mixed.
Key performance indicators of the cleaning composition of the invention include viscosity, foamability, pH, etc. of the cleaning composition.
Viscosity:
Viscosity of the cleaning composition of the invention is more than 10,000 cps.
Viscosity test is performed by DV-II+Pro Rotor Viscometer of Brookfield
Company (TC rotor, 10 rmp), and measurement is performed at three temperature points 5/25/45.
Evaluation of Foamability:
Ten trained volunteers use cleaning compositions to perform washing test, wherein each volunteer first wets both hands with clean water, places 2 g of a cleaning composition on the left palm and adds a proper amount of water to the palm, rubbing for 30 seconds according to their usual washing habits, and gives assessment according the following grade standard.
5 scores: very easy to foam by rubbing.
4 scores: easy to foam by rubbing.
3 scores: ordinary foaming speed by rubbing.
2 scores: relatively difficult to foam by rubbing.
1 score: very difficult to foam by rubbing.
The assessed scores are added together, and each composition is graded according to the following standard.
Grade A: 45 scores
Grade B: 35-44 scores
Grade C: 25-35 scores
Grade D: below 25 scores
pH Test:
A Mettler pH tester is used to test pH value of 10% aqueous solution of the cleaning composition.
Stability Evaluation:
The cleaning compositions of the invention are respectively placed in 60° C. and 45° C. ovens as well as 5° C. and −15° C. refrigerators for 6 months, and then the body state is visually observed and the viscosity at various temperature points is retested.
Differential scanning calorimetry (DSC) is used to judge temperature range and phase-transition temperature of liquid crystal phase.
Identification of Liquid Crystals:
Small angle X-ray scattering (SAXS) technology is used to identify liquid crystals.
The small angle X-ray scattering technology can be used to accurately judge the specific liquid crystal morphology of lyotropic liquid crystals. The lyotropic liquid crystals are periodic structures with long-range order formed after oriented arrangement of amphiphilic molecules in solvents. Since electron cloud densities of solvents and amphiphilic molecules are different, the small angle X-ray scattering technology can be used to determine the structure of liquid crystal phase and calculate lattice parameters. According to Bragg Equation 2d sin θ=nλ, interplanar spacings of liquid crystal phases with different morphologies have different proportional relations, scattering vectors corresponding to various levels of Bragg peaks on the SAXS curves have different proportions, and the specific morphology of liquid crystal phase of lyotropic liquid crystals can be distinguished based on different proportions.
Use
The thick cleaning composition provided by the invention is used for the purpose of cleaning skin, eyes, teeth and hair. Specifically, the examples include facial cleansers, facial washes, paste shampoos, hair conditioners, toothpastes, etc.
The invention further provides a new use of the long-chain fatty acyl acidic amino acid esters for inducing formation of liquid crystals, especially for inducing formation of surfactant lyotropic liquid crystals, preferably formation of at least one of the following liquid crystals: the lamellar liquid crystal, the hexagonal liquid crystal or the cubic liquid crystal.
The above features mentioned in the invention or features mentioned in the examples can be combined in any way.
The main advantages of the invention are as follows:
After adopting the above technical measures, the invention has the following benefits: the thick cleaning composition can achieve satisfactory thick appearance when used for cleaning skin and hair, can maintain relatively stable viscosity at different temperature conditions, and is easily daubed and quickly foamed with good foaming quality when used by consumers. The cleaning composition can form thick and stable appearance at a wide range of pH conditions, and is especially suitable for formulating cleaning compositions with low irritability and high safety which have neutral and weakly acidic pH.
BRIEF DESCRIPTION OF THE DRAWINGS
Small angle X-ray scattering results herein are determined by SAXsess X-ray Scatterometer manufactured by PANalytical B.V., Holland.
FIG. 1 shows the results determined by small angle X-ray scattering for the cleaning composition provided by Example 4 of the invention. In the figure, X axis represents scattering vector q corresponding to scattering peaks, and Y axis represents the intensity of the scattering peaks. FIG. 1 shows that after determination by the small angle X-ray scattering, the ratio of the scattering vectors corresponding to levels 1, 2 and 3 scattering peaks q1:q2:q3 is equivalent to 1:2:3 in the composition provided by Example 4 of the invention. This shows that the cleaning composition is a liquid crystal structure with lamellar phase.
FIG. 2 shows the results determined by the small angle X-ray scattering for the composition provided by Example 20 of the invention. In the figure, X axis represents scattering vector q corresponding to scattering peaks, and Y axis represents the intensity of the scattering peaks. FIG. 2 shows that after determination by the small angle X-ray scattering, the ratio of the scattering vectors corresponding to levels 1, 2 and 3 scattering peaks q1:q2:q3 is equivalent to 1:√{square root over (2)}, √{square root over (4)} in the composition provided by Example 20 of the invention. This shows that the cleaning composition is a liquid crystal structure with hexagonal phase.
FIG. 3 shows the differential scanning calorimetry results of the composition provided by Example 20 of the invention, and the DSC thermogram is obtained by measurement with DSC8000 Differential Scanning Colorimeter from PerkinElmer, USA. In the thermogram, X axis represents temperature, and Y axis represents rate of heat flow. It can be seen from the DSC thermogram that the liquid crystal phase of the thick cleaning composition obtained according to Example 20 of the invention stably exists at the temperature ranging from about 2° C. to 55° C.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be further described below in conjunction with the specific examples. It should be understood that these examples are only used for describing the invention, rather than limiting the scope of the invention. In the following examples, the experimental methods with no specific conditions indicated are implemented according to normal conditions or conditions suggested by manufacturers.
Unless otherwise indicated, various components are given by chemical names, or names of INCI (International Nomenclature of Cosmetic Ingredients) well-known in the art.
In the examples and comparative examples, the number of a component refers to weight percentage of the corresponding component in the example. See Table 1.
The unit of weight-to-volume percentage (w/v %) in the invention is well known by those skilled in the art. For example, it refers to the weight of a solute in 100 ml solution.
Unless otherwise defined, all the professional and scientific terms used herein have the same meanings well-known by those skilled in the art. In addition, any method and material that is similar or equivalent to the recorded content can be used in the method of the invention. The preferred implementation methods and materials as described herein are only used for demonstration.
Examples 1-20
TABLE 1
Comparative
Description
Chemical names of components
Example 1
Example 1
Example 2
Example 3
Component
N-lauroyl L-aspartic acid cetyl ester
/
1.5%
8%
/
a)
Component
N-lauroyl L-aspartic acid stearyl ester
/
2.5%
/
/
a)
Component
N-lauroyl L-aspartic acid docosyl
/
/
/
8%
a)
ester
Component
N-lauroyl L-glutamic acid cetyl ester
/
/
2%
/
a)
Component
Lauric acid
/
2%
1%
1%
b)
Component
Myristic acid
/
3%
/
/
b)
Component
Palmitic acid
/
/
1%
1%
b)
Component
Glyceryl stearate (monoester content
/
7%
1.5%
1.5%
b)
of more than 90%)
Component
Sodium polyoxyethylene 2EO lauryl
25%
25%
25%
25%
c)
ether sulfate
Component
Sodium cocoyl sarcosinate
2%
2%
2%
2%
c)
Component
Coco amidopropyl betaine
5%
5%
5%
5%
c)
Component
Cocodiethanolamide
3%
3%
3%
3%
c)
Component
Propanetriol
15%
15%
15%
15%
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
16300
34500
51040
47400
Viscosity at 25° C. (centipoise)
2750
32020
45080
41200
Viscosity at 45° C. (centipoise)
1200
30160
42200
38100
Evaluation of foamability
A
A
A
A
pH value
6.7
7.0
6.8
7.1
In Table 1, the components a) and b) of the invention are not added in Comparative Example 1. In spite of good foaming, the viscosity is very low at normal temperature and high temperature. According to Examples 1-3 of the invention, since the components (a), (b), (c) and (d) of the invention are used, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
Note: EO number indicated in the components is the addition mole number of polyoxyalkylene.
TABLE 2
Comparative
Description
Chemical names of components
Example 2
Example 4
Example 5
Example 6
Component
N-lauroyl L-glutamic acid stearyl
/
2
5
1
a)
ester
Component
N-lauroyl L-glutamic acid docosyl
/
3
/
/
a)
ester
Component
N-myristoyl L-aspartic acid cetyl
/
/
2
/
a)
ester
Component
N-myristoyl L-aspartic acid stearyl
/
/
3
/
a)
ester
Component
Lauric acid
/
5
/
5
b)
Component
Glyceryl stearate (monoester
/
2
/
5
b)
content of more than 70%)
Component
Mixture of palmitic acid and stearic
/
/
0.5
10
b)
acid
Component
Docosanoic acid
/
3
/
/
b)
Component
Potassium monolauryl phosphate
32
32
32
32
c)
Component
Coco amphoteric imidazoline
5
5
5
5
c)
Component
Cocodiethanolamide
3
3
3
3
c)
Auxiliary
PEG150 distearate
3
0.2
/
/
material
Component
Propylene glycol
15
15
15
15
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
65220
49020
42460
36880
Viscosity at 25° C. (centipoise)
27500
44120
38100
33100
Viscosity at 45° C. (centipoise)
8240
39200
32080
29600
Evaluation of foamability
D
B
A
A
pH value
6.8
6.9
6.6
7.2
In Table 2, after a thickening component PEG150 distearate is added in Comparative Example 2, although the viscosity of the cleaning composition is improved, the viscosity of the cleaning composition varies greatly due to temperature effect. Thus, the product has very poor foamability. According to Example 4 of the invention, after a small amount of a thickener PEG150 distearate is added, product viscosity is further improved due to synergism, but foaming property is still somewhat affected. According to Examples 4-6 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
TABLE 3
Comparative
Description
Chemical names of components
Example 3
Example 7
Example 8
Example 9
Component
N-myristoyl L-aspartic acid docosyl
/
1
/
2
a)
ester
Component
N-myristoyl L-glutamic acid cetyl
/
2
/
2
a)
ester
Component
N-myristoyl L-glutamic acid stearyl
0.2
a)
ester
Component
N-myristoyl L-glutamic acid docosyl
6
a)
ester
Component
Docosanoic acid
/
5
/
0.5
b)
Component
Mixture of lauric acid/myristic acid
/
3
5
/
b)
Component
Palmitic acid
/
1
/
/
b)
Component
Lauric acid
/
0.5
/
/
b)
Component
Sodium cocoyl sarcosinate
8
8
8
8
c)
Component
Coco amidopropyl betaine
2
2
2
2
c)
Auxiliary
Acrylate copolymer (trade name:
15.0
/
/
/
material
Carbopol AQUA SF-1)
Auxiliary
Potassium hydroxide
1.0
/
/
/
material
Component
Polyethylene glycol
30
30
30
30
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
70280
33920
15240
29080
Viscosity at 25° C. (centipoise)
27500
28400
12120
26100
Viscosity at 45° C. (centipoise)
9060
25020
10620
22060
Evaluation of foamability
D
B
B
B
pH value
7.1
6.7
6.9
7.0
In Table 3, after an associating thickening component, acrylate copolymer, is added in Comparative Example 3, although the viscosity of the cleaning composition is improved, the viscosity of the cleaning composition varies greatly due to temperature effect, and serious fruit jelly appearance tends to occur especially at low temperature. Thus, the product has very poor foamability.
According to Examples 7-9 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
TABLE 4
Comparative
Example
Example
Example
Description
Chemical names of components
Example 4
10
11
12
Component
N-palmitoyl L-aspartic acid cetyl
/
2
5
/
a)
ester
Component
N-palmitoyl L-aspartic acid stearyl
/
1
2
/
a)
ester
Component
N-palmitoyl L-aspartic acid docosyl
/
/
3
/
a)
ester
Component
N-palmitoyl L-glutamic acid cetyl
/
2
/
1
a)
ester
Component
Lauric acid
/
5
/
5
b)
Component
Myristic acid
/
2
/
5
b)
Component
Mixture of palmitic acid and stearic
/
/
0.5
10
b)
acid
Component
Stearic acid
/
3
/
/
b)
Component
Sodium lauroyl glutamate
15
15
15
15
c)
Component
Cocoamido hydroxysulfobetaine
10
10
10
10
c)
Component
Cocinic acid
3
3
3
3
c)
monoisopropanolamide
Component
Sorbierite
15
15
15
15
d)
Auxiliary
pH regulator, preservative and
Proper
Proper
Proper
Proper
materials
essence
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
35100
47080
43020
37580
Viscosity at 25° C. (centipoise)
10500
41000
39820
34100
Viscosity at 45° C. (centipoise)
5180
36140
34140
30800
Evaluation of foamability
B
B
A
A
pH value
6.9
7.0
6.8
7.0
In Table 4, the viscosity of the cleaning composition of Comparative Example 4 varies greatly due to temperature effect. According to Examples 10-12 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
TABLE 5
Comparative
Example
Example
Example
Description
Chemical names of components
Example 5
13
14
15
Component
N-palmitoyl L-glutamic acid stearyl
/
2
5
/
a)
ester
Component
N-palmitoyl L-glutamic acid docosyl
/
1
2
/
a)
ester
Component
N-stearoyl L-aspartic acid cetyl ester
/
/
3
/
a)
Component
N-stearoyl L-aspartic acid stearyl
/
1.5
/
1
a)
ester
Component
N-stearoyl L-aspartic acid docosyl
0.5
a)
ester
Component
Lauric acid
/
5
/
5
b)
Component
Myristic acid
/
2
/
5
b)
Component
Palmitic acid
/
/
0.5
10
b)
Component
Glyceryl stearate (monoester content
/
3
/
/
b)
of more than 90%)
Component
Potassium cocoyl glycinate
22
22
22
22
c)
Component
Lauryl amine oxide
8
8
8
8
c)
Component
Cocinic acid monoethanolamide
3
3
3
3
c)
Auxiliary
PEG120 glucoside dioleate
3
/
/
/
material
Component
Ethanol
5
5
5
5
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
34010
47020
40400
37280
Viscosity at 25° C. (centipoise)
9880
42120
36080
34100
Viscosity at 45° C. (centipoise)
6430
37200
30060
30880
Evaluation of foamability
D
A
A
A
pH value
7.0
7.0
6.7
7.0
In Table 5, the viscosity of the cleaning composition of Comparative Example 5 varies greatly due to temperature effect. According to Examples 13-15 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
TABLE 6
Chemical names of
Comparative
Description
components
Example 6
Example 16
Component
N-stearoyl L-glutamic acid
—
0.5
a)
cetyl ester
Component
N-stearoyl L-glutamic acid
—
0.5
a)
stearyl ester
Component
N-stearoyl L-glutamic acid
—
1.0
a)
docosyl ester
Component
Lauric acid
2
—
b)
Component
Myristic acid
—
3
b)
Component
Stearic acid
5
7
b)
Component
Potassium monolauryl
—
25
c)
phosphate
Component
Sodium laurate
20
—
c)
Component
Potassium stearate
15
—
c)
Component
Coco amidopropyl betaine
5
5
c)
Component
Sorbierite
15
15
d)
Auxiliary
Preservative and essence
Proper amount
Proper
materials
amount
Component
Water
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
41140
35100
Viscosity at 25° C. (centipoise)
34060
32800
Viscosity at 45° C. (centipoise)
29180
30140
Evaluation of foamability
A
A
pH value
10.2
6.9
In Table 6, the cleaning composition partly saponified by fatty acids such as sodium laurate, potassium stearate and the like is used in Comparative Example 6. Although the product has better foaming property and viscosity change over temperature is also acceptable, pH value of the cleaning composition is about 10. Thus, strong basicity may lead to skin irritation problems for consumers. After the components (a), (b), (c) and (d) of the invention are used in the cleaning composition of Example 16, good foaming property and stable viscosity are also achieved, and pH value of the cleaning composition is neutral. Thus, the cleaning composition has smaller irritability and good safety.
TABLE 7
Example
Example
Example
Example
Description
Chemical names of components
17
18
19
20
Component
N-lauroyl glutamic acid isotridecyl ester
0.01
10
0.5
1
a)
Component
N-palmitoyl glutamic acid isotridecyl ester
—
5
—
—
a)
Component
N-myristoyl aspartic acid isotridecyl ester
—
—
—
1.5
a)
Component
N-stearoyl aspartic acid isotridecyl ester
—
15
—
0.5
a)
Component
Lauric acid
—
10
5
5
b)
Component
Isostearic acid
0.1
15
30
1.5
b)
Component
Trilaurin
—
10
15
3
b)
Component
Sodium lauroyl sarcosinate
65
1
11
18
c)
Component
Coco amidopropyl betaine
5
—
1
5
c)
Component
Cocamide
10
—
3
2
c)
Component
Maltitol
5
5
5
5
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
37650
48710
42210
64210
Viscosity at 25° C. (centipoise)
34400
45320
39800
62100
Viscosity at 45° C. (centipoise)
32100
41200
36710
58910
Evaluation of foamability
A
C
B
A
pH value
7.0
6.8
6.6
7.0
In Table 7, according to Examples 17-20 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity within the temperature range of 5° C.-45° C. without affecting foaming property.
TABLE 8
Example
Example
Example
Example
Description
Chemical names of components
21
22
23
24
Component
N-lauroyl L-glutamic acid isostearyl
0.5
1
1.5
—
a)
ester
Component
N-palmitoyl L-aspartic acid isostearyl
—
—
—
0.2
a)
ester
Component
N-myristoyl L-glutamic acid isostearyl
—
1
1.5
—
a)
ester
Component
N-stearoyl L-aspartic acid isostearyl
—
—
—
0.5
a)
ester
Component
N-myristoyl L-glutamic acid isododecyl
—
2
—
0.1
a)
ester
Component
N-stearoyl L-aspartic acid octyldodecyl
—
—
—
0.5
a)
ester
Component
N-lauroyl L-glutamic acid hexyldecyl
—
1
—
—
a)
ester
Component
N-palmitoyl L-aspartic acid
—
—
0.5
—
a)
octyldodecyl ester
Component
Isotridecanol
2
3
2
3
b)
Component
Isostearic acid
1
—
—
2
b)
Component
Lauric acid
5
10
3
5
b)
Component
Glyeryl stearate
—
7
—
5
b)
Component
Sodium myristoyl sarcosinate
15
8
15
8
c)
Component
Sodium lauryl ether carboxylate
3
2
3
2
c)
Component
Alkyl glycoside
7
5
7
5
c)
Component
Sorbitol
10
10
10
10
d)
Auxiliary
Preservative and essence
Proper
Proper
Proper
Proper
materials
amount
amount
amount
amount
Component
Water
Balance
Balance
Balance
Balance
d)
Viscosity at 5° C. (centipoise)
28640
48610
38280
35110
Viscosity at 25° C. (centipoise)
26310
45310
36810
32060
Viscosity at 45° C. (centipoise)
23500
41180
32640
29980
Evaluation of foamability
A
A
A
A
pH value
7.0
6.9
6.7
7.0
In Table 8, according to Examples 21-24 of the invention, after the components (a), (b), (c) and (d) of the invention are used in the cleaning composition, the cleaning composition not only exhibits higher viscosity, but also has relatively stable viscosity and good foaming effect within the temperature range of 5° C.-45° C.
Description of Stability Results:
The cleaning compositions of Examples 1-20 of the invention are placed respectively in 60° C. and 45° C. ovens as well as 5° C. and −15° C. refrigerators. Six months later, state of the materials is visually observed, and there are no phase separation and other changes. The viscosity of the cleaning compositions of Examples 1-20 at 5° C., 25° C. and 45° C. is retested, showing that the result has no obvious change compared with that prior to placement. See Table 9 for details of the viscosity test results.
TABLE 9
Example 1
Example 2
Example 3
Example 4
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
34500
34480
51040
51020
47400
47300
49020
49000
at 5° C.
(centipoise)
Viscosity
32020
32020
45080
45100
41200
41200
44120
44110
at 25° C.
(centipoise)
Viscosity
30160
30200
42200
42180
38100
38110
39200
39300
at 45° C.
(centipoise)
Example 5
Example 6
Example 7
Example 8
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
42460
42500
36880
36900
33920
34000
15240
15240
at 5° C.
(centipoise)
Viscosity
38100
38080
33100
33100
28400
28410
12120
12120
at 25° C.
(centipoise)
Viscosity
32080
32100
29600
29640
25020
25000
10620
10640
at 45° C.
(centipoise)
Example 9
Example 10
Example 11
Example 12
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
29080
29100
47080
47040
43020
43080
37580
37600
at 5° C.
(centipoise)
Viscosity
26100
26100
41000
41020
39820
39810
34100
34110
at 25° C.
(centipoise)
Viscosity
22060
22000
36140
36180
34140
34100
30800
30820
at 45° C.
(centipoise)
Example 13
Example 14
Example 15
Example 16
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
47020
47000
40400
40410
37280
37300
35100
35110
at 5° C.
(centipoise)
Viscosity
42120
42120
36080
36100
34100
34110
32800
32800
at 25° C.
(centipoise)
Viscosity
37200
37220
30060
30080
30880
30900
30140
30140
at 45° C.
(centipoise)
Example 17
Example 18
Example 19
Example 20
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
37650
37660
48710
48700
42210
42220
64210
64200
at 5° C.
(centipoise)
Viscosity
34400
34400
45320
45340
39800
39820
62100
62100
at 25° C.
(centipoise)
Viscosity
32100
32180
41200
41210
36710
36700
58910
58900
at 45° C.
(centipoise)
Example 21
Example 22
Example 23
Example 24
Initial
Retest
Initial
Retest
Initial
Retest
Initial
Retest
Viscosity
28640
28600
48610
48610
38280
38300
35110
35100
at 5° C.
(centipoise)
Viscosity
26310
26320
45310
45300
36810
36850
32060
32100
at 25° C.
(centipoise)
Viscosity
23500
23550
41180
41200
32640
32600
29980
30000
at 45° C.
(centipoise)
All the documents mentioned in the invention are cited as references in the application, just as the same document is cited alone as reference. Additionally, it should be understood that those skilled in the art can make various changes or modifications to the invention after reading the above teachings of the invention, and these equivalents also fall into the scope defined by the appended claims of the application. | A thick cleaning composition, comprising a long-chain fatty acyl acidic amino acid ester; a fatty compound of fatty acid, fatty alcohol, fatty alcohol ether or polyol fatty acid ester; a surfactant; a solvent composed of water, lower alcohol, polyol and polyol ether; and further comprising a beautifying and cleaning adjuvant for skin, eyes, teeth and hair. The cleaning composition can achieve satisfactory thick appearance when used for cleaning skin and hair, and maintain stable viscosity at different temperatures. In use, the composition can be easily daubed, and foams quickly with good foaming quality. | 0 |
TECHNICAL FIELD
[0001] The disclosure relates to a transmission used in a power tool, and to a power tool, in particular an electric cutting tool, comprising such a transmission.
BACKGROUND ART
[0002] A power tool, such as an electric cutting tool, generally comprises an electric motor, a tool bit (for example, a cutting blade) and a transmission for transmitting a force between the electric motor and the tool bit. The transmission generally comprises a gear transmission mechanism for transmitting the output rotational movement of the electric motor to the tool bit at a certain transmission ratio. For achieving a sufficient transmission ratio, the gear transmission mechanism is generally of the type of dual-stage or multi-stage, so that the sizes and positions of the gears can be set properly. However, more stages of the gear transmission mechanism result in a lager size of it. The gears, the shafts and the bearings of the gear transmission mechanism should be arranged in a compact manner to minimize the size of the gear transmission mechanism.
[0003] As an example, an electric cutting tool as shown in FIG. 1 is disclosed in Chinese patent publication CN101336146A, wherein a start-end side gear 7 a is coupled with a motor shaft 6 a, a final-end side gear 7 b and a saw blade 1 are carried by a saw blade shaft 1 a, a first gear 7 c meshing with the start-end side gear 7 a and a second gear 7 d meshing with the final-end side gear 7 b are carried by an intermediate gear shaft 14 , the saw blade shaft 1 a is supported by bearings 13 and 12 at its proximal and distal sides respectively, and the intermediate gear shaft 14 is supported by bearings 17 and 16 at its proximal and distal sides respectively, wherein the proximal side bearings 13 and 17 are needle bearings which do not function well under axial forces.
[0004] According to the solution disclosed in CN101336146A, the needle bearing 17 on the proximal side of the intermediate gear shaft 14 cannot endure an axial force, which results in deficiencies of the electric cutting tool. For example, such a configuration cannot be used in a reversely operable power tool (a tool having a tool bit that is rotatable in both forward and reverse directions). Further, the strength of the needle bearing itself is low. In addition, high vibration and noise are likely to be generated because the needle bearing has a large radial fitting clearance. These factors will negatively affect cutting precision, operation comfortability and life time of the power tool.
SUMMARY OF THE INVENTION
[0005] An object of the disclosure is to provide an improved power tool which has a compact and/or durable structure.
[0006] For this end, the disclosure in one aspect provides a transmission for a power tool, the transmission comprising an input gear driven by a driver (for example, an electric motor) of the power tool; an intermediate shaft carrying first and second intermediate gears, the first intermediate gear being meshed with the input gear; an output shaft carrying an output gear, the output gear being meshed with the second intermediate gear for driving a tool bit of the power tool; and proximal and distal bearings supporting proximal and distal ends of the intermediate shaft respectively; wherein the first intermediate gear is formed with a receptacle portion which is recessed from a proximal end surface of the first intermediate gear in an axial direction towards a distal side, the proximal bearing being received in the receptacle portion at least in part in the axial direction. More specifically, the proximal bearing may be either located in the receptacle portion in part in the axial direction or located in the receptacle portion completely in the axial direction.
[0007] According to a preferred embodiment of the disclosure, each of the proximal bearing and the distal bearing is able to bear both an axial force and a radial force. For example, the proximal bearing and/or the distal bearing is a ball bearing or a conical roller bearing.
[0008] According to a preferred embodiment of the disclosure, the first intermediate gear is formed integrally with the intermediate shaft; alternatively, the first intermediate gear is formed separately and then fixed onto the intermediate shaft. On the other hand, the second intermediate gear is formed integrally with the intermediate shaft; alternatively, the second intermediate gear is formed separately and then fixed onto the intermediate shaft. The first and second intermediate gears are preferably proximate to each other in the axial direction.
[0009] According to a preferred embodiment of the disclosure, the proximal bearing comprises an inner ring which is supported by the proximal end of the intermediate shaft and an outer ring which is supported by a housing of the power tool. Alternatively, the proximal bearing comprises an inner ring which is supported by a housing of the power tool and an outer ring which is supported in the receptacle portion by the first intermediate gear, with an interference fit being formed between the outer ring and the receptacle portion.
[0010] The disclosure in a further aspect provides a power tool comprising a driver, a tool bit, and a transmission as described above, for transmitting an output movement of the driver to the tool bit.
[0011] The power tool is preferably an electric cutting tool, for example, a circular saw. Further, the power tool is preferably a portable power tool.
[0012] According to the disclosure, the proximal bearing on the intermediate shaft of the gear transmission mechanism of the power tool is accommodated at least partially in the axial direction in the receptacle portion formed in the first proximal intermediate gear, so that the gear transmission mechanism can be arranged in a compact manner. Further, the proximal and distal bearings are of the type that can endure both an axial force and a radial force, thus the supporting ability of the bearings on the intermediate shaft is increased. As a result, the power tool of the disclosure has a compact and/or durable overall structure. In addition, by forming the receptacle portion in the first proximal intermediate gear, the weight of it is reduced. Thus, the total weight of the movable elements and thus the energy loss can be reduced according to the disclosure.
[0013] Other features and benefits of the disclosure will be described later.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic view of a gear transmission mechanism of an electric cutting tool according to prior art.
[0015] FIG. 2 is a schematic sectional view of a gear transmission mechanism of a power tool according a preferred embodiment of the disclosure.
[0016] FIG. 3 is a schematic sectional view of a portion around the intermediate shaft shown in FIG. 2 .
[0017] FIG. 4 is a schematic sectional view of a portion around an intermediate shaft according to another preferred embodiment of the disclosure.
[0018] FIG. 5 is a schematic sectional view of a portion around an intermediate shaft according to yet another preferred embodiment of the disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Now some illustrative preferred embodiments of the disclosure will be described with reference to the drawings.
[0020] The disclosure relates to power tools, in particular portable power tools, such as saws, drills, grinding tools and the like, which may comprise various gear transmission mechanisms. A circular saw is used here as an example for describing the principle of the disclosure though, the disclosure is also applicable in other types of power tools.
[0021] FIG. 2 shows a portion of a circular saw (for example, a portable circular saw) according to a preferred embodiment of the disclosure. The circular saw comprises a housing 20 , an electric motor (not shown) mounted in the housing 20 , a saw blade (tool bit) 22 mounted at least partially outside the housing 20 , and a transmission for transmitting the rotational movement and torque of the electric motor to the saw blade. The electric motor has a motor shaft 24 which is supported in the housing 20 by a bearing 26 .
[0022] The transmission mainly comprises an input gear 28 carried by the motor shaft 24 , a first proximal intermediate gear 32 and a second distal intermediate gear 34 carried by an intermediate shaft 30 , and an output gear 38 carried by the output shaft 36 .
[0023] The first intermediate gear 32 is meshed with the input gear 28 , and the second intermediate gear 34 is meshed with the output gear 38 . In this way, a duel-stage gear transmission mechanism is formed by these two pairs of gears, in which the transmission ratio (speed ratio) of each stage of transmission mechanism can be determined properly to obtain a combined total transmission ratio (speed ratio) between the electric motor and the saw blade 22 . In the illustrated embodiment, the two pairs of gears are all cylindrical gears, so that the central axes of the motor shaft 24 , the intermediate shaft 30 and the output shaft 36 are parallel with each other. However, the disclosure does not exclude the conditions that one or both of the two pairs of gears are in the form of bevel gears or other types of gears. Further, the teeth of the two pairs of gears are preferably skewed teeth as illustrated; however the disclosure does not exclude the condition that the teeth of one or both of the two pairs of gears are straight teeth.
[0024] The intermediate shaft 30 is disposed completely in the housing 20 , with its proximal end and distal end respectively being supported by the housing 20 via bearings 40 and 42 . The distal end of the output shaft 36 extends out from the housing 20 , and the remaining portion of the distal end lies in the housing 20 . The output shaft 36 is supported at its proximal end and at a portion between its middle portion and distal end by the housing 20 via bearings 44 and 46 respectively. Here “proximal” refers to a direction towards or a location near the electric motor, while “distal” refers to a direction towards or a location near the saw blade 22 .
[0025] The input gear 28 is mounted to or formed integrally with the motor shaft 24 . In order to provide a sufficient speed ratio, the number of the teeth of the input gear 28 should be small enough (or the diameter of the input gear should be small enough). Thus, it is preferred to form the input gear 28 integrally with the motor shaft 24 , as illustrated. However, the input gear 28 may also be formed separately and then be fixed to the motor shaft 24 . In this case, a defective input gear 28 can be exchanged easily.
[0026] The intermediate shaft 30 is disposed kinetically between the motor shaft 24 and the output shaft 36 . The central axis of the intermediate shaft 30 may be coplanar with the central axis of the motor shaft 24 and the central axis of the output shaft 36 ; however, it may also be not coplanar with them.
[0027] For reasons related with assembling, the housing 20 may comprise at least two the housing portions 48 and 50 , one of the two housing portions (for example, 50 ) being detachable from the other one (for example, 48 ).
[0028] Since the motor shaft 24 is subjected to a relatively large radial force during operation, the bearing 26 which carries the motor shaft 24 is preferably a ball bearing, having an inner ring mounted around the motor shaft 24 and an outer ring fixed in the housing portion 48 , so that the motor shaft 24 is supported stably.
[0029] During operation of the circular saw, the proximal and distal ends of the intermediate shaft 30 is subjected to a relatively large radial force, thus the bearings 40 and 42 which carry the proximal and distal ends of the intermediate shaft 30 may be bearings having relatively large roller elements, for example, standard ball bearings. Further, during operation of the circular saw, the intermediate shaft 30 is also subjected to a certain axial force, thus the bearings 40 and 42 are preferably bearings that can bear an axial pushing force, such as one-direction thrust ball bearings, conical roller bearings or the like. The proximal bearing 40 is carried by a bearing support 48 - 1 of the housing portion 48 , and is able to bear an axial force applied in the proximal direction from the intermediate shaft 30 . The distal bearing 42 is carried by the housing portion 50 , and mainly bears an axial force applied in the distal direction from the intermediate shaft 30 . The bearing 42 has an outer ring which may abut against the housing portion 50 directly or abut against the housing portion 50 indirectly via a washer 68 . The washer 68 is preferably formed of a material having vibration damping property for reducing vibrations generated during operation of the circular saw.
[0030] During operation of the circular saw, the proximal bearing 44 which carries the output shaft 36 is subjected to a relatively small radial force, and is subjected to nearly no axial pushing force. Thus, the bearing 44 may be of any suitable type, such as ball bearing, conical roller bearing, needle bearing or the like. For saving space, the bearing 44 is preferably a needle bearing as illustrated. The bearing 44 having an inner ring mounted around the output shaft 36 and an outer ring fixed in the housing portion 48 .
[0031] The bearing 46 which carries the portion between the middle portion and the distal end of the output shaft 36 is supported by the housing portion 50 . Thus, the location of the bearing 46 in the axial direction is distal from the bearing 42 , so that a majority of the radial force from the output shaft 36 is taken by the bearing 46 . For this purpose, the bearing 46 may be a bearing having relatively large roller elements, for example, a standard ball bearing. Further, during operation of the circular saw, the output shaft 36 may also be subjected to a certain axial force, thus the bearing 46 is preferably a bearing that can bear an axial pushing force, such as a one-direction thrust ball bearing, a conical roller bearing or the like.
[0032] The output gear 38 is fixedly mounted to a middle portion of the output shaft 36 , for example, by means of a spring clamper 52 . The bearing 46 has an inner ring mounted around the output shaft 36 and an outer ring fixed in the housing portion 50 . The inner ring of the bearing 46 has a distal side which biases against a shoulder portion 54 on the output shaft 36 and a proximal side which is clamped tightly in the axial direction by the output gear 38 via a separation sleeve 56 .
[0033] The saw blade 22 is clamped onto the distal end of the output shaft 36 by a saw blade clamping device. The saw blade clamping device comprises inner and outer clamping disks 58 and 60 , with the inner clamping disk 58 biasing against a flange portion 62 on the output shaft 36 , and the outer clamping disk 60 being locked tightly by a fastening screw 64 via a washer 66 , so that the saw blade 22 is fixedly clamped between the inner and outer clamping disks 58 and 60 . Of course, other types of saw blade clamping devices can be used alternatively.
[0034] As mentioned above, the proximal bearing 40 which carries the intermediate shaft 30 is a bearing which can bear a relatively large radial force (preferably can also bear a certain axial force), thus it has an inevitably large size. However, since the bearing 40 is located near the bearing 26 which carries the motor shaft 24 , there is likely interference in the radial direction between them. In order to dispose the bearings 40 and 26 is a compact space without interference, the bearing 40 is displaced to the distal side so that it is misaligned from the bearing 26 in the axial direction according to the disclosure. Since the first intermediate gear 32 has a relatively large diameter (substantively larger than that of the input gear 28 , and larger than that of the second intermediate gear 34 to some extent), it is possible to form a receptacle portion 70 in the first intermediate gear 32 . The receptacle portion 70 is a space of a substantially cylindrical shape extending from a proximal side surface of the first intermediate gear 32 towards the distal side in the axial direction. The first intermediate gear 32 has a large size, thus it has a sufficient strength even if the receptacle portion 70 is formed in it.
[0035] FIGS. 3 to 5 show some possible configurations of a portion around the intermediate shaft.
[0036] As shown in FIG. 3 , according to an embodiment of the disclosure, the second intermediate gear 34 is formed integrally with the intermediate shaft 30 , and the first intermediate gear 32 is formed separately and then fixed to the intermediate shaft 30 . The distal end surface of the first intermediate gear 32 biases against the proximal end surface of the second intermediate gear 34 . The intermediate shaft 30 comprises a proximal end 30 - 1 and a distal end 30 - 2 which have reduced diameters relative to that of the main portion of the intermediate shaft 30 respectively. Mounting shoulders 30 - 3 and 30 - 4 are formed respectively between the proximal end 30 - 1 and the distal end 30 - 2 and the main portion of the intermediate shaft 30 . The inner ring of the bearing 40 is supported by the proximal end 30 - 1 and the mounting shoulder 30 - 3 , and the outer ring of the bearing 40 is supported by the bearing support 48 - 1 of the housing portion 48 (not shown in FIG. 3 ). The inner diameter of the receptacle portion 70 is larger than the outer diameter of the bearing 40 , so that a ring shaped space is formed therebetween for receiving the bearing support 48 - 1 . The inner ring of the bearing 42 is supported by the distal end 30 - 2 and the mounting shoulder 30 - 4 , and the outer ring of the bearing 42 is supported by a corresponding portion of the housing portion 50 (not shown in FIG. 3 ).
[0037] The proximal end 30 - 1 extends through the receptacle portion 70 in the first intermediate gear 32 in the axial direction towards the proximal side, and the proximal end surface of the proximal end 30 - 1 extends preferably beyond the proximal end surface of the first intermediate gear 32 in the axial direction towards the proximal side. Further, for mounting the bearing 40 , the proximal end surface of the shoulder 30 - 3 lies beyond a bottom surface 70 - 1 of the receptacle portion 70 which faces towards the proximal side in the axial direction towards the proximal side.
[0038] A locating member (not shown) can be used for preventing relative rotation between the first intermediate gear 32 and the intermediate shaft 30 , so that the first intermediate gear 32 is able to drive the intermediate shaft 30 to rotate with it. Preferably, this locating member or an additional locating member may prevent the first intermediate gear 32 from moving relative to the intermediate shaft 30 in the axial direction towards the proximal side.
[0039] FIG. 4 shows another embodiment of the intermediate shaft portion, wherein the first intermediate gear 32 is formed integrally with the intermediate shaft 30 , and the second intermediate gear 34 is formed separately and then fixed to the intermediate shaft 30 . The proximal end surface of the second intermediate gear 34 biases against the distal end surface of the first intermediate gear 32 . The proximal end 30 - 1 and the distal end 30 - 2 of the intermediate shaft 30 have reduced diameter relative to that of the main portion of the intermediate shaft 30 respectively, so that mounting shoulders 30 - 3 and 30 - 4 are formed between the proximal and distal ends 30 - 1 and 30 - 2 on one hand and the main portion of the intermediate shaft 30 on the other hand respectively. The proximal end 30 - 1 extends in the receptacle portion 70 in the axial direction towards the proximal side, and the proximal end surface of the proximal end 30 - 1 extends preferably beyond the proximal end surface of the first intermediate gear 32 in the axial direction towards the proximal side. Further, for mounting the bearing 40 , the shoulder 30 - 3 protrudes in the axial direction towards the proximal side from the bottom surface 70 - 1 of the receptacle portion 70 which faces towards the proximal side.
[0040] The inner ring of the bearing 40 is supported by the proximal end 30 - 1 and the mounting shoulder 30 - 3 , and the outer ring of the bearing 40 is supported by the bearing support 48 - 1 of the housing portion 48 (not shown in FIG. 4 ). The inner diameter of the receptacle portion 70 is larger than the outer diameter of the bearing 40 , so that a ring shaped space for receiving the bearing support 48 - 1 is formed therebetween. The inner ring of the bearing 42 is supported by the distal end 30 - 2 and the mounting shoulder 30 - 4 , and the outer ring of the bearing 42 is supported by a corresponding portion of the housing portion 50 (not shown in FIG. 4 ).
[0041] Other aspects of the embodiment shown in FIG. 4 are similar to that of the embodiment shown in FIG. 3 and are not described again.
[0042] FIG. 5 shows yet another embodiment of the intermediate shaft portion, wherein the first intermediate gear 3 is formed integrally with the intermediate shaft 30 , and the second intermediate gear 34 is formed separately and then fixed to the intermediate shaft 30 . The proximal end surface of the second intermediate gear 34 biases against the distal end surface of the first intermediate gear 32 . The distal end 30 - 2 of the intermediate shaft 30 has a reduced diameter relative to that of the main portion of the intermediate shaft 30 , so that a mounting shoulder 30 - 4 is formed between the distal end 30 - 2 and the main portion of the intermediate shaft 30 .
[0043] The proximal end of the intermediate shaft 30 is terminated at a bottom surface 70 - 1 of the receptacle portion 70 which faces towards the proximal side, rather than protruding from the bottom surface 70 - 1 .
[0044] The inner ring of the bearing 42 is supported by the distal end 30 - 2 and the mounting shoulder 30 - 4 , and the outer ring of the bearing 42 is supported by a corresponding portion of the housing portion 50 (not shown in FIG. 5 ). The inner ring of the bearing 40 is supported by the bearing support 48 - 2 of the housing portion 48 , and the outer ring of the bearing 40 is supported by the first intermediate gear 32 . More specifically, the inner diameter of an inner cylindrical wall defined in the receptacle portion 70 corresponds to the outer diameter of the bearing 40 , with interference fit formed therebetween, so that the outer ring of the bearing 40 is kept and supported in the receptacle portion 70 .
[0045] Other aspects of the embodiment shown in FIG. 5 are similar to that of the embodiments shown in FIGS. 3 and 4 and are not described again.
[0046] As an alternative to the embodiment shown in FIG. 5 , the second intermediate gear 34 may be formed integrally with the intermediate shaft 30 , and the first intermediate gear 32 may be formed separately and then fixed to the intermediate shaft 30 .
[0047] It is appreciated that, in a possible embodiment which is not shown, the first intermediate gear 32 and the second intermediate gear 34 may both be formed integrally with the intermediate shaft 30 ; alternatively, the first intermediate gear 32 and the second intermediate gear 34 may both be formed separately and then fixed to the intermediate shaft 30 .
[0048] Further, in the embodiments described above, the axial length of the receptacle portion 70 may be smaller than the axial length or the width of the bearing 40 , in order to avoid significant reducing of the strength of the first intermediate gear 32 caused by forming the receptacle portion 70 . In this case, the bearing 40 is located in part in the axial direction in the receptacle portion 70 . However, the disclosure does not exclude the condition that the axial length of the receptacle portion 70 equals to or is larger than the axial length of the bearing 40 . In other words, the disclosure covers both the conditions that the bearing 40 is located partly and completely in the receptacle portion 70 .
[0049] According to the disclosure, the proximal bearing 40 of the intermediate shaft 30 is located at least partially in the axial direction in the receptacle portion 70 formed in the first proximal intermediate gear 32 , so that the bearing 40 is misaligned in the axial direction with the bearing 26 on the motor shaft 24 . In this way, sufficient accommodating spaces in radial direction are provided for both the bearings 40 and 26 , so that the inner space in the housing 20 can be used efficiently, while the whole gear transmission mechanism can be disposed compactly.
[0050] Further, the proximal and distal ends of the intermediate shaft 30 are each supported by a bearing that can bear both a radial force and an axial force, thus the bearing on the intermediate shaft 30 can bear various loads that may be generated during operation of the circular saw. For example, even when the circular saw operates with its saw blade rotating in a reverse direction, the bearing on the intermediate shaft 30 can provide a sufficient support. As a result, the bearing on the intermediate shaft 30 is more durable, so that the life time of the whole the circular saw can be increased.
[0051] Furthermore, it is appreciated that, by using a dual-stage (or even multi-stage) gear transmission mechanism in the circular saw of the disclosure, and by disposing the gears of the gear transmission mechanism in a compact manner, the diameter of the output gear 38 can be reduced, and the cutting depth of the saw blade can be increased.
[0052] Furthermore, it is appreciated that, the basic principle of the disclosure, i.e., the proximal bearing on the intermediate shaft of the gear transmission mechanism is located at least partially in the axial direction in the receptacle portion formed in the first proximal intermediate gear, is also applicable in other types of power tools in which multi-stage gear transmission mechanisms are used, such as electric cutting tools, in particular portable electric cutting tools. In these cases, the technical effect of compactly disposing the gear transmission mechanism can be obtained similarly. Further, by forming the receptacle portion in the first proximal intermediate gear, the total weight of the movable elements and thus the energy loss can be reduced.
[0053] While certain embodiments of the disclosure have been described here, they are presented by way of explanation only and are not intended to limit the scope of the disclosure. Various modifications, substitutions and changes can be made by those skilled in the art within the scope and spirit of the disclosure as defined in the attached claims and their equivalents. | The disclosure relates to a transmission for a power tool, comprising an input gear driven by a driver, an intermediate shaft carrying first and second intermediate gears, the first intermediate gear being meshed with the input gear, an output shaft carrying an output gear, the output gear being meshed with the second intermediate gear for driving a tool bit, and proximal and distal bearings supporting proximal and distal ends of the intermediate shaft respectively. The first intermediate gear is formed with a receptacle portion which is recessed from a proximal end surface of the first intermediate gear in an axial direction towards a distal side, the proximal bearing being received in the receptacle portion at least in part in the axial direction. The disclosure also relates to a power tool comprising the above transmission. The disclosure provides a compact and robust structure. | 8 |
[0001] This application claims priority to Provisional Application 61/604,071.
[0002] Water skiing has been a popular activity and sport for many years. Participants enjoy the exhilaration of riding at speed over the surface of a body of water while being towed by a motorboat.
[0003] Skiers must grip a bar which is connected by a tow rope to the motorboat. Losing that grip means losing the speed which keeps the skier on the surface of the water. The obvious danger is hitting the water so hard that the skier loses consciousness and may drown. Broken bones and bruises, while not common, do occur.
[0004] Skiers have learned to protect themselves from drowning by wearing a life vest. There are other dangers, too. If the skier loses the grip on the tow rope, the rope, which has been under tension, is free to whip around and injure the skier. Worse yet, a skier could become entangled in a tow rope and be unable to disentangle before drowning or otherwise being injured. In an extreme case, the tow rope could wrap around the skier's neck and strangle the skier.
[0005] One of the reasons the rope is so dangerous is that the rope is pliable so it can bend and turn in any direction. The solution to the problem is to devise a way of limiting the pliability when the tow rope is suddenly released from tension.
[0006] Of course, this could be done by encasing the tow rope in a rigid material but, in order to maximize the benefit and enjoyment of water skiing, the tow rope must be able to bend and turn. So something short of rigidity is required. The present invention satisfies that long-felt need. The present invention is designed to all but eliminate the risk of a tow rope striking the skier.
[0007] It must be stated that the benefit of the present invention is not limited to those on water skis. The invention can help anyone being towed behind a boat at speed whether the person is on skis, a boogie board, an inner tube or even skiing barefoot. Since there is no real difference between the tow rope for a person on water skis and a person on one of the other forms, unless noted expressly, what applies to water skis applies to all other forms.
DEFINITIONS
[0008] The following terms shall have the meanings set out below:
[0009] Towable—water skis, boogie board, inner tube, person skiing barefoot, or any other object pulled behind a motorboat in the fashion of a water skier.
[0010] Binding—a strip of material that protects an edge of a larger piece of material, usually to prevent fraying the edges of the larger piece of material.
DESCRIPTION
[0011] The present invention consists of a set of components—a fabric sleeve, a foam tube, a length of tubing, usually PVC, and means for fastening the
[0012] The user may find assembly easier if user has or can make a “rope insertion” tool. This tool is made from a piece of rigid wire about two feet long. It should be possible to make such a tool from a wire coat hanger.
[0013] The fabric sleeve is wide at one end and tapers to a few inches in inner diameter. This inner diameter is large enough to accommodate the outer diameter of the foam tube plus a tolerance to make assembly, described below, easy. The wide end of the fabric sleeve is wide enough to accommodate the handle of the tow rope that a person on a towable might hold onto. The fabric sleeve will be better understood in the context of the drawings.
[0014] The fabric must be able to withstand being very wet without shrinking or coming apart The fabric must have sufficient strength not to tear apart during use. While other fabrics may work, in the preferred embodiment the fabric is nylon. Because fabrics sometimes unravel from edges, binding is attached by means well known in the art to the edges of the
[0015] There are two models used for the wide end of the sleeve. On one the wide end is circular and on the other the wide end is called “triangular” although it is as much a rectangle as a triangle. On the triangular model, three grommets are located, one each at the corners distal from the tube part of the sleeve. On the circular model there is one grommet distal from the tube part of the sleeve.
[0016] The grommets are used to fasten the wide end around the tow rope handle. On the triangular model, the three grommets, together with the fastening means, enable the user to secure the wide end to the tow rope handle. On the circular model, since there is only one grommet on the wide end, an extra length of canvas or other strong fabric is attached to the sleeve. This forms a tab. A bungee-type device, a commodity item, is inserted into the tab so that the fastening means can secure the two grommets to one another, thus securing the handle.
[0017] Due to the effects of salt water, it has been found that stainless steel is the preferred substance for grommets. If salt water corrosion is not an issue, grommets can be any durable metal, for example, brass.
[0018] We will call the wide end the “head” or “proximal” end. The end furthest from the head end we shall call the “tail” or “distal” end.
[0019] At the distal or tail end of the sleeve, the fabric has binding and elastic forming a “cuff”. At the part of the sleeve to which the wide end or head is
[0020] Another component is a piece of tubing, usually PVC. This will be used as a “coupler.” The inner diameter of this coupler must be large enough to easily fit around the outer diameter of the flotation tube and its outer diameter must be small enough to easily fit within the sleeve. Since most commercial tubing of this kind is thin-wall, a coupler that fits over the flotation tube should fit inside the sleeve.
[0021] Couplers are, in the preferred embodiment approximately ten inches long varying from five to twenty inches depending on the particular use for which is it is intended. Couplers need to be long enough to accommodate 4 or 5 inches of each of two flotation tubes.
[0022] In the preferred embodiment, the overall length of the device runs between ten feet and twenty feet but can be longer or shorter depending on the particular use for which it is intended.
DESCRIPTION OF DRAWINGS
[0023] FIG. 1 shows the proximal end of the model called “triangular”.
[0024] FIG. 2 shows the proximal end of the model called “circular”.
[0025] FIG. 3 shows the entirety of both the triangular and circular models.
DETAILS OF THE DRAWINGS
[0026] In FIG. 1 , 110 is the proximal end of the model called “triangular”. As noted elsewhere, the proximal end is as much rectangular as triangular.
[0027] Any 120 points to one of a plurality of grommets used for securing the handle of the tow rope to the device. 130 is the sleeve portion of the device. 140 is the binding, the reinforced fabric portion of 110 . 150 is the cuff at the proximal end of the sleeve 130 such that 150 is here open for permitting the tow rope to pass through. 160 is a representation of the distal end of the sleeve 130 . Because the sleeve is longer than can be shown in this detail drawing, the distal end is shown using one of the conventions of drawing to indicate the sleeve extends beyond the vertical line. 170 is a bungee type cord, a commodity item not part of the invention itself but used for securing the device to the tow rope.
[0028] FIG. 2 is similar to FIG. 1. 210 is the proximal end of the model called “circular”. 220 is a grommet used for securing the handle of the tow rope to the device. 230 is the sleeve. 240 is the binding, the reinforced fabric portion of 210 . 250 is the cuff at the proximal end of the sleeve 230 such that 250 is here open for permitting the tow rope to pass through. 260 is the distal end of the sleeve 230 . 260 is, as was 130 , shown using a common drawing convention to show that the sleeve extends beyond the vertical line. 270 are a pair of bungee cords, commodity items not part of
[0029] FIG. 3 shows both versions of the invention. The bottom drawing is of the model called “triangular”. As in FIG. 1 , 110 shows the proximal end of the device. 130 in this figure shows the entire length of the sleeve through the distal portion. The top drawing is of the model called “circular”. As in FIG. 2 , 210 shows the proximal end of the device. 230 in this figure shows the entire length of the sleeve through the distal portion.
IN USE
[0030] In use, the skier is towed behind a boat. The skier holds onto a handle which is attached by a long rope to the boat. If for any of a number of reasons, the rope no longer is fastened to the boat, the rope can whip around wildly and out of control or become so loose or have excessive slack as to entangle the skier. In any of a number of scenarios, the skier can be struck or entangled by the rope and injured. The invention stabilizes the rope so that it does not whip around or become so loose or have so much slack as to entangle or injure the skier. The invention has the further benefit of being sufficiently flexible that it does not interfere with operation of the tow rope in ordinary use. Thus, the device does not prevent the skier from enjoying the experience of water skiing. | This discloses a water ski rope safety device. Water ski ropes can become disconnected from the tow boat. They can also become loose or gain excessive slack. In such cases, the rope can whip around or entangle the skier. Any of these might injure the skier. The safety device prevents such a disconnected or loose rope from entangling or striking the skier. The device consists of a flexible sleeve into which the rope is contained along with other components which accomplish the purpose. | 1 |
This is a continuation of Ser. No. 08/344,484 having a filing date Nov. 21, 1994, now abandoned, which is a continuation of Ser. No. 08/049,532 having a filing date Apr. 20, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a tubular cast material and more particularly to a tubular cast material that is waterproof yet able to allow vapor and oxygen to pass through.
2. Background of the Invention
Fiberglass has taken the place of plaster of paris for use as an immobilizing material, i.e. cast. Typically the cast is applied on top of padding. The padding can be constructed from numerous materials, i.e. cotton, polyester, etc. A wearer of such cast and padding must avoid water or other liquids, as the padding underneath the cast is known to remain wet or damp for many hours after the initial contact with the liquid. After several hours of exposing the wearer's skin to the wet padding, skin maceration, chemical dermatitis, infections, as well as other irritations, to the skin have been commonly known to occur.
To avoid the above-identified problem, the prior art has attempted to develop ways of preventing the padding from becoming wet when the wearer is exposed to some form of liquid. One example of such attempts is U.S. Pat. No. 5,102,711 issued to Keller et al. in which the padding is provided between a top and bottom layer comprising a sheet of porous water impermeable, moisture-vapor-permeable film bonded to the middle layer.
It is, therefore, to the effective resolution of the aforementioned problems and shortcomings that the present invention is directed.
SUMMARY OF THE INVENTION
The present invention provides a tubular conformable, waterproof, breathable membrane which allows moisture protection for the skin and soft tissue and used in conjunction with a fiberglass cast which includes cast padding. This invention enables the user to have an easier application with the cast and provides greater protection against cast saw abrasions and cuts than previous water proof casting materials. Additionally, the present invention provides further protective defense when removing the cast to insure less cuts and abrasions from the oscillating saw.
The present invention includes a tubular membrane stocking, which enables moisture to vaporize from the skin after repeated liquid exposures. The membrane is waterproof, yet able to let vapor and oxygen to pass through outwardly. The membrane does not have any pores. As such, no clogging or leaking can occur.
The membrane repels water due to the fact that the water molecules are strongly attached to each other, thus forming a single molecule. Since the water molecules are attached to each other to form a single molecule they cannot attach to the positive and negative charges of the molecular chains within the membrane. Thus, the hydrophobic membrane literally repels water.
However, vapor is allowed to pass through the membrane since the vapor molecules are very independent from each other and move rather freely, similar to a cloud. Thus, the vapor molecules behave very differently from water molecules. As the vapor molecules are not attached to each other, they are able to attach to other molecules. The individual vapor molecules are attracted to the membrane by attaching themselves to the negative and positive charges within the membrane and are passed through the membrane from one side to another outwardly from the skin. The direction the vapor molecules travel within the membrane depends on the number of vapor molecules on each side. Additionally, the absolute number of vapor molecules depends on the temperature and relative humidity. As vapor molecules try to escape from the moister area, the vapor molecules will travel from inside the garment to the outside.
The stocking is thin which provides a less bulky application enabling surgeons and technicians to conform their casts which insures better immobilization of fractures and soft tissue injuries.
The stocking provides a waterproof liner and allows a physician or orthopedic technician to use the membrane stocking in combination with other cast paddings to provide adequate protection of bony prominences and soft tissue lesions. Thus, giving the surgeon or cast applicant a broad degree of thickness and conformity for controlled immobilization.
The membrane is non-porous and has no micropores that could clog with salt, dirt, or oil. Its waterproof properties are unaffected, even under severe condition, i.e. when the membrane is exposed to salt water.
The present invention uses the above-described membrane stocking in conjunction with a fiberglass cast and cast padding. When used in conjunction with a cast, the membrane allows for the evaporation of perspiration, enhancing comfort for the wearer and decreasing the associated odor producing problems commonly associated with conventional casting.
The present invention allows for an easier application by a physician or technician as compared to the prior art. The present invention is less bulky than the prior art and provides for better conformability to the casted extremity. By being less bulky, the present invention allows for proper setting of the bones. Furthermore, no overlapping or doubling of layers is needed and there are no open seams. There is no danger of burning the patients skin when removing the cast by a cast saw as the membrane gives with the cast saw. Finally, the present invention provides for a better fit under the patients clothing.
Thus, it is the primary object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which is waterproof yet breathable, keeping the skin dry at all times.
It is another object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which will allow for the evaporation of perspiration.
It is a further object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which will prevent the cast padding from being in direct contact with the wearer's skin, thus preventing skin maceration and chemical irritation.
It is yet another object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which will allow for better immobilization of fractures and soft tissue injuries.
It is still another object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which provides for greater protection against cast saw abrasions, cuts and burns at time of removal.
It is even still another object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which is cuffable.
It is even further another object of the present invention to provide a tubular membrane for use in conjunction with a conventional cast which decreases the odor producing problems associated with casting for extend periods.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood by reference to the drawings in which:
FIG. 1 is a perspective view showing the laminated membrane fitted onto a human arm;
FIG. 2 is a perspective view showing the cast padding wrapped around the laminated membrane of FIG. 1;
FIG. 3 is a perspective view showing the present invention in use on a human arm;
FIG. 4 is a cross sectional view of the present invention;
FIG. 5 is a perspective view showing the membrane fitted onto a human arm; and
FIG. 6 is a perspective view showing the edge portion of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to the drawings, the first embodiment of the present invention is shown at 10 and generally includes a cast or immobilizing material 12, cast padding 14 and tubular membrane 16. Tubular membrane 16 is waterproof but allows vapor and moisture to pass through. Thus, tubular membrane 16 allows perspiration to evaporate which reduces odors emanating from within the cast.
In this first embodiment, a cloth or fabric 22, such as polyester or the like, is laminated to one side of the tubular membrane 16. Fabric 22 provides a stretchable backing to the membrane for excellent conformability. In the second embodiment (FIG. 5) the tubular membrane 16 is shown without cloth 22. In either embodiment, all of the advantages and unique features of the present invention are achieved. However, the cloth 22 provides extra strength and reinforcement to the tubular membrane 16 and helps in preventing membrane 16 from tearing.
Preferably, tubular membrane 16 is constructed from a hydrophilic polyester block copolymer and is a homogeneous, non-porous flat film. Membrane 16 obtains its tubular form by providing a single flat waterproof seam 24. Membrane 16 provides comfort and coolness to the wearer and prevents the wearer's skin from being irritated by the garment material of padding 14. Membrane 16 is waterproof and provides moisture protection for the wearer's skin and soft tissue. Membrane 16 provides greater protection against cast saw abrasions and cuts over previous casts. Membrane 16 enables moisture to vaporize from the wearer's skin after repeated liquid exposures. Membrane 16 is very thin, thus, less bulky for allowing physicians, technicians or trainers to more accurately conform the cast/garment for insuring better immobilization of fractures and soft tissue injuries.
Membrane 16 repels water, as well as other liquids, due to the fact that the water molecules are strongly attached to each other, thus forming a single molecule. Since the water molecules are attached to each other'to form a single molecule they cannot attach to the positive and negative charges of the molecular chains within membrane 16. Thus, membrane 16 literally repels water and liquids from contacting the skin. It is a semipermeable biologic membrane and not just a finely porous barrier.
Vapor is allowed to pass through membrane 16 since the vapor molecules are very independent from each other and move rather freely. Thus, the vapor molecules behave very differently from water molecules. As the vapor molecules are not attached to each other, they are able to attach to other molecules. The individual vapor molecules are attracted to membrane 16 by attaching themselves to the negative and positive charges within membrane 16 and are passed through membrane 16 from one side to another, outwardly from the skin. The direction the vapor molecules travel within membrane 16 depends on the number of vapor molecules on each side. Additionally, the absolute number of vapor molecules depends on the temperature and relative humidity. As vapor molecules try to escape from the moister area, the vapor molecules will travel from inside the garment to the outside.
In application, the tubular membrane 16 is gloved around the body portion which is to be immobilized. Cast padding 14 can be constructed from either cotton, polyester, foam or the like. Cast padding 14 is then wrapped around a majority of membrane 16 except the first and second ends of membrane 16. Once padding 14 is wrapped around membrane 16 the first and second ends of membrane 16 are folded over cast padding 14 to provide first and second edges 18 and 20, respectively. Lastly the immobilizing material (cast 12) is applied around cast padding 14 and cuffed edges 18 and 20. Cuffed edges 18 and 20 are attached to inside of cast 12, by bonding, sealing or the like, to completely seal cast padding 14 from water as well as other liquids. Additionally, cuffed edges 18 and 20 prevent the usual unravelling problems after long term usage often associated with conventional casts. In the event that cast padding 14 does get wet, membrane 16 prevents the wet padding from being directly in contact with the wearer's skin. The present invention allows for post-operation hydro therapy with a whirlpool for upper and lower extremity as well as allowing the wearer to perform other activities which might cause the cast to become wet. In fact, swimming, showering and bathing are possible and encouraged for quicker recovery.
Though the present invention is only shown in use in conjunction with a human arm, it is to be understood that the present invention can be utilized on various other body parts. Other uses of the material can be expanded to provide the same skin protective advantages described above for application under braces, splints, stockings for amputated limbs, etc. In different sizes and shapes it can be used for protective footwear, caps and gowns used in the operating room or other medical settings.
It is to be understood that while I have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope and advantages of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. | A cast is disclosed comprising a membrane, padding and immobilizing material. The membrane repels water but allows oxygen and vapor to pass outwardly from the skin. The padding is disposed between the membrane and immobilizing material. The membrane prevents the wet padding from direct contact with the wearer's skin. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 61/286,090, filed on Dec. 14, 2009.
BACKGROUND
Conventional overbed tables include a substantially flat table surface that provides little if any support for a user's arms during use. Such lack of support runs the risk of causing the user to suffer arm, wrist, or hand strain resulting from use of the overbed table.
SUMMARY
In an embodiment, an overbed table comprising a pedestal, a telescoping support member, a table surface, and an arm support is disclosed. A first end of the telescoping support member is attached to the pedestal. The telescoping support member has means for adjusting a height. The table surface is positioned at a second end of the telescoping support member. The arm support is adjacent to the table surface.
In another embodiment, an overbed table comprising a pedestal, a support member, a table surface, and an arm support is disclosed. The support member has a first end attached to the pedestal. The table surface is positioned at a second end of the support member. The arm support has a roller affixed thereto. The roller is configured to engage a guide track fixed to a bottom surface of the table surface to move the arm support between a storage position and a use position.
In another embodiment, an overbed table comprising a pedestal, a telescoping support member, a table assembly, and an arm support assembly is disclosed. The telescoping support member has a first end attached to the pedestal and means for adjusting a height. The table assembly comprises a table base supported on a second end of the telescoping member. A table frame is attached to the table base and has a recess. A table surface is attached to the table frame. An arm support assembly is coupled to the table assembly. The arm support assembly comprises an arm support configured for storage in the recess and is moveable to a use position out of the recess. A guide track is fixed within the recess. A roller is fixed to the arm surface and is configured to engage the guide track to move the arm support between the use and storage positions.
These and other details, objects, and advantages of the disclosed overbed table will become better understood or apparent from the following descriptions, examples, and figures showing embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the overbed table with the arm supports in the extended position.
FIG. 2 is a perspective view of the overbed table shown in FIG. 1 with the arm supports in the closed position.
FIG. 3 is a front elevational view of the overbed table shown in FIG. 1 .
FIG. 4 is a side elevational view of the overbed table shown in FIG. 2 .
FIG. 5 is an exploded view of the overbed table shown in FIG. 1 .
FIG. 6 is a perspective view of the overbed table shown in FIG. 1 , showing the working surface in an inclined position.
FIG. 7 is a bottom view of the overbed table shown in FIG. 1 .
FIG. 8 is a perspective view of a second embodiment of the overbed table with one arm support in the closed position and one arm support in the extended position.
FIG. 9 is a bottom view of the overbed table shown in FIG. 8 .
DETAILED DESCRIPTION
An overbed table 100 is disclosed. Optionally, the overbed table 100 is configured to be reversible for use by both right-handed and left-handed patients. As described in more detail below, the overbed table 100 provides patients with a table surface 32 , such as an eating, working, or interactive playing surface, and includes at least one arm support 42 that can support a patient's arm during use, thereby reducing or substantially eliminating arm, wrist, or hand strain. Optionally, the overbed table 100 includes a right arm support and a left arm support. As described in more detail below, the overbed table 100 is designed to counter any weight that a user places on the arm supports. The overbed table 100 is configured for use in combination with a hospital bed, chair, or wheelchair. Optionally, the overbed table 100 is configured with features found in conventional hospital rooms, including, for examples, a call button, a telephone, a television, a remote control, a video device, storage container 70 , space, and a video monitor, and may be customized to the needs of a particular patient or of needs generally required by patients on a particular hospital floor or ward.
As shown generally in the figures, the overbed table 100 includes a pedestal 10 configured to be positioned under a hospital bed, wheel chair, or other chair. Pedestal 10 is generally H-shaped or C-shaped in plan view and includes a first member 15 positioned between two second members 16 , where first member 15 is substantially perpendicular to second members 16 and second members 16 are substantially parallel to each other. The outer boundaries of second members 16 define an area within which the central forces of the arm supports 10 are located, as discussed in greater detail below. Preferably, the members 15 , 16 of the pedestal are unitary. A plurality of casters 17 , wheels, or the like are affixed to the pedestal 10 to facilitate moving and positioning the overbed table 100 , such as for example at the four corners of the pedestal 10 as shown generally in the figures. Each caster 17 has a central axis.
The overbed table 100 also includes a support member 20 having a first end 25 attached to the pedestal 10 . As shown in FIG. 4 , the support member 20 has a central axis C that is offset from the center of the table surface 32 and is positioned closer to a first edge 35 of table surface in order to minimize sliding and tipping of the overbed table 100 when a user exerts downward force or pressure on one or both of the arm supports 42 . In an embodiment, the support member 20 is telescoping and includes first and second pieces 21 , 22 and means for adjusting a height 23 of the support member 20 to raise and lower the overbed table 100 in order to facilitate positioning of the overbed table 100 with respect to the hospital bed, wheel chair, chair, or the like. The support member 20 may include friction guides to prevent or minimize wear and damage as the support member 20 is raised and lowered. The telescoping support member 20 is controlled either manually and may be carried out by a gas-assisted method, or electronically, such as by a linear motor. In an example, first piece 21 is substantially square or rectangular. Optionally, the overbed table includes a pressure sensor (not shown) on a bottom surface of the table surface 32 (described below) or the table assembly 30 (described below) in order to control vertical movement of the overbed table 100 when a pressure is exerted, such as when the bed comes into contact with the patient, the bed, or the like.
As shown generally in the figures, the overbed table 100 also includes a table surface 32 positioned at a second end 26 of the support member 20 . Table surface 32 is generally rectangular in shape and is defined by first 35 and third 37 substantially parallel edges and second 36 and fourth 38 substantially parallel edges, where second 36 and fourth 38 edges are substantially perpendicular to first 35 and third 37 edges. Table surface 32 is positioned in a plane along a first longitudinal axis A. Optionally, table surface 32 includes a working surface 31 that is adjustable and can be positioned at an incline between about 0° to about 90° relative to the plane. In use, working surface 31 rotates about first longitudinal axis A towards the user. FIGS. 1-4 show the table surface 32 positioned at an incline of about 0°. FIG. 6 shows the table surface 32 positioned at an incline of about 45°. The working surface 31 is adjustable either manually or electronically, such as by a motorized inclination control. In an example, inclination of the working surface 31 is accomplished by at least one hinge 39 or friction hinge affixed to the table surface. In another example, inclination of the working surface 31 is accomplished by gas dampers affixed to table surface. Optionally, the electronic control is hand-held and may include controls for external devices, such as for examples, televisions, wireless ports, docking stations, gaming devices, reading lamps, and the like.
Optionally, first edge 35 of the table surface, which is positioned closest to the patient during use, is curved in order to conform to the contour of a human chest so that the overbed table 100 can be positioned close to the patient during use for ease of access. First edge 35 may also include a channel (not shown) configured to accumulate or collect spilled food or liquids in order to prevent such spillage from reaching the patient or soiling the patient's bed linens.
In an embodiment such as the one shown in FIG. 5 , the table surface 32 is part of a table assembly 30 that also includes a table base 3 and a table frame 13 . The table base 3 is attached to a second end 26 of the support member and the table frame 13 is attached to the table base 3 . Table base 3 and table frame 13 are positioned in plane along first longitudinal axis B. The table surface 32 , such as the one descried above, is attached to the table frame 13 .
Working surface 31 of table surface may include an adhesive (not shown) configured to engage a bottom surface of an object positioned thereon so as to maintain the object in a substantially stationary position even when the table surface is in an inclined position.
Optionally, table surface 32 includes at least one holder 50 . Holder 50 is configured to hold beverages containers and the like, and is configured to be adapted to hold an accessory such as a mirror, an iPad or a tablet mount. Holder 50 includes a channel 51 to capture an accessory cable through which the cable can be run during use to connect to an electrical outlet or the like.
The overbed table 100 also has at least one arm support 42 adjacent to the table surface 32 . The arm support 42 is configured to support a user's arm while the user is positioned at the overbed table 100 . The overbed table 100 is configured to support downward pressure on the arm support 42 without tipping the overbed table 100 , such as downward pressure from a user's arm, hands, and the like during use. Arm support 42 is substantially rectangular in shape and has an arm support surface 41 defined by four edges, where first 45 and third 47 edges are substantially parallel and second 46 and fourth 48 edges are substantially parallel, with the second 46 and fourth 48 edges being substantially perpendicular to the first 45 and third 47 edges. Arm support 42 has an internal frame (not shown). Arm support 42 includes sliding means 60 (described below) for moving arm support 42 between at least one extended position ( FIGS. 1 , 9 ) and a storage position ( FIG. 2 ). Optionally, there is a plurality of extended positions. In FIG. 8 , the right arm support 42 is shown in the extended position and the left arm support 42 is shown in the storage position. In the storage position, arm support 42 is positioned within plane and has a second longitudinal axis B that is substantially perpendicular to the first longitudinal axis A. In the extended position, arm support 42 is moveable about the first longitudinal axis A to an angle α of up to about 75° relative to the plane. This inclination creates an ergonomic fit adjustable to configure to a user's arms. In use, the central force of the arm support 42 is within the area defined by the pedestal 10 .
As shown generally in the figures, the overbed table 100 may include two arm supports 42 , one to support a user's right arm and one to support the user's left arm. The two arm supports 42 are positioned at opposite end portions of the table surface 32 .
In an embodiment such as the one shown in FIG. 8 , the arm support 42 is configured for storage below the table surface 32 , such that in the storage position, the arm support 42 is positioned below the table surface 32 and first edge 45 of arm support is substantially aligned with first edge 35 of table surface. In an embodiment such as the one shown in FIG. 1 , the table surface 32 has a recess 33 having dimensions configured to receive the arm support 42 such that arm support 42 is positioned in the recess 33 in the storage position. The first edge 35 of table surface has an opening 34 to the recess 33 . Optionally, arm support 42 has a handle 43 affixed to the first edge 45 to facilitate movement of the arm support 42 between the storage and extended positions.
In the example shown in FIG. 5 , sliding means 60 is an axle 61 that extends through second 46 to fourth 48 edges of arm support. Axle 61 is positioned closer to third edge 47 of arm support than to first edge 45 . Optionally, two axles 61 extend through support 42 to provide strength and integrity to the arm support 42 and to prevent or minimize the occurrence of the arm support 42 torquing to either side. Opposing walls of recess 33 each have a groove 62 therein. The groove 62 is configured to receive a tip of the axle 61 . Optionally, axle can include wheels that ride along groove 62 . A stop 63 is provided in each groove 62 that registers to the forward axle 61 . As described above, the arm support 42 is moveable about the first longitudinal axis A to tilt to an angle of up to about 75° relative to the plane. Sliding means 60 includes a locking mechanism (not shown) to lock the arm support 42 in the inclined and/or extended position. In use, axle 61 moves along grooves 62 to move arm support 42 between the storage and extended positions.
In another example (not shown), sliding means 60 is a roller affixed to arm support. Roller is configured to engage a guide track fixed to a bottom surface of the table surface to move the arm support between the storage position and the extended position.
In another example (not shown), sliding means is a groove 60 in each of the second and fourth edges of arm support that substantially aligns with a corresponding protrusion in table surface or table frame such that each protrusion engages the corresponding groove. In use, protrusion slides within groove to move arm support between the extended and storage positions.
As shown in FIG. 7 , in an embodiment there is an arm support assembly 40 coupled to the table assembly 30 . The arm support assembly 40 comprises an atm support 42 and sliding means 60 such as those described above. Arm support 42 is configured for storage in a storage position in the recess 33 . The arm support 42 is moveable between a storage and an extended position as described above.
While the foregoing has been set forth in considerable detail, it is to be understood that the drawings, detailed embodiments, and examples are presented for elucidation and not limitation. Design variations, especially in matters of shape, size, and arrangements of parts, may be made but are within the principles of the invention. Those skilled in the art will realize that such changes or modifications of the invention or combinations of elements, variations, equivalents, or improvements therein are still within the scope of the invention as defined in the appended claims. | An overbed table wherein a pedestal is attached to one end of a single support member and the other end of the support member is connected to a table assembly that includes a table surface. The center axis of the support member is located closer to a first edge of the table surface than the oppositely disposed edge of the table surface and arm supports connected to the table assembly are extendable past the first edge of the table assembly. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application which claims benefit under 35 USC §120 to U.S. application Ser. No. 14/524,722 filed Oct. 27, 2014, entitled “High Security Striker Box”, and that application is incorporated herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
FIELD OF THE INVENTION
[0003] This invention relates to strikes or striker plates used for locking doors. A strike or striker plate is typically installed in the jamb of a door to receive a bolt latch of a lock such as a deadbolt so that together, they securely hold the door closed.
BACKGROUND OF THE INVENTION
[0004] To securely lock a door, one needs or wants a strong door, a strong door frame, a strong latch and a strong strike or striker plate. Like a chain, the combined strength of the locked door is limited by the strength of the weakest of the elements.
[0005] Focusing on the strike or striker plate, at an outside door to be securely locked, it is common to have a strong striker plate comprised of steel that is screwed into and maybe through the door jamb into the underlying supporting structure. One might use extra-long screws to hold the striker plate not just to the jamb, but also to a 2×4 stud behind the jamb that is part of the structure of the wall. However, even thicker steel striker plates with extra-long screws may be quickly defeated by a motivated thief that is able to apply a powerful kick to the door near the lock and the striker plate. The screws may hold firm to the 2×4 stud, but the striker plate is typically spaced about an inch from the 2×4 stud. The screws may have a lot of tensile strength, but they do bend. With the screws extending an inch out from the stud, such impacts from kicking the door may bend the screws sufficiently to allow the striker plate to pivot inwardly so that the latch may slip out of the hole in the striker plate. The bending screws also are levers to break apart the jamb and the 2×4 studs, which is a second mode of failure of the striker plate. Regardless of the strength of the door and the strength of the latch, if the striker plate fails, the doorway may be breached based on the failure of the simplest and smallest element for an outside security door.
[0006] While stronger materials are being continually developed, there is a need for a simple, but effective strike or striker plate to work with stronger doors and stronger latches to provide better security for people and things. There is a need for an improved design for a striker plate to take better advantage of the underlying structure of a doorway opening.
BRIEF SUMMARY OF THE DISCLOSURE
[0007] The invention relates to a striker box assembly comprising first and second boxes that are each formed of four connected lateral walls. A first lateral wall is an inner wall, a second lateral wall is a back wall that is opposite the inner wall, a third lateral wall is an upper wall and the fourth of the four lateral walls is a lower wall, and these four lateral walls of each box are connected end to end to form a generally rectangular shape. Each box also has an open front and a boot flange opposite the open front and attached to at least three of the four connected lateral walls at a bottom of the box and arranged generally perpendicular to all four lateral walls. At least one primary screw hole is located in the boot flange of each box and is suited to receive a primary screw to hold the box to a stud in a wall adjacent the door jamb when the boxes are installed, one above the other, in the door jamb. The first and second boxes each further include a jack flange attached at or near the bottom of the inner wall that is arranged to extend away from the open front of the box beyond the boot flange of the box. Additionally, at least one jack screw hole is located in each jack flange that is suited to receive a jack screw through the jack screw hole in each jack flange and into the stud in the wall adjacent the door jamb to hold the jack flange to the stud when the boxes are installed one above the other in the door jamb. The primary screw hole and the jack screw hole each have an axis, and the axis of the primary screw hole is generally perpendicular to the axis of the jack screw hole. Each box further includes an upper wing that is attached to the upper wall at or near the open front of the box and is arranged to extend away from the lower wall. Similarly, each box includes a lower wing attached to the lower wall at or near the open front of the box and arranged to extend away from the upper wall and away from the upper wing. The wings are generally arranged to be in a common plane that is spaced apart and generally parallel to the boot flange and the plane of the wings of both boxes are intended to be in a generally common plane when the boxes are installed in the door jamb. The assembly further includes a cover plate for being attached to the wings of both boxes wherein the cover plate comprises a face plate and a back flange wherein the face plate comprises two spaced apart latch holes that, when installed to a door jamb, are each arranged to receive a latch of a door locking system and wherein each latch hole is arranged to overly an open face of one of the boxes installed in the door jamb. The face plate is generally flat and, when installed to a door jamb, lies in a plane that is generally flush on the wings of the boxes such that the latches of the door locking system may enter into their respective hole in the face plate and into the respective box such that the boxes and cover plate together resist against lateral movement of the latches which would occur when the door is to be opened. The assembly further includes at least one support screw attached to each boot flange of the two boxes where the support screws have a blunt end for being positioned flush against a stud or structural element within wall at the frame of a door in which the box is suited for installation. Thus, by the combination of the boxes with the support screws and cover plate, the assembly is suited to be installed in a door frame and, when installed, is very securely attached to the stud or structural element by screws oriented generally perpendicular to one another within the wall at the doorframe and strongly resist force and impacts that are intended to breach the door when closed and locked.
[0008] The invention further relates to an installed striker box assembly for providing a stronger, more secure striker for a latch of a door locking system wherein the assembly includes a jack stud in a wall defining one side of a rough door opening and a door jamb arranged generally along the jack stud wherein the door jamb defines a finished door opening within the rough door opening. A first box is installed in the door jamb at a position to receive a latch from a deadbolt lock and a second box is installed in the door jamb at a position to receive a latch from a doorknob lockset wherein the second box is also positioned in said door jamb and spaced below the first box. Each of the first and second boxes comprise four connected lateral walls where a first lateral wall is an inner wall, a second lateral wall is a back wall that is opposite the inner wall, a third lateral wall is an upper wall and the fourth of the four lateral walls is a lower wall, and wherein the four lateral walls of each box are connected end to end to form a generally rectangular shape. Each box further has an open front oriented toward the respective latches of the deadbolt and doorknob lockset and also has a boot flange opposite the open front and attached to at least three of the four connected lateral walls at a bottom of each box and arranged generally perpendicular to all four lateral walls and also oriented toward the jack stud and arranged to have firm contact indirectly with the jack stud. The assembly includes at least one primary screw hole located in the boot flange of each box along with a primary screw extending through each of the primary screw holes and into the jack stud to hold the respective box to the jack stud. Each box further includes a jack flange attached at or near the bottom of the inner wall and arranged to extend away from the open front of each box beyond the back flange of the box and be positioned flush against the jack stud. The jack flange includes at least one jack screw hole with a jack screw extending through each jack screw hole and into the jack stud holding the jack flange against the jack stud. With this arrangement, the primary screw hole and jack screw hole are also arranged to be generally perpendicular to one another. Each box further includes an upper wing attached to the respective upper wall at or near the open front of the box and arranged to extend away from the lower wall and similarly includes a lower wing attached to the lower wall at or near the open front of the box and arranged to extend away from the upper wall and away from the upper wing, wherein the wings are generally arranged to be in a common plane that is generally parallel to the boot flange. The assembly further includes a cover plate attached to the wings of both boxes wherein the cover plate comprises a face plate and a back flange wherein the face plate includes two spaced apart latch holes wherein a first latch hole is arranged to overly the open front of the first box and a second latch hole is arranged to overly the open front of the second box such that the respective latches of the deadbolt and the doorknob lockset extend through the respective latch holes and into the respective boxes and such that both boxes and the cover plate resist against lateral movement of the latches. The assembly also includes at least one support screw attached to each boot flange of the two boxes where the support screw has a blunt end for being positioned flush against the jack stud to both hold each box away from the jack stud a desired distance so the boxes and cover plate are desirably positioned flush with the door jamb and also so that any force applied to the boxes will be resisted by the support screws in contact with the jack stud. Machine screws are included to hold the cover plate to the boxes, and at least two secondary screws holding the cover plate to the boxes and firmly to the jack stud. The assembly, with the combination of the boxes with the support screws and the cover plate installed in the door jamb in contact with the jack stud and screwed to the jack stud using screws that are oriented in at least two generally perpendicular directions is very securely attached to the jack stud and strongly resists force and impacts that are intended to breach the door when closed and locked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete understanding of the present invention and benefits thereof may be acquired by referring to the follow description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 is a perspective view of a door having a door knob and a deadbolt lock each of which are arranged to latch into conventional prior art striker plates;
[0011] FIG. 2 is a top sectional view of the door closed with the latch of the deadbolt extended into and engaged with the conventional striker plate in the door jamb while the door is closed against the door stop;
[0012] FIG. 3 is a second top cross sectional view showing the failure of a conventional striker plate when the door has been kicked open;
[0013] FIG. 4 is an exploded view of the inventions showing two striker boxes with the single cover plate all shown to be installed into a door jamb;
[0014] FIG. 5 is a perspective view of a single box according to the present invention;
[0015] FIG. 6 is front view of a single box of the present invention;
[0016] FIG. 7 is a bottom perspective view of a single box providing an alternative angle to better understand the structure of the box;
[0017] FIG. 8 is a bottom perspective view of the cover plate suited for two boxes;
[0018] FIG. 9 is a top perspective view of the cover plate suited for two boxes;
[0019] FIG. 10 is a top cross sectional view of a box showing the support screws for holding the box away from the stud;
[0020] FIG. 11 is a top cross sectional view of the striker assembly showing how the face plate and box fit together to strengthen each other and resisting bending forces applied when the door is being kicked or impacted; and
[0021] FIG. 12 is a side cross sectional view showing the box and cover plate installed in the jamb and spaced from the stud, but where the box and cover plate are installed firmly to the stud using multiple screws securing both the base of the box to the stud and the top plate tightly to the stud.
DETAILED DESCRIPTION
[0022] Turning now to the detailed description of the preferred arrangement or arrangements of the present invention, it should be understood that the inventive features and concepts may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow.
[0023] Turning now to FIG. 1 , a conventional door D is shown that swings closed to a door jamb J and stops against door stop S. Once closed, a spring latch 11 engages a strike or striker plate 21 attached to the jamb by descending into the opening 25 in the striker plate 21 . The door D may be re-opened by turning the knob 10 to pull the spring latch 11 from the striker plate 21 . However, to securely lock the door D, a deadbolt 15 having a bolt latch 16 engages striker plate 22 by descending into opening 26 in the striker plate 22 . The bolt latch may be hardened steel and the deadbolt is designed to prevent the withdrawal of the bolt latch 16 unless the cylinder is properly engaged by a key or the inside thumb switch (neither of which is shown).
[0024] Referring to FIG. 2 , the bolt latch 16 is shown fully extended into the opening 26 in the striker plate 22 to resist opening of the door. As shown in FIG. 3 , if a powerful force is applied from the outside of the inwardly swinging door D, such as from a person kicking or charging the door or by some type of battering ram, the screws 23 holding the striker plate to the jamb J and perhaps the jack stud 31 tend to bend inwardly. Eventually, the jamb J breaks and the bolt latch 16 pops loose from the striker plate 22 as the striker plate rolls away from the door stop S. The length that the screws extend out from the jack stud 31 to the striker plate 22 also tends to give leverage to the forces being applied to the striker plate and tears up the jamb J and the jack stud 31 , especially if the screws 23 are installed close to the edge or inside lateral face of the stud 31 .
[0025] It should be noted that most conventional doors are framed with jack studs on either side of the opening with a header spanning across the top of the rough opening. The jack studs 31 are installed flush against king studs 32 which extend fully to the top plate.
[0026] FIGS. 1-3 are prior art arrangements.
[0027] Turning now to the present invention which is a double latch striker box assembly and shown in FIGS. 4-12 comprising a single cover plate 40 arranged to accommodate two latches, one of a top deadbolt with a first box 50 and the second latch from a doorknob lockset at a second box 150 . The boxes 50 and 150 are essentially identical, but are installed to catch the latch pins from the deadbolt and the doorknob lockset generally as shown in FIG. 1 and hold the door closed until the resident decides that the door should be open. One of the features of this present invention is that the single cover plate 40 works in conjunction with the first box 50 and the second box 150 to better resist a beating inflicted on the door by utilizing the combined strengths of all three elements together along with additional screws extending at least into the adjacent stud in the wall, but better yet, into both of two adjacent studs in the wall. This joint and combined strength will become better understood as the explanation of the invention progresses.
[0028] The central elements of the composite striker system or assembly are the two boxes 50 and 150 which should be made of strong and robust material. It would be expected that these boxes 50 and 150 would be made of steel and that the walls would have a robust dimension. For example, the thickness of the walls might be between about 1/32″ and about 3/16″ steel depending on the security desired for the door D.
[0029] Each of the boxes 50 and 150 includes four connected lateral walls. Box 50 is shown to be comprised of lateral walls 61 , 52 , 54 and 55 . The first lateral wall 61 is also an inner wall 61 . A second lateral wall 53 is also a back wall 52 that is opposite the inner wall 61 . A third lateral wall 54 is also an upper wall 54 and the fourth lateral wall 55 of the four lateral walls is a lower wall 55 . The four lateral walls are connected end to end to form a rectangular shape. The boxes 50 and 150 have an open front or top and a bottom wall 58 (sometimes called a boot flange) that is arranged to at least partially close the bottom of the box 50 or that side of the box facing the jack stud 31 . The bottom wall or boot flange 58 may optionally extend fully across that bottom of the box so that it is fully closed on five sides and open on the front or top. In the preferred embodiment, it is only partially closed on the bottom leaving an open gap or pass through along the first lateral wall 61 . The bottom wall 58 is also called the boot flange 58 and is arranged generally perpendicular to the four lateral walls 61 , 52 , 54 and 55 .
[0030] The back wall 52 , the upper wall 54 and lower wall 55 all have a common depth dimension when considering the dimension from the front or top of the box 50 to the bottom. However, inner wall 61 includes a portion that extends beyond the bottom wall 58 . This extended portion may be called a jack flange. It may be viewed by some that it is not clear where the inner wall 61 ends and the jack flange begins, but it may be viewed or understood that the jack flange begins about where the plane of the bottom wall or boot flange 58 intersects the inner wall 61 . The function of the jack flange 61 will be explained below.
[0031] Each box 50 and 150 further includes an upper wing 62 attached to the upper wall 54 and which extends generally flush with the open top of the box 50 and generally perpendicular to the upper wall 54 . Similarly, a lower wing 63 is attached to the lower wall 55 and which extends generally flush with the open top of the box and generally perpendicular to the lower wall 55 . It should be noted that these wings 62 and 63 extend away from the interior of the box.
[0032] Each box 50 and 150 further includes a base wing 65 that is somewhat similar to the upper and lower wings 62 and 63 , but attaches to the inner wall 61 and which extends generally flush with and away from open front of the box 50 and generally perpendicular to the inner wall 61 . Preferably, the three wings 62 , 63 and 65 generally lie in a common plane.
[0033] Each box 50 and 150 includes at least one primary screw hole 94 and at least one, but preferably two threaded support screw holes 77 located in the bottom wall or boot flange 58 . Each box further includes a pair of threaded assembly holes 74 in the base wing 65 and at least one secondary box hole 75 in each of the top and bottom wings 62 and 63 .
[0034] Looking back at FIG. 4 , the cover plate 40 includes a face plate 41 and a back flange 42 . The face plate 41 is arranged to cover the open top or front of the boxes 50 and 150 and includes two main openings or latch holes indicated at 43 and 143 that are aligned with the open faces of boxes 50 and 150 . Commonly the main openings or latch holes 43 and 143 are preferably 5.5 inches apart, which is the convention or standard in the United States, but may be a different spacing elsewhere. The face plate 41 further includes four inner screw holes 44 and four back screw holes 45 each generally surrounding the openings 43 and 143 . The inner screw holes 44 are arranged to align with threaded assembly holes 74 in the base wing 65 and the back screw holes 75 in the face plate are arranged to along with the secondary box holes in the top and bottom wings 63 and 65 , such that when the boxes and cover plate are installed into the jamb of the door opening, the screw holes 74 and 75 in the cover plate 40 are arranged to align with the screw holes 44 and 45 , respectively, in the boxes 50 and 150 . The cover plate 40 is attached to the boxes 50 and 150 by machine screws 83 extending through inner screw holes 44 and into threaded assembly holes 74 . The boxes 50 and 150 are sandwiched between the cover plate and the jamb J by secondary screws 85 that extend through the back screw holes 45 , the secondary box holes 75 , the jamb J and into the jack stud 31 and preferably through the jack stud 31 and into the king stud 32 . Inner screw holes 44 , back screw holes 45 and secondary box holes 75 do not have screw threads. Cover plate 41 further includes at least one tertiary hole 47 between the openings 43 and 143 for a tertiary screw 87 to further secure the cover plate 41 in place and to the studs 31 and 32 . Ideally, it there are several tertiary holes 47 , they will not all be along the same vertical line with the back screw holes 45 so that the secondary screws 85 and tertiary screws 87 will not likely all be in the same grain line of the wood of the studs 31 and 32 , but would enter multiple grain lines.
[0035] Still focusing on FIG. 4 , prior to installation of the striker box assembly, two portions of the door jamb J are cutout exposing the jack stud 31 along with a thinner portion between those cutouts so that the full vertical length of the cover plate 41 is arranged to be flush with the face of the jamb J. Similar cutouts are made in the drywall 28 exposing the side or lateral face of the jack stud 31 and possibly part of the king stud 32 . Into these cutouts, the box 50 and second box 150 are positioned for installation. Typically, a surface portion of the door jamb J would also be removed with a chisel by mortising a recess M both above and below the cutouts C to let the upper and lower wings 62 and 63 recess below the face surface of the door jamb J at a sufficient depth so that the cover plate 40 ends up generally flush with the same face surface of the door jamb J.
[0036] Turning to FIG. 11 , one of the key features of the present invention is the combination of support screws 92 positioned in threaded support screw holes 77 with the blunt ends of the support screws arranged firmly against the jack stud 31 . The support screws 92 maintain the bottom wall or boot flange 58 of each box, and in effect, each entire box 50 and 150 spaced from the jack stud 31 . That spacing may be adjusted by adjusting the depth of the support screws 92 in threaded support screw holes 77 . While support screws 92 are effectively pushing away from jack stud 31 , a primary screw 81 is arranged to hold the bottom wall or boot flange 58 to the jack stud 31 and also preferably to the king stud 32 . So, even though each of the boxes 50 and 150 are not up flush against the jack stud 31 , the boxes 50 and 150 are very strongly and stably attached to the jack stud 31 and through the jack stud 31 to the king stud 32 , but in a position that best seals and secures the door in the jamb when closed. The attachment of the striker box assembly is further supported by the secondary screws 85 and the at least one tertiary screw 87 noting that the secondary screws 85 and the tertiary screw 87 are further tightly holding the cover plate 40 , the boxes 50 and 150 to the jack stud 31 and the king stud 32 in a relatively tight sandwich. With the support screws 92 properly set to space the bottom wall or boot flange 58 from the jack stud 31 , the jamb J and cover plate 40 is preferably positioned so that the door D is able to close, but in close proximity to the jamb for any weather seal to properly and effectively function and also so that the latch from a deadbolt or doorknob are able to extend as far into the respective boxes 50 and 150 for the latches 11 and 16 to best set into the boxes 50 and 150 and openings 43 and 143 in the cover plate 40 to most strongly hold the door D closed while locked by the deadbolt 15 and doorknob lockset 10 .
[0037] As shown in FIG. 4 , the boxes 50 and 150 would first have the respective support screws 92 installed and then each be attached to the jack stud 31 by primary screws 81 through respective screw holes 94 . The attachment of the box 50 to the jack stud 31 is supposed to arrange the door jamb J so as to be spaced somewhat from the jack stud 31 to make the door jamb J square, straight and vertical. Also, the frame for the door (which includes door jamb J) is typically slightly smaller than the rough opening in the wall for the door where the rough opening is defined by a pair of jack studs (one on the latch side of the opening and the other on the hinge side of the opening) and a header (not shown). Centering the frame and the door in the rough opening creates space between the door jamb J and the jack stud 31 . Typically, shims are positioned at several vertical locations between the jamb J to the jack stud 31 where nails or screws attach the jamb J to the rough opening through those several shims. In the present invention as shown in support screws 92 fill the space between the bottom wall 58 and the jack stud 31 at that specific vertical elevation providing firm support to the box 50 and the striker assembly from the jack stud 31 . A shim is a thin wedge typically made of wood, but may be plastic or metal.
[0038] For all the embodiments, a set of jack screws 82 are used to attach the inner wall or jack flange 61 of each of the boxes 50 and 150 to the jack stud 31 via screw holes 76 . It should be noted that jack screws 82 are oriented generally perpendicular to the primary screw 81 , the secondary screws 85 and the tertiary screw 87 . Having the jack screw arranged at such a strongly divergent angle from the primary, secondary and tertiary screws makes it so that only one screw is always oriented in a strong orientation to resist failure under a destructive load while the other screw may be in a less strong orientation to resist failing. For example, if a fully inserted screw is weakest in pure tension, then if the boxes 50 and 150 were each being pulled straight out from the door jamb J, jack screw 82 would strongly resist that load and tend to provide support for primary screw 81 preventing the primary screw 81 from failing. So, a load imposed on the door D oriented to push the box 50 inwardly into the room in which the door D would swing when opened, the jack screws 82 would be in tension and the primary screws 81 would be in an orientation to the load that would be better able to provide the additional resistance to this type of load or force. Moreover, the jack screws 82 also create a different hinge point resisting failure of the striker box assembly compared to the failure shown in FIG. 3 . The jack screws 82 would resist the collapse of the inside edge of the boxes 50 and 150 such that as the door D was forced open, the boxes 50 and 150 would be forced to slide with the door D. However, the primary screw 81 along with the secondary screws 85 and tertiary screw 87 would strongly resist such sliding with the door. Clearly, there is a force that may be imposed on the door D that would overcome the strength of the weakest link of the door, the locks and latches, and the striker box assembly. But with the jack screws 82 at their position and orientation, that overpowering force would have to be higher for the striker box assembly to fail as compared to conventional strike plates shown in FIGS. 2 and 3 . In other words, with the boxes 50 and 150 secured by a jack flange 61 to the side of the jack stud 31 , the box 50 is better prevented from rolling or rotating in the cutout while the door D is being forced open.
[0039] After the boxes 50 and 150 are attached to the jack stud 31 by primary screws 81 and jack screws 82 , cover plate 40 is attached to the boxes by machine screws 83 . A third way of attaching the boxes 50 and 150 along with the cover plate 40 to the jack stud 31 is with secondary screws 85 that extend through screw holes 45 in the cover plate 40 and screw holes 75 in the box 50 and then through the jack stud 31 and into king stud 32 . The screw holes 45 and 75 align such that the screws 85 hold the cover plate 40 and the box 50 together while attaching to the jack stud 31 and king stud 32 . It should be noted that the screw holes 75 are off center relative to the box 50 (as identified by centerline 51 in FIGS. 5 and 6 ) and especially with respect to the main openings 43 and 143 in the cover plate 40 so that the secondary screws 85 will be positioned closer to the center of the jack stud 31 and further away from the edge of the jack stud 31 to avoid the vulnerability of tearing up the jack stud as described above when discussing FIGS. 2 and 3 above. Moreover, tertiary screw 87 is arranged to secure the cover plate 40 to the jack stud 31 between the boxes 50 and 150 providing more resistance to an impact load on the door and onto the striker assembly.
[0040] Focusing on FIG. 6 , the center line 51 is shown extending vertically across the face or front opening of the box 50 and the holes 75 are positioned on the opposite side of the centerline from the jack flange 61 and closer to the inner wall 52 . It should also be noted that the center bore 98 is arranged to be outside the alignment of the screw holes 75 and 77 to reduce the probability that all three screws will hit the same grain line in the wood. If all three screws hit the same grain line, the stud would be likely to split and be seriously weakened.
[0041] One feature of the invention that provides additional strength to the striker box assembly is the way the inner wall 61 , the base wing 65 and the back flange 42 are arranged to create a U-channel as seen in FIG. 10 . This U-channel provides resistance to distortion of the striker box assembly under a severe load in a manner similar to the way an I-beam or a piece of channel iron resists bending.
[0042] Another aspect of the striker box assembly is that the support screws 92 are arranged to be offset from where the latch 16 may set into the box 50 . The box 50 is generally preferred to be about ⅝″ in depth to work with a conventional jamb dimension of 11/16″.
[0043] When the drywall 28 and door trim 99 are attached, the striker box assembly will appear to be reasonably similar to conventional systems and the cutouts will not be visible.
[0044] Ultimately, the striker box assembly will only be as strong as the materials from which it is constructed and to which it is attached. This invention is intended to take as much advantage of the available structure within the wall surrounding the door as possible in a cost considered manner and reduce the likelihood of failure of the door system based on the striker being the weak link.
[0045] In closing, it should be noted that the discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as a additional embodiments of the present invention.
[0046] Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents. | A striker box assembly provides enhanced security when locking a door where the assembly includes two boxes and one common cover plate attached to the two boxes where each box is associated with a latch from a locking device. The combination of the two boxes and common cover plate make the assembly stronger where a deadbolt and doorknob lockset are both locked, but if the latch in the doorknob lockset itself breaks while the box associated with that latch is still firmly attached to a stud, that box continues to resist the breaching of the door through the common cover plate reinforcing the box associated with the deadbolt. | 4 |
This application claims the benefit of priority from U.S. Patent Application No. 61/430,329 filed Jan. 6, 2011, the entire disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to systems and devices for receiving and selectively maintaining imaging, sighting mechanisms and display devices. More specifically, the present invention relates to systems and devices for attaching imaging, sensing and/or transmitting devices to various sighting or aiming devices such as spotting scopes, rifle scopes, binoculars, etc.
BACKGROUND
The use of personal electronic devices is well known. Given the advancement of technologies such as the cellular telephone, still cameras, smart phones, video cameras, music players, personal digital assistants, and similar portable electronic devices, these devices have become exceedingly small, lightweight, portable, and common. Indeed, many of these devices or features of these devices are now commonly found in a single apparatus, and have imaging capabilities similar to a standalone camera.
In a heretofore unrelated industry, a number of devices have been developed for viewing, sighting, and/or targeting objects. These devices include, but are not limited to rifle scopes, binoculars, monoculars, telescopes, spotting scopes, range finders, and various other similar devices. These known systems and devices, commonly used by hunters, shooters, archers, bird watchers, golfers, etc., are devoid of features for accommodating, receiving, protecting, and/or selectively maintaining a portable electronic device, such as a camera-phone. Thus, there is a long-felt but unmet need to provide a device for receiving and securing an image-recording and/or displaying device on a portion of a viewing or sighting device such that the devices or systems may be used in concert with one another.
SUMMARY OF THE INVENTION
Accordingly, the present invention contemplates novel systems, methods and devices for attaching a portable electronic device, such as an image-sensing or image-displaying device such as a smart phone or camera, to a sighting or spotting device, such as a rifle or spotting scope.
In further support of the present disclosure, the following references are hereby incorporated by reference in their entireties: U.S. Pat. No. 3,545,356 to Nielsen, U.S. Pat. No. 3,682,070 to Kiceniuk, U.S. Pat. No. 4,309,095 to Buckley, U.S. Pat. No. 4,835,621 to Black, U.S. Pat. No. 5,020,262 to Pena, U.S. Pat. No. 5,826,363 to Olson, U.S. Pat. No. 6,088,053 to Hammack et al., U.S. Pat. No. 6,244,759 to Russo, U.S. Pat. No. 6,526,956 to Hankins, and U.S. Pat. No. 7,277,119 to Hammack et al., and US Patent Application Publication Numbers: 2002/0089201 to Seegmiller et al. and 2005/0179799 to Umanskiy et al.
In various embodiments, the present invention comprises a mount for attaching to a viewing device and for further receiving an image recording. For example, in a particular embodiment, the present invention comprises a mount for receiving or being secured around one or more pre-existing viewing features of a device (e.g. oculars or eye cups of a pair of binoculars). The device further comprises a portion for accommodating one or more additional devices, such as an iPod, digital camera, or camera-phone. In various embodiments, additional devices are received by the mount in a manner that allows for the alignment of lenses or image sensing components to align with a sight line of the viewing device. Thus, in various embodiments, the first and second devices are selectively secured and features of the second device are allowed to operate in conjunction with features of the first device and vice versa. For example, where camera phones are known to have limited range or zoom features due to their general lack of optical zoom, the range/zoom features of an additional device, such as a telescope, can be utilized to view, capture, and/or record images or events.
In one embodiment, the present invention comprises a mount that attaches or is secured to a viewing device with a clamp type of device, the clamp comprising one or more hinged arms biased toward a closed position and expandable by a user-applied force. The clamp may additionally comprise gripping features, such as protrusions, indentations, and/or rubber or other materials and members with a high coefficient of friction. The mount further comprises a device-receiving portion with one or more clamps or swing arms for receiving and securing an imaging device.
In an alternative embodiment, a mount for an imaging device is provided, the mount having a first aperture having an initial diameter comprising an elastic material, the aperture adapted for selectively attaching to a first device (e.g. scope). A second aperture may be provided, the second aperture adapted for selectively attaching, surrounding, or accommodating an imaging device (e.g. camera-phone). In one embodiment, an image sensing feature of the imaging device is aligned with a predetermined line of sight of the first device when the first device and the imaging device are selectively attached to the mount, such that images viewed by the first device may be similarly viewed and/or recorded by the imaging device.
In various embodiments, the present invention contemplates accommodating any number of viewing devices and/or personal electronic devices. For example, in one embodiment, the present invention comprises a gripping feature for receiving or accommodating a first viewing device wherein the gripping feature is selectively adjustable to securely accommodate or be affixed to different viewing devices and/or different portions/components of the viewing device(s). A variety of known devices may be employed or integrated with the present invention in order to provide this adjustability. For example, hose clamps, wire ties, elastomeric rings, clamps, vice grips, v-band clamps, and similar devices may be provided, alone or in combination, to secure a mount of the present invention to a first viewing device and/or securing a second device within the mount. In one embodiment, the elasticity of the mount device itself is adequate to secure the mount to a viewing device.
In various embodiments, the present invention comprises a mount adapted for connection to an archery bow. It is contemplated that a mount may be provided which is adapted for selectively removable interconnection with various components of a bow including, but not limited to a riser portion of a bow. Many existing risers comprise a threaded portion for receiving various items, such as a stabilizer bar. In one embodiment, a mount is provided that is capable of being connected with a bow riser in addition to or in lieu of a stabilizer bar or similar feature. For example, the mount may comprise an extension member with a threaded portion for being selectively connected to a pre-existing threaded aperture of a bow.
In various embodiments, the present invention comprises features for protecting and/or insulating devices from the elements, shock, abrasion, etc. In various embodiments, the present invention comprises a substantially elastomeric material, including, but not limited to rubber, natural rubber, synthetic polyisoprene, butyl rubber, polybutadiene, styrene-butadiene, nitrile rubber, chloropresne, ethylene propylene rubber, polyacrylic rubber, silicone rubber, ethylene-vinyl acetate, and various thermoplastics. In one embodiment, a sufficient amount of elastomeric material is provided, the elastomeric material being at least partially in contact with a device housed within the mount such that the device is substantially protected from shock. For example, where a mount is provided for attachment to a rifle scope and further adapted to house a sensitive electronic device, such as a camera-phone, it may be desirable to provide for shock protection to minimize potential adverse affects of a rifle's recoil on the camera-phone. Similarly, regardless of the viewing device to which a mount is to be secured, it may be generally desirable to protect a personal electronic device from impact-related damages. Accordingly, in various embodiments, a mount comprises elastomeric or shock absorbent material(s) adapted for contacting and/or protecting devices to be housed within the mount.
Furthermore, as the present invention is contemplated for use in various activities which may occur outdoors and in inclement weather conditions, it is contemplated that at least a portion of the mount be comprised of a material that is substantially impermeable to water. In one embodiment, at least a portion of the mount is comprised of a rubber substantially impermeable to water and adapted to surround sensitive features and/or apertures of an electronic device while still allowing for visibility of certain features (e.g. a screen) and access to necessary features or components (e.g. buttons and switches).
In various embodiments, the present invention comprises a mount for securely accommodating a portable electronic device. In one embodiment, the mount is sized so as to securely fit a known electronic device and requires manipulation of an at least partially elastic material in order to place or secure the device within the mount. Thus, an interference fit of sorts is provided wherein insertion and removal of a potentially valuable electronic device requires a degree of user manipulation so as to substantially reduce the risk of loss or unintentional removal of the device.
In one embodiment, a mount of the present invention is provided with a number of selectively removable and insertable spacers or inserts. It is known that there currently exist numerous devices which may capture or display images. For example, even within the camera-phone market alone, there exist hundreds and potentially thousands of devices which a user may desire to use in connection with the present invention. These devices are known to be of different sizes and shapes. Thus, in at least one embodiment, the present invention comprises spacers or other forms of adjustment mechanisms for selectively accommodating a wide variety of devices with different dimensions.
In various embodiments, more intricate and complex systems may be employed which allow movement and adjustment in a vertical and horizontal plane and a means for securing the device in a specified position.
In various embodiments, the present invention comprises features for accommodating a pre-existing lens or imaging component of personal electronic device. It is known that various image sensing devices comprise a lens element at various different locations. Thus, in one embodiment, various different apertures are formed in a portion of the mount, the apertures corresponding to known positions and/or orientations of pre-existing lenses on different image recording equipment. In one embodiment, the present invention comprises a mount capable of accommodating various different image recording devices wherein apertures are provided with selectively removable plugs or portions. For example, in one embodiment, a mount is provided with perforated portions representing locations which may be removed by a user in order to accommodate a specific device. In one embodiment, numerous apertures are provided with plugs or selectively removable/insertable portions so that a single mount can accommodate a number of different devices, yet without offering an excess number of apertures through which water and contaminants may enter.
Various embodiments contemplate and provide for the ability to rotate a mount device about at least one axis. For example, in a particular embodiment, the present invention comprises the ability to rotate a mount for receiving various devices to a position of non-use (e.g. where additional space or visibility through a sighting device is preferred). Thus, where viewing or recording of images on a device disposed within a mount of the present invention is not desired/required, the device may be rotated or folded out of the way. One of skill in the art will recognize that moving or rotating a mount to a position of non-use may be accomplished through rotation in any number of axis or combinations thereof. Thus, the invention is not limited to any particular axis of rotation.
In various embodiments, a telescoping attachment is provided for connecting a mount to a sighting, spotting, viewing or similar device. One of skill in the art will recognize that the optics of the viewing device and the image receiving device are dependent upon numerous factors, including, but not limited to the distance to the target object, focal length, zoom, etc. Thus, in order to capture the desired image (e.g. capture a focused image), it may necessary to obtain an appropriate physical relationship between a viewing device and an image sensing device. Accordingly, as mounting an image sensing device directly against a viewing device may not provide an optimal arrangement, embodiments of the present invention contemplate a connecting member that is telescoping or translatable such that the spatial relationship between the camera and the viewing device can be adjusted and the desired image obtained.
In various embodiments, the present invention comprises a mount with the ability to adjust the vertical and/or horizontal position of the mount once the mount is attached or secured to a viewing device. For example, in one embodiment, a mount is provided with one or more tracks adapted for translating the mount in a horizontal and/or vertical direction with respect to a viewing device so that an optimal spatial arrangement may be achieved between an imaging device and a viewing device.
U.S. Pat. No. 7,574,810 to LoRocco, which discloses features for adjusting a vertical and horizontal position of a device, is hereby incorporated by reference in its entirety. In one embodiment, a mount of the present invention is translatable with respect to a viewing device and comprises tracks or elongate apertures such that a viewing feature of lens of the imaging device is not obstructed when the mount is displaced to various positions.
Although various references are made herein with respect to a mount receiving an imaging device, it will be understood that the present invention is not limited to receiving any particular device. Indeed, with the development of devices such as iPods, iPads, PDA's, Global Positioning Systems (“GPS”) etc., it is contemplated that various mounts of the present invention may accommodate, for example, devices adapted for displaying rather than receiving information. For example, in one embodiment, a device adapted solely for displaying information is mounted to a viewing device and information related to latitude, longitude, wind, temperature, plant and/or animal identification, sunrise/sunset, etc. is displayed to a user.
In one embodiment of the present invention, a mount device is provided for mounting on a viewing device and further containing or receiving an electronic image sensing and/or displaying device. The mount is attached to a pair of binoculars, for example, such that the mount substantially surrounds an ocular and provides a stable platform for receiving an imaging device. The imaging device, which may be disposed in the mount either before or after the mount is positioned on the viewing device (i.e. binoculars), is securely positioned with the mount such that it is capable of viewing objects or receiving images through the binoculars. Accordingly, images viewed through the binoculars may be viewed on the imaging device and expanded, recorded, “blown-up,” and/or saved for later modification, dissemination, etc. Accordingly, in various embodiments, the present invention obviates the need for expensive and cumbersome recording equipment by enabling a user to leverage pre-existing and/or pre-owned devices.
Alternative embodiments contemplate a device adapted for use and/or attachment to more than one ocular. In such alternative embodiments, a user's ability to view objects directly through the binoculars is effectively replaced by the ability to view/capture a viewing devices' full field of view with a personal electronic (or similar) device.
In various embodiments of the present invention, wherein an electronic device is substantially surrounded by a mount, an aperture is formed in a periphery of the mount. In such embodiments, the aperture provides access to necessary features and/or controls of a personal electronic device. For example, as will be recognized by one of ordinary skill, it may often be necessary to interact with various features of a device to be inserted within the mount, such as to power on/off the device, take pictures, or navigate through various features of the device.
In various embodiments, at least a portion of the main aperture and/or additional aperture comprise features adapted for grasping or securing a device(s). For example, in one embodiment, the main aperture comprises an elastic diameter such that it may be stretched to fit over various portions of various different viewing devices in a secure manner. Similarly, additional apertures may comprise elastic properties such that an imaging device may not be inserted or removed from a mount without user manipulation.
In various embodiments, a mount is provided in connection with a scope or similar feature through permanent or semi-permanent connection means. Permanent and semi-permanent connection means include, but are not limited to various fasteners, compression and/or frictional fit members, adhesives, and clamps.
For example, in a particular embodiment, a mount is secured to a portion of a scope by a circular aperture designed to fit tightly around an existing scope such that a frictional fit is provided. The circular aperture may comprise plastic or rubber which allows the aperture to fit around existing scope features and further provides sufficient rigidity to support the weight of the remainder of the mount and associated device.
In yet another embodiment, a mount member is secured to a scope or similar device by one or more selectively adjustable circular clamps. For example, various features of known pipe clamps and hose clamps are employed in the present invention to fixedly secure the mount device to a scope or sighting device. Features of known worm gear clamps, for example, are provided to tighten and secure the mount around a scope at a desired location and in a manner that requires sufficient intentional action by a user (e.g. unscrewing the clamp with a tool) to loosen and/or remove the mount member.
In various embodiments, the mount member is secured to a scope or sighting device through one or more set screws which apply a force to or mate with the scope. That is, in addition to or in lieu of fasteners disposed generally tangential to a circular clamp for tightening the clamp, fasteners or set screws may be provided that project inwardly toward a portion of the sighting device to secure a mount member thereto.
In various embodiments, the present invention comprises a mount with various degrees of freedom for movement with respect to a sighting device. For example, in one embodiment, the present invention comprises features for fine adjustment of the mount with respect to a sighting device in a horizontal and/or vertical direction. Dials may be provided to translate the mount along one or more predetermined paths and thereby achieve a user-desired position with respect to the sighting device. In one embodiment, the mount is hinged or rotatable, either with respect to itself and/or with respect to a sighting device such that the mount and housed device may be selectively rotated (e.g. out of a primary line of sight of a sighting device when use of the mount/housed device is not desired). In various embodiments, the present invention comprises means, such as cam-locks and similar devices, for securing a rotatable or translatable mount in a desired position.
These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible using, alone or in combination, one or more of the features set forth above or described in detail below. Further, the summary of the invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the summary of the invention, as well as, in the attached drawings and the detailed description of the invention and no limitation as to the scope of the present invention is intended to either the inclusion or non-inclusion of elements, components, etc. in this summary of the invention. Additional aspects of the present invention will become more readily apparent from the detailed description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a front perspective view of an imaging device mount according to one embodiment;
FIG. 2 is an exploded perspective view showing various components of an imaging device mount according to one embodiment;
FIG. 3 is a front perspective view of an imaging device mount according to one embodiment attached to a sighting device;
FIG. 4 is a side elevation view of an imaging device mount according to one embodiment attached to a sighting device;
FIG. 5 is a cross-sectional perspective view showing various components of an imaging device mount according to one embodiment;
FIG. 6 is a front perspective view of an imaging device mount according to one embodiment attached to a sighting device and housing an imaging device.
FIG. 7 is a front perspective view of an imaging device mount according to one embodiment;
DETAILED DESCRIPTION
FIG. 1 is a front perspective view of one embodiment of an imaging device mount 2 . As shown, the mount 2 comprises a first portion 4 for securing the device 2 to a sighting device or similar object (not shown in FIG. 1 ) and a second portion 6 for selectively receiving an imaging device. In the embodiments shown, the first portion 4 comprises a clamp defining a space 38 within which a device may be received and lever arms 12 providing a user-interface portion for manipulating the position of the first portion 4 . The first portion 4 comprises protrusions and/or indentations 20 for providing a desirable gripping surface. In various embodiments, gripping features are provided on the first portion 4 , the gripping features comprising one or more materials having a relatively high coefficient of friction for contacting a sighting device.
In a preferred embodiment, the device 2 comprises a second portion 6 for receiving an imaging device, which may include but is not limited to a portable smart phone, a digital camera, a PDA, a digital music player, or any number of devices capable of capturing or recording images. The second portion 6 comprises a first substantially planar portion 16 and a second substantially planar portion 18 , wherein the first 16 and second 18 substantially planar portion are disposed substantially perpendicular to one another. A hinged member 8 is provided for selectively securing an imaging device, for example, with the second member 6 . A downwardly extending grip portion 9 is provided. The grip portion 9 , in one embodiment, comprises a rigid member extending downwardly from the second portion 6 and provides a user interface for aiding the application of force to and rotation of the hinged member 8 . In various embodiments, the grip portion 9 is ergonomically shaped to allow for ease of grip and or use and may comprise, for example, a plurality of recessions or protrusions for receiving fingers.
FIG. 2 is an exploded perspective of an imaging device mount 2 according to a preferred embodiment, showing various internal components thereof. The first portion 4 comprises lever arms 12 and a gripping area 38 disposed opposite a central portion comprising connecting means. A coil or torsion spring 26 is provided at or near the axis of rotation of the first portion 4 for biasing the first member 4 toward a closed or clamped position. a sleeve 28 or washer is provided to guide rotation
In a preferred embodiment, the hinged member 8 is biased by a torsion spring 24 . Torsion spring 24 biases the hinged member 8 and device contacting feature 10 toward at least one the first 16 and second 18 substantially planar portions. Accordingly, torsion spring 24 which may be secured by a pin 30 provides a rotational force on the hinged member 8 for selectively securing an electronic device within the second portion 6 . The device contacting feature 10 may comprise a number of different geometries for applying a force to an electronic device.
In the embodiment provided in FIG. 2 , the device contacting feature 10 comprises a transversely extending member convex about its longitudinal axis. The feature 10 may comprise a number of different surface textures and materials including, for example, rubber, foam, plastic, textile, and various other materials suitable for contacting an electronic device as will be recognized by one of ordinary skill in the art.
The first portion 4 and second portion 6 are connected by a fastener 22 . Fastener 22 comprises an elongate member extending through aligned apertures in the first 4 and second 6 portions. The fastener 22 is provided with a dial or knob 14 at a distal end, the knob 14 comprising a threaded female portion for receiving the distal end of the fastener 22 . At least a portion of the distal end of the fastener 22 comprises a threaded portion for communication with the knob 14 . The fastener 22 and knob 14 combination provides numerous benefits in addition to helping secure the first 4 and second 6 portions to one another. For example, the fastener 22 and knob 14 provide a structure whereby the first portion 4 is rotatable with respect to the second portion 6 . As one of skill in the art will recognize, it may be desirable to rotate the second portion 6 with respect to the first portion 4 to accommodate various dimensional limitations of an attached device or otherwise align a lens (for example) of an attached device with a sighting device (not shown). In order to adjust rotational position, a user may loosen the fastener 22 and knob 14 combination, selectively adjust rotation, and limit further rotation by tightening the fastener 22 and knob 14 . Additionally, the knob 14 and fastener 22 combination allow a user to apply a compression force between the first and second portions of the device and thereby adjust or enhance the clamping ability of the second portion 4 .
As will be described further, the clamp of the second portion 4 is biased toward a closed position by a torsion spring 26 , such that when external forces are not applied, the clamp will tend toward a closed position. Once the clamp and corresponding gripping area 38 are secured around a sighting device (not shown), a user may further secure the device 2 to the sighting device by tightening the knob 14 . Tightening the knob 14 will provide a compression force, as will be recognized, which acts in combination with the torsion spring 26 to prevent undesired opening of the gripping area 38 and/or undesired rotation of the device 2 with respect to the sighting device.
As shown in FIG. 2 , first portion 4 generally comprises two portions connected by a fastener 22 and through holes and comprising a biasing member 26 . In a preferred embodiment biasing member 26 comprises a torsion spring with extensions that bias a gripping area 38 toward a closed or contracted position. Gripping features 12 are provided opposite the gripping area 38 . Gripping features 12 comprise, for example, levers or extensions for user manipulation and for selectively overcoming the force of the torsion spring 26 and opening the gripping area 38 . Although shown as linearly extending members, gripping features 12 may comprise any number of ergonomic shapes or features.
Upper and lower portions of the first member 4 each comprise through holes which may be aligned and receive fastener 22 or similar hinge or locking element. In the embodiment shown in FIG. 2 , an upper portion of the first member 4 nests within a lower portion such that corresponding through holes are aligned and adapted to receive a fastener 22 which may be in threaded communication with a knob 14 disposed on the distal end of the device. A collar or washer 28 may additionally be provided within the biasing member 26 to further enable movement of the torsion spring 26 and prevent interference between the fastener 22 and torsion spring 26 .
Referring now to FIG. 3 , a device 2 is shown secured about a sighting device 32 . Sighting devices for use with the present invention include, but are not limited to, rifle scopes, spotting scopes, telescopes, binoculars, monoculars and various other devices and features through which a line of sight may be provided and as will be recognized by one of skill in the art. As shown, first portion 4 is secured to the sighting device 32 by means of a clamp comprising protrusions or indentations 20 to further assist in secure gripping of the device 32 . As shown, the first portion 4 is disposed at an angle relative to the second portion 6 . First portion 4 and second portion 6 may be positioned relative to each other in various rotational orientations in order to position an imaging or electronic device (not shown) with a line of sight of the sighting device 32 . For example, where an electronic device comprises a lens at a fixed location, it may be necessary to adjust the relative position of first portion 4 and second portion 6 such that the lens or similar feature is appropriately aligned with the central axis of the sighting device 32 . This alignment may be accomplished in part by the relative rotation of the first portion 4 and second portion 6 of the device 2 . Relative rotation may be limited or secured by adjusting knob 14 and corresponding fastener 22 .
As shown in FIG. 4 , a device 2 of the present invention is shown in a side elevation view and attached to sighting device 32 . As shown, second portion 6 comprises an area 34 for selectively receiving an electronic or imaging device. An electronic device may be disposed within the device 2 and aligned with an access of the sighting device 32 by selectively expanding space 34 . As previously described, second portion 6 comprises a hinged member 8 which is biased towards a closed position by torsion spring 24 . Space 34 may be selectively expanded by applying a force to hinge member 8 and/or grip portion 9 . Once expanded, an electronic device may be positioned within the space 34 and force removed from hinged member 8 . The hinged member and device contacting portion 10 thereafter operate to generally secure the device within the second member. As one of skill in the art will recognize, once a device is secured within space 34 of second member 6 , various features and operations of the device may be used in combination with various functionalities of the sighting device 32 .
FIG. 5 is a cross sectional perspective view of one embodiment of the present invention further illustrating the fastener 22 and knob 14 provided to secure first and second portions of the device 2 . As shown, fastener 22 provides an elongate axis of rotation. The elongate of axis of rotation provided by fastener 22 provides for an axis of rotation with respect to first member 4 and second member 6 as well as defines the rotation about which lever arms 12 may be rotated. Rotation of both lever arms 12 and second member 6 with respect to first member may be facilitated by loosening of the fastener 22 and knob 14 combination, and similarly may be restricted by the tightening of the fastener 22 and knob 14 combination.
Fastener 22 may comprise a threaded or partially-threaded bolt. In one embodiment, for example, at least a distal end of the fastener 22 is threaded for communicating with a portion of the knob 14 and for providing a clamping force on the device. In various embodiments, a central portion of the fastener 22 may be non-threaded, such that rotation of additional elements of the device is enabled. Accordingly, the present invention is not limited to any particular fastener device. Rather, a wide array of fasteners including threaded bolts, partially-threaded bolts, pins, rivets, and various other connectors and fasteners are expressly contemplated as being within the scope of the present invention.
Referring now to FIG. 6 , an electronic device 40 is provided in combination with the device mount 2 . As shown, a lens or similar feature provided on the electronic device 40 may be aligned with an axis of a sighting device 32 such that images viewed through the sighting device 32 are incident upon and/or recorded by the imaging device 40 . One of skill in the art will recognize that various electronic devices comprise lenses or other features in various locations and/or orientations. As such, features of the present invention contemplate various degrees of freedom and modes for adjustment of the position of the electronic device 40 within the mount 2 . Additionally, acquiring an image at the proper focus may require minor adjustment of the lens with respect to the central axis of the sighting device 32 . That is, a central axis of the sighting device 32 may not necessarily be the desired or preferred position of the lens of an electronic device. As such, the present invention contemplates accommodating an electronic device 40 at a non-discreet number of positions, such that it may be selectively aligned with a sighting device in order to record or view images through the sighting device 32 .
Features of the present invention therefore receive an electronic device 40 with various image acquisition or recording means 44 , such that a sighting device 32 and an electronic device 40 may be placed in communication. For example, an imaging device 40 may comprise a screen or viewing window 42 through which images received through or by a sighting device 32 and image acquisition means 44 may be displayed or viewed. In addition or in lieu of such image displays 42 , electronic devices may record images received by a sighting device 32 and image acquisition means 44 . Image acquisition means 44 may comprise, for example, one or more lenses and associated features provided on a device 40 .
FIG. 7 is a perspective view of a mount member according to an alternative embodiment. As shown, an alternative embodiment of a mount 50 is provided wherein the mount 50 is securable to a sighting device (not shown) through rigid or semi-rigid attachment means. In FIG. 7 , the attachment means comprise a substantially rigid cup 52 for connecting to a portion of a sighting device. The cup 52 preferably comprises an internal diameter that is substantially equal to or slightly larger than an outer diameter of a portion of a particular sighting device. Based on this dimensional relationship, the cup 52 may be press-fit or frictionally fit around the sighting device in a secure manner. Additional features may be provided to contract and/or secure the inner diameter of the cup 52 to a device. For example, hose clamps and similar features known to those skilled in the art may be employed to increase the range of an internal diameter of the cup feature. The cup may extend and/or be connected to various additional components as shown and described herein, including second component 6 and various associated features.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items. | A device for use in connection with various viewing and imaging devices is disclosed. More specifically, a mount is provided that is both capable of being attached to preexisting viewing devices, such as spotting scopes, rifle scopes, and other magnification devices, and further accommodating preexisting image recording and/or displaying devices, such as cameras and cameras phones. Features and advantages of both preexisting viewing and image recording devices may therefore be used in concert with one another. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an ice-breaking apparatus for a structure for use in icy waters.
With recent increase of demand for energy sources and because of uneven distribution of petroleum resources and rise in prices of petroleum products, the importance of exploitation of submarine oil resources has been increasing, and even icy water regions are now objects of this exploitation. The exploitation of submarine oil resources involves a serious problem; how to protect an oil-drilling structure, for example, an oil-drilling platform, from external forces of floating ice lumps or floes surging upon the structure.
In order to cope with this problem, the configuration or framework of the structure has heretofore been especially arranged or designed as shown in FIGS. 7-(a) to 7-(h) of the accompanying drawing, but in many cases, no sufficient ice-breaking capacity can be obtained. Therefore, the operation region or time is often restricted.
The present invention is to overcome this defect involved in the conventional techniques. It is therefore a primary object of the present invention to provide an ice-breaking apparatus in which ice lumps are positively broken to reduce external forces imposed on an oil-drilling structure without adopting negative means of improving the ice-resisting capacity by changing the configuration of the structure.
Another object of the present invention is to provide an ice-breaking apparatus in which ice lumps are broken mainly by utilizing the flexural load.
Still another object of the present invention is to provide an ice-breaking apparatus which can be operated any time and anywhere with restrictions on the operation time and region being completely removed.
BRIEF SUMMARY OF THE INVENTION
The present invention is based on the principle that ice is relatively inferior in the strength or resistance against the flexural load and the ice-breaking operation is performed in the present invention by utilizing this special physical property of ice. More specifically, according to the present invention, a rotary ice-breaking body having a spiral rotary blade is attached to a structure at a part falling in contact with an ice lump, and the rotary blade is driven by driving means in the state where it is biting into the ice lump, whereby the ice lump is lifted up or pressed down and is broken by a flexural stress caused in the ice lump by this lifting-up or pressing-down. Accordingly, since the ice-breaking mode is not a compression breaking mode, the energy necessary to break the ice lump is relatively small. Further, broken ice pieces are discharged sideway of the structure with rotation of the rotary blade, and the structure is not damaged at all by broken ice pieces.
The above-mentioned and other objects and features of the present invention will be apparent from the following detailed description made by reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view illustrating one embodiment of the ice-breaking apparatus of the present invention;
FIG. 2 is a front view illustrating another embodiment of the ice-breaking apparatus of the present invention;
FIG. 3 is a sectional side view illustrating a driving mechanism for a rotary ice-breaking body to be used for the embodiments shown in FIGS. 1 and 2;
FIG. 4 is a view showing the section taken along the line A--A in FIG. 3;
FIG. 5 is a front view illustrating still another embodiment of the ice-breaking apparatus of the present invention;
FIG. 6 is a sectional side view illustrating a driving mechanism for a rotary ice-breaking body to be used for the embodiment shown in FIG. 5; and
FIGS. 7-(a) to 7-(h) are diagrams illustrating conventional techniques, in which FIGS. 7-(a) to 7-(d) are front views and FIGS. 7-(e) to 7-(h) are corresponding plan views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first embodiment illustrated in FIG. 1, the ice-breaking apparatus of the present invention is applied to an oil-drilling platform. Referring to FIG. 1, a rotary ice-breaking body 3 is disposed in the upper portion of a column 1 of the oil-drilling platform in the vicinity of a position falling in contact with an ice lump or ice floe 2 floating on the water face, and a spiral rotary blade 4 having an upwardly expanded, reverse-frustoconical shape is mounted on the periphery of the ice-breaking body 3.
In the present embodiment, when the rotary blade 4 is rotated in a clockwise direction seen from above in the state where the rotary blade 4 bites in the ice lump 2, since the rotary blade 4 is spirally arranged, the ice lump 2 is gradually lifted up. Since the rotary blade 4 has a reverse-frustoconical shape as described above, biting of the rotary blade 4 into the ice lump 2 is assuredly maintained, and the portion of the ice lump 2 closer to the column 1 is lifted up more highly than the portion farther from the column 1. Accordingly, the weight of the ice lump per se and the surging force of ice are added, and a high flexural stress is produced in the ice lump 2 and it is broken into relatively large plate-like pieces as shown in the drawing. The so formed ice pieces are pushed away sideway of the column 1 by rotation of the rotary blade 4 and the column 1 is not damaged by these ice pieces at all.
FIG. 3 is a side view illustrating an example of the driving means for a rotary ice-breaking body 3 in FIG. 1 and a rotary ice-breaking body 3a in FIG. 2, and FIG. 4 is a view showing the section taken along the line A--A in FIG. 3. Referring to FIGS. 3 and 4, a supporting stand 6 is mounted on a columnar portion 5, and a plurality of direct current electric motors 7 are disposed on this supporting stand 6 to drive inner gears 9 on the inside of the rotary ice-breaking body 3 through small gears 8. In the present embodiment, the rotary ice-breaking body 3 is disposed between the platform 10 and the column 1 and the driving electric motors are mounted in the interior of the rotary ice-breaking member 3. The embodiment may be modified so that the driving mechanism is disposed on the platform 10 or in the column 1 to drive the rotary ice-breaking body 3 through an appropriate power transmission mechanism such as gears and chains.
In the second embodiment shown in FIG. 2, the ice-breaking apparatus of the present invention is applied to an oil-drilling platform. Also in this embodiment, a rotary ice-breaking body 3a is mounted on a column 1 at a part falling in contact with an ice lump floating on the water face, but a spiral rotary blade 4a mounted on the periphery of the ice-breaking body 3a has a downwardly expanded frustoconical shape reverse to the shape of the rotary blade 4 shown in FIG. 1. In this case, the rotary blade 4a is caused to bite in the ice lump 2 by the surging force of ice, and when the rotary blade 4a is slowly rotated in this state, the ice lump 2 is gradually lifted up or pressed down. The portion of the ice lump 2 closer to the rotary blade 4a is lifted up more highly or pressed down more lowly than the portion farther from the rotary blade 4a. Accordingly, the flexural load is produced in the ice lump 2 and the surging force is added thereto, and the ice lump 2 is broken into plate-like pieces in the position relatively close to the column 1 as shown in the drawing.
In the third embodiment shown in FIG. 5, the ice-breaking apparatus of the present invention is applied to an oil-drilling platform. In this embodiment, a plurality of rotary ice-breaking bodies 3b are disposed along the periphery of of a conical portion 1a of a column 1 of the platform in the vicinity of the water face, and a spirally rotary blade 4b is mounted on the periphery of each ice-breaking body 3b. In this embodiment, if only an ice-breaking body 3b facing a floating ice lump 2 is actuated, the ice lump 2 is broken by the rotary blade 4b mounted on said ice-breaking body 3b. Accordingly, the energy required for ice-breaking is diminished to a minimum and this embodiment is advantageous from the economical viewpoint.
FIG. 6 is a sectional side view illustrating an example of the driving mechanism for the rotary ice-breaking body shown in FIG. 5. Referring to FIG. 6, a shaft 21 is fixed to arms 20 and 20' extended from a column 1, and a fixing member 22 is fixed to the shaft 21 and a rotor 23 fixed on the inner face of the rotary ice-breaking body 3b is disposed on the periphery of the shaft 21 to face the fixing member 22. A rectifier 24 is disposed to apply an electric current to the rotor 23 so that the rotary ice-breaking body 3b is rotated with rotation of the rotor 23.
In a modification of the embodiment illustrated in FIG. 6, bearings are disposed in the arms 20 and 20' to support rotatably the shaft 21, and the rotary ice-breaking body 3b is fixed to the shaft 21 and the shaft 21 is driven through a power transmission mechanism such as gears and chains.
The ice-breaking apparatus of the present invention can be applied to not only a monopod type fixed structure as shown in the foregoing embodiments but also tripodal or tetrapod multi-column structures. In the case where the ice-breaking apparatus of the present invention is applied to such multi-column structure, especially good results are attained if the directions of the rotary blades and rotation directions thereof are arranged in the respective columns so that ice pieces formed by one rotary blade are prevented from impinging against other columns.
As will be apparent from the foregoing illustration, according to the present invention, since ice lumps are positively broken by utilizing the flextural load, the energy required for breaking ice lumps can be remarkably saved and the external force imposed to the structure can be remarkably diminished. Therefore, the resistance of the structure against surging ice lumps can be highly improved, and restrictions on the application time and region of the structure can be greatly moderated.
Further, according to the present invention, since broken ice pieces can be discharged sideways as soon as ice lumps are broken, the broken ice pieces form ridges and a risk that destructive forces of these broken ice pieces are imposed on the structure can be completely expelled.
Still further, if a plurality of rotary ice-breaking bodies having a spiral rotary blade on the periphery are disposed on the periphery of the structure, an intended ice-breaking effect can be attained if only a rotary ice-breaking body located at the ice-breaking-required position is driven, and therefore, the ice-breaking energy can be remarkably saved.
As is apparent to those skilled in the art, the ice-breaking apparatus of the present invention may be arranged so that the rotary body is rotated in a direction pushing down an ice lump into water on the contrary to the ice-breaking manner in the foregoing embodiments. | A rotary ice-breaking body having a spiral rotary blade is attached to a structure for use in icy waters at a part falling in contact with an ice lump or ice floe. The rotary blade is actuated to bite into the ice lump and to lift up or press down the ice lump. The ice lump is broken by the flexural stress and the structure is protected from influences of the ice lump. One rotary ice-breaking body may be disposed to constitute the outer periphery of the structure. Alternately, a plurality of rotary ice-breaking bodies may be disposed to surround the structure so that they are driven and rotated simultaneously or independently. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional application No. 60/480,493 filed Jun. 23, 2003.
FIELD OF THE INVENTION
[0002] The invention relates to a device for levitating a ball. In particular, a device is shown which provides entertainment and amusement, by levitating a light weight ball having at least one fin extending therefrom.
BACKGROUND OF THE INVENTION
[0003] Suspension of balls by directing air at the ball for entertainment and amusement are available. For example, U.S. Pat. No. 4,045,906 discloses a hand-held fixed force blower unit for levitating a ball. The ball may be a lightweight foam plastic ball or a ping pong ball. With the ball levitated in the air by the blower, a user moves the blower unit to maneuver the ball to pass through certain obstacles. Similarly, U.S. Pat. No. 2,911,745 discloses a device that blows a stream of air upward at a light, hollow ball or balloon to suspend it in mid-air for display purposes. Both of these prior art references disadvantageously levitate a ball at a specific vertical axial position with no variation. Once the ball is levitated and suspended in mid-air, the ball is relatively static and provides minimal entertainment and amusement values.
[0004] U.S. Pat. No. 2,897,607 discloses a simulated satellite being suspended in the air with an electro magnetic device that counter balances a current of air directed at the satellite. The simulated satellite is a ball having a plurality of elongated arcuate fins extending peripherally about the ball. When the air strikes the arcuate fins, the ball rotates about its own axis. Although the ball is of a light weight material, it must have a metal cap for the magnetic forces to act on, which disadvantageously increases the weight of the ball and results in the need of substantial forces of air to maintain the ball in mid-air.
[0005] Therefore, there is a need for a device that levitates a ball in mid-air and yet allows the ball to be in motion using minimal forces of air to provide entertainment and amusement values.
SUMMARY OF THE INVENTION
[0006] The present invention provides a device that levitates a ball having at least one fin extending therefrom with air, imparting motion to the ball.
[0007] The device of the present invention comprises a base and a ball for levitating above the base by means of the Bernoulli Effect. The base comprises a pivotable blower assembly, which comprise a ball interface assembly, a blower that generates a stream of air, and an air laminating means directing the air perpendicularly away from the blower towards the ball, which could be at an angle less than ninety degree (90°) from a horizontal surface supporting the blower. The ball interface assembly includes a basket for holding the ball when it is not levitated. The ball is made of a lightweight material, such as an inflated balloon or a ball made of waxed paper, such that minimal forces of air are required to levitate the ball. At least one fin extends from the ball, either about the equator/circumference or randomly around the ball. When a stream of air strikes the ball, the ball is levitated and may rotate about its axis or spin and stop erratically, depending on the location of the fins, to provide entertainment and amusement values. The blower may be pivoted to direct the stream of air at an angle to the horizontal blower support surface while continuing to levitate the ball in mid-air, which appears to defy logic, also adding to the entertainment and amusement values.
[0008] In an alternate embodiment, a set of lights in the base illuminate the levitated ball. The lights, ball and fins may be of more than one color, including fluorescent and phosphorescent colors. Using UV LEDs to illuminate a ball having fluorescent colors provides additional unusual visual effects with entertainment and amusement value.
[0009] The device of the present invention is non-intrusive in a home environment with respect to noise level due to the lightweightness of the ball such that a low velocity blower is adequate to sufficiently levitate the ball. Further, a low velocity, but high volume blower in the form of a large air flow cross-section provides a large lift area for the ball.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred embodiments of the present invention have been chosen for purposes of illustration and description and are shown in the accompanying drawings forming a part of the specification wherein:
[0011] FIG. 1 is a partial cross-sectional view of the levitated finned ball device of the present invention.
[0012] FIG. 2 is a top view of the ball for use with the levitated finned ball device of the present invention.
[0013] FIG. 3 is an optional stabilization mast for use with the levitated finned ball device of the present invention.
[0014] FIG. 4 is a partial cross-sectional view of an alternate embodiment of the ball having indented top and bottom portions for use with the levitated finned ball device of the present invention.
[0015] FIG. 5 is another alternate embodiment of the ball having two rows of fins for use with the levitated finned ball device of the present invention.
[0016] FIG. 6 is another alternate embodiment of the ball having random fins for use with the levitated finned ball device of the present invention.
[0017] FIG. 7 is an enlarged view of a single fin for attaching to the ball for use with the levitated finned ball device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] With reference to the drawings, wherein the same reference number indicates the same element throughout, there is shown in FIG. 1 a levitated finned ball device 1 of the present invention. Device 1 comprises a ball 2 and a base 3 for levitating the ball 2 above the base 3 .
[0019] As shown in FIG. 1 , the base 3 includes a blower assembly 4 and a power and control box 5 which supplies low voltage power to the blower assembly 4 via a cable bundle or wires 6 . The base 3 may be pivotable to direct air from blower assembly 4 at different directions. The power and control box 5 includes plugs adapted to be plugged into a wall outlet. Alternatively, the blower assembly 4 may be powered by batteries. Although the power and control box 5 is shown as a distinct unit separate from the base 3 , the power and control box 5 may be incorporated into the housing of the base 3 .
[0020] The blower assembly 4 includes a ball interface assembly 7 , a blower 8 and an air laminating means that directs the air perpendicularly away from the blower 8 towards the ball 2 . The blower 8 may be of the type similar to a household blow dryer, but preferably has a larger air flow cross section and at a lower velocity to reduce the noise produced by the blower 8 . For example, a typical household blow dryer runs its impeller at 1,500 to 2,400 rpm and the impeller of blower 8 may be ran at 600 to 900 rpm, which is sufficient to lift a hand-grippable ball 2 12 to 24 inches. As shown in the cross-sectional portion of FIG. 1 , the air laminating means includes a laminar flow duct 9 and laminar flow baffles 10 , which results in a stream of laminar air flow 11 directed parallel to the baffles 10 and perpendicular to the blower 8 . The ball interface assembly 7 further includes a basket ring 13 supported by a plurality of struts 12 for cradling and holding the ball when the blower 8 is not actuated.
[0021] As shown in FIGS. 1 and 2 , ball 2 is made of a light weight material, preferably waxed paper. The ball 2 may be deflated for packing and shipping and inflated with air by blowing into one of the two holes 19 and 20 while covering the other hole with a finger. As air is blown into the ball 2 , the paper expands to form a ball shape that is rigid enough to hold its shape without any air pressure. Other lightweight material that holds its shape with or without air pressure known to one skilled in the art may be used. Due to the lightness of the ball, the blower 8 can be run at a very low speed and with minimal noise.
[0022] The ball 2 may be constructed of one or more pieces of material as known to one skilled in the art. Ball 2 as shown in FIGS. 1 and 2 is constructed of eight wedges 21 . With each wedge 21 of the ball 2 colored with the same or different colors provide added entertainment and amusement value. The wedges 21 are joined to each other and to a paper disk 22 at each of the top and bottom portions of the ball 2 .
[0023] A plurality of fins 15 are evenly spaced around the equator or circumference of the ball 2 . Each fin is tilted at an angle from horizontal. As a stream of air 11 is directed towards ball 2 , the stream of laminar flow air as shown by arrow 17 is deflected by the fins 15 and imparts a rotary motion to the ball 18 about its axis 18 .
[0024] FIG. 7 illustrates an enlarged view of a single paper fin 15 for attaching to ball 2 . Fin 15 includes a tab portion 23 and a fin portion 24 . The tab portion 23 is for attaching to the surface of the ball 2 . The attachment can be accomplished by any method known to one skilled in the art, such as by gluing, sewing, stapling, hook and loop combination, etc. The tab portion 23 is generally rectangular in shape and the fin portion 24 is generally semi-circular in shape.
[0025] In an alternate embodiment, one or more lights 14 are used to illuminate the ball 2 . Preferably, LEDs are used, which are small and can be imbedded in the basket ring 13 to be directed towards the ball 12 . The LEDs are powered by the power and control box 5 or batteries in the base 3 (as discussed above) via wiring through strut 14 a . The lights 14 may be controlled by the power and control box 5 to flicker (i.e. on and off) at particular or variable frequencies, which can be accomplished as known to one skilled in the art of electronic circuitry.
[0026] With the wedges 21 and fins 15 of the ball 2 having fluorescent or phosphorescent color, and using UV LEDs as lights 14 will provide a stunning and exceptional visual lighting effect for added entertainment and amusement value. Similarly, using red, green and blue (RGB) LEDs as lights 14 can provide a totally different visual effect depending on the phase relationship and relative intensity of the RGB LEDs. The control of the phase relationship and relative intensity of the RGB LEDs can be accomplished by the power and control box 5 , which is known to one skilled in the art of electronic circuitry. Another way to provide another different visual effect is to provide patterns at a specific order or location, such as by preprinting and applying patterns on the ball 2 or by painting patterns directly on the ball 2 , on the wedges 21 . For example, a spiral pattern on the wedges 21 of ball 2 can yield images that coherently cross over the wedge boundaries.
[0027] The power and control box 5 uses common electrical elements known to one skilled in the art to produce the proper current for the blower assembly 4 . The power and control box 5 may include a button or switch 26 a that controls the speed of the blower 8 , i.e. high, medium, low or an automatic sequence of high, medium to low to impart a variable stream of air 11 to provide a bouncing motion to the ball 2 . The power and control box 5 may also include a button or switch 26 b that controls the sequence, intensity and/or blinking pattern of the lights 14 to provide different visual effects of the ball 2 .
[0028] FIG. 3 shows an optional stabilization mast 28 for use with the ball 2 when the ambient wind condition is too strong for the ball 2 to stay captured by the Bernoulli Effect alone. Mast 28 has an upper end and a lower end 29 , with the lower end 29 adapted to fit into a central shaft mounting hole 30 at the base 3 (see FIG. 1 ). After the mast 28 is inserted into the central shaft mounting hole 30 , ball 2 is placed on the mast 28 through its holes 19 and 20 . A cap 31 is provided at the upper end of mast 28 to prevent the ball 2 from levitating beyond the length or height of the mast 28 . The mast 28 is sufficient in length to accommodate the vertical height of the levitated ball 2 . With the use of mast 28 , the ball 2 may still spin, rise and fall with the air flow 11 , as confined by the vertical axis of the mast 28 .
[0029] FIG. 4 shows an alternate ball 2 ′, which is similar to ball 2 of FIGS. 1 and 2 , except that the top and bottom portions of the ball 2 ′ adjacent holes 19 and 20 are indented. Ball 2 ′ performs well and more stable than ball 2 when the ball 2 ′ spins around its axis at a high speed.
[0030] FIG. 5 shows another alternate ball 2 ″, which is similar to ball 2 of FIGS. 1 and 2 , except that two rows of fins 34 are spaced an equidistant from the equator. Ball 2 ″ is advantageous over balls 2 and 2 ′ to facilitate packing of the ball 2 ″ in a folded manner with minimal damage to the fins 15 without having fins 15 at the equator.
[0031] FIG. 6 shows another alternate ball 2 ′″, which is similar to ball 2 of FIGS. 1 and 2 , except that fins 15 are randomly placed on the surface of the ball 2 ′″ such that a stream of air 11 directed at ball 2 ′″ will cause the ball 2 ′″ to spin and stop and tumble in an erratic and random fashion.
[0032] The features of the invention illustrated and described herein is the preferred embodiment. Therefore, it is understood that the appended claims are intended to cover the variations disclosed and unforeseeable embodiments with insubstantial differences that are within the spirit of the claims. | A levitated finned ball device includes a ball made of a lightweight material and a base that generates laminar air flow to levitate the ball in mid-air. The ball has at least one generally semi-circular shaped fin extending therefrom. When the laminar air flow strikes the fin, it imparts motion to the ball. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for producing ultrafine powder, and more particularly, to a method for producing nano-sized titanium dioxide (TiO 2 ) ultrafine powder from titanium tetrachloride (TiCl 4 ) in the vapor phase by the gas phase oxidation reaction using flames.
[0003] 2. Description of the Related Art
[0004] Nano-sized ultrafine powder, which refers to a powder having a particle size of less than 50 nm, is widely used as a new material due to its large specific surface area per unit weight and high activity.
[0005] For example, nano-sized titanium dioxide ultrafine powder is used as a high-quality pigment and a photocatalyst, as well as cosmetics, medicines and coating material for transparent sound proof plates.
[0006] There are two conventional methods to produce nano-sized titanium dioxide (hereinafter, referred to as “TiO 2 ”) ultrafine powder: a physical method that comprises vaporizing a metal by heating and condensing the metal vapor into ultrafine powder, and a chemical method that involves the chemical reaction of metal compounds.
[0007] The physical method for producing nano-sized TiO 2 ultrafine powder requires great energy consumption for vaporization of the metal with the result of high production cost and low productivity but makes it possible to product high-purity powder. On the other hand, the chemical method provides low-purity powder at a low production cost with high productivity, and includes a gas phase method and a liquid phase method.
[0008] Now, a description will be given as to a method for producing nano-sized TiO 2 ultrafine powder by the chemical method related to the present invention.
[0009] In the preparation of nano-sized TiO 2 ultrafine powder by the gas phase chemical reaction method, it is necessary to provide a high temperature of at least 1000° C. and large gas flow rate. For this purpose, an approach for providing reaction conditions in the gas phase and high temperature using flames is known, wherein flame temperature, gas flow rate, concentration of reactants, and additives are critical reaction parameters that control the size and crystal form of the primary particles in the preparation of ultrafine powder.
[0010] The conventional approach for producing ultrafine powder by the gas phase chemical reaction using flames is disclosed in U.S. Pat. No. 5,698,177 under the title of “Process for producing ceramic powders, especially titanium dioxide useful as a photocatalyst” as filed on Jun. 8, 1995; and U.S. Pat. No. 5,861,132 under the title of “Vapor phase flame process for making ceramic particles using a corona discharge electric field” as filed on Sep. 4, 1997.
[0011] U.S. Pat. No. 5,698,177 suggests various methods in regard to the control of reaction parameters, the use of additives and the effect of the corona electric field formed over the burner of the reactor to produce TiO 2 powder for photocatalyst in the reaction system composed of TiCl 4 , air, and hydrocarbon-based fuel gas. The claims of this patent define the preparation of TiO 2 powder by the gas phase reaction of TiCl 4 and oxygen, the flame reactor used in the preparation, how to inject the sample, the added amount of sample and air, the voltage of the electric field, and the amount of additives.
[0012] In addition, U.S. Pat. No. 5,861,132 discloses a process for producing powders of various metal oxides (e.g., silica, alumina, zirconia, etc.) including TiO 2 powder with various flame reactors (e.g., pre-mixed flame reactor, turbulent flame reactor, or larminar diffusion flame reactor) while providing the corona electric field over the reactor.
[0013] In the preparation of nano-sized powder using the gas phase chemical reaction, the concentration of the sample in the reaction gas has to be considerably low and an excess of gas has to be introduced into the reaction region (flame) with increasing the added amount of the reactant in order to increase the yield of the nano-sized powder per unit time.
[0014] However, the reaction system of the combustion gas composed of TiCl 4 , air and hydrocarbon introduced into the three pipes as suggested in U.S. Pat. No. 5,698,177 has a problem that the linear velocity of the gas increases in the burner due to an excess of air to reduce the retention time of the reactant, thus resulting in existence of non-reacted materials and incomplete combustion of the fuel gas.
SUMMARY OF THE INVENTION
[0015] It is, therefore, an object of the present invention to solve the problem and to provide a method for producing nano-sized TiO 2 ultrafine powder from TiCl 4 using the reaction system of TiCl 4 -argon-hydrogen-oxygen-air, TiCl 4 -argon-hydrogen-air-air, or TiCl 4 -argon-hydrogen-oxygen/air-air with a five-piped turbulent diffusion flame reactor, the method comprising: maintaining a low concentration of the sample in the reaction gas, minimizing the amount of non-reacted materials and completely combusting the fuel gas (hydrogen) to increase the yield of the nano-sized powder per unit time.
[0016] To achieve the above object of the present invention, there is provided a method for producing nano-sized TiO 2 ultrafine powder through oxidation with a mixed gas system passed through flames having a high temperature, the mixed gas system being composed of TiCl 4 -argon-hydrogen-oxygen-air, TiCl 4 -argon-hydrogen-air-air, or TiCl 4 -argon-hydrogen-oxygen/air-air and obtained from vaporization of a liquid reactant, TiCl 4 . In the preparation method, the TiO 2 ultrafine powder can have optimum particle size and crystal form by varying critical parameters such as the TiCl 4 content in the reaction gas, the flow rate and composition of the gas, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a schematic diagram of an apparatus for producing ultrafine powder as used in the present invention;
[0018] [0018]FIG. 2 is an electron micrograph of the TiO 2 ultrafine powder produced with various concentrations of TiCl 4 in the reaction gas;
[0019] [0019]FIG. 3 is a diagram showing the analysis results for the crystal structure of the TiO 2 ultrafine powder produced with various flow rates of oxygen; and
[0020] [0020]FIG. 4 is a diagram showing the change in the average particle size and the crystal form of the TiO 2 ultrafine powder produced with various flow rates of oxygen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Hereinafter, a description will be given in detail with reference to the accompanying drawings as to a method for producing nano-sized TiO 2 ultrafine powder while controlling the amount of TiCl 4 vapor, hydrogen, oxygen, air and argon injected into the flame reactor.
[0022] [0022]FIG. 1 is a schematic diagram of an apparatus for producing the TiO 2 ultrafine powder as used in the present invention, in which the apparatus includes a sample vaporizer 10 for vaporizing liquid TiCl 4 as a reactant, and a five-piped burner 20 for producing flames through which the TiCl 4 vapor is passed to form nano-sized TiO 2 ultrafine powder by the oxidation reaction.
EXAMPLE 1
[0023] This example is to control the particle size of the TiO 2 ultrafine powder produced by varying the concentration of TiCl 4 in the reaction gas.
[0024] TiCl 4 (99.9%) as a liquid sample was injected into a vaporization container 11 of the sample vaporizer 10 with a syringe pump 12 while maintaining the temperature of a vaporization tank 13 at 180° C. After vaporization of TiCl 4 , the TiCl 4 vapor together with argon (Ar) as a carrier gas was injected into a first pipe 14 disposed in the center of the burner 20 . Argon, hydrogen, oxygen and air were injected into the five-piped burner 20 via second to fifth pipes 15 , 16 , 17 and 18 at the rate as presented in Table 1 to form flames, and Reynolds numbers at each tube are also presented in Table 1.
[0025] The concentration of TiCl 4 in the gas injected into the burner 20 was controlled in the range of 1.13×10 −5 to 4.54×10 −5 mol/l. The flow rate of the gas injected into the five-piped burner was checked with eyes to maintain the stable flame state and controlled as presented in Table 1.
TABLE 1 Division Gas Flow Rate (λ/min) N Re First Pipe Argon and TiCl 4 (g) 2 16,500 Second Pipe Ar 5 41,200 Third Pipe Hydrogen 6 5,000 Fourth Pipe Oxygen 15 90,600 Fifth Pipe Air 60 272,500
[0026] The temperature distribution of the flame thus formed was measured with a R-type thermocouple. The flame temperature was constant at about 850° C. in the center of the burner and maximum (1700° C.) at around 7 mm from the center of the burner in the radius direction.
[0027] The powder formed by changing the concentration of TiCl 4 in the reaction gas under the combustion conditions as shown in Table 1 was measured in regard to particle size and crystal structure. The average particle size was determined from the results of a BET analysis performed to measure the specific surface area of the particle per unit weight assuming that the particles are non-porous globular particles, according to a reduced equation (d p =6/(ρ p ·A, wherein ρ p is the density (g/cm 3 ) of TiO 2 ; and A is the specific surface area (m 2 /g)).
[0028] The average particle size of the TiO 2 ultrafine powder was increased from 19 nm to 28 nm with an increase in the concentration of the sample.
[0029] [0029]FIG. 2 shows an electron micrograph of the nano-sized TiO 2 ultrafine powder produced by the above-described method (initial concentration of TiCi 4 : (a) 1.13×10 −5 mol/l, (b) 2.27×10 −5 mol/l, (c) 3.45×10 −5 mol/l, and (d) 1.54×10 −5 mol/l). As apparent from the figure, the particle size was increased with an increase in the concentration of the reactant in the almost same manner as the results of the BET analysis. An XRD analysis was performed to determine the crystal form of the TiO 2 powder, showing that about 45% of the powder was of the anatage type under the experimental conditions of the present invention.
EXAMPLE 2
[0030] This example is to produce TiO 2 powder by reducing the flow rate of oxygen injected into the reactor to lower the temperature of the flame. For experimental conditions, the flow rate of oxygen injected into the fourth pipe 17 was reduced from 15 to 5 l/min from the gas injection conditions presented in Table 1. Subsequently, the flow rate of air injected into the fifth pipe 18 was increased to maintain the total flow rate constant so that the concentration of TiCl 4 in the reaction gas was maintained at a constant level (2.27×10 −5 mol/l). The maximum temperature of the flame in this case was lowered from 1700° C. to 1400° C.
[0031] TiO 2 powder was produced under the experimental conditions, in which case the average particle size of the TiO 2 fine powder was reduced from 23 nm to 14 nm with a decrease in the flow rate of oxygen. Such a reduction of the average particle size resulted from the decreased growth rate of the particles due to agglomeration as the maximum temperature of the flame was lowered.
[0032] The analysis results for the crystal form of the TiO 2 powder produced by the above-described method are illustrated in FIG. 3 (the flow rate of oxygen: (a) 15 l/min, (b) 10 l/min, and 5 l/min). It is apparent from the results of FIG. 3 that the anatage content hardly changed with a decrease in the flow rate of oxygen to 10 1/min but sharply increased at the flow rate of oxygen dropped to 5 l/min.
[0033] A quantitative analysis of the anatage content revealed that the anatage content was 41%, 45% and 80% with a decrease in the flow rate of oxygen.
EXAMPLE 3
[0034] This example is to analyze the particle size and the crystal form of TiO 2 powder produced under constant reaction conditions with various flow rates of oxygen injected into the reactor in the range from 4 to 8 l/min.
[0035] For experimental conditions, the concentration of TiCl 4 was maintained at a constant level of 2.27×10 −5 mol/l, and the amount of the gas except for hydrogen was 5 l/min at the second pipe 15 for argon (Ar), 10 l/min at the fourth pipe 17 for air, and 65 l/min at the fifth pipe 18 for air.
[0036] In this example, the gas injected into the fourth pipe 17 of the burner was air instead of oxygen in order to minimize the amount of oxygen. At this time, the temperature of the flam thus formed was measured with a change in the flow rate of hydrogen and the maximum temperature of the flame was varied from 1,300° C. to 1,000° C.
[0037] TiO 2 powder was produced under the conditions, in which case the average particle size of the TiO 2 fine powder was reduced from 29 nm to 14 nm with a decrease in the flow rate of hydrogen from 8 l/min to 4 l/min. But, the average particle size was constant when the flow rate of hydrogen was less than 5 l/min.
[0038] As for the crystal size of the TiO 2 powder, the anatage content was increased from 27% to 75% (FIG. 4) with a decrease in the flow rate of hydrogen from 8 l/min to 4 l/min.
EXAMPLE 4
[0039] This example is to produce TiO 2 powder by mixing air with the oxygen gas injected into the fourth pipe 17 under conditions of Example 2. As for the experimental conditions, the concentration of TiCl 4 and the total flow rate were maintained as described in Example 2. The flow rate of hydrogen was 5 l/min in the third pipe 15 , while a mixture of oxygen having a flow rate of 4 l/min and air having a flow rate of 6 l/min was injected into the fourth pipe 17 .
[0040] The TiO 2 powder thus obtained had an average particle size of 15 nm and an anatage content of 77%.
[0041] As described above, the present invention uses a five-piped reactor in preparation of nano-sized TiO 2 ultrafine powder by the gas phase chemical reaction using flames, in which the TiO 2 ultrafine powder is produced in the reaction system of TiCl 4 -argon-hydrogen-oxygen-air, TiCl 4 -argon-hydrogen-air-air, or TiCl 4 -argon-hydrogen-oxygen/air-air, thereby providing a design data for large-scaled production. | Disclosed is a method for producing nano-sized titanium dioxide (TiO 2 ) ultrafine powder from titanium tetrachloride (TiCl 4 ) in the vapor phase by the gas phase oxidation reaction using flames, in which the method comprises: simultaneously introducing titanium tetrachloride (TiCl 4 ), vapor, argon, oxygen, hydrogen and air into a five-piped flame reactor to form a flame having a temperature of greater than 1,000° C.; and producing nano-sized titanium dioxide ultrafine powder having an average particle size of less than 50 nm. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to foundry mold and core blowing machines incorporating a sand/resin mixture. More particularly this invention relates to the mixing chamber or nozzle of such a blowing machine.
2. Description of the Prior Art
In the foundry art, cores or molds are made from mixtures of aggregate materials, ordinarily sand, which have been combined with polymerizable or curable material. After the sand and binder have been mixed, the resulting sand/binder mix is rammed, blown or otherwise introduced into a pattern, thereby causing it to assume the shape defined by the adjacent surfaces of the pattern. Polymerization or curing is induced by one means or another (catalyst, heat, etc.) thereby converting the formed, uncured, plastic, foundry sand mix into a hard, solid, cured state.
In recent years an increasing demand for dimensionally accurate cores has been felt by the foundry industry. Another pressure felt by the industry is the ever present need to reduce the core or mold cure time to a minimum. One way to reduce the machine cycle time and thereby increase production is to reduce the curing time of the curable resin.
In response to this need, the foundry industry has developed machines, processes and resin/catalyst mixtures that allow increasingly rapid cure and correspondingly short machine recycle time. See U.S. Pat. Nos. 3,255,500; 3,494,412 and 3,472,307, which patents are illustrative of the prior art techniques.
One of the methods developed in the prior art is the process of mixing a resin and a catalyst which react rapidly without heat, called the kold box process. The resin and catalyst are independently mixed with two separate charges of sand and then brought together and mixed only at the last minute before blowing the sand/resin/catalyst mixture into the core box. In practice, the sand/resin/catalyst mixture is delivered, after mixing, to a second chamber which is closed off and pressurized to blow the sand into the core box. After a short period at room temperature, the cured core may be removed from the box. Reasonable results in both the areas of dimensional accuracy and minimum recycle time have become possible with improved binders.
A major difficulty that has been encountered in the prior art is that any residual sand/catalyst/resin mixture remaining anywhere in the mixing and blowing chambers of the blow machine cure just as rapidly as the blown core or mold. Once cured, these sand/resin/catalyst residues adhere to the surfaces of the machine and tend to impede the passage of subsequent charges of sand through the machine thereby preventing its proper operation. In addition, if the volume of the charges of the originally prepared sand/resin/catalyst mixture are greater than the volume of the core to be blown, a small amount of overflow remains in the blow nozzle, necessitating swinging the machine aside and cleaning the nozzle before the short time period required for the resin to cure. A final difficulty in the prior art blowing machines arises if, for some reason, the blow operation is interrupted after the sand/resin/catalyst mixture has been mixed and delivered to the blow chamber but before actual blowing into the core box. This mixed charge must be immediately removed and discarded or the mixture will cure within the blow chamber rendering the blow machine inoperable.
One attempted solution to the above-mentioned problems has been to premeasure the sand charges so that there is no excess sand after the blow of the core. This attempted solution has proved unsatisfactory since the measurement process is subject to error and also increases the machine cycle time. If the prepared charge is short, the core fails and the entire charge of sand must be discarded.
SUMMARY OF THE INVENTION
The present invention is directed to the mixing chamber or nozzle of a core or mold blowing machine. Sand mixed with resin and sand mixed with catalyst are introduced into the mixing chamber in alternating streams by alternating ducts. Within the mixing chamber is positioned a baffle that induces turbulence and mixing in the flow of the sand in its passage through the chamber. An alternative arrangement is provided where the sand introduced into the chamber has been previously mixed with either resin or catalyst. The other element, i.e., the resin or catalyst not mixed with the sand, is independently introduced into the chamber in predetermined amounts, in close mixing relation with the sand so that adequate mixing occurs.
In either arrangement, after mixing, the sand/resin/catalyst is delivered into the core or mold box through an exit opening. Any remaining sand/resin/catalyst residue is immediately swept from the nozzle or mixing chamber by a movable sweep or plunger which has the same cross section as the chamber. The movement of the plunger causes the turbulence inducing baffle to be carried outside of the nozzle where it may be flushed or cleaned of any and all sand/resin/catalyst particles adhering thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of a kold box core making machine.
FIG. 2 is a plan view of the alternating inlet ductwork of FIG. 1 taken along sight lines 2--2.
FIG. 3 is a sectional drawing of a kold box core making machine as shown in FIG. 1 but with an alternative resin/catalyst introduction arrangement.
FIG. 4 is a cross-sectional picture of the mixing chamber of FIG. 3 taken along sight lines 4--4.
FIG. 5 is an exploded view of converging section 22 of FIG. 1 in position above shuttle 34, which is shown in perspective in its cleaning position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will now be further described with reference to the accompanying drawings. FIG. 1 illustrates a cross-sectional view of the apparatus suitable for carrying out the process of the invention. At the upper end of the apparatus is provided a premix storage hopper 16 separated into two chambers A and B by separating wall 18. A foundry sand/resin mixture and a foundry sand/catalyst mixture may comprise the two foundry materials to be contained by chambers A and B. At the lower end of the storage chambers is provided a converging section 22 composed of intermeshing delivery ducts 24 and 26. As shown in FIG. 5, the duct-forming members 29 form ducts 24, which conduct material from chamber A to mixing chamber 32, while duct-forming members 31 form ducts 26, which conduct material from chamber B. Through these ducts the respective materials in chambers A and B are introduced in alternating array into mixing chamber 32 through rectangular apertures 28 (see FIG. 2). Mixing chamber 32 is made up of a plurality of stationary surfaces and two opposite movable surfaces. Within the mixing chamber 32 is positioned a turbulence inducing baffle 30 (see FIG. 4 for cross-sectional detail) which interrupts the flow of sand by separating the sand flow into two parts with each part passing around opposite sides of the baffle 30. By separating and compressing the sand flow in its movement around the baffle 30 and by subsequently releasing the compression and inducing expansion, the alternating materials from chambers A and B are caused to be turbulently mixed within the chamber 32. Subsequent to this mixing, the mixed material passes through an outwardly diverging exit opening 36 for immediate delivery into a core or mold box 38.
The impetus required to force materials from chambers A and B through the mixing chamber 32 and into the core box 38 is provided by pressure administered to the foundry material contained in storage chamber 16 by means of pressurized air passing through valve 10 and air pressure lines 12. A movable cap plate 14 is positioned at the top of premix storage hopper 16 so that it may be clamped down in an air-tight connection on the top of premix storage hopper 16. The pressurized air from the air pipes 12 is introduced into the respective chambers A and B through holes in cap plate 14 thereby "blowing" the materials contained in chambers A and B through the converging ducts 24 and 26 and the mixing nozzle 20.
The turbulence inducing baffle 30 is held within the mixing chamber 32 in a fixed position between the two opposite movable surfaces which themselves are carried by movable shuttle member 34. This movable shuttle member 34 and the mixing nozzle 20 are adapted so that the shuttle member 34 may be moved through the mixing chamber 32 thereby moving one of the movable surfaces across the stationary surfaces. By so moving the shuttle member 34, mixing chamber 32 is swept of any residual mixed materials. Also by pushing the movable shuttle 34 through mixing chamber 32 parallel to the lengths of the rectangular apertures 28, the partitions 27 between alternating apertures 28 are cleaned off and the apertures 28 are then closed off by shuttle 34. The motion of the shuttle 34 along the length of the apertures 28 insures a good wiping and cleaning of the partitions 27 separating the apertures 28. The premix nozzle, generally indicated as 20, may be adapted in such a manner that upon motion of the movable shuttle member 34 the mixing baffle 30 is removed to a position outside of the mixing nozzle 20 to a cleaning position 40. At this position any residual mixed material that has been moved out of the mixing chamber by the movement of shuttle 34 may be discarded and any residual matter adhering to the shuttle 34 or the mixing baffle 30 may be immediately cleaned off by a cleaning means 42. Shuttle 34 may be left in a flow blocking position until the next blow operation, or it may be moved back to re-position baffle 30 in the mixing chamber 32 in preparation for the next blowing operation.
An alternative arrangement is provided wherein premix storage hopper 16 consists of only one chamber (see FIG. 3). Storage chamber 16 may hold one material, sand, which has previously been mixed with either resin or catalyst. The sand mixture is delivered through a converging section, generally indicated by 22, into the mixing chamber 32 wherein the missing component, resin or catalyst, is introduced in close mixing relation with the turbulently flowing sand that is passing through the nozzle 20. In FIG. 3 one possible arrangement has been illustrated wherein the missing resin or catalyst is introduced into the mixing chamber 32 through a passage 14 located in the movable shuttle 34. Passage 44 may be adapted to deliver the missing element, catalyst or resin, into the mixing chamber through spraying orifices 46 in the turbulence inducing baffle 30 (see FIGS. 3 or 4). Another arrangement (not shown) would be to introduce the missing element, catalyst or resin, into the mixing chamber 32 by a spray or flow of the material from the side walls of the mixing chamber 32.
The operation of the apparatus is described as follows. The premix nozzle and premix storage hopper are swung to the side to receive loads of foundry sand mixed with resin and foundry sand mixed with catalyst in the respective chambers A and B. Subsequent to filling storage hopper 16, the apparatus is swung back into a blowing position. Movable cap plate 14 is then lowered into an air-sealing position thereby clamping off the top of storage hopper 16 and chambers A and B. Valve 10 is opened to introduce pressurized air through air pipes 12 into chambers A and B to force the sand/resin mixture and the sand/catalyst mixture through the converging section 22 into the mixing chamber 32. In the mixing chamber intermixing occurs and immediate discharge of the mixed sand/catalyst/resin is made to the core or mold box 38 where it cures to form the desired core or mold. Upon the termination of the blowing operation, the movable shuttle 34 is immediately moved through the mixing chamber 32 thereby sweeping and cleaning the mixing chamber 32 of any residual sand/catalyst/resin mixture. The immediate sweeping and cleaning of chamber 32 prevents mixed sand/resin/catalyst from adhering and accumulating in the interior of the mixing chamber. Without this clean-out feature, the accumulation would eventually prevent proper subsequent operation of the mixing nozzle and the blowing machine. The baffle 30 is also moved to a cleaning position and immediately cleaned.
In the prior art virtually all kinetic energy of the sand entering the mixing chamber was expended within the mixing chamber. It was therefore necessary to transfer the sand/resin/catalyst mixture to a blow tube. In a separate step the blowing tube was sealed off and new impetus was given to the sand for blowing into the mold by a second source of pressurized air applied to this separate blowing tube. Such is not the case in the present invention. During blowing, the mixing chamber of the disclosed invention is always essentially full of sand. The sand being blown into the chamber continually pushes the sand already in the chamber through the chamber's exit with sufficient force to accomplish direct and immediate blowing of the core. Therefore, the need for a separate blowing tube is eliminated. Also in the prior art any accumulation that occurs in the separate blowing chamber or in the mixing nozzle itself necessitates swinging the machine out of blowing position for cleaning. In the present invention the slide-through shuttle enables complete cleaning while the blowing machine remains in its blowing position. An additioanl feature which reduces machine recycle time is that the premix storage hopper can be of sufficient volume to blow more than one core without requiring the interruption of swinging the machine aside and refilling the hopper. One feature of the present invention, unlike the prior art, is that there is no need to carefully premeasure the charges of sand since the blowing operation can be terminated when the core is full by removing the air pressure on the sand or by simply sliding the shuttle through the mixing chamber and into a flow blocking position. When the blowing machine has been "shut off" in this manner, no residual sand/catalyst/resin mixture remains within the machine which can cure and cause subsequent obstruction.
It will be understood that the embodiment shown and described herein is merely illustrative and that changes may be made without departing from the scope of the invention as claimed. | A foundry mold or core blowing premix nozzle for use in connection with the kold core process. The nozzle contains a mixing chamber that allows thorough mixing to occur during the blowing process. Immediately after the blowing operation the nozzle may be cleaned of any residual sand/catalyst/resin mixture which would ordinarily set up and clog the nozzle if allowed to remain within the nozzle. This cleaning feature is provided by a push through shuttle that sweeps the mixing chamber and moves a turbulence inducing baffle, normally positioned within the chamber, to a position external to the nozzle where it may readily be cleaned. | 1 |
PRIORITY Claim
[0001] The present application claims priority from U.S. Provisional Patent Application No. 60/228,937 and filed Aug. 30, 2000, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to apparatuses for the treatment of hydrocephalus or the like, and more particularly relates to cerebrospinal fluid (“CSF”) shunts.
BACKGROUND OF THE INVENTION
[0003] CSF shunts are well known and used broadly to treat patients with chronic hydrocephalus. In simple terms, such shunts typically have an inlet located in the patient's brain, and an outlet into some portion of the body which can accept and expel the excess fluid. A detailed discussion of prior art CSF shunts can be found in Drake et al, The Shunt Book , ©1995 Blackwell Science, Inc. Massachusetts, (“Drake”) the contents of which are incorporated herein by reference.
[0004] More particularly, ventriculoperitoneal (“VP”) shunts are designed to drain CSF from the brain into the peritoneal cavity. VP shunts are used in a variety of medical conditions and are implanted in both young and old patients. Certain configurations of prior art VP shunts can include a ventricular catheter, a flow-valve that can be changed by an external magnet, and a tunneled abdominal catheter. Further discussion on this type of shunt can be found in Reinprecht A., et al., “The Medos Hakim programmable valve in the treatment of pediatric hydrocephalus.”, Childs Nerv Syst, 1997 November-December; 13(11-12):588-93. The ventricular cather and flow-valve are inserted through a scalp incision. The major complications from these and other prior art shunts include infection, obstruction, disconnection, under draining, and over draining, all of which can lead to serious injury and even death. The symptoms of shunt failure and malfunction are nonspecific and include fever, nausea, vomiting, irritability and malaise. A patient presenting to a medical facility with such symptoms warrants a thorough radiological, laboratory, and occasionally a surgical evaluation. As known to those of skill in the art, insertion of CSF shunts requires a highly skilled surgeon or radiologist working under CT X-Ray guidance, but once inserted, such shunts are frequently prone to failure.
[0005] More recent shunts that attempt to overcome some disadvantages of older shunts include the use of telemetry, as discussed in Miyake H. et al., “A new ventriculpertoneal shunt with a telemetric intracranial pressure sensor: clinical experience in 94 patients with hydrocephalus”, Neurosurgery, 1997 May; 40(5): 931-5 and Munshi H., “Intraventricular pressure dynamics in patients with ventriculopleural shunts: a telemetric study”, Pedatr Neursurg, 1998 February; 28(2): 67-9 Despite the fact that Miyake and Munshi teach the use of telemetrics with shunts, the shunts taught therein are still prone to failure due to infection, blockages and other difficulties, such that failures of such shunts can still require complete replacement of the shunt.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide a CSF shunt that obviates or mitigates at least one of the disadvantages of the prior art.
[0007] In an aspect of the invention, there is provided a shunt for draining cerebral spinal fluid comprising a first catheter for insertion into an area of the patient that has excess CSF, and for receiving CSF therefrom. The shunt also includes a second catheter for insertion into a drainage cavity for draining the CSF, and a master control unit for insertion into the patient in a biocompatible location. The master control unit interconnects the catheters via a catheter line, and has a regulator for selectively draining an excess of the CSF. The shunt also includes at least one access port intermediate the first catheter and the second catheter, and which is placed subcutaneously such that when the access port is inserted into the patient, the access port provides a point of access to the shunt for allowing a treatment a condition associated with the shunt without requiring the shunt's removal.
[0008] In a particular implementation of the first aspect, the CSF space is a ventricle.
[0009] In a particular implementation of the first aspect, the drainage space is one of the patient's peritoneum, pleural space or vascular space.
[0010] In a particular implementation of the first aspect, the biocompatible location is one of the patient's skull, chest cavity or abdomen.
[0011] In a particular implementation of the first aspect, the regulator is a mechanical flow-valve regulator.
[0012] In a particular implementation of the first aspect, the regulator is a microprocessor based valve-gauge assembly for determining when the CSF requires draining and allowing the CSF to drain from the ventricle to the drainage cavity.
[0013] In a particular implementation of the first aspect, the microprocessor based valve-gauge assembly has a normally-open position to allow a preset amount of drainage of CSF in the event of a power-failure to valve-gauge assembly.
[0014] In a particular implementation of the first aspect, the shunt further comprises a diagnostic unit for detecting abnormal metabolic activity within the patient, and a transmitter for delivering the activity to a receiver external to the patient.
[0015] In a particular implementation of the first aspect, the transmitter is operable to perform the delivery wirelessly to the receiver.
[0016] In a particular implementation of the first aspect, the transmitter includes a memory buffer for accumulating data from the diagnostic unit prior to the delivery,
[0017] In a particular implementation of the first aspect, the condition is a blockage and the at least one access port allows an introduction point of introduction of a blockage-ablation device within the catheter line for physically breaking-up the blockage.
[0018] In a particular implementation of the first aspect, the blockage-ablation device is a micro-catheter with a tip suitable for piercing the blockage.
[0019] In a particular implementation of the first aspect, blockage-ablation device is a radio-frequency ablation device.
[0020] In a particular implementation of the first aspect, the at least one access ports is mounted on an exterior of the master control, the control unit further having a fluid bladder accessible via the access port for injection of at least one solution for treatment of a condition.
[0021] In a particular implementation of the first aspect, condition a blockage and a solution for treatment thereof and injection via the access port is an anticoagulant or a thrombolytic.
[0022] In a particular implementation of the first aspect, the condition is an infection and a solution for treatment thereof and injection via the access port is an antibiotic.
[0023] In a particular implementation of the first aspect, the at least one access port includes a self-healing plastic membrane.
[0024] In a particular implementation of the first aspect, there at least two access ports and wherein one of the access ports is located on the catheter line intermediate the master control unit and the second catheter and wherein a second one of the access ports is located on the catheter line intermediate the first catheter and the master control unit.
[0025] In a particular implementation of the first aspect, the shunt further comprises a transmitter connected to the valve-gauge assembly for gathering pressure information therefrom, the transmitter for reporting the pressure information to a receiver external to the patient.
[0026] In a particular implementation of the first aspect, at least a portion of the shunt has an antibiotic coating.
[0027] A shunt for draining cerebral spinal fluid from the brain is provided. In an embodiment, the shunt includes a master control unit that is located in the abdomen, chest wall, in the skull, on the skull or other suitable location, which interconnects a first catheter and a second catheter that is typically located in the peritoneal cavity. In a specific embodiment, the master control unit is located in the abdomen, and includes a variety of intelligent features including at least one access port to allow the injection of solutions for the prevention or removal of blockages in the catheter, and/or antibiotics. Additionally, such ports can allow a radiologist (or the like) to navigate within the shunt to physically remove blockages or perform other remedial and/or diagnostic activities throughout the shunt system. Additionally, the master control unit includes a diagnostic unit that transmits, either wirelessly or through a wired connection via the access port, diagnostic information about the status of the patient and/or the shunt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Preferred embodiments of the invention will now be discussed, by way of example only, with reference to the attached Figures, in which:
[0029] [0029]FIG. 1 is a schematic representation of a CSF shunt in accordance with an embodiment of the invention; and,
[0030] [0030]FIG. 2 is a schematic representation of a CSF shunt in accordance with another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to FIG. 1, a schematic representation of a CSF shunt is indicated generally at 20 . Shunt 20 comprises a master control unit 24 (which can also be referred to as the active component) that interconnects a first catheter 28 , and a second catheter 32 via a catheter line 34 . Master control unit 24 is preferably minitiarized and made of a biocompatible material such that it can be safely inserted in the patient's abdomen, either intra-peritoneal or extra-peritoneal, using a standard abdominal incision, and remain therein as needed to drain CSF.
[0032] After master control unit 24 is inserted into the patient's abdomen, first catheter 28 can then be tunneled from the abdomen rostrally (or caudaly) into a CSF space in the scalp to serve as an inlet for excess CSF, which in a present embodiment is a ventricle. (As used herein, the term CSF space includes any space in the body that can generate an excess of CSF requiring drainage.) A small incision in the scalp can then be used to assist in the final positioning of first catheter 28 within the patient's head. By tunneling into the scalp, it is contemplated that this can obviate the need to separately connect catheter 28 to control unit 24 .
[0033] Similarly, second catheter 32 can be tunneled from below, up into the peritoneal cavity to serve as an outlet for the CSF. The tip of second catheter 32 is chosen to increase the flow of CSF drainage, and to reduce the likelihood of obstruction thereat. In one embodiment, the tip of catheter 32 is static, having a conical shape with drainage ports along the surface and underside thereof. In another embodiment, the tip of catheter 32 is resiliently expandable, for breaking up debris, adhesions or other occlusions that can develop over time. A suitable expandable tip is an appropriately modified angioplasty balloon, which can be inflated to break up adhesions.
[0034] Master control unit 24 is powered by a battery 36 (or other self-contained power source), such as a high-capacity battery such as already widely used in pacemakers, stimulators, defibrillators and the like. It is presently preferred that battery 36 be located external to master control unit 24 and inserted in subcutaneous tissue to provide easy access for replacement in the event of failure. It is also contemplated, however, that battery 36 could be integrally housed within master control unit 24 .
[0035] Master control unit 24 is also characterized by a first access port 40 and a second access port 42 , which provide access to certain other components within shunt 20 , the details of which will be discussed in greater detail below. Thus, as master control unit 24 is inserted in the abdomen, is it also oriented within the patient subcutaneously, such that access ports 40 and 42 are readily accessible. Further, the placement of master control 24 is preferably particularly chosen to reduce the likelihood of rotation or other movement of master control unit 24 , to reduce the likelihood that ports 40 and 42 become inaccessible due to rotation or shifting in the patient over time.
[0036] Access ports 40 and 42 include a self-healing plastic membrane, which can be punctured with a sharp instrument (i.e. a needle, catheter, or the like) and then reseal seal itself upon withdrawal the instrument. Such self-healing plastic membranes can be adapted from currently available membranes used in vascular access devices and other applications requiring puncturing and resealing.
[0037] Master control unit 24 houses a first fluid bladder 44 proximal to first access port 40 , and a second fluid bladder 46 proximal to second access port 42 . Thus, when access port 40 or 42 is opened, the bladder 44 or 46 respective thereto, is accessible for filling via injection or for providing other access to shunt 20 . Bladders 44 and 46 are typically made of silicon or other biocompatible material. Such injections could include heparin (or some other anti-thrombotic or anti-collagen agent) and/or an antibiotic solution, such as for prophylaxis treatment or treatment of infection. Bladders 44 , 46 are connected to catheter line 34 within control unit 24 , via a one-way valve 48 , 50 respectively. Thus, for example, an injection into bladder 44 can eventually work its way into catheter line 34 (particularly the portion between control unit 24 and the second catheter 32 ) and thereby dissolve any blockages therein, without the need for more invasive surgery required to replace the entire shunt 24 . Alternatively, an injection may be desired to be eventually introduced into the patient, and using bladder 44 such an injection can be eventually introduced into the patient's peritoneal cavity. It will be understood by those of skill in the art that the size of bladder 44 , and the mechanical flow characteristics of valves 48 are chosen to allow an appropriate quantity and rate of delivery of the injection into line 34 . By the same token, access port 42 , bladder 46 and valve 50 can also provide access to shunt 20 , and in particular to the portion of shunt 20 between master control unit 24 and first catheter 28 , and in turn, the patient's skull. In other embodiments, it is contemplated that additional access ports, bladders and valves could be provided in order to provide additional means to introduce injections into shunt 20 and/or the patient in a manner with reduced intrusion to the patient. Where a patient is indicated for other injection therapies, such as chemotherapy, the present invention thus has the added benefit of providing means for introducing such injections without the need for vascular access devices.
[0038] Also housed within master control unit 24 is a microprocessor-based valve-gauge assembly 52 . Valve-gauge assembly 52 includes known components, including a pressure gauge for monitoring the pressure of CSF present in line 34 , and a valve for selectively allowing CSF to flow through line 34 and towards second catheter 32 . Valve-gauge assembly 52 also includes a ventricular-gauge 54 that is located proximal to ventricular-catheter 28 and connected to the portion of assembly 52 housed within master control unit 24 via a control line 56 , which is preferably inserted into the patient in conjunction with first catheter 28 . Accordingly, in certain configurations control line 56 can be physically connected in parallel to the portion of catheter line 34 that runs between first catheter 28 and master control unit 24 , thereby allowing control line 56 and that portion of catheter line 34 to be inserted simultaneously.
[0039] Valve-gauge assembly 52 further includes a microprocessor (or other processing means) that is operable to receive inputs from the pressure gauges associated with assembly 52 and to output control signals to the valve within assembly 52 . The microprocessor is programmed with various criteria that determine when the valve should be opened or closed. Any decision-making criteria that determines the appropriate and/or desired drainage of CSF from the ventricles (or other CSF space) to the peritoneal cavity (or other drainage space) can be used. For example, such decision making criteria could be based on different times of day. Additionally, valve-gauge assembly 52 could also be provided with an accelerometer or other movement sensor, and/or a mercury switch or other type of position sensor that provides additional feedback as to the movement and/or position of the patient. Such information can be included with the information provided by the pressure gauges of assembly 52 , as part of the decision making critera as to how much CSF drainage to allow. One known valve-assembly 52 that could be extended beyond its current functionality to incorporate the additional functionality described hereabove (and thereby provide a novel shunt over the prior art) is taught in Reinprecht, previously cited.
[0040] It is also presently preferred that the valve portion of valve-gauge assembly 52 be configured to be normally-open to provide a pre-set rate of flow of CSF in the event of a power failure of battery 36 .
[0041] Master control unit 24 additionally houses a diagnostic unit 60 , that includes a probe operable to sample CSF passing through line 34 , and the outer surface of line 34 to detect the presence abnormal metabolic activity within the patient. Diagnostic unit 60 can be based on any means for detecting such abnormal metabolic activity, such as a ph/Redox. Diagnostic unit 60 further includes a microprocessor for interpreting the data gathered by the probe, and, based on a predefined set of diagnostic criteria, make determinations as to whether shunt 20 is operating properly. Such diagnostic criteria would include, for example, whether the pH level of CSF flowing through unit 60 changes by a predetermined amount, thereby indicating the presence of infection.
[0042] The processing units of valve-gauge assembly 52 and diagnostic unit 60 are both connected to a transmitter 64 . Transmitter 64 is operable to receive information from valve-gauge assembly 52 and diagnostic unit 60 and emit that information to a computing device external to the patient. In a present embodiment, transmitter 64 operates wirelessly, emitting an RF signal detectable by a receiver located proximal to the patient. In order to reduce battery consumption, it is preferred that transmitter 64 emit at a low power level. The external computing device that receives the emitted signal can then use the information to either automatically to diagnose any malfunction or infection, and/or simply pass the data in human-readable format to the patient's doctor or other skilled professional for review and analysis.
[0043] Referring now to FIG. 2, in another embodiment of the invention there is provided a shunt 20 a . Like components in shunt 20 a of FIG. 2 to the components of shunt 20 of FIG. 1 are given like reference numbers, followed by the suffix “a”. Thus, the components and operation of shunt 20 b are substantially identical to the components of shunt 20 , except that in shunt 20 a two additional access ports 70 and 74 are provided. Access port 70 is located along catheter line 34 a intermediate first catheter 28 and master control unit 24 , while access port 74 is located along catheter line 34 a at a point intermediate master control unit 24 and second catheter 32 . Access ports 70 and 74 are thus characterized by a chamber with an opening oriented towards the periphery of the patient's body, and covered with a self-healing plastic membrane, such as that previously described for access ports 40 , 42 .
[0044] Thus, access ports 70 and 74 provide additional points for injection, similar to access ports 40 and 42 . Access ports 70 and 74 also provide a means for a radiologist (or the like) to use X-ray guidance in order to physically navigate items such as catheters, wires, radio-frequency blockage ablation devices, imaging devices based on fiber optics or ultra sound, within the various passageways of catheter line 34 and other components of shunt 20 a . In this manner, blockages within catheter line 34 can by physically broken up using a catheter to tunnel through such blockages within line 34 . Other uses for navigation within catheter line 34 will occur to those of skill in the art.
[0045] Shunt 20 can be placed in patient using traditional surgical techniques, or it can be placed using an image-guidance technique such as radiological, CT, MR, fluoroscopy, or the like. Additionally, each component of shunt 20 can be coated with, or made from a material that allows such component to be readily viewed using a complementary imaging system. For example, such components could be radio-opaque for viewing under X-ray.
[0046] While only specific combinations of the various features and components of the present invention have been discussed herein, it will be apparent to those of skill in the art that desired subsets of the disclosed features and components and/or alternative combinations of these features and components can be utilized, as desired. For example, the embodiments discussed herein refer to a fluid bladder, it will be understood that other means for injecting a solution can be provided.
[0047] Furthermore, while the embodiments discussed herein contemplate the placement of master control unit 24 in the abdomen, it is contemplated that master control unit 24 can be modified for placement in other suitable areas intermediate first catheter 28 and second catheter 32 , such as the chest wall (similar to a pacemaker) or in the skull.
[0048] It is also to be understood that the access ports 40 , 42 of FIG. 1 can also be used for physically accessing shunt 20 for repairing master control unit 24 , or for introducing a microcatheter or the like, in addition to using such ports 40 , 42 for injections.
[0049] In addition, while not a requirement it is presently preferred that all or part of the components of shunt 24 are made from infection-resistant materials, such as using silicon tubing coated/impregnated with an antibiotic for catheter line 34 .
[0050] It is also contemplated that all or part of the various components of shunt 24 can be covered with an adhesion resistant coating.
[0051] While it is presently preferred to include microprocessor-based valve gauge assembly 52 , it is contemplated that in other embodiments of the invention such an assembly 52 could be replaced with another type of regulator, such as a traditional mechanical flow-valve currently found in CSF shunts, and thereby still provide an advantageous and novel shunt having access ports that can be used to treat conditions affecting the patient, such as those typically associated with the shunt's failure or infection of the patient, or the like.
[0052] While the embodiments herein teach the locating of first catheter 28 in the ventricles, it will now be apparent to those of skill in the art other types of receiving catheters for receiving excess CSF depending on the location from which the CSF is to be drained.
[0053] In addition, while the embodiments herein discuss the use of one-way valve 48 in conjunction with bladders 44 and 46 , in other embodiments it can be desired to incorporate different types of valves in order to allow aspiration, in addition to or in lieu of injection. For example, it can be desired to have one way valves 48 and 50 shown in FIG. 1 replaced with two-way valves, and include a one-way way valve on the portion of catheter line 34 intermediate master control unit 24 and second catheter 32 in order to ensure that fluids only flow from master control unit 24 towards second catheter 32 —thereby freeing up ports 40 and 42 for use as aspiration ports.
[0054] It is also contemplated that transmitter 64 can be substituted for a transceiver, that would not only permit downloading of data from shunt 20 to an external computing device, but would also accept uploaded information to shunt 20 from an external computing device. Such uploaded information can include, for example, reprogramming instructions for software programming used in the operation of in valve-gauge assembly 52 and/or diagnostic unit 60 .
[0055] Furthermore, while the embodiments discussed herein refer to two access ports with associated bladders and other means to access catheter line 34 , in other embodiments it is contemplated that there may be only one access port, or more than two access ports, as desired. Furthermore, it is contemplated that such additional or fewer access ports could also be provided with additional bladders per access port, as desired.
[0056] Furthermore, while transmitter 64 of the embodiments discussed herein is wireless, it is also contemplated that transmitter 64 could function wirelessly, by attaching a data port, such as a serial port to transmitter 64 , that is accessible via port 40 . Further, it is also contemplated that transmitter 64 can include a memory buffer to allow an accumulation of data to be gathered, prior to downloading the data by transmission, and thereby providing a greater sampling of data without the need for interfering with the patient's mobility and/or relying on the patient's full-time proximity to a receiver to detect the transmission.
[0057] The present invention provides a novel shunt for draining CSF that has a main control unit that is located in the abdomen of the patient. The main control unit includes an access port that allows the injection of a solution into the shunt. Such a solution can include an anticoagulant or collagenase to treat an obstruction in the catheter. Other solutions can be injected, as desired. By providing one, two or more access ports, problems with the shunt can be addressed without the need for invasive surgery, such as removing and/or replacing the shunt. The access ports can also be used to allow physical navigation within the passageways of the shunt, thereby allowing repair of the shunt under radiological guidance, or to allow blockages to be broken-up under radiological guidance. Additionally, diagnostic functions are included within the shunt to provide information as to the operation of the shunt and/or information about the pressures and rates of drainage of CSF in the patient. Such diagnosis can also mitigate the need for invasive surgery, as can be required in certain prior art shunts, to ascertain the cause of a shunt failure. The shunt of the present invention can thus allow the diagnosis of shunt failure, and treatment thereof, without the need for additional surgery on the patient. | A shunt for draining cerebral spinal fluid from the brain is provided. In an embodiment, the shunt includes a master control unit that is located in the abdomen, which interconnects a ventricular catheter and a second catheter, typically located in the peritoneal cavity. In a specific embodiment, the master control unit includes a variety of ‘smart’ features including at least one access port to allow the injection of solutions for the prevention or removal of blockages in the catheter, and/or antibiotics. The access port can have other uses, such as allowing a point of access for physical navigation of a catheter or the like within the shunt, thereby providing another option for breaking-up blockages, and/or allowing an access point for repairing the shunt's components. Additionally, the master control unit includes a diagnostic unit that transmits, either wirelessly or through a wired connection via the access port, diagnostic information about the status of the patient and/or the shunt. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a novel L-glutamic acid oxidase and its production.
More specifically, the present invention relates to an L-glutamic acid oxidase which exhibits a strong affinity and a high substrate specificity for L-glutamic acid, but has substantially no action on other amino acids and yet has a high stability, and to a microbiological method of production thereof.
Recently, an L-amino acid oxidase having a substrate specificity for L-glutamic acid has been found to be produced by cultivation of a microorganism belonging to the genus Streptomyces (hereinafter sometimes abbreviated as "S."), more specifically Streptomyces violascens (See Japanese Patent Laid-Open Publication No. 43685/1982). The physicochemical properties of the glutamic acid oxidase (hereinafter sometimes abbreviated as "known enzyme") as a protein have not yet been clarified, but the known enzyme is described to have enzymological properties as follows.
(1) Substrate specificity
When the velocity of enzymatic reaction for L-glutamic acid is given as 100, the known enzyme has a relative activity of 8.4 for L-glutamine and 6.8 for L-histidine, exhibiting substantially no activity for other amino acids.
(2) Optimum pH
pH 5-6
(3) pH stability
Stable in the range of pH 3.5-6.5 (37° C., maintained for one hour)
(4) Temperature stability
Stable up to 50° C. (maintained for 10 minutes)
(5) Influence of inhibitors
Substantially completely inhibited by mercury ions, copper ions and diethyldithiocarbamate.
The specification of the above Laid-Open Publication states that a liquid culture of the aforesaid microorganism is preferable for production of the known enzyme.
For utilization of the known enzyme for analysis of L-glutamic acid, various problems are involved. Specifically, although the known enzyme has a higher substrate specificity for L-glutamic acid as compared with other L-amino acid oxidases known in the art, it still exhibits clear activities for other amino acids as mentioned above, and therefore it cannot be used for specific quantitative determination of L-glutamic acid in the presence of these amino acids. Also, the known enzyme does not have a high pH stability and heat stability, and it cannot be considered to always have a good storage stability and stability during use as a reagent for analysis. Further, when copper ions exist in a sample to be analyzed, the activity of the known enzyme is markedly inhibited, whereby analysis may be considered to become difficult. Furthermore, the pH of reaction solutions employed in various clinical biochemical diagnostic analysis, especially in analysis of the activity of enzymes in blood, is usually around neutral, while the known enzyme will completely lose its activity at a pH of 7.5 when treated at 37° C. for one hour. For this reason, it may be difficult to use the known enzyme in analysis around the neutral pH range.
SUMMARY OF THE INVENTION
We have made investigations concerning enzymes which can oxidatively deaminate L-amino acids among the cultured products of microorganisms, and as a result have found that there exists an L-amino acid oxidase having an extremely high substrate specificity for L-glutamic acid in the cultured product of an actinomycete newly isolated from a soil sample. We have isolated and purified the enzyme of the present invention as a single enzyme protein from such a cultured product of the microorganism to accomplish the present invention.
The present invention provides an L-glutamic acid oxidase which is an L-amino acid oxidase having the ability to oxidatively deaminate the α-amino group of L-glutamic acid in the presence of water and oxygen to form α-ketoglutaric acid, ammonia and hydrogen peroxide. This oxidase has an extremely high substrate specificity for L-glutamic acid substantially without acting on L-glutamine and L-histidine, and also a high stability.
Further, the present invention also provides a method of producing an L-glutatic acid oxidase, which comprises culturing a microorganism belonging to the genus Streptomyces and having an ability to produce the aforesaid L-glutamic acid oxidase on a medium capable of growing the microorganism, and collecting the L-glutamic acid oxidase from the cultured product.
The enzyme of the present invention acts specifically on L-glutamic acid substantially without action on other amino acids, and therefore it is suitable for quantitative determination of L-glutamic acid in a system containing many kinds of amino acids. Its specificity for L-glutamic acid is so high that no pretreatment whatsoever of the sample, such as fractionation of amino acids in the sample, is required in carrying out the analysis. For example, it can be used for simple, rapid and specific measurement of glutamic acid content in foods containing many kinds of amino acids such as soy sauce, extracts, liquid seasonings, etc., the glutamic acid content being an important index in quality evaluation, for process control or process analysis in such fields as glutamic acid fermentation and production of soy sauce, and for screening of glutamic acid producing microorganisms. Also, since activity assays of enzymes forming glutamic acid as the product such as glutaminase, glutamic acid-oxaloacetic acid transaminase (GOT), glutamic acid-pyruvic acid transaminase (GPT), and γ-glutamyl transpeptidase (γ-GTP) can easily be done by the use of the enzyme of the present invention, this enzyme is useful in clinical diagnosis or in the field of biochemistry.
The enzyme of the present invention also has an advantage in the assay of its enzyme activity since its enzymatic reaction is an oxidase reaction most widely practiced in clinical diagnosis or food analysis.
Further, the enzyme of the present invention has a high stability when compared with enzymes for analysis in general including known enzymes, and therefore it can be utilized as an enzyme electrode for a glutamic acid sensor. It can also be expected to be utilized as a labelling enzyme in enzyme immunoassay (see Japanese Patent Laid-Open Publication No. 37261/1982), and further, the reagent for analysis is stable in storage and use, resulting in general applicability and economical advantage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing active pH ranges of the enzyme of the present invention (solid line) and the known enzyme (broken line);
FIG. 2 is a graph showing stable pH ranges (37° C., maintained for 60 minutes) of the enzyme of the present invention (solid line) and the known enzyme (broken line);
FIG. 3 is a graph showing the stable pH range (45° C., maintained for 15 minutes) of the enzyme of the present invention;
FIG. 4 is a graph showing the stable pH range (60° C., maintained for 15 minutes) of the enzyme of the present invention;
FIG. 5 is a graph showing the optimum acting temperature range of the enzyme of the present invention;
FIG. 6 is a graph showing stable temperature ranges of the enzyme of the present invention for different pH values (solid line), and the known enzyme (broken line); and
FIG. 7 is a graph showing the UV-absorption spectrum of the enzyme of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The enzyme of the present invention may be any L-glutamic acid oxidase which has a high stability and a very high substrate specificity for L-glutamic acid, substantially without action on amino acids other than L-glutamic acid, regardless of its preparation method.
An example of the enzyme of the present invention, is the enzyme obtained from the cultured product of a microorganism belonging to the genus Streptomyces, the properties and the method for preparation of this exemplary enzyme being detailed below.
(A) Enzymological and physicochemical properties of the enzyme of the present invention
The purified enzyme sample of the L-glutamic acid oxidase prepared according to the method of the Example hereinafter described has enzymological and physicochemical properties as set forth below.
(1) Action:
The enzyme of the present invention, when employing L-glutamic acid as substrate, demands 1 mol of oxygen and 1 mol of water per 1 mol of L-glutamic acid, and forms 1 mol of α-ketoglutaric acid, 1 mol of ammonia and 1 mol of hydrogen peroxide, as shown in the following reaction scheme. ##STR1##
(2) Substrate specificity:
Table 1 shows the results obtained when the purified preparation of the enzyme of the present invention was caused to catalyze the oxidation of various amino acids. The concentration of each substrate was 10 mM, and the reactions were carried out at pH 7.4 (0.1 M potassium phosphate buffer) and pH 6.0 (0.1 M acetate buffer). The enzyme activities were measured according to the oxygen electrode method as hereinafter described, and expressed as the relative values of activities to L-glutamic acid.
TABLE 1______________________________________ Relative Activity (%)Substrate pH 7.4 pH 6.0______________________________________L-Glutamic acid 100.0 100.0D-Glutamic acid <0.1 <0.1L-Aspartic acid 0.6 <0.1L-Glutamine <0.1 <0.1L-Asparagine <0.1 <0.1Glycine <0.1 <0.1L-Alanine <0.1 <0.1L-Valine <0.1 <0.1L-Leucine <0.1 <0.1L-Isoleucine <0.1 <0.1L-Serine <0.1 <0.1L-Threonine <0.1 <0.1L-Phenylalanine <0.1 <0.1L-Tyrosine <0.1 <0.1L-Proline <0.1 <0.1L-Lysine <0.1 <0.1L-Ornithine <0.1 <0.1L-Histidine <0.1 <0.1L-Arginine <0.1 <0.1L-Cysteine <0.1 <0.1L Methionine <0.1 <0.1______________________________________
As described above, the enzyme of the present invention has a high substrate specificity for L-glutamic acid. For other amino acids, it exhibits only a little activity (0.6%) for L-aspartic acid at pH 7.4, exhibiting substantially no activity for other L-amino acids including L-glutamine and L-histidine, or for D-glutamic acid. It also exhibits substantially no activity even for L-aspartic acid at pH 6.0.
As contrasted to the enzyme of the present invention, the known enzyme as described above exhibits no activity for L-aspartic acid (0.1% or less), but exhibits activities of 8.4% for L-glutamine and 6.8% for L-histidine, respectively. Thus, both enzymes are different from each other in substrate specificity.
The enzyme of the present invention has a km value for L-glutamic acid of 2.1×10 -4 M at pH 7.4, and a km value for L-aspartic acid of 2.9×10 -2 M at pH 7.4.
(3) Assay of activity:
The activity of the enzyme of the present invention was assayed according to the oxygen electrode method. That is, 1 ml of 0.1 M potassium phosphate buffer (pH 7.4) containing 10 mM sodium L-glutamate was charged into an oxygen electrode cell and 10 μl of an enzyme solution was added thereto to measure the oxygen consumption rate. One unit of enzyme was determined as the amount of enzyme which consumes 1μ mol of oxygen per minute at 30° C. in the absence of catalase (unit: hereinafter abbreviated as "U").
Since the dissolved oxygen concentration is reduced with elevation of the temperature, the above method cannot be used for activity assay at higher reaction temperatures. In such a case, the activity assay is conducted according to the MBTH method [Anal. Biochem., 25, 228 (1968)]. That is, a reaction mixture containing sodium L-glutamate, catalase and the enzyme of the present invention is incubated at an appropriate temperature for 20 minutes and the reaction is terminated with addition of trichloroacetic acid (TCA). To the terminated reaction mixture are added an acetate buffer (pH 5.0) and 3-methyl-2-benzothiazolinonehydrazone hydrochloride (MBTH) for incubation at 50° C. for 30 minutes, followed by cooling to room temperature, and thereafter the absorbance at 316 nm is measured to determine quantitatively the α-ketoglutaric acid formed from a calibration curve.
(4) Optimum pH:
The optimum pH is around pH 7 to 8.5 as shown in FIG. 1. The enzyme activities at respective pH values were assayed at 30° C. by using sodium L-glutamate as a substrate in 0.2 M acetate buffer (pH 3.5-6.0), 0.2 M potassium phosphate buffer (pH 6.0-8.5) and 0.2 M glycine-sodium chloride-sodium hydroxide buffer (pH 8.5-12.0).
In FIG. 1, for the purpose of comparison with respect to the optimum pH between the enzyme of the present invention and the known enzyme, both of the pH activity curves of the enzyme of the present invention (solid line) and the known enzyme (broken line: reference is made to FIG. 1 in Japanese Patent Laid-Open Publication No. 43685/1982) are shown.
As is apparent from FIG. 1, the enzyme of the present invention is different from the known enzyme also in the optimum pH.
Also, when employing aspartic acid as the substrate, the acting pH range is narrow, the optimum pH being 7 to 8, and the enzyme has substantially no action on L-aspartic acid at pH of 6.0 or less or at pH 10.0 or more (at pH 6.0, 0.1% or less of the relative activity for glutamic acid).
(5) pH stability:
After maintaining the enzyme at respective pH values of from pH 3.5 to 11.5, under the conditions of 37° C. for 60 minutes, 45° C. for 15 minutes and 60° C. for 15 minutes, the enzyme activity for glutamic acid was assayed at pH 7.4.
As a result, under the conditions of 37° C. for 60 minutes, the enzyme was stable at a pH range from 5.5 to 10.5 (FIG. 2, solid line); stable at a pH range from 5.5 to 9.5 under the conditions of 45° C. for 15 minutes (FIG. 3); and stable at a pH range from 5.5 to 7.5 under the conditions of 60° C. for 15 minutes (FIG. 4).
In FIG. 2, for the purpose of comparison relative to pH stability between the enzyme of the present invention and the known enzyme, both of the pH stability curves of the known enzyme (broken line: reference is made to FIG. 2 in Japanese Patent Laid-Open Publication No. 43685/1982) and the enzyme of the present invention are shown.
As is apparent from FIGS. 2, 3 and 4, when stable pH ranges are compared between the enzyme of the present invention and the known enzyme, both are clearly different from each other, the former being stable at a wider pH range as compared with the latter.
(6) Suitable acting temperature range:
At respective temperatures of 30° C. to 80° C., the reactions were carried out for 20 minutes with the use of sodium L-glutamate as a substrate, and the enzyme activity was assayed according to the MBTH method as described above.
As a result, the suitable acting temperature range of the enzyme of the present invention was found to be 30° to 60° C., with the optimum acting temperature being around 50° C. (FIG. 5).
(7) Thermal stability:
After maintaining the enzyme at respective temperatures of 40° C. to 90° C. under the respective conditions of pH 5.5, pH 7.5 and pH 9.5, for 15 minutes, the enzyme activity for glutamic acid was assayed at pH 7.4.
As a result, the enzyme was found at pH 5.5 to be stable up to 65° C., exhibiting a residual activity of about 50% at 85° C. (FIG. 6, - ). At pH 7.5, it was stable up to 50° C., exhibiting a residual activity of about 60% at 75° C. (FIG. 6, - ). At pH 9.5, it was stable up to 45° C., exhibiting a residual activity of about 50% at 70° C. (FIG. 6, - ).
For the purpose of comparison with regard to thermal stability between the enzyme of the present invention and the known enzyme, the temperature stability curve of the known enzyme (broken line: reference is made to FIG. 3 in Japanese Patent Laid-Open Publication No. 43685/1982) and that of the enzyme of the present invention are shown in the same drawing.
As is apparent from FIG. 6, the enzyme of the present invention has a higher thermal stability than the known enzyme.
(8) Inhibition, Activation and Stabilization:
For examination of the effects of various additives on the enzyme activity of the present invention, enzymatic reaction was carried out in a reaction mixture (pH 7.4) containing each of the substances shown in Table 2 at a concentration of 1 mM.
The results are as shown in Table 2.
TABLE 2______________________________________ Relative RelativeAdditives activity Additives activity______________________________________(No addition) 100 MnSO.sub.4 102.1KCl 111.1 CoSO.sub.4 100.7NaCl 95.8 Al.sub.2 (SO.sub.4).sub.3 93.8KI 100.7 EDTA.sup.1 96.5NaF 107.6 NEM.sup.2 94.4CaCl.sub.2 100.0 PCMB.sup.3 55.6CuCl.sub.2 100.7 o-phenanthroline 97.8BaCl.sub.2 95.1 α, α'-dipyridyl 94.4NiCl.sub.2 96.5 NaN.sub.3 100.6StCl.sub.2 97.2 DDTC.sup.4 100.7Li.sub.2 SO.sub.4 93.8 Tiron.sup.5 100.7 (trade mark)ZnSO.sub.4 90.3______________________________________ .sup.1 EDTA: ethylenediaminetetraacetic acid .sup.2 NEM: N--ethylmaleimide .sup.3 PCMB: pchloromercuribenzoate .sup.4 DDTC: diethyldithiocarbamate .sup.5 Tiron: 4,5dihydroxy-1,3-benzenedisulfonic acid disodium salt
As is apparent from Table 2, the activity of the enzyme of the present invention is inhibited by about 45% by p-chloromercuribenzoate but is not inhibited at all by cupric chloride and diethyldithiocarbamate. On the other hand, the activity of the known enzyme is completely inhibited by cupric chloride and diethyldithiocarbamate. Therefore, both of the enzymes are different from each other also with respect to the effect by inhibitors.
At present, no activator and stabilizer have been found for the enzyme of the present invention.
(9) UV-absorption spectrum (see FIG. 7):
λ max : 273 nm, 385 nm, 465 nm.
Shoulder: around 290 nm, around 490 nm.
(10) Coenzyme:
The absorption spectrum of the supernatant obtained by heat treatment or trichloroacetic acid (TCA) treatment of the enzyme of the present invention was identical with that of flavin adenine dinucleotide (FAD). The supernatant activated the apoenzyme of D-amino acid oxidase, and therefore the coenzyme of the enzyme of the present invention was found to be FAD.
The yellow compound in the supernatant was also identified as FAD from the Rf value in thin layer chromatography.
FAD was estimated to exist in an amount of 2 mol per 1 mol of the enzyme of the present invention.
(11) Polyacrylamide gel electrophoresis:
The purified enzyme of the present invention exhibited a single band.
(12) Molecular weight:
The enzyme of the present invention was estimated to have a molecular weight of 135,000±10,000 according to the gel filtration method by the use of Sephadex G-200 (produced by Pharmacia Fine Chemicals, Inc.).
(13) Isoelectric point:
The isoelectric point was measured by electrophoresis by the use of Ampholine (produced by LKB Co.) to find that PI was 6.2.
(14) Crystalline structure and elemental analysis:
The enzyme of the present invention was not crystallized, and no measurement has been performed.
(15) Purification method:
The enzyme of the present invention can be purified according to procedures involving salting out, isoelectric point precipitation, precipitation by an organic solvent, adsorption with diatomaceous earth, activated charcoal, etc., various chromatographies, and others. Examples of the purification methods are shown in the Example.
(B) Preparation of the enzyme of the present invention
The method for producing the enzyme of the present invention will now be described in detail.
Microorqanism employed
The microorganism employed in the production of the enzyme of the present invention belongs to the genus of Streptomyces and is a microorganism capable of producing the enzyme of the present invention.
Illustrative of such a microorganism is the X-119-6 strain isolated as a single strain from a soil sample in Tonosho-machi, Katori-gun, Chiba-ken, Japan. The properties of this strain are described below.
A. Microscopic observation
Aerial mycelia are straight with widths of 0.9 to 1.0μ, exhibiting simple branching. Sporophores consist of a number of chains of spores, forming spirals of 2 to 5 rotations. Spores are somewhat ellipsoidal with sizes of 0.9-1.0×1.1×1.2μ, and the surface is observed by electron microscope to have a spiny structure. No breaking of the basal mycelia is observed.
B. Observation by naked eye
The results of observation by naked eye after growth on various media (30° C., 16 days' cultivation) are as follows.
(1) Sucrose-nitrate agar medium:
Its growth is poor. The basal mycelia are grayish brown and do not penetrate into the agar, and the aerial mycelia are powdery and spread radially on the agar. The aerial mycelia are grayish brown, with formation of gray spores. No formation of pigment into the medium is observed.
(2) Glucose-asparagine agar medium:
Its growth is good. The basal mycelia are white yellow, penetrate into the agar, and are also slightly raised. The aerial mycelia are white with no formation of pigment into the medium.
(3) Glycerin-asparagine agar medium:
Its growth is good. The basal mycelia are white yellow, penetrate into the agar, and are also raised. No aerial mycelium is formed, and no formation of pigment into the medium is observed.
(4) Starch-inorganic salts agar medium:
Its growth is good. The basal mycelia are white yellow, penetrate into the agar, and are also raised. The aerial mycelia are white and abundant with formation of gray spores. No pigment formation into the medium is observed.
(5) Tyrosine-agar medium:
Its growth is good. The basal mycelia are white yellow. The aerial mycelia are white and abundant with formation of gray spores. No pigment formation into the medium is observed.
(6) Nutrient-agar medium:
Its growth is very good. The basal mycelia are white yellow, penetrate into the agar, and are also raised. The aerial mycelia are white, with no formation of spore being observed. No pigment formation into the medium is observed.
(7) Yeast-malt agar medium:
Its growth is very good. The basal mycelia are white yellow, penetrate into the agar, and are also raised. The aerial mycelia are white and abundant with formation of gray spores. No pigment formation into the medium is observed.
(8) Oatmeal-agar medium:
Its growth is very good. The basal mycelia are white, penetrate into the agar, but are not raised on the medium. The aerial mycelia are white and abundant with formation of gray spores. No pigment formation into the medium is observed.
C. Physiological properties
Growth temperature range is 8° to 40° C., the optimum temperature being around 35° C.
In both of the tyrosine-agar medium and the peptone-yeast-iron-agar medium, no melanin-like pigment is formed; gelatin is slightly liquefied; and starch is hydrolyzed.
D. Assimilability of various carbon sources
Utilizations of various carbon sources on the Pridham-Gottrieb agar medium are as shown in Table 3.
TABLE 3______________________________________Carbon source Utilization*______________________________________D-Glucose +D-Xylose -L-Arabinose +L-Rhamnose -D-Fructose +Raffinose +Mannitol +Inositol +Sucrose +______________________________________ *+: utilized, -: not utilized.
The above properties may be summarized as follows. That is, aerial mycelia are spiral, the surfaces of the spores being spiny. Growth on media exhibits white yellow color or grayish brown color, aerial mycelia being colored white to grayish brown, and no formation of soluble pigment and melanin-like pigment is observed. Furthermore, starch hydrolyzability is rather strong.
On the basis of these results and assimilability of carbon sources shown in Table 3, the present microorganism strain was classified according to the taxonomic system in Bergey's Manual of Determinative Bacteriology, eighth edition (1974), whereby it was found that the present microorganism strain belongs to the genus Streptomyces, but no known species sufficiently coinciding in characteristics with the present strain was found, and hence the present strain was identified to be a new microorganism strain and named Streptomyces sp. X-119-6.
The present microorganism strain was deposited at the Fermentation Research Institute, Agency of Industrial Science and Technology (FRI), 1-3, Higashi 1-chome, Yatabe-machi, Tsukuba-gun, Ibaraki-ken, Japan on June 5, 1982, and given the deposition number FERM P-6560. This strain was delivered directly from FRI to American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md., U.S.A. and acquired the deposition number ATCC 39343 on April 26, 1983.
The above microorganism strain is one example of the microorganism strains having high capability of producing the enzyme of the present invention, and the microorganism to be used in the present invention is not limited thereto. It is also possible to suitably use any of the mutant strains highly capable of producing the enzyme of the present invention obtained by subjecting the microorganism producing the enzyme of the present invention to conventional microorganism mutating methods such as physical treatment by UV-ray, X-ray or γ-ray irradiation, chemical treatments with reagents such as nitrosoguanidine, etc. Further, the methods for the enzyme production are based on the function of the synthesis of the enzyme protein by the structure and regulator DNA gene in the aforesaid microorganism producing the enzyme of the present invention. Accordingly, also included within the scope of the present invention is the production method using a microorganism, which is obtained by gene manipulation procedure, for example, by incorporating such a gene DNA into an appropriate vector which is in turn transferred by way of transformation into a microorganism belonging to a genus other than the aforesaid genus, or by permitting the gene DNA to be taken up in an a microorganism belonging to the other genus by cell fusion according to the protoplast method.
Cultural method and conditions
The cultural method and conditions for cultivating the above microorganism to be used in the present invention are not particularly limited, as long as the microorganism can sufficiently grow and the enzyme of the present invention can be sufficiently produced, but it is preferred to use a solid cultivation method or similar method.
The solid medium to be used in solid cultivation is not different in any way from those conventionally used. That is, the solid medium is mainly composed of one or more kinds of natural solid materials such as wheat bran, defatted soy bean, rice bran, corn, rapeseed dregs, wheat, rice, rice hulls, etc., further containing, if desired, nutrient sources assimilable by the microorganism employed in the present invention, as exemplified by carbon sources such as glucose, sucrose, arabinose, fructose, mannitol, inositol, soluble starch, ethanol, etc., nitrogen sources such as various amino acids, peptone, soybean powders, protein hydrolysates, corn steep liquor, meat extract, yeast extract, various ammonium salts, various nitrates, urea, etc., growth promoters exemplified by salts such as various sodium salts, potassium salts, calcium salts, manganese salts, magnesium salts, zinc salts, iron salts, phosphates, sulfates, etc., and vitamins such as thiamine, riboflavin, nicotinic acid, pantothenic acid, biotin, p-aminobenzoic acid, cyanocobalamin, etc. These media may also be granulated in suitable formulations, sizes and shapes. Such a solid medium may be sterilized or denatured according to conventional procedures and then inoculated with a seed microorganism to carry out solid cultivation.
It is also possible to employ a cultivation method other than the above method, as long as the microorganism employed can proliferate and produce the enzyme of the present invention well, such as the method in which a liquid medium is absorbed into or coated over a suitable carrier such as sponge, etc. (see Japanese Patent Laid-Open Publication No. 14679/1974), and a seed microorganism is inoculated into the medium to be cultured therein.
The cultural conditions are not particularly limited and may be selected for optimal production of the enzyme depending on the kind of the microorganism employed. Generally, cultivation may be conducted under the conditions of, for example, 20°-30° C., pH 5-7 and 5-15 days.
Collection of the enzyme of the present invention
The enzyme of the present invention produced by cultivation of the microorganism employed may be separated by extraction from the cultured product, namely, the medium and/or the cultured microorganism cells, according to a suitable extraction method. The enzyme may be used as the crude enzyme solution or purified according to a conventional enzyme purification method to a purification degree which depends on the purpose of use.
The extraction method is not particularly limited but may be a conventional method. For example, extraction from the solid cultured product is ordinarily conducted with water or a buffer. The enzyme of the present invention in microorganism cells is extracted after crushing the microorganism cells in a conventional manner and solubilizing the enzyme.
In order to indicate more fully the nature of the present invention, the following specific example of practice constituting a preferred embdiment of the invention is set forth, it being understood that this example is presented as illustrative only and is not intended to limit the scope of the invention.
Example
Into an Erlenmeyer flask of 500-ml capacity were charged 20 g of wheat bran and 16 ml of water, and the sterilization was conducted at 120° C. for 30 minutes. Into the wheat bran medium thus prepared, Streptomyces sp. X-119-6 (FERM P-6560, ATCC 39343) was inoculated and cultured at 28° C. for 7 days to prepare seed culture.
Into each of 25 Erlenmeyer flasks of 5-liter capacity were charged 200 g of wheat bran and 160 ml of water, and after sterilization at 120° C. for 30 minutes, the above seed culture was inoculated and cultured at 28° C. for 2 days and further at 20° C. for an additional 2 weeks.
The cultured product obtained was immersed in 37.5 liters of water for one hour, filtered and further passed through diatomaceous earth to obtain about 34 liters of a crude enzyme solution. Ammonium sulfate was added to the crude enzyme solution to 50% saturation, and the precipitates formed were collected by centrifugation and dissolved in 3.9 liters of 0.02 M acetate buffer (pH 5.5). The resultant solution was heated at 57° C. for 30 minutes. The heat treated enzyme solution was cooled to 5° C. or lower, and then to this solution was added a two-fold amount of previously cooled ethanol. The precipitates thus formed were collected by centrifugation, dissolved in 0.02 M phosphate buffer (pH 7.4), and dialyzed against the same buffer overnight.
The precipitates formed during dialysis were removed by centrifugation. The supernatant was passed through a DEAE (diethylaminoethyl) - cellulose column (3.5×50 cm) equilibrated with the same buffer, and the enzyme adsorbed was eluted with the same buffer containing 0.35 M sodium chloride. The active fractions eluted were collected, and dialyzed against 0.05 M acetate buffer (pH 5.5) containing 0.05 M sodium chloride. The inner dialyzed solution was passed through a column (2×10 cm) of DEAE-Sepharose CL-6B (produced by Pharmacia Fine Chemicals, Inc.) equilibrated with the same buffer, and the enzyme adsorbed was eluted with 0.05-0.75 M linear gradient of sodium chloride.
The active fractions eluted were collected, concentrated by dialysis, and then subjected to gel filtration by use of a Sephadex G-200 (produced by Pharmacia Fine Chemicals, Inc.) column (2.5×120 cm). The active fractions were collected and, after concentration, dialyzed against 0.02 M potassium phosphate buffer (pH 7.4). The inner dialyzed solution was centrifuged, and the supernatant was subjected to microfiltration, which was followed by lyophilization to obtain 30 mg of a purified preparation of L-glutamic acid oxidase (specific activity 55.1 U/mg-protein, yield 18.4%). | L-glutamic acid oxidase, which is an L-amino acid oxidase catalyzing the oxidative deamination of the α-amino group of L-glutamic acid in the presence of water and oxygen to form α-ketoglutaric acid, ammonia and hydrogen peroxide, and having a very high substrate specificity for L-glutamic acid substantially without acting on L-glutamine and L-histidine, and also having a high stability, and a microbiological method of production thereof. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application No. 60/938,328 filed on May 16, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for sensing oil in an internal combustion engine, and more particularly to such sensors that detect the level of oil in a reservoir of the engine and that provide a signal indicating the viscosity of the oil.
2. Description of the Related Art
Internal combustion engines are lubricated by oil that is stored in a reservoir, typically an oil pan located underneath the cylinder block of the engine. An oil pump draws the oil from the reservoir and forces it through passages to the top of the cylinder block. After exiting those passages, the oil lubricates various components of the engine, as it flows downward through the cylinder block by gravity ultimately returning into the reservoir.
A sensor often has been used to detect pressure at the outlet of the oil pump to provide an indication to the operator of the engine whether there is sufficient oil for proper lubrication. However, this pressure sensor does not provide an indication of the oil's viscosity. Engine lubricating oil is commercially available in different viscosities and a particular engine is designed to use a specific type of oil. If oil of an improper viscosity for a given engine is used, the components of that engine may not be properly lubricated and damage to those components may result.
Therefore, it is desirable to determine whether there is a sufficient amount of oil within the reservoir and whether that oil is the proper viscosity.
Operation of an engine usually is controlled by a microcomputer that monitors the level of engine usage and the operating conditions. From such monitoring the microcomputer is able to determine when the lubricating capability of the oil becomes depleted and the oil needs to be replaced. At that time the microcomputer provides an indication of that need to the engine operator. When the oil is changed, the service technician must manually reset that indication, a process that differs for each make of motor vehicle. Therefore, it is desirable to provide a mechanism by which the microcomputer can detect when the oil has been changed and automatically reset the oil change indication.
SUMMARY OF THE INVENTION
A sensor is provided to detect a characteristic of oil within a reservoir of an internal combustion engine. The sensor comprises a chamber for receiving oil from the reservoir, a ferromagnetic detector member movably received in the chamber, and an electromagnetic coil that produces a magnetic field. The detector member preferably is biased by a spring. Energizing the electromagnetic coil produces the magnetic field that moves the detector member in one direction through the chamber and deactivation of the electromagnetic coil terminates the magnetic field allowing the spring to drive the detector member in the opposite direction.
Oil from the reservoir enters the chamber within the sensor and affects the rate at which the detector member moves. Specifically, the absence of oil within the chamber, which then is filled with air, provides minimal resistance to the motion of the detector member. Because oil is more viscous than air, its presence within the sensor chamber provides a greater resistance to motion of the detector member. In fact, the amount of that resistance is a function of the viscosity of the oil, thus the rate at which the detector member moves is related to the viscosity of the fluid (air or oil) in the sensor chamber.
Movement of the ferromagnetic detector member with respect to the electromagnetic coil changes the permeance of the sensor's magnetic circuit which affects electric current flowing through that coil. By analyzing the waveform of that electric current, the relative speed of the detector member can be determined and then analyzed to determine whether oil is present within the sensor chamber and the viscosity of that oil. Specifically the amount of time that it takes the detector member to move between two positions in the chamber is measured from features of the electric current waveform. That amount of time is employed to determine the characteristic of the oil in the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an oil pan on an internal combustion engine with a sensor according to the present invention mounted in a wall of the oil pan;
FIG. 2 is a cross sectional view through the sensor mounted on the oil pan;
FIG. 3 is a block schematic diagram of a control circuit for operating the sensor and analyzing the electric current flowing through the sensor;
FIG. 4 is an exemplary waveform of the electric current flowing through the sensor; and
FIG. 5 is a flowchart of the process by which the control circuit determines the presence or absence of oil and the viscosity of any oil that is present.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an internal combustion engine 10 that has a cylinder block 12 at the bottom of which an oil pan 14 is attached. The oil pan 14 serves as a reservoir for lubricating oil used in the engine 10 . An oil sensor 16 is located in an aperture on one side wall of the oil pan 14 at a position such that should the oil within the pan drop beneath the location of the sensor, there would be an undesirably small amount of oil in the reservoir. The sensor 16 is an electrically operated device that receives a signal via a cable 18 .
With reference to FIG. 2 , the oil sensor 16 is located within an aperture 20 in the oil pan 14 and has a housing 22 that engages a shoulder 24 in that aperture to limit how far the sensor can be inserted into the aperture. The housing 22 has a cup shaped piece 21 with an open end that is closed in a fluid tight manner by a disk 23 . An O-ring 25 extends within a groove around the exterior of the sensor housing 22 to provide a fluid seal with respect to the oil pan 14 . When the sensor housing 22 abuts the shoulder 24 , a snap ring 26 is inserted in an annular groove 28 around the oil pan aperture 20 to secure the sensor in place.
The sensor housing 22 contains a solenoid 30 that has an electromagnetic coil 32 wound on a conventional plastic bobbin 34 . The electromagnetic coil 32 and bobbin 34 are held within a magnetic core 35 formed by components of a ferromagnetic material, such as steel. Specifically the magnetic core 35 comprises a cup 36 and a cylindrical pole piece 38 located centrally within the cup and abutting the flat inside surface of the cup, thereby forming a core that has an E-shaped cross section. The interior of the cup 36 opens into a chamber 40 within the housing 22 . A disc-shaped plate of ferromagnetic material forms a detector member 41 that is located within the chamber 40 and slides along a guide pin 43 that is embedded in a wall of the housing 22 . The detector member 41 is biased away from the solenoid 30 by a coil spring 42 . This biasing forms two working gaps 45 and 46 in the magnetic circuit between the core 35 and the detector member 41 . One is an annular gap 46 around the lip of the cup 36 and the other gap 45 is at the exposed end of the cylindrical pole piece 38 .
A first aperture 47 at the bottom of the sensor housing 22 provides a fluid drain passage between the sensor chamber 40 and the interior cavity 39 of the oil pan 14 . The sensor housing 22 and the oil pan aperture 20 are keyed so that the sensor 16 only can be mounted on the oil pan 14 with the first aperture 47 facing downward, so that oil drains through that aperture by gravity. A second aperture 48 near the top of the sensor housing 22 provides another fluid passage between the sensor chamber 40 and the oil pan's interior cavity 39 . The second aperture 48 extends through a boss 49 on an interior surface of the sensor chamber 40 against which the detector member 41 rests in the de-energized state of the solenoid 30 , thereby closing the fluid passage provided by the second aperture. Two additional bosses 44 (only one being visible in FIG. 2 ) also are provided on that surface of the sensor chamber 40 , so that the detector member 41 rests perpendicular to the axis of the guide pin 43 .
The spring 42 normally biases the detector member 41 away from the solenoid 30 and its electromagnetic coil 32 . When an electric voltage is applied to the solenoid, the electromagnetic 32 generates an magnetic field which attracts the detector member 41 toward the solenoid. The force of the magnetic field overcomes the force of the spring 42 , thereby causing the detector member 41 to abut the open end of the cup 36 of the solenoid core 35 . When the electric voltage is removed from the electromagnetic coil 32 , the magnetic field ceases and the force of the spring 42 moves the detector member 41 away from the solenoid 30 returning that plate to the position illustrated in FIG. 2 .
The speed at which the detector member 41 moves toward the solenoid 30 , each time electric voltage is applied to the electromagnetic coil 32 , is affected by the fluid within the chamber 40 , and particularly the viscosity of that fluid. When there either is no oil within the oil pan 14 , as occurs during an oil change, or the level of that oil is below the position of the sensor 16 , any oil that was previously within the sensor chamber 40 drains out through the first aperture 47 and air enters that chamber. Air has a relatively low viscosity, as compared to conventional lubricating oils, thereby air in the chamber 40 allows more rapid motion of the detector member 41 in response to energizing the solenoid 30 .
When the oil pan 14 is refilled with oil, the air in chamber 40 is trapped and prevents the oil from entering through the first aperture 47 at the bottom of the sensor housing 22 . Note that in the de-energized state of the solenoid 30 , the detector member 41 closes the second aperture 48 near the top of the housing. Thereafter, cycling the solenoid 30 on and off repeatedly moves the detector member 41 back and forth within the chamber 40 , thereby intermittently opening the second aperture 48 to allow the air to escape and oil to enter through the first aperture 47 . Typically the solenoid 30 is cycled at a frequency of one Hertz, for example, and five to seven cycles are adequate to exchange the fluid so that the chamber 40 becomes filled with oil. More or less cycles may be necessary depending on the operating frequency, the viscosity of the oil and the volume of the sensor chamber. When the chamber 40 contains oil, the greater viscosity of the oil, as compared to air, causes the detector member 41 to move slower.
With reference to FIG. 3 , the sensor 16 , electrically represented by its electromagnetic coil 32 , is part of an oil detecting system 50 and is connected to a control circuit 52 . The control circuit 52 comprises a coil driver 51 , a controller 53 and a current sensor 54 . The electromagnetic coil 32 is energized by a fixed level of electric voltage produced by a coil driver 51 in response to a command from a controller 53 in the motor vehicle. The controller 53 may be a dedicated controller for the oil sensing or it may be one of the microcomputer based controllers already present for operating other components of the engine or the motor vehicle powered by the engine. The controller 53 executes a software program that is stored along with data in the controller's internal memory. That program activates the coil driver 51 to apply the fixed voltage across the electromagnetic coil 32 . The resultant electric current flowing through the electromagnetic coil 32 is measured by a current sensor 54 , which may be any of several well known types for sensing a direct current. The current sensor 54 provides an input signal to the controller 53 indicating the magnitude of the electric current flowing through the electromagnetic coil 32 .
With reference to the graph FIG. 4 , when a drive voltage is initially applied to the electromagnetic coil 32 , the resultant electric current begins to rise to a peak 57 and then drops precipitously to a cusp 58 at a time designated T 1 when the detector member 41 strikes the solenoid core 35 . The depth of the cusp, designated ΔI, is a function of the velocity of the detector member and the changing magnetic permeance with the stroke of the solenoid. After the cusp 58 at time T 1 , the current rises again.
The controller 53 is able to detect when the input signal from the current sensor 54 indicates the occurrence of the cusp 58 . The length of time ΔT between the initially applied electric current to the electromagnetic coil 32 and the cusp 58 varies depending upon the viscosity of the fluid within the sensor chamber 40 . Therefore, by analyzing the current waveform, as provided by the signal from the current sensor 54 , and particularly measuring the length of period ΔT, the controller 53 is able to determine whether the chamber 40 is filled with air, indicating an abnormally low level of oil in the pan 14 , or has oil therein, which denotes that the oil pan is adequately filled. The duration of period ΔT also varies as a function of the particular viscosity of the oil within the pan, i.e. the greater the viscosity, the longer the period ΔT. Thus the controller 53 also is able to determine whether the oil within the pan has the proper viscosity for this particular engine. The controller 53 provides information about the oil level and viscosity via a communication link 55 to the instrument panel for the motor vehicle in which the engine 10 is located. The communication link 55 also can carry that information to other computers in the motor vehicle. As an alternative or an additional feature, the controller is connected to a separate indicator 56 through which the oil level and viscosity information are presented to a human operator.
To make those determinations the controller 53 performs a process 60 implemented by a software routine, such as the one depicted in FIG. 5 . The process 60 commences at step 62 by the controller initializing the variables, counters and a timer used during the process. The coil driver 51 is signaled to apply a predefined, constant level of electric voltage to the valve's electromagnetic coil 32 at step 64 . Next at step 66 , the controller starts a software timer that measures how long it takes for the detector member 41 to travel from the position shown in FIG. 2 to the lip of the cup 36 , at which time the cusp 58 occurs in the current waveform.
At step 68 , the controller 53 reads the input signal from the current sensor 54 and determines the magnitude of the electric current (I NEW ) flowing through the electromagnetic coil 32 in the oil sensor 16 . The present level of the electric current (I NEW ) is compared to the previous sensed level, designated I OLD , which is stored temporarily in the controller's memory. When the oil sensor is initially activated, the current increases, i.e. presently sensed electric current level (I NEW ) is greater than the previously sensed electric current level (I OLD ). If that relationship exists, as determined at step 70 , the process branches to step 72 at which the value (COUNT 1 ) of a first counter stored in memory is reset to zero. Then a check is made whether a software flag is set. During the initial waveform segment 75 , while the current level is increasing the counter remains a zero and the flag is not set. As a result, the process branches from step 74 to step 76 near the beginning of the process at which the value of I OLD is set equal to the most recently sensed electric current level. The cycle repeats by again reading the input signal from the current sensor 54 to obtain a new electric current measurement (I NEW ).
Eventually the coil current reaches a peak 57 (see FIG. 4 ) and begins decreasing during a subsequent waveform segment 77 . During that waveform segment 77 , the presently sensed electric current level (I NEW ) is less than the previously sensed electric current level (I OLD ), so that at step 70 the process now branches to a section the detects the downward portion of the current waveform after the peak 57 . At step 78 , the value (COUNT 1 ) of a first software counter is incremented and the value COUNT 2 of a second software counter is reset to zero at step 80 . Then the first counter value COUNT 1 is tested to determine if the count is greater than a threshold value X. Until that determination is true the process continues looping through steps 68 , 70 , 78 - 82 and 76 . After X number of consecutive passes, COUNT 1 is greater than X and the process branches from step 81 to step 82 where the flag is set.
If while the current was initially increasing waveform segment 75 ( FIG. 4 ), a sporadic new current level measurement was less that the previous current level (I NEW <I OLD ), this anomaly also causes the process to branch from step 70 to step 78 even though the current peak 57 has not occurred. As a result the first counter's value (COUNT 1 ) is incremented during the anomaly, however due to the short duration of that anomaly, the COUNT 1 never reaches a value of X and the flag does not get set at step 82 . Thus when the current begins to increase again, i.e., I NEW >I OLD , in waveform segment 75 and the process advances once more from step 70 to step 74 the flag will not be found set and the process returns back through step 76 to obtain a new electric current measurement at step 68 , just as though the anomaly never occurred.
In due course during waveform segment 77 after the current peak 57 , the more than X consecutive electric current samples I NEW will be acquired that are less than the previously sensed electric current level (I OLD ), so that repeated branching through steps 78 and 80 results in the flag being set at step 82 . Setting the flag indicates that the electric current waveform has reached the peak 57 and begun the downward waveform segment 77 toward the cusp 58 . Until that cusp occurs the process continues to loop through steps 68 , 70 , 78 - 82 and 76 .
Occurrence of the cusp 58 , causes the coil current to again begin increasing in another waveform segment 79 . The next time thereafter that step 70 is executed the process branches through step 72 to step 74 . Now the controller 53 finds that the flag has been set which causes further advancement to step 84 . A transient increase in the current level that may occur between the current peak 57 the cusp 58 is prevented from erroneously being considered as the cusp, by requiring that the current level remain increasing for a plurality (Y) of consecutive processing cycles. That requirement is implemented by incrementing the value COUNT 2 of the second software counter on each pass through this processing branch and determining that the cusp 58 occurred only after the COUNT 2 is greater than Y. Note that after a transient increase in the current level lasting less than Y consecutive processing cycles, the process again branches from step 70 through step 78 to step 80 at which the value COUNT 2 of the second counter is reset to zero.
When the coil current level now increases for more than Y consecutive processing cycles as occurs during waveform segment 79 , a determination is made that the cusp 58 occurred and the process branches to step 88 . At this juncture, the controller 53 stops the timer and at step 90 signals the coil driver 51 to terminate applying the voltage to the sensor's electromagnetic coil 32 .
The operation of the controller 53 enters a phase in which the timer value is analyzed to ascertain whether there is an adequate level of oil in the oil pan 14 and, if so, to determine the viscosity of that oil. Therefore at step 92 , the controller checks whether the timer's value (ΔT) is less than a period of time T AIR which indicates that air is present in the oil sensor chamber 40 . As noted previously, the length of time ΔT between when the voltage was initially applied to the electromagnetic coil 32 , at which current began to flow, and the cusp 58 in the current waveform varies depending upon the viscosity of the fluid (oil or air) within the sensor chamber 40 . Because oil is more viscous than air, its presence within the sensor chamber provides a greater resistance to motion of the plate causing a longer time interval ΔT. Therefore, if the timer's measurement of ΔT is less than T AIR , air is present in the sensor chamber 40 and the amount of oil in the oil pan 14 is below a desired level. Conversely, if the timer's measurement of ΔT is greater than T AIR then there is an adequate level of oil, because oil is present in the sensor chamber 40 . The value of T AIR is a function of the particular design of the oil sensor 16 and is determined empirically.
If at step 92 , the timer's measurement of time interval ΔT is less than the threshold value T AIR , the process 60 provides an indication of a low oil level at step 94 . The controller 53 sends that indication to via a communication link 55 to the instrument panel for the motor vehicle in which the engine 10 is located and activates the indicator 56 .
Otherwise, when at step 92 , the timer's measurement of ΔT is found greater the threshold T AIR , as occurs when there is a desirable amount of oil, the process advances to step 96 . At this point, any low oil indication that might have been set previously now is reset, as occurs after additional oil was added to the engine. Then the time interval ΔT is employed to determine the viscosity of the oil. The duration of time interval ΔT is directly related to the viscosity of the oil, i.e. the greater the viscosity, the longer the period ΔT. The measurement of the time interval ΔT is used to address a lookup table stored in the memory of the controller 53 with the output of the lookup table being the viscosity value for the oil. That viscosity value can be displayed on the indicator 56 . In addition the controller can compare the viscosity value from the lookup table to the known proper oil viscosity for the engine and when an improper viscosity is found a warning indication is provided via indicator 56 and the instrument panel of the motor vehicle.
After the oil detecting system 50 determines that the oil level is unacceptably low for proper engine operation, the system also can detect when oil has been added to an acceptable level. When the oil level in the oil pan 14 drops below the oil sensor 16 , the oil drains from the sensor chamber 40 through the first aperture 47 at the bottom of the sensor housing 22 . At that time, air enters the sensor chamber. Adding oil brings the level above the sensor 16 , but does not immediately fill the sensor chamber 40 with oil because air is trapped therein preventing entry of oil. As a consequence, after a low oil indication has been given by the controller 53 , the sensor 16 preferably is cycled by repeatedly energizing and de-energizing the solenoid's electromagnetic coil 32 to move the detector member 41 back and forth several times. This action to opens the second aperture 48 , allowing the air to escape from the sensor chamber 40 and be replaced with oil, if the pan was refilled. If the oil pan 14 was not refilled, air will remain in the sensor chamber 40 . At the end of the recycling when the sensor chamber 40 is filled with oil, the oil analysis process 60 determines that fact at step 92 as explained above and the previous low oil indication is reset at step 96 .
The present oil sensor and signal processing also can be used to indicate when the engine oil has been changed. Many motor vehicles illuminate a light on the instrument panel when the oil should be changed. Presently a service technician must manually reset that light, the process for doing so differs with each make of motor vehicle. A determination by the present oil analysis process 60 that the oil has been changed can be used to turn off that light automatically. When oil is drained from the oil pan 14 , the oil also drains from the sensor chamber 40 and is replaced by air. Refilling the oil pan 14 does not immediately fill the sensor chamber 40 with oil because the air is trapped therein preventing the entry of oil. Therefore while the change oil indicator light is illuminated, the sensor 16 is cycled by repeatedly energizing and de-energizing the solenoid's electromagnetic coil 32 to move the detector member 41 back and forth several times to open the second aperture 48 to allow the air to escape from the sensor chamber 40 and be replaced with oil, if the pan was refilled. During this cycling of the sensor solenoid 30 after an oil change, the controller 53 observes the time interval ΔT between the inception of the electric current and the cusp 58 getting significantly longer within five to seven cycles, due to the air being replaced by oil. In response to that observation, the controller 53 determines that the oil had been drained from the oil pan 14 and replaced. In response an indication that the oil has been changed is send via the communication link 55 to the controller that governs illumination of the oil change light on the instrument panel.
The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure. | A system for detecting a characteristic of oil in a reservoir includes a sensor at least partially located in the reservoir. The sensor has a chamber for receiving oil from the reservoir, a detector member in the chamber, and an electromagnetic coil. Application of voltage across the electromagnetic coil moves the detector member and the presence and viscosity of oil in the chamber affects the rate of that movement. The electric current through the electromagnetic coil is measured and analyzed to determine an amount of time that the detector member took to move between two positions in the chamber. That amount of time is used to determine whether there is at least a predefined amount of oil in the reservoir and, if so, the viscosity of the oil. | 6 |
RELATED APPLICATIONS
[0001] This is a divisional application of U.S. patent application Ser. No. 13/198,294, filed Aug. 4, 2011, entitled MULTIPLE BONDING LAYERS FOR THIN-WAFER HANDLING, incorporated by reference herein. The '294 application claims the priority benefit of U.S. Provisional Patent Application No. 61/371,517, entitled MULTIPLE BONDING LAYERS FOR THIN-WAFER HANDLING, filed Aug. 6, 2010, the entire disclosure of which is incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH/DEVELOPMENT PROGRAM
[0002] This invention was made with government support provided through a subcontract issued under prime contract number FA8650-05-D-5806 awarded to General Dynamics Information Technology by the Air Force Research Laboratory. The United States government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention is broadly concerned with novel temporary wafer bonding methods utilizing multiple layer bonding systems. The inventive methods can support a device wafer on a carrier substrate during wafer thinning and other backside processing.
[0005] 2. Description of the Prior Art
[0006] Integrated circuits, power semiconductors, light-emitting diodes, photonic circuits, microelectromechanical systems (MEMS), embedded passive arrays, packaging interposers, and a host of other silicon- and compound semiconductor-based microdevices are produced collectively in arrays on wafer substrates ranging from 1-12 inches in diameter. The devices are then separated into individual devices or dies that are packaged to allow practical interfacing with the macroscopic environment, for example, by interconnection with a printed wiring board. It has become increasingly popular to construct the device package on or around the die while it is still part of the wafer array. This practice, which is referred to as wafer-level packaging, reduces overall packaging costs and allows a higher interconnection density to be achieved between the device and its microelectronic environment than with more traditional packages that usually have outside dimensions several times larger than the actual device.
[0007] Until recently, interconnection schemes have generally been confined to two dimensions, meaning the electrical connections between the device and the corresponding board or packaging surface to which it is mounted have all been placed in a horizontal, or x-y, plane. The microelectronics industry has now recognized that significant increases in device interconnection density and corresponding reductions in signal delay (as a result of shortening the distance between electrical connection points) can be achieved by stacking and interconnecting devices vertically, that is, in the z-direction. Two common requirements for device stacking are: (1) thinning of the device in the through-wafer direction from the backside; and (2) subsequently forming through-wafer electrical connections, commonly referred to as through-silicon-vias or “TSVs,” that terminate on the backside of the device. For that matter, semiconductor device thinning has now become a standard practice even when devices are not packaged in a stacked configuration because it facilitates heat dissipation and allows a much smaller form factor to be achieved with compact electronic products such as cellular telephones.
[0008] There is growing interest in thinning semiconductor devices to less than 100 microns to reduce their profiles, especially when they or the corresponding packages in which they reside are stacked, and to simplify the formation of backside electrical connections on the devices. Silicon wafers used in high-volume integrated circuit production are typically 200 or 300 mm in diameter and have a through-wafer thickness of about 750 microns. Without thinning, it would be nearly impossible to form backside electrical contacts that connect with front-side circuitry by passing the connections through the wafer. Highly efficient thinning processes for semiconductor-grade silicon and compound semiconductors based on mechanical grinding (back-grinding) and polishing as well as chemical etching are now in commercial use. These processes allow device wafer thickness to be reduced to less than 100 microns in a few minutes while maintaining precise control over cross-wafer thickness uniformity.
[0009] Device wafers that have been thinned to less than 100 microns, and especially those thinned to less than 60 microns, are extremely fragile and must be supported over their full dimensions to prevent cracking and breakage. Various wafer wands and chucks have been developed for transferring ultra-thin device wafers, but the problem still exists of how to support the wafers during back-grinding and TSV-formation processes that include steps such as chemical-mechanical polishing (CMP), lithography, etching, deposition, annealing, and cleaning, because these steps impose high thermal and mechanical stresses on the device wafer as it is being thinned or after thinning. An increasingly popular approach to ultra-thin wafer handling involves mounting the full-thickness device wafer face down to a rigid carrier with a polymeric adhesive. It is then thinned and processed from the backside. The fully processed, ultra-thin wafer is then removed, or debonded, from the carrier by thermal, thermomechanical, or chemical processes after the backside processing has been completed.
[0010] Common carrier materials include silicon (e.g., a blank device wafer), soda lime glass, borosilicate glass, sapphire, and various metals and ceramics. The carriers may be square or rectangular but are more commonly round and are sized to match the device wafer so that the bonded assembly can be handled in conventional processing tools and cassettes. Sometimes the carriers are perforated to speed the debonding process when a liquid chemical agent is used to dissolve or decompose the polymeric adhesive as the means for release.
[0011] The polymeric adhesives used for temporary wafer bonding are typically applied by spin coating or spray coating from solution or laminating as dry-film tapes. Spin- and spray-applied adhesives are increasingly preferred because they form coatings with higher thickness uniformity than tapes can provide. Higher thickness uniformity translates into greater control over cross-wafer thickness uniformity after thinning. The polymeric adhesives exhibit high bonding strength to the device wafer and the carrier.
[0012] The polymeric adhesive may be spin-applied onto the device wafer, the carrier, or both, depending on the thickness and coating planarity (flatness) that is required. The coated wafer is baked to remove all of the coating solvent from the polymeric adhesive layer. The coated wafer and carrier are then placed in contact in a heated mechanical press for bonding. Sufficient temperature and pressure are applied to cause the adhesive to flow and fill into the device wafer structural features and achieve intimate contact with all areas of the device wafer and carrier surfaces.
[0013] Debonding of a device wafer from the carrier following backside processing is typically performed in one of four ways:
[0014] (1) Chemical—The bonded wafer stack is immersed in, or sprayed with, a solvent or chemical agent to dissolve or decompose the polymeric adhesive.
[0015] (2) Photo-Decomposition—The bonded wafer stack is irradiated with a light source through a transparent carrier to photo-decompose the adhesive boundary layer that is adjacent to the carrier. The carrier can then be separated from the stack, and the balance of the polymeric adhesive is peeled from the device wafer while it is held on a chuck.
[0016] (3) Thermo-Mechanical—The bonded wafer stack is heated above the softening temperature of the polymeric adhesive, and the device wafer is then slid or pulled away from the carrier while being supported with a full-wafer holding chuck.
[0017] (4) Thermal Decomposition—The bonded wafer stack is heated above the decomposition temperature of the polymeric adhesive, causing it to volatilize and lose adhesion to the device wafer and carrier.
[0018] Each of these debonding methods has drawbacks that seriously limit its use in a production environment. For example, chemical debonding by dissolving the polymeric adhesive is a slow process because the solvent must diffuse over large distances through the viscous polymer medium to effect release. That is, the solvent must diffuse from the edge of the bonded substrates, or from a perforation in the carrier, into the local region of the adhesive. In either case, the minimum distance required for solvent diffusion and penetration is at least 3-5 mm and can be much more, even with perforations to increase solvent contact with the adhesive layer. Treatment times of several hours, even at elevated temperatures (>60° C.), are usually required for debonding to occur, meaning wafer throughput will be low.
[0019] Photo-decomposition is likewise a slow process because the entire bonded substrate cannot be exposed at one time. Instead, the exposing light source, which is usually a laser having beam cross-section of only a few millimeters, must be focused on a small area at a time to deliver sufficient energy for decomposition of the adhesive bond line to occur. The beam is then scanned (or rastered) across the substrate in a serial fashion to debond the entire surface, which leads to long debonding times.
[0020] While thermo-mechanical (TM) debonding can be performed typically in a few minutes, it has other limitations that can reduce device yield. Backside processes for temporarily bonded device wafers often involve working temperatures higher than 200° C. or even 300° C. The polymeric adhesives used for TM debonding must neither decompose nor soften excessively at or near the working temperature, otherwise, debonding would occur prematurely. As a result, the adhesives are normally designed to soften sufficiently at 20-50° C. above the working temperature for debonding to occur. The high temperature required for debonding imposes significant stresses on the bonded pair as a result of thermal expansion. At the same time, the high mechanical force required to move the device wafer away from the carrier by a sliding, lifting, or twisting motion creates additional stress that can cause the device wafer to break or produces damage within the microscopic circuitry of individual devices, which leads to device failure and yield loss.
[0021] Thermal decomposition (TD) debonding is also prone to wafer breakage. Gases are produced when the polymeric adhesive is decomposed, and these gases can become trapped between the device wafer and the carrier before the bulk of the adhesive has been removed. The accumulation of trapped gases can cause the thin device wafer to blister and crack or even rupture. Another problem with TD debonding is that polymer decomposition is often accompanied by the formation of intractable, carbonized residues that cannot be removed from the device wafer by common cleaning procedures.
[0022] The limitations of these prior art methods have created the need for new modes of carrier-assisted thin wafer handling that provide high wafer throughput and reduce or eliminate the chances for device wafer breakage and internal device damage.
SUMMARY OF THE INVENTION
[0023] The present invention overcomes the prior art problems by providing a temporary bonding method comprising providing a stack comprising:
[0024] a first substrate having a back surface and a device surface;
[0025] a first bonding layer adjacent the device surface and having a softening temperature;
[0026] a second bonding layer adjacent the first bonding layer and having a softening temperature, wherein the softening temperature of the first bonding layer is at least about 20° C. greater than the softening temperature of the second bonding layer; and
[0027] a second substrate having a carrier surface, the second bonding layer being adjacent the carrier surface. The first and second substrates are then separated.
[0028] The invention also provides an article comprising a first substrate having a hack surface and a device surface. The article further comprises a first bonding layer adjacent the device surface and having a softening temperature. There is a second bonding layer adjacent the first bonding layer and having a softening temperature, with the softening temperature of the first bonding layer being at least about 20° C. greater than the softening temperature of the second bonding layer. The article also includes a second substrate having a carrier surface, with the second bonding layer being adjacent the carrier surface.
[0029] In a further embodiment of the invention, a temporary bonding method is provided. In the method, a stack is provided, and the stack comprises:
[0030] a first substrate having a back surface and a device surface;
[0031] a first rigid layer adjacent the device surface;
[0032] a bonding layer adjacent the first rigid layer; and
[0033] a second substrate having a carrier surface, the bonding layer being adjacent the carrier surface. The stack further comprises one or both of the following:
[0034] a lift-off layer between the device surface and the first rigid layer; or
[0035] a second rigid layer between the bonding layer and the carrier surface.
[0000] The first and second substrates are then separated.
[0036] The invention also provides an article comprising a first substrate having a back surface and a device surface. The article further comprises a first rigid layer adjacent the device surface, a bonding layer adjacent the first rigid layer, and a second substrate having a carrier surface. The bonding layer is adjacent the carrier surface, and the article further comprises one or both of the following:
[0037] a lift-off layer between the device surface and the first rigid layer; or
[0038] a second rigid layer between the bonding layer and the carrier surface.
[0039] In yet another embodiment of the invention, a temporary bonding method is provided where the method comprises providing a stack comprising:
[0040] a first substrate having a back surface and a device surface, the device surface having a peripheral region and a central region;
[0041] a second substrate having a carrier surface;
[0042] an edge bond adjacent the peripheral region and the carrier surface; and
[0043] at least one layer selected from the group consisting of:
a lift-off layer between the edge bond and the device surface; a lift-off layer between the edge bond and the carrier surface; an adhesion promoter layer between the edge bond and the device surface; an adhesion promoter layer between the edge bond and the carrier surface; a bonding layer between said edge bond and said device surface; and a bonding layer between said edge bond and said carrier surface.
The first and second substrates are then separated.
[0050] In a final embodiment of the invention, an article is provided. The article comprises a first substrate having a back surface and a device surface, and the device surface has a peripheral region and a central region. The article further comprises a second substrate having a carrier surface, an edge bond adjacent the peripheral region and the carrier surface, and at least one layer selected from the group consisting of:
[0051] a lift-off layer between the edge bond and the device surface;
[0052] a lift-off layer between the edge bond and the carrier surface;
[0053] an adhesion promoter layer between the edge bond and the device surface;
[0054] an adhesion promoter layer between the edge bond and the carrier surface;
[0055] a bonding layer between said edge bond and said device surface; and
[0056] a bonding layer between said edge bond and said carrier surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 is a cross-sectional view of a schematic drawing showing a preferred embodiment of the invention, as further exemplified in Examples 5-9;
[0058] FIG. 2 is a cross-sectional view of a schematic drawing illustrating how thicknesses are determined;
[0059] FIG. 3 is a cross-sectional view of a schematic drawing depicting another embodiment of the invention, as further exemplified in Examples 10-16;
[0060] FIG. 4 is a cross-sectional view of a schematic drawing showing an alternative embodiment of the invention, as further exemplified in Example 17;
[0061] FIG. 5 is a cross-sectional view of a schematic drawing illustrating a variation of the embodiment of the invention that is shown in FIG. 4 ;
[0062] FIG. 6 is a cross-sectional view of a schematic drawing showing an alternative embodiment of the invention;
[0063] FIG. 7 is a cross-sectional view of a schematic drawing depicting a variation of the embodiment that is shown in FIG. 6 ;
[0064] FIG. 8 is a cross-sectional view of a schematic drawing showing an alternative embodiment of the invention; and
[0065] FIG. 9 is a cross-sectional view of a schematic drawing depicting a variation of the embodiment that is shown in FIG. 6 , with this variation being similar to the process that is exemplified in Example 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] In more detail, the present invention provides methods of forming microelectronic structures using multilayer bonding schemes. While the drawings illustrate, and the specification describes, certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. Embodiments of the present invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments of the present invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. There is no intent to limit the principles of the present invention to the particular disclosed embodiments. For example, in the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. In addition, embodiments of the present invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated as a rectangle may have rounded or curved features. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region of a device or of topography and are not intended to limit the scope of the present invention.
1. Bilayer Bonding Scheme I
[0067] Referring to FIG. 1( a ), a precursor structure 10 is depicted in a schematic and cross-sectional view. Structure 10 includes a first substrate 12 . Substrate 12 has a front or device surface 14 , a back surface 16 , and an outermost edge 18 . Although substrate 12 can be of any shape, it would typically be circular in shape. Preferred first substrates 12 include device wafers such as those whose device surfaces comprise arrays of devices (not shown) selected from the group consisting of integrated circuits. MEMS, microsensors, power semiconductors, light-emitting diodes, photonic circuits, interposers, embedded passive devices, and other microdevices fabricated on or from silicon and other semiconducting materials such as silicon-germanium, gallium arsenide, and gallium nitride. The surfaces of these devices commonly comprise structures (again, not shown) formed from one or more of the following materials: silicon, polysilicon, silicon dioxide, silicon (oxy)nitride, metals (e.g., copper, aluminum, gold, tungsten, tantalum), low k dielectrics, polymer dielectrics, and various metal nitrides and silicides. The device surface 14 can also include at least one structure selected from the group consisting of: solder bumps; metal posts; metal pillars; and structures formed from a material selected from the group consisting of silicon, polysilicon, silicon dioxide, silicon (oxy)nitride, metal, low k dielectrics, polymer dielectrics, metal nitrides, and metal silicides.
[0068] A composition is applied to the first substrate 12 to form a first bonding layer 20 on the device surface 14 , as shown in FIG. 1( a ). Bonding layer 20 has an upper surface 21 remote from first substrate 12 , and preferably, the first bonding layer 20 is formed directly adjacent the device surface 14 (i.e., without any intermediate layers between the first bonding layer 20 and substrate 12 ). The composition can be applied by any known application method, with one preferred method being spin-coating the composition at speeds of from about 500 rpm to about 5,000 rpm (preferably from about 500 rpm to about 2,000 rpm) for a time period of from about 5 seconds to about 120 seconds (preferably from about 30 seconds to about 90 seconds). After the composition is applied, it is preferably heated to a temperature of from about 80° C. to about 250° C., and more preferably from about 170° C. to about 220° C. and for time periods of from about 60 seconds to about 8 minutes (preferably from about 90 seconds to about 6 minutes). Depending upon the composition used to form the first bonding layer 20 , baking can also initiate a crosslinking reaction to cure the layer 20 . In some embodiments, it is preferable to subject the layer to a multi-stage bake process, depending upon the composition utilized. Also, in some instances, the above application and bake process can be repeated on a further aliquot of the composition, so that the first bonding layer 20 is “built” on the first substrate 12 in multiple steps.
[0069] A second precursor structure 22 is also depicted in a schematic and cross-sectional view in FIG. 1( a ). Second precursor structure 22 includes a second substrate 24 . In this embodiment, second substrate 24 is a carrier wafer. That is, second substrate 24 has a front or carrier surface 26 , a back surface 28 , and an outermost edge 30 . Although second substrate 24 can be of any shape, it would typically be circular in shape and sized similarly to first substrate 12 . Preferred second substrates 24 include silicon, sapphire, quartz, metals (e.g., aluminum, copper, steel), and various glasses and ceramics.
[0070] A second composition is applied to the second substrate 24 to form a second bonding layer 32 on the carrier surface 26 , as shown in FIG. 1( a ). Second bonding layer 32 has an upper surface 33 remote from second substrate 24 , and a lower surface 35 adjacent second substrate 24 . Preferably, the second bonding layer 32 is formed directly adjacent the carrier surface 26 (i.e., without any intermediate layers between the second bonding layer 32 and second substrate 24 ). The composition can be applied by any known application method, with one preferred method being spin-coating the composition at speeds of from about 500 rpm to about 5,000 rpm (preferably from about 500 rpm to about 2,000 rpm) for a time period of from about 5 seconds to about 120 seconds (preferably from about 30 seconds to about 90 seconds). After the composition is applied, it is preferably heated to a temperature of from about 80° C. to about 250° C., and more preferably from about 170° C. to about 220° C. and for time periods of from about 60 seconds to about 8 minutes (preferably from about 90 seconds to about 6 minutes). Depending upon the composition used to form the second bonding layer 32 , baking can also initiate a crosslinking reaction to cure the layer 32 . In some embodiments, it is preferable to subject the layer to a multi-stage bake process, depending upon the composition utilized.
[0071] The thickness of first and second bonding layers 20 and 32 (as well as other layers as described herein) can best be illustrated by reference to FIG. 2 , where like numbering has been used to represent like parts. Device surface 14 has been drawn in FIG. 2 to schematically depict the variation in topography on device surface 14 due to the presence of the above-described devices as well as of raised features, contact holes, via holes, lines, trenches, etc., that are present on or in device surface 14 . Among the various features found on device surface 14 are highest feature 36 and lowest feature 38 . (As used herein, “highest” refers to the feature extending the farthest from back surface 16 of first substrate 12 , while “lowest” refers to the feature whose lowest point is closest to back surface 16 of first substrate 12 .) Highest feature 36 has an uppermost surface 36 a , while lowest feature 38 has a lowermost surface or point 38 a . When referring to the thickness of a layer that has been applied to a topographical (i.e., non-planar) surface, two thicknesses may be references. T 1 refers to the distance from a lower plane 40 defined by lowermost surface or point 38 a and extending to upper surface 21 , as exemplified in FIG. 2 . T 2 refers to the layer's thickness as measured above the uppermost surface 36 a . Specifically, and as shown in FIG. 2 , this thickness T 2 begins at upper plane 42 and extends to the upper surface 21 . When referring to the thickness of a layer that has been applied to a planar (or substantially planar) surface, that thickness is represented by T 3 in FIG. 2 , and is the distance between lower surface 35 and upper surface 33 of layer 32 . Finally, in some instances, thickness T 4 is used, and it refers to the distance from lower plane 40 to upper plane 42 . All thicknesses refer to average thicknesses taken over live measurements.
[0072] In the embodiment of this invention, first bonding layer 20 preferably has a thickness T 1 that is at least equal to T 4 , preferably from about 1.1T 4 to about 1.5T 4 , and more preferably from about 1.2T 4 to about 1.3T 4 . This will typically result in a thickness T 1 of at least about 24 μm, more preferably from about 45 μm to about 200 μm, and even more preferably from about 50 μm to about 150 μm. Furthermore, first bonding layer 20 preferably has a thickness T 2 of at least about 5 μm, more preferably from about 5 μm to about 50 μm, and even more preferably from about 10 μm to about 30 μm. Second bonding layer 32 has a thickness T 3 of less than about 35 μm, preferably from about 1 μm to about 35 μm, more preferably from about 1 μm to about 25 μm, and even more preferably from about 1 μm to about 15 μm.
[0073] First bonding layer 20 preferably has a softening point (ring and ball) that is at least about 20° C. higher than the softening point of second bonding layer 32 , more preferably from about 20° C. to about 200° C. higher, and even more preferably from about 20° C. to about 100° C. higher. This will typically result in first bonding layer 20 having a softening point that is at least about 100° C., preferably from about 150° C. to about 400° C., and more preferably from about 200° C. to about 300° C. Furthermore, typical softening points of second bonding layer 32 will be less than about 220° C., preferably from about 50° C. to about 220° C., and more preferably from about 100° C. to about 150° C.
[0074] The materials from which first and second bonding layers 20 and 32 are formed should be capable of forming a strong adhesive bond with the first and second substrates 12 and 24 , respectively, as well as with one another. Anything with an adhesion strength of greater than about 50 psig, preferably from about 80 psig to about 250 psig, and more preferably from about 100 psig to about 150 psig as determined by ASTM D4541/D7234, would be desirable for use as first and second bonding layers 20 and 32 .
[0075] Advantageously, the compositions for use in forming first and second bonding layers 20 and 32 can be selected from commercially available bonding compositions that would be capable of being formed into layers possessing the above properties. Typical such compositions are organic and will comprise a polymer or oligomer dissolved or dispersed in a solvent system. The polymer or oligomer is typically selected from the group consisting of polymers and oligomers of cyclic olefins, epoxies, acrylics, silicones, styrenics, vinyl halides, vinyl esters, polyamides, polyimides, polysulfones, polyethersulfones, cyclic olefins, polyolefin rubbers, and polyurethanes, ethylene-propylene rubbers, polyamide esters, polyimide esters, polyacetals, and polyvinyl butyral. Typical solvent systems will depend upon the polymer or oligomer selection. Typical solids contents of the compositions will range from about 1% to about 60% by weight, and preferably from about 3% to about 40% by weight, based upon the total weight of the composition taken as 100% by weight. Some suitable compositions are described in U.S. Patent Publication Nos. 2007/0185310, 2008/0173970, 2009/0038750, and 2010/0112305, each incorporated by reference herein.
[0076] Structures 10 and 22 are then pressed together in a face-to-face relationship, so that upper surface 21 of first bonding layer 20 is in contact with upper surface 33 of second bonding layer 32 ( FIG. 1( b )). While pressing, sufficient pressure and heat are applied for a sufficient amount of time so as to effect bonding of the two structures 10 and 22 together to form bonded stack 34 . The bonding parameters will vary depending upon the compositions from which bonding layers 20 and 32 are formed, but typical temperatures during this step will range from about 150° C. to about 375° C., and preferably from about 160° C. to about 350° C., with typical pressures ranging from about 1,000 N to about 5,000 N, and preferably from about 2,000 N to about 4,000 N, for a time period of from about 30 seconds to about 5 minutes, and more preferably from about 2 minutes to about 4 minutes.
[0077] At this stage, the first substrate 12 can be safely handled and subjected to further processes that might otherwise have damaged first substrate 12 without being bonded to second substrate 24 . Thus, the structure can safely be subjected to backside processing such as back-grinding, CMP, etching, metal and dielectric deposition, patterning (e.g., photolithography, via etching), passivation, annealing, and combinations thereof, without separation of substrates 12 and 24 occurring, and without infiltration of any chemistries encountered during these subsequent processing steps. Not only can first bonding layer 20 and second bonding layer 32 survive these processes, they can also survive processing temperatures up to about 450° C., preferably from about 200° C. to about 400° C., and more preferably from about 200° C. to about 350° C.
[0078] Once processing is complete, the substrates 12 and 24 can be separated by any number of separation methods (not shown). One method involves dissolving one or both of the first and second bonding layers 20 , 32 in a solvent (e.g., limonene, dodecene, propylene glycol monomethyl ether (PGME)). Alternatively, substrates 12 and 24 can also be separated by first mechanically disrupting or destroying the periphery of one or both of first and second bonding layers 20 , 32 using laser ablation, plasma etching, water jetting, or other high energy techniques that effectively etch or decompose first and second bonding layers 20 , 32 . It is also suitable to first saw or cut through the first and second bonding layers 20 , 32 or cleave the layers 20 , 32 by some equivalent means. Regardless of which of the above means is utilized, a low mechanical force (e.g., finger pressure, gentle wedging) can then be applied to completely separate the substrates 12 and 24 .
[0079] The most preferred separation method involves heating the bonded stack 34 to temperatures of at least about 100° C., preferably from about 150° C. to about 220° C., and more preferably from about 180° C. to about 200° C. It will be appreciated that at these temperatures, second bonding layer 32 will soften, allowing the substrates 12 and 24 to be separated (e.g., by a slide debonding method, such as that described in U.S. Patent Publication No. 2008/0200011, incorporated by reference herein). After separation, any remaining first or second bonding layer 20 and 32 can be removed with a solvent capable of dissolving the particular layer 20 or 32 . In some embodiments, the composition for forming first bonding layer 20 will be selected so that it is suitable leave some or all of it on the first substrate 12 permanently. In these instances, first bonding layer 20 will serve some function (e.g., gap fill) in subsequent wafer processing steps, an advantage missing from prior art processes.
[0080] It will be appreciated that this bilayer embodiment provides a number of advantages. The bonding temperatures and overall thermal stability of the structure can be controlled due to the inventive methods. That is, the inventive method allows the use of higher processing temperatures while simultaneously making bonding and debonding possible at lower temperatures.
2. Bilayer Bonding Scheme II
[0081] The second bilayer bonding scheme is shown in FIG. 3 , with like numbers representing like parts. In this embodiment, a “cleaning” or lift-off layer 44 having an upper surface 46 and lower surface 48 is formed on device surface 14 . Lift-off layer 44 can be formed by any known application method, with one preferred method being spin-coating the composition used to form layer 44 at speeds of from about 500 rpm to about 5,000 rpm (preferably from about 500 rpm to about 2,000 rpm) for a time period of from about 5 seconds to about 120 seconds (preferably from about 30 seconds to about 90 seconds). After the composition is applied, it is preferably heated to a temperature of from about 60° C. to about 250° C., and more preferably from about 80° C. to about 220° C. and for time periods of from about 60 seconds to about 4 minutes (preferably from about 90 seconds to about 2 minutes). In some embodiments, it is preferable to subject the layer to a multi-stage bake process, depending upon the composition utilized. Depending upon the composition used to form the lift-off layer 44 , baking can also initiate a crosslinking reaction to cure the layer 44 .
[0082] Lift-off layer 44 preferably has a thickness T 1 of less than about 3 μm, more preferably from about 0.5 μm to about 3 μm, and even more preferably from about 1 μm to about 1.5 μm. In other embodiments, lift-off layer 44 is a conformal layer, so it would not have the above thickness.
[0083] The compositions used to form lift-off layer 44 should be selected so that layer 44 is soluble in solutions selected from the group consisting of 1% hydrochloric acid aqueous solution, 50% acetic acid aqueous solution, isopropanol, 1-dodecene, R-limonene, cyclopentanone, PGME, and tetramethylammonium hydroxide (TMAH). More specifically, lift-off layer 44 will be at least about 95%, preferably at least about 99%, and preferably 100% dissolved/removed after about 4-5 hours of contact with the particular remover solution.
[0084] Preferred compositions for forming lift-off layer 44 can be selected from commercially available compositions possessing the above properties. Examples of such compositions include those selected from the group consisting of polyvinyl pyridine) and polyamic acids. Two preferred such compositions are ProLIFT® and the WGF series of wet-developable materials (available from Brewer Science, Inc.). A particularly preferred composition for use is described in U.S. Patent Publication No. 2009/0035590, incorporated by reference herein.
[0085] Next, a bonding layer 20 is formed on lift-off layer 44 ( FIG. 3( b )). Bonding layer 20 preferably has a thickness T 1 as described with respect to FIG. 1 , and a thickness T 2 of at least about 5 μm, more preferably from about 5 μm to about 50 μm, and even more preferably from about 10 μm to about 30 μm. A second substrate 24 is then bonded to bonding layer 20 (FIG. 3 ( c )), as described previously, to form a bonded stack 50 . The bonded stack 50 can then be subjected to further processing as described above.
[0086] Once the first and second substrates 12 and 24 are ready to be separated, the bonded stack 50 is exposed to one of the above remover solutions (preferably for time periods of from about 1 minute to about 5 hours, and more preferably from about 2 minutes to about 60 minutes), so that the solution will dissolve lift-off layer 44 , thus allowing the substrates 12 and 24 to be separated. Advantageously, in embodiments where lift-off layer 44 is functioning as a “cleaning” layer, the substrates 12 and 24 can be separated by heating to soften bonding layer 20 sufficiently to allow substrates 12 and 24 to be separated. Once the substrates 12 and 24 have been separated, lift-off/cleaning layer 44 can be removed with a remover solution, and this will simultaneously cause any remaining residue of bonding layer 20 to also be removed.
3, Trilayer Bonding Scheme I
[0087] The first trilayer bonding scheme is shown in FIG. 4 , with like numbers representing like parts. The embodiment shown in FIG. 4 is similar to that shown in FIG. 3 , except that first bonding layer 20 of FIG. 3 has been changed to second bonding layer 32 and an additional layer is added between “cleaning” or lift-off layer 44 and second bonding layer 32 . Specifically, after the lift-off layer 44 has been formed on device surface 14 (as described previously, and see FIG. 4( a )), a rigid layer 52 having an upper surface 54 and a lower surface 56 is formed on upper surface 46 of lift-off layer 44 ( FIG. 4( b )). As used herein, “rigid” refers to a layer that has a high shear modulus of at least 1 GPa, as determined by a rheometer. Furthermore, “rigid” refers to layers that do not flow at process temperatures (typically from about 150° C. to about 400° C., and preferably from about 200° C. to about 300° C.).
[0088] The compositions used to form rigid layer 52 would be the same types of compositions discussed above with respect to first bonding layer 20 . Furthermore, rigid layer 52 would be formed in a manner similar to that described above with respect to first bonding layer 20 (including similar thicknesses, as described with respect to FIG. 1 , if lift-off layer 44 is conformal in nature). Rigid layer 52 preferably has a thickness T 3 (if lift-off layer 44 is not conformal in nature) of from about 1 μm to about 35 μm, more preferably from about 1 μm to about 25 μm, and even more preferably from about 1 μm to about 15 μm.
[0089] Referring to FIG. 4( c ), second bonding layer 32 is formed on upper surface 54 of rigid layer 52 , using the same application methods and types of compositions described previously. In this embodiment, the thickness T 3 of second bonding layer 32 is from about 1 μm to about 35 μm, more preferably from about 1 μm to about 25 μm, and even more preferably from about 1 μm to about 15 μm.
[0090] Rigid layer 52 preferably has a softening point that is at least about 20° C. higher than the softening point of second bonding layer 32 , more preferably from about 20° C. to about 300° C. higher, and even more preferably from about 20° C. to about 100° C. higher. This will typically result in rigid layer 52 having a softening point that is at least about 100° C., preferably from about 150° C. to about 400° C., and more preferably from about 200° C. to about 300° C.
[0091] Second substrate 24 is bonded to bonding layer 32 , as described previously, to form a bonded stack 58 ( FIG. 4( d )). The bonded stack 58 can then be subjected to further processing as described above. Once the first and second substrates 12 and 24 are ready to be separated, the bonded stack 58 is exposed to one of the previously-described remover solutions, so that the solution will dissolve lift-off layer 44 , thus allowing the substrates 12 and 24 to be separated. Alternatively, separation can be effected by heating stack 58 so as to soften bonding layer 32 , as described previously. In this latter instance, lift-off layer 44 is again functioning as a cleaning layer, and bonding layer residue can be removed by removing layer 44 with a remover solution.
4. Trilayer Bonding Scheme II
[0092] Another trilayer bonding scheme is shown in FIGS. 5( a )- 5 ( d ), with like numbers representing like parts. This embodiment is a variation on the above embodiments in that the multilayer bonding system includes two rigid layers 52 , with a layer of second bonding layer 32 between the two layers 52 . Composition selection, processing parameters and steps, etc., are the same as described above for the corresponding layer. Although not shown, this embodiment could be modified by reversing the bonding layer 32 with one of the rigid layers 52 (and preferably the rigid layer 52 closest to second substrate 24 ).
5. Multiple Layers at Substrate Edge
[0093] Further embodiments of the present invention are illustrated in FIGS. 6 and 7 , with like parts being numbered in a like manner. For these embodiments, reference is made to U.S. Patent Publication No. 2009/0218560, incorporated by reference herein.
[0094] Referring to FIG. 6( a ), in this embodiment, structure 55 is depicted. The device surface 14 of first substrate 12 includes a peripheral region 57 , a central region 59 , and a bilayer bonding system 60 at the peripheral region 57 . System 60 includes thin layer 62 , which has an upper surface 64 and a lower surface 66 as well as a bonding segment 68 , which includes exterior surface 70 , interior surface 72 , lower surface 74 , and bonding surface 76 . Lower surface 66 of thin layer 62 is adjacent device surface 14 of first substrate 12 at peripheral region 57 , while lower surface 74 of bonding segment 68 is adjacent thin layer 62 .
[0095] Thin layer 62 can be a lift-off layer similar to that described above with respect to lift-off layer 44 , or thin layer 62 can be an adhesion promoter layer. In instances where it is an adhesion promoter layer, any commercially available adhesion promoter composition can be used for this purpose. Some examples of such compositions include organo silanes (e.g., ProTEK® primer, available from Brewer Science, Inc.).
[0096] Thin layer 62 can be formed by conventional methods, such as spin-coating, followed by baking at temperatures suitable for the particular composition. For example, the methods followed to form lift-off layer 44 as described above could be used to form thin layer 62 . Additionally, although FIG. 6( a ) depicts this layer as only being present at peripheral region 57 , thin layer 62 could also extend entirely across device surface 14 , so that it is also present in central region 59 . The thin layer 62 preferably has a thickness T 3 at peripheral region 57 of from about 1 μm to about 35 μm, more preferably from about 1 μm to about 25 μm, and even more preferably from about 1 μm to about 15 μm. In instances where thin layer 62 extends across the entire device surface 14 , it will have a thickness T 1 of from about 0.1 μm to about 20 μm, preferably from about 0.25 μm to about 10 μm, and more preferably from about 1 μm to about 3 μm. In other instances, thin layer 62 could be a conformal layer, and thus would not have the above thicknesses.
[0097] Bonding segment 68 can be formed from any commercially available bonding composition, including those discussed above with respect to first and second bonding layers 20 and 32 . Bonding segment 68 will typically have a width “D” of from about 2 mm to about 15 mm, preferably from about 2 mm to about 10 mm, and more preferably from about 2 mm to about 5 mm. Furthermore, bonding segment 68 preferably has a thickness T 3 of from about 5 μm to about 100 μm, more preferably from about 5 μm to about 50 μm, and even more preferably from about 10 μm to about 30 μm.
[0098] At this point, structure 55 could be bonded to a second substrate 24 , as described with previous embodiments, or a fill layer 78 can be formed at central region 59 of device surface 14 , as shown in FIG. 6( b ). Fill layer 78 would have the same thicknesses as those described above with respect to bonding segment 68 . Fill layer 78 is typically formed of a material comprising monomers, oligomers, and/or polymers dispersed or dissolved in a solvent system. If the fill layer 78 will be applied via spin-coating, it is preferred that the solids content of this material be from about 1% by weight to about 50% by weight, more preferably from about 5% by weight to about 40% by weight, and even more preferably from about 10% by weight to about 30% by weight. Examples of suitable monomers, oligomers, and/or polymers include those selected from the group consisting of cyclic olefin polymers and copolymers and amorphous fluoropolymers with high atomic fluorine content (greater than about 30% by weight) such as fluorinated siloxane polymers, fluorinated ethylene-propylene copolymers, polymers with pendant perfluoroalkoxy groups, and copolymers of tetrafluoroethylene and 2,2-bis-trifluoromethyl-4,5-difluoro-1,3-dioxole being particular preferred. It will be appreciated that the bonding strength of these materials will depend upon their specific chemical structures and the coating and baking conditions used to apply them.
[0099] In this embodiment, the fill layer 78 preferably does not form strong adhesive bonds, thus facilitating separation later. Generally speaking, amorphous polymeric materials that: (1) have low surface free energies; (2) are tack-free and known to not bond strongly to glass, silicon, and metal surfaces (i.e., would typically have very low concentrations of hydroxyl or carboxylic acid groups, and preferably no such groups); (3) can be cast from solution or formed into a thin film for lamination; (4) will flow under typical bonding conditions to fill device wafer surface topography, forming a void-free bond line between substrates; and (5) will not crack, flow, or redistribute under mechanical stresses encountered during backside processing, even when carried out at high temperatures or under high vacuum conditions, are desirable. As used herein, low surface free energy is defined as a polymeric material that exhibits a contact angle with water of at least about 90° and a critical surface tension of less than about 40 dynes/cm, preferably less than about 30 dynes/cm, and more preferably from about 12 dynes/cm to about 25 dynes/cm, as determined by contact angle measurements.
[0100] Low bonding strength refers to polymeric materials that do not stick or can be peeled from a substrate with only light hand pressure such as might be used to debond an adhesive note paper. Thus, anything with an adhesion strength of less than about 50 psig, preferably from less than about 35 psig, and more preferably from about 1 psig to about 30 psig would be desirable for use as fill layer 22 . Examples of suitable polymeric materials exhibiting the above properties include some cyclic olefin polymers and copolymers sold under the APEL® by Mitsui, TOPAS® by Ticona, and ZEONOR® by Zeon brands, and solvent-soluble fluoropolymers such as CYTOP® polymers sold by Asahi Glass and TEFLON® AF polymers sold by DuPont. The bonding strength of these materials will depend upon the coating and baking conditions used to apply them.
[0101] At this point, a second substrate can be bonded to the structure 55 using the steps described with previous embodiments to form bonded stack 82 as shown in FIG. 6( c ). After the desired processing is completed on stack 82 , first substrate 12 and second substrate 24 can be readily separated. In one separation method, the bonding segment 68 is first dissolved with the aid of a solvent or other chemical agent. This can be accomplished by immersion in the solvent, or by spraying a jet of the solvent onto bonding segment 68 in order to dissolve it. The use of thermoplastic materials is especially desirable if solvent dissolution is to be used to disrupt the bonding segment 68 . Solvents that could typically be used during this removal process include those selected from the group consisting of ethyl lactate, cyclohexanone, -methyl pyrrolidone, aliphatic solvents (e.g., hexane, decane, dodecane, and dodecene), and mixtures thereof.
[0102] The substrates 12 and 24 can also be separated by first mechanically disrupting or destroying the continuity of the bonding segment 68 using laser ablation, plasma etching, water jetting, or other high energy techniques that effectively etch or decompose the bonding segment 68 . It is also suitable to first saw or cut through the bonding segment 68 or cleave the bonding segment 68 by some equivalent means.
[0103] Regardless of which of the above means is utilized, a low mechanical force (e.g., finger pressure, gentle wedging) can then be applied to completely separate the substrates 12 and 24 . Advantageously, separation does not require having to overcome strong adhesive bonds between the fill layer 78 and the substrates 12 or 24 . Instead, it is only necessary to release the adhesive bonds at bonding segment 68 in the peripheral region 57 for separation to occur. The surfaces of the substrates 12 and/or 24 can then be rinsed clean with appropriate solvents as necessary to remove any residual material.
[0104] With respect to the above embodiment, it should be noted that the formation of bonding segment 68 before the formation of fill layer 78 is only one possible order of formation. It is also possible to form the fill layer 78 first, followed by formation of bonding system 60 or bonding segment 68 . Order of formation is not critical to the invention and can be varied by one of ordinary skill in the art.
[0105] Referring to FIG. 7 , a further embodiment of the invention is shown, with like numbering representing like parts. This embodiment is similar to FIG. 6 , except that the first and second substrates 12 and 24 have been switched. That is, the thin layer 62 is in contact with carrier surface 26 of second substrate 24 rather than device surface 14 of first substrate 12 , and the bonding surface 76 of bonding segment 68 is bonded to device surface 14 of first substrate 12 . Thus, thin layer 62 can be adjacent lower surface 74 or bonding surface 76 of bonding segment 68 , or both, depending upon the needs of the particular application. In this embodiment, thin layer 62 will have the thickness T 3 described with respect to the FIG. 6 embodiment, and these thicknesses will hold true across the entire thin layer 62 .
[0000] 6. Multiple Layers with Zone Region at Substrate Edge
[0106] FIG. 8 depicts a further embodiment of this invention, with like numbers representing like parts. Referring to FIG. 8( a ), a second bonding layer 32 is formed at only the peripheral region 57 of first substrate 12 . Application methods, desired properties (including softening point), and possible compositions for use as second bonding layer 32 are as described previously. Referring to FIG. 8( b ), a fill layer 78 is formed in central region 59 of device surface 14 , as described with respect to FIGS. 6 and 7 above.
[0107] Next, and as shown in FIG. 8( c ), a first bonding layer 20 is formed on upper surface 33 of second bonding layer 32 and on upper surface 80 of fill layer 78 to form a structure 84 . Again, application methods, desired properties, and possible compositions for use as first bonding layer 20 are as described previously. Second substrate 24 can be bonded to the structure 84 using the steps described with previous embodiments to form bonded stack 86 as shown in FIG. 8( d ). (Alternatively, as described in Example 18, first bonding layer 20 could instead be formed on carrier surface 21 of second substrate 24 , and then the two structures could be pressed together to form bonded stack 86 , similar to the order of steps shown in FIG. 1 .)
[0108] The bonded stack 86 can then be subjected to further processing as described above. Once the first and second substrates 12 and 24 are ready to be separated, the bonded stack 86 is exposed to a remover solution (e.g., limonene, dodecene, PGME), so that the solution will dissolve second bonding layer 32 , thus allowing the substrates 12 and 24 to be separated. Alternatively, separation can be effected by heating stack 86 so as to soften second bonding layer 32 , which has a lower softening point than first bonding layer 20 , so that the substrates 12 and 24 can be separated, as described previously.
[0109] Referring to FIG. 9 , a further embodiment of the invention is shown, with like numbering representing like parts. This embodiment is similar to that of FIG. 8 , except that the first and second substrates 12 and 24 have been switched. That is, the second bonding layer 32 and fill layer 78 are in contact with carrier surface 26 of second substrate 24 rather than device surface 14 of first substrate 12 , and the first bonding layer 20 is bonded to device surface 14 of first substrate 12 . Thus, the location of second bonding layer 32 and fill layer 78 can be adjusted, depending upon the needs of the particular application.
[0110] For each of the above bonding schemes where the various bonding, lift-off, and rigid layers have been shown to substantially and even completely cover the particular substrate surface, it will be appreciated that one or more of these layers could be modified to span only part of the particular substrate (even if not shown). In other words, only a portion of the particular substrate surface would be in contact with that particular layer, and this would still be in the scope of the present invention.
[0111] Furthermore, even in instances where layers have been shown to be formed one on top of another on a first substrate (device) followed by bonding with a second substrate (carrier), all layers could instead be formed one on top of another on the second substrate and then bonded with the first substrate. Or, one or more layers could be formed on the first substrate while other layers are formed on the second substrate, and then the two substrates are bonded together. Order is not critical, so long as the resulting structure has the layer systems shown and/or described herein.
EXAMPLES
[0112] The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
[0113] Examples 1 through 9 illustrate the invention's improved bonding performance. Examples 10 through 16 illustrate the improved ability of the bonding compositions to be cleaned after debonding.
Example 1
Composition of Cyclic Olefin Copolymer (COC) Bonding Composition A
[0114] In this formulation, 250 grams of an ethene-norbornene copolymer (APL 8008T, obtained from Mitsui Chemicals America, Inc., Rye Brook, N.Y.) and 3.125 grams of a phenolic antioxidant (IRGANOX 1010, obtained from BASF, Germany) were dissolved in 373.45 grams of R-limonene (obtained from Florida Chemical Co., Winter Haven, Fla.) and 373.45 grams of cyclooctane (obtained from Sigma-Aldrich, Inc., St. Louis, Mo.). The mixture was allowed to stir at room temperature until all of the components dissolved. The final solution had 25.31% solids.
Example 2
Composition of COC Bonding Composition B
[0115] In this formulation, 210.31 grams of an ethane-norbornene copolymer (Topas 8007, obtained from Topas Advanced Polymers, Florence, Ky.) and 62.4 grams of a low-molecular-weight COC polymer (Topas™, obtained from Topas Advanced Polymers, Florence, Ky.) were dissolved in 706 grams of R-limonene along with 4.0 grams of a phenolic antioxidant (Irganox 1010) and 14.5 grams of polyisobutylene (obtained from Scientific Polymer Products, Inc., Ontario, N.Y.) with a molecular weight of 2,800 Daltons. The mixture was allowed to stir at room temperature until all of ingredients were in solution. The solution had 29% solids.
Example 3
Composition of COC Bonding Composition C
[0116] In this formulation, 50 grams of COC Bonding Composition B from Example 2 were mixed with 50 grams of R-limonene. The mixture was allowed to stir at room temperature to form a solution. The solution had 14.5% solids.
Example 4
Composition of Bonding Composition D
[0117] In this formulation, 120 grams of WaferBOND® HT-10.10 material (obtained from Brewer Science, Inc.) were mixed with 80 grams of 1-dodecene (Sigma-Aldrich, St. Louis, Mo.). The mixture was allowed to stir at room temperature to form a solution.
Example 5
Thick COC Bonding Composition a Layer on Device Wafer and Thin COC Bonding Composition C Layer on Carrier Wafer
[0118] In this procedure, 10 mL of the COC Bonding Composition A from Example 1, which was a cyclic olefin polymer coating layer designed to flow sufficiently at 270° C. to achieve effective bonding between the coated substrate and a second substrate, were spin-coated on a 200-mm silicon wafer and baked (using the spin and bake parameters described below) to form a film of COC Bonding Composition A. This process was exactly repeated with a second aliquot of 10 mL of the COC Bonding Composition A from Example 1, with this second aliquot being used to form a film on top of the first film. The final film thickness after both application steps was 96 μm.
[0119] COC Bonding Composition C from Example 3, which was a cyclic olefin polymer coating layer designed to flow sufficiently at 220° C. to achieve effective bonding between the coated substrate and a second substrate, was spin-coated on another 200-mm silicon wafer. The thickness of COC Bonding Composition C was about 3 μm. The spin-coating and baking parameters were the same for COC Bonding Composition A and COC Bonding Composition C and were as follows.
Spin-coating conditions: 800 rpm spin-coat for 60 seconds, with 10,000 rpm/sec acceleration. Baking conditions, in order: 80° C. for 2 minutes, 110° C. for 2 minutes, 160° C. for 2 minutes, and 220° C. for 6 minutes.
[0122] The two silicon wafers coated with COC Bonding Composition A and COC Bonding Composition C as described above were bonded in a face-to-face relationship under vacuum at 220° C. for 3 minutes in a heated vacuum in a pressure chamber with 5,800 N of bonding pressure. A debonder that uses a sliding process similar to that described in U.S. Patent Publication No. 2010/0206479, incorporated by reference (obtained from Brewer Science, Inc., Rolla, Mo.) then separated the bonded wafers at 220° C.
Example 6
Thick COC Bonding Composition A and Thin COC Bonding Composition C
[0123] In this procedure, 10 mL of the COC Bonding Composition A from Example 1, which was a cyclic olefin polymer coating layer designed to flow sufficiently at 270° C. to achieve effective bonding between the coated substrate and a second substrate, were spin-coated on a 200-mm silicon wafer and baked (using the spin and bake parameters described below) to form a film of COC Bonding Composition A. This process was exactly repeated with a second aliquot of l 0 mL of the COC Bonding Composition A from Example 1, with this second aliquot being used to form a film on top of the first film. The final film thickness after both application steps was 93 μm.
[0124] COC Bonding Composition C from Example 3, a cyclic olefin polymer coating layer designed to flow sufficiently at 220° C. to achieve effective bonding between the coated substrate and a second substrate, was spin-coated on top of the COC Bonding Composition A film. The thickness of the COC Bonding Composition C film was 8 μm. The spin-coating and baking parameters were the same for COC Bonding Composition A and COC Bonding Composition C and were as follows:
Spin-coating conditions: 800 rpm spin-coat for 60 seconds, with 10,000 rpm/second acceleration. Baking conditions, in order: 110° C. for 4 minutes, 160° C. for 2 minutes, and 220° C. for 6 minutes.
[0127] The center of another 200-mm silicon wafer was coated with fluorinated silane (heptadecafluoro-1,1,2,2-tetrahydrodecyl trichlorosilane), while a 3-mm region along the outer edge of the wafer was left without the fluorinated silane. The detailed process for coating the fluorinated silane is described in Example 1 of U.S. Patent Publication No. 2009/10218560, incorporated by reference herein.
[0128] The wafer pair described above was bonded in a face-to-face relationship at 220° C. for 3 minutes in a heated vacuum and under pressure with 5,800 N of bonding pressure. The wafer pair was bonded together strongly, and it underwent the grinding process that thinned the device wafer to 50 μm. The bonded wafer pair was soaked in R-limonene for 24 hours, and then the wafers were debonded by a peel-off process using a peel-off debonder (ZoneBOND™ Separation Tool, obtained from Brewer Science, Inc., Rolla, Mo.). During the peel-off debonding process, the device wafer was held by vacuum on a flat surface, and the carrier wafer (silanated wafer) was held tightly by a metal clamp. The device wafer was then separated from the carrier wafer by peeling the clamp.
Example 7
Thick Polysulfone with Thin Bonding Composition D
[0129] In this formulation, 280 grams of polysulfone (Ultrason E2020P; BASF, Flortham Park, N.J.) were dissolved in 520 grams of dimethylacetamide (Sigma-Aldrich, St. Louis, Mo.). The mixture was allowed to stir at room temperature until the polysulfone dissolved to form a solution. The solution had 35% solids.
[0130] The above polysulfone solution was spin-coated on a 200-mm silicon wafer at a spin speed of 600 rpm for 60 seconds. The coated wafer was baked for 2 minutes at 80° C. and then for 2 minutes at 150° C. and then for 5 minutes at 180° C. The thickness of resulting polysulfone film was 51.64 μm. Bonding Composition D from Example 4 was then spin-coated on top of the polysulfone film at a spin speed of 1400 rpm for 60 seconds. The wafer was baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 180° C. for 5 minutes. The total thickness of the diluted WaferBOND® HT-10.10 film was about 2 μm.
[0131] The wafer pair was soaked for 24 hours at room temperature in R-limonene, and the wafers were then separated using a peel debonder (ZoneBOND™ Separation Tool).
Example 8
Thick Polysulfone with Thin COC Bonding Composition C
[0132] In this formulation, 280 grams of polysulfone (Ultrason E2020P) were dissolved in 520 grams of dimethylacetamide (Sigma-Aldrich, St. Louis, Mo.). The mixture was stirred at room temperature until the polysulfone dissolved to form a solution.
[0133] The above polysulfone solution was spin-coated on a 200-mm silicon wafer at a spin speed of 600 rpm for 60 seconds. The coated wafer was baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 180° C. for 5 minutes to remove the casting solvent completely. The thickness of the polysulfone film was 52.9 μm. COC Bonding Composition C from Example 3 was then spin-coated on top of the polysulfone film at a spin speed of 1,400 rpm for 60 seconds. The wafer was baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 180° C. for 5 minutes. The total thickness of COC Bonding Composition C was about 2 μm.
[0134] The wafer pair above was soaked for 24 hours at room temperature in R-limonene and then separated using a peel debonder (ZoneBOND™ Separation Tool).
Example 9
Thick COC Bonding Composition A and a >20-μm Film of COC Bonding Composition B for Slide Debonding
[0135] In this Example, 10 mL aliquots of the COC Bonding Composition A from Example 1, a cyclic olefin polymer coating layer designed to flow sufficiently at 270° C. to achieve effective bonding between the coated substrate and a second substrate, was spin-coated twice on a 200-mm silicon wafer. The first spin-coating was carried out at 600 rpm for 60 seconds, and the second spin-coating was carried out at 800 rpm for 60 seconds. After each coating, the wafer was baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 220° C. for 5 minutes. The thickness of the resulting COC Bonding Composition A film was 99.14 μm.
[0136] COC Bonding Composition B from Example 2, a cyclic olefin polymer coating layer designed to flow sufficiently at 220° C. to achieve effective bonding between the coated substrate and a second substrate, was spin-coated on the same wafer that was coated with COC Bonding Composition A. COC Bonding Composition B was coated at a spin speed of 1500 rpm for 60 seconds. The wafer was baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 220° C. for 5 minutes. The thickness of the resulting COC Bonding Composition B film was about 29 μm.
[0137] The wafer described above was bonded in a face-to-face relationship with another 200-mm silicon wafer under heated vacuum at 220° C. for 3 minutes in a pressure chamber with 5,800 N of bonding pressure.
[0138] A slide debonding process using a slide debonder (obtained from Brewer Science, Inc.) separated the bonded wafer pair. The debonding process was carried out at a debonding rate of 2 mm/second and at a temperature of 220° C.
Example 10
Poly(vinyl pyridine) and COC Bonding Composition B Cleaned With HCl Solution
[0139] In this formulation, 2 grams of poly(vinyl pyridine) (obtained from Sigma-Aldrich, St. Louis, Mo.) were dissolved in cyclopentanone. The mixture was allowed to stir at room temperature until the polymer dissolved. The total weight concentration of poly(vinyl pyridine) in cyclopentanone was 2%. The solution was filtered through a 0.1-μm filter.
[0140] The above poly(vinyl pyridine) composition was spin-coated on a 100-mm silicon wafer at a spin speed of 2,000 rpm for 60 seconds. The coated wafer was baked at 80° C. for 2 minutes and then at 220° C. for 2 minutes. The thickness of the resulting poly(vinyl pyridine) film was 0.0579 μm (57.9 nm). COC Bonding Composition B was then spin-coated on top of the poly(vinyl pyridine) film at a spin speed of 1,100 rpm for 60 seconds. The wafer was baked at 80° C. for 2 minutes, then at 160° C. for 2 minutes, and then at 220° C. for 6 minutes. The total thickness of the resulting polymer film was about 22 μm.
[0141] The coated wafer was dipped in 1% hydrochloride (HCl) aqueous solution at room temperature for about 4 to 5 hours until the COC Bonding Composition B film lifted off from the wafer. The wafer was clean by visual observation, but some residue was still evident when it was viewed under a microscope.
Example 11
Poly(vinyl pyridine) and COC Bonding Composition B Cleaned with Acetic Acid Solution
[0142] A wafer was prepared with the same compositions and in the same manner as the one in Example 10. The coated wafer was dipped in 50% acetic acid aqueous solution at room temperature for about 4 to 5 hours until the COC Bonding Composition B film lifted off the wafer.
[0143] The wafer cleaned with the acetic acid solution was clean by visual observation, but some residue was still evident when it was viewed under a microscope.
Example 12
Poly(vinyl pyridine) and COC Bonding Composition B Cleaned with R-limonene, Cyclopentanone, and Isopropanol
[0144] Another wafer coated with the same formulation and in the same manner as in Example 10 was allowed to spin at room temperature at a speed of 900 rpm while R-limonene was dispensed for 400 seconds as the first cleaning solvent to remove the COC Bonding Composition B film. Then further cleaning was performed at room temperature by dispensing cyclopentanone at a spin speed of 900 rpm for 400 seconds to remove the poly(vinyl pyridine) polymer film. The wafer was spin rinsed with isopropanol for 120 seconds at a spin speed of 900 rpm. Final drying was performed by spinning the wafer at a speed of 1200 rpm for 60 seconds. The wafer cleaned by this process was defect-free by visual observation.
Example 13
Poly(vinyl pyridine) and COC Bonding Composition B Cleaned with R-limonene and Isopropanol
[0145] Another wafer coated with the same formulation and in the same manner as in Example 10 was allowed to spin at room temperature at a speed of 900 rpm while R-limonene was dispensed for 400 seconds as the first cleaning solvent to remove the COC Bonding Composition B film. Then further cleaning was performed at room temperature by dispensing isopropanol for 400 seconds at a spin speed of 900 rpm to remove the poly(vinyl pyridine) polymer film. Final drying was performed by spinning the wafer at a speed of 1,200 rpm for 60 seconds. The wafer cleaned by this process was defect-free by visual observation.
Example 14
ProLIFT® 100-16 Coating and WaferBOND® HT-10.10 Material
[0146] ProLIFT® 100-16 coating (obtained from Brewer Science, Inc., Rolla, Mo.) was spin-coated on a 200-mm silicon wafer at 3,000 rpm for 90 seconds. The coated wafer was baked at 120° C. for 90 seconds and then at 205° C. for 90 seconds to produce a layer that was about 1 μm thick. WaferBOND® HT-10.10 material was spin-coated on top of the ProLIFT® 100-16 film at 1,500 rpm for 30 seconds. The wafer was baked at 120° C. for 2 minutes and then at 160° C. for 2 minutes to produce a layer that was about 16 μm thick. Another 200-mm silicon wafer was bonded to the coated wafer in a face-to-face relationship at 220° C. for 3 minutes under a pressure of 15 psi for 1 minute. The bonded wafer pair was cooled to 160° C. for 1 minute and gradually to room temperature. The bonded wafer pair was separated by using a slide debonder at a rate of 2.00 mm/second and at a temperature of 200° C.
[0147] The coating on the debonded wafer was cleaned first by dispensing 1-dodecene at a spin speed of 250 rpm for 60 seconds to remove the WaferBOND®′ HT-10.10 polymeric film and then by dispensing ProLIFT® Remover (obtained from Brewer Science, Inc., Rolla, Mo.) at a spin speed of 300 rpm for 10 seconds to clean the ProLIFT® film. The wafer was dried by spinning at a speed of 1,400 rpm for 15 seconds. The wafer was visually defect-free after cleaning.
Example 15
ProLIFT® 100 Coating and COC Bonding Composition B
[0148] ProLIFT® 100-16 coating was spin-coated on a 200-mm silicon wafer at 3,000 rpm for 90 seconds. The coated wafer was baked at 100° C. for 120 seconds and then 245° C. for 60 seconds. COC Bonding Composition B from Example 2 was spin-coated on top of the ProLIFT® 100-16 film at 300 rpm for 5 seconds. The speed was ramped up, and the wafer was spun at 1,200 rpm for 60 seconds. The coated wafer was baked at 60° C. for 60 seconds, then at 80° C. for 60 seconds, and then at 220° C. for 120 seconds.
[0149] The wafer was cleaned first by using R-limonene to remove the COC Bonding Composition B polymer film and then by dispensing PD523-AD developer (JSR Microelectronics, Sunnyvale, Calif.) to remove the ProLIFT® 100-16 film. The specific cleaning procedure was as follows:
[0150] Cleaning the COC Bonding Composition B:
1. Puddle R-limonene: 0 rpm for 60 seconds 2. Spin off: 2,000 rpm for 5 seconds 3. Manually dispense R-limonene: 500 rpm for 60 seconds 4. Spin off: 2,000 rpm for 5 seconds 5. Manually dispense isopropanol to rinse: 500 rpm for 30 seconds 6. Spin dry: 2,000 rpm for 15 seconds
[0157] Cleaning the ProLIFT® 100-16 coating:
1. Puddle PD523-AD developer: 0 rpm for 20 seconds 2. Spin off: 2,000 rpm for 5 seconds 3. Manually dispense deionized water: 500 rpm for 20 seconds 4. Manually dispense isopropanol to rinse: 500 rpm for 5 seconds 5. Spin dry: 2,000 rpm for 15 seconds
[0163] The wafer was confirmed to be clean by defect inspection using a Candela CS20 tool (obtained from KLA Tencor, Milpitas, Calif.).
Example 16
WGF 300-310 Material and COC Bonding Composition B
[0164] WGF 300-310 material (a developer soluble gap fill composition obtained from Brewer Science, Inc., Rolla, Mo.) was spin-coated onto a 200-mm silicon wafer at 3,000 rpm for 90 seconds. The coated wafer was baked at 100° C. for 120 seconds and then at 245° C. for 60 seconds to produce a film that was about 720 Å thick. COC Bonding Composition B from Example 2 was spin-coated on the top of the WGF 300-310 film at 300 rpm for 5 seconds, and then the speed was ramped up and the wafer was spun at 1,200 rpm for 60 seconds. The coated wafer was then baked at 60° C. for 60 seconds, then at 80° C. for 60 seconds, and then at 220° C. for 120 seconds.
[0165] The wafer was cleaned first by using R-limonene to remove the COC Bonding Composition B polymer film and then by dispensing F′D523-AD developer to remove the WGF 300-310 film. The specific cleaning procedure was as follows:
[0166] Cleaning the COC Bonding Composition B
1. Puddle R-limonene: 0 rpm for 60 seconds 2. Spin off: 1,500 rpm for 5 seconds 3. Manually dispense R-limonene: 500 rpm for 60 seconds 4. Spin off: 1,500 rpm for 5 seconds 5. Manually dispense isopropanol for rinsing: 500 rpm for 0 seconds 6. Spin dry: 2,000 rpm for 15 seconds
[0173] Cleaning the WOE 300-310 coating:
1. Puddle PD523-AD developer: 0 rpm for 20 seconds 2. Spin off: 1,500 rpm for 5 seconds 3. Manually dispense deionized water: 500 rpm for 20 seconds 4. Manually dispense isopropanol for rinsing: 500 rpm for 5 seconds 5. Spin dry: 2,000 rpm for 15 seconds
[0179] The wafer was confirmed to be clean by defect inspection using a Candela CS20 tool.
Example 17
WGF 300-310 material, COC Bonding Composition A, and COC Bonding Composition B
[0180] WGF 300-310 material was spin-coated on a 100-mm silicon wafer at 3,000 rpm for 90 seconds. The wafer was baked at 100° C. for 120 seconds and then at 245° C. for 60 seconds. The thickness of the WGF 300-310 film was 0.0632 μm (63.2 nm). COC Bonding Composition A from Example 1 was spin-coated on top of the WGF 300-310 film at a speed of 600 rpm for 60 seconds. The wafer was then baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then 220° C. for 5 minutes. The thickness of the COC Bonding Composition A layer was 41 μm. COC Bonding Composition B from Example 2 was spin-coated on top of the COC Bonding Composition A film at a speed of 1,400 rpm for 60 seconds. The wafer was then baked at 80° C. for 2 minutes, then at 150° C. for 2 minutes, and then at 220° C. for 5 minutes. The thickness of the COC Bonding Composition B layer was 8.2 μm.
[0181] The wafer described above was first cleaned by immersing it in R-limonene for 24 hours to remove the COC Bonding Composition A and B polymer layers. Then a second step to clean the WGF 300-310 film with PD523-AD developer was carried out as follows:
1. Puddle PD523-AD developer: 0 rpm for 20 seconds 2. Spin off: 2,000 rpm for 5 seconds 3. Manually dispense deionized water: 500 rpm for 20 seconds 4. Manually dispense isopropanol to rinse: 500 rpm for 5 seconds 5. Spin dry: 2,000 rpm for 15 seconds
[0187] The wafer was clean, by visual observation.
Example 18
Using Multiple Layers to Assist in ZoneBOND™ Edge Cutting
[0188] An approximately 1 thick layer of WaferBOND® HT-10.10 was coated onto a 3-5-mm wide ring around the edge of the surface of a 200-mm silicon carrier wafer. This wafer was baked at 110° C. for 2 minutes, followed by a second bake at 160° C. for 2 minutes. A fluorinated silane ((heptadecafluoro-1,1,2,2-tetrahydradecyl)trichlorosilane, a perfluoro compound with primarily C 12 , sold under the name Fluorinert by 3M) was diluted to a 1% solution using FC-40 solvent (obtained from 3M). The solution was spin-coated onto the center section of the carrier. The carrier was baked on a hotplate at 100° C. for 1 minute, rinsed with FC-40 solvent in a spin coater and baked on a hotplate at 100° C. for an additional 1 minute.
[0189] The surface of another 200-mm silicon device wafer was coated with a COC bonding composition via spin-coating. This water was baked at 80° C. for 2 minutes followed by 120° C. for 2 minutes and finally 220° C. for 2 minutes. The device and carrier wafers were bonded in a face-to-face relationship under vacuum at 220° C. for 3 minutes in a heated vacuum and pressure chamber.
[0190] The assembly was soaked in 1-dodecene for approximately one hour to soften and partially dissolve the thin layer of WaferBOND® HT-10.10 at the edge of the carrier. The 1-dodecene did not affect the bulk of the experimental bonding adhesive, only the WaferBOND® HT-10.10. The carrier was separated from the assembly using a ZoneBOND™ Separation Tool. | Multiple bonding layer schemes that temporarily join semiconductor substrates are provided. In the inventive bonding scheme, at least one of the layers is directly in contact with the semiconductor substrate and at least two layers within the scheme are in direct contact with one another. The present invention provides several processing options as the different layers within the multilayer structure perform specific functions. More importantly, it will improve performance of the thin-wafer handling solution by providing higher thermal stability, greater compatibility with harsh backside processing steps, protection of bumps on the front side of the wafer by encapsulation, lower stress in the debonding step, and fewer defects on the front side. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/518,993 filed May 16, 2011, hereby incorporated by reference.
BACKGROUND
[0002] Prefabricated modular bathrooms are structures that are completely built in factory conditions. One common type of modular bathroom comprises a wood frame mounted on a structural floor of plywood. This structural arrangement provides high strength and rigidity for the transport and final placement but the structure is very heavy and prone to damage during shipping and placement.
[0003] Another type of prefabricated bathroom is manufactured for the noncombustible market. Typically, these structures are constructed using conventional metal stud framing, metal blocking for the support of fixtures and accessories, and metal bridging, cross bracing and/or shear sheathing. These components are required to keep the prefabricated unit rigid and counteract the stresses experienced by bathroom during the delivery and setting process.
[0004] The typical manufacture process of these prefabricated bathrooms comprises a main production assembly line where the bathrooms are assembled from smaller subassemblies such as floors, walls, and ceiling panels. Individual floor, wall, and ceiling panels are fabricated elsewhere in the production facility offline of the main assembly line and delivered and to the main assembly line for incorporation into the manufactured bathroom unit. The wall and ceiling panels comprise conventional metal studs that typically include multiple pieces of stud and track and require precise assembly jigs.
[0005] The typical small footprints of these bathrooms typically have framed corners that are in close proximity to each other and require additional stud placement for corner reinforcing. Nailers are also typically used and add to the complexity of the coordination of mechanical infrastructure occupying and passing through this same geometry. Also, additional cross bracing and/or corner bracing typically is required for door openings. Arrangement of this cross bracing is often limited based on the arrangement of fixtures.
[0006] These modular bathrooms are more lightweight and less prone to damage during shipment then the wood frame design but the offsite manufacturing process is long. Mostly due to the frame design but also because manufacturers want to completely furnish the pod with all contents such as fixtures and finishes at the off-site manufacturing plant so that a builder may simply insert the pod into position and connect to building services. That is, once the prefabricated shell is completed, the bathroom is outfitted with plumbing and electrical systems, tiled, bathroom accessories are installed and then the final testing, cleaning and quality control is performed. The process as a whole is time consuming.
SUMMARY OF THE DISCLOSED TECHNOLOGY
[0007] The disclosed technology relates to a method of assembling a modular bathroom in less time.
[0008] A prefabricated bathroom of the disclosed technology comprises a bent metal panel framing wall and ceiling system that solves many problems associated with the design, fabrication, delivery, setting, field completion, and finishes punch list of a prefabricated bathroom. The disclosed prefabricated bathroom is a monolithic structural frame system that includes individually designed and fabricated bent metal panels incorporating all embedded architectural and mechanical design elements. The frame system enables a more efficient fabrication and assembly process of a prefabricated bathroom by using a bent metal panel system that creates a rigid structure and continuous substrate for the installation of bathroom fixtures, accessories, and finishes. The bent metal panel assemblies by their nature also aid in the reduction of finish punch list items typically experienced during delivery and setting of prefabricated bathrooms comprised of conventional metal stud framing.
[0009] In one embodiment, a modular structure comprises a floor, a ceiling and at least four walls. The floor may be a honeycomb substrate and the walls and ceiling may be constructed from a plurality of bent metal panels. These bent metal panels may include tabs and flanges so that the panels may be connected to one another, as needed thereby creating a rigid and continuous substrate. The walls may also be prefabricated to incorporate embedded architectural and mechanical design elements, e.g, punch-outs, notches, spacing, gypsum boards and tiles.
[0010] During the main assembly phase, the floor is mounted to the walls with screws and/or adhesives, the sides of the walls are mounted to each other with screws and/or adhesives and the ceiling is mounted to the walls with screws and/or adhesives thereby forming a monolithic frame structure. Once the monolithic structure is formed, bathroom fixtures, accessories, and finishes are installed. This monolithic structure enables a more efficient fabrication and main assembly process. The monolithic structure also aids in the reduction of punch list items typically experienced during delivery and setting of the monolithic structures.
[0011] In another embodiment, a prefabricated room module for use in the construction of a modular building comprises a floor having at least four edges, at least four walls being mounted atop the edges of the floor, and a ceiling being mounted to a top section of the walls. The floor may be a honeycomb substrate and the walls and ceiling may be constructed from a plurality of bent metal panels. These bent metal panels may include tabs and flanges so that the panels may be connected to one another, as needed thereby creating a rigid and continuous substrate. The walls may also be pre-fabricated to incorporate embedded architectural and mechanical design elements, e.g, punch-outs, notches, spacing, gypsum boards and tiles.
[0012] During the main assembly phase, the floor is mounted to the walls with screws and/or adhesives, the sides of the walls are mounted to each other with screws and/or adhesives and the ceiling is mounted to the walls with screws and/or adhesives thereby forming a monolithic frame structure. Once the prefabricated room module is formed, bathroom fixtures, accessories, and finishes are installed. This prefabricated room module enables a more efficient fabrication and main assembly process. The prefabricated room module aids in the reduction of punch list items typically experienced during delivery and setting of the modules.
[0013] In another embodiment, a modular structure may be made by the following process. At least four walls and a ceiling structure are pre-assembled. The walls and ceiling may be constructed from a plurality of bent metal panels that include tabs and flanges so that the panels may be connected to one another, as needed. This creates a rigid structure and continuous substrate and may include embedded architectural and mechanical design elements. The walls are then mounted to a substrate and the sides of the walls are adhered to one another. A ceiling structure is then mounted on top sections of the walls. Once the modular structure is formed, bathroom fixtures, accessories, and finishes may be installed. This modular structure aids in the reduction of punch list items typically experienced during delivery and setting of modular structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a prospective view of a modular bathroom in accordance with the disclosed technology;
[0015] FIG. 2 is a top view of a floor of a modular bathroom used in accordance with the disclosed technology;
[0016] FIG. 3 is a top view of a panel framing plan in accordance with the disclosed technology;
[0017] FIGS. 4 a - f are side views of a wall panels of a modular bathroom used in accordance with the disclosed technology;
[0018] FIG. 5 is a top view of a ceiling of a modular bathroom used in accordance with the disclosed technology;
[0019] FIGS. 6 a - d are fire rating detail used in accordance with the disclosed technology;
[0020] FIGS. 7 a - c are plumbing details of a modular bathroom used in accordance with the disclosed technology;
[0021] FIG. 8 are electrical details of a modular bathroom used in accordance with the disclosed technology;
[0022] FIG. 9 is a top view of a floor plan for a modular bathroom used in accordance with the disclosed technology;
[0023] FIGS. 10 a - d are side views of elevation heights for modular bathroom used in accordance with the disclosed technology; and
[0024] FIG. 11 shows a side view of an entry threshold used in accordance with the disclosed technology.
DETAILED DESCRIPTION
[0025] FIG. 1 shows a modular bathroom structure 1 . The disclosed embodiment consists of six panel walls 3 - 8 , a ceiling 9 and a floor 2 . Please note that the modular structure may come in many different shapes, sizes and uses, e.g., kitchens, garages, etc.
[0026] The bathroom structure 1 is prefabricated in a factory and then installed on site. These structures 1 may be used in conjunction with any modular or pre-existing structures, e.g., houses, high-rise buildings, hospital, dorms, etc. In this embodiment, manufacturers may completely furnish the structure 1 with all contents, such as, fixtures and finishes at the off-site manufacturing plant as shown in FIGS. 8 , 9 and 10 a - d. A builder then simply inserts the structure 1 in position at site and connects to the building services.
[0027] FIG. 2 shows a floor 2 of the bathroom pod. The floor 2 may be a honeycomb floor substrate of ¼″-3″ preferably ¾″. Honeycomb floor substrates are lightweight and have a high strength. The substrate 2 has excellent stiffness and deflection properties. These substrates can withstand extreme moisture and humidity. When used as a bathroom floor, they are durable and will not rot due to wetness. These floors also make the pods lightweight so they are easier to transport and install. The floors are strong enough to support the weight of the bathroom components during shipping and installation while also having a thickness that is approximately the same height as an adjacent floor, e.g., a wood floor. A saddle 12 may be used for the transition as shown in FIG. 1 .
[0028] As shown in FIG. 3 , the floor 2 may be marked with a panel wall framing plan. In the disclosed embodiment, six panel walls 3 - 8 are used to construct the structure 1 but the invention is not limited to this layout. The panel walls 3 - 8 are constructed during a pre-assembly process as will be discussed more fully below. These panel walls 3 - 8 solve many problems associated with the design, fabrication, delivery, setting, field completion, and finishes punch list of a existing prefabricated bathrooms because the panel walls 3 - 8 comprise individually designed and fabricated bent metal panels incorporating all embedded architectural and mechanical design elements which enables a more efficient fabrication and assembly process of a prefabricated bathrooms.
[0029] The bent metal panel system creates a rigid structure and continuous substrate for the installation of bathroom fixtures, accessories, and finishes. The bent metal panel assemblies also by their nature also aid in the reduction of finish punch list items typically experienced during delivery and setting of prefabricated bathrooms comprised of conventional metal stud framing. (In the U.S. construction industry, a punch list is the name of a contract document used in the architecture and building trades to organize the completion of a construction project. Examples of punch list items include damaged building components (e.g. repair broken window or appliances, replace stained wallboard, repair cracked paving, etc.), or problems with the final installation of building materials or equipment (e.g., reinstall broken tiles, reinstall peeling carpet, replace missing roof shingles, fire and pressure test boiler, obtain elevator use permit, activate security system, etc.).)
[0030] The panel walls 3 - 8 may be constructed using any number of metal panels. The metal panels may be eighteen-gauge, galvanized metal panels but other types of material and gauges of metal may be used. The individual panels vary in width but typically are 16 ″. The panel walls 3 - 8 are made in a pre-manufacturing process where multiple individual panels are pieced together using a bent metal panel design 13 a - d and 14 a - c shown in FIG. 1 . That is, in a bent metal panel design, each panel includes a bent tab and a bent tab with flange. In use, panels are connected to one another by marrying the bent tab to the bent tab with flange from an adjacent panel. Other attachment methods are contemplated.
[0031] Incorporation of a bent metal panel system over conventional metal stud framing has the following benefits:
[0032] 1. Integration of imbedded architectural and mechanical infrastructure in the individual panel walls 3 - 8 and ceiling 9 provides a more consistent and quality product.
[0033] 2. Elimination of multiple studs, track, blocking, and cross bracing and corner bracing simplifies production and increases output of sub-assembled panel wall 3 - 8 and ceiling 9 .
[0034] 3. Elimination of additional reinforcing and corner bracing on the assembly line increases output of the assembled bathrooms 1 .
[0035] 4. Bent panel technology creates a rigid and continuous substrate for the installation of bathroom fixtures, accessories, and finishes thus eliminating the need for additional metal blocking, cross bracing and corner bracing.
[0036] 5. Reduce delivery related punch list issues by creating a more rigid structure to counteract the stresses experienced by bathroom 1 during the delivery and setting process.
[0037] Each wall panel 3 - 8 is constructed as needed as shown in FIGS. 4 a - f. For example, in the disclosed embodiment, (1) panel wall 2 includes bent panels 41 a - d, a door frame section 42 and a punched-out electric outlet and switch section 43 . (2) panel wall 4 includes five bent panels 44 a - f, ( 3 ) panel wall 5 includes bent panels 45 a - e, punch-outs for the sink, toilet and electrical components 46 , 47 , 49 and 50 and a framing member for a medicine cabinet 48 , (4) panel wall 6 is a single bent panel 51 that includes a wall notch for an adjacent panel wall 5 and punch-outs for plumbing and electrical components 53 - 56 , (5) panel wall 7 includes bent panels 57 a - b and punch-outs for bathtub and shower components 58 - 62 , and (6) panel wall 8 has bent panels 65 a - d.
[0038] Once the panel walls 3 - 8 are constructed, the panel walls 3 - 8 may be finished as much as possible during the pre-assembly phase. For example, the panel walls 3 - 8 may be embedded with architectural and mechanical design elements, e.g., gypsum boards to cover the skin of the wall panel 3 - 8 and tiles may be attached to the gypsum board as needed. It is important to note that each step performed in the pre-assembly phase streamlines the assembly process by allowing each 3-D structure to be built within a minimal time requirement.
[0039] FIG. 5 shows a ceiling 9 for the bathroom pod 1 . The ceiling 9 is also made with a galvanized bent panels 70 a - e and outer frame channels 73 . The outer frame channels 73 are used for attaching the ceiling 9 to the top portions of the wall panels 308 . The ceiling 9 may also include a ceiling fan 72 .
[0040] During a main assembly process, the wall panels 3 - 8 may be attached atop the floor 2 using any adherence methods, e.g., adhesive glue or screws. The panel walls 3 - 8 are then adhered to each other at the ends and the ceiling 9 is set on top of the panel walls and secured into place. Each of the components are adhered to each other by screws or adhesives or both. This design does not need any traditional framing such as stud or bracing which allows the 3-D structure to be built quickly and efficiently. The metal panels also allow the exterior of the pod to withstand more impact with considerable less damage potential.
[0041] FIGS. 6 a - d show the fire rating plan for the bathroom pod. The perimeter of the ceiling may have a fire stop of gypsum board, steel studs, and fire caulking 80 - 91 .
[0042] FIGS. 7 a - c show the plumbing design for the bathroom pod. The plumbing may also be assembled during a pre-assembly phase. That is, vents, vent outlets, water supplies, waste pipes, water spouts and shower heads 90 - 106 may be partially or fully assembled according to the design and installed as a single unitary piece during the main assembly phase.
[0043] FIG. 8 shows a wiring diagram for the electric of the bathroom pod. The bathroom 1 , during the main assembly phase, may be equipped with lighting components, GFCI circuits and electrical plugs 110 , 113 .
[0044] FIGS. 9 and 10 a - d shows floor plan and elevation heights for the final assembly phase. In a final assembly phase, the bathroom may be equipped with the toilet, sink, tub, doors, towel racks, toilet paper holders, soap dishes, hooks, vanities 200 - 213 and any other functional or aesthetic piece needed. In this phase, all edges are caulked and sanded. This phase begins after the pod in assembled into a 3-D box.
[0045] FIG. 11 shows the entry threshold of the bathroom door using gypsum leveling compound 90 , 92 , floor 2 , crack suppressant and grout layer 88 , hardwood flooring 91 and saddle 12 .
[0046] The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. Those skilled in the art could implement various other feature combinations without departing from the scope and spirit of the invention. | The disclosed technology relates to a modular structure having a floor, a ceiling and at least four walls. The walls being constructed from a plurality of bent metal panels. These bent metal panels create a rigid and continuous substrate. The walls are also pre-fabricated to incorporate embedded architectural and mechanical design elements. During the main assembly phase the floor is mounted to the walls, the sides of the walls are then mounted to each other and the ceiling is then mounted to the walls thereby forming a monolithic frame structure. This monolithic structure enables a more efficient fabrication and assembly process. | 4 |
BARGE BUMPER ASSEMBLY
1. Field of the Invention
This invention relates to a barge bumper assembly utilizing dual shock cells for use in preventing damage to offshore tubular members and the like from boats, barges, and other vessels.
2. Description of the Prior Art
It is well known to utilize certain bumper fendering and other type assemblies for protecting docks and tubular members such as flow line risers or legs of drilling platforms such as that disclosed in U.S. Pat. No. 4,005,672 and U.S. Pat. No. 3,991,582.
The main problem with such assemblies has been the lack of provision for any lateral movement of the barge bumper assembly and the failure to provide for shock assemblies at the lower end of the barge bumper assembly which thus caused the lower ends to become crushed or bent which meant that sometimes the whole assembly or at least the bottom shock cell assembly had to be replaced.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new and improved rugged and reliable barge bumper assembly which will withstand the wear, tear, and shock from offshore vessels to prevent damage to flow line risers, legs of drilling platforms, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a side sectional view of the barge bumper assembly of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in the FIGURE, an offshore flow line riser or leg 10 of the present invention is partly shown, and as is well known, the leg is normally mounted with a drilling rig or the like which includes a plurality of legs extending downwardly to the floor (not shown) of the ocean to support the drilling rig and the like. As further illustrated, the drilling leg or flow line riser 10 extends upwardly from the floor of the ocean to the surface or wave action area W of the body of water to upwardly support the drilling rig, platform, or other structures (not shown).
The barge bumper assembly of the present invention is illustrated by the numeral 15 and includes upper and lower connection members generally designated at 16 and 17, respectively. As illustrated, upper connection member 16 includes a plate 20 fitted to the contour of the member 10 and welded thereon.
A shock cell generally designated at 22 includes an outer diameter cylinder 23 secured at 24 as by welding to plate 20 and a plurality of support ribs 25 is mounted to the side walls of the cylinder 23 and the plate 20 to provide support for such cylinder 23. An end of ram plate 28 shown by the dotted lines is mounted to the circumferential inside walls 23a of cylinder walls 23 for a purpose to be explained hereinafter. A piston 29 extends inwardly into the interior area 30 adjacent said wall 28 such that movement of the piston 29 into the area 30 causes the cylinder head 31 to contact the wall 28 to prevent further movement of the piston member 29. As further illustrated in the FIGURE, a plurality of resilient material 36 such as castable polyurethane is mounted to the interior wall 23b forward of the wall 28 and sealingly grips the piston exterior wall 29a as illustrated about such cylindrical wall 29a such that inward movement of piston 29 causes the polyurethane to deform and move downwardly toward the wall 28, and when the force sufficient to cause such inward movement has been eliminated, the polyurethane pushes the piston outwardly to the position illustrated in the FIGURE. As further illustrated, the castable polyurethane is further cast such that it extends outwardly at 40 to form an outwardly extending annular lip seal around such piston member 29.
A pivot pin 41 connects the end 42 of the piston 29 to an upper portion 43 of a bumper retaining member 44.
As further illustrated in the FIGURE, a retaining member 47 includes a plate 48 and a plurality of support ribs 49 mounted with a suitable eye attachment 50 by pin means (not shown) to a chain 51 secured at one end 52 to the eye 50 and at the other end 55 to a suitable shackle member 56 as is well known in the art which is suitably and pivotally mounted with a pad eye member 57 which is welded as at 58 to the leg or flow line riser 10 for supporting the shock cell assembly 22 in an upright parallel position and for preventing undesirable or unwanted lateral movement (in this instance into and out of the sheet of drawings) in the shock cell assembly 22.
As further illustrated in the FIGURE, yet another chain 60 is secured at one end 61 to a rib member 20a extending outwardly from the attaching means 20 and at its other end 62 to the upper portion 43 of the bumper assembly member 44.
The lower connection member 17 includes two half plates 68 and 69 which are welded or otherwise suitably attached to the member 10 and which are connected to each other along ribs 68a and 69a by any suitable means such as welding or by bolts, and as further illustrated, each plate includes support ribs 70. It is to be understood that if plates 68 and 69 are bolted suitably around the flow line riser or leg 10, that a lateral blow to a shock cell assembly 75 would enable such shock cells to move slightly relative to such blow to prevent undue shearing and damage to the total barge bumper assembly 15.
The shock cell assembly 75 operates in the same manner as the shock cell assembly 22 and thus has been given the same numerals to indicate the similarity of operation including the positioning of the cstable polyurethane 36.
As further illustrated, the end 77 of the piston 29 extending outwardly from the interior of the cylinder 23 is suitably secured such as by welding at 78 to a stinger or stabbing base member 80. The stabbing base member 80 extends upwardly and is tapered inwardly as at 81 and further tapered inwardly at section 82 to form a stinger or stabbing member 84 which extends upwardly to terminate at end 85. As further illustrated, the member 44 is pivotally attached at 51 through a suitable pivot pin (not shown) to the end 42 of piston member 29 in the upper shock assembly 22 and extends downwardly such that member 44, which is a cylindrical hollow member, is positioned concentrically relative to stabbing member 85 to terminate at 90 on base member 80 by wedging base member 80 due to the taper of such base member 80 such that base member 80 has a larger cylindrical diameter than member 44.
As further illustrated in the FIGURE, base member 80 also extends upwardly and includes a straight cylindrical wall portion 91 which extends upwardly and is attached to rigid support plate 92 which receives and supports a loose barge bumper support plate 93. It is to be understood that both plates 92 and 93 have openings (not shown) therein for enabling the base 80 of the stabbing member and the member 44 to extend therethrough.
As further illustrated in the FIGURE, a support member such as chain 100 is mounted at one end 101 to a support rib 102 which is mounted to the piston member 29 and stabbing base 80 and at the other end 105 of such chain member 100 to a suitable shackle member 106 which in turn is mounted through a pivotal pin support 107 to support member 20a.
As further illustrated in the FIGURE, a plurality of polyurethane bumpers 110 is positioned to fit such that openings 112 in the bumpers 110 loosely and circumferentially fit around cylindrical member 44 from the loose bumper support plate 93 upwardly to adjacent the upper portion 43 of such member 44.
In operation, as a vessel, barge, tug, or the like approaches offshore platforms or flow line risers, there is a real danger that such flow line risers and legs might crushed or severely damaged to cause structural damage to such legs to cause same to be replaced. Such replacement cost is extremely expensive and time consuming, and thus the barge bumper assembly 15 of the present invention is designed to attempt to eliminate any unwarranted damage to such flow line risers, legs, and the like. As a vessel (not shown) approaches the structure, due to the positioning of the barge bumper assembly 15 relative to the wave action area, the vessel contacts the polyurethane or rubber bumpers or cylindrical rubber bumpers 110 which exerts force on the bumpers 110 and transmits same to the member 44. Due to the fact that the plate 93 is loose, the bumper assemblies, which are unconnected to each other, are permitted to move or rotate as desired.
The lateral vector of the force would normally attempt to shear each of the shock cells 22 and 75, but the upper shock cell assembly 22 is prevented from being laterally sheared off the member 15 by chain members 51 and 60, and the welded attachment at plate 20. The lower shock cell assembly 75 is prevented from being sheared laterally by the chain member 100 and the plate assembly 17.
If the shock force is parallel with the sheet of drawing of the FIGURE, either or both of the shock cells operate to absorb the force of the blow such that the member 44 drives the piston 29 relative to the upper shock cell assembly 22 inwardly until the head 31 of piston 29 strikes the plate 28 to prevent further movement thereof. The resistant material 36 then drives the piston member 29 back outwardly relative to the cylinder 23 as the resistant member 36 overcomes the force which originally moved the piston inwardly. It is to be understood that the bottom shock cell assembly 75 operates in exactly the same way except that pressure upon the bumpers 110 causes the stabbing member 80 to drive the piston 29 inwardly relative to the wall 28.
If the shock cell assemblies 22 and 75 or the member 44 are damaged, it is quite simple to disassemble some portion of the barge bumper assembly without the necessity of replacing the whole system, which thus aids greatly in the economy of the barge bumper assembly.
While only one embodiment has been disclosed herein, it is to be understood that the claims of the present invention are not limited to the particular or specific embodiment disclosed but other embodiments are entitled to all equivalents of this embodiment as consistent with constraints imposed by any of the prior art. | A bumper assembly for a marine structure is disclosed, comprising an essentially vertical frame member mounted by energy absorbing shock members at each end thereof to a stationary offshore structure, the vertical member carrying annular bumper members stacked thereon. The vertical member comprises concentric cylinders in order to extend the length thereof slightly as the shock absorbing members are actuated so that the movement of such shock absorbing members remains linear. At each end of the vertical support member, at the point of attachment of the shock absorbing member, a supporting chain or cable is attached to support such vertical member to prevent the vertical member from creating a cantilever effect on the shock absorbing members. | 4 |
TECHNICAL FIELD
[0001] The present invention generally relates to Machine-to-Machine or M2M networks, and particularly relates to tracking service provider affiliations for events within an M2M network, such as for charging when M2M entities affiliated with one M2M Service Provider, SP, use or operate within the M2M network of another M2M SP.
BACKGROUND
[0002] Machine-to-Machine, M2M, networks involve the automated exchange of data and control signaling between various M2M entities. Here, a M2M “entity” is a logically distinct and separately identifiable thing within the M2M network. A M2M entity comprises, for example, the particular instance of a M2M application, as instantiated on a supporting device or node that provides a communication interface usable for communicating with one or more other M2M entities in the M2M network. While the term “M2M entity” has a logical connotation to it, it should be understood that, unless specified otherwise, the term “M2M entity” as used herein shall be understood as at least implicitly referring to the processing and communication circuitry by which the functionality of the M2M entity is realized. Of course, the same physical node may be used to implement more than one M2M entity. For example, a node having suitable processing circuitry and storage may host more than one M2M application—each such application instance operates as a distinct M2M entity within the overall M2M network and thus has its own identity and “location” within the network. However, unless otherwise noted for the sake of clarity, the terms “M2M entity” and “M2M node” are used interchangeably herein.
[0003] In a working M2M example, M2M nodes having various sensing capabilities are embedded in the heavy equipment used in a mining or large construction project. These M2M nodes are configured to send vehicle health and usage data to a remote application server hosting a software application that uses the reported data for scheduling vehicle maintenance. Many other examples come to mind, including the use of M2M nodes embedded in a network of geographically distributed vending machines, where each M2M node provides connectivity back to a network-based application that tracks item stock levels, machine functionality, etc. Broadly, M2M technology may be applied to an essentially unlimited range of applications and contexts and, in general, can be understood as being part of the evolving Internet of Things, IoT.
[0004] In a base scenario, a M2M Service Provider, SP, owns or otherwise controls certain network infrastructure, such as various M2M gateways and other “support” nodes, that provide for the registration of M2M nodes within the network, and for the organized collection of data and exchange of signaling between one or more M2M application servers and a potentially large number of M2M entities deployed in the field. The deployed M2M entities included in a given M2M network may all be of the same type, or there may be a mix of M2M entities types. Here, an M2M node may be dedicated to M2M usage, or it may have other or additional functionality. For example, a given node may host one or more M2M software applications, along with one or more other non-M2M software applications.
[0005] The M2M network infrastructure provided by the M2M SP may be used strictly for the needs of that particular M2M SP. For example, a large company or public utility may implement its own M2M network to support its own M2M devices. In other scenarios, however, the M2M SP allows third parties to use all or parts of its network infrastructure, e.g., on a subscription basis. This latter arrangement represents an example of potentially different companies subscribing to or otherwise paying for M2M network support, as provided by the involved M2M SP.
[0006] It should also be noted that other communication networks may be involved, such as where the field-deployed M2M entities use cellular networks to access the M2M network. The cellular network operator or operators may be distinct from the M2M SP that operates the M2M network. Of course, the M2M network infrastructure provided by a given M2M SP may be accessible through the Internet, and cellular networks represent merely one example of the mechanisms by which remote M2M devices may communicate with a M2M network.
[0007] To better understand M2M networks, one may refer to the examples provided in the standardization specifications promulgated by the “oneM2M” organization. For example, the technical specification TS-0001-V1.6.1 defines the functional architecture of a M2M network configured according to the oneM2M standards. According to oneM2M, a “Machine-to-Machine Solution is a combination of devices, software and services that operate with little or no human interaction,” and a M2M network shall be understood as comprising one or more “Application Entities” or AEs.
[0008] A given AE may be an ADN-AE, where “ADN” denotes an “Application Dedicated Node”. ADN-AEs generally are part of the “field domain” of a M2M network. AEs may also exist in the so-called “middle nodes” or MNs that interconnect M2M entities in the field domain to supporting M2M entities in the “infrastructure domain”. For example, a MN “Common Services Entity” or MN-CSE is a type of M2M support entity, and may act as a gateway for coupling any number of field-domain AEs to an Infrastructure Node CSE or IN-CSE. An IN-CSE is a type of “top-level” M2M support entity within the M2M network domain, and there generally is only one IN-CSE within a given M2M network. An IN-CSE may include or may otherwise communicate with one or more IN-AEs. The IN-AEs comprise, for example, the top-level M2M applications that collect data from field-domain AEs and/or provide overall control or management for the field-domain AEs and their data.
[0009] In the oneM2M context, a CSE represents an instantiation of a set of common service functions that are exposed to other M2M entities through defined communication interfaces, known as “reference points”. Example CSE functions include data management, subscription service management, and location services. Of course, the applicability of the teachings presented in this disclosure is not limited to M2M networks implemented according to the oneM2M standards, and it will be appreciated that CSEs can be understood as an example of a M2M “support node” or “support entity” that supports other M2M entities in the M2M network, such as by providing registration services, resource hosting, etc.
[0010] With the increasing sophistication of M2M applications and the increasing scale and diversity of M2M deployments, it is recognized herein that M2M SPs face significant design challenges and expenses in deploying and maintaining their M2M networks. Indeed, it is recognized herein that in some scenarios, it may be much more feasible for one M2M SP to lease or otherwise pay to use at least certain parts of an M2M network that is owned by another M2M SP. For example, it is contemplated herein for a first M2M SP to lease usage of the MN-CSEs or other gateway nodes of a second M2M SP having a larger or more strategically deployed M2M network. Such an arrangement would provide an economical mechanism for communicatively linking AEs of the first M2M SP to the back-end infrastructure of the first M2M SP, via the gateways of the second M2M SP. Other usage scenarios are also contemplated, such as where one M2M SP pays for the use of processing time and/or storage on the IN-CSE of another M2M SP.
[0011] Notably, the existing M2M protocols and standards provide for certain interoperability between the M2M networks of different M2M SPs. However, it is recognized herein that the current protocols and standards do not provide for an efficient and ready mechanism for tracking usage of M2M network nodes or resources by different M2M SPs within the same M2M network domain.
SUMMARY
[0012] According to one aspect of the teachings disclosed herein, a Machine-to-Machine, M2M, support entity within a M2M network is configured to identify the M2M Service Provider, SP, affiliations of the M2M entities and the M2M resources involved in a given transaction supported by the support entity. Moreover, the support entity is configured to generate corresponding transaction records that are tagged with or otherwise store the M2M SP affiliation information, for billing usage. Consequently, usage of the M2M support entity by more than one M2M SP can be differentiated for billing purposes. This functionality allows, for example, a second, smaller or less financially capable M2M SP to use the M2M gateways and/or other M2M support entities of a larger or better-established M2M SP, and, in turn, allows the larger M2M SP to increase its revenue by expanding usage of its M2M network.
[0013] One embodiment involves a method at a M2M support entity operating in a M2M network. The M2M support entity provides support for M2M transactions involving given M2M entities and given M2M resources in the M2M network. According to the method, the M2M support entity identifies the transaction initiator and the transaction target, for any given M2M transaction being supported by it. Here, the transaction initiator is the particular M2M entity in the M2M network that initiated the transaction and the transaction target is the particular M2M resource in the M2M network that is targeted by the given transaction.
[0014] The method further includes identifying M2M SP affiliations of the transaction initiator and the transaction target, generating a transaction record for the given transaction, and including in the transaction record the M2M SP affiliations of the transaction initiator and the transaction target. Still further, the method includes storing the transaction record at least temporarily in storage at the M2M support entity, and forwarding the transaction record, or a Charging Data Record, CDR, derived therefrom, towards a billing system associated with the M2M network, for billing in dependence on the M2M SP affiliations of the transaction initiator and the transaction target.
[0015] In another embodiment, a M2M support entity is configured for operation in a M2M network that includes a number of M2M entities, where various ones of the M2M entities may be affiliated with different M2M SPs. The M2M support entity is implemented at a first M2M node configured for operation in the network and comprises one or more communication interfaces and processing circuitry operatively associated with the one or more communication interfaces. The one or more communication interfaces are configured to send and receive M2M signaling to one or more other M2M entities and the processing circuitry is operative to support M2M transactions involving given M2M entities and given M2M resources in the M2M network. In particular, the processing circuitry is configured to identify the transaction initiator and the transaction target, for a given transaction being supported by the M2M support entity. The transaction initiator comprises the given M2M entity in the M2M network that initiated the transaction and the transaction target comprises the given M2M resource in the M2M network that is targeted by the given transaction.
[0016] The processing circuitry is further configured to identify the M2M SP affiliations of the transaction initiator and the transaction target, generate a transaction record for the given transaction, and include in the transaction record the M2M SP affiliations of the transaction initiator and the transaction target. Further, the processing circuitry of the M2M support entity is configured to store the transaction record at least temporarily in storage at the M2M support entity, and forward the transaction record, or a CDR derived therefrom, towards a billing system associated with the M2M network. This forwarding provides for billing in dependence on the M2M SP affiliations of the transaction initiator and the transaction target.
[0017] In another example embodiment, a first M2M support entity is configured for operation in a M2M network that includes a number of other M2M entities, where given ones of the M2M entities may be associated with different M2M SPs. The M2M support entity, M2M SE, comprises a communication module for sending and receiving M2M signaling to one or more of the other M2M entities and a number of further modules for supporting M2M transactions involving given M2M entities and given M2M resources in the M2M network that are affiliated with different M2M SPs.
[0018] The further modules include: a first identifying module for identifying a transaction initiator and a transaction target, for a given transaction being supported by the M2M SE, where the transaction initiator comprises the given M2M entity in the M2M network that initiated the transaction and the transaction target comprises the given M2M resource in the M2M network that is targeted by the given transaction; a second identifying module for identifying M2M SP affiliations of the transaction initiator and the transaction target; a generating module for generating a transaction record for the given transaction, and including in the transaction record the M2M SP affiliations of the transaction initiator and the transaction target; a storing module for storing the transaction record at least temporarily in storage at the M2M SE; and a forwarding module for forwarding the transaction record, or a CDR derived therefrom, towards a billing system associated with the M2M network, for billing in dependence on the M2M SP affiliations of the transaction initiator and the transaction target.
[0019] Of course, the present invention is not limited to the above features and advantages. Indeed, those skilled in the art will recognize additional features and advantages upon reading the following detailed description, and upon viewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a block diagram of one embodiment of a M2M network.
[0021] FIG. 2 is a block diagram of one embodiment of a given M2M entity acting as a transaction initiator that initiates a transaction targeting a given M2M resource, and a M2M support entity that is configured to support the transaction.
[0022] FIG. 3 is a block diagram of known structure for storing M2M resources at a M2M node.
[0023] FIG. 4 is a logic flow diagram of one embodiment of a method of operation at an M2M node configured for operation in a M2M network as an Infrastructure Node Common Services Entity or IN-CSE, as an example of a M2M support entity.
[0024] FIGS. 5-8 are call or signaling flow diagrams for tracking M2M SP affiliations within an M2M network, according to one or more embodiments.
[0025] FIG. 9 is a block diagram of another embodiment of an M2M network, showing multiple instances of CSEs, as different M2M support entities that are affiliated with different M2M SPs and are interconnected within a M2M network.
[0026] FIGS. 10-13 are call or signaling flow diagrams for tracking M2M SP affiliations within an M2M network, according to one or more embodiments.
[0027] FIG. 14 is a block diagram of another embodiment of a M2M support entity.
DETAILED DESCRIPTION
[0028] FIG. 1 illustrates a Machine-to-Machine, M2M, network 10 , which may be regarded as defining a M2M network domain. It will be appreciated that M2M networks are subject to significant variation and that the M2M network 10 is offered as a non-limiting example for discussing various embodiments of the teachings herein.
[0029] The M2M network 10 may be regarded as comprising various M2M entities. As noted earlier in this disclosure, an M2M entity is any logically defined entity within the M2M network domain, such as any instance of an M2M application or any M2M service instance within the M2M network 10 . Each M2M entity has an M2M identity within the M2M network domain and each M2M entity necessarily is realized or otherwise instantiated via processing circuitry and, in general, one or more types of memory and/or storage. As such, this disclosure uses the terms “M2M node” and “M2M entity” interchangeably, unless a specific distinction is needed for clarity. Consequently, references herein to a “M2M node” can be understood as implicitly referencing a particular M2M entity within the M2M network domain.
[0030] The various M2M entities in the M2M network 10 create, manage, access and use M2M “resources”. For example, registration resources maintained by a given M2M entity indicate the various other entities that have registered with the given M2M entity. Of more interest herein, however, are data resources associated with the collection and processing of data, e.g., “field data” collected by one or more M2M entities that are deployed in the field domain of the M2M network 10 . These data resources may be transferred between M2M entities, or one M2M entity may read or write the data resources maintained by another M2M entity in the same or another M2M node. Of course, the acquisition, transfer, processing, aggregation and accessing of data resources may be strictly controlled based on defined ownership and permission/access-control policies and managed according to the M2M Identifiers, IDs, of the various M2M entities.
[0031] With the above general concepts in mind, the example M2M network 10 includes a number of M2M entities, such as M2M support entities, SEs, 12 - 1 and 12 - 2 , which are hosted on respective nodes 14 and 16 , along with a number of field-deployed M2M application entities, AEs, 22 - 1 , 22 - 2 and 22 - 3 , which are hosted on respective nodes 20 - 1 , 20 - 2 , and 20 - 3 . There may be a fewer or more AEs 22 and/or more or fewer SEs 12 in the M2M network 10 . Correspondingly, the reference number “ 12 ” without suffixing is used herein to generically refer to any given SE or SEs in the M2M network 10 . Likewise, the reference number “ 22 ” without suffixing is used herein to generically refer to any given AE or AEs in the M2M network 10 .
[0032] The M2M network 10 further includes or is associated with a provisioning application 24 hosted at a provisioning application server 26 , and further includes or is associated with a number of M2M network applications, NAs, 28 . By way of example, three NAs 28 are shown, NA 28 - 1 is associated with a first M2M Service Provider or SP, SP 1 , and is hosted on a server 30 - 1 , NA 28 - 2 is associated with a second M2M SP, SP 2 , and is hosted on a server 30 - 2 , and NA 28 - 3 is associated with a third M2M SP, SP 3 , and is hosted on a server 30 - 3 .
[0033] Note that the AE 22 - 1 is affiliated with SP 1 , the AE 22 - 2 is affiliated with SP 2 , and the AE 22 - 3 is affiliated with SP 3 . Assuming that the overall M2M network 10 is affiliated with SP 1 —e.g., owned or operated by SP 1 —the diagram can be understood as illustrating a case where SP 2 and SP 3 use all or at least a portion of the M2M network 10 to gain access to and/or provide M2M services for their field-deployed AEs 22 . It may be that a given M2M SP does not own or deploy anything other than NAs 28 and AEs 22 , while relying on another M2M SP to provide all of the supporting M2M infrastructure. In other instances, a given M2M SP may deploy AEs 22 and one or more gateways—a type of M2M SE 12 —to connect its AEs 22 to the network infrastructure of another M2M SP. Of course, other permutations are possible, with respect to how different M2M SPs share or make use of M2M entities owned by another M2M SP.
[0034] Further, the various AEs 22 may be homogenous (of the same type) or heterogeneous (of mixed types). For example, in a utility metering context, a public utility may install “smart” meters at each of its metering locations, where each smart meter operates as an AE 22 . More generally, each AE 22 may create various data resources and/or may transmit data for storage in resources managed or otherwise held at other M2M entities in the M2M network 10 . Consequently, the M2M network 10 will be understood as supporting M2M transactions involving M2M entities and/or M2M resources that have differing M2M SP affiliations. Of course, the M2M network also supports transactions involving M2M entities and resources having the same SP affiliations.
[0035] A provisioning application 24 running on a provisioning application server 26 is configured in one or more embodiments herein to provide provisioning information to the top-level SE M2M SE 12 - 1 , regarding the M2M SP affiliations of the various M2M entities that are registered, or will be registered in the M2M network 10 . For example, the provisioning application 24 provides the M2M SE 12 - 1 with the M2M SP affiliations of various AEs 22 , which are identified by AE-IDs, such that the M2M SP affiliation will be known for any given AE 22 that registers with any given M2M SE 12 in the M2M network 10 . The top-level SE M2M SE 12 - 1 may be configured to distribute or otherwise provide M2M SP affiliation information to any other M2M entity in the M2M network 10 , such as by providing M2M SP affiliation information for AEs 22 that register with the M2M SE 12 - 2 .
[0036] The availability, distribution and use of M2M SP affiliation information allows the M2M network 10 to identify the M2M SP affiliations of the M2M entities and resources involved in any transaction supported by the M2M network 10 . In turn, that allows the controlling M2M SP to differentiate such transactions according to the M2M SPs involved in the transaction. Ultimately, generating transaction records that include the M2M SP affiliation information for the M2M entities and/or M2M resources involved in the transactions enables billing that is differentiated on a M2M SP basis.
[0037] The provisioning information provided in this example case by the provisioning server 26 enables the SP 1 to identify the affiliations of the various M2M entities that register and operate in the M2M network 10 , and that affiliation information in turn allows the involved M2M entities to dynamically determine the M2M SP affiliations for subsequently created M2M resources. Thus, a billing system 32 , which comprises a charging server 34 , for example, can be provided with information indicating which M2M SPs were involved in each chargeable event that is transacted within the M2M network 10 . This arrangement means that SP 2 and SP 3 can act as full-serve M2M SPs with respect to their subscribers, despite not actually owning or controlling the M2M network 10 —i.e., SP 2 and SP 3 in this example can be viewed as being “virtual” M2M SPs in the sense that they need not own or maintain the M2M network that allows them to provide M2M services to their subscribers or users.
[0038] Of course, it is also contemplated that a virtual M2M SP may own at least some M2M nodes. For example, a given M2M SP may own gateways that couple to the infrastructure of another M2M SP. Conversely, a given M2M SP may own its own top-level M2M SE 12 , but may not own any the gateway or middle nodes needed to interface its top-level SE 12 to its field-deployed AEs 22 . The teachings herein address these and other ownership/use scenarios, by allowing any given M2M node to know and track the M2M SP affiliations of the M2M entities and resources involved in any given M2M transaction supported by the node.
[0039] In an example embodiment, then, this disclosure teaches a first M2M node 14 or 16 that is configured for operation as a M2M SE 12 in a M2M network 10 that includes the first M2M node 14 or 16 . The M2M network 10 includes a number of other M2M entities, e.g., other SEs 12 , any number of AEs 22 , and any number of network applications 28 . Here, the phrase “ 14 or 16 ” shall be understood as being one or the other, or both. Indeed, the same “and/or” connotation applies to the use of “or” in this disclosure, unless otherwise noted or unless a “one or the other” meaning is clear from the context.
[0040] The first M2M node 14 or 16 and the M2M network 10 are affiliated with a first M2M SP, e.g., SP 1 . The first M2M node 14 or 16 comprises one or more communication interfaces 40 or 60 that are configured to send and receive M2M signaling to one or more of the other M2M entities 12 , 22 , and/or 28 . The M2M node 14 or 16 further includes processing circuitry 42 or 62 and corresponding memory or storage, e.g., the M2M node 14 includes one or more types of computer-readable media 44 and the M2M node 16 includes one or more types of computer-readable media 64 .
[0041] In at least one embodiment, the computer-readable media 44 of the M2M node 14 stores SP affiliation information 46 and may also store a computer program 48 . The computer program 48 comprises computer program instructions that, when executed by a microprocessor or other digital processing circuitry, specially adapt one or more programmable circuits to operate as the processing circuitry 42 described herein. Similarly, in at least one embodiment, the computer-readable media 64 of the M2M node 16 stores SP affiliation information 66 and may also store a computer program 68 . The computer program 68 comprises computer program instructions that, when executed by a microprocessor or other digital processing circuitry, specially adapt one or more programmable circuits to operate as the processing circuitry 62 described herein.
[0042] Note, too, that the SP affiliation information 46 as stored in the M2M node 14 may include information for all M2M entities that are or will be registered in the M2M network 10 , and may include information for all M2M resources 50 - 1 that exists or will be created in the M2M network 10 , or just for the M2M resources 50 that are hosted at the SE 12 - 1 implemented by the M2M node 14 . The SP affiliation information 66 as stored in the M2M node 16 may include information for those M2M entities that are or will be registered at the SE 12 - 2 implemented by the M2M node 16 , and may include information for the M2M resources 50 - 2 that are hosted at the SE 12 - 2 . Note that the reference number “50” is used without suffixing to generically refer to any given M2M resource or resources, at any given M2M entity in the M2M network 10 .
[0043] It will be appreciated that the processing circuitry 42 of the M2M node 14 is operatively associated with the one or more communication interfaces 40 , and that the processing circuitry 62 of the M2M node 16 is operatively associated with the one or more communication interfaces 60 . The processing circuitry 42 or 62 is operative to support M2M transactions involving given M2M entities 12 , 22 and/or 28 and given M2M resources 50 in the M2M network 10 that are affiliated with different M2M SPs. Here, the term “M2M resources 50 ” particularly refers to M2M data that is collected, processed, accessed or modified by given M2M entities within the M2M network 10 .
[0044] The processing circuitry 42 or 62 is, in particular, configured to identify a transaction initiator and a transaction target, for a given transaction being supported by the involved M2M SE 12 . The transaction initiator comprises the given M2M entity in the M2M network 10 that initiated the transaction and the transaction target comprises the given M2M resource 50 in the M2M network 10 that is targeted by the given transaction. The processing circuitry 42 or 62 is further configured to identify the M2M SP affiliations of the transaction initiator and the transaction target, generate a transaction record for the given transaction, and include in the transaction record the M2M SP affiliations of the transaction initiator and the transaction target. Still further, the processing circuitry 42 or 62 is configured to store the transaction record at least temporarily in storage at the involved M2M SE 12 , and forward the transaction record, or a CDR derived therefrom, towards the billing system 32 , for billing in dependence on the M2M SP affiliations of the transaction initiator and the transaction target.
[0045] Referring now to FIG. 2 , one sees an example of transaction initiator 100 , e.g., a given M2M entity 12 , 22 or 28 within the M2M network 10 , that initiates a transaction targeting another M2M entity or resource 50 as a transaction target 102 . The diagram further shows a M2M SE 12 in the M2M network 10 supporting the transaction. The illustrated M2M SE 12 is implemented in the node 14 or 16 of FIG. 1 , for example, and therefore has access to SP affiliation information 46 or 66 , so as to identify the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 . Also note that FIG. 3 illustrates a known structure for storing a data resource 50 at a given M2M entity/node in an M2M network.
[0046] In at least one embodiment, the processing circuitry 42 or 62 is configured to identify the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 based on at least one of: information received by the M2M SE 12 in conjunction with the given transaction, and affiliation information stored in the M2M SE 12 in advance of the given transaction.
[0047] In the same or other embodiments, the processing circuitry 42 or 62 is configured to identify the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 by at least one of: receiving a M2M identifier of the transaction initiator 100 and a M2M identifier of the transaction target 102 , in M2M signaling received by the involved M2M SE 12 , in conjunction with the transaction; and identifying the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 , using the affiliation information stored at the M2M SE 12 , where the affiliation information maps the M2M identifiers received for the transaction initiator 100 and the transaction target 102 to respective M2M SP identifiers.
[0048] The teachings herein provide for M2M SP affiliation tracking in various cases or scenarios. Broadly, in one or more example embodiments, and for any given M2M event, any given M2M node involved in the event is configured to determine and record the M2M SP affiliations of some or all of M2M entities and M2M resources 50 involved in the event. In an example case, the transaction initiator 100 and the transaction target 102 are registered with or are otherwise hosted by the same M2M node. For example, an AE 22 is registered at a given M2M SE 12 and it initiates a transaction towards a M2M resource 50 that is stored at the same M2M SE 12 . In such cases, the affiliation information for both transaction initiator 100 and the transaction target 102 is fetched by the involved M2M SE 12 , e.g., using stored affiliation information.
[0049] In a second case, the transaction initiator 100 and the transaction target 102 are registered to or hosted by different M2M entities in separate nodes. In such cases, each M2M entity/node involved in the end-to-end transaction will have to determine the M2M SP affiliations from signaling. For example, assume that the transaction initiator 100 is registered at a first M2M SE 12 and that the transaction target 102 is stored at a second M2M SE 12 . The end-to-end transaction thus involves both the first and second M2M SEs 12 , and each one generates a corresponding transaction record that includes or indicates the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 . The second M2M SE 12 generally will have local SP affiliation information stored for the transaction target 102 and the first M2M SE 12 generally will have local SP affiliation stored for the transaction initiator 100 .
[0050] In order for the first M2M SE 12 to also have SP affiliation information for the transaction target 102 , for recording in its record of the transaction, the second M2M SE 12 sends the SP affiliation information for the transaction target 102 to the first M2M SE 12 in return signaling. Similarly, in order for the second M2M SE 12 to have the SP affiliation information for the transaction initiator 100 , for recording in its record of the transaction, the first M2M SE 12 sends the SP affiliation information for the transaction initiator 100 to the second M2M SE 12 . This inter-entity signaling between the first and second M2M SEs 12 may be carried out as part of or in conjunction with the M2M signaling going between them for the M2M transaction.
[0051] In another example case, the transaction initiator 100 is registered at a first M2M SE 12 that is acting as a gateway or middle node with respect to a second M2M SE 12 , and the transaction target 102 is a M2M resource 50 held at second M2M SE 12 . In cases like this, the initiating M2M SE 12 , here, the first M2M SE 12 may provide the SP affiliation of the transaction initiator 100 to the second M2M SE 12 , as part of or in conjunction with the transaction. However, the second M2M SE 12 in such cases generally will be a top-level SE and thus will have previously received provisioning information indicating the SP affiliation of the transaction initiator 100 and it may additionally or alternatively use that previously provisioned SP affiliation information when generating the transaction record. Similarly to previous example, the second M2M SE 12 may return SP affiliation information for the transaction target 102 to the first M2M SE 12 in return signaling.
[0052] Thus, in an example scenario or use case, a given M2M SE 12 in the M2M network supports a given M2M transaction. The given M2M SE 12 is associated with the transaction initiator 100 or with the transaction target 102 . Correspondingly, the processing circuitry 42 or 62 of the given M2M SE 12 is configured to obtain the SP affiliation information for the transaction initiator 100 and/or the transaction target 102 , based on signaling received at the M2M SE 12 as part of, or in conjunction, with the transaction.
[0053] In another example case, with respect to a given M2M SE 12 involved in a given M2M transaction, the M2M SE 12 knows the SP affiliation of the transaction initiator 100 and/or the transaction target 102 based on prior registration activities. For example, when an AE 22 is registered at the given M2M SE 12 , the M2M SE 12 may already have provisioned service profile information that indicates the SP affiliation of the registering AE 22 , or the M2M SE 12 may obtain such information from another M2M SE 12 during the registration process. For example, when an AE 22 is being registered at a given M2M SE 12 - 2 that is supported by a top-level M2M SE 12 - 1 , the M2M SE 12 - 1 may provide SP affiliation information to the M2M SE 12 - 2 . Similar operations also apply to the creation and storage of M2M resources 50 .
[0054] It should also be noted that in some embodiments, the processing circuitry 42 or 62 of a given M2M SE 12 forwards its stored transaction records, or derived records, to the billing system 32 . Advantageously, these forwarded records include M2M SP affiliation information for the involved transaction initiators 100 and the involved transaction targets 102 . For example, when the M2M SE 12 in question comprises the M2M SE 12 - 2 shown in FIG. 1 , it may not generate formal CDRs, and instead may forward the transaction records themselves to the billing system 32 . On the other hand, if the M2M SE 12 in question is the top-level M2M SE 12 - 1 shown in FIG. 1 , it may be configured to generate formal CDRs from the transaction records and to forward the CDRs, with or without forwarding the underlying transaction records, to the billing system 32 . In either approach, however, the billing system 32 receives M2M SP affiliation data for chargeable events, which allows it to identify the M2M entities and resources involved in each such event.
[0055] These transaction records and/or derived CDRs may be forwarded individually to the billing system 32 , or aggregated batches of them may be forwarded. For example, the transaction records and/or derived CDRs generated over some window of time may be batched together and forwarded, or batching may be based on record count.
[0056] FIG. 4 illustrates a corresponding method 400 at a given M2M SE 12 involved in a given M2M transaction. It will be appreciated that the M2M SE 12 is configured for operation in a M2M network 10 , and that the M2M SE 12 in general is configured to support M2M transactions involving given M2M entities, e.g., entities 12 , 22 , 28 , and given M2M resources 50 in the M2M network 10 that are, or can be, affiliated with different M2M SPs. In this context, the method 400 includes identifying (Block 402 ) a transaction initiator 100 and a transaction target 102 , for a given transaction being supported by the M2M SE 12 . Here, the transaction initiator 100 comprises a given M2M entity in the M2M network 10 that initiated the transaction, e.g., another M2M SE 12 , a given AE 22 , or a given network application 28 . The transaction target 102 comprises a given M2M resource 50 in the M2M network 10 that is targeted by the given transaction. For example, the transaction initiator 100 targets a given M2M resource 50 for reading or writing, or for some other type of access.
[0057] The method 400 further includes identifying (Block 404 ) M2M SP affiliations of the transaction initiator 100 and the transaction target 102 , generating (Block 406 ) a transaction record for the given transaction, and including in the transaction record the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 . Correspondingly, the method 400 includes storing (Block 408 ) the transaction record at least temporarily in storage at the M2M SE 12 , and forwarding (Block 410 ) the transaction record, or a derived CDR, towards a billing system 32 associated with the M2M network 10 , for billing in dependence on the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 .
[0058] FIG. 5 illustrates a call flow—also referred to as a signaling flow—for provisioning SP affiliation information in the M2M network 10 . As a non-limiting but useful example, the M2M entity/node names are presented using the nomenclature of oneM2M, see, e.g., TS-0001-V1.6.1. Thus, the M2M SEs 12 seen in FIG. 1 , are denoted as Common Service Entities or CSEs. In particular, the M2M SE 12 - 2 is referred to as the MN-CSE 12 - 2 , to denote its “middle node” role with respect to the M2M SE 12 - 2 , which is referred to as the IN-CSE 12 - 1 , to denote its “infrastructure node” or top-level role in the M2M network 10 .
[0059] In the illustrated signaling flow, the NA 28 - 2 of SP 2 provides information to the provisioning application 24 that identifies a particular ADN 20 . Such information may include, for example, the M2M SP-ID associated with SP 2 , the M2M ADN-ID associated with the ADN 20 , and possibly additional related information. For example, the provisioning information may include the AE-IDs of any AEs 22 to be instantiated at or otherwise hosted by the ADN 20 .
[0060] The provisioning application 24 validates the provisioning request from SP 2 , and provides the ADN-related provisioning information to the IN-CSE 12 - 1 of the M2M network 10 . In this example, one may assume that SP 1 owns the M2M network 10 and the IN-CSE 12 - 1 and that SP 1 acts as a lessor of the M2M network 10 and the IN-CSE 12 - 1 , with SP 2 acting as a lessee with respect to its use of the M2M network 10 and the IN-CSE 12 - 1 .
[0061] The IN-CSE 12 - 1 creates a record that logically “binds” the M2M SP affiliation information to the ADN-ID and any dependent M2M identities received from the provisioning application 24 . For example, the IN-CSE 12 - 1 may create a service profile for the ADN 20 and any other involved M2M entities. The service profile may be a separate data item or structure, or it may be embodied in the “resource trees” or other normal data storage used by the IN-CSE 12 - 1 to represent the ADN 20 in the M2M network 10 .
[0062] FIG. 6 illustrates an example of resource creation for an AE 22 - 1 , for which the IN-CSE 12 - 1 previously received provisioning information and for which service profile information exists. In particular, one may assume that the IN-CSE 12 - 1 has service profile information for the AE 22 - 1 . Thus, when the AE 22 - 1 sends a registration request towards the MN-CSE 12 - 2 , the MN-CSE 12 - 2 will be able to retrieve the corresponding service profile from the IN-CSE 12 - 1 . More generally, the MN-CSE 12 - 2 will be able to retrieve service provider affiliation information from the IN-CSE 12 - 1 , so that the MN-CSE 12 - 2 can determine and store the SP affiliation of the AE 22 - 1 . Such data may be stored in a SP affiliation table, where the table is denoted in the diagram as a “SP Table” and it indicates the SP affiliations for the M2M entities registered with the MN-CSE 12 - 2 and for the M2M resources 50 that are stored and managed by the MN-CSE 12 - 2 . In turn, such information enables the MN-CSE 12 - 2 to tag or otherwise mark subsequent transactions involving the AE 22 - 1 , such as resource creation request, with the correct SP affiliation information.
[0063] FIG. 7 illustrates another example call flow, where the AE 22 - 1 makes a read request towards a M2M resource 50 that is maintained in the IN-CSE 12 - 1 . The supporting MN-CSE 12 - 2 forwards the request from the AE 22 - 1 towards the IN-CSE 12 - 1 , and tags the forwarded request with M2M SP affiliation information for the AE 22 - 1 . Here the AE 22 - 1 will be understood as the transaction initiator 100 and the targeted M2M resource will be understood as the transaction target 102 .
[0064] The IN-CSE 12 - 1 receives the forwarded request and uses the SP affiliation information included in the request signaling from the MN-CSE 12 - 2 , along with its knowledge of the SP affiliation of the targeted M2M resource 50 , to generate a transaction record and/or CDR with the proper SP affiliation tagging. Note that the IN-CSE 12 - 1 may return the SP affiliation of the targeted M2M resource 50 to the supporting MN-CSE 12 - 2 , for use by the MN-CSE 12 - 2 in recording a transaction record with complete SP affiliation information for the transaction initiator 100 and the transaction target 102 .
[0065] In another contemplated variation, the MN-CSE 12 - 2 does not tag or otherwise include SP affiliation information in the forwarded read request, based on the fact that the IN-CSE 12 - 1 will, in at least some embodiments, already have service profiles or other information that identifies the SP affiliations of every M2M entity and M2M resource in the M2M network 10 . It is also possible to omit the transaction target SP affiliation information included in the read request response sent from the IN-CSE 12 - 1 to the MN-CSE 12 - 2 . For example, the transaction target 102 could have been previously announced to the MN-CSE 12 - 2 , to make it visible to the AE 22 - 1 , and the announcement may include SP affiliation information.
[0066] FIG. 8 illustrates the transfer, use and/or storage of M2M SP affiliation information in the context of resource creation for a network application, “NA” in the diagram, where a network application 28 - 1 with a given M2M SP affiliation registers with an IN-CSE 12 - 1 . Subsequently, the network application 28 - 1 sends a resource creation request to the IN-CSE 12 - 1 , requesting the creation of a M2M resource 50 . The resource request indicates that the M2M resource 50 is to be created in a MN-CSE 12 - 2 .
[0067] Thus, the transaction initiator 100 in this example is the network application 28 - 1 and the transaction target 102 is the M2M resource 50 to be created at the MN-CSE 12 - 2 . Generally speaking, the M2M SP affiliation of a given M2M resource 50 will be that of the M2M entity that created it. For example, the network application 28 - 1 and the MN-CSE 12 - 2 may have different SP affiliations but the network application 28 - 1 can create a M2M resource 50 at the MN-CSE 12 - 2 that is tagged with the same SP affiliation as that of the network application 28 - 1 . Despite the network application 28 - 1 and the corresponding M2M resource 50 at the MN-CSE 12 - 2 , M2M transactions involving the network application 28 - 1 and the M2M resource 50 stored at the MN-CSE 12 - 2 may still be regarded as involving different M2M SPs, because the storage and/or processing resources of the MN-CSE 12 - 2 are being used by network application 28 - 1 and the stored M2M resource 50 .
[0068] To enable such differentiation, the MN-CSE 12 - 2 receives the affiliation of NA 28 - 1 in signaling from IN-CSE 12 - 1 , and stores it in the SP affiliation table for M2M resources 50 hosted at the MN-CSE 12 - 2 for NA 28 - 1 . Then, when the NA 28 - 1 accesses one of those hosted resources 50 via the IN-CSE 12 - 1 , the MN-CSE 12 - 2 creates a M2M event record that records the M2M SP affiliation of the NA 28 - 1 as the transaction initiator 100 and the M2M SP affiliation of the targeted resource 50 as the transaction target 102 . The MN-CSE 12 - 2 may also include an indication of its M2M SP affiliation in the record. In any case, any downstream billing processing of the record can differentiate charging based on these recorded M2M SP affiliations.
[0069] FIG. 9 provides one example of a more complicated scenario, and it should be appreciated that even more complicated scenarios, in which the lessor SPs own their own IN-CSE, but lease capacity from the M2M SP that owns the overall network for MN-CSE 12 . Still further, the M2M network 10 may include or be associated with more than one provisioning application 24 , e.g., applications 24 - 1 and 24 - 2 , and more than one provisioning application server 26 due to the fact that each IN-CSE 12 has to be provisioned the necessary information in accordance with FIG. 5 by the M2M SP that owns the IN-CSE 12 . A given M2M-CSE 12 will be pre-configured with the IN-CSEs 12 that can provision information in them based on business agreements.
[0070] In an example case, the MN-CSE 12 - 2 and MN-CSE 12 - 4 are owned by the M2M SP that owns the M2M network 10 at large. Furthermore, the M2M SP that owns the overall M2M network 10 owns IN-CSE 12 - 1 . M2M SP 3 , a lessor SP, owns IN-CSE 12 - 3 .
[0071] With these possibilities in mind, FIG. 10 illustrates a registration process, followed by resource creation. Here, the AE 22 - 1 , the MN-CSE 12 - 2 and the IN-CSE 12 - 1 are all associated with a lessor M2M SP, while another MN-CSE 12 - 4 is affiliated with a different M2M SP.
[0072] The AE 22 - 1 registers with the MN-CSE 12 - 2 , which obtain SP affiliation for the AE 22 - 1 from the IN-CSE 12 - 1 , e.g., by obtaining a service profile for the AE 22 - 1 . Subsequent to this registration, the AE 22 - 1 creates a M2M resource 50 that will be announced to the MN-CSE 12 - 4 . The MN-CSE 12 - 2 provides announcement signaling that includes the SP affiliation information for the created M2M resource 50 . This announcement signaling allows the MN-CSE 12 - 4 to record the M2M SP affiliation for the M2M resource 50 , and to generate a CDR or other event record that includes the M2M SP affiliation of the announced resource.
[0073] More particularly, in the context of the diagram, the registration transaction will result in a CDR or other record being generated at MN-CSE 12 - 2 , while the resource creation request will cause the MN-CSE- 12 - 2 to generate a transaction record and the announcement signaling causes the MN-CSE 12 - 4 to record the SP affiliation information in an event record.
[0074] FIG. 11 illustrates another example where one may assume that an AE 22 - 2 is affiliated with a first M2M SP, and that a MN-CSE 12 - 4 is affiliated with a different, second M2M SP. One may further assume that the MN-CSE 12 - 4 hosts a M2M resource 50 that is affiliated with the first M2M SP. The depicted MN-CSE 12 - 2 may be affiliated with either the first or second M2M SPs, or with yet another M2M SP.
[0075] In any case, the AE 22 - 2 here acts as a transaction initiator 100 , by making a read request towards the M2M resource 50 hosted at the MN-CSE 12 - 4 , as the transaction target 102 . The MN-CSE 12 - 2 in some sense “proxies” this request, by receiving the request from the AE 22 - 2 and forwarding it to the MN-CSE 12 - 4 . Advantageously, the forwarded read request includes M2M SP affiliation information for the AE 22 - 2 . Here the AE 22 - 2 necessarily will have already been registered at the MN-CSE 12 - 2 . Thus, the MN-CSE 12 - 2 already knows the M2M SP affiliation of the AE 22 - 2 , based on previously storing the SP affiliation information for the AE 22 - 2 in its SP affiliation table, in conjunction with registration of the AE 22 - 2 .
[0076] The M2M SP affiliation information included in the forwarded read request allows the MN-CSE 12 - 4 to generate a CDR or other transaction record that includes the M2M SP affiliations of the targeted resource 50 , the host node—i.e., the MN-CSE 12 - 4 —and the transaction initiator AE 22 - 2 . Correspondingly, the MN-CSE 12 - 4 returns M2M SP affiliation information for the targeted M2M resource 50 , along with the requested data. This return signaling allows the MN-CSE 12 - 2 to generate a CDR or other transaction record that includes all relevant M2M SP affiliation information.
[0077] FIG. 12 illustrates a similar resource reading example. Notably, however, the read request in FIG. 12 involves two different IN-CSEs 12 - 1 and 12 - 3 . Here AE 22 - 3 and IN-CSE 12 - 3 may be associated with a given M2M SP, while the IN-CSE 12 - 1 may belong to another M2M SP that owns the overall M2M network 10 . The transaction records recorded at each of the involved M2M entities for the illustrated transaction(s) include the relevant SP affiliation information, based on retrieving such information from locally stored information and/or receiving at least some of the affiliation information in the relevant transaction signaling. The locally-stored information at a given MN-CSE and/or IN-CSE comprises, for example, a SP affiliation table that maps the M2M entities and/or M2M resources registered with or hosted by the MN-CSE or IN-CSE to their respective M2M SPs.
[0078] FIG. 13 illustrates an example case that involves distinguishing between inter-SP traffic and is based on a NA 28 - 1 that belong to a given M2M SP and registers with an IN-CSE 12 - 3 that belongs to the same M2M SP. The NA 28 - 1 subsequently makes a read request towards a M2M resource 50 which belongs to another M2M SP, and which is hosted at the MN-CSE 12 - 2 . The request is forwarded by the IN-CSE 12 - 1 , which is owned by the owner of the network 10 . Note that this owner may be the same M2M SP that owns the MN-CSE 12 - 2 .
[0079] In any case, IN-CSE 12 - 3 provides the IN-CSE 12 - 1 with M2M SP affiliation information for the NA 28 - 1 as the transaction initiator 100 , and the IN-CSE 12 - 1 in turn provides that affiliation information to the MN-CSE 12 - 2 . Correspondingly, the MN-CSE 12 - 2 provides the target affiliation information to the IN-CSE 12 - 1 , and the IN-CSE 12 - 1 also may provide that affiliation information to the IN-CSE 12 - 3 , as part of providing the requested data. The inclusion of M2M SP affiliation information in the exchanged transaction signaling allows each of the involved M2M nodes to record the relevant M2M SP affiliation information in the corresponding transaction record generated at the M2M node.
[0080] Additional operational aspects worth noting are that the ADNs 20 belonging to a lessee M2M SP may be identical or essentially identical to the ADNs 20 belonging to a lessor M2M SP, thus the various M2M entities/nodes through which ADN-related traffic flows must be able to identify the SP affiliations of the different traffic flows. In general, the teachings herein provide a mechanism for distinguishing the M2M resources 50 associated with different M2M entities, e.g., associated with different ADNs 20 , according to the respective SP affiliations of the ADNs 20 . This SP affiliation information can be included as attributes in the signaling and in the transaction records, regardless of whether the transaction target 102 in a transaction involving an AE 22 is where the AE 22 created resources or registered.
[0081] Thus, the teachings herein broadly provide for tagging or identifying traffic—M2M data and/or control signaling—according to the M2M SPs that are involved and allows traffic involving lessor/lessee relationships to be distinguished from, e.g., “normal” inter-SP traffic going between M2M network domains owned by different M2M SPs. That is, according to the teachings herein, different M2M entities and/or resources within the same M2M network domain may be affiliated with different M2M SPs, such as where one M2M SP leases CSE services to another M2M SP, and where individual M2M transactions conducted within the M2M network in question are tagged at the respective entities/nodes supporting those transactions, so that billing can be differentiated between transactions involving the lessor SP and those involving the lessee SP.
[0082] FIG. 14 illustrates a M2M SE 12 configured accordingly, wherein the M2M SE 12 is configured for operation in a M2M network 10 that includes any number of other M2M entities, e.g., entities 12 , 22 and/or 28 . The M2M SE 12 includes a communication module 70 for sending and receiving M2M signaling to one or more of the other M2M entities 12 , 22 , 28 , and a number of further modules for supporting M2M transactions involving given M2M entities 12 , 22 , 28 and given M2M resources 50 in the M2M network 10 , where given ones of the other M2M entities may be affiliated with different M2M SPs.
[0083] In an example configuration, the M2M SE 12 includes a first identifying module 72 for identifying a transaction initiator 100 and a transaction target 102 , for a given transaction being supported by the M2M SE 12 . Here, the transaction initiator 100 comprises the given M2M entity in the M2M network 10 that initiated the transaction and the transaction target 102 comprises the given M2M resource 50 in the M2M network 10 that is targeted by the given transaction. The M2M SE 12 in this example embodiment further includes a second identifying module 74 for identifying M2M SP affiliations of the transaction initiator 100 and the transaction target 102 , and a generating module 76 for generating a transaction record for the given transaction, and including in the transaction record the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 . Further, the M2M SE 12 includes a storing module 78 for storing the transaction record at least temporarily in storage at the M2M SE 12 , and a forwarding module 80 for forwarding the transaction record, or a CDR derived therefrom, towards a billing system 32 associated with the M2M network 10 , for billing in dependence on the M2M SP affiliations of the transaction initiator 100 and the transaction target 102 .
[0084] In an example business model, a first M2M SP allows other M2M SPs to use the gateway nodes and infrastructure nodes of the first M2M SP, for storing resources belonging to applications managed by the other M2M SPs. The other M2M SPs still own the applications and the corresponding M2M subscriptions, but they lease the actual M2M network capabilities from the first M2M SP. They use the hardware from another large M2M SP for a fee.
[0085] In another contemplated business model, a first M2M SP allows other M2M SPs to use the gateway nodes of the first M2M SP only for storing resources belonging to the other M2M SPs. These other M2M SPs own their M2M applications and the corresponding M2M subscriptions, and the supporting IN-CSE, but they lease rather than own the MN-CSEs acting as gateways between their subscribers' ADNs and their IN-CSE.
[0086] In another aspect contemplated herein, the type of service level agreement, SLA, between a lessor M2M SP and a lessee M2M SP can be recorded in the M2M event records or CDRs generated for any given M2M event that is tracked and tagged with M2M SP affiliation information. This enables distinguishing different SLAs for an M2M SP that has multiple business models with the same M2M SP. This type information adds a further dimension to differentiated billing, wherein the billing for a given M2M transaction may be differentiated based on the specific M2M SPs, or mix of SPs, involved in the transaction, and further based on the type of the transaction.
[0087] Notably, modifications and other embodiments of the disclosed invention(s) will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention(s) is/are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this disclosure. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | According to one aspect of the teachings disclosed herein, a Machine-to-Machine, M2M, support entity within a M2M network is configured to identify the M2M Service Provider, SP, affiliations of the M2M entities and the M2M resources involved in a given transaction supported by the M2M support entity. Moreover, the support entity is configured to generate corresponding transaction records that are tagged with or otherwise store the M2M SP affiliation information, for billing usage. Consequently, usage of the support entity by more than one M2M SP can be differentiated for billing purposes. This functionality allows, for example, a second, smaller or less financially capable M2M SP to use the M2M gateways and/or other support entities of a larger or better-established M2M SP, and, in turn, allows the larger M2M SP to increase its revenue by expanding usage of its M2M network. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bonding structure for a metal plate and a piezoelectric body, such as a piezoelectric vibration plate for use in a driver of a piezoelectric microblower or other suitable piezoelectric device, and a bonding method therefor.
2. Description of the Related Art
Piezoelectric microblowers have been known as blowers for effectively releasing heat produced in housings of portable electronic devices, or as blowers for supplying oxygen required for the generation of electricity in fuel cells (see, for example, WO2008/069266). The piezoelectric microblower refers to a kind of pump using a vibration plate which produces a bending vibration by applying a voltage, and has the advantages of having a simple structure, being able to be configured to have a small and thin size, and providing low power consumption.
FIG. 1 shows an example of a vibration plate for use in a piezoelectric microblower. In FIG. 1 , a piezoelectric body (piezoelectric ceramic plate) 2 including electrodes 3 , 4 on front and back sides thereof is bonded onto a metallic diaphragm 1 . One electrode 3 and the diaphragm 1 are electrically connected to each other. When a predetermined alternating-current voltage is applied between the diaphragm 1 and the electrode 4 of the piezoelectric body 2 , the entire vibration plate produces a bending vibration, thereby enabling it to pump the air. It is to be noted that the vibration plate is not limited to the piezoelectric body 2 directly bonded onto the diaphragm 1 , and may have various configurations, such as a vibration plate which has another metal plate bonded onto the diaphragm 1 and the piezoelectric body 2 bonded thereon, and a vibration plate which has a piezoelectric body 2 bonded onto both of the front and back sides of the diaphragm 1 .
FIGS. 2A to 2C show examples of a bonding structure between the electrode 3 of the piezoelectric body 2 and the metal plate 1 (diaphragm).
FIG. 2A is an example of using an adhesive 5 including no electrically conductive aid, which is intended to provide electrical conduction through contact (ohmic contact) between the electrode 3 and the metal plate 1 by reducing the adhesive thickness between the piezoelectric body 2 and the metal plate 1 to the greatest extent possible.
In FIG. 2B , carbon spheres 6 are added as an electrically conductive aid to the adhesive 5 , thereby providing conductivity through the carbon spheres 6 . The carbon spheres 6 have a diameter, for example, on the order of 20 μm, and the electrode 3 is not directly connected to the metallic plate 1 .
In FIG. 2C , carbon black 7 with an average particle size of several tens of nm is added as an electrically conductive aid to the adhesive 5 , thereby providing conductivity through the carbon black 7 in addition to conductivity through contact between the electrode 3 of the piezoelectric body 2 and the metal plate 1 .
In the case of using the adhesive 5 including no electrically conductive aid as shown in FIG. 2A , the problem of an increase in resistance value (a decrease in conductivity) is caused when the adhesive is swollen in a humidity test after the bonding. In the case of using the adhesive 5 with the carbon spheres 6 added thereto as in FIG. 2B , the piezoelectric body 2 is likely to have cracks caused from the carbon spheres 6 , and moreover, the thickness of the adhesive is increased, thereby resulting in the problem of degraded vibration characteristics of the piezoelectric body 2 . In addition, the problem of increased resistance value is caused because of the contact with the electrode function as point contact, or because the largest particle functions as a spacer, whereas the smaller-size particles fail to contribute to electrical conduction. In the case of using the carbon black 7 with a minute particle size as in FIG. 2C , the viscosity-thixotropy of the adhesive is affected significantly by the content of the carbon black 7 , which has the problem of having an adverse effect on the workability and application property. Furthermore, the problem of an increase in resistance value (a decrease in conductivity) is also caused when the adhesive is swollen in a humidity test after the bonding.
Japanese Patent Application Laid-Open No. 2001-316655 discloses an electrically conductive adhesive which is used for bonding between an active material layer and a collector in an energy storage element. This adhesive is an electrically conductive adhesive in a paste form, which includes carbon powder (for example, carbon black) as an electrically conductive material, a resin as a binding agent, and water as a solvent, in which primary particles of the carbon powder have a weight-average particle size in the range of 5 nm to 100 nm, the amount of the carbon powder falls within the range of 5 weight % to 50 weight % with respect to the total amount of the carbon powder and resin, and the moisture content of the electrically conductive adhesive in the paste form is supposed to fall within the range of 70 weight % to 95 weight %.
FIG. 2D shows an example of a bonding structure using the electrically conductive adhesive disclosed in Japanese Patent Application Laid-Open No. 2001-316655. As in the case of FIG. 2C , the carbon black 7 is added as an electrically conductive aid to the adhesive 5 , thereby providing conductivity through the carbon black 7 without direct electrical conduction between the electrode 3 and the metal plate 1 . Since a larger amount of carbon black 7 is added than in FIG. 2C , the conductivity is believed to be improved more than in FIG. 2C .
However, when the carbon black 7 having a particle size of 5 nm to 100 nm is contained in the resin in a large amount of weight % to 50 weight %, the viscosity or thixotropy of the adhesive is greatly increased so as to adversely affect the application stability (variations in the amount of application, leveling properties after the application). Therefore, this problem is solved by water (70 weight % to 95 weight %) included in the paste in Japanese Patent Application Laid-Open No. 2001-316655. For this reason, it is not possible to solve the problem described in the case of a reaction system (such as an epoxy resin) which does not use water. In addition, the larger content of the carbon black 7 relatively reduces the amount of resin, thus decreasing the adhesion. Furthermore, the large amount of water included as a solvent provides a porous formation when the adhesive is hardened, thereby resulting in the problem of making the adhesive more likely to be swollen by absorption of water, and thus, lacking long-term reliability.
SUMMARY OF THE INVENTION
To overcome the problems described above, preferred embodiments of the present invention provide a bonding structure and a bonding method which have excellent conductivity and bonding property between a piezoelectric body and a metal plate.
A preferred embodiment of the present invention provides a bonding structure that preferably includes a metal plate, a piezoelectric body including an electrode on the side opposed to the metal plate, and an electrically conductive adhesive including carbon black as an electrically conductive aid, and bonding the metal plate and the electrode of the piezoelectric body so as to have electrical conductivity, wherein the electrically conductive adhesive before hardening includes carbon black with a nano-level average particle size, and is a paste included in a solventless or solvent-based resin so that the carbon black provides an aggregate with an average particle size of about 1 μm to about 50 μm, for example, and wherein the bonding structure is configured by applying the electrically conductive adhesive in the paste form between the metal plate and the electrode of the piezoelectric body, subjecting the metal plate and the piezoelectric body to heating, and pressurization to deform the carbon black aggregate, and hardening the electrically conductive adhesive.
Another preferred embodiment of the present invention provides a bonding method in which a metal plate and a piezoelectric body including an electrode on the side opposed to the metal plate are bonded to each other via an electrically conductive adhesive including carbon black as an electrically conductive aid, so as to have electrical conductivity between the metal plate and the electrode of the piezoelectric body, and the bonding method preferably includes the steps of applying the electrically conductive adhesive in a paste form between the metal plate and the electrode of the piezoelectric body, which includes carbon black with a nano-level average particle size, and is included in a solventless or solvent-based resin so that the carbon black forms an aggregate with an average particle size of about 1 μm to about 50 μm, for example, and after applying the electrically conductive adhesive, subjecting the metal plate and the piezoelectric body to heating and pressurization to deform the carbon black aggregate, and hardening the electrically conductive adhesive.
The electrically conductive adhesive preferably includes carbon black with a nano-level average particle size, and is a paste included in a resin so that the carbon black forms an aggregate with an average particle size of about 1 μm to about 50 μm, for example. The aggregate refers to primary particles of the carbon black bonded by an intermolecular force or other relevant force to provide a cluster with an average particle size of about 1 μm or more, for example. Therefore, as compared to the same amount of carbon black included in a dispersed state in a resin, the viscosity or thixotropy of the adhesive is much less affected, thereby resulting in improved workability and application property. The aggregate itself has no rigidity, and is deformed to follow a concavity and a convexity of the metal plate and piezoelectric body when the metal plate and the piezoelectric body are subjected to heating and pressurization. Thus, conductivity can be provided with less damage to the piezoelectric body and without significantly contributing to an increase in the thickness of the adhesive. The electrical conductivity between the metal plate and the piezoelectric body can preferably be achieved by not only the electrical conduction through the carbon black, but also by direct contact between the metal plate and the electrode of the piezoelectric body, thus providing a higher electrical conductivity (lower resistance value).
The average particle size in preferred embodiments of the present invention can preferably be obtained by, for example, capturing a SEM image of powder, applying binarization processing to the obtained image to obtain the area of the powder, and converting the area into circles with a diameter. It is possible to capture SEM images of both primary particles and secondary particles.
The particle size of the aggregate preferably has a lower limit size of about 1 μm, for example, because the size less than about 1 μm greatly increases the resin viscosity, and on the other hand, the upper limit size of greater than about 50 μm makes the size of the aggregate larger than the concavity and convexity at the surfaces of the metal plate and electrode, thus increasing the thickness of the adhesive. Therefore, the upper limit size is preferably about 50 μm, for example.
In a preferred embodiment of the present invention, the carbon black is preferably hardened while remaining as the aggregate rather than in a dispersed state, and thus, the metal plate and the electrode of the piezoelectric body can be electrically connected to each other in the dispersed state in island shapes (anisotropic electrical conductivity), rather than electrical conduction over the entire surface (isotropic electrical conductivity) as in the case of an electrically conductive adhesive using conventional carbon black. More specifically, while conductivity is provided in the direction in which the metal plate is opposed to the electrode, no conductivity is provided in the planar direction. This anisotropically conductive structure greatly improves the contact probability of the carbon black spectacularly, as compared to a case in which the same or substantially the same amount of carbon black in provided a dispersed state, thereby enabling a higher conductivity (lower resistance value) to be achieved. Furthermore, when the piezoelectric body is bonded to the metal plate, a fillet is formed by the electrically conductive adhesive around the piezoelectric body, and there is a possibility that short-circuiting may be caused if the fillet partially wraps around the upper electrode of the piezoelectric body. The electrically conductive adhesive according to various preferred embodiments of the present invention has anisotropic electrical conductivity, and thus, effectively and securely prevents this short-circuiting.
While the electrically conductive adhesive according to various preferred embodiments of the present invention may preferably be any solventless or solvent-based electrically conductive adhesive, at least electrically conductive adhesives using a water-based solvent are excluded. The solventless electrically conductive adhesive refers to an electrically conductive adhesive including carbon black that is added to a liquid resin, whereas the solvent-based electrically conductive adhesive refers to an electrically conductive adhesive including carbon black that is added to an organic solvent in which a polymer is dissolved. Solventless resins include, for example, an epoxy resin, whereas solvent-based resins include, for example, an acrylic resin. In each case, the hardened state is not porous, is less likely to cause swelling of the adhesive due to absorption of water in terms of long-term reliability, and is free of the problem of decrease in conductivity.
The carbon black included in the electrically conductive adhesive preferably has a nano-level average particle size, and is preferably, for example, carbon black with an average particle size of about 5 nm to about 300 nm, for example. The carbon black is added to the resin so that primary particles of the carbon black preferably form an aggregate with an average particle size of about 1 μm to 50 μm, for example, in the resin. Therefore, an appropriate dispersing/kneading treatment is preferably performed so that the carbon black forms an aggregate with an intended particle size in the resin.
The metal plate and the electrode of the piezoelectric body are preferably subjected to pressurization so that the distance between the metal plate and the electrode is less than the average particle size for the aggregate. More specifically, the distance between the metal plate and the piezoelectric body is preferably less than the average particle size for the aggregate in the electrically conductive adhesive in the paste form. This distance sandwiches most of the aggregate between the metal plate and the electrode of the piezoelectric body, thereby enabling reliable electrical conductivity to be achieved.
The resin included in the electrically conductive adhesive is preferably a resin which has a dense composition in a hardened state, has high weather resistance and heat resistance, and is less likely to undergo swelling even in a humidity test after bonding. Specifically, the resin may preferably be an epoxy resin, an acrylic resin, a urethane resin, other suitable resin, for example.
The amount of the carbon black in the electrically conductive adhesive is preferably about 1 weight % to about 10 weight % with respect to the total amount of the carbon black and resin, for example. This low content of the carbon black reduces the viscosity or thixotropy of the adhesive, thereby resulting in favorable workability and application property, and even with the low content of the carbon black, the formation of the aggregate can provide favorable electrical conductivity.
As described above, according to various preferred embodiments of the present invention, the electrically conductive adhesive in a paste form which has the carbon black added to a solventless or a solvent-based resin so as to form an aggregate with an average particle size of about 1 μm to about 50 μm is preferably used to apply the electrically conductive adhesive between the metal plate and the electrode of the piezoelectric body, and the metal plate and the piezoelectric body are subjected to heating and pressurization to harden the electrically conductive adhesive. Thus, the aggregate is deformed so as to follow the concavity and the convexity of the metal plate and of the electrode of the piezoelectric body, thereby enabling outstanding conductivity to be provided with less damage to the piezoelectric body and without significantly contributing to the increase in the thickness of the adhesive. In addition, since favorable electrical conduction is achieved while the content of the carbon black is reduced, the absolute amount of the resin can be increased, thereby resulting in a decrease in the viscosity or thixotropy of the adhesive, and in favorable workability and application property, and favorable adhesion can be achieved between the metal plate and the piezoelectric body. Furthermore, since the resin does not include any water, the hardened state is advantageously not porous, is less likely to cause swelling of the adhesive due to absorption of water, and thus has a significantly improved long-term reliability.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a known example of a piezoelectric vibration plate which includes a piezoelectric body bonded to a metal plate.
FIGS. 2A to 2D are enlarged cross-sectional views illustrating conventional bonding structures.
FIGS. 3A and 3B are cross-sectional views of a bonding structure according to a preferred embodiment of the present invention before and after heating and pressurization.
FIG. 4A is a diagram showing the relationship between an aggregate size and an adhesive viscosity, and FIG. 4B is a diagram showing the relationship between an aggregation size and an adhesive thickness.
FIG. 5 is a diagram for evaluating the conductivity in the case of bonding two metal plates with the use of an electrically conductive adhesive.
FIGS. 6A and 6B are diagrams for comparing the viscosity-thixotropy and series resistance characteristics between a case of adding dispersed carbon black and a case of adding aggregated carbon black.
FIG. 7 shows another example of a piezoelectric vibration plate which includes a piezoelectric body bonded to a metal plate with an intermediate plate interposed therebetween.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 3A and 3B show a bonding structure of a piezoelectric vibration plate according to a first preferred embodiment of the present invention, where FIG. 3A shows the bonding structure before heating and pressurization and FIG. 3B shows the bonding structure after the heating and pressurization. As in the case of FIG. 1 , a piezoelectric body 2 including electrodes 3 , 4 on both sides thereof is bonded onto a metal plate 1 , such as a diaphragm, with an electrically conductive adhesive 10 interposed therebetween. The electrically conductive adhesive 10 is preferably a paste including a solventless resin 11 such as, for example, an epoxy resin including carbon black 12 a therein which has an average particle size of about 5 nm to about 300 nm, and preferably about 5 nm to about 100 nm, for example, added thereto, and the additive amount of the carbon black 12 a is preferably about 1 weight % to about 10 weight %, for example, with respect to the total amount of the carbon black 12 a and resin 11 . The carbon black 12 a is preferably primarily present in clusters in the resin 11 so as to form an aggregate 12 with an average grain size of about 1 μm to about 50 μm, for example, rather than present as primary particles in the resin 11 . The aggregate 12 refers to primary particles of the carbon black 12 a bonded by an intermolecular force to provide a size of about 1 μm or more, for example.
Before heating and pressurization, as shown in FIG. 3A , the aggregate 12 is floating in the resin 11 , without making contact with the metal plate 1 or the electrode 3 . Therefore, the metal plate 1 is not electrically connected to the electrode 3 . The lower content of the carbon black 12 a included in the electrically conductive adhesive 10 and the larger amount of the resin 11 reduces the viscosity-thixotropy of the adhesive, thereby resulting in favorable workability and application property.
When the metal plate 1 and the piezoelectric body 2 are subjected to heating and pressurization, the aggregate 12 is deformed so as to follow the concave-convex surfaces of the metal plate 1 and the electrode 3 as shown in FIG. 3B , and thus, is sandwiched between the metal plate 1 and the electrode 3 . Therefore, the metal plate 1 is effectively and securely electrically connected to the electrode 3 . Since the carbon black 12 a is hardened while remaining as the aggregate 12 rather than in a dispersed state, the metal plate 1 and the electrode 3 of the piezoelectric body 2 are electrically connected to each other at multiple points in island shapes (anisotropic electrical conductivity). The electrically conductive structure with anisotropic conductivity greatly improves the contact probability of the carbon black 12 a , as compared to a case in which the same amount of carbon black 12 a is in a dispersed state, thereby enabling a higher conductivity (a lower resistance value) to be achieved.
In the case of FIG. 3B , when pressurization is performed so that the distance d between the metal plate 1 and the piezoelectric body 2 is less than the average particle size of the aggregate 12 , the metal plate 1 and the electrode 3 can preferably not only be electrically connected to each other with the aggregate 12 interposed therebetween, but can also be directly connected to each other. Therefore, the conductivity is further improved for the both the metal plate 1 and the electrode 3 . It is to be noted that the distance d between the metal plate 1 and the piezoelectric body 2 can be obtained as a value, in such a way that the region (area) surrounded by the surface of the metal plate 1 and the electrode 3 of the piezoelectric body 2 is divided by a predetermined length when the predetermined length is extracted in the horizontal direction of FIG. 3B . More specifically, the distance d refers to the interval between the position of the center line with respect to the profile curve at the surface of the metal plate and the position of the center line with respect to the profile curve at the surface of the electrode of the piezoelectric body.
FIG. 4A shows the relationship between the aggregate size and the adhesive viscosity, and FIG. 4B shows the relationship between the aggregate size and the adhesive thickness. It is to be noted that the content of the carbon black was about 3.0 weight %. As shown in FIG. 4A , the particle size of the aggregate less than about 1 μm sharply increases the viscosity of the adhesive, and the particle size of the aggregate is thus preferably about 1 μm or more, for example. On the other hand, as shown in FIG. 4B , the adhesive thickness increases with the increase in the particle size of the aggregate, and in particular, the particle size greater than about 50 μm increases the rate of increase in adhesive thickness, and thus, makes vibrations of the piezoelectric body less likely to be transmitted to the metal plate, thereby resulting in a degradation of product characteristics. Therefore, the average particle size of the aggregate is preferably about 1 μm to about 50 μm, for example.
FIG. 5 is a diagram for evaluating the conductivity in the case of bonding two metal plates 20 , 21 with the use of an electrically conductive adhesive 22 . For this evaluation, on the assumption that the adhesive thickness varies, the metal plates 20 , 21 were bonded with the electrically conductive adhesive 22 including insulating spacers 23 having a diameter of about 3 μm interposed therebetween, so as to provide a thickness of about 3 μm, and the series resistance was measured between the metal plates 20 , 21 . The evaluation results are shown in Table 1. It is to be noted that the amount of the components in the adhesive was about 3 weight % for carbon black and about 97 weight % for an epoxy resin. The carbon black (primary particles) had an average particle size of about 50 nm, the aggregate had an average particle size of about 5 μm, and spherical carbon had a particle size of about 3 μm.
TABLE 1
Electrically Conductive Adhesive
Carbon
Dispersed
Aggregated
Spherical
Free
Carbon
Carbon
Carbon
Series
7500
105
10
100
Resistance (Ω)
As is clear from Table 1, when using aggregated carbon black according to preferred embodiments of the present invention, the series resistance is dramatically low, as compared to when no carbon black is included, and furthermore, the resistance value can be reduced to about 1/10 or less as compared to when the dispersed carbon black or the spherical carbon is included. More specifically, the electrical conductivity is dramatically improved.
FIGS. 6A and 6B are diagrams for comparing the viscosity-thixotropy and series resistance characteristics between a case in which dispersed carbon black is added and a case in which aggregated carbon black is added. FIG. 6A is a diagram showing the relationship between the additive amount of carbon black and the viscosity-thixotropy, where the change in viscosity-thixotropy is smaller with respect to the additive amount of carbon in the case of the aggregated carbon black, as compared to the dispersed carbon black. Therefore, when an allowable line L 1 is set for the viscosity-thixotropy, the additive amount of carbon can be further increased for the aggregated carbon black as compared to the dispersed carbon black. In addition, when a comparison is made with the same additive amount of carbon, the aggregated carbon black has lower viscosity-thixotropy, and thus, provides favorable application stability (variations in the amount of application, leveling properties after the application) in the step of applying the adhesive. On the other hand, as shown in FIG. 6B , there is an inverse relationship between the additive amount of carbon black and the series resistance, and when a predetermined allowable line L 2 is set, a smaller amount of the aggregated carbon black achieves a desirable resistance value. More specifically, the additive amount of the aggregated carbon black can be reduced to a greater extent when the same viscosity or resistance value is to be achieved. Therefore, the cost is reduced.
As described above, the advantageous effects of the bonding structure according to preferred embodiments of the present invention are summarized as follows.
Since the aggregate of carbon black is deformed in a flexible manner, an increase in thickness is less affected by the adhesive.
Since the aggregate of carbon black is deformed in a flexible manner during bonding by pressurization, damage to the piezoelectric body is prevented or minimized.
Since the carbon black is present as aggregates (in clusters), the contact probability of the carbon black is greatly improved, and a higher conductive effect (anisotropic conductivity) is achieved as compared to the case in which the same amount of carbon black is present in a non-aggregated (primary particle) state.
Since the electrically conductive adhesive has anisotropic conductivity in the bonded state, short-circuiting s prevented even when a fillet formed around the piezoelectric body partially wraps around the electrode at the surface.
The reliability of electrical conductivity is improved because the flexible deformation of the carbon black aggregate more effectively responds to a swelling adhesive in a humidity test.
As compared to primary particles of carbon black dispersed in a resin, the fluidity of the resin is greater, and the influence on the viscosity-thixotropy is substantially suppressed.
The bonding structure according to preferred embodiments of the preset invention is not limited to the structure with the piezoelectric body 2 directly bonded onto the diaphragm 1 as shown in FIG. 1 , and may be a structure in which a metallic intermediate plate 8 is bonded on the diaphragm 1 and the piezoelectric body 2 is bonded thereon as shown in FIG. 7 . In this case, the electrically conductive adhesive 10 according to a preferred embodiment of the present invention is disposed between the diaphragm 1 and the intermediate plate 8 and between the intermediate plate 8 and the piezoelectric body 2 , and because the electrically conductive adhesive 10 is highly conductive and provides excellent adhesion as described above, favorable conductivity and bonding properties are ensured among the electrode 3 of the piezoelectric body 2 , the intermediate plate 8 , and the diaphragm 1 . In the bonding structure according to preferred embodiments of the present invention, the metal plate and the piezoelectric body may have any suitable shape, such as a disk shape, a quadrangular plate shape, or an annular shape, for example. The piezoelectric vibration plate according to preferred embodiments of the present invention can be used not only for piezoelectric microblowers for the transportation of compressible fluid such as air, but also for piezoelectric fans, piezoelectric micropumps for the transportation of incompressible fluid such as water, piezoelectric speakers, piezoelectric buzzers, piezoelectric sensors, and other suitable piezoelectric devices, for example.
While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims. | A bonding structure that provides excellent conductivity and bonding between a piezoelectric body and a metal plate includes a metal plate and an electrode of a piezoelectric body bonded to one another with an electrically conductive adhesive so as to provide electrical conductivity, the electrically conductive adhesive includes carbon black with a nano-level average particle size, and has a paste form included in a solventless or solvent-based resin so that the carbon black forms an aggregate with an average particle size of about 1 μm to about 50 μm. The electrically conductive adhesive is applied between the metal plate and the electrode of the piezoelectric body, and the metal plate and the piezoelectric body are subjected to heating and pressurization so that the carbon black aggregate is deformed, thereby hardening the electrically conductive adhesive. | 8 |
RELATED APPLICATION
This is a divisional application of Ser. No. 07/804,250, filed Dec. 9, 1991, now U.S. Pat. No. 5,261,925 which is a continuation-in-part of application Ser. No. 07/560,357, filed Jul. 31, 1990 now U.S. Pat. No. 5,118,322 of Hall et al entitled "Ozone Decolorization of Garments".
FIELD OF THE INVENTION
The present invention relates to the fading or decolorization of dyes or coloring agents on fabrics. More particularly, the invention is concerned with the decolorization and/or fading of garments containing cellulosic materials which contain an oxidizable dye or coloring agent through the use of oxidizing gases without any substantial deterioration of the garment. The invention is particularly useful in preparing fashion garments such as faded denim blue jeans, and the like, without the use of harsh chemical bleaches or the abrasive effects of stones, pumice, sand or the like.
BACKGROUND OF THE INVENTION
Denim blue jeans which have been faded, "stone-washed", ice washed, or sand blasted to produce a particular appearance are very popular. However, to produce the desired effect it has been necessary to utilize processes which cause substantial deterioration or degradation of the fabric. Bleaching solutions containing chlorine or actual pelleting of the garment with sand or stones to produce a fashion effect causes damage to the fabric which affects its wear,life.
The woven goods that are made into denim are typically manufactured from warp yarns (yarns that are in the machine direction on the loom) that have been dyed with Indigo (CI vat blue 1). The crosswise or filling yarns are typically undyed. The yarns are woven in such a way so as to place a high proportion of the colored (blue dyed) yarns on the face of the fabric. This is typically done by weaving the yarns using one of the twill weaves. The result is a fabric which is characteristically known as Blue Jeans when fabricated into garments. It has been discovered that bleaching of the Indigo color by one of a number of techniques can lead to desirable styling effects. Several of the bleaching or decolorizing treatments involves potassiums(or sodium) permanganate. This compound is the agent of choice when obtaining staying effects by the acid wash or stone wash technique.
Occasionally, garments which have been treated by these methods undergo yellowing during storage of the garments during warehousing and prior to shipment to the retailer or while in the retailers possession if he stores them for any length of time.
The precise causes for the yellowing phenomena is not known. Several possible causes have been identified to include finishing agents (added to the garment to provide a softer hand etc.), atmospheric pollutants or to degradation products associated with the permanganate reactions Which are not properly removed during the treatments among other causes. However, not all garments will be yellowed in a particular lot or shipment. The yellowing phenomena may not manifest itself until after the garments have been stored or shipped to the customer. Most likely the yellowed garments do emanate from a particular laundry cycle or machine; however, after the treated garments are removed from the machine the garments from the affected treatment cycle may then become mixed with those from other machines such that their processing lot identity becomes lost. Usually the contaminated (yellow) garments are returned to the seller or are sold at a considerably reduced price.
Another source of yellowing is the usual type of yellowing that is encountered world wide, that is, in all areas of the world and on all types of fibers. Usually the causative agent works on the fibers themselves or on some material that was either accidentally or deliberately added to the fabric. Some of the factors which are found to cause such yellowing in fabrics or garments are optical brighteners and finishing agents, atmospheric pollutants, sulfides and lignins in paper and cardboard, antioxidants used in packaging materials among others. Perhaps the most common and major cause for yellowing is due to the reaction of antioxidants with oxides of nitrogen to produce yellow compounds. Of these, butylated hydroxytoluene (BHT), is the most common contaminate causing such yellowing. It has been found that as little as 2 ppm of this compound on the fabric or garment can result in significant yellowing. This compound has widespread use in the industry because of its effectiveness, and the fact that it is fairly inexpensive and easy to obtain.
Ozone has been used in the bleaching of cellulosic materials. U.S. Pat. No. 4,283,251 to Singh discloses the bleaching of cellulosic pulp with gaseous ozone in an acidic pH followed by an alkaline treatment.
U.S. Pat. Nos. 4,214,330 and 4,300,367 to Thorsen, which are herewith incorporated by reference, describe a method and an apparatus for treatment of undyed fabrics with a ozone-steam mixture. The process is used to shrinkproof the fabric with a minimum amount of deterioration of the fabric fibers. The ozone treatment reacts with the undyed fibers and provides whiter fibers. The treatment is stated to increase subsequent dyeability and dye fastness of the garment.
W. J. Thorsen et al in their paper entitled, "Vapor-Phase Ozone Treatment of Wool Garments",Textile Research Journal, Textile Research Institute, 1979, p. 190-197, describe the treatment of wool fabrics and garments with ozone and steam to provide shrink resistance to the fabric or garment. The process is based on the reaction of the ozone with the wool fibers.
It should be understood that the term "dye" as used herein is meant to include any of the materials which are used to provide a color to a fabric such as conventional dyes, pigments, or the like. The term "fabric" as used herein is meant to include woven and non-woven cloth, knitted fabrics, garments, and the like.
It should be understood that the term "ozone and steam" as used herein denotes a preferable method of the invention and is meant to include ozone alone or ozone diluted with inert gases.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a process for selectively decolorizing a fabric containing cellulosic material having an oxidizable coloring agent such as a dye, pigment, organic or inorganic residues, and the like. The fabric may comprise cotton, linen, or other bast fibers or rayon alone or in combination with other materials including natural and synthetic fibers, for example, wool, nylon, polyester, and the like.
The oxidizing agent can be gaseous or a liquid or a solid oxidant in a vapor state. Gaseous oxidizing agents include ozone, NO x and SO x . These gases can be used alone, in admixture or diluted with a inert or low reactive gases such as air. The oxidizing gases can be used in combination with steam or in an aqueous system.
The non-gaseous oxidants:should be used in a vapor phase, preferably with wetted fabrics. More preferably, the non-gaseous oxidants are used in combination with steam. Hydrogen peroxide solution diluted with steam is a preferred non-gaseous oxidant.
The oxidant, for example, ozone primarily reacts with the colorant on the fabric When the fabric is wet. Therefore, the garment is wetted or treated in a wet state. The water content of the wetted fabric when treated in the vapor phase is preferably about 20 to 40% by weight or higher depending upon the degree of treatment, the type of oxidant and the effect desired. The process may either be batchwise or continuous and is performed in a chamber in which the oxidant is generally present in an amount of about 10 to 100 mg. per liter. The oxidant and the steam are injected into the chamber so as to provide a temperature in the chamber of about 40° to 100° C., preferably 50° to 65° C. In the absence of steam, heating elements in the chamber can be used to maintain the temperature. Any excess oxidant emitted may be recycled back into the chamber or used to treat any effluent of the process.
In accordance with a preferred embodiment of the invention, one or more fabrics having an oxidizable coloring agent which have been treated with an oxidation blocking agent or dyes of different reactivity or sensitivity to an oxidant are placed in an enclosed chamber. The oxidant is emitted into the chamber so as to react with the colorant of the fabric. The concentration of the oxidant in the chamber in a vapor phase is maintained between 10 to 100 mg per liter by monitoring with an ozone photometer. When the fabric reach a predetermined color, that is, the colorant has undergone a desired degree of decoloration with the oxidant whereby a desired color is obtained, the reaction is terminated prior to any substantial reaction of the oxidant with the cellulosic material of the fabric.
According to another embodiment of the invention, a cellulosic fabric with an oxidizable colorant is contacted with ozone or other oxidants with or without steam in an extractor.
Still another embodiment of the invention provides the recycling of the oxidizing gas alone or within a liquid to other steps of the fabric treatment process to either treat the fabric or the effluent to make it environmentally safe.
It is a general object of the invention to fade or decolorize fabrics containing an oxidizable colorant.
It is a further object of the invention to decolorize dyed garments with ozone without degrading the fabric.
It is yet still further object of the invention to selectively and/or evenly decolorize or fade dyed garments to produce fashion garments.
It is another object of the invention to provide garments with different degrees of color by use of dyes of varying ozone sensitivity and/or to provide different levels of colorization throughout the garment.
It is also an object of the invention to either avoid yellowing or to eliminate yellowing in fabrics and garments.
It is yet another object of the invention to recycle the oxidizing agents used in the process to either further treat the fabric or to treat effluent from the process and make it environmentally acceptable.
Other objects and a fuller understanding of the invention will be had by referring to the following description and claims of a preferred embodiment, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one form of a fabric treatment apparatus of the invention, and,
FIG. 2 is a schematic view of a process of the invention for treating garments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.
FIG. 1 schematically represents a typical fabric treatment process with several treatment areas which includes the various embodiments of the present invention so as to result in a dyed cellulosic fabric in which undesirable colorants are oxidized and/or the dye is decolorized or faded. The treatment also reduces the yellowing which occurs upon long term storage of the fabric.
As shown, a dyed cellulosic fabric 10 is preferably passed in countercurrent flow through a scouring bath 14 by means of rolls 12 in a continuous process. However, the process may be carried cut step-wise or batchwise depending upon the fabric.
The scouring bath 14, which generally comprises a 2 to 10% solution of sodium hydroxide and about 0.1 to 0.5% detergent, is at ambient to elevated temperature (about 100° C.). If desired, an oxidizing gas such as ozone may optionally be added to the bath according to the process.
Following the scouring bath, the fabric is conveyed to a steamer 18 after passage through contact or squeegee rolls 16, 16' and a conveyor roll 17. The treatment in the steamer 18 is usually for a period of about one half hour.
After the steam treatment the fabric is conveyed from the steamer 18 over a conveyor roll 17 to a vacuum or aspirator means 20 for removal of a substantial portion of any residual sodium hydroxide solution. Also, the fabric may be washed with brine or water to remove alkaline residue from the fabric in bath 31.
The fabric 10 can be further steamed in J-box 22 and passed into a wash bath so as to wet the fabric prior to treatment with ozone.
The wet fabric is then passed into an ozone treatment apparatus 26. The length of time that the fabric 10 remains in contact with ozone within the apparatus 26 is dependent upon the purpose of the ozone treatment. A shorter stay of the fabric 10 within the apparatus 26 usually occurs if the ozone treatment is to prevent or remove yellowing. When the fabric 10 is to be faded or decolorized, ozone may be injected into the apparatus 26 together with steam. Excess ozone or ozone and steam may be recycled back into apparatus 26 or sent through line 27 to other treatment areas including the treatment of waste. The recycling is beneficial since excess ozone need not be further treated before passing into the environment and ozone treatment of waste effluent satisfies environmental guidelines.
It is understood that in combination with ozone or in lieu of ozone there may be used other oxidizing gases such as chlorine, nitrous oxides and/or sulfur oxides. For example chlorine when added to water produces hypochlorous acid (HOCl). Even under alkaline conditions a portion of the sodium hypochlorite (NaOCl) exists as the hypochlorous acid. For example in the study by Ridge and Little (J. Text. Inst., 1942, 33T, p. 59) the equilibria at different pH values are governed by the reactions:
HOCl→H.sup.+ +OCl.sup.-
and
HOCl+H.sup.+ +Cl.sup.- →Cl.sub.2 +H.sub.2 O
The fraction of the hypochlorite existing as free hypochlorous acid increases as the pH falls below 10. At pH of 5, all of the chlorine is in the hypochlorous acid form. Under neutral conditions about 73% exists in this form. Thus, chlorine added to neutral or slightly acidic steam will contain high amounts of oxidant as hypochlorous acid. Areas of the fabric which may need to be protected from the oxidizing effects of the hypochlorous acid can be coated with a preferential reaction product (blocking agent) such as starch. That is, the starch will be preferentially attacked by the hypochlorous acid and the underlying substrate (cotton, rayon etc.) will be protected and not undergo any significant bleaching or decolorization. Also, if the fabric is wet, chlorine gas will primarily react with the water to form HOCl according to the reaction.
H.sub.2 O+Cl.sub.2 →HOCl
and will bleach the fabric only in the wet areas. If dyed wool is to be processed by this method it may be satisfactory to use sulfur dioxide in the steam to achieve the same bleaching effect that chlorine will have on the non-wool garment.
Another oxidant that will be somewhat soluble in the steam is peracetic acid. It is used primarily as a bleaching agent for nylon.
Following treatment with the oxidizing gases the fabric can be further steamed in J-box 28 and passed into the final wash 30 prior to passage for further treatment.
FIG. 2 illustrates the process of the invention in connection with the treatment of garments such as denim jeans. The jeans which have been previously dyed and sized are placed in an abrading and desizing apparatus 40. The desizing and abrasion steps are conventional in the field. Chemicals or enzymes can be used to desize. The abrasion aids in the desizing and in addition provides a fashion look. Addition of ozone in this stage of the process not only aids in desizing but also initiates the start of decolorizing the garment. In some cases only partial desizing may be required since the sizing can act as a blocking agent for the oxidant.
After the abrasion and desizing, the garments are washed in a washer 42 one or more times to remove the sizing and other chemicals. The garments while still wet from the wash can be optionally treated with an ozone blocking agent in apparatus 44. Typically, clay is sprayed onto the garments while still wet so that the clay adheres. Alternatively, the garments could be dried and hydrocarbon oils, greases or waxes are sprayed onto the garments. Masking tape can also be used to provide special effects. Some starch may be left in the garments so as to act as a preferential reaction medium for the ozone.
Preferably, the garments while still wet are placed in an extractor in which an oxidizing gas such as ozone is injected. Preferably, the extractor 46 is provided with a heating means 47 such as steam coils or thermocouples. When steam is injected together with ozone a furthers heating means is generally not required. The temperature within the chamber is generally about 40° C. to 100° C. preferably about 50° to 65° C. The ozone in the chamber of the extractor 46 may be monitored with an ozone photometer, such as a Dasibi Model 1003 HC ozone photometer. There are alternative methods for determining the termination or end period for the ozone treatment. One method involves the prior use of test fabrics to determine the operating parameters. Another method which can be used is visual inspection.
It is understood that dry garments may be placed in the ozone chamber and that they are wetted by the steam.
Excess ozone and ozone containing extract can be recycled back into the extractor 46 or through lines 48 and/or 49 to initiate decolorization at an earlier stage. It has been found to be helpful to include ozone in the desizing step when the desizing is performed with a chemical.
The ozone and ozone containing fluid from the extractor can also be used to treat the effluent from the desizing and wash apparatuses 40 and 42 prior to release in the environment.
After the ozone treatment the garment can be washed or post treated to remove the oxidation blocking agents in apparatus 50 and then dried in apparatus 51.
The type of dye used on the garment is not critical. It is only important that the dye is ozone reactive where intended. Cellulose substantive dyes, such as vat dyes, which are common in the garment industry, are preferably used. Exemplary of the dyes which are substantive to cellulose or blends of cellulose with synthetic fibers that can be used include, Sevron Brilliant Red 2B, indigo vat dye, a cationic dye, Sulfonine Brilliant Red B, an anionic dye, Brilliant Milling Red B, C. I. Disperse Blue, pyrazolone azomethine dye, hydroxy azo dyes, or the like. Where the dye is a xanthene dye, treatment also gives rise to chemiluminescence in the process. Other suitable dyes that can be used are identified in the paper of Charles D. Sweeney entitled, "Identifying a Dye can be Simple or it Can Involve Hours of Laboratory Analysis", Textile Chemist and Colorist, Vol. 12, No. 1, January 1980, pp 26/11.
The garments may be treated with one or more dyes. Utilizing dyes of differing degrees of ozone reactivities provides the garment with zones of different appearances or effects. For example, faded, stone washed, ice-washed, sand blasted or mottled effects may be obtained. The same effect can be achieved by utilizing ozone blocking agents. The ozone blocking agents may comprise organic materials such as pearl starch, modified or derivitized starches, hydrocarbon oils, greases or waxes or inorganic materials such as clay. Masking tape, or other coverings may be used. A further alternative method to achieve a special effect is to partially or selectively wet the garment since the ozone-dye reaction effectively takes place where the garment is wet. The ozone generally does not react with the fabric where it is not wet.
The blocking agent can also be any chemical agent which itself is reactive with ozone but prevents or blocks a dye or portion of a dye on the fabric and prevents it from becoming decolorized.
It is understood that the reaction period and amount of ozone utilized is dependent upon different factors. That is, the time and amount of ozone depends upon the effect desired, the type of dye utilized, the temperature, degree of wetness, etc. Longer treatment at lower concentrations of ozone can result in the same effect as a short treatment with a large excess of ozone on the same dyes. Therefore, the sensing of the conditions in the reaction chamber is essential to optimize the present process.
The ozone within the chamber is preferably measured periodically and kept at a minimal and within the range of about 10 to 100 mg per liter. The ozone can be generated by on ozone generator of the type available from Griffin Technics, Inc., Model GTC-2B which produces ozone from dry air or oxygen using electrical circuit breakers or Corona discharge. The ozone may be used alone or diluted with inert gases.
A garment to be faded, such as denim blue jeans, is generally first laundered to remove any sizing or fashion process coatings or materials which may interfere with the process of the invention. For example starch can act as an ozone blocking agent. The washing operation could include desizing using enzymes, as is common in the industry followed by laundering to cleanse the garment. The garment is then hydroextracted or padded dry so as to remove excess water. The water content of the garment should be about 20-40% by weight. If the garment is not wet, then it can be wetted by water spraying or placing it within a water bath.
The garment is treated with a blocking agent which is determined on the effect desired. For example, if a sand blasted or stone washed effect is desired, the wet garment can be sprayed with clay or some other inorganic powder to act as an ozone blocker. However, if a mottled look is desired, the garment may be treated with a suitable hydrocarbon oil, grease or wax which shields parts of the garment from the effects of ozone in a selected manner. The garment can be printed, the color can be applied by painting or using a mordant.
In lieu of the ozone blocking, special effects can also be achieved by selectively treating the garment with dyes having different degrees of ozone reactivity. The different dyes can be added earlier in the process so that the use of ozone blocking agents becomes optional. The non-reactive or lesser ozone reactive dyes may be applied by spraying, brushing, dipping, or the like in the same manner as placing the oxidation blocking agents. The non-reactive dyes include the pigment colors.
The following example is illustrative of the invention, but is not to be construed as to limiting the scope thereof in any manner. The percentages herein disclosed relate to percent by weight.
EXAMPLE 1
A. A lot of 30 cotton denim blue jeans vat dyed with a blue indigo dye (CI Vat Blue 1) were washed in a standard laundry detergent at 120° F. in a conventional washer which includes a spin extractor. The garments after extraction had a moisture content of about 35% by weight. One half (15) garments were removed and the remaining were treated for 25 minutes in an ozone atmosphere while still in the laundering machine.
All of the garments were dried and stored for six (6) months.
The garments which were not treated with ozone showed significant yellowing. The garments which were post treated with ozone did not show any signs of yellowing.
B. All of the garments which showed yellowing were washed as in Step A and placed in the extractor. After extraction the garments had a moisture content of about 35%. The garments were treated with ozone for twenty five (25) minutes the same as in Step A. The yellow color disappeared.
EXAMPLE 2
The following experiments were performed to determine the degree of degradation of the fabric based on the warp yarn which contains the dye.
Experimental Procedures
Grab Break tests were determined using ASTM Test method D-1682 Five breaks for the warp yarn were made for each sample and averaged. Abrasion tests were determined according to ASTM method D-3885 (stoll flex). Five samples were run and averaged. The fabrics were standard Levi style 501 garments.
Results
The overall results are given in Table 1. A standard ice wash procedure was used as the control.
A. Comparison of Ozone treated fabrics to chlorine treated fabrics.
The results for chlorine (Sodium Hypochloride) treatments are shown both in Table 1. The treatment was done at normal (C1) medium (C2) and high (C3) chlorine contents in order to obtain increasing levels of color removal ranging from a medium blue to white. These treatments were matched to various ozone treatment times needed to achieve the same level of color removal. For example, C1 matched the ozone treatment for 1 hour while C2 matched the ozone treatment for 1.5 hours. No ozone treatment matched the C3 (totally white) jeans which is included for completeness. From the results it is observed that the ozone treated fabrics do not loose as much warp strength as the chlorine bleached fabrics. It is the warp yarns which contain the indigo dye.
B. Ozone Treatments
Fabrics were treated with ozone for 0.5 to 2.0 hours. The test results are given in Table 1 and shown graphically in the attached bar graphs. The fabric color become lighter with increasing time of ozone treatment. The color (dye) level in the garments was monitored by a Bausch and Lomb Color Scan Spectrophotometer
C. Ozone treatment of an ice washed garment.
An ice washed garment (control) was treated for 15 minutes in an ozone atmosphere (sample 03 1/4 hr.). Some loss in strength resulted, however, considerable abrasion resistance was restored (See Table 1 or bar graphs). The other surprising result was that the blue shade of the unbleached portion of the ice washed fabric could be further reduced in color to give a shading affect that cannot be achieved by the original ice washing technique. Further, ice washing produces a yellow color (staining) in the white (bleached) regions of the garment which reduces the garment attractiveness. This yellow color (dye) is due to breakdown fragments (compounds) of the indigo dye which remain in the fabric to discolor the white background. The ozone treatment was effective in decolorizing these yellow compounds and gave a superior "white" background to the garments. That is, the ozone treatment corrects a major defect of ice wash treatments.
TABLE 1______________________________________Comparison of strength (Grab Break and Abrasion) forvarious Fabric Treatments Test ResultsTreatment Grab Break (lbs) Abrasion(Cycles) W W______________________________________Ice Washed (Control) 174 5473Ozone (03) 0.25 Hrs 139 9014 0.50 Hrs 224 9527 1.0 Hrs 245 20428 1.5 Hrs 195 8906 2.0 Hrs 174 5588Chlorine(C1) Medium Blue 225 14080(C2) Light Blue 179 5823(C3) White 143 3266______________________________________
Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A process for selectively decolorizing a fabric containing cellulosic material oxidizable colorants which comprises the steps of wetting the fabric and then contacting the wetted fabric with an oxidizing gas or vapor. The contact with the oxidizing gas or vapor is terminated before any substantial degradation of the fabric occurs. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to the control of intercom systems for motorcycles and other vehicles.
Intercoms allowing the driver and a passenger of a motorcycle to communicate with each other by means of speakers and microphones mounted in their helmets are well known. It is also well known to use the same speakers and microphones to allow the driver and the passenger to communicate with others by means of a CB radio, and/or to utilize the speakers to allow them to listen to entertainment audio which may be selected from audiotape players, CD players, MP 3 players and AM/FM radio. An example of the controls for such a multifunction audio system is described in U.S. Pat. No. 6,225,584. Voice actuated (VOX) circuits such as those described in U.S. Pat. No. 4,754,486 are often included in such multifunction audio systems to reduce or eliminate the entertainment signal to the speakers when one of the microphones or the CB receiver is actuated.
When using a multifunction system of the type described above, it will often be considered inconvenient to have the intercom on only when communication is desired. However, leaving the intercom in the “on” state can result in the undesired transmission of sounds originating from one of the users or from the environment. Such undesired transmissions can be annoying in themselves and may also degrade the entertainment audio by undesired activation of the VOX circuitry. Safety is a concern if the intercom volume control is used to eliminate undesired transmissions, since this requires the driver to remove a hand from the handlebars to access the volume control, which is usually located in the center tank area of the motorcycle. This can result in the driver having one hand removed from the handlebars for a significant amount of time.
SUMMARY OF THE INVENTION
Because a multifunction audio system for a motorcycle may include a CB radio, the controls for such a system usually include PTT (push to talk) switches conveniently located for activation by the driver and the passenger. The present invention provides means for switching the helmet mounted microphones of both the driver and the passenger both on and off by use of one of the PTTs. Regardless of their prior state (“on” or “off”), activation of a PTT immediately causes both microphones to be “on.” If the PTT is released during a predetermined short period of time (for example, 0.5 sec), the microphones are turned “off” if they were “on” before activation of the PTT and remain “on” if they were “off” prior to the activation of the PTT. If the PTT is released after the predetermined period of time, the microphones remain on only if they were “on” before activation. The intercom can thus be activated and deactivated by short activation of the conveniently located PTTs. This permits the driver and the passenger to conveniently communicate with each other, while avoiding undesired transmissions over the intercom when communication is not desired. Since this is accomplished by activation of the PTTs that the users are accustomed to using for CB communication, the present invention avoids having to locate another communication control switch in the limited space available on a motorcycle and avoids requiring the user to decide upon and find the proper control for the desired type of communication. This enhances the safety of the operation of the motorcycle by eliminating or minimizing the time that the driver will not have both hands on the handle bars.
A motorcycle communication system equipped with the controller of the present invention will permit conventional push-to-talk operation of the intercom if the CB radio is turned off, or is not present.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block schematic of a multifunction audio system incorporating the present invention.
FIG. 2 is a schematic of one embodiment of the intercom control of FIG. 1 .
FIGS. 3–4 make up a flow chart of the logic of a second embodiment of the intercom control of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a multifunction audio system for use by the driver and a passenger of a motorcycle which includes driver's helmet mounted speakers 2 and passenger's helmet mounted speakers 4 , both of which are capable of accepting inputs from the driver's microphone 6 , the passenger's microphone 8 , the CB radio 10 and the entertainment system 12 . The speakers 2 and 4 and microphones 6 and 8 are conventionally mounted in helmets worn by the driver and passenger respectively. Speakers mounted on the chassis of the motorcycle may, however, supplement or replace such helmet mounted speakers. The microphones 6 and 8 are connected to the speakers 2 and 4 by an intercom circuit 32 which can be activated and deactivated by means of a conventional switch 14 . The entertainment system 12 may comprise an AM/FM radio, an audiotape player, a CD player, a MP3 player or any combination thereof. A VOX attenuator 16 is conventionally provided to reduce or eliminate the entertainment signal to the speakers 2 and 4 when either the CB receiver 18 or one of the microphones is activated.
An audio control 20 is conventionally mounted on a handlebar 22 of the motorcycle. The audio control 20 includes a driver's PTT 24 conventionally disposed close to the handlebar 22 so that it can be conveniently activated by the driver. A passenger's PTT 26 is also provided. Both the driver's PTT 24 and the passenger's PTT 26 are conventionally provided to activate the transmitter 28 of the CB radio 10 .
The intercom controller 30 of the present invention is electrically connected to the driver's PTT 24 and the passenger's PTT 26 so as to be responsive to the activation of either PTT. The intercom controller 30 is also connected to the intercom circuit 32 so as to be capable of activating and deactivating that circuit. It has been found convenient to connect the intercom controller 30 to the portion of the intercom circuit 32 comprising the output cable 34 from the driver's microphone 6 and output cable 36 from the passenger's microphone 8 . The intercom controller 30 may, however, be connected to the intercom circuit 32 at any point that would not interfere with signals to the speakers 2 and 4 from either the receiver 18 or the entertainment system 12 . Unless overridden by the opening of switch 14 , when either PTT 24 or PTT 26 is activated, intercom controller 30 operates to activate intercom circuit 32 if it was inactive prior to activation of the PTT and will have no immediate effect if the intercom circuit 32 was active prior to activation of the PTT. If the activated PTT is then released during a predetermined short period of time, the intercom controller 30 allows the intercom circuit 32 to remain active if, but only if, it was inactive prior to the activation of the PTT. If the activated PTT is released after said predetermined period, the intercom controller 30 permits the intercom circuit 32 to remain active only if it was active prior to the activation of the PTT. The intercom circuit 32 can thus be toggled between the active and inactive states by short activations of the PTTs 24 and 26 without interfering with the operation of the CB radio. To accomplish this objective, it has been found preferable to set said predetermined period of time at between 0.1 seconds and 0.75 seconds, approximately 0.5 seconds being best for most users. In some cases, however, it may be found desirable to set said predetermined delay for as long as 2 seconds.
FIG. 2 is a detailed schematic of one embodiment of the intercom controller 30 . The controller 30 is powered by a motorcycle's conventional electrical system; an externally fused 13.8 volt DC source. This source voltage is applied to the controller 30 through series wired diode D 1 and parallel wired capacitor C 1 for the purpose of power supply filtering. This creates 13.2 volts for the controller 30 while diode D 1 also provides reverse polarity protection. U 1 is a LM339 quad comparator with two of it's comparator stages spared in this design. Both U 1 -A and U 1 -B are given the same inputs and therefore react to input changes concurrently. The negative input 37 of U 1 -A (pin 4 ) and the negative input 39 of U 1 -B (pin 10 ) are referenced with 0.97 volts via voltage divider R 2 /R 5 . Positive input 41 of U 1 -A (pin 5 ) and positive input 43 of U 1 -B (pin 11 ) are created by voltage divider R 1 /R(CB) through blocking diode D 2 , from PTT switches 24 and 26 . R(CB) is the internal resistance of the PTT detection circuit which is a part of a conventional motorcycle CB radio, and thus external to the controller 30 . Capacitor C 2 functions with resistor R 3 to provide switch debounce and pulse stretching. When both PTT switches 24 and 26 are open (not activated), U 1 's positive inputs are 1.8 volts, which is greater than negative inputs 0.97 volt reference. Due to the comparator's open collector outputs design, open circuit to ground is present at outputs 38 and 40 (pins 2 and 13 respectively). Pull-up resister R 3 causes a logic 1 at U 2 -A input 42 (pin 1 ) and U 2 -C input 44 (pin 8 ). When either PTT 24 or PTT 26 is closed U 1 's positive inputs are 0.6 volts, which is less than negative inputs 0.97 volt reference. Due to the comparator's open collector outputs design, closed circuit to ground is now present at U 1 outputs 38 and 40 (pins 2 and 13 ). Logic 0 will be applied to U 2 -A input 42 (pin 1 ) and U 2 -C input 44 (pin 8 ). A base biasing current is thereby provided from U 1 -B output 40 to transistor Q 1 .
U 2 is a CD4093 two input NAND Schmitt Trigger quad gate. U 2 -A/U 2 -B forms a one-shot timer output to U 2 -C input 46 (pin 9 ) when initiated from U 1 -A output 38 (pin 2 ) by PTT switch closure. A pulse at U 2 -A output 48 (pin 3 ) of approximately 0.5 sec. results from RC network resister R 4 , capacitor C 3 values and the chips Schmitt Trigger input design. If the activated PTT switch is re-opened during this 0.5 sec. window, a logic 1 would be presented to both NAND gate U 2 -C inputs 44 and 46 (pins 8 and 9 ), and the output of U 2 -C at 48 (pin 10 ) is logic 0. U 2 -D forms an inverter, it's output a logic 1 at 64 (pin 10 ) applies a clock pulse to U 3 at 58 (pin 11 ). U 3 is a CD4013 dual type D flip flop with one of the flip flop stages spared in this design and it is configured to provide a toggle at it's output. The primary connection to U 3 are shown in FIG. 2 with reference numbers 50 , 52 , 54 , 56 , 58 , 60 and 62 referring to pins 7 , 8 , 9 , 10 , 11 , 12 and 14 respectively. Not shown, pins 1 , 2 and 13 of U 3 have no connection, pins 3 , 5 and 6 are grounded and pin 4 is connected to the positive voltage line from diode D 1 . On initial energization (motorcycle ignition turn on), the combination of capacitor C 4 and resister R 8 provide a pulse to 52 (pin 8 ), causing the utilized circuit of U 3 to latch it's output at 60 to logic 0. This causes the microphones to be turned on at motorcycle start up. U 3 output state at 60 toggles on rising edge clock pulse at 58 from U 2 -D output 64 . Q 1 is a 2N3906 PNP transistor used as a switch. It is forward biased by a logic 0 caused by open collector ground from U 1 -B output 40 —OR— by U 3 output 60 . Diode D 3 provides this OR circuit. When Q 1 is forward biased it's collector current will energize both relay coils 66 and 68 . D 4 suppresses back emf (electro motive force) caused when the relays de-energize (drop out).
In another embodiment of my invention, the intercom controller 30 comprises a synchronous microcontroller which operates as shown in FIG. 3 .
Many other changes and modifications in the embodiments of the invention can also be carried out without departing from the scope thereof. | A motorcycle audio system is provided with circuitry to toggle the helmet mounted microphone of both the driver and the passenger on and off by use of the PTT (push to talk) switches commonly provided for use with a CB radio. Activation of a PTT immediately causes both microphones “on” regardless of their prior state. If the PTT is released during a predetermined short period, the microphones are turned off only if they were on prior to activation of the PTT and remain on only if they were off prior to activation. If the PTT is released after the predetermined period, the microphones remain on only if they were on prior to activation. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 10/379,332 entitled, “A METHOD FOR IMPROVED DATA COMMUNICATION DUE TO IMPROVED DATA PROCESSING WITHIN A TRANSCEIVER” filed on Mar. 4, 2003, by Noel C. Canning, et al., which is currently pending, and is a continuation of EP Patent Application No. 02006793.0 entitled, “A METHOD FOR IMPROVED DATA COMMUNICATION DUE TO IMPROVED DATA PROCESSING WITHIN A TRANSCEIVER,” filed on Mar. 25, 2002, by Noel Charles Canning, et al. The above-mentioned applications are commonly assigned with the present application and incorporated herein by reference in their entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention is directed, in general, to data communications systems and, more specifically, to a transceiver having improved data processing.
BACKGROUND OF THE INVENTION
[0003] Methods for improving the speed and security of data transmissions via modern data networks, such as an Integrated Services Digital Network (ISDN), a Global Standard for Mobile Communications (GSM) network, a General Packet Radio Service (GPRS) network or a Public Switched Packet Data Network (PSPDN), such as the Internet and X:25 networks are well known. Yet, state of the art improvement methods often struggle with a conflict between increasing security or speed. Thus, an improvement in security in most cases results in a reduction of speed.
[0004] For example, a data transmission scheme may be implemented via a wireless GPRS network. A wireless GPRS network is a type of packet-switched radio network that employs multiplexed data blocks of transmission frames that are serially ordered and transmitted in accordance with a transmission protocol over a shared link. A GPRS transmission procedure, for example operating in a confirmation mode, typically retransmits faulty transmitted data blocks of a transmission frame from a mobile station to a base station until a correct receipt of the respective data blocks is acknowledged. The re-transmitting is usually limited by a certain number of retries or a certain amount of time. After reaching the re-transmitting limit, a more secure but also slower coding of the transmission frame data is chosen. Thus, it could be that for a single outstanding data block, an entire transmission frame of data has to be transmitted again using better coding but at a slower rate.
[0005] Moreover, the GPRS is a multi-slot application running in dynamic allocation mode with tight requirements for reaction time. The mobile station, or transceiver, therefore, has to react within a short time period after receiving an Uplink State Flag (USF) from the base station to transmit the data blocks. Typically, the USF is provided separately for each timeslot with the timing constraint for the USF managed by a Digital Signal Processor (DSP). The speed, therefore, of data transmission between the micro-controller and the DSP within a transceiver is quite crucial.
[0006] Accordingly, what is needed in the art is an improved method of data transmission that increases both the speed and the security of modern data networks.
SUMMARY OF THE INVENTION
[0007] In one aspect, a method for transmitting data is disclosed. In one embodiment, the method includes: (1) generating data blocks of a data package in a first transceiver to transmit to a second transceiver, the first transceiver including a micro-controller coupled to a digital signal processor, (2) generating identification data in the first transceiver for the data blocks, wherein the identification data is an index of a list of the data blocks to be transmitted and each of the data blocks is transmitted with the index and (3) identifying the data blocks to be transmitted to the second transceiver based on the identification data, wherein the microcontroller employs the index to manage transmission of the data blocks.
[0008] In another aspect, a transceiver capable of transmitting data blocks is disclosed. In one embodiment, the transceiver includes: (1) a micro-controller configured to generate data blocks to transmit to a second transceiver and generate identification data for the data blocks, wherein the identification data is an index of a list of the data blocks to be transmitted and each of the data blocks is transmitted with the index, the micro-controller configured to employ the index to manage transmission of the data blocks and (2) a digital signal processor configured to receive the data blocks from the micro-controller and store the data blocks until time for the transmit, the digital signal processor further configured to provide, to the micro-controller, the identification data that has been returned from the second transceiver after being transmitted thereto with the data blocks.
[0009] In yet another aspect, another transceiver is disclosed. One embodiment of this transceiver includes: (1) a micro-controller configured to generate at least one data block and identification data associated with the data block, wherein the identification data is an index of a list of the data blocks to be transmitted and the micro-controller employs the index to manage transmission of the data block, (2) a digital signal processor configured to receive the data block and the information data from the micro-controller and store the data block until time for transmission and (3) a transmit/receive buffer configured to receive the data block and information data from the digital signal processor for transmission to a second transceiver
[0010] The foregoing has outlined preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 illustrates a block diagram of a data communications system constructed in accordance with the principles of the present invention; and
[0013] FIG. 2 illustrates a flow diagram of an embodiment of a method for improved data communication constructed in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0014] As noted above, a method of transmitting data is disclosed herein. In one embodiment of the method, the second transceiver transmits acknowledgment signals with the identification data to a receiving buffer of the first transceiver. A Digital Signal Processor (DSP) coupled to the receiving buffer provides the acknowledgment signals with the identification data to a micro-controller to indicate a transmission status of the data blocks. The combination of both the identification data and the acknowledgments assist in determining a beginning and end, or vice versa, of the data blocks transmission thereby increasing the security of data transmission.
[0015] Referring initially to FIG. 1 , illustrated is a network diagram of a data communications system, generally designated 100 , constructed in accordance with the principles of the present invention. In addition to a first mobile station 110 , the data communications system 100 includes a base station 120 , a second mobile station 130 and an air interface 140 . The first mobile station 110 includes a micro-controller 112 , a digital signal processor (DSP) 114 , a transmit/receive buffer 115 , a timing unit 116 and a radio frequency unit 118 . In a general sense, the first and second mobile stations 110 , 130 , are examples of transceivers constructed in according to the principles of the present invention.
[0016] The data communications system 100 may be a data packet-switched radio network. In a preferred embodiment, the data communications system 100 may be a General Packet Radio Service (GPRS) network. Of course, one skilled in the art will understand that the data communications system 100 may be a Integrated Services Digital Network (ISDN), a Global System for Mobile communications (GSM) network or a Public Switched Packet Data Network (PSPDN), such as the Internet and X:25 networks.
[0017] The first mobile station 110 and the second mobile station 130 may be mobile telephones. The second mobile station 130 may operate similar to and be configured similar to the first mobile station 110 . The micro-controller 112 and the DSP 114 may include conventional microprocessor circuitry and conventional DSP circuitry commonly employed in data communication devices. The transmit/receive buffer 115 may be a standard buffer configured to buffer data blocks to transmit and data blocks that are received.
[0018] The timing unit 116 and the radio frequency unit 118 may include standard components of mobile stations operating in a data communications system. The timing unit 116 may be configured to control the radio frequency unit 118 to provide the proper timing for data transmission over the air interface 140 . The timing for data transmission may be synchronized and conform to GSM specifications for multi-slot applications. The radio frequency unit 118 may be configured to transmit and receive data blocks via the air interface 140 . For example, the radio frequency unit 118 may include an antenna. The radio frequency unit 118 may transmit and receive data blocks to/from the base station 120 or directly to the second mobile station 130 . The base station 120 may include standard base station systems that are configured to operate within a data communications system.
[0019] In one embodiment, data blocks may be passed from the micro-controller 112 to the DSP 114 wherein the data blocks are stored until transmitted. The time for transmission may be determined by specific messages received via the air interface 140 . When the time for transmission has been determined, the DSP 114 sends the data blocks to the transmit/receive buffer 115 and sends a request to the micro-controller 112 to send a next data block for transmission. The data blocks are transmitted over the air interface 140 via the radio frequency unit 118 which is controlled by the timing unit 116 .
[0020] The data blocks to be transmitted may be sent from the micro-controller 112 to the DSP 114 in advance of transmission to insure timing requirements of a multi-slot network are fulfilled. In a GPRS multi-slot application running in a dynamic allocation mode, there are tight requirements for reaction time when transmitting data. The first mobile station 110 may have to react within ten (10) timeslots (i.e., 10*577 μs) after having received, for example, an Uplink State Flag (USF) from the base station 120 indicating the time to transmit data. A USF may be provided separately for each timeslot. In the first mobile station 110 , the DSP 114 may process the USF to satisfy the reaction time since the data blocks to be transmitted are passed in advance to the DSP 114 wherein they are stored until transmission.
[0021] Each of the data blocks may be passed from the micro-controller 112 to the DSP 114 with an associated identification data which may be generated or selected freely by the micro-controller 112 . In an advantageous embodiment, the micro-controller 112 may choose the identification data to be an index of lists or data packages to be transmitted. Each data list which may be transmitted may carry the index such that the processing of the lists, particularly between the micro-controller 112 and the DSP 114 , is eased.
[0022] The base station 120 may send the USF to the first mobile station 110 to start transmission of the data blocks and indicate via which channel or slot to use for transmission. The micro-controller 112 may receive acknowledgments, such as ACKs, indicating how many and which of the data blocks were transmitted. The acknowledgments may by a data message, such as DataACK, which includes the identification data of the transmitted data blocks.
[0023] Since the identification data has been generated by the micro-controller 112 , the identification data may be used for various purposes such as for managing lists containing the next data blocks to be transmitted. Additionally, contents of an identification data byte may be free and can be used for such purposes as carrying an index of a list of data blocks to be transmitted. The index may ease list management and assist in safely determining the transmitted data blocks.
[0024] Turning now to FIG. 2 , illustrated is a flow diagram of an embodiment of a method for improved data communication constructed in accordance with the principles of the present invention. More specifically, the flow diagram provides an example of a message exchange between a micro-controller, designated MC in FIG. 2 , and a DSP of a transceiver such as the first mobile station 110 of FIG. 1 .
[0025] For example, in a Frame X, eight (8) data blocks are acknowledged and hence eight (8) new blocks may be sent from the micro-controller to the DSP. In Frame X+1, two (2) data blocks are acknowledged and two (2) new data blocks may be sent to the DSP from the micro-controller. Of course one skilled in the art will understand that the acknowledgment sent to the micro-controller may be a negative acknowledgment signal.
[0026] This interleaved communication between the micro-controller and the DSP may result in an improvement of security of transmission and in an acceleration in speed for transmitting the data blocks. The present invention, therefore, advantageously provides during communication between the micro-controller and the DSP, a possibility that data blocks of a data package or a data list which relates to a data frame may be mixed with or incorporated into other data packages or data lists that are not yet fully transmitted. Thus, data frames may be provided that are filled with a maximum number of data blocks which may be transmitted. Consequently, transmission of an entire frame containing the data blocks which were not transmitted, may not be needed. Thus, the interleaving data management may improve efficiency of buffering during data communication which is especially important within multi-slot applications with tight time constraints.
[0027] Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form. | The present invention provides a method for transmitting data and a transceiver. In one embodiment, the method includes: (1) generating data blocks of a data package in a first transceiver to transmit to a second transceiver, the first transceiver including a micro-controller coupled to a digital signal processor, (2) generating identification data in the first transceiver for the data blocks, wherein the identification data is an index of a list of the data blocks to be transmitted and each of the data blocks is transmitted with the index and (3) identifying the data blocks to be transmitted to the second transceiver based on the identification data, wherein the microcontroller employs the index to manage transmission of the data blocks. | 7 |
PRIORITY INFORMATION
This application is a continuation-in-part of U.S. patent application Ser. No. 09/350,955 filed Jul. 9, 1999, U.S. Pat. No. 6,273,117.
FIELD OF THE INVENTION
This invention relates to fluid pressure regulators, and particularly to regulators well suited for controlling the output pressure of elastomeric balloon or mechanical pumps. More specifically, the present invention relates to a variable fluid pressure regulator which allows for convenient adjustment of fluid outlet pressure.
BACKGROUND OF THE INVENTION
Pressure regulators that reduce or cut off inlet flow of a fluid when the outlet pressure starts to exceed a predetermined maximum and that open or increase flow when the outlet pressure has been sufficiently reduced are well known in the art. Such regulators generally include a coil spring that biases a valve member open, and a pressure-sensing element responsive to excess inlet pressure which closes the valve member. In this arrangement, increasing liquid pressure compresses the spring to force the valve member towards a valve seat. As the valve member approaches the valve seat, liquid flow through the regulator becomes more restricted. When the defined pressure level is reached, further flow restriction is stopped, or the valve member contacts the valve seat to cut off flow. When the output pressure drops below the defined pressure, the valve member moves away from the valve seat and flow increases. This cycle is rapidly repeated over and over to maintain the output pressure at the desired setting.
Numerous pressure regulating devices teach the use of a coil spring, such as U.S. Pat. No. 3,412,650 by Stang, U.S. Pat. No. 3,547,427 by Kelly, U.S. Pat. No. 3,603,214 by Murrell, U.S. Pat. No. 3,747,629 by Bauman, U.S. Pat. No. 3,825,029 by Genbauffe, U.S. Pat. No. 4,074,694 by Lee, U.S. Pat. No. 4,621,658 by Buezis et al., U.S. Pat. No. 4,744,387 by Otteman, U.S. Pat. No. 5,141,022 by Black, and U.S. Pat. No. 5,732,736 by Ollivier. However, a need exists for a pressure regulator device without a spring coil, thereby resulting in a more reliable device with fewer parts which is easier to assemble and costs less.
The majority of the subject pressure regulators of the above-referenced patents are manufactured to provide a single, specific fluid outlet pressure or be adjustable between a high and a low setting. However, there also exists a need for a variable pressure regulator device that allows for the selection, from a range of values, of a desired fluid outlet pressure by a user. This capability is particularly desirable in connection with small pumps used in the medical field wherein fluids are being dispensed to a patient.
SUMMARY OF THE INVENTION
A goal of preferred embodiments is to provide a simplified pressure regulator having fewer parts thereby making it easier to assemble, less expensive and less likely to break. Instead of having the traditional springs located above and below a flexible diaphragm, a resilient diaphragm is employed that by itself controls input flow and regulates output pressure. The diaphragm is made of an elasticomeric material, and is designed not only to act as a diaphragm, but also to replace the pressure sensing spring and the valve seat spring.
Preferably, the diaphragm is manufactured to be flat, however, after installation into the regulator, an adjuster is moved to deflect the diaphragm. The amount of deflection corresponds with the desired outlet fluid pressure. The diaphragm resists deflection when outlet pressure is less than the desired level, but flexes towards a closed position when the outlet pressure exceeds this level. Thus, this diaphragm uniquely has the additional advantage of functioning as a spring without having any of the disadvantages.
Additionally, a preferred embodiment of the fluid pressure regulator includes a cover, which engages the adjuster such that rotation of the cover results in rotation of the adjuster to deflect the diaphragm and adjust the fluid outlet pressure, as described above. Such a construction advantageously allows convenient adjustment of the fluid outlet pressure by medical personnel and, thus, permits the variable fluid regulator to accommodate a variety of fluid dispensing needs.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawing wherein:
FIG. 1 is a cross-sectional view of a preferred embodiment of a pressure regulator;
FIG. 2 is a cross-sectional view of an additional embodiment of a pressure regulator;
FIG. 3 is an exploded, perspective view of the pressure regulator of FIG. 2 as viewed from above;
FIG. 4 is an exploded, perspective view of the pressure regulator of FIG. 2 as viewed from below;
FIG. 5 is a cross-sectional view of another embodiment of a pressure regulator;
FIG. 6 is an exploded, perspective view of the pressure regulator of FIG. 5 as viewed from above;
FIG. 7 is an exploded, perspective view of the pressure regulator of FIG. 5 as viewed from below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the pre-set pressure regulator, indicated generally by the numeral 10 , comprises a base 15 , a resilient wall or diaphragm 20 , a retainer 25 , and an initial adjuster in the form of a cap 30 . The base 15 has an inlet 35 where fluid is introduced into the regulator 10 and an outlet 40 where the fluid exits at the desired pressure. A central, axial passage 45 extends through the base 15 , and is in fluid communication with the inlet 35 . The diameter of the open end at the top of the passage 45 which is smaller than the lower portion forms a valve seat 50 . A plug 55 closes the lower end of the passage.
The top surface of the base 15 is concave and forms the lower boundary of a fluid pressure-sensing chamber 60 . The perimeter of the top surface of the base member has an angled, annular shoulder 65 which defines a seating and gripping surface for the diaphragm 20 . The shoulder 65 has an externally threaded lip 70 which mates with interior threads on the retainer 25 , which is generally ring shaped. The outlet conduit 40 in fluid communication with the chamber 60 extends from the top surface of the base 15 to an exterior surface of the base 15 .
The diaphragm 20 is a generally circular, preferably generally flat member which has an outer annular portion clamped between the base shoulder 65 and a flat annular surface 90 on the retainer 25 to seal that area. This causes the bottom surface of the diaphragm to form the upper boundary of the pressure-sensing chamber 60 . The diaphragm is preferably made of an elastomeric material, such as silicone so that it will be responsive to fluid pressure changes in the chamber 60 and has a significant “memory” so that it is self-restoring. Depending from the diaphragm 20 is an integral valve stem 75 which extends axially through the chamber 60 and into the passage 45 . A valve element 80 on the lower end of the valve stem is positioned in the passage 45 to cooperate with the valve seat 50 . The valve element is preferably ball-shaped as illustrated, but may be in the form of a disk or other suitable shape that will properly mate with the valve seat. During assembly, the valve element 80 may be lubricated with alcohol to enable it to be pushed through the valve seat into the passage 45 .
The retainer 25 may be ultrasonically welded to the base 15 if desired. An annular area 95 of the retainer 25 slopes upwardly, and inwardly to an interiorly threaded collar 105 , which is part of the retainer. The adjuster cap 30 has a flat upper wall 110 and a cylindrical flange 115 extending downward into the collar 105 . The exterior surface of the flange 115 is threaded to mate with the threads of the collar 105 . The cap 30 is adjusted so that its lower annular end contacts the top surface of the diaphragm 20 . The circular, central section of the diaphragm, which is bounded by the cylindrical flange 120 , is responsive to fluid pressure in the chamber 60 . The loading by the adjusting cap 30 pushes the diaphragm 20 downward, thereby unseating the valve element 80 , as shown in the drawing. The adjuster may also be in sliding or cam-like engagement with the retainer.
The upper surface of the diaphragm 20 and the initial adjusting cap 30 form an upper interior space 130 that is separated from the pressure-sensing chamber 60 by the diaphragm 20 . Vents 125 extend through the flat surface 110 of the adjusting cap 30 to prevent pressure build-up in the upper interior space 130 , and to facilitate turning the adjuster cap 30 when setting the desired pressure.
The base 15 , plug 55 , adjusting cap 30 , and retainer 25 are preferably made of polyvinyl chloride, but may be made of other durable, inexpensive materials known to those of ordinary skill in the art.
When the diaphragm 20 is assembled within the pressure regulator 10 , between the angled shoulder 65 of the base 15 and the flat surface 90 of the retainer 25 , the valve member 80 is seated in a sealed closed position. After a pressure source is attached to the inlet 35 , the cap 30 is advanced against the diaphragm causing the annular tip of the cap flange 115 to deflect the diaphragm 20 , thereby unseating the valve element 80 from the valve seat 50 . While the valve element 80 is unseated, fluid travels through the inlet 35 and the valve seat 50 , flows into the fluid sensing chamber 60 , and out through outlet 40 . The cap is adjusted until the desired outlet pressure is attained. For a preset pressure device, a suitable adhesive or the like is applied to the threads at 115 to prevent changes in the output pressure setting.
When the pressure of the fluid in the chamber 60 exerts a force against the bottom of the diaphragm 20 greater than the desired value initially set by the adjusting cap 30 , a force imbalance occurs. The force of the fluid in the chamber 60 pushes the resilient central section of the diaphragm 20 upward causing the valve member 80 to move in a flow-reducing or flow stopping direction towards the valve seat 50 . When the outlet pressure drops below the desired level, the resilient diaphragm central section moves the valve member 80 away from the valve seat 50 and fluid flow into the chamber 60 increases. The resiliency of diaphragm 20 provides its central section the self-restoring flexibility to respond to the pressure of the fluid in the fluid pressure-sensing chamber 60 . Consequently, diaphragm 20 is an active member responsive to pressure changes without the need for a conventional spring.
The valve stem and the valve may be made of the same material as the diaphragm 20 and the valve member 80 , and may be made as a one piece unit. However, a valve stem 75 made from a material stiffer than that used to make the diaphragm 20 is better able to maintain a constant pressure over a wider range of input pressures. To increase stiffness and obtain this improved effect, a rigid pin (not shown) may be inserted into the valve stem 75 , after the diaphragm 20 is assembled into the valve body but before the adjusting cap 30 is installed. Alternatively, the cross section of the valve stem 75 may be increased over part or all of its length to increase stiffness. Further, the valve stem may be a completely separate part that links a separate valve element to the diaphragm.
The pressure regulator is useful in many applications but is particularly suited to control the output pressure of elastomeric balloon or other mechanical pumps.
FIGS. 2-4 illustrate an additional embodiment of a fluid pressure regulator, indicated generally by the reference numeral 10 ′. The pressure regulator 10 ′ is similar in construction and function to the pressure regulator 10 of FIG. 1 . Accordingly, like reference numerals will be used to denote like components, except that a (′) will be added.
With similarity to the embodiment of FIG. 1, pressure regulator 10 ′ comprises a valve body including a base 15 ′ and a retainer 25 ′, a resilient wall or diaphragm 20 ′, and an adjuster in the form of a cap 30 ′. The base 15 ′ has an inlet 35 ′ where fluid is introduced into the regulator 10 ′ and an outlet 40 ′ where the fluid exits at the desired pressure. A central, axial passage 45 ′ extends through the base 15 ′, and is in fluid communication with the inlet 35 ′. The diameter of the open end at the top of the passage 45 ′, which is smaller than the lower portion, forms a valve 50 ′. A plug 55 ′ closes the lower end of the passage.
As with the embodiment of FIG. 1, the diaphragm 20 ′ of the present pressure regulator 10 ′ is clamped between the base 15 ′ and the retainer 25 ′. Therefore, the bottom surface of the diaphragm 20 ′ forms the upper boundary of the pressure sensing chamber 60 ′. An upper surface of the base 15 ′ forms the lower boundary of the pressure sensing chamber 60 ′. Depending from the diaphragm 20 ′ is an integral valve stem 75 ′, which extends axially through the chamber 60 ′ and into the passage 45 ′. A valve element 80 ′ on the lower end of the valve stem is positioned in the passage 45 ′ to cooperate with the valve seat 50 ′.
As in the embodiment of FIG. 1, the adjuster cap 30 ′ of the present pressure regulator 10 ′ is threadably engaged within a central portion of the retainer 25 ′. The adjuster 30 ′ may be advanced or retracted relative to the retainer 25 ′ such that a lower annular end 120 ′ contacts the top surface of the diaphragm 20 ′. Advancing or retracting the adjuster 30 ′ alters the force necessary to close the valve element 80 ′ against the valve seat 50 ′, thereby adjusting the fluid outlet pressure of the pressure regulator 10 ′, as described above with respect to the embodiment of FIG. 1 .
The pressure regulator 10 ′ of FIGS. 2-4 additionally comprises a cover 150 . Preferably, the cover 150 is rotatably supported on the retainer 25 ′ and engages the adjuster 30 ′ such that the adjuster 30 ′ is fixed for rotation therewith. Thus, rotation of the cover 150 results in corresponding rotation of the adjuster 30 ′ such that the deflection of the diaphragm 20 ′ is altered, thereby adjusting the fluid outlet pressure.
With reference to FIGS. 3 and 4, the cover 150 preferably includes a plurality of flexible lock tabs 152 . The lock tabs 152 engage the retainer 25 ′ to hold the cover 150 in a substantially fixed axial relationship with the retainer 25 ′, while allowing rotation with respect thereto.
Each lock tab 152 includes a substantially transversely extending lock surface 154 configured to engage a retaining surface 156 of the retainer 25 ′. The retaining surface 156 may be a transversely extending uninterrupted annular surface. However, the retaining surface 156 may also include a series of interrupted surfaces, preferably with the interruptions being less than a width of any one of the flexible lock tabs 152 .
The illustrated pressure regulator 10 ′ includes four, equally spaced lock tabs 152 (FIG. 4 ), however, a lesser or greater number of lock tabs 156 may be used. Advantageously, the lock tabs 152 and retaining surface 156 construction allow assembly of the cover 150 to the retainer 25 ′ without the use of tools or additional fasteners. However, other suitable coupling methods may also be used.
With reference to FIG. 2, the cover 150 includes a pair of downwardly extending shafts or pins 157 which engage vent holes 125 ′ of the adjuster cap 30 ′. The shafts 157 may be of a smaller diameter than that of the vent holes 125 ′ such that pressure build-up in the upper chamber 130 ′ is avoided.
The pair of shafts 157 fix the adjuster cap 30 ′ for rotation with the cover 150 , while simultaneously allowing the adjuster cap 30 ′ to move axially with respect to the cover 150 by sliding on the shafts 157 . Thus, when the cover 150 is rotated, the adjuster cap 30 ′ both rotates, due to its engagement with the cover 150 via the shafts 157 , and moves axially with respect to the cover 150 , due to its threaded engagement with the retainer 25 ′.
The pressure regulator 10 ′ also includes a catch, or detent, mechanism 158 arrangement for locating the cover 150 in a desired angular position with respect to the retainer 25 ′. Each of a plurality of recesses 160 define a plurality of angular positions relative to the base 15 ′. The cover 150 includes a depending flexible tab 162 adjacent the cover periphery. The tab 162 includes an inwardly extending projection 164 (FIG. 4 ). The illustrated projection 164 is hemispherical in shape and each of the recesses 160 are substantially semi-cylindrical in shape. However, other suitable mating shapes may also be used, as can be determined by one of skill in the art.
With reference to FIG. 2, the catch mechanism 158 is constructed such that the projection 164 is biased into engagement with a recess 160 by the inherent biasing force of the flexible tab 162 . As a result, the cover 150 and thus the adjuster cap 30 ′ are held in one of the annular positions defined by the plurality of recesses 160 . When the cover 150 is rotated relative to the base 15 ′ with a sufficient force, the projection 164 is disengaged from its current recess 160 and moves into engagement with the next adjacent recess 160 in the direction of rotation of the cap 150 . Preferably, the inherent biasing force of the flexible tab 162 is such that a caregiver and/or patient may rotate the cover 150 by hand, while also inhibiting undesired rotation of the cover 150 due to vibrations or inadvertent contact.
Advantageously, with such a construction, rotation of the cover 150 results in rotation of the adjuster cap 30 ′ which, in turn, alters the deflection of the flexible diaphragm member 20 ′. As discussed above, the outlet fluid pressure is influenced by the deflection of the flexible diaphragm member 20 ′. Accordingly, the pressure regulator 10 ′ allows a caregiver and/or patient to easily adjust the fluid outlet pressure to a desired value.
With reference to FIG. 3, the fluid pressure regulator 10 ′ includes an indicator arrangement 166 , which correlates the angular position of the cover 150 with a resulting fluid outlet pressure. Advantageously, with such a construction the caregiver is able to adjust the variable pressure regulator 10 ′ to a proper outlet pressure for a specific fluid being dispensed.
The illustrated indicator arrangement 166 comprises an annular scale 168 on the retainer 25 ′. A reference indicia 170 is provided on the cap 150 and, when the cap 150 is assembled to the retainer 25 ′, is aligned such that at least a portion of the scale 168 is indicated by the reference indicia 170 . In the illustrated embodiment, the reference indicia 170 comprises a window 172 and an arrow 174 . The window 172 is sized and shaped preferably to display one demarcation of the scale 168 . The arrow 174 allows for rapid identification of the location of the window 172 , and may or may not be provided.
The scale 168 of the illustrated embodiment is an index scale, which provides a relative indication of outlet pressure. Thus, each range of the index scale 168 may correspond to a predetermined value, or a range of values, for the fluid outlet pressure. Alternatively, the scale 168 may provide actual fluid pressure outlet values.
In an alternative arrangement, the scale 168 may be provided on the cap 150 and the reference indicia 170 may be located on the retainer 25 ′, or possibly the base 15 ′. In this arrangement, the reference indicia 170 may comprise a projection and/or colored region of the retainer 25 ′ or base 15 ′. Of course, other suitable arrangements for indicating a value on a scale may also be used. As such, it is not intended for the indicator arrangement 166 to be limited simply to the embodiments disclosed herein, but to include other suitable variations.
FIGS. 5-7 illustrate an alternative arrangement of the catch mechanism 158 . In this embodiment, the recesses 160 are defined on an upper annular surface of the retainer 25 ′ and the flexible tab 162 is correspondingly located on an upper surface of the cover 150 . In addition, the recesses 160 are generally triangular in cross-section, as viewed in FIG. 5, with the radially innermost wall portion being rounded (FIG. 6 ). With reference to FIG. 7, the projection 164 is semi-cylindrical in shape. Otherwise, the embodiment of FIGS. 5-7 is similar in construction and function to the embodiment described immediately above.
Although this invention has been described in terms of certain embodiments, other embodiments apparent to those of ordinary skill in the art are also within the scope of this invention. Thus, various changes and modifications may be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is intended to be defined only by the claims that follow. | A variable device for regulating the outlet pressure of a fluid from a valve body, includes a pressure-sensing chamber having a wall formed by a resilient self-restoring diaphragm which is responsive to pressure in the chamber. A valve element connected to the diaphragm controls flow into the chamber. Increased pressure in the chamber decreases the flow into the chamber and decreasing pressure increases flow whereby fluid flow out from the chamber is maintained at a desired pressure. The outlet pressure is adjusted by deflecting the diaphragm in a direction to open the valve while permitting a section of the diaphragm connected to the valve member to remain responsive to the pressure in the chamber. An adjustment cover is provided to adjustably deflect the diaphragm and includes a catch mechanism to allow adjustment of the fluid outlet pressures and also retain the device at a desired value. An indicator arrangement may be provided to visually indicate the fluid outlet pressure. | 8 |
BACKGROUND OF THE INVENTION
This invention relates generally to turbine engines, and more specifically to turbine blades used with turbine engines.
At least some known turbine engines include a turbine that includes a plurality of rotor blades that extract rotational energy from fluid flow entering the turbine. Because the turbine is subjected to high temperatures, turbine components are cooled to reduce thermal stresses that may be induced by the high temperatures. Accordingly, at least some known rotating blades include hollow airfoils that are supplied cooling air through cooling circuits defined within the airfoil. More specifically, the airfoils include a cooling cavity bounded by sidewalls that define the cooling cavity.
To fabricate the cooling passages, at least some known turbine blades are cast using an internal core that forms the internal cooling passageways within the blades. Because of the relative large size of blades and/or vanes that may be used within industrial turbine engines, at least some known cores are reinforced to enable the core to withstand the injection pressures of the wax and the subsequent casting process. More specifically, a tip of at least some known casting cores is supported during the casting process by at least one rod that has a substantially constant diameter along its length.
When the casting process is complete, a print out coupled between the rod and the core is removed. An opening created by the rod may provide a channel for cooling the tip cap portion of the blade. In some known blade designs, the opening is sealed to facilitate cooling other portions of the blade. In such cases, the openings are sealed using known sealing techniques, such as welding or brazing. To facilitate forming a smaller diameter opening, some known castings use rods that have a diameter less than approximately 0.035 inches. However, as an overall size and/or weight of the casting is increased, a smaller diameter rod may not provide enough structural support to the core.
BRIEF SUMMARY OF THE INVENTION
In one aspect of the invention, a method for casting an airfoil for a turbine engine is provided. The method includes forming a casting core to define a hollow portion in the airfoil and forming a print out region at one end of the casting core. The method also includes coupling the casting core to the print out region with at least one frusto-conical member to facilitate structurally supporting the casting core.
In another aspect, an airfoil casting core for a turbine blade is provided. The casting core includes at least one of a leading edge path region, a center path region, and a trailing edge path region. The casting core also includes a core print region coupled to at least one of a leading edge path region, a center path region, and a trailing edge path region by at least one frusto-conical member.
In a further aspect of the invention, an airfoil core for use in casting an airfoil is provided. The airfoil core includes at least one of a leading edge path region, a center path region, and a trailing edge path region, extending between a core tip and a core root. The airfoil core also includes a print out region coupled to at least one of the core tip and the core root by at least one frusto-conical rod.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective partial cut away view of an exemplary turbine;
FIG. 2 is a partial perspective view of an exemplary rotor assembly that may be used with the turbine shown in FIG. 1 ;
FIG. 3 is a perspective view of an exemplary airfoil core that may be used to fabricate an airfoil used with the rotor assembly shown in FIG. 2 ; and
FIG. 4 is an enlarged schematic view of a portion of the airfoil core shown in FIG. 3 and taken along area 4 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic illustration of a gas turbine engine 10 including a generator 12 , a compressor 14 , a combustor 16 and a turbine 18 . Engine 10 has an inlet or upstream side 20 , an exhaust or downstream side 22 , and a gas fuel inlet 24 . The gas fuel passes through a gas control module 26 containing an isolation valve 27 , known as the stop-ratio valve (SRV) and a gas control valve (GCV) 28 . In one embodiment, engine 10 is a turbine engine commercially available from General Electric Power Systems, Schenectady, N.Y.
In operation, highly compressed air is delivered from compressor 14 to combustor 16 . Gas fuel is delivered to the combustor 16 through a plurality of fuel nozzles (not shown in FIG. 1 ) and hot exhaust gas from combustor 16 is discharged through a turbine nozzle assembly (not shown in FIG. 1 ) and is used to drive turbine 18 . Turbine 18 , in turn, drives compressor 14 and generator 12 .
FIG. 2 is a perspective view of a rotor assembly 40 that may be used with a turbine, such as turbine engine 10 (shown in FIG. 1 ). Assembly 40 includes a plurality of rotor buckets or blades 42 mounted to rotor disk 44 . In one embodiment, blades 42 form a high-pressure turbine rotor blade stage (not shown) of turbine engine 10 .
Rotor blades 42 extend radially outward from rotor disk 44 , and each blade 42 includes an airfoil 50 , a platform 52 , a shank 54 , and a dovetail 56 . Each airfoil 50 includes first sidewall 60 and a second sidewall 62 . First sidewall 60 is convex and defines a suction side of airfoil 50 , and second sidewall 62 is concave and defines a pressure side of airfoil 50 . Sidewalls 60 and 62 are joined at a leading edge 64 and at an axially-spaced trailing edge 65 of airfoil 50 . More specifically, airfoil trailing edge 65 is spaced chord-wise and downstream from airfoil leading edge 64 . A plurality of trailing edge slots 67 are formed in airfoil 50 to discharge cooling air over trailing edge 65 . The cooling air facilitates reducing the temperatures, thermal stresses, and strains experienced by trailing edge 65 .
First and second sidewalls 60 and 62 , respectively, extend longitudinally or radially outward in span from a blade root 68 positioned adjacent platform 52 , to an airfoil tip cap 70 . Airfoil tip cap 70 defines a radially outer boundary of an internal cooling chamber (not shown in FIG. 2 ). The cooling chamber is bounded within airfoil 50 between sidewalls 60 and 62 , and extends through platform 52 and through shank 54 and into dovetail 56 . More specifically, airfoil 50 includes an inner surface (not shown in FIG. 2 ) and an outer surface 74 , and the cooling chamber is defined by the airfoil inner surface.
Platform 52 extends between airfoil 50 and shank 54 such that each airfoil 50 extends radially outward from each respective platform 52 . Shank 54 extends radially inwardly from platform 52 to dovetail 56 . Dovetail 56 extends radially inwardly from shank 54 and facilitates securing rotor blade 42 to rotor disk 44 . More specifically, each dovetail 56 includes at least one tang 80 that extends radially outwardly from dovetail 56 and facilitates mounting each dovetail 56 in a respective dovetail slot 82 . In the exemplary embodiment, dovetail 56 includes an upper pair of blade tangs 84 , and a lower pair of blade tangs 86 .
FIG. 3 shows an exemplary airfoil core 100 used in fabricating turbine blades 42 (shown in FIG. 2 ). FIG. 4 is an enlarged schematic view of a portion of airfoil core 100 taken along area 4 (shown in FIG. 3 ). In one embodiment, core 100 is used to fabricate Stage 2 Bucket castings. Airfoil core 100 includes a leading edge path 102 , a center path 104 , a trailing edge path 106 , and a root cooling path 108 . Trailing edge path 106 has a plurality of fingers 110 extending from trailing edge path 106 .
During casting, leading edge path 102 and center path 104 form a first cooling passage (not shown), and a second cooling passage (not shown), respectively, in the resulting airfoil. Trailing edge path 106 forms a third cooling passage (not shown), and fingers 108 extending from trailing edge path 106 , form a plurality of trailing edge slots, such as slots 67 (shown in FIG. 2 ). In one embodiment, at least one of leading edge path 102 , center path 104 , and trailing edge path 106 includes an extension that forms a recess in the resulting airfoil cooling chamber. Thus, after a cooling passage is formed, the recess facilitates controlling airflow within the cooling cavity by forming an air flow restriction in the cooling chamber.
Airfoil core 100 also includes at least one “print out” region that facilitates handling of core 100 . More specifically, in the exemplary embodiment, airfoil core 100 includes a core tip print out region 112 . Core tip print out region 112 is coupled to at least one of leading edge path 102 , center path 104 , and trailing edge path 106 by at least one member 116 . First member 116 includes a first end 118 and a second end 120 . Specifically, first end 118 is coupled to at least one of leading edge path 102 , center path 104 , and trailing edge path 106 and second end 120 is coupled to core tip print out region 112 . Alternatively, core tip print out region 112 is coupled to root cooling path 108 by at least one member 116 .
Member 116 is frusto-conical and has a first end 118 that has a smaller diameter d 1 than a diameter d 2 at a second end 120 . Frusto-conical rod 116 reduces the area of weak mechanical strength in the regions of airfoil core 100 which exhibit break potential and subsequent loss of the casting. In another embodiment, member 116 can have any cross-sectional shape, such as a substantially square or triangular shape, with first end 118 having a smaller cross-sectional dimension than second end 120 .
Airfoil core 100 is fabricated by injecting a liquid ceramic and graphite slurry into core die (not shown). The slurry is heated to form a solid ceramic airfoil core 100 . The airfoil core 100 is suspended by core print out 112 in an airfoil die (not shown) and hot wax is injected into the airfoil die to surround the ceramic airfoil core. The hot wax solidifies and forms an airfoil (not shown in FIG. 1 ) with the ceramic core suspended in the airfoil.
The wax airfoil with the ceramic core is then coated with multiple layers of ceramic and heated to remove the wax, thus forming a cavity shell having the shape of the airfoil. The shell is then cured in a heated furnace. Molten metal is then poured into the shell and thus forming a metal airfoil with the ceramic core remaining in place. The airfoil is then cooled, and the ceramic core is removed from the solidified casting by leaching or other means, leaving a casting having a hollow interior corresponding to the configuration of the airfoil core 100 .
The above-described airfoil core is cost-effective and highly reliable. The airfoil core includes at least one conical rod for attaching a core print out to the airfoil core. An area/diameter of the rods increases from the first end to the second end adding mechanical strength in regions of the airfoil core which exhibit break potential and subsequent loss of the casting. Additionally, the increased strength of the conical rod enables the conical rod to suspend a larger airfoil core. As a result, the geometry design of the conical rod, allows for the expansion of as cast feature geometry into the original casting design with an acceptable approach for manufacturing introduction, the conical rod facilitates maintaining material fatigue life and extending a useful life of the airfoil core during the casting process in a cost-effective and reliable manner.
Exemplary embodiments of airfoil casting cores are described above in detail. The systems are not limited to the specific embodiments described herein, but rather, components of each assembly may be utilized independently and separately from other components described herein. Each airfoil casting core component can also be used in combination with other airfoil casting cores and turbine components.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A method for casting an airfoil for a turbine engine is provided. The method includes forming a casting core to define a hollow portion in the airfoil and forming a print out region at one end of the casting core. The method also includes coupling the casting core to the print out region with at least one frusto-conical member to facilitate structurally supporting the casting core. | 1 |
TECHNICAL FIELD
The present invention relates to child safety devices for preventing unsupervised use of electrical equipment and appliances. More particularly, the invention relates to an electric plug locking device affixable to an electrical plug.
BACKGROUND OF THE INVENTION
Various kinds of electric plug locking devices exist to prevent unsupervised use of electrical equipment and to appliances. Exemplary of such is the one disclosed in U.S. Pat. No. 4,488,764. This plug locking device entirely encloses an electrical plug, including its body and terminals, within a device cavity that has an opening through which an electrical cord extends. Access to the cavity is controlled by a cavity cover with a key lock. When the plug locking device is unlocked to allow use of the plug, the plug is completely removed.
Distinct disadvantages exist with this type of plug locking device. For example, a key must be readily available to unlock it. If the key is off the premises, delay occurs in accessing the plug. If the key is misplaced, a new key must be made. Once the device is unlocked, it too may be misplaced.
Another plug locking device, as disclosed in U.S. Pat. No. 4,865,557, eliminates the need for a key by permanently locking the plug into a chamber with a post and cap latch. However, the post must be severed to permit the device to open and release the plug. Such a plug locking device, therefore, can be used only once.
Thus, there exists a need for a plug locking device to secure an electrical plug from use which remains affixed to the plug even in an unlocked position, which does not necessarily require the use of a key, and which is capable of repeated use. Accordingly, it is to the provision of such an improved plug locking device that the present invention is primarily directed.
SUMMARY OF THE INVENTION
The present invention provides an electric plug locking device for preventing unsupervised use of electrical equipment that has a lower housing member, in which the plug may be seated, mounted to an upper housing member which has an opening for receiving therethrough a plug terminal. The upper housing member moves relative to the lower housing member between a position that shields the plug terminal to prevent it from being inserted into an electrical socket and a position that unshields the plug terminal to permit it to be inserted into the socket. The plug locking device has lock means for locking the upper housing member in its shielding position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the plug locking device of the present invention in its preferred form, the device shown mounted to an electrical plug.
FIG. 2 is an exploded view, in perspective, of the plug locking device of FIG. 1.
FIG. 3A is a side view, in cross-section, of the plug locking device of FIG. 1 shown in an unlocked position, while FIG. 3B is a side view, in cross-section, of the plug locking device of FIG. 1 shown in a locked position.
FIG. 4 is a transverse cross-sectional view of the plug locking device of FIG. 1 taken along plane 4--4 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views, an electric plug locking device 10 is shown in FIG. 1 in an unlocked position with the locked position shown in phantom. The plug locking device 10 has an upper housing member 11 movably attached to a lower housing member 12 to form housing which encases a conventional electrical plug 13. The plug 13, as best illustrated in FIG. 2, has a body 14, two terminals 15, a ground prong 16, a strain relief 17, and a cord 18 which connects the plug to an unshown appliance or other electrical apparatus. A conventional three-wheel locking system 40 is mounted along one side of the device.
With reference to FIG. 2, the upper housing member 11 is seen to comprise a top 19, two side walls 20 and 20', a rear wall 21, and a front wall 22 that has two parallel slots 23 for receiving the two terminals 15 of the electrical plug. Three pairs of outwardly facing, L-shaped snap hooks 24 constructed of resilient material are mounted along the side walls 20 and 20'. Each hook in each respective pair is transversely aligned with the other hook of the pair. The pairs of hooks are spaced apart such that a front pair is adjacent the front wall 22 and two rear pairs are grouped closer together adjacent the rear wall 21. Two parallel plates 25 having three indentations 26 are mounted adjacent the side wall 20. These plates 25 are part of the locking system 40 which is best detailed in FIGS. 3A and 3B.
The lower housing member 12 has a bottom 27, two side walls 28, 28', a front wall 29 having an opening 30 for receiving the ground prong 16 of the electrical plug 13, and a rear wall 31 having a U-shaped opening 32 for receiving the cord 18. An interior rear wall 33 also has a U-shaped opening 34 aligned with the opening 32 for receiving the cord 18. A U-shaped barrier wall 35 is mounted centrally within the interior of the lower housing member 12. A support wall 36 is mounted forwardly of the barrier wall 35 toward the front wall 29 to hold the strain relief 17 of the plug 13 in place between the barrier wall 35 and the front wall 29. A rim 37 extends coplanarly inwardly from the side walls 28 and 28' from which five pairs of shelves or ledges 38 extend. Each shelf of each respective pair is transversely aligned with the other shelf of the pair. Two front pairs of shelves are grouped together between the front wall 29 and the barrier wall 35. Three rear pairs of shelves are grouped together between the barrier wall 35 and the interior rear wall 33. Three U-shaped in-molded spring supports 39, which are part of the locking system 40, are located within the lower housing member 12 adjacent the side wall 28 and between the interior rear wall 33 and the barrier wall 35.
With reference to FIG. 3A, the locking system 40 has three wheels 41 each mounted at their center to rods 42 which are journaled in the valleys of the supports 39. The wheels 41 are disposed on the opposite side of the support 39 to the wheels 44. Each wheel 41 has a flat 41' in its annular perimeter. Exterior wheels 44, best shown in FIG. 1, mount at their center to the rods 42 for rotation of the rod and the wheel 41. The wheels 44 are disposed between the supports 39 and the side wall 28. The wheels 44 display a symbol on their perimeter, such as a numerical digit, which is visible from the exterior of the lower housing member 12.
FIG. 4 best illustrates the slidable attachment of the upper housing member 11 to the lower housing member 12. The three pairs of resilient snap hooks 24 of the upper housing member 11 interlock with the rim 37 of the lower housing member 12 along a bearing surface 43 which allows for the upper housing member 11 to slide between the unlocked and locked positions. When the snap hooks 24 are located between the shelves 38, the overlap that occurs is small. In this position, the resilient upper housing member 11 may be squeezed to disengage the snap hooks 24 thereby causing the upper and lower housing members to be detached.
Referring again to FIG. 3A, the plug 13 is seen mounted within the plug locking device 10 in an unlocked position with terminals 15 and ground prong 16 unsheathed and free to be inserted into an electrical socket. The terminals 15 extend through the slots 23 of the front wall 22 of the upper housing member 11 and the ground prong 16 extends through the opening 30 of the front wall 29 of the lower housing member 12. The body 14 of the plug 13 is snugly held within the plug locking device 10 between the front wall 22 of the upper housing member 11 and the front wall 29 of the lower housing member 12 and the support wall 36 which also supports the plug strain relief 17. The rear wall 21 of the upper housing member 11 and the rear wall 31 of the lower housing member 12 hold the cord 18 that extends through the opening 32. The wheels 41 of the locking system 40 in the unlocked position, shown in FIG. 3A, are set such that their flats 41' are parallel to the flat edge of the plates 25 and the annular perimeters of the wheels 41 are not in contact with the indentations 26 of the plates. Thus in this position the upper and lower housing members may be slid relative to each other.
Conversely, as illustrated in FIG. 3B, the plug locking device 10 is shown in its locked position, the upper housing member 11 having been slid forwardly upon the lower housing member 12 so that its front wall 22 shields and hoods the terminals 15. This prevents terminals from being inserted into an electrical socket. The rear wall 21 of the upper housing member 11 and the interior rear wall 33 of the lower housing member 12 hold the cord 18 that extends through the opening 34. The locking system 40 in the locked position is set randomly such that the at least one flat 41' of a wheel 41 is not parallel to the flat edges of the plates 25. This causes the annular perimeter of that wheel 41 to be in mated contact with one of the indentations 26 of the plates 25, thereby preventing movement of the upper housing member 11 which engages the plug locking device 10. Unshown detent means also frictionally hold the wheels in their various angular positions.
It thus is seen that an electric plug locking device is now provided that affixes to a plug both in locked and unlocked positions. While this invention has been described in detail with particular reference to the preferred embodiment thereof, it should be understood that many modifications, additions and deletions may be made thereto without departure from the spirit and scope of the invention as set forth in the following claims. | An electric plug locking device (10), which remains affixed to an electric plug (13) for preventing unsupervised use of electrical equipment, has an upper housing member (11) movably mounted to a lower housing member (12). The upper housing member which has an opening (23) for receiving a plug terminal (15) moves from a position that shields the terminal to prevent it from being inserted into an electrical socket to a position that unshields the plug terminal to permit it to be inserted into the socket. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 442,908, filed Feb. 15, 1974.
BACKGROUND OF THE INVENTION
This invention relates to apparatus for conducting a continuous chemical reaction with internal recycle and, more particularly, relates to apparatus useful for the esterexchange conversion of ethylene glycol-degraded polyethylene terephthalate.
High molecular weight polyesters of terephthalic acid and aliphatic dihydric alcohols are well known in the art. Polyethylene terephthalate is a commercially preferred polyester of this class due to its exceptional physical and chemical properties.
Polyethylene terephthalate is typically prepared by contacting an organic ester of terephthalic acid, such as dimethyl terephthalate, with ethylene glycol in the presence of an ester exchange catalyst to form dihydroxyethyl terephthalate monomer, and then polymerizing the monomer to high molecular weight using condensation polymerization techniques. Details of this process are disclosed in U.S. Pat. No. 2,465,319 to Whinfield and Dickson. Various inert additives, such as slip additives, are generally added during the process to adapt the polyester for its intended commercial use as a packaging film, fiber, electrical insulator, molded article, etc.
Considerable waste is generated as the polyester is manufactured into commercial form. For instance, edge trim, slitting trim, and reject material is accumulated as polyethylene terephthalate is extruded, biaxially stretched, and slit into film widths desired by customer industries. The industry has proposed a variety of processes for reclaiming these wastes in order to conserve resources and eliminate ecological problems associated with waste disposal.
One proposal has been to (1) degrade the polyester wastes with the glycol used in making the polyester to prepare dihydroxyalkyl/terephthalate, followed by (2) reacting the degraded wastes with a monohydric alcohol to convert the terephthalic acid values to dialkyl terephthalate. The dialkyl terephthalate, when recovered, would be recycled to prepare fresh polyester.
East German Pat. No. 69,500, for instance, discloses a waste recovery procedure wherein (1) polyethylene terephthalate is degraded with ethylene glycol, and (2) the degraded product is reacted with methanol in the presence of an ester exchange catalyst under superatmospheric pressure and at an elevated temperature to prepared solution containing dimethyl terephthalate. After the release of the superatmospheric pressure, the solution is cooled to crystallize dimethyl terephthalate which is then recovered using a centrifuge.
Although the glycol-degradation step disclosed in the German patent is satisfactory, the methanol ester exchange and recovery steps are not readily adapted for continuous commercial operation. Cooling of the solution to crystallize dimethyl terephthalate causes a substantial heat loss since excess methanol contained in the solution must be reheated for recycle. Also, the recovered dimethyl terephthalate contains occluded contaminants which detract from the properties of polyester made therefrom, inert additives present in the wastes, and some of the ester exchange catalyst. Presence of these materials complicates quality control in manufacture of polyester made from recovered dimethyl terephthalate. Moreover crystallization recovery techniques are better adapted to a batch process than the more desirable continuous process.
Thus, there is a need for an improved process and apparatus for preparing dialkyl terephthalate from glycol-degraded polyester wastes. Especially desirable is apparatus which can readily be integrated in a continuous commercial polyester waste recovery operation.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides apparatus for conducting a continuous chemical reaction in the liquid state under pressure, while maintaining internal recycle of the more volatile liquid present. The apparatus comprises:
1. a closed reaction vessel with an upper reaction zone and a lower reboiler zone, said reaction zone having an entrance port for reactants and said reboiler zone having an exit port for reaction product;
2. a perforated barrier plate mounted in the reaction vessel to separate said reaction zone from said reboiler zone;
3. liquid level sensing means mounted in said reaction zone to detect the level of liquid reactants therein;
4. a conduit by-passing the perforated barrier plate to transport liquid from said reaction zone to said reboiler zone;
5. control means mounted in said by-pass conduit responsive to said reaction zone liquid level sensing means to maintain liquid in the reaction zone at a predetermined level;
6. liquid level sensing means mounted in the reboiler zone to detect the level of liquid therein;
7. a conduit to remove liquid product from the reboiler zone having mounted therein control means responsive to said reboiler liquid level sensing means, maintaining liquid in the reboiler zone at a predetermined level; and
8. heating means to maintain liquid in said reboiler zone at a higher temperature than liquid in said reaction zone.
DESCRIPTION OF THE DRAWING
The drawing is a vertical view, in partial section, of a chemical reactor useful for converting glycol-degraded waste to dialkyl terephthalate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The reaction zone is a right cylinder section of the closed vessel, 40, and is provided with an entrance line, 42, mounted in the upper portion thereof for the introduction of reactants, and an injection nozzle, 46, mounted in the lower portion thereof for the introduction of catalyst sequestering agent. A hemispherical top, 41, is provided having a port for the continuous removal of vapors, primarily methanol, from the vessel. The vapors are continuously fed to a condensor, COND, by line 43, wherein the vapors are condensed. Liquid from the condensor is continuously returned to the vessel by line 44.
A purge line (not shown) is installed in condenser vapor line 43. The purge line has a pressure relief valve to control column temperature and pressure, providing smooth continuous operation in the case of feed fluctuations and preventing undue buildup of inert gases in the condenser recycle loop and vapor space above the reaction zone. A typical control valve setting is 500 psi. The column pressure, and temperature, equilibrates at the control valve setting, resulting in a small flow of vapors in the purge line when the feed fluctuates or inerts accumulate.
Perforated trays, 45, baffles, or other structures having a suitable design to impede downward flow of reactants and to promote liquid-vapor contact, without being plugged by solids present in the glycol-degraded wastes, are mounted in the reaction zone. Preferred perforated trays, shown in the enlargement, have a lip which extends below the tray, and the holes are sized small enough to impede downward flow of liquids through the holes but large enough to permit upward flow and bubbling of vapors through the holes. In this design the lip serves to trap vapor beneath the tray, restricting the upward flow of vapor to passage through the perforated tray. Trays having holes of about 0.25 inch diameter on a 1.25 inch triangular spacing are suitable under the operating conditions described hereinafter for the preparation of dimethyl terephthalate.
The reboiler zone forms the bottom section of the closed vessel. This zone is constructed to have a large surface area for transfer of heat into liquid contained therein, and to contain a limited volume of liquid so that residence time in the reboiler zone is short enough to minimize reactions between dimethyl terephthalate and other constituents of the liquid.
In the embodiment shown in the drawing, the reboiler zone is defined by a right cylinder section 47 of smaller diameter than the reaction zone wall 40, a truncated conical section 48 which connects the walls of the reaction and reboiler zones, and a hemispherical bottom section 49 having an exit port which communicates with line 50 for removal of product from the closed vessel. The reboiler zone is internally heated by immersed heated tubes (not shown).
A perforated barrier plate 51 is mounted in the closed vessel below the lowest tray 45 and extending across the entire cross-section area of the vessel. This barrier plate divides the vessel into the reaction and reboiler zone. The perforations are sized small enough to prevent any substantial liquid flow through the barrier plate, but large enough to permit upward flow of vapors from the reboiler to the reaction zone. A barrier plate having 0.25 inch diameter holes on a 2.25 inch triangular spacing is suitable under the operating conditions described herein for the preparation of dimethyl terephthalate.
A by-pass conduit, 52, is provided which communicates with an exit port located in the reaction zone above the barrier plate and with an entrance port located below the liquid level in the reboiler zone. Mounted in the by-pass line is a control valve, 53, responsive to a float, 54, mounted in the reaction zone to maintain a constant liquid level in the reaction zone. The by-pass line presents a sufficient liquid head to prevent reverse flow of liquids from the reboiler to the reaction zone. If necessary, a pump or other means can be installed in the by-pass line to ensure that liquid only flows from the reaction zone to the reboiler zone. A predetermined liquid level is maintained in the reboiler zone by a control valve, 55, mounted in line 50 for the withdrawal of liquid. This valve is responsive to a level sensing device, 56, such as a manometer, which detects the reboiler liquid level.
In operation, premixed ethylene-glycol degraded polyethylene terephthalate waste, methanol, and zinc acetate are heated to 190° to 230°C. and then pumped to the vessel through line 42. The feed contains a sufficient amount of methanol to maintain a stoichiometric excess in the reaction zone, generally a weight ratio of at least 2 to 1, preferably at least 3 to 1, methanol to glycol-degraded waste. The feed contains about 200 ppm by weight of zinc acetate catalyst, based on weight of the glycol-degraded waste.
Pressure of the reaction zone is maintained substantially at the partial vapor pressure of methanol in the reaction zone to prevent any significant quantity of methanol feed from evaporating. The pressure is controlled by a valve in the purge line as discussed hereinbefore. In the reaction zone dimethyl terephthalate and ethylene glycol are formed by ester exchange between methanol and the glycol-degraded waste.
The liquid reaction solution slowly passes downward through the reaction zone, by passage through spaces between the perforated trays. At a point in the lower region of the reaction zone where the ester exchange has reached the desired degree of completion (e.g., when about 90% or more of the terephthalate values in the feed solution have been converted to dimethyl terephthalate), the solution comes into contact with a catalyst sequestering agent, typically phosphoric acid, introduced through line 46. At this point the catalyst is deactivated and methanol can be removed from the solution without significantly reversing the ester exchange reaction.
After the catalyst has been deactivated, the hot solution is withdrawn from the reaction zone and introduced to the reboiler zone through line 52. The reboiler zone is heated to a temperature sufficiently higher than that of the reaction zone to evolve methanol vapor having a pressure high enough to overcome resistance to upward vapor flow presented by the liquid head, superatmospheric pressure, and trays in the ester exchange column. Methanol vapors continuously pass through the barrier plate and bubble upward through liquid in the reaction zone, continuously agitating the liquid, and into the vapor space at the top of the vessel. Ascending vapors, as they pass through the reaction zone, collect beneath the trays, 45, and are redispersed as bubbles by passing through the tray perforations.
Ethylene glycol and other vapors evolved in the reboiler also pass through the barrier plate but are condensed as they rise through the reaction zone. Condensation primarily occurs in the lower region of the reaction zone and does not affect the ester exchange dimethyl terephthalate yield to any significant extent.
Pressure in the vapor space at the top of the vessel is maintained substantially at the partial vapor pressure of methanol at the reaction zone temperature so that significant quantities of methanol are only evolved in the reboiler zone; i.e., methanol is evaporated after the ester exchange catalyst has been deactivated. Vapors at the top of the column, primarily methanol, exit the vessel through line 43, are condensed, and are returned to the vessel by line 44.
The reaction zone is typically maintained at 200°C. and at a pressure of about 500 to 550 psia, with liquids in the reboiler zone being heated to 220° to 230°C. Under these conditions, and employing about a 60 minute holding time in the reaction zone and up to a 10 minute holding time in the reboiler zone, dimethyl terephthalate yields up to about 87% or more of the theoretical yield are obtained while reducing the methanol content in the solution by up to about 70% or more.
Hot solution withdrawn from the reboiler zone by line 50 contains dimethyl terephthalate, residual methanol, diethylene glycol, ethylene glycol, catalyst residues, solids introduced with the wastes, and small quantities of uncompletely reacted wastes and condensation by-products. Dimethyl terephthalate is conveniently recovered from the solution by, in sequence, distilling off the residual methanol, removing the solids using sedimentation, filtration or centrifugation techniques, distilling off the aliphatic components, and distilling off dimethyl terephthalate from the remaining solution. The process disclosed and claimed in copending, coassigned application Ser. No. 442,910 of R. M. Currie et al. filed herewith for Polyester Waste Recovery, incorporated herein by reference, can be used for recovery purposes.
The apparatus of this invention reduces the methanol feed requirements since it provides for internal methanol recycle, and conserves heat since the methanol is recycled at an elevated temperature. Moreover, the apparatus permits process flexibility in that it can accommodate waste containing various additives and is readily integrated in a continuous waste recovery operation. The process can be used to recover terephthalate values from textile or film wastes, as well as from polyester articles returned for recycle. For example, polyethylene terephthalate articles, such as used bottles, can be collected and transported to a central location where they can be glycol-degraded to serve as feed to the polyethylene terephthalate manufacturing process.
While the apparatus has been described in detail with respect to the conversion of polyester wastes, it will be understood that the apparatus may be equally useful in other processes to achieve internal recycle of at least a portion of the more volatile reactants, or solvents, present. | Apparatus for conducting a continuous, pressurized liquid-state reaction while maintaining internal recycle. The apparatus has a perforated barrier plate which separates a reaction zone from a reboiler zone and has a by-pass conduit which connects these two zones. Control devices maintain the liquid levels in the reaction and reboiler zones. A heater in the reboiler zone evolves vapors in that zone, which vapors return to the reaction zone through the perforated barrier plate. | 8 |
BACKGROUND OF THE INVENTION
Meat skinning machines characteristically include a frame which includes a meat supporting surface, a cylindrical gripping roll with a plurality of teeth on the outer surface thereof, and a blade holding device which maintains a cutting blade closely adjacent the teeth of the gripping roll. The meat, fish or poultry to be skinned is moved into contact with the teeth of the gripping roll which pulls the meat into engagement with the cutting edge of the blade. The blade severs the skin of the meat product whereby the separated skin is pulled underneath the blade by the gripping roll, and the skinned meat product passes over the top of the blade to a suitable receptacle.
The thickness of the skin or layer of material to be removed from the meat product in conventional skinning machines has heretofore been varied by adjusting the position of the cutting edge of the blade with respect to the teeth of the gripping roll. Thus, when the cutting edge is positioned closely adjacent the cutting teeth a thinner layer is removed from the meat product. Conversely, when the cutting edge is spaced further from the periphery of the gripping teeth of the gripper roll a thicker layer of skin and/or fat is removed from the meat product.
While great advances have been made in skinning machines over the years, the precision at which skin or membranes are removed from meat products has been less than perfect. Obviously, valuable meat products are wasted if too much material is removed, and the quality of the meat product is depreciated if less than the desired skin or membrane is removed.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides an elongated shelf means immediately adjacent the cutting edge of the blade with the shelf means extending radially beyond the periphery of the gripping roll to support the meat product until just prior to the time when the meat product moves into contact with the cutting edge of the blade. The shelf means permits the meat product to then move in an angular direction towards the gripping roll and into contact with the cutting edge of the blade to permit the cutting edge to separate the membrane or skin from the meat product. The separated skin or membrane will engage the teeth of the gripping roll to be pulled away from the cutting edge by these teeth in a path between the cutting blade and the teeth. Variations in the depth of cut of the cutting blade are achieved by varying the distance between the shelf means and the cutting edge of the blade. A greater distance creates a deeper cut, and a close spacing results in a thinner cut.
The shelf means of this invention is presented in several embodiments. The first embodiment includes conventional skin stripping elements having a base portion and an arcuate open hook portion having a peripherial edge, with the hook portion being received into an annular groove cut in the gripping roll. A meat supporting edge extends radially beyond the outer peripheral surface of the hook portion. When a plurality of the stripper elements are placed in a plurality of annular groove in the gripper roll, the protruding meat supporting edges on the stripper elements provide the supporting shelf means of this invention.
Alternate forms of the invention provide the supporting shelf mounted on the frame of the skinning machine independent of any stripper elements. The second embodiment has a plurality of meat supporting fingers which extend into the annular grooves of the gripping roll in a position closely adjacent the cutting edge of the cutting blade to provide the necessary shelf means. A third embodiment with either fingers or of solid construction is positioned similarly except that it is positioned beyond the periphery of the teeth of the gripping roll and allows a gripping roll without annular grooves to be utilized.
The above-described stripping elements and shelf means are adjustably mounted so that the distance between the shelf means and the cutting edge of the blade can be selectively varied.
The method of this invention contemplates the support of the meat product immediately adjacent the cutting edge of the blade at a position radially beyond the periphery of the gripping roll to support the meat product until just prior to the time that the meat product moves into contact with the cutting edge to permit the meat product to move in an angular direction towards the gripping roll and into contact with the cutting edge to permit the blade to separate the membrane from the meat product. The separated membrane will then engage the teeth and be pulled away from the cutting edge by the teeth in a path between the cutting blade and the teeth.
A principal object of the invention is to provide a skinning machine which will more accurately and efficiently allow a predetermined amount of skin or membrane to be removed from a meat product.
A further object of the invention is to provide a skinning machine that provides a support means for the meat product at a location immediately adjacent the cutting edge of the cutting blade at a location beyond the periphery of the teeth of the gripping roll to allow the meat product to move in an angular direction into contact with the cutting edge whereby the blade will remove the desired skinner membrane from the meat product and the separated skin will be pulled by the teeth of the gripping roll into a path between the blade and the roll.
A still further object of this invention is to provide a skinning machine that can be easily adjusted to vary the space between the meat supporting shelf and the cutting edge of the blade to achieve variations in the thickness of the skin or membrane being removed from the meat product.
A further object of this invention is to provide a method of skinning meat products whereby the meat is supported closely adjacent the cutting edge of the cutting blade in a position beyond the periphery of the teeth of the gripping roll, and whereby the meat product is then permitted to move in an angular path towards the cutting edge of the blade whereby the blade can separate the skin or membrane from the meat product and the teeth of the gripping roll can pull the separated skin or membrane away from the cutting edge.
A still further object of this invention is to provide a stripper element for a meat skinning machine which will have a meat supporting edge at one end of an arcuate open-ended hook portion which, when assembled with other stripper elements in the spaced annular grooves of a gripping roll, will provide a meat supporting surface immediately adjacent the cutting edge of the blade.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the meat skinning machine of this invention;
FIG. 2 is an enlarged scale sectional view through the gripper roll of the skinning machine of this invention, and shows the stripper elements and meat supporting edges associated therewith;
FIG. 3 is an enlarged scale view of the upper portion of FIG. 2;
FIG. 4 is an enlarged scale view of the upper portion of FIG. 2, but with the stripper elements in an adjusted position to create a greater space between the meat supporting edges of the stripper elements and the cutting edge of the blade;
FIG. 5 is a plan view of a gripper roll of this invention with the stripper elements of FIGS. 2-4 inserted in the annular grooves therein;
FIG. 6 is a sectional view through an alternate form of the invention wherein a shelf means having a plurality of fingers inserted into annular grooves of the gripping roll are positioned to provide a meat supporting surface immediately adjacent the cutting edge of the blade;
FIG. 7 is a partial perspective view of the shelf means of FIG. 6; and
FIG. 8 is a sectional view similar to that of FIG. 6 but showing a third embodiment of the invention where the shelf means is supported at a position beyond the periphery of the teeth of the gripping roll.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The term "meat product" as used herein will be understood to include meat, poultry and fish products. The terms "skin" and "membrane" will be used synonymously herein unless specifically designated otherwise.
With reference to FIGS. 1 and 2, the machine 10 is generally comprised of a frame 12 having supporting legs 14. An upper meat support surface 16 is located on the upper portion of frame 12, and a second meat support surface 18 is provided on the top of frame 12 opposite to meat support surface 16. A conventional toothed gripping roll 20 is rotatably mounted by conventional means on frame 12. Gripping roll 20 can have conventional annular grooves 22 cut therein as best seen in FIG. 5. A plurality of teeth 24 are cut on the outer surface of roll 20. A shelf means 26 (FIG. 1) is positioned on the machine in a position parallel to grippng roll 20 and positioned slightly over the gripping roll. A conventional blade holder 28 is mounted on the machine and holds conventional cutting blade 30 having a cutting edge 32 at a position closely adjacent the teeth 24 on roll 20.
The first embodiment of the invention is best shown in FIGS. 1-5 and includes a plurality of stripper elements 34 which have a base portion 36 and an arcuate open hook portion 38 extending from the base portion. The hook portion 38 has an upper peripheral surface 40 which terminates in a meat support edge 42. The hook portion 38 is complementary in shape to the annular groove 22 and has a vertical thickness such that the upper peripheral surface 40 dwells at a position radially inwardly from the outer tips of teeth 24. However, as clearly shown in FIGS. 2, 3 and 4, the meat support edge 42 dwells in a plane radially beyond the tips of the teeth 24. When the support edges 42 of a plurality of stripper elements 34 are mounted in a plurality of annular grooves 22 of a gripping roll 20, a collective shelf 26 is formed to support a meat product at a position beyond the outer periphery of the teeth 24 of roll 20.
As shown in FIG. 2, a shaft 44 extends through a suitable aperture in each of the stripper elements 34 in a direction parallel to the axis of gripper roll 20. Lugs 46 are mounted on the ends of shaft 44 and the inner ends of threaded bolt 48 are rotatably journaled in any convenient fashion with lugs 46. Aperture 50 in frame member 12A slidably receives the threaded bolt 48. Lock nut 52 is threadably mounted on bolt 48 and control knob 54 is mounted on the outer end of bolt 48.
The pivotal position of stripper element 34 is changed from the position shown in the solid lines of FIG. 2 to the position shown by the dotted lines merely by grasping knob 54, pulling bolt member 48 outwardly so that shaft 44 moves from position A to position B, and lock nut 48 is then rotated to a position adjacent frame member 12A to hold the shaft 44 in this adjusted position. This rotation of stripper element 34 causes the support edge 42 to move from a closely spaced position with respect to the cuttng edge 32 of blade 30 (FIG. 3) to a greater spaced position as shown in FIG. 4. The position illustrated in FIG. 3 of these components is better adapted to strip the thin membrane of steak or the like from the steak, and the greater space illustrated in FIG. 4 is better suited to strip heavier skin from chicken or other poultry products.
A second embodiment of the invention is shown in FIG. 6 wherein a conventional meat conveying device 56 is utilized in place of the meat support 16. A shelf 58 is positioned on the machine adjacent the cutting edge 30 of blade 32. Shelf 58 includes a solid base portion 59 which terminates in a plurality of spaced apart fingers 60. Fingers 60 have an upper meat support edge 62 similar to the meat support edge 42 on stripper element 34. The fingers 60 are received in the grooves 22 of roll 20 but the meat support edges 62 of fingers 60 extend radially outwardly beyond the periphery of the teeth 24 of roll 20.
An elongated slot 64 appears in the base 59 of shelf 58 and receives adjustment screw 65 which is threadably mounted in frame member 66. Frame member 68 has a suitable vertical aperture to slidably receive threaded bolt 70 which has its upper end rotatably journaled by any convenient means in frame member 66. A lock nut 72 is threadably mounted on bolt 70, and knob 74 is located on the lower end of bolt 70.
Shelf 58 can be moved laterally towards or away from blade 30 by loosening screw 65 and moving the shelf to the desired position whereupon screw 65 is tightened to maintain the new position. Similarly, shelf 58 can be raised or lowered by adjusting the lock nut 72 on bolt 70 and moving bolt 70 upwardly or downwardly to move frame member 66 and shelf 58 upwardly or downwardly. Frame member 66 is movably mounted by any convenient means on frame 12. Thus, the adjustment of frame 58 in a horizontal or vertical direction can be easily implemented.
A third alternate form of the invention is shown in FIG. 8. The structure of FIG. 8 is similar to that of FIG. 6, except that a shelf 76 is attached to frame member 66 at a position beyond the periphery of the teeth of gripping roll 78. Shelf 76 has an upper meat support edge or surface 80 which can be either of solid and continuous construction, or can be divided into a plurality of fingers similar to the fingers 60 on shelf 58. Shelf 76 can be utilized in the position shown in FIG. 8 either with a solid roll 78 having continuous teeth 24A, or a roll similar to gripping roll 20 utilizing conventional stripper elements without the support edge 42 which comprise a part of stripper element 34.
The normal operation of the device of FIGS. 1-5 involves the adjustment of the desired spacing between the support edge 42, and the cutting edge 32 of blade 30. See the variations in this spacing between FIGS. 3 and 4.
The meat product is moved from left to right on meat support surface 16 as seen in FIGS. 2-4 and as the meat product leaves the surface 16 it is supported on the edges 42 in a position radially beyond the teeth of gripping roll 20. As the meat product moves past the forward edge 82 of support edge 42, it moves instantaneously in an angular direction downwardly towards the teeth of gripping roll 20. The meat is instantaneously engaged by the cutting edge 32 of blade 30, and the membrane or skin 84 is gripped by the teeth 20 and pulled downwardly between the teeth and the blade 30 as it is separated from the meat product 86. This phenomenon is best shown in FIGS. 3 and 4.
This angular "bite" that the structure of this invention creates is afforded by the meat support edges 42 which dwell beyond the outer periphery of the teeth 24 on gripping roll 20. Unlike prior art skinning machines, the meat product is not gripped and supported on the teeth of the gripping roll as the meat product moves into position with respect to the cutting blade of the machine.
The shelves 58 and 76 in the embodiments shown in FIGS. 6, 7 and 8 function similar to the device of FIGS. 2-5 in that the shelves 58 and 76 both provide a meat support surface beyond the periphery of the teeth of the respective gripping rolls to support the meat product until it is closely positioned with respect to the cutting edge 32 of the blade 30. The positions of the shelves 58 and 56 can be moved towards or away from the cutting edge 32 and can be raised or lowered vertically as required. Again, a close spacing of the shelves with respect to the cutting edge of the blade results in the removal of a thinner layer of material from a meat product, and a wider space results in a thicker layer of material being removed from the meat product.
From the foregoing, it can be seen that this invention achieves at least its stated objectives. | A meat skinning machine and method for skinning wherein a shelf means is adjustably positioned between a meat support surface and the cutting edge of a skinning knife just beyond the periphery of the teeth of a gripping roll wherein the meat is supported immediately adjacent the cutting edge at a position beyond the periphery of the gripping roll just prior to the time the meat moves into contact with the cutting edge to permit the meat to move in an angular direction towards the roll and into contact with the edge. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Serial No. 60/442,622, filed Jan. 27, 2003, entitled “Grilling Oven”.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an improved grilling station having a plurality of identical improved grilling ovens particularly adapted for use in a food preparation environment, such as, a commercial restaurant or the like.
[0003] A problem frequently encountered in the operation of a commercial food preparation facility, such as a restaurant revolves around grilling foods. In a typical restaurant environment, a grill or broiler is used to cook foods such as steak, fish and chops. The steak is placed on the grill and the grilling person turns the steak after a period of time. The steak is then removed after a time to produce the steak with the desired amount of cooking, such as, rare, medium rare, medium, medium well, or well done. The degree of cooking of the steak is in great part dependant upon the experience, skill, ability, mood and judgment in particular of the grilling person.
[0004] As a further example, should an order come into the kitchen for several steaks, one or more of which is to be well done, one or more of which is to be rare, one or more of which is to be medium, and one or more of which is to be medium well, the grilling person must place the steaks on the grill at different times, stagger the times that the steaks are on the grill for turning and for removal from the grill. Failure of the grilling person to monitor the cooking time of each of the steaks may result in one or more of the steaks being overcooked or undercooked. In the event that a steak is overcooked or undercooked and delivered at a temperature that is not desired when the steak is overcooked or undercooked, the customer is dissatisfied and the steak is sent back to the kitchen which disrupts the operation of the kitchen. Service is disrupted at the table. In addition, the restaurant may have steaks which may not be readily sold and a dissatisfied customer.
[0005] It is an object of the present invention to provide a grilling station having a plurality of individual locations to grill individual foods, such as, steaks, to produce food which is cooked a proper amount of time. In addition, the food is grilled on the top and the bottom at the same time to eliminate the need for turning of the food. Furthermore, an indicator light is provided with each unit which indicates that the cooking for a particular unit has been completed. It follows that if it is not necessary for a grilling person to watch food on a grill. Thus, an experienced grilling person is not required, thereby effecting an economy in the labor rate. It is a further object to provide an improved grilling oven heated electrically so that the electricity may be interrupted when the oven is not is use to effect economy in operation. An additional object of the present invention is to provide a grilling oven wherein food may be easily loaded onto the grill and easily removed therefrom. The unit will also operate with the upper grill raised for use of cooking fish or melting cheese or other foods above burgers, steaks, or the like. Other objects and uses of the present invention will become readily apparent to those skilled in the art upon perusal of the following specification in light of the accompanying drawing.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is an improved grilling station for grilling a variety of foods simultaneously. The station includes a plurality of individual grilling ovens. Each of the ovens has a housing with an opening in the housing for loading food into the respective housing. Each oven has a first grilling unit for supporting food in the respective housing. Each grilling oven also includes a second grilling unit positionable above the respective first grilling unit and being movable relative to the first grilling unit. A control assembly is connected to the grilling units to determine selectively the length of time energy is supplied to the grilling units in each of the individual ovens to provide a separate grilling time in each of the grilling ovens.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0007] [0007]FIG. 1 is a perspective view of a grilling station embodying this invention, in this instance, the station having six individual grilling ovens with a control assembly connected to the grilling ovens for regulating the grilling time in each of the ovens;
[0008] [0008]FIG. 2 is a perspective view of a portion of one of the grilling ovens of FIG. 1 with a top removed and shown in an open attitude for loading or unloading food in the oven, and a fillet positioned on a first grilling unit;
[0009] [0009]FIG. 3 is a side elevational view of a portion of the grilling oven of FIG. 2 showing the door in an open attitude and a fillet resting on a first grilling unit, a portion of a regulator is shown broken away to show the interconnection between a slotted link and a stud on a lower platen;
[0010] [0010]FIG. 4 is a side elevational view of the grilling oven of FIG. 3 but with the door shown in a closed attitude with a fish on the first grilling unit and a regulator holds a second grilling unit spaced away from the fillet;
[0011] [0011]FIG. 5 is a side elevational view of the grilling oven of FIG. 2 with the door closed, but the regulator not connected to the second grilling unit, but rather the second grilling unit resting on a fillet; and
[0012] [0012]FIG. 6 is a front elevational view of the control assembly in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring now to the drawings, and especially FIG. 1, a grilling station 8 is shown therein including six improved individual grilling ovens 10 , 12 , 14 , 16 , 18 and 20 enclosed in a cabinet 21 . The construction of each of the grilling ovens is identical to each other grilling oven. The station includes a control assembly 24 which is electrically connected to each of the grilling ovens to deliver electrical energy to each of the individual grilling ovens and to regulate the time of heating of each of the grilling ovens.
[0014] Grilling ovens 10 and 12 have a common grease tray 26 , and grilling ovens 16 and 18 have a common grease tray 28 . Grilling ovens 14 and 20 have individual grease trays 30 and 32 , respectively. The grease trays collect grease generated by cooking in the ovens and are connected to the troughs to receive grease from the troughs.
[0015] Referring now to FIG. 2, grilling oven 18 is shown therein with the top removed in order to show better the construction of the oven. Grilling oven 18 includes a housing 34 with an opening 36 on one side. A hinged door 38 is pivotally connected to the housing for selectively closing opening 36 . Hinged door 38 includes a face portion 40 with a handle 42 connected thereto. Face portion 40 is hingedly connected to yolk 44 , which is an integral portion of housing 36 . Door 38 has a inner panel 46 with elongated ears 48 and 50 formed integral therewith.
[0016] Referring now to FIG. 3, one side of a mechanism interconnecting door 38 with an upper grilling unit 52 and a lower grilling unit 54 is shown therein. Upper grilling unit 52 includes a grooved platen 56 with a serpentine electric heating unit 58 in thermal engagement with the platen. The electrical heating unit 58 is electrically connected by cables 59 to a source of electric power through the control assembly 24 . In like manner, the lower grilling unit 54 includes a grooved platen 60 with a serpentine electric heating unit mounted on the lower side of the platen and having its construction identical to electrical heating unit 58 . The electrical heating unit connected to platen 60 is thermally connected thereto and is electrically connected to the control assembly through cables 61 .
[0017] Ear 50 has an elongated link 62 connected at one end through a pin 64 . The other end of link 62 is connected to a bowed lever 66 through a pin 68 on one end of the bowed lever. Lever 66 pivots on an axle 70 which axle is mounted on housing 34 . As may be seen in FIG. 3, lever 66 has a roller 72 mounted on a roller axle 74 at the end opposite to the end connected to link 62 . Roller 72 is rotatably mounted in a track 78 connected to one side of platen 56 . A slotted link 80 has one end connected to ear 50 through a pin 82 . Slotted link 80 includes a slot 84 at the opposite end. A stud 86 connected to platen 60 is slidably mounted in slot 84 . The lower platen 60 is mounted on a support 88 which is rotatably supported on a rail 90 .
[0018] It may be appreciated that only one side of the interconnected linkage between the door and the platens has been described in detail above. The linkage on the other side of the door and the platens is a mirror image of the linkage described above.
[0019] Brackets 92 and 94 are secured to platen 56 . Each of the brackets 92 and 94 has an identical roller 96 rotatably mounted thereon. Rails 98 and 100 which are parallel to each other and mounted on the housing, as seen in FIG. 2. A second pair of rails 102 and 104 identical to rails 98 and 100 is mounted on the housing opposite to respective rails 98 and 100 .
[0020] A manual control regulator 106 includes a lever 108 which is mounted on a pivot 110 supported by the housing. The regulator has a handle 112 for moving lever 108 about pivot 110 . Lever 108 includes an ear 114 which is engageable with a control flange 116 mounted on platen 56 . It may be appreciated that the position of regulator 106 determines the amount that platen 56 may move toward the lower grilling unit 54 thereby determining the spacing between the upper and lower grilling units.
[0021] The control assembly 24 is a well known and conventional control assembly for controlling the length of time that electricity flows to the heating elements of each of the grilling ovens. The face of the control assembly is shown in FIG. 6. The controls for each grilling oven are in line. Each of grilling ovens 10 , 12 , 14 , 16 , 18 and 20 is identified by number in tags 118 , 120 , 122 , 124 , 126 and 128 , respectively. Readout windows 130 , 132 , 134 , 136 , 138 and 140 are positioned adjacent to tags 118 , 120 , 122 , 124 , 126 and 128 , respectively. Set time switches 142 , 144 , 146 , 148 , 150 and 152 are positioned adjacent to respective readout windows 130 , 132 , 134 , 136 , 138 and 140 . Stop clear switches 154 , 156 , 158 , 160 , 162 and 164 are positioned adjacent to respective set time switches 142 , 144 , 146 , 148 , 150 and 152 . Start switches 166 , 168 , 170 , 172 , 174 and 176 are positioned adjacent to the stop clear switches 154 , 156 , 158 , 160 , 162 and 164 , respectively. A well-known and conventional keypad 178 is positioned below the switches for entering cooking times for each of the individual ovens.
[0022] Signal lights 180 , 182 , 184 , 186 , 188 and 190 are mounted in each housing for grilling ovens 10 , 12 , 14 , 16 , 18 and 20 , respectively. Each of the signal lights is connected to the control assembly for its respective oven.
[0023] When a selected oven is put into use, the stop clear switch for that oven is actuated, which clears the circuit and extinguishes the signal light for the oven. Next, that oven's set time switch is actuated to allow acceptance of a time from the keypad. Keypad 178 is used to set the numerical number of minutes that electrical energy is to be supplied to the grilling units for the selected oven. The selected time in minutes is displayed on the respective readout window to allow the grilling person to determine whether the proper time for grilling has been keyed into the times through a conventional time circuit. The start switch is actuated so that a conventional timer in the timer circuit for the oven closes the circuit to allow energy to flow to the grilling units in the oven. Upon expiration of the selected time, the flow of energy to the grilling units is interrupted by the timer circuit and the respective signal light is actuated to indicate that the grilling is complete.
[0024] The use of grilling oven 18 is described below, however each of the other ovens operates in a like manner. Hinge door 38 is pulled down to open the grilling oven. Downward pivoting of the hinge door moves the slotted link 80 . The initial movement of the slotted link causes the slot 84 to slide on stud 86 until the stud engages the oven end 192 of the slot. Then, the stud firmly engages the link to move the lower grilling unit partially into the opening for the grilling oven. Simultaneous with the movement of the lower grilling unit, pivoting of door 38 pulls elongated link 62 into the opening which causes lever 66 to pivot about axle 70 and swing roller 74 upward thereby pushing the upper grilling unit upward away from the lower grilling unit. It may be appreciated that initial movement of the hinge door has no effect on the movement of the lower grilling unit in view of the fact that the length of slot 84 must slide past stud 86 before there is any movement of the lower grilling unit. Thus, there is an initial vertical movement of the upper grilling unit away from the lower grilling unit before there is horizontal movement of the lower grilling unit.
[0025] Once door 38 is open, the grilling oven may be loaded. Referring now to FIG. 2 by way of example, a beef fillet 194 is positioned on platen 60 of lower grilling unit. Door 38 is pivoted upward to close the door. The upward pivoting of door 38 moves the slotted link 80 causing slot 84 to slide on stud 86 until the stud engages the door end 196 of slot 84 . Further pivoting of the door with the stud in engagement with the door end of the slot causes the lower grilling unit to move into the housing. The upward pivoting of door 38 pushes elongated link 62 into the housing pivoting lever 66 about axle 70 to lower roller 74 which allows the upper grilling unit to drop down by the force of gravity. The upper grilling unit drops down until it rests on top of fillet 192 as shown in FIG. 5.
[0026] It may be appreciated that it is desirable for the upper grilling unit to engage the upper surface of certain foods, such as, a beef fillet. However, other foods, such as, fish, may not withstand the weight of the upper grilling unit. A fish 198 is shown in FIG. 4 resting on the lower grilling unit. The descent of the upper grilling unit toward the lower grilling unit is controlled by regulator 102 . The cook or grilling person simply moves regulator 102 until the ear of the regulator is in a position to engage flange 78 and thereby prevent the upper grilling unit from coming into engagement with fish 198 .
[0027] Irrespective of whether the upper grilling unit comes in contact with the food to be cooked or not, it is only necessary for the grilling person to first press the stop clear switch 162 to clear the time circuit, then press the set time switch 150 to activate the time. The grilling person then punches the numerical time on the keypad 178 which is displayed in the window 138 . Once the appropriate numerical time is set, start switch 174 is pressed to start the timer and connect the upper and lower grilling units to the source of electrical energy to be heated by their respective heating elements. Upon expiration of the time selected, the timer interrupts the flow of electricity to the heating elements and energizes signal lamp 188 to indicate that the cooking cycle is completed. Door 38 is opened and the food is removed from the grilling oven. Any grease that is generated by the cooking operation flows from the platen to a grease trough 200 positioned below and adjacent to the oven end of the platen. The grease flows from the trough to the grease tray 28 which may be readily removed for cleaning.
[0028] It may be appreciated that with the instant station six different grilling times may be utilized, and it is not necessary for the grilling person to keep in mind which grilling oven is used for what purpose. The present arrangement reduces the opportunity for making an error by leaving the food too long on a grill, inasmuch as a time is selected and the grilling is interrupted upon the expiration of the selected time.
[0029] Although a grilling station is shown with six grilling ovens, it is readily apparent that a grilling station may contain more or fewer grilling ovens to effect the required cooking in the amount which may be required for an establishment, such as, a restaurant.
[0030] Although a detailed description of the present invention has been described in detail above, it is readily apparent that those skilled in the art may make various modifications and changes in the instant invention without departing from the spirit and scope of the present invention. It is to be expressly understood that the instant invention is limited only by the appended claims. | A grilling station for simultaneously grilling a variety of foods. The station includes a plurality of grilling ovens. Each of the grilling ovens has a housing with an opening for loading food into that housing. A first grilling unit is mounted in each housing for supporting food. A second grilling unit is mounted in each housing positionable above each respective first grilling unit and being vertically moveable in relation to the respective first grilling unit. The first and second grilling units in each of the housings connected to a respective control assembly to determine selectively the length of time energy is supplied to the grilling units providing selective separate grilling times in each of the housings. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of light structures for manufacturing packs, panels, or any other element for absorbing impact and shock energy, sound energy, for isolating spaces from temperature, and preferably the invention relates to a process for obtaining a light structure composed of threads and microfibers, preferably employed in the ballistic field for manufacturing antitrauma ballistic jackets, armored panels and any other element for absorbing the energy of a bullet and retaining the bullet trapped into the microfiber structure, thus preventing a bullet or any other impinging objet from passing through the jacket or panel or similar element for protecting the user.
While specific reference may be made in this specification to the application of the inventive structure in the ballistic field, this structure is well applied to the temperature and sound isolation field.
2. Description of the Prior Art
It is well known to provide synthetic fibers or threads like aramids for manufacturing ballistic jackets or armored panels for armoring cars, for example. The concept employed for manufacturing this armored products were based in providing combined woven materials and resin materials strong enough and having a high resistance so as to present a solid barrier to a projectile in order to stop the projectile against a “wall” formed generally by a compact panel. The projectile generally impinges against these solid materials and deform. The excessive weight of these materials causes these armored or ballistic jackets and panels to be uncomfortable for personal use and no cost effective for use in cars.
Other jackets and panels employ the above mentioned synthetic fibers forming a mat or a plurality of mats and webs or fabrics. These webs and fabrics are woven with threads forming warps and wefts thus leaving a lot of free spaces, interstices and voids, particularly in the weft-warp crossings and, while a plurality of layers of these webs are employed to manufacture a panel or jacket, any impinging object, particularly a bullet having a sharp tip, may pierce and run through the interstices in the multi layer pack.
Both, the solid or multi layer packs, panels or jackets, do not address the penetration problem by trying to form a kind of “spider web” to receive the projectile and retain the same into the web. The several ballistic packs neither took advantage of the rotation that a projectile is provided of when shoot from a corresponding weapon. This rotation could be used for facilitating the trapping of the bullet into the pack.
It would be therefore convenient to have a convenient and light structure to manufacture any kind of ballistic jacket, armored panel and similar elements for trapping any projectile impinging on the panel or jacket and preventing the projectile from passing through the structure. It would also desirable that the structure be useful for isolating sound and temperature.
SUMMARY OF THE INVENTION
It is therefore one object of the present invention to provide a new method for manufacturing a light structure made of threads and microfibers, wherein the structure is based in a shapeless fiber-entangled mass capable of being shaped into any desired shape to form ballistic jackets, armored panels, temperature isolating panels or sound isolating panels. The entangled fibers, microfibers or threads in the structure are arranged in such aleatory and/or curling pattern that no voids, interstices or free spaces are provided for preventing any impinging projectile, sound wave or heat front passing through the structure.
It is still another object of the present invention to provide a process and apparatus for manufacturing a microfiber structure for absorbing impact energy, sound energy and/or temperature, the structure being used in the ballistic field and in the sound and temperature isolation fields, wherein the method comprises to provide a plurality of threads consisting of microfibers, subjecting the threads to a pressurized air jet to open the threads by separating the microfibers into each thread, and entangling the threads to form a mass of loosely-entangled microfibers, with the mass being confined into a pack which may be appropriately compacted.
It is even another object of the present invention to provide a process and apparatus for manufacturing a microfiber structure for absorbing impact energy, preferably from a bullet provided with rotating movement, wherein the inventive structure is formed into a fiber-entangled structure, with the fibers forming preferably curls, thus taking advantage of the rotation of the bullet and causing the bullet to be wrapped by the fibers or curls when penetrating the structure. When wrapped by the fibers the bullet increases its mass and size and it is prevented from passing through the structure.
It is a further object of the present invention to provide a process for obtaining a microfiber structure for use in absorbing at least one of impact energy, sound energy and temperature, the method comprising the steps of:
i. providing a plurality of spools containing polymeric threads, each thread consisting of microfibers;
ii. unwinding from the spools the threads and guiding the threads into a collecting-guiding means;
iii. pulling the threads from the collecting-guiding means;
iv. bringing the threads into a microfiber separating station for transversely separating the microfibers into the threads but maintaining the longitudinal continuity of the microfibers into each thread;
v. bringing the separated and spaced apart microfibers into entangling means for entangling the threads all together to form a mass of loosely-entangled microfibers;
vi. providing an outer cover all around the mass in order to confine the mass into a pack; and
vii. compacting the pack.
It is even another object of the present invention to provide an apparatus for manufacturing a microfiber structure according to the method of claim 1, the apparatus comprising,
i. a support including a plurality of spools containing polymeric threads, each thread consisting of microfibers;
ii. pulling means for pulling and unwinding the threads from the spools;
iii. collecting-guiding means for collecting the threads from the spools and guiding the threads into the pulling means;
iv. a microfiber separating station for transversely separating the microfibers into each thread and maintaining the longitudinal continuity of the microfibers into each thread; and
v. entangling means for receiving the threads with their microfibers separated in the separating station and for entangling all the threads together to form a mass comprising loosely-entangled microfibers.
It is still a further object of the present invention to provide a process for obtaining a microfiber structure for use in absorbing at least one of impact energy, sound energy and thermal energy, the method comprising the steps of:
i. providing a plurality of spools containing polymeric threads, each thread consisting of microfibers;
ii. unwinding from the spools the threads and guiding the threads into a collecting-guiding means;
iii. pulling the threads from the collecting-guiding means;
iv. bringing the threads into a microfiber separating station for transversely separating the microfibers into the threads but maintaining the longitudinal continuity of the microfibers into each thread;
v. bringing the separated and spaced apart microfibers into entangling means for entangling the threads all together to form a mass of loosely-entangled microfibers; and
vi. wrapping longitudinal portions of the mass around a core support to form a pack.
The above and other objects, features and advantages of this invention will be better understood when taken in connection with the accompanying drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example in the following drawings wherein:
FIG. 1 shows a perspective, diagrammatical view of an apparatus of the invention carrying out the inventive method for obtaining the entangled microfibres;
FIG. 2 shows a perspective, diagrammatical view of another embodiment of the entangling means to be used in the apparatus of FIG. 1;
FIG. 3 shows a cross sectional view of the microfiber structure of the invention, confined into a wrap or outer cover, before compaction;
FIG. 4 shows a cross sectional view of the structure of the invention as being compacted by a press, to form a pack;
FIG. 5 shows a cross sectional view of an application of the invention comprising a multi-layer jacket or panel formed by side by side placed packs of FIG. 4;
FIGS. 6-8 show three cross sectional views of the inventive structure in three different sequences, when a bullet is approaching the structure, when the bullet is entering the structure and when the bullet is trapped into the structure, respectively; and
FIG. 9 shows a perspective view of another application of the method of the invention for obtaining a pack with a core support;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring in detail to the drawings it may be seen from FIG. 1 that a preferred apparatus may be employed to carry out the method of the invention, for manufacturing a microfiber structure. According to the invention, the apparatus comprises a support board 1 including a plurality of spools 2 each one containing a polymeric thread consisting of a plurality of fibers or, also called microfibers. The threads and fibers employed in this invention are preferably high tensile fibers, threads, yarns, etc., such as those known in the market under the names aramid, polyester, synthetic threads, Kevlar® (aramid fibers), Twaron® (aramid fibers), Dyneema® (ultra high resistance polyethylene fibers), roving (thread fibers), Carbon and/or mixtures thereof. Each spools 2 is preferably mounted in a rotatably manner in a shaft S which in turn is connected to the support board, and shafts S may be horizontally or vertically arranged in the support.
The apparatus also comprises pulling means 4 comprising two cylinders 5 rotating in opposite directions, as indicated by the arrows at one end of the cylinders, for pulling and unwinding the threads from the spools. The cylinders may be made of any convenient material, metal or plastics, or lined by any gripping material such as rubber.
Before entering between the cylinders, the threads passes through collecting-guiding means 6 , preferably comprising a length of tube 7 provided with a plurality of transverse orifices 8 with each orifice being arranged for receiving one thread passing therethrough and for keeping the threads close to each other. Thus, the threads are collected from the spools and guided into the pulling means.
A complementary guiding sleeve 9 may be also provided to better keep together the threads before entering into a microfiber or fiber separating station 10 for transversely separating the microfibers into each thread and maintaining the longitudinal continuity of the microfibers into each thread. Station 10 preferably comprises at least one air ejecting nozzle 11 providing a pressurized air jet 12 ejected transversely to the threads exiting the pulling means. Nozzle 11 may be connected to an air compressor 13 .
The microfiber or fiber separating station may be anyone for transversely separating the microfibers into the threads but for maintaining the longitudinal continuity of the microfibers into each thread, that is, while the microfibers composing a thread are spaced apart or separated in the. separating station, such microfibers remain continuous into the thread in order to guarantee the thread continuity, resistance and strength, particularly the tensile strength.
When exiting separating station 10 , the threads present their fibers separated from each other but still integrated within the corresponding thread. Under these conditions the threads are fed into a entangling means 14 comprising at least one non abrasive rough surface, for receiving the threads with their microfibers separated in the separating station and for entangling all the threads together to form a mass comprising loosely-entangled microfibers.
The entangling means may comprise any means with a rough non abrasive surface such as a plurality of hook-shaped projections, or a plurality of nail projections. These rough surface may be provided in one or more plates as illustrated in FIG. 2 with the threads passing over one the plates or between the plates. The plates may be stationary or provided with relative movement. If two plates 17 , 18 are provided, the same should be faced to each other and close enough to receive the threads therebetween and entangling the threads through the rough surface, hook-shaped projections 19 for example, provided in their facing sides. Plates 17 , 18 may be flat as illustrated or may be curved.
According to FIG. 1, entangling means 14 preferably comprise at least two cylinders 15 and 16 rotating in opposite directions as indicated by the arrows at the ends of the cylinders. In this embodiment, cylinders 15 , 16 include respective outer non abrasive rough surfaces 20 , 21 , which surfaces are preferably comprised of projections, such hook-shaped projections or nail projections. These projections may be like the ones of plates 17 , 18 .
The term “entangling” must be understood in this specification as a generic term including the actions of carding, entangling, wrinkling, rumpling, disheveling, etc. which action has the purpose of arranging the threads and microfibers aleatory and, even loosely, accommodated into a formless, shapeless, amorphous, body or mass, with the threads and microfibers being arranged for preventing any free direct passage being formed through the body, mass or structure. The threads and microfibers are most preferably carded and entangled in a manner to form loops, curls, or ringlets. As will be explained in connection to FIGS. 6-8, these curls will be wrapped around the projectile when it enters the mass with a spinning or rotating movement as shoot from the corresponding weapon.
At the exit of the entangling station, a rolling cylinder 22 may be provided for receiving the entangled threads and for rolling up the threads or forming the threads into rolls, for storage purposes.
According to the method of the invention, the microfiber structure is manufactured by the steps of:
i. providing a plurality of spools 2 , which spools are preferably freely rotatably mounted in corresponding shafts connected to a support, with the spools containing the polymeric threads 3 , wherein each thread consists of fibers, microfibers or filaments and the threads are selected from the group comprising aramid threads, polyester threads, synthetic threads, Kevlar®, Twaron®, Dyneema®, Roving®, and mixtures thereof;
ii. unwinding from the spools the threads and bringing the threads into the collecting-guiding means 6 ;
iii. pulling the threads from the collecting-guiding means;
iv. bringing the threads into separating station 10 , thus passing the threads through pressurized air jet 12 ejected transversely to the threads from an air ejecting nozzle, therefore transversely separating the microfibers into the threads but maintaining the longitudinal continuity of the microfibers into each thread;
v. bringing the threads with their separated and spaced apart microfibers into the entangling means 14 for entangling the threads all together to form a mass 23 of loosely-entangled microfibers;
vi. providing an outer cover 24 all around the mass in order to confine the mass into a pack 25 ; and
vii. compacting the pack.
For the purposes of the present description, the term “microfiber” must be understood as encircling all kind of fibers, filaments and the like. The prefix “micro” does not refer to the fiber as being very short or short but is rather employed to refer to thinness of the fibers.
To form a pack, a determined amount of mass 23 may be wrapped into cover 24 which may comprise a laminar synthetic material, a “Kevlar” clothe, etc. Then, the pack may be compacted into a conventional press 26 , as illustrated in FIG. 4 . Alternatively, the pack may be compacted by extracting the air from the pack by means of a vacuum chamber not illustrated because it is a well know technique.
According to the inventive method, the threads may be guided only by passing through tube 7 or by passing through tube 7 , located downstream cylinders 5 , and through sleeve 9 , as illustrated in FIG. 1, for guiding all the threads intimately close to each other.
The step of bringing the threads into the entangling means may comprise passing the separated microfibers through at least one non abrasive rough surface which surface may comprise a plurality of hook-shaped projections or nail projections. The at least one surface may comprise a plate or two opposing plates, either flat or curved, or at least two cylinders including respective outer non abrasive surfaces, with the surface or surfaces being non abrasive and rough, or being provided with a plurality of hook-shaped projections or nail projections.
Once the pack is compacted, as indicated by numeral reference 27 in FIG. 4, the same may be employed to form a multi layer panel or jacket as shown in FIG. 5 . Panels may be adhered by any adhesive or any other appropriate means.
FIGS. 6-8 show three sequences of the operation of a pack of the invention when used for ballistic purposes. As it will be explained in connection to these FIGS. the entangled fiber structure of the invention operates adequately as an antitrauma ballistic panel or jacket because the bullet energy is entirely absorbed and the projectiles is retained into the structure.
As shown in FIG. 6, a bullet 28 is approaching a front face 29 of pack 27 with a spinning or rotation movement as indicated by the curved arrows. When penetrating the pack, FIG. 7, outer cover 24 is pierced and the leading tip of the bullet, which is still under rotation, enter into contact with the entangled and/or curled fibers. As a result of the rotating movement of the bullet the fibers are wrapped around the bullet and the fibers result completely retained or “adhered” to the bullet. As the bullet continues moving ahead and rotating, more fibers wrap around the bullet increasing thus the bullet size and mass, therefore trapping, stopping and retaining the bullet wrapped in the fibers mass, as shown in FIG. 7 . As may be seen, the bullet energy is entirely absorbed and not transmitted to a rear face 30 of the pack, thus preserving the life of the user of a ballistic jacket and preventing the user from any trauma. As resulted from the several tests, the bullet is finally deformed into the entangled mass and the fibers closest to the bullet body have found embedded in the bullet metal.
The following Table shows a comparative analysis between the fiber structure of the present invention and other conventional armor systems. In this Table the plates are made of steel, Local Steel, namely Argentine made steel, and Swiss made steel.
Three kinds of ammunition are analyzed, bullets that are lined or sleeved, common bullets, and bullets with a high piercing or perforating capacity.
It may be seen from the table that the inventive structure is lighter than the conventional systems for ballistic purposes.
TABLE
SPEED
THICKNESS
WEIGHT
SYSTEM
CALIBER
AMMUNITION
m/s
mm.
kg/m2
PLATE 1010
3.57
Sleeved
430
4
32
National
7.62
Common
855
19
162
7.62
Perforat.
840
25
200
PLATE 500 “S”
3.57
Sleeved
430
2
16
Armor Sweden
7.62
Common
855
7
56
7.62
Perforat.
840
15
128
ARAMID (1)
3.57
Sleeved
430
10
6
7.62
Common
855
30
55
7.62
Perforat.
840
35
77
CERAMICS
3.57
Sleeved
430
8
10
7.62
Common
855
20
65
7.62
Perforat.
840
30
85
COMPOSITE
3.57
Sleeved
430
8
8
MATERIALS (2)
7.62
Common
855
20
60
7.62
Perforat.
840
25
75
INVENTIVE
3.57
Sleeved
430
10
4
STRUCTURE
7.62
Common
855
25
31
7.62
Perforat.
840
30
40
(1) Includes Kevlar ®, Twaron ®, Dyneema ®, Spectra ®.
(2) Includes Polycarbonates.
“Perforat.” means perforating ammunition.
Still according to a further embodiment of the present invention, the step of providing an outer cover all around the mass in order to confine the mass into a pack, indicated by reference “vi” in the above disclosed method may be replaced by providing a core support such as a plate 31 illustrated in FIG. 9, made, for example, of an elastic material, such as EVA, or any other supporting material. The mass of loosely-entangled microfibers, obtained in the entangling means, may be wrapped around the core support as shown in FIG. 9, in several directions in order to prevent the formation of interstices through the several layers formed by the plurality of crossed wraps 32 , of the entangled threads or fibers. The core is shown not completely covered by the thread wraps for illustrative purposes, however, the core is entirely and completely covered by the curled or entangled wraps.
While preferred embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined in the appended claims. | A process and apparatus for manufacturing a microfiber structure for absorbing impact energy, sound energy and/or temperature, the structure being used in the ballistic field and in the sound and temperature isolation fields, wherein the method comprises to provide a plurality of threads consisting of microfibers, subjecting the threads to a pressurized air jet to open the threads by separating the microfibers into each thread and entangling the threads to form a mass of loosely-entangled microfibers, with the mass being confined the mass into a pack which may be appropriately compacted. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national phase entry under 35 U.S.C. §371 of International Patent Application PCT/AU2015/000684, filed Nov. 11, 2015, designating the United States of America and published in English as International Patent Publication WO 2016/077863 A1 on May 26, 2016, which claims the benefit under Article 8 of the Patent Cooperation Treaty to Australian Patent Application Serial No. 2014904634, filed Nov. 18, 2014.
TECHNICAL FIELD
[0002] The present application relates broadly to a process, system and apparatus for manufacture of calcined or partially calcined minerals. The present disclosure may have specific application for the manufacture or production of dolime for magnesium production, which is adapted to facilitate carbon capture; and for the general production of materials from calcination processes that require a high degree of specification of the degree of calcination and/or sintering.
BACKGROUND
[0003] Magnesium metal production can be produced either in an electrolytic process from magnesium chloride which is electrolyzed to form magnesium metal, or using a silicothermic reduction process to reduce the magnesium from dolime. The electrolytic process is costly to operate because of the power consumption, and has been replaced by the silicothermic process.
[0004] The silicothermic process has three stages. In the calcination stage, a dolomitic mineral (MgCO 3 ) x .(CaCO 3 ) y .(Mg(OH) 2 ) z is calcined to dolime (MgO) x+z (CaO) y . The mineral is a composite of brucite (Mg(OH) 2 ), magnesite (MgCO 3 ), and dolomite (MgCO 3 .CaCO 3 ), and may contain impurities such as silica and iron oxides. The composition of this input stream may be optimized for the process by blending minerals. This process produces significant, unavoidable, carbon dioxide (CO 2 ) as well as steam (H 2 O). In the silicothermic stage, the dolime is ground and mixed with a reductant, usually ferrosilicon, to form a briquette to give contact between the dolime particles and the ferrosilicon, and the briquette is processed in a reactor at high temperature and low pressure to produce magnesium metal vapor and a slag of calcium silicate and iron. The magnesium metal vapor is condensed to a solid in the reactor, and cooled to form the solid metal in the reactor. The reactor is opened, and the magnesium crust removed and processed to an ingot in the third stage.
[0005] There are four industrial processes for the silicothermic stage, namely the Pidgeon™ process, the Balzano™ process, the Magnatherm™ process, and the Mintek™ process.
[0006] The Mintek™ process is a continuous process in which the feed materials are separately introduced into the furnace, whereas the other processes are batch processes in which the ground feed material is a briquette, which is formed by pressing the powders. The Pidgeon™ and Balzano™ processes are based on solid-state reactions at about 1100° C.-1200° C., whereas the Magnatherm™ and Mintek™ processes are liquid-phase reactions at 1550° C.-1750° C., and to achieve melting, these processes include the addition of aluminium oxide or aluminium. The Pidgeon™ process uses a stainless steel retort, which may be heated by electrical power or combustion, while the other processes use electrical heating. In the solid-state reactions, the briquetting process is essential for the solid-state processing. This process brings the reactants of dolime and ferrosilicon, each in powder form of less than 100 microns diameter, into close physical contact to allow the reactions to occur. Additives such as calcium chloride are used in the briquette to promote the fusion of the solids in the furnace. The condensation of magnesium to the solid takes place within a cooled segment of the furnace, which is typically run under vacuum to lower the operating temperature. A variation of these processes is to use rapid quenching of the magnesium vapor in a supersonic expansion to produce a solid powder.
[0007] These silicothermic processes use dolime as an input, and the requirements on the dolime inputs are all similar, principally a high degree of calcination. It would be appreciated by a person skilled in the art that any gaseous emissions from the silicothermic process will be deleterious because the process is generally a low-pressure process. Specifically, any residual carbon in the dolime will be calcined to CO 2 during the process, and the CO 2 may be reduced to carbon or carbon monoxide by the ferrosilicon. This consumes the ferrosilicon, and the carbon may condense with the magnesium. It is highly desirable that the carbon content of the dolime is as small as possible, typically less than 0.1%.
[0008] For the calcination stage, the current technology produces the dolime from crushed rocks in a kiln. In a kiln, the CO 2 from the carbonate calcination is mixed with the heating gas from combustion, such that the total amount of CO 2 arises from this process mixed the CO 2 from combustion. Typically, in a coal-fired, best practice kiln, 60% of the CO 2 emitted is from the carbonate calcination. This disclosure describes a process for production of the dolime in which the carbonate emissions are significantly reduced.
[0009] A common feature of all the magnesium production processes is their energy intensity and associated high carbon dioxide emissions. For example, the majority of the world's magnesium is now produced using the Pidgeon process in which the heat for the dolime furnace and the silicothermic process are produced from the gasification of coal. The Global Warming Potential (GWP) for magnesium has been reported as 43.3 kg of CO 2 per kg of magnesium metal, whereas the average GWP for aluminium ingot is 12.7 kg CO 2 per kg of Aluminium. The substitution of aluminium by magnesium is desirable because of the lower weight and higher strength of the metal. There is a need to reduce the CO 2 emissions from the production of magnesium to be as low as, or preferably lower than, that of aluminium so that the products have a comparable, or lower, carbon footprint.
[0010] The CO 2 emissions can be considerably reduced by the use of natural gas in the calcination stage, and by the use of hydroelectric power to electrically heat the furnace for the silicothermic process. It has been reported that the GWP can be used to lower the emissions to 9.1 kg CO 2 per kg Mg using these alternative sources of energy. If the natural gas is replaced by a biofuel, such as charcoal from natural products, the fossil fuel emissions can be further reduced. However, in all these processes, the process emissions from dolomite calcination are released to the atmosphere, and contribute to greenhouse warming.
[0011] A lifecycle analysis has been reported for the use of magnesium metals in automobiles. The model is based on the replacement of 318 kg of iron, steel and aluminium with 154 kg of magnesium metal in a standard automobile. The lower weight means a decrease in the CO 2 emissions from petrol consumption. The lifecycle analysis considers both the CO 2 emissions in the production of the metals, and the emissions from petrol combustion. The results are expressed in the number of kilometers that the automobile has to be driven to reach a breakeven point between the emissions savings from lower petrol consumption arising from the reduction in weight, and the increase in emissions from production of the magnesium compared to the metals they replace. The Pidgeon process using coal as the fuel gives a breakeven of distance of about 275,600 km, while the use of natural gas and hydropower reduces this to about 69,500 km. (See, “Making Magnesium a More Cost and Environmentally Competitive Option,” Douglas J. Zuliani and Douglas Reeson, Global Automotive Lightweight Materials Conference (Apr. 25-26, 2012).) It follows that the capture of the process emissions would reduce this breakeven to about 12,500 km. This is a small fraction of the total distance travelled by a car during its lifetime, so that the environmental savings would be significant if the process CO 2 could be prevented from being emitted. There is a need to reduce the CO 2 emissions from the manufacture of magnesium in order to make lightweight metal vehicles that lead to a net reduction of emissions.
[0012] This disclosure primarily pertains to the reduction of emissions for the first stage of the silicothermic magnesium production process, namely, the production of dolime from dolomite in a calcination process. If hydroelectric power was used for the silicothermic process, and biomass for the calcination fuel, then magnesium metal could be produced with near zero emissions. Further, if hydroelectric power is also used for the calcination process, the magnesium metal may be produced with zero emissions or substantially zero emissions.
[0013] In one embodiment, the disclosure describes a means of direct separation of carbon dioxide from the calcination of the dolomite mineral by combustion of a fuel, such that the carbon dioxide is never mixed with any combustion gas flue and/or air, and does not have to be separated. This stream can be compressed, and sequestered to avoid the emissions. The avoidance of a flue gas capture process reduces the energy and expense of deploying such post-combustion capture processes. In another embodiment, electric power may also be used for the calcination of dolomite in CO 2 and/or steam. The primary disclosure described is the means of capture of the CO 2 gas from processing the dolomite to an oxide while maintaining the high degree of calcination of the dolomite required for the silicothermic process.
[0014] The preferred requirement is that that dolime should be processed to give a residual amount of bound CO 2 that is preferably less than 0.1% for magnesium metal production, and which is energy efficient in its own right so as to minimize the consumption of fuel.
[0015] Generally, the production of highly calcined products from crushed rocks or granules in kilns provides a wide variation in the degree of calcination of powders that arises from the fact that calcination occurs from the outside of the rocks inwards. To achieve a high degree of calcination, the residence time in the kiln is very long, in which case, the particles have a wide distribution of surface areas, hence reactivities because the sintering of the particles occurs after the reaction zone has progressed into the rocks or granules. The need for controlled sintering and calcination is difficult to achieve. In principle, the grinding of the powder and processing in a flash calciner can resolve these problems. However, flash calciners that inject the particles into a hot combustion gas generally result in wide range of calcination and sintering because each particle experiences a different environment. The use of indirectly heated counterflow reactors produce materials that have a uniform processing, such that the surface area and degree of calcination can be controlled. However, the limited residence time is such that a high degree of calcination cannot be achieved. This disclosure provides a calcination process in which the degree of calcination and sintering can be controlled.
[0016] There are many processes in which the calcination process requires a specific gaseous environment, for example, where the oxidative/reduction potential of the reaction requires specific control of the gas composition. In this case, mixing of the solids with the heating gas cannot be deployed. There is a need for a calcination process in which a degree of calcination and sintering and gas environment can be controlled.
BRIEF SUMMARY
[0017] A first aspect of the present disclosure may include a method, system, process or device adapted for the production of dolime for magnesium metal production.
[0018] Preferably, the disclosure specifically provides improvements to processes and apparatus for magnesium metal manufacture that may overcome some or all of the above-described deficiencies of the conventional processes, including without limitation, facilitating carbon dioxide capture from the dolomite calcination stage, and producing dolime with a small residual amount of carbonate, which is suitable for use in the production of magnesium with a high thermal efficiency.
[0019] A first aspect of the present disclosure may include a process for producing dolime from dolomite including the steps of: crushing and grinding the dolomite to a powder with a composition (MgCO 3 ) x .(CaCO 3 ) y .(Mg(OH) 2 ) z ; and calcining the powder in a sequence of calcination stages that substantially capture the CO 2 to produce dolime (MgO) x+z .(CaO) y−w .(CaCO 3 ) w with a low residual carbon content w that meets the specifications for magnesium production. The sequence has a first calcination stage at low temperature in which the CO 2 from the MgCO 3 and the H 2 O from the Mg(OH) 2 are released into a gas stream of H 2 O and CO 2 , to give a solid semidolime (MgO) x+z .(CaCO 3 ) y ; a second calcination stage at an intermediate temperature in which the CO 2 from the CaCO 3 is substantially released into a gas stream of CO 2 to give a partially calcined dolime (MgO) x+z .(CaO) y−w (CaCO 3 ) w ; and a third stage at a high temperature to produce dolime (MgO) x+z .(CaO) y−v (CaCO 3 ) v , in which the residual carbon, v, in CaCO 3 is reduced to the specification required for magnesium production. Preferably, at least one of the first and the second calcination stages are indirectly heated, and more preferably, both of the first and the second calcination stages are indirectly heated.
[0020] In terms of carbon capture, the complexity of the third capture reactor may be simplified by allowing the small amount of CO 2 , w−v, to be released. In this case, the relative amounts of carbonate carbon captured is x+y−w and the amount ultimately exhausted in the process is no larger than w. It is preferable that w/(x+y) is less than 5%, so that the process CO 2 emissions reduction in this aspect is at least 95%.
[0021] In a further embodiment using a combustion gas for the calciner heat, it may also be preferable such that the heat in the dolime, the CO 2 streams, the slag and the flue gas streams is extracted and used to preheat the dolime and the air, used in the combustion systems. Such heat recuperation measures may reduce the fuel consumption, and the CO 2 emissions from such fuels is therefore minimized, such that the overall carbon footprint for the production of magnesium metal is greatly reduced. For the embodiment using electric power for the calciner energy, it may also be preferable that the heat in the dolime, the CO 2 and the slag streams, is extracted and used to preheat the dolime. Such heat recuperation measures may reduce the fuel consumption, and the CO 2 emissions from such fuels is therefore minimized, such that the overall carbon footprint for the production of magnesium metal may be significantly reduced. In the case of the Mintek™ liquid process for magnesium production, the hot dolime powder can be introduced directly into the reactor, and the heat may be recovered from the silicothermic stage, to increase the thermal efficiency of the overall process of magnesium production.
[0022] Preferably, the final process gas stream, comprising carbon dioxide, may be cooled and compressed, and may be sequestered, or otherwise used to avoid or reduce emissions. Optionally, the cooled and compressed CO 2 may be stored.
[0023] In a second aspect of the disclosure, the CO 2 from the third calcination step may be captured as a pure gas stream, so that the emissions are no larger than v/(x+y).
[0024] In a third aspect of the disclosure, the first two stages of the first or second aspects may be combined into a single stage. This aspect has no impact on the emissions when applied to either the first or second aspects.
[0025] In a fourth aspect, all three stages of the second aspect may be combined into a single stage. This aspect has no impact on the emissions when applied to the second aspect.
[0026] There is a benefit to processing in separate stages at different temperatures associated with the control of the process, and the cost and performance of the materials that can be used in the construction of the stages.
[0027] While magnesium metal is used as an example, there are other industrial processes, such as the production of refractories, catalyst supports from hydroxides, carbonates and other volatile materials that can benefit from sequential processing and the separation of the flue gases from the process gas stream. Other such processes include the processing of minerals in an inert or reducing atmosphere. In many such cases, the final high temperature process is a sintering process, or a solids reaction, that may take considerable time to complete. The third stage of the first aspect of this disclosure can be used for the high temperature processes, and the primary benefit is the control of the process derived from separating the initial processing steps associated with large gas emissions from the solid state reactions that require intimate contact between particles. This disclosure applies to such processes.
[0028] Preferably, the fossil fuel carbon emissions from the flue gas are reduced by using non-fossil fuels, such as fuels from biomass and waste, hydrogen, or using natural gas, which has a low carbon footprint. Also, the use of carbon capture processes such as oxyfuel, pre-combustion or post-combustion capture may be used to reduce the carbon emissions from the fuel.
[0029] A further aspect of the present disclosure may comprise a process for producing a highly calcined and uniformly calcined product from a feedstock including the steps of: grinding the feedstock to a powder; preheating the powder; and calcining the powder in a reactor plant that comprises a number of reactor segments in which a flash calciner is used in each progressive reactor segment to incrementally react the powder by raising the temperature in each segment. The last segment is a high-temperature reactor that has a controlled residence time and temperature that allows the controlled finishing of the calcination process to achieve the desired degree of calcination and sintering of the product; and cooling the product.
[0030] Preferably, the last reactor segment is a circulating fluidized bed reactor. The preferred circulating fluidized bed is directly heated by a heating gas, and the exhaust gas is separately treated from the exhaust gas of the indirectly heated reactors in the earlier segments.
[0031] The reactor segments may constructed, formed or mounted into a tower formation in which the reaction proceeds from the top to the bottom.
[0032] Preferably, reactor segments are indirectly heated reactors configured such that the temperature of the materials in the reactor may increase as the materials pass through the reactor.
[0033] Preferably, an inert gas, a reducing gas, or any specific gas is used to entrain the solids in the reactors without mixing with the flue gas. The powder may include an average diameter of equal to or less than 100 microns.
[0034] The preferred calcination process may result in the evolution of gases and the ducting off of these gases at the end of each reactor segment facilitates the progress of the reaction in subsequent segments.
[0035] Preferably, the gas streams are ducted upwards and combined such that the gas streams are progressively cooled by the downflowing reactants.
[0036] The feedstock may be a carbonate such as magnesite, dolomite or limestone minerals or mixtures thereof, which may also contain hydrated minerals, and may also be synthetic carbonate compounds, such that the carbon dioxide liberated in the indirectly heated reactor segments is not mixed with the flue gas, so as to enable carbon capture.
[0037] The feedstock may also be is a dolomitic magnesite mineral of a composition, including hydrated compounds, suitable for the production of magnesium metal.
[0038] The feedstock may also have a composition suitable for the production of a porous substrate through the calcination of volatiles that may include hydrated water, carbon dioxide, ammonia and organic materials, in which it is desired to control the pore size distribution of the product through controlled sintering.
[0039] A further aspect of the present disclosure may comprise a device adapted for producing a highly calcined and uniformly calcined product from powdered feedstock, wherein the device comprises a chain of indirectly heated reactor segments having first and last reactor segments, wherein each reactor segment forms a flash calciner and wherein each reactor segment is adapted to be operated at a higher temperature than the previous reactor segment, and wherein the last reactor segment is adapted to include: a predetermined residence time for the processing of feedstock; and a predetermined temperature that is adapted to allow for the controlled finishing of the calcination process to achieve a desired degree of calcination and sintering of the product.
[0040] It would be appreciated by a person skilled in the art that the basis for the disclosure is a calcination process that can process the solids in a number of stages without mixing of the process gases with the heating gases.
[0041] Further forms of the disclosure will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Embodiments of the disclosure will be better understood and readily apparent to one of ordinary skill in the art from the following description, by way of example only, and in conjunction with the drawings, in which:
[0043] FIG. 1 shows a schematic drawing of a process for production of dolime and a relatively pure CO 2 stream from reactors according to a first embodiment.
[0044] FIG. 2 illustrates an embodiment of the flash calciner reactor of FIG. 1 .
DETAILED DESCRIPTION
[0045] A first preferred embodiment of the present disclosure is described is for the specific application for the production of dolime from dolomite for magnesium production using indirect heating from a combustion process. This calcined product may have a specification for the maximum carbon content that is allowable in the furnace that vaporizes the magnesium, and a desirable requirement that the product has as high a surface area as possible to optimize the solid-state reaction between the dolime and the ferrosilicon in the furnace. This is a specific example or embodiment of a general method in which the calcined product must meet requirements of both reactivity and calcination.
[0046] The dolime production process can be described by consideration of the process flow of FIG. 1 . In this embodiment, that carbonate is dolomite with an appropriate magnesium to calcium ratio to optimize the production of magnesium metal using ferrosilicon. Such a feedstock may include brucite, Mg(OH) 2 , and mixtures of pure dolomite MgCO 3 .CaCO 3 and magnesite MgCO 3 , to achieve the desired ratio. The described process may be adapted to a device, method or system to achieve the same or similar outcomes or results.
[0047] A suitable pre-heater and flash calciner reactor is of the type as described by Dr. Mark Sceats in published PCT Patent Application No. WO 2012/145802, which is incorporated herein by reference, may be suitable for an embodiment that uses combustion to supply the calcination energy. In that reactor, the separation of the heating gas from the calcination process gas this is achieved using indirect heating from the heating gas. This may be achieved using a metal or ceramic wall between the two flows. The heating gas and the process streams are in counterflow, such that such that the energy efficiency is high, in the same way that counterflow heat exchangers have a high energy efficiency. The solids fall under gravity and are entrained by the process gas steam, while the heating gas rises. The products have a high surface area because the residence time of the mineral is short to achieve the preferable counterflow.
[0048] The residence time in the reactor of FIG. 2 of the above-mentioned document is determined by the entrainment of the solids in the gas, and the large amounts of CO 2 produced in the reactor is such that the residence time cannot be readily increased in this reactor. In practice, the short residence time in this reactor is such that the residual amount of CO 2 in the calcined product is in the range of 2%-5%. This product does not meet the specification for use in the production of magnesium.
[0049] In this first preferred embodiment and as depicted in FIG. 1 , the reactor comprises three reactor segments, in which the low and intermediate temperature segments are based on indirect counterflow processing, and the high temperature “polishing” reactor is a conventional direct mixing reactor typical of conventional flash calciners. The use of two indirect counter flow reactors is to increase the residence time of the solids, because the CO 2 is released in two separate processes. The low temperature process is the calcination of magnesium hydroxide and magnesium carbonate, in magnesite or dolomite, which occurs in the range of below 750° C., while the intermediate temperature process is the calcination of the calcium carbonate, which occurs in the range of 800° C.-900° C. If the CO 2 from the calcination of magnesium is not removed, the partial pressure of CO 2 is sufficiently high that the reaction of the calcium site does not take place until the temperature of the heated solids is such that equilibrium partial pressure exceeds the CO 2 pressure, namely about 900° C. The release of CO 2 then occurs rapidly and the process becomes difficult to control. Most importantly, the combination of the two CO 2 gas streams is such that entrainment of the solids by the gas is such that the residence time of the solids is low.
[0050] In this embodiment, the plant for the production of the dolime for magnesium production comprises a crushing and grinding plant 100 which is adapted to grind feedstock into a powder, a calciner tower 102 and a CO 2 processing plant 103 . The calciner tower 102 is a structure that comprises a preheater reactor segment 110 in which the powder is preheated and the brucite Mg(OH) 2 is calcined to MgO; a low temperature flash calciner 111 using indirect heating from a heating gas produced in the first combustor 112 in which the magnesium carbonate, as the mineral component magnesite MgCO 3 and the dolomite MgCO 3 .CaCO 3 , is calcined to magnesia MgO; a first solids gas separator 113 in which the partially processed powder is separated from the CO 2 and steam; an intermediate temperature flash calciner 114 using indirect heating from a second combustor 115 in which the powder is processed such that any residual carbonate from the magnesium carbonate is calcined and the calcination of the calcium carbonate from the dolomite is substantially complete; a second solids gas separator 116 in which the substantially calcined power is separated from the CO 2 ; a high temperature flash calciner 117 using direct heating from a third combustor 118 in which the degree of calcination of the powder is reduced to the specification required by control of the temperature and residence time; and a solids cooler 119 in which the product is cooled for storage and, for briquette production.
[0051] The raw dolomite rock 200 is crushed and ground in the crushing and grinding plant 100 . In this plant 100 , moisture (not shown in FIG. 1 ) is removed by using the flue gas streams 246 and 247 from the calciner tower 102 . The exhaust 248 from the plant 100 is fed into a filter (not shown) to remove fines and is exhausted in stack or tower 102 . The dolomite is ground to particles, preferably, of less than 100 microns diameter and, more preferably, to less than 50 microns diameter. The ground, substantially dry dolomite 201 is transported to the calciner tower 102 where it is processed to dolime.
[0052] In this process, the dolomite 201 is heated in a preheater segment 110 to a temperature of about 600° C., which marks the onset of the calcination reaction that removes CO 2 from the magnesium carbonate, MgCO 3 sites in the mineral powder. During pre-heating, steam is liberated from any excess moisture from brucite, Mg(OH) 2 in the mineral powder. The steam entrains with the powder in the preheater 110 . Stream 202 comprises the partly processed mineral (MgCO 3 ) x .(CaCO 3 ) y .(MgO) z . and the steam. The details of the preheater segment 110 are described below. The stream 202 heated intermediate is injected into the flash calciner segment 111 . This flash calciner 111 uses indirect heating to ensure that the carbon dioxide liberated during calcination does not mix with the heating gases used to provide the energy of the reaction. A suitable flash calciner is of the type described by Sceats, for example, in published PCT Patent Application No. WO 2012/145802, incorporated herein by reference. A schematic illustration of an example flash calciner reactor is illustrated in FIG. 2 hereof. As the powder and gas in stream 202 falls through the reactor 111 , they are heated in the range of 650° C.-750° C. by the heating gas streams 242 and 244 , externally applied. At this temperature, the decarbonation of the magnesium occurs to give an exhaust stream 203 comprising the intermediate processed powder semidolime (MgO) x+z .(CaCO 3 ) y and a gas of CO 2 and steam. The calcination of the magnesium is substantially complete. The stream 203 enters the first solids gas separator 113 , in which the solids 204 are separated and flow into an intermediate temperature flash calciner 114 . The gas stream is exhausted into a central tube (not shown in FIG. 1 ) that transports the gas to an exhaust at the top of the reactor as stream 213 and is cooled in the preheater 110 . This stream also contains the CO 2 stream 211 from the intermediate temperature flash calciner 114 described below. The cooled CO 2 stream 214 from the preheater 110 is fed into the CO 2 Processing plant 103 where it is dewatered, with a stream of water 211 , compressed or liquefied for sequestration as 215 . The partially hot semidolime stream 203 is substantially completely calcined in the intermediate flash calciner 114 by a heating gas stream 241 , externally provided. A process steam 205 contains the calcined powder and the CO 2 , and this stream and these are separated in the second solid gas separator 116 to give a substantially calcined dolime stream 206 and a CO 2 stream 210 . The CO 2 stream 210 is exhausted into a central tube and is exhausted as stream 211 . The powder 206 is (MgO) x+z .(CaO) y−v .(CaCO 3 ) v , with v<<y, and is metered into the high-temperature flash calciner 117 , which is directly heated by heating gas 240 from the third combustor 118 . In reactor 117 , the excess carbonate is reduced from v to w to give (MgO) x+z .(CaO) y−w .(CaCO 3 ) w , where w is sufficiently low that the product 207 meets the specifications. The v−w CO 2 is mixed with the heating gas as stream 243 , and is cooled in the preheater 110 to give stream 244 which is used to dry the ground dolomite. The design of this reactor 117 is a fluidized bed in which the temperature of the product and the exhaust gas can exceed 1200° C. The residence time and temperature are controlled such that the desired degree of residual carbonate w is obtained. The mass flow of heating gas 240 is relatively small compared to those from the other combustors because the energy required to calcine the residual CaCO 3 is small. This stream (heating gas 240 ) may be a slip stream from the other combustors. The hot calcined product 207 is cooled in the solids cooler 119 , and this product is provided to the briquetting plant. Briquetting must be conducted in an inert gas to prevent recarbonation from CO 2 in the atmosphere.
[0053] The combustors 112 , 115 , 118 use cold, sub-stoichiometric primary air streams 224 , 225 and 226 to transport the fuels 230 , 231 and 232 into the combustors, where they are combusted with preheated air streams from the preheater 110 and solids cooler segments (not shown). The preheater 110 heats the air stream 227 , and the heated air is split as streams 228 and 229 to the first and second combustors 112 and 115 , respectively. The solids cooler (not shown) provides heat to air stream 220 for the provision of heated air in streams 221 and 222 for the third and second combustors 118 and 115 , respectively.
[0054] The preferred design of the preheater 110 and solids cooler are based on the following principles. Firstly, flows that are dominantly powders are restricted to vertical pipes that have diameters that are wide enough to prevent blocking, namely about 100 mm or more and the flow is downwards. There is an array of such pipes to manage the flows, and the flows are such that the powders are entrained in gas in a dilute flow. Where appropriate, steam is used to promote such flows. In this embodiment, in the preheater 110 , the solid flow is the feed 201 , and in the solids cooler 119 , the solids flow is the product 207 . Secondly, gas streams that contain minor amounts of process flow solids are also ducted through pipes, and in this embodiment such flows are upwards and forced by the gas streams. In this embodiment, in the preheater 110 , the flows that contain some powders are the streams 243 and 213 . It is preferable that these streams carry as small as possible solids, and where practical, there may be cyclones, including in-line cyclones, (not shown) that remove a large proportion of the solids and direct that flow back into the solids streams. Third, pure gas streams, such as air or heating gas are directed through the systems in a cross-flow pattern through horizontal ducts with a duct width chosen to give a gas velocity that is sufficiently high to achieve efficient heat transfer to or from the pipe walls. The gas streams move from one horizontal duct to another through shafts. In the solids cooler 119 , the ducted gas stream is the air 220 , and in the preheater 110 the ducted gases are the air 227 and the heating gas 245 . Fourth, the heat flows are such that the ducted streams of gases are injected into the segments such that the vertical flow is a counterflow to the solids flows. Thus, in the preheater 110 , the top of the preheater 110 is colder than the base, so the cool streams, as inputs or outputs are at the top and all the hot streams are at the base. Thus, streams 227 (in), 201 (in), 214 (out) and 247 (out) are at the top, and are cooler than the respective streams 228 (out), 202 (out), 213 (in) and 243 (in) at the base. In the solids cooler 119 , the hot streams 207 (in), 221 (out), 222 (out), and 223 (out) are at the top, while the cool streams 208 (out) and 220 (in) are at the base. Using these principles, these segments may have a high thermal efficiency, and are compact.
[0055] The preferred design of the flash calciners 111 and 114 are such that the CO 2 streams from the respective gas solids separators 113 and 116 are ducted back through the reactors in a central tube. This aspect is a preferred embodiment in WO 2012/145802, and allows the reactors to be compact. The flows in that central tube are preferably in a vortex motion induced by the shape and orientation of the pipes in the preheater 110 , and by deflector plates of the streams 203 and 205 entering the gas solids separators 113 and 116 . This motion deflects the particles onto the wall of the central tube, and the particles flow down the walls into the gas solids separators 113 and 116 . In effect, the tube is part of the design for the gas solids separators 113 and 116 . The walls of the central tube shown in FIG. 2 are heated by the radiation from the reactor tube walls and the CO 2 gas streams, and this assists the efficiency of the calcination processes in the reactor annuli.
[0056] The sequence of the three reactors enables the product to meet the desired specifications of the product degree of calcination. The amount of CO 2 that is captured in the first reactor represents about 50% of the total carbon input, the amount of CO 2 that is captured in the second reactor amounts to about 45%, and the amount of CO 2 that is discharged into the flue gas is about 5%. In this case, the capture efficiency of the system is 95%. The control of the residence time and temperature in the third reactor is important because the calcined particles rapidly sinter at high temperatures, and the consequential reduction of the surface area lowers the reactivity of the particles. In the case of magnesium production, on the one hand, the extent of sintering lowers the reaction rate with the ferrosilicon in the heated briquette, and on the other hand, the longer the sintering, the greater the degree of calcination, and the less carbon is introduced into the magnesium reactors. It would be appreciated by a person skilled in the art that the calcination of dolomite rocks is difficult to control because the inner part of the rocks calcine more slowly that the outer parts. Generally, when ground there is a wide distribution of the degree of calcination of the product. To achieve the specifications for the dolime, a large fraction of the particles from the outer parts of the rock have been “overcooked” and are highly sintered and unreactive. This overcooking leads to longer residence times, and that creates an energy penalty. The wide range of the reactivity of the dolime in the ferrosilicon process also leads to longer processing times, and inefficiencies. This disclosure optimizes the production process efficiency, as well as captures the CO 2 .
[0057] Yet a further embodiment may use electrical power to heat a furnace to provide the energy for calcination. The energy for calcination may be produced, using, for example, resistive heating. In this embodiment, the furnace wiring is segmented to provide control of the heat transfer to the products such that the temperature profile of the solids passing down through the calciner is one in which, preferably, increases monotonically. Otherwise, the process is as described in the first embodiment.
[0058] While particular embodiments of this disclosure have been described, it will be evident to those skilled in the art that the present disclosure may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. It will further be understood that any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates. | A process for producing a highly calcined and uniformly calcined product from a feedstock. The process comprising the steps of grinding the feedstock to powder, preheating the powder, and calcining the powder in a reactor plant that comprises a number of reactor segments in which a flash calciner is used in each progressive reactor segment to incrementally react the powder by raising the temperature in each segment. The last segment may be a high-temperature reactor that has a controlled residence time and temperature that may allow controlled finishing of the calcination process to achieve a desired degree of calcination and sintering of the product; and cooling of the product. | 2 |
This application claims the benefit of U.S. Provisional Application No. 60/757,638, filed Jan. 10, 2006.
TECHNICAL FIELD
This invention relates generally to a climate control system for the interior of an operator platform or cabin of a self-propelled work machine such as a tractor, agricultural harvesting machine, or the like, and more particularly, to a controller area network based climate control system therefor, and a method of operation of the same.
BACKGROUND ART
U.S. Provisional Application No. 60/757,638 filed Jan. 10, 2006 is incorporated herein in its entirety by reference.
Environmental conditions, such as, but not limited to, temperature, humidity and/or air pressure, within an enclosed operator platform or cabin of a self-propelled work machine are typically controlled or regulated using a climate control system, also commonly referred to as a heating, ventilating and air-conditioning (HVAC) system. The climate control or HVAC system of a work machine typically includes several operator operable controls located within the cabin including, but not limited to, a mode selector, a temperature selector, and a fan speed selector. The mode selector will typically allow selecting a heat mode, an air conditioning mode, a window defrost defog mode, an air recirculation mode, and a fresh air mode. Additionally, some systems may be operable in an automatic temperature control (ATC) mode wherein the system controls the cabin air temperature to or within a range of an operator selectable value. Reference in this regard, Panoushek et al., U.S. Pat. No. 5,993,312, which illustrates a representative HVAC system for a work machine including this latter feature. Still further, some systems may be operable in a mode which automatically controls the fan speed and other elements of the system to maintain the cabin air pressure at a level above that of outside air, to limit infiltration into the cabin of outside air, dust and other contaminants from the outside environment. This feature has particular utility in work machines used in off-road applications such as construction, mining and agricultural applications, and, more particularly, such as agricultural tractors and harvesting machines, which are sometimes operated in very dusty environments, for instance, wherein the dust is so dense as to significantly limit visibility. A cabin pressure sensor may be provided for use in regulating cabin air pressure.
Operation in such intense dust can cause problems, including for instance, the partial or full clogging of the air intake filter or filters for the cabin, as well as of radiators and heat exchangers, including the air conditioning condenser, which is typically cooled using external air. As a consequence, in the instance of the air-conditioning system, the system may be required to operate for longer periods, and/or more frequently, to achieve or maintain a selected climate setting for the operator cabin. Such dust problems may be sufficiently severe so as to make it impossible for the air-conditioning system to achieve the climate setting. Such conditions, if allowed to exist, can result in increased power usage, system and component degradation and shut-down or failure, downtime for cleaning and/or repair, and operator and/or machine owner dissatisfaction.
Other conditions that can lead to or result in system, operation and component degradation and failure include, but are not limited to, operation of high electrical current using items such as the cabin air fan when the engine is not operating or is operating at less than an adequate level, drive belt slippage and failure, air-conditioning system refrigerant and oil leakage and internal blockages, coolant leakage in the lines and heat exchanger of the heating system, fan motor failure, sensor failure, cabin seal failure, and control failure.
Still further, the operation of the climate control system, and, in particular, the compressor of the air-conditioning component thereof driven by the engine of the work machine, can have power requirements which can be significant for a smaller engine, and/or an engine under heavy load, such as when the engine is being started, the work machine is accelerating, going uphill, and/or the engine is powering components such as harvesting and crop processing equipment, load bearing fluid lift cylinders and the like, such that if the air-conditioning compressor is operated, or is allowed to initiate operation, when the engine is under heavy load, the performance of the air-conditioning system, engine, and/or other components powered by the engine, and/or the engine itself, may be degraded.
It is well known to provide devices in connection with the air-conditioning system operable for sensing a condition or conditions representative of engine load and/or operating conditions, such as the engine intake vacuum and temperature, and devices for automatically controlling the engagement of the air-conditioning compressor clutch and/or the compressor, for avoiding or minimizing overloading the engine and/or degrading operation of the air-conditioning system and other systems of a vehicle. It is also well known to provide sensors, such as thermal sensors and the like, in association with various of the components of the climate control system, and operable for sensing problem conditions and outputting a signal and/or shutting down the system or component when a problem is indicated, for instance, when a component of the system such as the compressor or the condenser is clogged or obstructed, beginning to overheat, or the evaporator is freezing. Such sensors are typically connected to an air-conditioning electronic control unit (ECU), which may be operable for storing information representative of a problem condition in a memory for retrieval for use in diagnosing the problem. The ability to rapidly diagnose problems with work machines is a particularly sought after capability, as downtime for such machines can be costly.
Presently, the known climate control or HVAC systems in work machines used for off-road applications are stand-alone units having dedicated ECUs. These controllers operate in isolation and do not communicate or interface effectively with other controllers in the vehicle. This isolation has been found to restrict the ability of the HVAC system to optimally use available resources and hence ends up making the HVAC system a higher cost system.
More recently, it has been observed that work machines commonly utilize controller area networks (CANs) connecting multiple system controllers and operable for sharing both raw and processed data and information, in real-time, relating to a variety of machine systems and components, including information relating to the engine, via the engine controller, to function in a coordinated and integrated fashion. It is also observed that some CANs have a controller including software capable of automatically troubleshooting and diagnosing problems with a system or component on the CAN. It has also been found that, often, a variety of controllers on work machines have under-utilized processing capacity.
Accordingly, what is sought is a climate control system, and a method of operation of the same, which advantageously and economically integrates into and utilizes the resources and capabilities of a CAN of a work machine, including, but not limited to, shared data from other systems of the machine, particularly engine control data from an engine controller, for controlling climate control system operation, as well as for troubleshooting and diagnosing problems.
SUMMARY OF THE INVENTION
What is disclosed is a controller area network based climate control system for a work machine, and a method of operation of the same, which advantageously and economically integrates into and utilizes the resources and capabilities of a CAN of a work machine, including, but not limited to, shared data from other systems of the machine, particularly engine data including engine operating speed and temperature, for controlling climate control system operation, as well as for troubleshooting and diagnosing problems.
According to a preferred aspect of the invention, the climate control or HVAC control system is implemented through the use of a CAN bus topology to communicate with others of the vehicle components. In this approach, one or more functions of the HVAC system are distributed to other controllers of the CAN to carry out various tasks. In this way, the CAN networked devices share raw and processed information in real-time to function in a coordinated and integrated fashion. This is preferably implemented using a bidirectional messaging architecture.
According to another preferred aspect of the invention, the climate control system includes an electronic programmed processor based controller, also referred to as the Automatic Temperature Controller (ATC), which is programmed for automatically controlling the temperature of the air within the cabin interior to within a range of a temperature selected using an input device. The ATC is connected to a CAN of the work machine and is operable for sharing data and information with other controllers and devices on the network, including the engine controller or ECU. Operator input devices can include, for instance, one or more switches, potentiometers, and/or other device connected directly to an input/output port or ports of the ATC, or to another device or controller of the network. Component inputs, such as condenser temperature, evaporator temperature, refrigerant pressure, and the like can be received directly by the ATC through input ports thereof, or by other controllers of the network and shared. This can be determined on an application by application basis and can be configured so as to economize wiring requirements.
Information such as system status, mode, temperature, and the like is displayed by an instrument cluster unit (ICU) connected to the network, on a display located in the cabin. The ICU and display can also be used for displaying information relating to other systems such as the engine and/or operating or functional systems of the machine, e.g. harvesting systems of a combine, power takeoff system of a tractor, etc., and can be optionally configured to provide an input capability, for instance, for inputting climate control system commands, e.g., temperature, fan speed, mode (A/C, heat, defog) using a touch screen type display device in lieu of using discrete devices such as switches, potentiometers, and the like. The engine controller is operable for sharing engine speed information and also engine temperature on the network. The ATC controller, or another controller on the network, will preferably include a memory, such as a resetable flash type, for temporarily storing information relating to fault conditions or flagged events. The network can include a connector for connection of a diagnostic service tool thereto, to enable quickly troubleshooting and diagnosing problems.
According to another preferred aspect of the invention, in operation, the ATC controller will monitor the engine speed information shared on the network by the engine controller. The ATC controller will be programmed to prevent initiation of operation of high electrical current drain components, e.g., the cabin air blower or fan, if the engine speed is below a threshold level. This will increase the power available for engine cranking and other tasks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an agricultural windrower including a CAN based climate control system according to the present invention;
FIG. 2 is a diagrammatic representation of the CAN of the invention;
FIG. 3 is a simplified schematic representation of an air-conditioning system of the climate control system of FIG. 1 ;
FIG. 4 is a diagrammatic representation of operation of the CAN based climate control system of the invention; and
FIG. 5 is a high-level flow diagram of steps of an operating method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings wherein aspects of a preferred embodiment of a controller area network (CAN) based climate control system 10 of the invention is shown, in FIG. 1 , system 10 is shown incorporated into an agricultural work machine, which is a self-propelled windrower 12 . Windrower 12 is contemplated to be representative of a wide variety of work machines with which CAN based climate control systems of the present invention can be utilized, which can include, but are not limited to, other harvesting machines, such as combines and cotton pickers, tractors, earth movers, mining machines, off-road trucks, and the like. Windrower 12 includes an engine 14 operable for propelling it through fields from which crops will be cut, while powering a variety of systems thereof, including climate control system 10 , and apparatus of a crop cutting header 16 , including a cutter mechanism 18 extending across a lower forward end thereof, and crop gathering and processing apparatus including a reel, various conveyors, and processing rollers, operation of which are coordinated and controlled by an electronic microprocessor based controller 20 in the well known manner. The propulsion and steering of windrower 12 is controlled by an electronic drive controller 22 which is also a micro-processor based controller and operates fluid motors in driving connection to drive wheels, as represented by wheel 24 . Engine 14 is controlled by an electronic engine control unit (ECU) in the well known manner. A micro-processor based climate control system controller or automatic temperature controller (ATC) of system 10 , the ECU, and optionally controller 20 are connected together by a communications network or bus of the CAN, over which bus data and information are shared. Other systems of a work machine can also be connected to the CAN bus, and can include, but are not limited to, a display controller which is preferably an instrument cluster unit (ICU) connected to a display device 26 located in an interior space 28 of an operator cabin 30 of windrower 12 , and other electronic controllers.
Referring also to FIG. 2 , the CAN bus is shown connected to the ATC of climate control system 10 , to the ECU, to the ICU, and to a representative electronic controller, which is representative of controllers of other systems, such as controllers 20 and 22 , which can be connected to the CAN bus. Additionally, a service tool is shown removably connected to the CAN bus via a suitable interface, which can be for instance, a conventional RS 232 plug interface 32 . Climate control system 10 is illustrated configured for operator commands to be inputted to the ATC via suitable input devices connected directly to the ATC, which can include, but are not limited to, conventional rotary or linear potentiometers, switches, and the like, typically located in cabin 30 . Alternatively, system 10 could be configured such that operator inputs will be received via an interactive display device, such as a touchscreen (not shown), in connection with the CAN bus via the ICU.
The ATC is programmed to output current and/or set system conditions and operating mode information over the CAN bus to the ICU, which, in turn, is programmed to process and display the information on a suitable display device, such as device 26 located within operator cabin 30 . Display device 26 can be, for instance, an LCD or CRT device, and can be configured for displaying such useful climate control system information as cabin blower or fan speed, cabin interior temperature, outside temperature, cabin pressure, and system operating mode, as well as additional information relating to other systems, such as engine speed and temperature, and information from other controllers such as controller 20 for elements of the crop gathering and processing apparatus and/or drive controller 22 . Fault condition information can also be displayed, such as a high temperature condition representative of clogging of a condenser of the system (discussed below). Sensors utilized by the ATC for the operation of the climate control system can be connected directly to the ATC, or to others of the electronic controllers, as denoted by dotted lines in FIG. 2 .
Referring also to FIG. 3 , elements of the air-conditioning system 34 of climate control system 10 , are shown. The ATC is shown connected to the CAN bus, as is another representative electronic controller, in the above-described manner. The ATC is shown also connected to several components of air-conditioning system 34 by suitable conductive paths 36 , which can be, for instance, wires of a wiring harness of the work machine. Such components include, but are not limited to, a compressor clutch 38 , a high pressure valve or sensor 40 , and a low pressure valve or sensor 42 . Other components to be connected to a controller include temperature sensors 44 and 46 which are illustrated by dotted lines as being connected alternatively to the ATC or another electronic controller, to illustrate the flexibility afforded by the present system.
Compressor clutch 38 is controllable by the ATC to connect a refrigerant compressor 48 of the air-conditioning system with a drive, such as an auxiliary belt drive driven by the engine of the windrower, for compressing refrigerant of the air-conditioning system in the well known manner. The refrigerant will be compressed to a designated high pressure and will flow, as denoted by the arrows, through refrigerant lines 50 which connect to a heat exchanger or condenser 52 of a high pressure side of system 34 . Condenser 52 will typically be located in a rack with other heat exchangers, such as the engine radiator, located in this application near the rear end of engine 14 in FIG. 1 . Compressor 48 may be located near this end of the engine also.
Temperature sensor 46 will be a suitable device such as a thermistor and will be positioned for monitoring a temperature of condenser 52 . A high temperature reading from sensor 46 will typically indicate a fault condition, that is, inadequate dissipation of heat therefrom, such as can result from a clogging or blocking of air passages through the condenser with dust. Sensor 46 may be connected by a suitable conductive path 36 directly to the ATC, or, because of its location at the end of the machine, it may be more economical or convenient to connect it to a closer electronic controller on the CAN bus other than the ATC. In either instance, the receiving controller can process the signals, and share information representative of the temperatures over the CAN bus. For instance, information indicating a high temperature condition can be displayed on device 26 to inform an operator that the condenser may need cleaning. The information can also be stored for retrieval with a service tool when connected to the bus.
High pressure sensor 40 is located in high-pressure side line 50 and is operable for detecting under pressure conditions, and possibly over pressure conditions also, in the high pressure side of the system, and outputting signals representative thereof to the ATC. Again, like sensor 46 , sensor 40 can be connected directly to the ATC, or to another electronic controller on the CAN bus. The ATC can be programmed such that if sensor 40 indicates a pressure problem, the ATC can determine that a fault condition exists and place that information on the bus. And, the ATC, or another of the controllers, can be programmed to diagnose a problem in connection with the sensor, or any of the other sensors connected thereto, such as an open connection, a short, or the like.
From condenser 52 , the pressurized refrigerant will flow through lines 50 of the high pressure side to a receiver dryer 54 , and from there, through an expansion valve 56 . The refrigerant will exit expansion valve 56 at a lower pressure, and flow at the lower pressure through a low pressure side of the system to a second heat exchanger or evaporator 58 , through which cabin air is directed by a blower fan 60 for cooling the interior space of the cabin in the well known manner.
Sensor 44 , which also can be a thermistor or other suitable device, is positioned for sensing a temperature condition in relation to evaporator 58 , particularly, temperatures indicative of an ice build up or freezing on the outer surfaces thereof which could impede air flow therethrough. Sensor 44 , like sensor 46 , can be connected by a suitable conductive path 36 directly to the ATC, or it may be more economical or convenient to connect it to another electronic controller on the CAN bus other than the ATC. In either instance, the receiving controller can process the signals, and share information representative of the temperatures over the CAN bus. Again, the ATC, or other of the controllers, can be programmed to diagnose a problem in connection with this sensor, or any of the other sensors connected thereto, such as an open connection, a short, or the like.
From evaporator 58 , the lower pressure refrigerant will pass through expansion valve 56 en route to compressor 48 , completing a closed loop.
Referring also to FIG. 4 , the ATC will also be connected to other sensors, which can include, but are not limited to, a cabin air temperature sensor, an outside air temperature sensor, a cabin air pressure sensor, and/or a light sensor positioned for determining presence of direct sunlight, a fan blower driver 62 ( FIG. 3 ), and one or more actuators including a mode door actuator controllably operable for directing air flows to different regions of the operator cab interior space. Alternatively, as another advantage of the present CAB based system, these devices can be connected to other controllers on the CAB bus. Using information outputted by these and the other above discussed sensors, whether connected directly to the ATC, or shared over the CAB bus, the ATC will be equipped so as to be automatically operable for controlling the temperature of the interior space of the operator cab to or within a range of a set temperature as selected by an operator using conventional input devices such as pushbuttons and rotary knobs, in a selected operating mode, e.g. heat, A/C, defog. The operator will be capable of viewing visual data on the display device driven by the ICU, in real-time, including the current operating mode, blower speed, cabin temperature, outside temperature, and cabin pressure, as well as new operator settings for such data. Additionally, the ATC, or any of the controllers, can be programmed to diagnose a problem in connection with these sensors or actuators, such as an open connection, a short, or other malfunction and store or share information regarding the condition over the CAN bus. And, by connecting a service tool to the CAN interface via the RS 232 plug 32 , such stored information relating to, for instance, current or past system conditions and fault conditions can be retrieved, for problem troubleshooting, diagnosing and repair of any of the systems connected to controllers on the CAB bus.
Referring also to FIG. 5 , as another operational advantage of providing shared data over the CAB bus, the ATC can be programmed so as not to turn on high current load devices, for instance, the fan blower driver, or to restrict the operation thereof to lower speed settings, under certain conditions, such as prior to starting of the engine, or when the engine is operating at a speed which is less than a predetermined value, so as to preserve electrical and/or charging system power for other purposes such as cranking the engine for starting. As another desirable feature, the ATC can be programmed such that functions such as conversion from Celsius to Fahrenheit operation can be accomplished by the toggling of a switch connected to any controller on the CAN bus.
It will be understood that changes in the details, materials, steps, and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | A controller area network based climate control system for a work machine, and a method of operation of the same, which advantageously and economically integrates into and utilizes the resources and capabilities of a CAN of a work machine, including, but not limited to, shared data from other systems of the machine, particularly engine data including engine operating speed and temperature, for controlling climate control system operation, as well as for troubleshooting and diagnosing problems. | 1 |
BACKGROUND OF THE INVENTION
Increasing use of sheets of waterproof membrane, usually made of a plastic or rubber material, has created problems in attaching these sheets of membrane material to the upper surface of the roof. One method employed is to glue the entire sheet to the roof or to the insulation which has been previously placed on the roof. The cost of doing this adds considerable expense to the construction. Another method that is employed is mechanically to fasten blocks or disk to the roof and then glue the sheet to the mechanically fastened blocks or disk. Again, this can result in weak points involving leaks and is an expensive procedure. Another approach is merely to attach the sheets to the periphery of the roof and lay ballast consisting of small stones on the roof. In large span industrial applications this creates a structural problem since the ballast weighs one-half ton per 100 square feet and also the ballast is reflective so that there are no solar heat advantages possible.
If there were no wind, the membrane could merely be laid on the roof, perhaps sealed around the edges, and no problems would arise. However, when the wind blows over the roof, it will cause the membrane to rise up because of the negative pressure created above the roof by the wind blowing and also as a result of the effect of vortexes formed from other buildings in the area and, as a result, frontal pressure and wind drag can stretch or dislodge the membrane causing failure and leaks in the roof.
One approach to solve this problem is shown in U.S. Pat. No. 4,223,486, Kelly, which provides a plurality of one-way or duckbilled valves which are connected between the membrane and the support on which the membrane is placed so that when a negative pressure is created above the membrane, the presence of the exhaust valve will tend to equalize the pressure, and thus prevent uplift of the loosely-laid membrane. While this system has merit, all it does is equalize the pressure above and below the membrane but does not create any positive force to hold the membrane down and in position against the roof surface as the wind velocity increases.
SUMMARY OF THE INVENTION
Applicant's roof construction system involves the use of one or more fans which are positioned on the roof so that they will have their inlet between the loose membrane and the roof surface, the fan being actuated by the wind and creating a suction force underneath the membrane so as to result in a higher pressure above the membrane than under the membrane. This pressure differential increases as the wind velocity increases since the fan suction is increased as the wind velocity increases.
It is therefore an object of this invention to provide a roof construction system, on a flat roof or on an inclined roof, which permits the use of a loosely-laid membrane material in conjunction with a positive displacement fan which will create a partial vacuum between the membrane and the roof surface so as to hold the membrane down in a stable position on the roof and wherein the suction pressure created by the fan will increase in proportion to the velocity of the wind attempting to lift and drag the membrane from the roof.
It is a further object of this invention to provide such a roof construction system which is relatively inexpensive and is easy to install.
Additional objects and advantages of the present invention will become more readily apparent to those skilled in the art when the following general statements and descriptions are read in the light of the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a roof on a building showing the membranes laid on the building and a single fan positioned with its suction opening between the membrane and the top of the roof.
FIG. 2 is a section on lines 2--2 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now more particularly to FIG. 1, a building structure is shown at 10 which has three waterproof membrane sections 11--11 loosely laid on the top thereof. These membrane sections 11--11 are glued to each other at 12--12 and are also sealed around the periphery of the top edge of the building as shown at 13--13. While the membranes 11--11 vary in size, a common width is approximately 20 feet wide. The fan indicated generally at 14 is placed in the middle of the roof with its suction portion 23 resting on the roof deck with the membrane 11 sealed around the base 15 of the fan and above the lower suction portion.
This will be better understood by reference to FIG. 2 which is a sectional view showing a typical roof construction where 16 is a steel deck, 17 is insulation material, 18 is an air separation layer fixedly attached to said insulation material 17, and 11 is the waterproof membrane. Separation layer 18 is used to keep heated air in the building. The fan 14 is provided with a windmill 19 connected by a shaft 20 to the exhaust fan 21. The upper portion 22 of the exhaust fan 14 is rotatably mounted on the lower suction portion 23 on suitable bearings 24--24 and is provided with a vane 25 so that the fan 14 will always face the windmill 19 into the wind. A cone-shaped exhaust portion 26 induces drag to help pull air out of the exhaust fan 14. A flapper valve 27 is provided and the membrane 11 is sealed around the base 15 of the fan 14. Holes 28--28 are provided in the base 15 of the lower portion 23 of the fan 14 to connect the fan 14 to the space between the membrane 11 and the separation layer 18.
In operation, when the wind blows the fan 14 will rotate and face the wind. This causes the windmill 19 to rotate the shaft 20 which in turn rotates the exhaust fan 21 causing any air in the space between the membrane 11 and the separation layer 18 to be drawn through the holes 28--28 up through the lower portion 23 of the exhaust fan 14 and out through the exhaust portion 26 of the fan 14, thus creating a partial vacuum underneath the membrane 11 and holding the membrane 11 down on the roof.
As the velocity of the wind increases it tends to create higher negative pressures above the membrane 11 and thus tends to lift the membrane 11. However, the faster the windmill 19 rotates, the faster the exhaust fan 21 will operate creating a greater partial vacuum between the membrane 11 and the separation layer 18, thus tending to hold the membrane 11 down on the separation layer.
This system may be used on existing roofs and is not limited to flat roofs but may also be used on sloping roofs. The separation layer 18, of course, is optional and the membrane 11 can be laid directly on the insulation 17, if desired.
Depending upon the size of the roof, a plurality of fans 14 may be used, or air channels under the membrane 11 can be created to aid in the evacuation of air in remote sections of the roof.
The flapper valve 27 is provided to prevent a gust of wind from blowing in the exhaust portion 26 of the fan 14, and lifting up the membrane 11 before the fan 14 can rotate to face the windmill 19 into the wind and turn so as to produce a partial vacuum between the membrane 11 and the separation layer 18.
While this invention has been described in its preferred embodiment, it is appreciated that variations therefrom may be made without departing from the true scope and spirit of the invention. | A roof construction system wherein loosely-laid membranes on the top of a roof are held in place on the roof by suction forces when the wind blows, the suction forces varying directly in proportion to the wind velocity which would otherwise tend to lift the membrane so that frontal pressure and drag could dislodge or damage the roofing. | 4 |
[0001] Relevant subject matter is disclosed in the co-pending U.S. patent applications (Attorney Docket Nos. US14020, US14022, US14023, US14024) filed on the same date and entitled “INJECTION MOLDING DEVICE”, “METHOD FOR MANUFACTURING A FOIL DECORATED MOLDING”, “VALVE DEVICE OF INJECTION MOLDING DEVICE”, “INJECTION MOLDING DEVICE”, respectively, which are assigned to the same assignee with this patent application.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for elongating a foil in an injection molding device.
[0004] 2. Description of Related Art
[0005] Conventionally, various kinds of methods for manufacturing a foil decorated molding, which is molded by an injection molding process and has a transfer layer removed from a substrate foil of a transfer foil and placed on the surface of the molding after the transfer foil is inserted into cavities in an injection mold, have been known in the art. Since the use of the method requires an alignment of the transfer foil along a cavity-forming face of the mold, the transfer foil is preheated before the injection molding process so as to be easily aligned along the cavity-forming face of the mold where the cavity-forming face thereof is greatly recessed or projected from a parting face of the mold.
[0006] A traditional injection molding method includes transferring a heater between the male mold and the female mold to heat the foil before matching the molds, and removing the heater after the foil is heated. However, because of the need for the heater and the space it occupies, cost and volume of the injection mold is increased.
[0007] What is needed is to provide an effective method for elongating a foil in an injection molding device.
SUMMARY
[0008] In one embodiment, a method for elongating a foil, comprising steps of: providing an injection molding device, the injection molding device comprising a male mold having a projecting part protruding and a female mold defining a cavity; transmitting the foil into the injection molding device and between the male and female molds; clamping the male and female molds to form a molding space, the molding space being separated into a first airproof space adjacent to the female mold and a second airproof space adjacent to the male mold by the foil; vacuuming the first airproof space to suck the foil toward the first airproof space; and inputting thermal medium into the second airproof space to press the foil to cling to the inner surface of the cavity of the female mold.
[0009] Other advantages and novel features of the present invention will become more apparent from the following detailed description of an embodiment when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cross-sectional view of an injection molding device actualizing a method for elongating a foil in accordance with an embodiment of the present invention, the injection molding device including a male mold and a female mold;
[0011] FIG. 2 is a cross-sectional view of the female mold, similar to FIG. 1 ;
[0012] FIGS. 3 and 4 are enlarged, partially cutaway views of the male mold of FIG. 1 , showing two using states respectively;
[0013] FIG. 5 is a cross-sectional view of the female mold of FIG. 1 , but showing the foil extending into the cavity of the female mold;
[0014] FIG. 6 is similar to FIG. 1 , but showing the foil extending along an inner surface of the cavity of the female mold and the male and female molds matched together;
[0015] FIG. 7 is similar to FIG. 6 , but showing a state after injection; and
[0016] FIG. 8 is a flow chart of the method for elongating the foil.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , an injection molding device actualizing a method for elongating a foil in accordance with an embodiment of the present invention is provided for elongating a foil 100 . The injection molding device includes a transport 10 , a mold including a male mold 20 and a female mold 30 , a plurality of pressing members 40 , and a thermal medium source 90 .
[0018] The male mold 20 forms a projecting part 21 protruding toward the female mold 30 . A plurality of air discharging holes 23 is defined in the male mold 20 around the projecting part 21 and extending from a side, facing the female mold 30 , of the male mold 20 to an opposite side of the male mold 20 . A pressure release valve 80 is connected to each air discharging hole 23 . The pressure release valve 80 is adjustable according to need during molding. A plurality of receiving slots 25 is defined in the male mold 20 in vicinity of edges of the male mold 20 . A plurality of hermetic rings 27 is received in the corresponding receiving slots 25 .
[0019] Referring to FIG. 2 , the female mold 30 defines a cavity 31 therein. The cavity 31 includes a bottom surface A 3 , a first side surface A 1 extending from an edge of the bottom surface A 3 and a second side surface A 2 extending from an opposite edge of the bottom surface A 3 to a surface that faces the male mold 20 , with an opening formed on the corresponding surface of the female mold 30 . A length of the opening of the cavity 31 is L. A plurality of air discharging holes 32 is defined in the male mold 20 and extending from a side, facing the male mold 20 , of the female mold 30 to an opposite side of the female mold 30 . At least two of the air discharging holes 32 extend from the bottom surface A 3 of the cavity 31 to the corresponding side of the female mold 30 opposite to the male mold 20 . Each air discharging hole 32 is connected to a vacuum pump at the side of the female mold 30 opposite to the male mold 20 . A plurality of hermetic rings 33 is attached to the female mold 30 adjacent to an edge of the female mold 30 .
[0020] Referring also to FIGS. 3 and 4 , the male mold 20 defines a plurality of channels 29 therein extending from a side, facing the female mold 30 , of the projecting part 21 to a side of the male mold 20 opposite to the female mold 30 . Each channel 29 includes a bell-mouthed recessed portion 291 defined in the projecting part 21 with a large end thereof in the surface facing the female mold 30 , of the projecting part 21 , a conduit 295 defined in the male mold 20 communicating with a small end of the recessed portion 291 , and an L-shaped slender duct 296 with one end communicating with the conduit 295 and the other end passing through the surface opposite to the female mold 30 , of the male mold 20 . A block 298 protrudes in from one end opposite to the recessed portion 291 , of the conduit 295 . One end of a pipe 91 is connected to the end opposite to the female mold 30 , of each slender duct 296 , and the other end of the pipe 91 is connected to the thermal medium source 90 . A through hole is defined in the block 298 .
[0021] A plug 70 is attached in each channel 29 . The plug 70 includes a taper-shaped obturating portion 71 for obturating the recessed portion 291 of the channel 29 , and a pole 73 extending from a small end of the obturating portion 71 . The pole 73 extends through the through hole of the block 298 . A fastening member 75 is fixed to a distal end of the pole 73 . A resilient member 79 , such as a spring, fits about the pole 73 and is resiliently located between the block 298 and the fastening member 75 .
[0022] The thermal medium source 90 has thermal medium contained therein, such as thermal liquid or high-pressure gas. In this embodiment, the thermal medium is thermal high-pressure gas. The thermal medium is capable of being heated by an electric heater or an infrared ray heater (IR heater).
[0023] The transport 10 includes two transporting rollers 13 and two guiding rollers 15 positioned at two opposite ends of the mold respectively, for transporting the foil 100 into the mold. The foil 100 includes a base layer, and a printed layer attached to the base layer and having printed patterns or characters.
[0024] Referring also to FIG. 8 , the method includes the following steps. The foil 100 is transported into the mold between the male and female molds 20 , 30 . The male, female molds 20 , 30 , and the pressing members 40 are clamped together to form a molding space among an inner surface of the cavity 31 of the female mold 30 , the projecting portion 21 of the male mold 20 , and parts around the projecting portion 21 . The pressing members 40 are received in the corresponding receiving slots 25 of the male mold 20 , and press the corresponding hermetic rings 27 , 33 to airproof the molding space. The molding space is separated into a first airproof space adjacent to the female mold 30 and a second airproof space adjacent to the male mold 20 by the foil 100 . The vacuum pump is connected to the air discharging holes 32 of the female mold 30 to vacuumize the first airproof space, thus the foil 100 is sucked toward the first airproof space, as shown in FIG. 5 . The pressure release valve 80 is shut, and the value of the pressure release valve 80 is predetermined according to the molding condition. The thermal medium source 90 inputs heated gas to the channels 29 via the pipes 91 . The plugs 70 are driven by the heated gas to move toward the female mold 30 , therefore the channels 29 open. The heated gas is blown into the second airproof space to press the foil 100 to cling to the inner surface of the cavity 31 of the female mold 30 . The foil 100 is intenerated by the heated gas to cling to the inner surface of the cavity 31 easily, as shown in FIG. 6 .
[0025] Referring also to FIG. 7 , molten resin is injected through an injection opening defined in the male mold 20 into the molding space. The molten resin presses the plugs 70 into the corresponding channels 29 against resistance of the corresponding resilient members 79 . The heated gas in the second airproof space is released via the air discharging holes 23 of the male mold 20 when the pressure in the molding space is greater than the predetermined value of the pressure release valve 80 . The molten resin is cooled to form a mold body. The mold is opened, with the male mold 20 being separated from the female mold 30 . The base layer of the foil 100 is released from the mold body. Thus, the printed layer of the foil 100 is attached to a surface of the mold body.
[0026] In this embodiment, the injection molding device is used for elongating the foil 100 between the male and female molds 20 , 30 by exhausting air from the cavity 31 via the air discharge holes 32 of the female mold 30 and pressurizing the foil 100 via the heated gas. For example, a length of the first side surface A 1 is a 1 , a length of the second side surface A 2 is a 2 , and a length of the bottom surface A 3 is a 3 , when the first, second, and bottom surface A 1 , A 2 , A 3 of the cavity 31 and the length L accord with an expressional a 1 +a 2 +a 3 >=(1+20%)*L, the foil 100 is capable of being elongated for suiting the cavity 31 of the female mold 30 .
[0027] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A method for elongating a foil, comprising steps of: providing an injection molding device, the injection molding device comprising a male mold having a projecting part protruding and a female mold defining a cavity; transmitting the foil into the injection molding device and between the male and female molds; clamping the male and female molds to form a molding space, the molding space being separated into a first airproof space adjacent to the female mold and a second airproof space adjacent to the male mold by the foil; vacuuming the first airproof space to suck the foil toward the first airproof space; and inputting thermal medium into the second airproof space to press the foil to cling to the inner surface of the cavity of the female mold. | 1 |
FIELD OF THE INVENTION
The present invention relates to transaction processing in a heterogeneous transaction processing system, and more specifically, to a system, method and article of manufacture for providing interoperability between different transaction processing systems.
BACKGROUND OF THE INVENTION
A significant number of customers and vendors are either rewriting their current transaction-oriented business applications, or writing new ones, using object-oriented methodology and languages. This reengineering has caused many of them to look not only at object-orientation, but also at distributed object-computing infrastructure, (such as Object Request Brokers (ORB)s and related services), for deploying applications. Using an ORB provides an "open" (platform-and vendor-independent) style of application.
Object oriented programming (OOP) has become increasingly used to develop complex applications. As OOP moves toward the mainstream of software design and development, various software solutions require adaptation to make use of the benefits of OOP. A need exists for these principles of OOP to be applied to a universal transaction interface for a plurality of heterogeneous transaction processing systems such that a set of OOP classes and objects for the messaging interface can be provided.
OOP is a process of developing computer software using objects, including the steps of analyzing the problem, designing the system, and constructing the program. An object is a software package that contains both data and a collection of related structures and procedures. Since it contains both data and a collection of structures and procedures, it can be visualized as a self-sufficient component that does not require other additional structures, procedures or data to perform its specific task. OOP, therefore, views a computer program as a collection of largely autonomous components, called objects, each of which is responsible for a specific task. This concept of packaging data, structures, and procedures together in one component or module is called encapsulation.
In general, OOP components are reusable software modules which present an interface that conforms to an object model and which are accessed at run-time through a component integration architecture. A component integration architecture is a set of architecture mechanisms which allow software modules in different process spaces to utilize each others capabilities or functions. This is generally done by assuming a common component object model on which to build the architecture. It is worthwhile to differentiate between an object and a class of objects at this point. An object is a single instance of the class of objects, which is often just called a class. A class of objects can be viewed as a blueprint, from which many objects can be formed.
Object-Oriented Programming (OOP) allows the programmer to create an object that is a part of another object. For example, the object representing a piston engine is said to have a composition-relationship with the object representing a piston. In reality, a piston engine comprises a piston, valves and many other components; the fact that a piston is an element of a piston engine can be logically and semantically represented in OOP by two objects.
OOP also allows creation of an object that "depends from" another object. If there are two objects, one representing a piston engine and the other representing a piston engine wherein the piston is made of ceramic, then the relationship between the two objects is not that of composition. A ceramic piston engine does not make up a piston engine. Rather it is merely one kind of piston engine that has one more limitation than the piston engine; its piston is made of ceramic. In this case, the object representing the ceramic piston engine is called a derived object, and it inherits all of the aspects of the object representing the piston engine and adds further limitation or detail to it. The object representing the ceramic piston engine "depends from" the object representing the piston engine. The relationship between these objects is called inheritance.
When the object or class representing the ceramic piston engine inherits all of the aspects of the objects representing the piston engine, it inherits the thermal characteristics of a standard piston defined in the piston engine class. However, the ceramic piston engine object overrides these ceramic specific thermal characteristics, which are typically different from those associated with a metal piston. It skips over the original and uses new functions related to ceramic pistons. Different kinds of piston engines have different characteristics, but may have the same underlying functions associated with it (e.g., how many pistons in the engine, ignition sequences, lubrication, etc.). To access each of these functions in any piston engine object, a programmer would call the same functions with the same names, but each type of piston engine may have different/overriding implementations of functions behind the same name. This ability to hide different implementations of a function behind the same name is called polymorphism and it greatly simplifies communication among objects.
With the concepts of composition-relationship, encapsulation, inheritance and polymorphism, an object can represent just about anything in the real world. In fact, our logical perception of the reality is the only limit on determining the kinds of things that can become objects in object-oriented software. Some typical categories are as follows:
Objects can represent physical objects, such as automobiles in a traffic-flow simulation, electrical components in a circuit-design program, countries in an economics model, or aircraft in an air-traffic-control system.
Objects can represent elements of the computer-user environment such as windows, menus or graphics objects.
An object can represent an inventory, such as a personnel file or a table of the latitudes and longitudes of cities.
An object can represent user-defined data types such as time, angles, and complex numbers, or points on the plane.
With this enormous capability of an object to represent just about any logically separable matters, OOP allows the software developer to design and implement a computer program that is a model of some aspects of reality, whether that reality is a physical entity, a process, a system, or a composition of matter. Since the object can represent anything, the software developer can create an object which can be used as a component in a larger software project in the future.
If 90% of a new OOP software program consists of proven, existing components made from preexisting reusable objects, then only the remaining 10% of the new software project has to be written and tested from scratch. Since 90% already came from an inventory of extensively tested reusable objects, the potential domain from which an error could originate is 10% of the program. As a result, OOP enables software developers to build objects out of other, previously built, objects. This process closely resembles complex machinery being built out of assemblies and sub-assemblies. OOP technology, therefore, makes software engineering more like hardware engineering in that software is built from existing components, which are available to the developer as objects. All this adds up to an improved quality of the software as well as an increased speed of its development.
Programming languages are beginning to fully support the OOP principles, such as encapsulation, inheritance, polymorphism, and composition-relationship. With the advent of the C++ language, many commercial software developers have embraced OOP. C++ is an OOP language that offers a fast, machine-executable code. Furthermore, C++ is suitable for both commercial-application and systems-programming projects. For now, C++ appears to be the most popular choice among many OOP programmers, but there is a host of other OOP languages, such as Smalltalk, common lisp object system (CLOS), and Eiffel. Additionally, OOP capabilities are being added to more traditional popular computer programming languages such as Pascal.
The benefits of object classes can be summarized, as follows:
Objects and their corresponding classes break down complex programming problems into many smaller, simpler problems.
Encapsulation enforces data abstraction through the organization of data into small, independent objects that can communicate with each other. Encapsulation protects the data in an object from accidental damage, but allows other objects to interact with that data by calling the object's member functions and structures.
Subclassing and inheritance make it possible to extend and modify objects through deriving new kinds of objects from the standard classes available in the system. Thus, new capabilities are created without having to start from scratch.
Polymorphism and multiple inheritance make it possible for different programmers to mix and match characteristics of many different classes and create specialized objects that can still work with related objects in predictable ways.
Class hierarchies and containment hierarchies provide a flexible mechanism for modeling real-world objects and the relationships among them.
Libraries of reusable classes are useful in many situations, but they also have some limitations. For example:
Complexity. In a complex system, the class hierarchies for related classes can become extremely confusing, with many dozens or even hundreds of classes.
Flow of control. A program written with the aid of class libraries is still responsible for the flow of control (i.e., it must control the interactions among all the objects created from a particular library). The programmer has to decide which functions to call at what times for which kinds of objects.
Duplication of effort. Although class libraries allow programmers to use and reuse many small pieces of code, each programmer puts those pieces together in a different way. Two different programmers can use the same set of class libraries to write two programs that do exactly the same thing but whose internal structure (i.e., design) may be quite different, depending on hundreds of small decisions each programmer makes along the way. Inevitably, similar pieces of code end up doing similar things in slightly different ways and do not work as well together as they should.
Class libraries are very flexible. As programs grow more complex, more programmers are forced to reinvent basic solutions to basic problems over and over again. A relatively new extension of the class library concept is to have a framework of class libraries. This framework is more complex and consists of significant collections of collaborating classes that capture both the small scale patterns and major mechanisms that implement the common requirements and design in a specific application domain. They were first developed to free application programmers from the chores involved in displaying menus, windows, dialog boxes, and other standard user interface elements for personal computers.
Frameworks also represent a change in the way programmers think about the interaction between the code they write and code written by others. In the early days of procedural programming, the programmer called libraries provided by the operating system to perform certain tasks, but basically the program executed down the page from start to finish, and the programmer was solely responsible for the flow of control. This was appropriate for printing out paychecks, calculating a mathematical table, or solving other problems with a program that executed in just one way.
The development of graphical user interfaces began to turn this procedural programming arrangement inside out. These interfaces allow the user, rather than program logic, to drive the program and decide when certain actions should be performed. Today, most personal computer software accomplishes this by means of an event loop which monitors the mouse, keyboard, and other sources of external events and calls the appropriate parts of the programmer's code according to actions that the user performs. The programmer no longer determines the order in which events occur. Instead, a program is divided into separate pieces that are called at unpredictable times and in an unpredictable order. By relinquishing control in this way to users, the developer creates a program that is much easier to use. Nevertheless, individual pieces of the program written by the developer still call libraries provided by the operating system to accomplish certain tasks, and the programmer must still determine the flow of control within each piece after it's called by the event loop. Application code still "sits on top of" the system.
Even event loop programs require programmers to write a lot of code that should not need to be written separately for every application. The concept of an application framework carries the event loop concept further. Instead of dealing with all the nuts and bolts of constructing basic menus, windows, and dialog boxes and then making these things all work together, programmers using application frameworks start with working application code and basic user interface elements in place. Subsequently, they build from there by replacing some of the generic capabilities of the framework with the specific capabilities of the intended application.
Application frameworks reduce the total amount of code that a programmer has to write from scratch. However, because the framework is really a generic application that displays windows, supports copy and paste, and so on, the programmer can also relinquish control to a greater degree than event loop programs permit. The framework code takes care of almost all event handling and flow of control, and the programmer's code is called only when the framework needs it (e.g., to create or manipulate a proprietary data structure).
A programmer writing a framework program not only relinquishes control to the user (as is also true for event loop programs), but also relinquishes the detailed flow of control within the program to the framework. This approach allows the creation of more complex systems that work together in interesting ways, as opposed to isolated programs, having custom code, being created over and over again for similar problems.
Thus, as is explained above, a framework basically is a collection of cooperating classes that make up a reusable design solution for a given problem domain. It typically includes objects that provide default behavior (e.g., for menus and windows), and programmers use it by inheriting some of that default behavior and overriding other behavior so that the framework calls application code at the appropriate times.
There are three main differences between frameworks and class libraries:
Behavior versus protocol. Class libraries are essentially collections of behaviors that you can call when you want those individual behaviors in your program. A framework, on the other hand, provides not only behavior but also the protocol or set of rules that govern the ways in which behaviors can be combined, including rules for what a programmer is supposed to provide versus what the framework provides.
Call versus override. With a class library, the code the programmer instantiates objects and calls their member functions. It's possible to instantiate and call objects in the same way with a framework (i.e., to treat the framework as a class library), but to take full advantage of a framework's reusable design, a programmer typically writes code that overrides and is called by the framework. The framework manages the flow of control among its objects. Writing a program involves dividing responsibilities among the various pieces of software that are called by the framework rather than specifying how the different pieces should work together.
Implementation versus design. With class libraries, programmers reuse only implementations, whereas with frameworks, they reuse design. A framework embodies the way a family of related programs or pieces of software work. It represents a generic design solution that can be adapted to a variety of specific problems in a given domain. For example, a single framework can embody the way a user interface works, even though two different user interfaces created with the same framework might solve quite different interface problems.
Thus, through the development of frameworks for solutions to various problems and programming tasks, significant reductions in the design and development effort for software can be achieved. A preferred embodiment of the invention utilizes an object-oriented paradigm that is seen by customers and vendors to provide significantly cheaper application development, in terms of resources required and re-usability of functions and code. However, nearly everyone who has business-and mission-critical applications currently uses a Transaction Processing (TP) monitor system. Today, the most prevalent TP monitor is the Customer Information Control System (CICS) from IBM, followed closely by Information Management System (IMS) from IBM. Other key TP monitors are Pathway from Tandem and Tuxedo from BEA systems. TP monitoring systems are of increasing importance to major banks and airlines.
In the future, the Object Management Group (OMG)-defined Common Object Request Broker Architecture (CORBA), Object Request Broker (ORB) and CORBA Object Transaction Services (OTS), and Microsoft's OLE TP/Network TP will be used to deploy distributed applications, may eventually replace today's special purpose TP monitors. CORBA (Common Object Request Broker Architecture) is a standard for distributed objects being developed by the Object Management Group (OMG). The OMG is a consortium of software vendors and end users. Many OMG member companies are then developing commercial products that support these standards and/or are developing software that use this standard. CORBA provides the mechanisms by which objects transparently make requests and receive responses, as defined by OMG's ORB. The CORBA ORB provides interoperability between applications built in (possibly) different languages, running on (possibly) different machines in heterogeneous distributed environments. It is the cornerstone of OMG's CORBA architecture.
Interoperability between existing TP monitors and new styles of distributed computing using ORBs will be key to an orderly and low-risk migration to new business applications. Thus, there is a requirement for a product that provides transaction interoperability components that run on the popular client platforms, e.g. NT, Sun, HP and DEC and inter-operate with large server systems, e.g. MVS, Tandem, SP2 and HP. These components must allow new (object-oriented) business applications to inter-operate with current TP monitors, using APIs based on a standard object model. The goal of the API design is to allow an application programmer access to services and data residing in an existing TP monitor environment, without requiring the programmer to understand the TP monitor programming model.
SUMMARY OF THE INVENTION
A computer implemented universal, user interface to a plurality of heterogeneous transaction processing systems which allows an application program to access transactions and data residing in an existing transaction processing system is disclosed. The system utilizes a communication link between the application and a transaction processor interoperability component. Then, the system determines which of the one or more transaction processors will process transactions for the application and establishes a communication link between the transaction processor interoperability component and the transaction processor that will process transactions for the application. Then, as the application transmits a transaction from the application to the transaction processor interoperability component, the transaction is formatted by the transaction processor interoperability component for compatability with the transaction processor that will process transactions for the application, and finally transmitting the formatted transaction to the transaction processor that will process transactions for the application. Externalization processing has been extended to provide direct support for communicating to transaction processors.
DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects and advantages are better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
FIG. 1 illustrates a typical hardware configuration of a workstation in accordance with a preferred embodiment;
FIG. 2A illustrates the three major architectural components in accordance with a preferred embodiment;
FIGS. 2B & 2C illustrate block diagram of a system architecture in accordance with a preferred embodiment;
FIG. 3 is an object model system diagram in accordance with a preferred embodiment;
FIG. 4 is an illustration of a diagram for an application starting a transaction in accordance with a preferred embodiment;
FIG. 5 is an illustration of an application setting a default context in accordance with a preferred embodiment;
FIG. 6 is an illustration of an application invoking a service in accordance with a preferred embodiment;
FIG. 7 is an illustration of an application continuing a service conversation with a TP in accordance with a preferred embodiment;
FIG. 8 illustrates an application commit on a transaction in accordance with a preferred embodiment;
FIG. 9 illustrates a scenario where the naming context is known in accordance with a preferred embodiment;
FIG. 10 illustrates a case where the naming context is unknown in accordance with a preferred embodiment;
FIG. 11 is a Booch diagram of an object model of TPInterop in accordance with a preferred embodiment;
FIG. 12 is a Booch diagram of externalization processing in accordance with a preferred embodiment;
FIG. 13 illustrates a simple interaction for an application object using a request object to help the TPXXX object build a request buffer, invoke the request and send back the response;
FIG. 14 is a Booch diagram illustrating the relationship between objects in accordance with a preferred embodiment;
FIG. 15 is a Booch diagram illustrating the Interaction processing in accordance with a preferred embodiment;
FIG. 16 is a Booch diagram setting forth the architecture of the TP monitor in accordance with a preferred embodiment;
FIGS. 17 and 18 set forth some details of CICS processing in accordance with a preferred embodiment;
FIGS. 19 and 20 set forth some details of IMS processing in accordance with a preferred embodiment;
FIGS. 21 and 22 forth some details of Pathway processing in accordance with a preferred embodiment;
FIG. 23 illustrates a Tuxedo request/response transactions within an explicit transaction in accordance with a preferred embodiment; and
FIG. 24 illustrates a Tuxedo conversational transaction within an implicit transaction in accordance with a preferred embodiment.
DETAILED DESCRIPTION
A preferred embodiment of a system in accordance with the present invention is preferably practiced in the context of a personal computer such as the IBM PS/2, Apple Macintosh computer or an UNIX based workstation. A representative hardware environment is depicted in FIG. 1, which illustrates a typical hardware configuration of a workstation in accordance with a preferred embodiment having a central processing unit 10, such as a microprocessor, and a number of other units interconnected via a system bus 12. The workstation shown in FIG. 1 includes a Random Access Memory (RAM) 14, Read Only Memory (ROM) 16, an I/O adapter 18 for connecting peripheral devices such as disk storage units 20 to the bus 12, a user interface adapter 22 for connecting a keyboard 24, a mouse 26, a speaker 28, a microphone 32, and/or other user interface devices such as a touch screen (not shown) to the bus 12, communication adapter 34 for connecting the workstation to a communication network (e.g., a data processing network) and a display adapter 36 for connecting the bus 12 to a display device 38. The workstation typically has resident thereon an operating system such as the Microsoft Windows NT or Windows/95 Operating System (OS), the IBM OS/2 operating system, the MAC OS, or UNIX operating system. Those skilled in the art will appreciate that the present invention may also be implemented on platforms and operating systems other than those mentioned.
FIG. 2A illustrates the three major architectural components in accordance with a preferred embodiment. A client 200 consists of C, C++, Java and Smalltalk applications which converse with an Object Request Broker (ORB) or an Object Transaction System (OTS) to prepare transactions to the Gateway 201. The Gateway 201 provides the interoperability functioning to interface with any of a number of TP monitors on the Server 202, such as CICS, IMS, Pathway and Tuxedo.
FIGS. 2B and 2C illustrate block diagrams of a system architecture in accordance with a preferred embodiment. The application programmer is provided with a single model for accessing existing TP monitor services and data. The model has a gateway side 215 and a server side 205. The server side contains each of the TP servers for CICS 270, IMS 280, Tuxedo 290 and Pathway 295.
Underlying the TP inter-operability component are three TP monitor specific components (concrete implementations of TP monitor independent interfaces) LU 6.2 230, Tuxedo 240 and the Pathway 250 component. The LU6.2 230 component is used for the CICS and IMS interaction, the Tuxedo 240 component is used to support both native and/WS interface and the Pathway 250 component is used to support the RSC interface. Applications 209 are connected via a runtime 210 or ORB 260 to a TP interoperability/externalization component 220 to the appropriate TP component (230, 240 or 250) based on application requirements.
FIG. 3 is an object model system diagram in accordance with a preferred embodiment. Each of the individual objects are described in more detail later in the specification, so for now, an overview of their interconnection and function is provided. The OMG naming service 300 is the principal means for objects to locate other objects. The names given to the objects should be easily recognizable and readable within the problem domain of the application. The naming service will map these user-defined "names" to object references. The name-to-object association is called a "name binding". A "naming context" is an object that contains a set of "name bindings" in which each name is unique. Every object has a unique object ID or reference. One or more names can be associated with the same object reference at the same time, however there is no requirement for all objects to be named.
The admin tool 305 is used to provide an interface between a human administrator and programmatic interfaces offered by internal classes.
Processing comprises the following basic steps. First, get a name context from the user, then present the user with either an existing or default set of property values for modification, and finally store the name context and set of property values.
The property list classes 308 encapsulate property list handling for various concrete TPInterop classes. TPInterop::TPmgr 320 executes on the gateway and accepts a request along with a description of the destination from front-end clients and delegates them to a specific interoperable object 340 (370)(e.g. TPCICS::CallContext 385, TPIMS::CallContext 390, TPTux::CallContext 380 and TPPW::CallContext 395) according to the destination. Since the whole invocation is carried out in a distributed environment, parameters are passed via Extern::Streamable objects 350.
The TPTX class category 360 supports a "mini" transaction interface, useful until OTS can be used. A TPxxx::callMgr inherits from TxRcvr to get the transaction commit signals, and registers itself with the TxXMgr 340 using its factory name as the "id". Applications 330 communicate to the various system objects via transactions.
Scenarios
The following scenarios provide descriptions of sample interaction between major objects of the system.
FIG. 4 is an illustration of a diagram for an application starting a transaction in accordance with a preferred embodiment. When an application 400 starts a transaction, an application request 410 is transmitted to the TP manager 410.
FIG. 5 is an illustration of an application setting a default context in accordance with a preferred embodiment. Processing commences when an application 500 sends a setDefaultContext transaction to the TPInterop TP Manager 520 which results in a the default context being set by the service resolver 530.
FIG. 6 is an illustration of an application invoking a service in accordance with a preferred embodiment. Processing commences when an application 601 transmits a write request to a TP. The request generates an invoke transaction 602 to the Tpinterop which results in a resolution of the name 603. The resolved name is utilized in another invoke 604 to register the name via the call manager to the TP transmit manager 605. Then the call manager transmits the registered name 606 which results in a creation operation 607 for the particular transaction. The call manager for the particular TP allocates a buffer 608 and then sets the buffer in preparation for the write operation 609.
Then, the call manager externalizes the write operation 610 in preparation for the actual write operation 611 performed by the external object stream IO processor. Next, the call manager must get the buffer 612 that the external object has streamed back from the target TP. Then, the call manager performs a do operation 613 and sets the buffer 614 in preparation for internalizing 615 the information. Finally, a read is requested from the application 616 and the information is read 617.
FIG. 7 is an illustration of an application continuing a service conversation with a TP in accordance with a preferred embodiment. In the scenario illustrated in FIG. 6, the invoke on the TPInterop::TPMgr, and the subsequent invoke on the TPxxx::callMgr, may return a CallContext object. For the purposes of this scenario, the invoke did return a CallContext object and the application is now invoking an operation on it 702. The invoke operation 702 was initiated in response to the write request 701 and initially must create an object for streaming the information externally 703. Then a buffer must be allocated 704 and the buffer must be set 705 for the upcoming externalize 706 and write 707 operations. To read the reply 713, first the buffer length must be obtained 708 and a d operation 709 must be performed to set the buffer 710 and internalize 711 the results. Then, the read 712 operation can transpire resulting in the reply being read 713.
FIG. 8 illustrates an application commit on a transaction in accordance with a preferred embodiment. Processing commences with a commit operation 801 from the application to the transaction manager. This action results in the TP call manager preparing 802 utilizing a prepare operation 803. Then, the TP manager commits 804 and the commit operation is performed 805.
TPTX
The TPTX class category supports a "mini" transaction interface, useful until OTS can be used. A TPxxx::callMgr inherits from TxRcvr to get the transaction commit signals, and registers itself with the TxXMgr using its factory name as the "id".
Source code for the module is provided below for detailed logic. ##SPC1##
Admin
The admin tool is used to bridge an interface between a human administrator and programmatic interfaces offered by internal classes. The general algorithm is to do the following:
get a name context from the user
present the user with either an existing or default set of property values for modification
store the name context and set of property values This module presents no new objects.
Usage Scenarios
FIG. 9 illustrates a scenario where the naming context is known in accordance with a preferred embodiment. An initial transaction querying for the name context 901 triggers a get property transaction from the admin tool to the Service resolver 902 which returns the "known" property. Then the admin tool sends out another transaction to get the factory 903 from the interoperability tool. The values are returned from the admin tool to the user 904. Then, a check of the values is initiated by the admin tool 905 and the properties are set in the service resolver 906.
FIG. 10 illustrates a case where the naming context is unknown in accordance with a preferred embodiment. An initial transaction querying for the name context 1011 triggers a get property transaction from the admin tool to the Service resolver 1002 which returns a "unknown" property. The user is queried for the factory type 1003. Then the admin tool sends out another transaction using the factory 1003 type to the interoperability tool to get the factory 1004 and to get the defaults from the TP manager 1005. The values are returned from the admin tool to the user 1006 to determine if they meet with user approval. Then, a check of the values is initiated by the admin tool 1007 and the properties are set in the service resolver 1008.
PropList
The property list classes encapsulate property list handling for various concrete TPInterop classes. ##SPC2##
TP Interoperability
TPInterop::TPmgr executes on the gateway and accepts a request along with a description of the destination from front-end clients and delegates them to a specific interoperable object (e.g. TPCICS::CallContext, TPIMS::CallContext, TPTux::CallContext and TPPW::CallContext) according to the destination. Since the whole invocation is carried out in a distributed environment, parameters are passed via Extern::Streamable objects. Externalization referred in this section is based on OMG's Object Externalization Service Specification.
Detail Object Model
FIG. 11 is a booch diagram of an object model of TPInterop in accordance with a preferred embodiment. TPInterop::CallContext is an abstract base class. All subclasses have to override invoke method, and the method invokeObject on TPInterop::CallMgr 1102. TPInterop::TPmgr 1104 is the interface exported to the application. Since registerCallMgr is specific for TPInterop::CallMgr, TPInterop::TPmgr -- Ex is used internally. There is only one instance of TPInterop::TPmgr 1104 per process. Each TPInterop::CallMgr object within the process registers itself with TPInterop::TPmgr object. RegisterCallMgr and unregisterCallMgr are the facilities provided by the TPInterop::TPmgr 1104 object.
An externalization service is a standard service for streaming objects to and from transport streams, persistent storage, etc. It consists of two main pieces: an abstract Extern::Streamable class 1112 which an application object inherits from, and an abstract Extern::StreamIO class 1110 which the externalization service provides an implementation for. Externalize is called by a TPIterop:TPConversation class 1106 which passes an Extern::StreamIO 1108 subclass object, and the object 1108 is expected to write its state out using the Extern::StreamIO::writeXxx calls 1110. When internalize is called, the object is expected to read its state from the Extern::Streamable object 1112 using the Extern::StreamIO::readXxx calls. The Extern::StreamIO class is similar in function to a C++ iostream class, but uses explicit method calls to read and write data types rather than use operator overloading. ##SPC3##
Major Behavior Description
A preferred embodiment provides the application developer with two transaction models: explicit model and implicit model.
The syntax of the code using explicit model is similarly to the following code segment:
tptxObject.Begin -- Transaction();
cicsObject.go(request1, response1);
cicsObject.go(request2, response2);
tptxObject.End -- Transaction();
In implicit model, invocation of invoke method starts and commits the transaction. The syntax of the code looks as follows:
tpinteropMgr.go("debit1", request1, response1);
tpinteropMgr.go("debit2", request2, response2);
Data and Format Conversion Between Systems
The purpose of this section is to identify the data conversion required for a specific TP component, running on the gateway platform and the server platform on which the TP server is running.
Little & Big Endian
Little and big Endian relates to the format integers (2 or 4 byte) are stored on a specific platform Floating point numbers are stored in different formats, e.g. IEEE.
Big Endian SUN, HP, RS/6000, Tandem, System/390 systems.
______________________________________ Integer (2 byte) 12 Integer (4 byte) 1234______________________________________
Little Endian
Intel systems
______________________________________ Integer (2 byte) 21 Integer (4 byte) 4321______________________________________
ASCII & EBCDIC
ASCII and EBCDIC formats relates to the way character data is formatted. The IBM System/390 platform is the only platform that uses the EBCDIC data format.
CICS & IMS
______________________________________Gateway Server Endian Data RepresentationPlatform Platform Conversion Conversion______________________________________Intel - S/390 Little Endian ASCII to EBCDIC(NT,OS/2) (MVS) to Big EndianRS\6000 - S/390 None ASCII to EBCDIC(AIX) (MVS)SPARC - S/390 None ASCII to EBCDICSUN (MVS)HP-PA S/390 None ASCII to EBCDIC7100 - HP (MVS)______________________________________
Pathway
______________________________________Gateway Server Endian Data RepresentationPlatform Platform Conversion Conversion______________________________________Intel - Tandem Little Endian None(NT,OS/2) to Big EndianRS/6000 - Tandem None None(AIX)SPARC - Tandem None NoneSUNHP-PA Tandem None None7100 - HP______________________________________
Tuxedo
Note: the Tuxedo workstation service performs internal little and big Endian conversions.
______________________________________Gateway Server Endian Data RepresentationPlatform Platform Conversion Conversion______________________________________Intel - SUN/HP None None(NT,OS/2)RS/6000 - SUN/HP None None(AIX)SPARC - SUN/HP None NoneSUNHP-PA SUN/HP None None7100 - HP______________________________________
Externalization
The OMG Externalization Service is a standard service for streaming objects to and from transport streams, persistent storage, etc. It consists of two main pieces an abstract Extern::Streamable class which an application object inherits from, and an abstract Extern::StreamIO class which the externalization service provides an implementation for.
The Extern::Streamable class provides to methods: externalizeToStream, and internalizeToStream. When externalize is called, an Extern::StreamIO subclass object is passed to the application object, and object is expected to write its state out using the Extern::StreamIO::writeXxx calls. When internalize is called, the object is expected to read its state from the Extern::StreamIO subclass object using the Extern::StreamIO::readXxx calls. The Extern::StreamIO class is similar in function to a C++ iostream class, but uses explicit method calls to read and write data types rather than use operator overloading.
The externalization service acts as a bridge between the TP monitor communication buffer and the ORB world. The application object creates a request and reply object. The request object supports the externalize function to create a request buffer for the TP link object, and the reply object supports the internalize function to read the reply buffer. The request and reply object act as a bridge between the ORB world and the TP monitor world--the TP monitor buffers are never seen, but the request and reply objects know the exact order of the data in
Data Types
The following data types are supported: char*, char, octet, short, unsigned short, long, unsigned long, float, double and bool, where both bool and octet are defined as unsigned short.
StdStreamIO's data format is OMG Object Externalization Specification compliant. TPStreamIO's data format is different. It does not have data type and data length fields. TPStreamIO is the class used for externalization and internalization at Stage1A. ##SPC4##
TPStreamIO provides methods to set up the buffer pointer, for the reason that Tuxedo needs to use buffer allocated by its own memory allocation APIs.
Data Format Conversion
Since the Gateway platform and Server platform might be different, and different platforms might have different scheme for data representation, program running on Gateway need converting the data format to be compliant with that of the server platform. The following tables show what operations need to be performed for data conversion based upon different Gateway and Server platform configurations.
FIG. 12 is a Booch diagram of externalization processing in accordance with a preferred embodiment. Every Extern::TPStreamIO 1220 object has two internal flags of bool types; they are flagLtoB and flagAtoE. When an Extern::TPStreamIOFactory 1270 is asked to create an Extern::TPStreamIO 1230, it must be given the information about Gateway platform and Server platform. According to the message, it looks up the table and sets the flags of the Extern::TPStreamIO 1230 correspondingly. When the Extern::TPStreamIO 1230 object is asked to write or read, it will check those flags also. The Extern::TPStreamIOFactory 1270 object is a singleton object.
Interactive Diagram
FIG. 13 illustrates a simple interaction for an application object using a request object to help the TPXXX object build a request buffer, invoke the request and send back the response.
CORBA ORB portability
To minimize dependencies on the ORB, the concrete implementation of the streamIO objects should be built as stand-alone C or C++ objects, with the ORB implementation classes delegating work to the C++ classes.
Non-CORBA ORB portability
Most distributed object managers have this notion of object streaming, and there is only so much variation. Using the same technique as for "CORBA ORB portability", any future service, such as an Distributed OLE streaming mechanism, can be used.
ISNaming and SvcResolve
The OMG naming service is the principal means for objects to locate other objects. The names given to the objects should be easily recognizable and readable within the problem domain of the application. The naming service will map these user-defined "names" to object references. The name-to-object association is called a "name binding". A "naming context" is an object that contains a set of "name bindings" in which each name is unique. Every object has a unique object ID or reference. One or more names can be associated with the same object reference at the same time, however there is no requirement for all objects to be named.
Because a naming context is an object, it too can be bound to a name in a naming context. Binding naming contexts to other naming contexts creates a "naming graph". The "naming graph " is a directed graph or tree where the nodes are naming contexts and the leaves are name bindings to non-naming context objects. Given a context in a naming graph a sequence of names can reference an object.
ISNaming Naming contexts and names
In the OMG Naming service a "name component" is a structure with two attributes, an identifier which includes the object's name string, and a kind which includes a string that is a description of the objects name, ie. file type etc. A name with a single "name component" is called a "simple name", a name with "multiple components" is called a "compound name." Each component except the last is used to name a context; the last component denotes the bound object.
The kind attribute for the Name component will be assumed to be NULL and will be omitted from the NameComponent definition. Compound names will simply be defined as a unique string similar to a directory name in common PC files systems, with a "/" character delimiting each substring representing the NameComponent within the compound name. Names are specified without the trailing "/" character, the process of binding a name to a context will be equivalent to the operation of adding the "/" character to the string. The following names
BANKING/RETAIL/CHECKING/DEBIT
and
BANKING/RETAIL/CHECKING/CREDIT
refer to bound objects.
SvcResolve
The SvcResolve class provides a naming service and server for names and objects associated with the TPInterop::TPMgr. It maintains naming contexts and name-object associations for TPInterop::CallMgr objects and subclasses for this release.
Object Model
FIG. 14 is a Booch diagram illustrating the relationship between the TPInterop::TPMgr 1400, TPInterop::CallMgr 1410, TPInterop::CallContext 1420 classes and the SvcResolve::Resolver 1420 naming service components. ##SPC5##
Usage examples and scenarios Names to Object Table
The following table maps name/naming contexts to objects.
______________________________________ Re-Name/Naming Context ference Property List______________________________________/BANK/RETAIL/CHK/DEBIT TUXE- RequestType = DO request/response BufferType = VIEW startTx = YES/BANK/RETAIL/CHK/CREDIT TUXE- RequestType = DO request/response BufferType = VIEW startTx = YES/BANK/COMM/TRADE/BOND/SELL CICS CICSPGM = CICSAPP/BANK/COMM/TRADE/BOND/BUY CICS CICSPGM = CICSAPP/BANK/RETAIL/SAV/DEBIT IMS TRANCODE = SAV001TR/BANK/RETAIL/SAV/CREDIT IMS TRANCODE = SAV002TR______________________________________ ##SPC6##
TPInterop::TPMgr Interaction
FIG. 15 is a Booch diagram illustrating the Interaction processing in accordance with a preferred embodiment. The TPInterop::TPMgr creates the SvcResolve::Resolver object, (during its initialization or startup). and calls the SvcResolve::Resolver method "setGlobalNamingContext"
1. The Application is activated, and calls the TPInterop::TPMgr method "invoke" with the following parameters as shown at 1501.
Name representing the TPInterop::CallMgr
application streamable input object.
application streamable output object.
2. The TPInterop::TPMgr get the input name representing the TPInterop::CallMgr object as shown at 1502.
3. The TPInterop::TPMgr calls resolveTPServiceDestination on the SvcResolve::Resolver object with the name representing the transaction as an input parameter. The method returns an object reference, and the associated property list as shown at 1503.
4. The TPInterop::TPMgr calls the getCallMgr method with the object reference obtained in 3) to locate the appropriate TPInterop::CallMgr object as shown at 1504.
5. The property list is used as input for the invoke method on the TPInterop::TPCallMgr object as shown at 1505.
TPxxx--Typical TP Monitor Model
This section describes a typical implementation of a set of TPxxx classes, such as TUXEDO, CICS, etc.
Object Model
FIG. 16 is a Booch diagram setting forth the architecture of the TP monitor in accordance with a preferred embodiment.
IDL
A typical implementation of TPxxx classes introduces no new methods, but overrides the abstract class interfaces shown in the object model.
Usage Scenarios
See the scenario in the overview chapter for an overview, and see the specific TPxxx chapters for specific details.
CICS
FIGS. 17 and 18 set forth some details of CICS processing in accordance with a preferred embodiment. The purpose of this component is to provide connectivity between the TP inter-operability module and a CICS system running on another computer. Connectivity to CICS is achieved through the CICS LU 6.2 service and the CICS user transaction is invoked via the CICS Program Link interface. The LU 6.2 service allows a client LU 6.2 application (written to the basic LU 6.2 level or using the CPIC interface) to connect to a CICS system running on a server through the CICS LU 6.2 service. A CICS LU 6.2 transaction will be provided by this project to inter-operate with the CICS LU 6.2 service and the client LU 6.2 application. The CICS LU 6.2 transaction will convert the data received from an LU 6.2 client and then perform a CICS Program Link command to invoke the appropriate CICS user application.
In FIG. 17, processing commences at 1701 and immediately passes to 1702 to invoke a transaction and connect to a CICS LU 6.2 service. At 1703 a register operation occurs and a get request 1704 to allocate a streamIO, setbuffer, externalize the transaction and obtain the buffer length. Then, at 1705 a LU 6.2 allocate operation is performed and at 1706 a send operation is performed. Finally, at 1707, a put reply is performed to allocate streamIO, internalize the transaction and obtain the buffer length of the transaction. A second invoke operation 1708 is performed in which the first operation is a register operation 1709 which will fail since the transaction is already registered. Then a get request 1710 is performed which initiates a send/recieve 1711 transaction which invokes a put reply 1712 and ultimately an end transaction 1713 which invokes a prepare 1714 transaction and sends a prepare message 1715 which results in a commit 1716 and a syncpoint message 1717 and ultimately an LU 6.2 dealloc 1718.
In FIG. 18 processing commences at 1803 where an invoke operation occurs which returns a context object. Then, at 1804 a register operation is performed which fails if there is no transaction. At 1805, a get request is sent and at 1806 an LU 6.2 allocate operation is performed which is followed by an LU 6.2 send/recieve 1807 and a put reply 1808 is used to transmit the transaction to the CICS system. At 1809 another invoke operation is performed and a get request 1810 is utilized to initiate a send/receive transaction 1811 which prepares a message to send 1812 and invokes a send syncpoint message 1801 which results in an LU 6.2 deallocate operation 1802 and a put reply 1813.
The CICS Program Link interface requires a program name which is the name of the CICS user application that will be invoked. This program will run under CICS transaction id associated with the user program. The Program Link interface also requires an input and output buffer the so called Commarea. The Commarea is used for both input and output data. The input data will be as a result of the object attributes being streamed and the output data will be the data returned by the CICS user application.
The connectivity between the CICS inter-operability module and CICS system will be via LU 6.2. The CPIC interface can be used to perform the LU 6.2 communication using sync level 1 or confirm protocol.
Usage Scenarios
See the "overview" chapter for a generic interaction diagram. The following are some specific details.
Usage Notes
In conversational or request/response mode, it is invalid for there to be a NULL request and/or reply object.
If there is not a current transaction, the StartTransaction property will be checked. If it is set to yes, a transaction will be committed at the end of a successful LU 6.2 send/receive (request/response mode) or at the end of a conversation (conversational mode) initiated by LU 6.2 allocate.
CICS transactions are started implicitly by the first EXEC CICS LINK request.
Request/response will always return a nil callContext object. Conversational mode always returns a callContext object, unless the conversation is ended on the LU 6.2 deallocate.
Service Parameters
The following service parameters are defined:
______________________________________Name Description Values______________________________________Partner Name of CPIC side file char 8!NameProgram Name of CICS application char 8!Name programStart Start a transaction when Implicit, NoneTransaction there isn't a current one______________________________________
IMS
FIGS. 19 and 20 set forth some details of IMS processing in accordance with a preferred embodiment. The processing set forth in these figures corresponds very closely to the processing in FIGS. 17 and 18. The purpose of this component is to provide connectivity between the TP inter-operability module and an IMS system running on another computer. Connectivity to IMS is achieved through the IMS LU 6.2 to LU 6.1 adapter which will place an IMS transaction on the IMS transaction queue. The IMS adapter allows a client LU 6.2 application (written to the basic LU 6.2 level or using the CPIC interface) to connect to an IMS system running on a server through the IMS LU 6.2 to LU 6.2 adapter.
Usage Notes
With IMS it is not easy to determine when an IMS transaction is started or ended, therefore whether a transaction is started explicitly or implicitly is irrelevant to the IMS transaction on the server side.
If there is not a current transaction, the StartTransaction property will be checked. If it is set to yes, the conversation will be ended at the end of a successful LU 6.2 send/receive (request/reply mode) or at the end of a conversation initiated by LU 6.2 allocate.
Request/response will always return a nil callContext object. Conversational always returns a callContext object, unless the conversation is ended after the LU 6.2 send/receive.
Service Parameters
The following service parameters are defined:
______________________________________Name Description Values______________________________________Partner Name Name of CPIC side file char 8!TP Name IMS Transaction name char 8!______________________________________
Pathway
FIGS. 21 and 22 set forth details of Pathway processing in accordance with a preferred embodiment. The processing set forth in these figures corresponds very closely to the processing in FIGS. 17 and 18. The purpose of this component is to provide interoperability between the TP inter-operability module and a Pathway system running on a Tandem computer. Connectivity to Pathway is achieved through the RSC service which runs on the client and server (Tandem) side. The RSC service allows a client application to connect to a Pathway system running on a server through TCP/IP.
Usage Notes
In conversational mode, to initiate a RscWrite, pass in a NULL reply object. Otherwise for a RscWriteRead a non-NULL response and reply objects are required.
If there is not a current transaction, the StartTransaction property will be checked. If it is set to yes, a transaction will be started and committed at the end of a successful RscWrite or RscWriteRead (request/reply mode) or at the end of a conversation initiated by RscBeginSession.
Request/response will always return a nil callContext object. Conversational always returns a callContext object, unless the conversation is ended on the RscEndSession.
Service Parameters
The following service parameters are defined:
______________________________________Name Description Values______________________________________Pathway Name of the application Char 16!Server Class Pathway server class.NameRSC INI File File name for initiation char 8!Name parametersStart Start a transaction when Implicit, NoneTransaction there isn't a current one______________________________________
Tuxedo
The Tuxedo TP interop component is a concrete implementation of several abstract classes. It supports the following features:
Request/response (tpcall) access to Tuxedo services is supported.
Conversational (tpconnect) access to Tuxedo services is supported.
The Tuxedo TP interop component will run on a machine supporting either native Tuxedo or/WS.
The four types of Tuxedo communication buffers, CARRAY, String, VIEW and FML, are supported to facilitate access to transaction demarcation verbs.
Usage Scenarios
FIG. 23 illustrates Tuxedo request/response transactions within an explicit transaction in accordance with a preferred embodiment. FIG. 24 illustrates a Tuxedo conversational transaction within an implicit transaction in accordance with a preferred embodiment. The processing set forth in these figures corresponds very closely to the processing in FIGS. 17 and 18.
Usage Notes
In conversational mode, to initiate a tprecv without a previous tpsend, pass in a NULL request object. To initiate a tpsend without a subsequent tprecv, pass in a NULL reply object.
If there is not a current transaction, the StartTransaction property will be checked. If it is set to yes, a transaction will be started and committed at the end of a successful tpcall or at the end of a conversation initiated by tpconnect.
Request/response will always return a nil callContext object. Conversational always returns a callContext object, unless the conversation is ended on the tpconnect.
While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A computer implemented transaction processing system is presented for processing transactions between an application and one or more transaction processors. The system utilizes a first communication link between the application and a transaction processor interoperability component. Then, the system determines which of the one or more transaction processors will process transactions for the application and establishes a communication link between the transaction processor interoperability component and the transaction processor that will process transactions for the application. Then, as the application transmits a transaction from the application to the transaction processor interoperability component, the transaction is formatted by the transaction processor interoperability component for compatability with the transaction processor that will process transactions for the application, and finally transmitting the formatted transaction to the transaction processor that will process transactions for the application. Externalization processing has been extended to provide direct support for communicating to transaction processors. | 6 |
[0001] There are no related patent applications.
[0002] The present application was not subject to federal research and/or development funding.
TECHNICAL FIELD
[0003] Generally, the present invention relates to a reusable food pouch that stores puree for feeding infants and small children. More specifically, the reusable food pouch includes a flexible resilient material having a solid neck that accepts both a storage cap and an interchangeable dispensing nozzle.
BACKGROUND OF THE INVENTION
[0004] There are several types of storage containers for use in storing food. For instance, there are glass and metal cans which are vacuum sealed. Other types of storage containers include flexible plastic bags such as sandwich bags or bags which include tracks and rails which mate to one another to create a seal. Still other containers include a foil material or a paper-based substrate. By way of example, the following patents and publications are representative of the state of the art.
[0005] U.S. Pat. No. 5,116,105 discloses a paper container device that consists of a cuboid container body with a round hole made of aluminum foil paper and a sucking pipette having an extending portion with a sharp end. The round hole is disposed at the uppermost middle portion of the right side of the container body. The upper right folded triangle portion on the upper side is folded down and glued to the surface of the right side, the pipette is partly glued between the right folded triangle portion and the surface of the right side. The pipette together with the triangle portion can be torn apart and its sharp end can pierce through the aluminum foil into the container body for sucking out the drink in it.
[0006] U.S. Pat. No. 5,188,261 discloses a collapsible dispensing container for beverages and other products. The body of the container is capable of being completely collapsed in a horizontal plane. The body of the container comprises two flat, parallel, and flexible body members sealed or otherwise positioned together to form a flat, envelope-like pouch. One body member incorporates an access port for introducing product into and withdrawing product from the dispensing container. The configuration access port prevents spills or leaks by narrowly circumscribing access to the product held in the dispensing container.
[0007] U.S. Pat. No. 6,076,968 discloses a flexible pouch formed from a first sheet and second sheet which are in sealing engaged along their side edges. Two gussets are provided at the top and bottom, respectively, of the sheets. The bottom of the'uppermost gusset is recessed such that a pocket is formed at one end of the pouch. A compartment is formed within the pouch by the two sheets and the two gussets. A straw or other suitable instrument can be used to puncture the uppermost gusset in order to remove the contents from the compartment of the pouch. This pocket has a wide mouth and will enable easy insertion of the straw while minimizing or eliminating product spillage.
[0008] U.S. Pat. No. 6,651,845 discloses a container system for dispensing flowable materials and includes a prefilled, disposable bag, a reusable outer support and a reusable cap. The bag fits into the outer support and has a flat top with a collar that is held between the cap and outer support. The cap includes a tube for dispensing the material. The tube punctures the top of the bag when the cap is assembled to the outer support.
[0009] U.S. Pat. Pub. 2008/0175520 discloses a food storage bag formed from a planar sheet of polymeric material. The bag has two food storage compartments defined therein, each with a closure for items received therein. In one version the bag is formed with two, differently sized compartments integrally secured to each other on a single backing.
[0010] U.S. Pat. Pub. 2009/0238495 discloses a portable storage container that consists of multiple compartments that are used to separate different components of a stored item. The storage device is made from a plurality of polymeric film sheets that are connected through a perimeter seal that leaves a vacant space within the perimeter seal between the polymeric film sheets for creating multiple compartments. The compartments are separated through frangible sealing structures that are made up of a plurality of individual seals of varying types. When the device is operated, the frangible sealing structure is ruptured, therefore allowing the separated components to mix. Using a sealing structure made up of multiple seals ensures that the compartments remain separated when the storage container is subjected to harsh environmental conditions.
SUMMARY OF THE INVENTION
[0011] The instant invention is a reusable food pouch having a first end that includes a threaded neck through which food passes into a semi-rigid food storage compartment. The first end is substantially flat when viewed from a front or back end of the pouch. The pliable sides of the food storage compartment may be gently squeezed to remove food stored within the pouch or evacuate air from within when depositing food therein to ensure longevity of the stored food. A storage cap mates with the threaded neck to seal air and air-borne contaminants from spoiling the stored food. The storage cap is removed by twisting it from the threaded neck; thereafter, food may be squeezed from within the pouch. Otherwise, the storage cap may be replaced with a dispensing cap which comprises a straw that passes through the cap and through which food in the pouch may be squeezed. The food pouch and caps may be formed from a food safe material such as a polymer comprising Polyethylene Terephthalate, High Density Polyethylene, Low Density Polyethylene or Polypropylene. In an additional embodiment, a removable, thin, plastic insert is provided in the food pouch storage area. The removable plastic insert may include rigid neck or an elongated neck which extends over the end of the threaded to prevent the insert from being entirely displaced into the storage area.
[0012] In a preferred embodiment, the reusable food pouches are used to dispense pureed food for infants, toddlers, and children. The reusable food pouch may vary in size from one to three ounces or multiples thereof and is formed from a plastic material such as a polymer. The unique shape of the reusable food pouch is absent of sharp edges to prevent injury to the user's hands as well as scrapes to other parts of the body.
[0013] An object of the invention is to teach a reusable food storage container into which a small portion of food may be deposited for consumption at a later time.
[0014] A further object of the invention is to teach a flexible reusable food storage container that includes flexible resilient sides into which food is deposited and which may be viewed to ensure that stored food is not spoiled.
[0015] An additional object of the invention is to provide a reusable food storage container which is shaped to prevent spillage of food from therein when the container rests on a surface.
[0016] 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 from practicing the invention. The objects and advantages of the invention will be obtained by means of instrumentalities in combinations particularly pointed out in the appended claims.
DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a front view of the food storage pouch.
[0018] FIG. 2 is a cross section side view of the food storage pouch.
[0019] FIG. 3A is an enlarged perspective view of a dispensing cap. FIG. 3B is an enlarged perspective view of a storage cap.
[0020] FIG. 4A is a cross section view of an embodiment that includes a disposable inner liner. FIG. 4B is a cross section view of a further embodiment including the disposable inner liner.
[0021] FIG. 5 shows a plurality of food storage pouches maintained within a tray.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The embodiments of the invention and the various features and advantageous details thereof are more fully explained with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and set forth in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and the features of one embodiment may be employed with the other embodiments as the skilled artisan recognizes, even if not explicitly stated herein. Descriptions of well-known components and techniques may be omitted to avoid obscuring the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples and embodiments set forth herein should not be construed as limiting the scope of the invention, which is defined by the appended claims. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
[0023] FIGS. 1 and 2 are views of the food storage pouch 1 and showing a first end that includes a threaded neck 3 onto which a threaded cap 10 A, 10 B is fitted. Curved sidewalls 2 A, 2 B substantially form a bullet-shape when viewed from the side and include shoulders which taper into the threaded neck. Each sidewall is rounded such that when the pouch is placed on a flat surface on either side, the neck will be maintained above a plane of the flat surface such that the neck does not come into contact with the flat surface. Each sidewall terminates in a second end 4 which is closed and substantially round, when viewed from the side to prevent the user from standing up the pouch on end. This rounded end prevents spillage should the pouch be inadvertently knocked over.
[0024] FIG. 3A shows a dispensing cap 10 A having a straw 11 that extends through an opening having a diameter substantially equal to an exterior diameter of a cross section of the straw to create a substantially air-tight seal between the opening and exterior of the straw. A dispensing end of the straw 11 A extends above the threaded cap 10 A. An intake end of the straw 11 B extends downward into the interior of a cavity 15 such that food may be squeezed or sucked from within. FIG. 3B shows a storage cap 10 B which comprises a solid top and interior threads that mate with the threads on the neck of the storage pouch.
[0025] FIG. 4A is a cross section view of an embodiment that includes a disposable inner liner 20 that defines a cavity 21 . The inner liner 20 is stuffed into the pouch 1 through the open end of neck 3 . Thereafter, food or fluids may be deposited into the cavity 21 . When the contained food is removed, the inner liner 20 may be withdrawn from within the pouch 1 and discarded. A new inner liner may thereafter be inserted into the pouch 1 . As can be easily understood from FIGS. 4A and 4B , an open end of the inner liner 20 may be comprise a portion 22 that extends only over the open end of the neck 3 as shown in FIG. 4A . Otherwise, a portion 23 of the open end of the inner liner 20 may extend across the open end of the neck 3 and onto the threaded exterior of the neck to be secured against the neck via the cap 10 A, 10 B.
[0026] FIG. 5 shows a plurality of food storage pouches 1 maintained within a tray 30 . The tray 30 is helpful in holding the pouches 1 in an upright position when food or fluids are being deposited into the pouches 1 . The tray 30 includes a plurality of docks 31 to receive the pouches 1 .
[0027] 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 the scope of the invention as defined in the following claims. While the invention has been described with respect to preferred embodiments, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in limiting sense. From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof. | A reusable food pouch includes a rigid neck through which food is passed and into a storage reservoir. The rigid neck includes threads onto which either a storage cap or dispensing cap is attached. Resilient, pliable sidewalls form the storage reservoir and are generally bullet shaped when viewed from either the front or rear. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a process for charging at least one free-flowing component with gas in the preparation of cellular plastics from at least two free-flowing reaction components. The gas is metered into a hollow stirrer from the outside, sucked in by it and is dispersed into the component in a gassing chamber.
In order to achieve certain properties in such plastics, it is necessary to charge at least one component with gas, for example air. The quality of the properties desired in the end product very largely depends on the dispersion and homogenization of the gas in the component. Such processes are used in particular in the preparation of preferably foamed polyurethane plastics, polyisocyanurate plastics and polyurea plastics. Dispersion of the gas into the component in a gassing tank provided with a hollow stirrer, with the gassing tank being intermediately positioned in a line leading from the storage tank to the mix head, is known from German Offenlegungsschrift No. 3,434,443. The stirrer blades of the hollow stirrer and/or the stirrer speed thereof are adjustable, so that a desired amount of gas per unit time can be sucked in. Other gassing processes with hollow stirrers are known and are described in published European application Nos. 110,244 and 175,252, and in German Offenlegungsschrift No. 3,434,444.
All the above processes have the deficiency that the dispersion and homogenization of the gas in the component is not adequate, which manifests itself in particular in the gassing of highly viscous components and with sparingly soluble gases.
An object of the present invention was to improve the processes of the above-mentioned type to the extent that the degree of dispersion of the gas in the component and the rate of solution are increased. At the same time, it was an object to allow the the devices of the above type to be used successfully for components of relatively high viscosity.
BRIEF DESCRIPTION OF THE DRAWING
The drawing illustrates an apparatus for performing the process of the present invention.
DESCRIPTION OF THE INVENTION
The above objects are achieved by operating the hollow stirrer at a higher gas throughput capacity (standard liter per minute) than that corresponding to the amount of gas (standard liter per minute) available to it. In this way, a relatively high pressure difference (reduced pressure) is achieved at the hollow stirrer, which means that the gas is taken up faster and more homogeneously by the component. A higher solubility is thereby effected. As a rule, a constant higher speed of rotation is set in comparison with the known processes in order to achieve the higher gas throughput capacity. The same effect would be achieved by a corresponding change in the position or length of the stirrer blades, but this would be more expensive industrially.
A device for carrying out the new process is shown schematically in section in the drawing and will be explained in more detail below.
Polyol (as the component to be charged with gas) is introduced from a storage tank, not shown, via a line 1 into the upper region of a closed gassing tank 2. A line 4 leads from the bottom 3 of the gassing tank to a mix head, not shown. In the mixhead, the polyol charged with gas is mixed with isocyanate as a further component. After the mixture has left the mix head, polyurethane foam is formed from it. The stirrer unit 5 consists of a drive motor 6 of adjustable speed of rotation and a hollow stirrer 7, which is passed through the tank lid 9 by means of a seal 8. Outside the stirrer tank 2, the hollow stirrer 7 has a suction opening 10, which is connected to openings 12 provided at the ends of the stirrer arms 11. In the region of the suction opening 10, the hollow stirrer 7 is surrounded by a housing 13 in which a gas feed line 14 merges. The gas feed line is connected to a gas source 15. A gas metering unit 16 which consists of a gas flow meter 17 and a gas flow regulating valve 18 is positioned in the line 14. Both the polyol and the gas are fed continuously in a constant flow and the mixture is removed. The stirrer 5 operates at a constant speed of rotation, which is adjusted so that a higher gas throughput capacity than that corresponding to the amount of gas available from the gas metering unit 16 is achieved.
In one example of use, the gassing tank 2 has a volume of 2 liters. It is under an operating pressure of 3 bar. The hollow stirrer 7 operates at 3,000 rpm, which corresponds to a suction capacity of 10 standard 1/1 min. However, the amount of gas available from the gas metering unit 16, in this case air, is only 5 standard 1/min. In this way, a suction effect (pressure difference) of 0.4 bar is generated. 6 1/min polyol are fed in. The mean residence time of the polyol in the stirrer tank 2 is 20 sec. The gassed polyol has a bubble content of 27/cm 2 at an average bubble size of 0.9 mm.
(It is usual to determine the number of bubbles per square centimeter. The gassed component is introduced into a transparent vessel and the bubbles, present within a defined area of the vessel wall, are counted.) | The present invention is directed to a process for charging a component with a gas. The gas is metered through a hollow stirrer into the component to be charged with gas. The stirrer is operated at a higher gas throughput capacity than the amount of gas metered. | 1 |
GOVERNMENT LICENSE RIGHTS
This invention was made with United States Government support under Contract No. NBCH020055 awarded by the Defense Advanced Research Projects Administration. The United States Government has certain rights in the invention.
BACKGROUND
1. Field of the Invention
The present invention relates to techniques for routing signals across a semiconductor chip. More specifically, the present invention relates to a method and an apparatus for routing differential signals across a semiconductor chip in a manner that reduces effective capacitance and differential coupling.
2. Related Art
As processor clock speeds continue to increase at an exponential rate, data must be transferred at correspondingly faster rates between computer system components. This can be a problem for conventional bus structures because the faster switching speeds and smaller voltage swings in the latest generation of semiconductor chips cause signal lines to be more sensitive to noise.
To remedy this problem, designers are beginning to use differential signaling to transmit signals across a semiconductor chip. Differential signaling uses two signal lines to carry a “true” and “complement” version of each signal, wherein the value of the signal is indicated by the voltage difference between the two signal lines. Because currents are balanced between power and ground rails, differential signaling reduces power supply noise and effectively provides return currents. Moreover, differential signaling is less sensitive to ground shifts (or other common mode noise) between sender and receiver because differential signaling relies on voltage differences between pairs of signal lines, instead of relying on an absolute voltage level of a single signal line.
As the demand for higher bandwidth continues to increase, designers are beginning to pack differential wires tightly together to increase the total number of communication channels. However, when differential wires are packed tightly together, they can potentially interfere with each other through energy coupling, which can have deleterious effects on performance and reliability. For example, FIG. 1 illustrates a differential pair of wires, A and Ā, which carry complementary signals. Hence, if A moves up, Ā moves down, and vice versa. The differential pair, B and {overscore (B)}, operates in the same manner. Note that these differential pairs typically belong to a wider signal bus, which includes additional differential pairs of the same length that run in the same direction.
In the arrangement of wires as illustrated in FIG. 1 , signals in neighboring wires can potentially interfere with each other. For example, if a signal in wire B moves up, the corresponding complement signal in wire {overscore (B)} moves down. Since wire Ā is adjacent to wire B, this can couple energy into wire Ā, which can potentially cause errors or reduce performance. Furthermore, note that signals in wires Ā and B can disturb each along the entire length of the wires.
In order to remedy this problem, designers sometimes “twist” differential pairs of wires. For example, FIG. 2 illustrates a “fully-twisted” wiring scheme. In this fully-twisted scheme, if wire B moves up, it couples wire Ā upwards for ¼ of the wire length, but it also couples wire A upwards for ¼ of the wire length. At the same time, wire Ā has the same downward effect on both B and {overscore (B)}. Hence, the net coupling effect is zero in the first order.
Note, however, that wires A and Ā (and wires B and {overscore (B)}) are adjacent, and typically with minimal spacing. The line-to-line capacitance of two adjacent wires in a modem technology is approximately 70% of the total capacitance of the wire. In addition, the effective capacitance between any two physical structures doubles when the voltage on those two structures swings in opposite directions. Consequently, this fully-twisted scheme doubles the wire-to-wire “effective” capacitance seen by each wire, thereby causing higher power dissipation as well as longer delay.
Hence, what is needed is a method and an apparatus for routing differential signals across a semiconductor chip in a manner that reduces effective capacitance as well as differential coupling.
SUMMARY
One embodiment of the present invention provides an arrangement of differential pairs of wires that carry differential signals across a semiconductor chip. In this arrangement, differential pairs of wires are organized within a set of parallel tracks on the semiconductor chip. Furthermore, differential pairs of wires are organized to be non-adjacent within the tracks. This means that each true wire is separated from its corresponding complement wire by at least one intervening wire in the set of parallel tracks, thereby reducing coupling capacitance between corresponding true and complement wires. Moreover, this arrangement may include one or more twisting structures, wherein a twisting structure twists a differential pair of wires so that the corresponding true and complement wires are interchanged within the set of parallel tracks.
In a variation on this embodiment, the one or more twisting structures are arranged so that substantially zero net differential coupling capacitance exists for each differential pair of wires.
In a variation on this embodiment, the set of parallel tracks includes a possibly repeating pattern of four adjacent tracks, including a first track, which is adjacent to a second track, which is adjacent to a third track, which is adjacent to a fourth track. Furthermore, the differential pairs of wires include a first differential pair, A and Ā, and a second differential pair, B and {overscore (B)}, wherein A starts in the first track, B starts in the second track, Ā starts in the third track and {overscore (B)} starts in the fourth track. A first twisting structure causes B and {overscore (B)} to interchange, so that A is in the first track, {overscore (B)} is in the second track, Ā is in the third track and B is in the fourth track. A second twisting structure causes A and Ā to interchange, so that Ā is in the first track, {overscore (B)} is in the second track, A is in the third track and B is in the fourth track. Finally, a third twisting structure causes {overscore (B)} and B to interchange, so that Ā is in the first track, B is in the second track, A is in the third track and {overscore (B)} is in the fourth track.
In a variation on this embodiment, the first twisting structure is located approximately one quarter of the way down the set of parallel tracks; the second twisting structure is located approximately one half of the way down the set of parallel tracks; and the third twisting structure is located approximately three quarters of the way down the set of parallel tracks.
In a variation on this embodiment, the first twisting structure is located more than one quarter of the way down the set of parallel tracks; the second twisting structure is located more than one half of the way down the set of parallel tracks; and the third twisting structure is located more than three quarters of the way down the set of parallel tracks.
In a variation on this embodiment, the set of parallel tracks includes a possibly repeating pattern of four adjacent tracks, including a first track, which is adjacent to a second track, which is adjacent to a third track, which is adjacent to a fourth track. Furthermore, the differential pairs of wires include a first differential pair, A and Ā, and a second differential pair, B and {overscore (B)}, wherein A starts in the first track, B starts in the second track, Ā starts in the third track and {overscore (B)} starts in the fourth track. A first twisting structure causes A and Ā to interchange, so that Ā is in the first track, B is in the second track, A is in the third track and {overscore (B)} is in the fourth track.
In a variation on this embodiment, the first twisting structure is located approximately one half of the way down the set of parallel tracks.
In a variation on this embodiment, the first twisting structure is located more than one half of the way down the set of parallel tracks.
In a variation on this embodiment, the set of parallel tracks includes a possibly repeating pattern of six adjacent tracks, including a first track, which is adjacent to a second track, which is adjacent to a third track, which is adjacent to a fourth track, which is adjacent to a fifth track, which is adjacent to a sixth track. Furthermore, the differential pairs of wires include a first differential pair, A and Ā, a second differential pair, B and {overscore (B)}, and a third differential pair, C and {overscore (C)}, wherein A starts in the first track, B starts in the second track, Ā starts in the third track, C starts in the fourth track, {overscore (B)} starts in the fifth track and {overscore (C)} starts in the sixth track. A first twisting structure causes A and Ā to interchange, so that Ā is in the first track, B is in the second track, A is in the third track, C is in the fourth track, {overscore (B)} is in the fifth track and {overscore (C)} is in the sixth track.
In a variation on this embodiment, the first twisting structure is located approximately one half of the way down the set of parallel tracks.
In a variation on this embodiment, the first twisting structure is located more than one half of the way down the set of parallel tracks.
In a variation on this embodiment, the set of parallel tracks are located within the same metal layer in the semiconductor chip, and the one or more twisting structures use at least one other metal layer to interchange signals between tracks.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates an untwisted wire set.
FIG. 2 illustrates a fully-twisted wire set.
FIG. 3 illustrates an intertwisted wire set in accordance with an embodiment of the present invention.
FIG. 4 illustrates a pairwise-minimal intertwisted wire set in accordance with an embodiment of the present invention.
FIG. 5 illustrates a three-way-minimal intertwisted wire set in accordance with an embodiment of the present invention.
FIG. 6 illustrates a wire twist in accordance with an embodiment of the present invention.
FIG. 7 illustrates an untwisted wire set in accordance with an embodiment of the present invention.
FIG. 8A illustrates a bend in a set of parallel tracks.
FIG. 8B illustrates another bend in a set of parallel tracks.
FIG. 8C illustrates a bend in a set of parallel tracks in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
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 a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present 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.
Intertwisted Wire Set
Although the conventional fully-twisted wire set illustrated in FIG. 2 works reasonably well, it fully exposes each wire to its complement. As a result, on any wire's transition, the capacitance between that wire and its neighboring complement will always be maximal.
More specifically, assuming a line-to-grounded-line coupling capacitance of C c for the full length of the wire, and assuming all wires are homogenous so that C c is the same for each pair of wires, in the fully-twisted scheme any switching wire will have a total effective coupling capacitance of 3C c . Of this coupling capacitance, 2C c is due to its complement, because its complement moves in the opposite direction, and C c is due to its neighbor because exactly half of its neighbor will switch in the opposite direction (causing an effective capacitance of 2C c for half the length of the wire) and the other half switches in the same direction (causing an effective capacitance of zero), or its neighbor does not switch, in which case the entire length of the wire still has an effective capacitance of C c to its unrelated neighbor.
By contrast, the intertwisted wire set illustrated in FIG. 3 interleaves wires pairwise to break apart this close coupling between a wire and its complement. As with the fully-twisted scheme illustrated in FIG. 2 , a voltage step on either wire set A or wire set B will introduce no net coupling on the other wire set.
In addition, a significant improvement arises from the interleaving of two pairs of wires. This interleaving separates A from its complement Ā, as well as B from its complement {overscore (B)}. Hence, when A moves up and Ā moves down, they do not suffer from the increased capacitance cost present in the fully-twisted scheme. This means that the intertwisted scheme consumes less power to charge this capacitance, and furthermore takes less time to transmit voltage signals down the wire. Consequently, in the intertwisted scheme, any wire's coupling capacitance is 2C c , which is about a 30% improvement. This is the same as if both neighboring wires were grounded.
Note that this intertwisted scheme saves quite a bit of energy and delay, since coupling capacitance makes up close to 70% of the total wire capacitance in modem technologies with tall wires. Moreover, this intertwisted scheme rejects noise just as well as the fully-twisted scheme does.
Pairwise-Minimal Intertwisted Wire Set
For wire systems that care about differential noise but not common-mode noise, a simpler pattern can reduce the number of twists with no loss in differential noise rejection. FIG. 4 illustrates this “pairwise-minimal intertwisted” scheme in accordance with an embodiment of the present invention. In this scheme, only wire set A is twisted, while wire set B runs straight through. As with the intertwisted scheme, wire sets A and B do not interfere differentially with each other and they also do not couple into themselves, which reduces capacitance and thereby saves power and delay.
In this scheme, there are fewer twists, and hence fewer wire obstructions on the metallization layers immediately above and below the wires A and B. On the other hand, the drawback is that if wire B switches up (and {overscore (B)} switches down), then wires A and Ā see a uniform upward disturbance. Note that this is not a differential noise, but a common-mode noise, which can often be ignored in digital systems.
In the FIG. 4 , wire C represents the bottom of the next pair of wire sets. Note that this pattern can be repeated with no differential coupling between repeated patterns.
Three-Way-Minimal Intertwisted Wire Set
FIG. 5 illustrates a “three-way-minimal intertwisted” wire set in accordance with an embodiment of the present invention. This three-way-minimal intertwisted wire set offers the same benefits in rejecting differential noise as the pair-wise-minimal intertwisted scheme illustrated in FIG. 4 . Except here, wire sets A, B, and C can coexist with no differential coupling between each other, while only paying the cost of a single twist among them. Like the pairwise-minimal intertwisted scheme, this three-way-minimal intertwisted scheme does not reject common-mode noise.
In FIG. 5 , wire D represents the bottom of the next three-way pattern of wire sets. Note that this pattern can be repeated with no differential coupling between repeated patterns.
Also note that the wires need not be part of the same bus that transmits from location X to location Y on a chip. In particular, if wires A and Ā are part of a bus from X to Y, and wires B and {overscore (B)} are part of a different bus, either running in the reverse direction (from Y to X), or even to and from wholly different sources and receivers, the scheme is still applicable. To minimize noise as well as delay and power, the wires need only twist in an interleaved fashion.
Wire Twists
As is illustrated in FIG. 6 , in one embodiment of the present invention a wire twist requires side routes in another routing layer to accomplish a twist between wires A and Ā across an intervening wire B. More specifically, the wire A moves from the first track to the third track directly, without a side route through another layer. The wire B does not changes tracks, but passes under (or over) the wire A. This is accomplished by passing through a via (indicated by cross-hatching) to another routing layer (indicated by a diagonal pattern) before returning through another via to its original layer. The wire Ā similarly passes (from left to right) through a via into a vertical strip in the other layer, which passes under (or over) wire B and then passes underneath wire A for some distance before returning through a via to its original layer.
Note that in technologies that allow wires at 45 degrees, twists can cost less than in this Manhattan layout. Also note that fully-landed and fully-enclosed vias typically require more room than a wire's minimum-allowed width, but these are long wires and are typically wider than minimum.
Using too few vias to connect two wires leads to poor performance. Technologies with aluminum wires use poorly-conducting tungsten vias, and consequently have resistance values of 5–10 Ohms per via. In this case, one via is certainly not sufficient, and even four may not be, either. Processes with copper help significantly, because they pour the vias in the same step as pouring the wires, making a via equivalent to an extra square of length. However, even in copper technologies it is advantageous to array many vias together, because vias serve as nucleation sites for voids that migrate down the wire during operation.
Hence, the true cost of twists is probably closer to five or more wire pitches. In a wire several thousand microns long, this may be seem insignificant but still leads to inconvenient layout constraints.
Twists also lead to a slight imbalance in the wire characteristics. With enough vias to minimize twist resistance, the effects of the twist are trivial relative to the rest of the long wire. In addition, on-chip wires are not “transmission-line-like” enough to make twists meaningful from an impedance-matching perspective.
Location of Wire Twists
For the schemes depicted in FIGS. 4 and 5 , one might wonder if twisting at the mid-way point is best. Any wires that run bi-directionally would best be served by twists at the midway position.
Consider, however, in FIG. 4 the noise coupled onto {overscore (B)} from A and Ā, with the twist at the mid-way position. Here, we are concerned about the noise at the receiver end, or the far right, of wire {overscore (B)}. The current injected onto {overscore (B)} from A is closer to {overscore (B)}'s right end than the current injected onto {overscore (B)} from Ā. This matters because the current injected onto {overscore (B)} will split: some will go left, and some will go right. The further from the right that the current enters, the less that will actually go to the right.
Note that moving the twist to the right can help because it makes more of the injected current from Ā go to the right to balance out the injected current from A. However, moving it too far makes the injected current from Ā too strong.
Twists Can Occur at Bends in Parallel Tracks
Note that a set of parallel tracks can bend (for example, by ninety-degrees) in order to connect two components on the semiconductor die. This is typically performed as is illustrated in FIGS. 8A and 8B . Note that in an integrated circuit layout it is common to have one metal layer dedicated to horizontal signal lines and another adjacent metal layer dedicated to vertical signal lines. Hence, if a wire bends by ninety degrees (from horizontal to vertical or from vertical to horizontal) a via is typically used to connect the horizontal signal line to the vertical signal line. Hence, in the examples illustrated in FIGS. 8A and 8B , note that when the set of parallel tracks bends ninety degrees, the wires move through vias (indicated by cross-hatching) to another metal layer (indicated by a diagonal pattern). Also note that the bend illustrated in FIG. 8A reverses the order of the wires, whereas the bend illustrated in FIG. 8B does not.
In the embodiment of the present invention, a true wire can be easily exchanged with its complement by staggering the bends in the true and complement wires relative to each other so that the true and complement wires cross as is illustrated in FIG. 8C . In FIG. 8C note that signals A and Ā are interchanged at the ninety-degree bend. Furthermore, note that since vias are already used to perform a ninety-degree bend (as is illustrated in FIGS. 8A and 8B ) no additional vias are required to accomplish this interchange, and hence there is no additional cost for this crossover.
Untwisted Wire Set
FIG. 7 illustrates an untwisted wire set in accordance with an embodiment of the present invention. In this wire set, each wire is separated from its complement by an intervening wire. For example, wire A is separated from wire Ā by the intervening wire B. Note that this untwisted pattern repeats for additional wires. Moreover, this untwisted pattern provides similar power reduction benefits of the previous embodiments (illustrated in FIGS. 3–6 ), as well as some noise cancellation benefits, without the need for twisting structures to interchange the wires.
The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description only. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims. | One embodiment of the present invention provides an arrangement of differential pairs of wires that carry differential signals across a semiconductor chip. In this arrangement, differential pairs of wires are organized within a set of parallel tracks on the semiconductor chip. Furthermore, differential pairs of wires are organized to be non-adjacent within the tracks. This means that each true wire is separated from its corresponding complement wire by at least one intervening wire in the set of parallel tracks, thereby reducing coupling capacitance between corresponding true and complement wires. Moreover, this arrangement may include one or more twisting structures, wherein a twisting structure twists a differential pair of wires so that the corresponding true and complement wires are interchanged within the set of parallel tracks. | 7 |
The present invention relates to a high-pressure pump with an on-off valve for feeding fuel to an internal combustion engine, particularly a vehicle engine.
BACKGROUND OF THE INVENTION
Various types of high-pressure fuel feed pumps are known, and which are generally supplied with fuel from a normal tank by a low-pressure pump powered by an electric motor. The high-pressure pump normally comprises an on-off valve, which is opened automatically by the fuel fed to it by the low-pressure pump.
The body of known high-pressure pumps encloses at least a fuel compression chamber, and an actuating chamber housing pump actuating members; and the on-off valve comprises a shutter designed to ensure fuel flow to the actuating chamber, even when the valve is closed, to lubricate and cool the actuating members.
In one known radial-piston pump in particular, the pump body houses three cylinders, in which slide respective pistons activated by a common cam carried by a shaft activated by the drive shaft; the cam is housed inside the actuating chamber or case of the pump; and the shutter is in the form of a hollow cylinder and slides along the wall of a radial hole in the pump body.
The pump body also has a fuel feed conduit for feeding fuel from the radial hole to the cylinders; the feed conduit is closed by the lateral wall of the shutter; and, to lubricate and cool the pump shaft, the cam, and the various pump body and piston friction surfaces, the shutter also has a calibrated axial hole permitting continuous fuel flow to the case.
To prevent fuel accumulating in an engine cylinder, in the event the respective injector breaks down, or to prevent fuel from being drawn from the actuating chamber in the event of poor or no supply by the low-pressure pump, e.g. due to a fault, the shutter is closed automatically by a compression spring when the pressure of the incoming fuel falls below a given value.
The compression spring is housed inside the shutter and rests on a perforated plate, which has a surface for receiving the end of the spring and is normally fixed, e.g. welded, to the opposite end of the guide hole of the shutter.
In this known type of pump, machining the radial hole in the pump body, fixing the plate, and assembling the spring are difficult, high-cost operations involving considerable time and highly skilled personnel. Moreover, the perforated plate at the end of the hole facing the case limits to a certain extent the outside diameter of the cam and, hence, the capacity of the pump under given conditions.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an extremely straightforward, reliable high-pressure pump having an on-off valve which is cheap to produce and easy to assemble, so as to eliminate the aforementioned drawbacks of known pumps with on-off valves
According to the present invention, there is provided a high-pressure pump with an on-off valve for feeding fuel to an internal combustion engine, wherein the pump comprises a body including at least a fuel compression chamber and an actuating chamber enclosing actuating members of said pump, and wherein said valve comprises a shutter sliding inside a hole in said body to close a fuel feed conduit; said feed conduit being formed in said body, between said hole and said compression chamber; and said shutter being held in the closed position by a compression spring; characterized in that said spring rests directly or indirectly on a shoulder inside said hole; said shoulder being formed in one piece with said body.
In a first embodiment of the invention, the spring rests on the shoulder by virtue of means fixed removably inside the hole and comprising a perforated disk inserted removably inside the hole, and an elastic C-shaped metal element located, between the disk and the shoulder, inside an annular groove adjacent to the shoulder
In a further embodiment of the invention, the spring rests directly on the shoulder, and the wall of the hole has an annular groove permitting precision machining of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
Two preferred, non-limiting embodiments of the invention will be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows a partly sectioned side view of a high-pressure pump with an on-off valve for feeding fuel to an internal combustion engine, in accordance with the invention;
FIG. 2 shows a larger-scale section of the valve and a portion of the pump, according to a first embodiment of the invention;
FIG. 3 shows a larger-scale plan view of a detail in FIG. 2;
FIG. 4 shows a section of a further detail of a variation of FIG. 2;
FIG. 5 shows a larger-scale section of the valve and a portion of the pump, according to a further embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Number 5 in FIG. 1 indicates as a whole a high-pressure pump for feeding fuel to an internal combustion engine, e.g. of a vehicle. Pump 5 is supplied with fuel from a normal tank by a low-pressure pump (not shown) powered by an electric motor energized when the engine is turned on.
High-pressure pump 5 is of the type comprising three radial pistons 6 , which slide inside three cylinders 7 arranged radially inside a body 8 of pump 5 ; each cylinder 7 is closed by a plate 9 supporting an intake valve 11 and a delivery valve 12 ; and each cylinder 7 and respective plate 9 are locked to body 8 by a corresponding lock head 13 .
Pistons 6 are activated in sequence by a single cam integral with a shaft 16 powered by the internal combustion engine drive shaft. Cam 14 acts on pistons 6 via a ring 17 having, for each piston 6 , a faced portion 18 cooperating with a shoe 19 fixed to piston 6 ; and each shoe, 19 is pushed towards the cam by a corresponding spring 21 .
The gap between the end of each piston 6 and respective plate 9 defines a compression chamber 22 , so that; the three compression chambers 22 are obviously housed inside body 8 . The space inside body 8 housing cylinders 7 and in which shaft 16 and cam 14 rotate forms an actuating chamber 23 of pump 5 , which chamber is closed by a flange 24 fixed in known manner to body 8 ; shaft 16 is fitted in rotary and fluidtight manner to flange 24 ; and chamber 23 communicates in known manner with a drain conduit 25 draining into the tank.
Body 8 is made of cast iron, and heads 13 of steel; body 8 and heads 13 have three intake conduits 26 communicating with a conduit defined by an annular groove 27 on flange 24 ; each conduit 26 also communicates with the corresponding compression chamber 22 via corresponding intake valve 11 ; and each head 13 also has a compression conduit 28 , which, via corresponding delivery valve 12 , connects compression chamber 22 to a delivery conduit 29 of pump 5 .
Body 8 also has a feed conduit 30 formed by two holes 31 arranged crosswise to each other and closed outwards by two plugs 32 At one end, conduit 30 communicates with annular groove 27 of flange 24 and, therefore, with compression chambers 22 ; and, at the other end, conduit 30 comes out at a cylindrical wall 33 of a cylindrical radial hole 34 formed in body 8 . Hole 34 communicates with actuating chamber 23 and projects partly towards flange 24 ; and an inlet conduit 36 connected to the low-pressure pump is inserted inside hole 34 .
Hole 34 houses an on-off valve indicated as a whole by 37 and comprising a hollow, cylindrical shutter 38 . More specifically, shutter 38 is piston- or cup-shaped, and comprises a lateral wall 39 , which slides accurately along wall 33 of hole 34 , so that both wall 33 of hole 34 and wall 39 of shutter 38 must be precision machined.
Shutter 38 also comprises a flat wall 40 , which has a calibrated hole 41 permitting the passage of a certain amount of fuel, even when conduit 30 is closed by shutter 38 . A helical compression spring 42 is inserted inside shutter 38 and rests on a supporting element fixed to the end of hole 34 facing actuating chamber 23 ; and the supporting element must be perforated to permit fuel passage from hole 34 to actuating chamber 23 , as described in Italian Patent Application N TO95A 000010.
According to the invention, the supporting element of spring 42 is defined by a shoulder 43 of hole 34 , formed in one piece with body 8 and located at the end of hole 34 adjacent to actuating chamber 23 . Shoulder 43 defines a circular opening 45 (FIG. 2) smaller in diameter than hole 34 ; and spring 42 rests directly or indirectly on shoulder 43 , thus simplifying assembly of on-off valve 37 .
In the FIG. 2 embodiment, spring 42 rests on shoulder 43 by virtue of means fixed removably inside hole 34 and comprising a disk 44 having a central opening 46 permitting fuel passage from hole 34 to actuating chamber 23 . Advantageously, the difference in diameter between hole 34 and opening 45 ranges between 1 and 3 mm, and shoulder 43 is of a thickness ranging between 2 and 4 mm.
Opening 46 in disk 44 has a protruding edge 47 for guiding one of the ends of spring 42 ; and disk 44 , together with opening 46 and protruding edge 47 , may be formed cheaply from sheet metal by means of a punching and cold forming or embossing press.
The means fixed removably inside hole 34 also comprise a radially flexible C-shaped metal element 48 , e.g. a standard retaining ring (FIG. 3 ), housed inside hole 34 (FIG. 2 ), between disk 44 and shoulder 43 . More specifically, wall 33 of hole 34 has an annular groove 49 adjacent to shoulder 43 , and into which ring 48 clicks removably; and the diameter of opening 45 is such as to enable groove 49 to be machined through opening 45 .
Ring 48 is fitted inside groove 49 or removed from the groove by bringing the two ends of ring 48 together, so that the parts of valve 37 are obviously also easy to assemble, the only precaution being to assemble disk 44 with edge 47 facing spring 42 .
To eliminate even the above precaution and/or simplify automatic assembly of valve 37 , in the FIG. 4 variation, opening 46 of disk 44 may be provided with a ring 51 forming two edges symmetrical with respect to disk 44 and projecting axially in two opposite directions. Ring 51 may be welded to or formed in one piece with disk 44 by compacting and sintering metal powder.
In the FIG. 5 embodiment, spring 42 rests directly on shoulder 43 . Advantageously, the diameter of opening 45 ranges between 3 and 5 mm, and shoulder 43 is of a thickness ranging between 5 and 8 mm. To permit fine machining of wall 33 of hole 34 from outside body 8 , an annular groove 52 is machined in wall 33 , and which may be shallower than groove 49 in FIG. 2, so that valve 37 in FIG. 5 is even cheaper to produce than that in FIG. 2 .
As compared with known pumps, the advantages of the high-pressure pump according to the invention will be clear from the foregoing description. In particular, removable assembly of disk 44 and ring 48 reduces production cost of the pump; shoulder 43 eliminates the need to fix the supporting element of spring 42 inside hole 34 ; and there is no interference between cam ring 17 and the supporting element of spring 42 , so that the diameter of cam 14 can be increased to increase pump capacity.
Clearly, changes may be made to the high-pressure pump as described herein without, however, departing from the scope of the accompanying Claims. For example the pistons of pump 5 may be arranged otherwise than as described; and the pump may be applied to other than a vehicle engine. | The pump has a body including at least a fuel compression chamber and an actuating chamber enclosing the actuating members of the pump. The on-off valve has a shutter sliding inside a hole in the body to close a fuel feed conduit. The shutter is held in the closed position by a compression spring, which rests directly or indirectly on a shoulder in the hole. In one embodiment, the spring rests on the shoulder via a perforated disk held by a retaining ring, which clicks removably inside an annular groove in the hole. In a further embodiment, the spring rests directly on the shoulder. | 5 |
FIELD OF INVENTION
[0001] The invention relates generally to planetary gears, and more particularly to reels carrying coiled tubing for coiled tubing injectors and similar mechanisms driven by a planetary gearing system.
BACKGROUND
[0002] Coiled tubing well intervention has been known in the oil production industry for many years. A great length, often exceeding 15,000 feet of steel tubing, is handled by coiling it on a large reel, which explains the name of coiled tubing. The tubing reel cannot be used as a winch drum. The stresses involved in using it as a winch would destroy the tubing. The accepted solution in the oil industry is to pull tubing from the reel as it is required and pass it around a curved guide arch so that it lies on a common vertical axis with the well bore. To move the tubing into and out of the well bore, a device called a coiled tubing injector is temporarily mounted on the wellhead, beneath the guide arch. Examples of coiled tubing injectors include those shown and described in U.S. Pat. Nos. 5,309,990, 6,059,029, and 6,173,769, all of which are incorporated herein by reference.
[0003] Coiling tension is controlled by a tubing reel drive system and remains approximately constant no matter if the injector head is running tubing into or out of the well, or if it is pulling or snubbing. The coiling tension is insignificant by comparison to tubing weight and payload carried by the tubing in the well bore and therefore is no danger to the integrity of the tubing.
[0004] Although other methods of achieving this aim are known, injector heads used for well intervention and drilling utilize a plurality of chain loops, on which are mounted grippers for gripping the tubing. There are many examples of such injector heads. Most rely on roller chains and matching sprocket forms as a means of transmitting drive from the driving shafts to the chain loop assemblies. For the injector head to manipulate tubing, it pushes, from opposite sides, the grippers against the tubing and then concurrently moves the grippers by rotating to move the tubing in and out of the well bore.
[0005] A coiled tubing reel assembly includes a stand for supporting a spool on which tubing is stored, a drive system for rotating the reel and creating back-tension during operation of the reel, and a “level winding” system that guides the tubing as it is being unwound from and wound onto the spool. The level winding system moves the tubing laterally across the reel so that the tubing is laid across the reel in a neat and organized fashion. The coiled tubing reel assembly must rotate the spool to feed tubing to and from the injector and well bore. The tubing reel assembly must also tension the tubing by always pulling against the injector during normal operation. The injector must pull against the tension to take the tubing from the tubing reel, and the reel must have sufficient pulling force and speed to keep up with the injector and maintain tension on the tubing as the tubing is being pulled out of the well bore by the injector. The tension on the tubing is always being maintained in an amount sufficient to wind properly the tubing on the spool and to keep the tubing wound on the spool.
[0006] Although a spool can be rotated by means of a chain and a sprocket mounted on the axle of the coiled tubing spool, planetary gear drives are typically used to rotate the spool. A planetary gear drive is capable of delivering high torque at low speeds without the heaviness and expense of a chain and sprocket. Closed center planetary gear drives are usually preferred. Such drives have all of their components mounted symmetrically about the center of rotation, including the drive motor, which may be electric or hydraulic.
[0007] In a typical arrangement, the output of a planetary gear drive supports one end of the reel, connecting directly to the axle of the reel. Integral brakes are usually fitted to the planetary drive to provide a parking brake for preventing unwinding of the stored tubing when the drive motor is not powered. Planetary gearing is also referred to as epicyclic gearing. Planetary gearing comprises one or more gears, called planet gears, that revolve around a central gear called a sun gear. The planet gears are mounted to a carrier, which may rotate relative to the sun gear. An outer gearing, called an annulus, meshes with the planet gear. Planetary gearing may be either simple or compound. A simple planetary gear has one sun, one ring, one carrier and one set of planet gears. A compound planetary gearing has a more complex structure. There exist many examples of compound structures too numerous to list. In a coiled tubing reel application, the planetary gear drive functions as reduction gearing that takes a relatively high speed, low-torque input, such as from a hydraulic motor, and provides a relatively low speed, high-torque output that is coupled with the hub of the reel, with the input to the planetary gearing rotating about the same axis as its output and the spool.
[0008] A fluid swivel connects to the other end of the axle of the reel for coupling a fluid source to the coiled tubing wound on the reel. Because the planetary gear drive is connected to one end of the spool's central axle, and the fluid axle is connected to the other end, a concentric rotary union or a slip ring assembly is used to run electrical and other wires into the coiled tubing for transmitting electrical signals to and from sensors and other equipment connected to the end of the coiled tubing. The concentric rotary union must have a sufficiently large internal hub that can be bored out to pass over the axle of the reel. Alternately, to avoid having to incorporate concentric rotary ring, a chain and sprocket is used.
SUMMARY
[0009] The invention pertains generally to a modified planetary gear box or drive and arrangement of the gear box with a drive motor that permits electrical, optical, hydraulic or other types of cabling, wiring, or lines to be passed through the planetary gear box. When the planetary gear is connected to one end of a reel of coiled tubing, cabling is able to be passed through the planetary gear box directly into one end of a hub of the reel, and then into the end of the coiled tubing that is being injected into a wellbore, while the other end of the reel's hub is connected to a swivel joint that can be connected to a pump for pumping fluid into the coiled tubing.
[0010] In one representative embodiment, a conduit extends through the center of the planetary gear box housing and its sun gear, the axis of the conduit being aligned with the axis of rotation of the input to the planetary gear box and to its output, the output being coupled to the axle of, for example, a coiled tubing reel. An output shaft of a drive motor that is offset from the central axis of the planetary gear is coupled to the rotary input of the planetary gear box through, for example, one or more gears, chains, or other means for coupling the output shaft of the drive motor to the input of the planetary gear box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side view of a representative example of a coiled tubing unit deployed at a well site, with a cooled tubing reel assembly mounted on a trailer feeding coiled tubing into a coiled tubing injector connected to a riser on top of a well head.
[0012] FIG. 2 is a side view, partially section, of a coiled tubing reel comprising a stand and spool.
[0013] FIG. 3 is an enlarged portion of the side view of FIG. 2 showing the details of a planetary gear drive.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0014] In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the invention. In the drawings and description that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures may not be to scale. Certain features of the invention may be shown exaggerated in scale or in a schematic form, and details of conventional elements may be omitted in the interest of clarity and conciseness. The terms “including” and “comprising” are meant to be inclusive or open-ended, and not exclusive. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.
[0015] Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct contact between the elements unless the context plainly states otherwise. It may include indirect interaction between the elements. The phrases “hydraulically coupled,” “hydraulically connected,” “in hydraulic communication,” “fluidly coupled,” “fluidly connected,” and “in fluid communication” refer to a form of coupling, connection, or communication related to fluids, and the corresponding flows or pressures associated with these fluids. Reference to a fluid coupling, connection, or communication between two components describes an arrangement that allows fluid to flow between or among the components. Hydraulically coupled, connected, or communicating components may include certain arrangements where fluid does not flow between the components, but in which fluid pressure may be transmitted such as via a diaphragm or piston. Similarly, electrical coupling, connection, or communication between two or more components describes an arrangement that allows for transmission of information between the components by one or more electrical circuits or electro-magnetic waves. The terms “seal”, “sealing”, “sealing engagement,” and “sealingly-coupled” are not intended to imply, unless the context otherwise states, formation of a perfect seal or a seal that works under all circumstances.
[0016] FIG. 1 illustrates one example of a coiled tubing injector unit. The example is not intended to be limiting. It is intended to be representative generally of coiled tubing injector units and their components. A reel 10 of coiled tubing is mounted on a trailer 11 for transport to the site. A coiled tubing injector, control cabin and other equipment for operating the injector is sometimes referred to collectively as a “coiled tubing unit,” and is generally designated in the figures by the reference number 12 . As coiled tubing 14 is unspooled from the reel, or is spooled back onto the reel, it is guided into alignment with the chains of the coiled tubing injector by a tubing support guide 16 . Because such guides are typically arched, they are sometimes referred to as “gooseneck” supports. When the coiled tubing injector is deployed, the guide is connected to the frame of the coiled tubing injector so that it has a fixed relationship with the coiled tubing injector while the injector is being operated. Generally, the guidance arch is positioned or oriented so that the coiled tubing is threaded into the top of the head of the injector, between its rotating chains or, optionally, into a straightener mounted to the frame, on top of the injector head, for removing the bend in the tubing before it enters the injector head. (As used in this description, “coiled tubing injector” refers to the injector head with or without the straightener, unless the context indicates otherwise.) The reel must maintain tension on the coiled tubing in order to wind the tubing coiled on the reel and to keep it wound on the reel, as it is being unspooled or spooled. The guidance arch prevents the coiled tubing from kinking or otherwise being damaged by the tension the reel is applying to the tubing. However, a guidance arch is typically attached to the frame of the coiled tubing injector in a manner that allows it to be attached or connected in different positions or orientations. For example, the best positioning or orientation may depend on the diameter of tubing being used and whether the tubing is being lowered or pushed into the well bore or pulled out of the well bore. When the pipe is coming off a reel, it has relatively more curve than when it is pulled from the well, which may affect how the guidance arch is fixed to the injector. Thus, “fixed relationship” does not imply one that cannot allow for adjustment.
[0017] When being used, the coiled tubing injector is positioned over the well head, high enough to accommodate one or more blow out preventers 20 , a riser 22 , and other equipment that might be connected to the wellhead through which the coiled tubing must pass before entering the well bore. The riser is made up from one or more sections of straight pipe that extends from the blow out preventers attached to the wellhead. The riser is used to accommodate elongated, rigid tools that are attached to the end of the coiled tubing prior to being lowered into the well bore. The coiled tubing injector is connected to the riser with a stripper, through which the coiled tubing is pushed or pulled. Because there is no derrick or platform, a temporary structure erected above the wellhead, or a mobile crane driven to the site, is used to position and hold the injector in place.
[0018] A coiled tubing reel assembly includes a stand for supporting a spool on which tubing is stored, a drive system for rotating the reel and creating back-tension during operation of the reel, and a “level winding” system that guides the tubing as it is being unwound from and wound onto the spool. The level winding system moves the tubing laterally across the reel so that the tubing is laid across the reel in a neat and organized fashion. The coiled tubing reel assembly must rotate the spool to feed tubing to and from the injector and well bore. The tubing reel assembly must also tension the tubing by always pulling against the injector during normal operation. The injector must pull against the tension to take the tubing from the tubing reel, and the reel must have sufficient pulling force and speed to keep up with the injector and maintain tension on the tubing as the tubing is being pulled out of the well bore by the injector. The tension on the tubing must always be maintained. The tension must also be sufficient to wind properly the tubing on the spool and to keep the tubing wound on the spool. Consequently, a coiled tubing reel assembly is subject to substantial forces and loads. Historically, tubing reel assemblies have been shipped to wells with the required coiled tubing wound on the spool, and the spool installed in a reel assembly. Such spools are specially designed for the particular reel assembly and typically not meant to be disconnected or removed from the reel assembly during normal operation. However, systems exist that permit spools from being removed from reel assemblies, such as the ones shown in U.S. Pat. No. 6,672,529, which is incorporated herein by reference.
[0019] A high capacity, self-propelled crane 26 is used to lift and hold the coiled tubing injector 18 and guidance arch in the proper position during the well servicing job. The crane is generally placed opposite the wellhead of the coiled tubing reel 10 or, if necessary, to one side. Some or all of the weight of the injector and the tubing is transferred to the boom of the crane.
[0020] FIGS. 2 & 3 are partially-sectioned side views of a representative example of a coiled tubing reel assembly with a planetary gear drive. No coiled tubing is shown wrapped around the reel in this figure. It has been omitted to show details of the hub of the reel. The reel assembly 30 includes a spool 32 mounted on a stand that is generally indicated by reference number 34 . The spool is comprised of central section, or drum 36 , a left flange or rim 38 and a right flange or rim 40 . The stand is comprised of a frame 42 (partially illustrated). The drum is connected to a central hub by a framework 46 of struts. The hub 44 has a hollow, cylindrical shape in this example. It rotates with the spool. The hub 44 is supported on the frame 42 of the stand at opposite ends so that it may rotate on the stand when turned.
[0021] A planetary gearing drive, which is generally designated by reference number 48 , is mounted directly within one end of hub 44 . An outer housing 50 of the planetary gear drive, functioning as its output, is connected with the hub 44 in this example by fitting it inside an open end of the hub and connecting it to an end flange 52 . The planetary gear drive 48 is connected to the stand at flange 54 , which is part of frame 42 . The input to the planetary drive is a shaft 56 that is connected to a sun gear 58 . The shaft 56 rotates the sun gear. It is supported by front radial bearing 60 and rear radial bearing 62 . The shaft extends from one side of the planetary gear box drive to the other. Through the center of the shaft is formed a hollow passageway or conduit 64 , with an outside or front opening 66 and an inside or rear opening 68 . Although indicated as a single piece, the drive shaft may be comprised of multiple, co-axial elements that rotate together and collectively form a conduit that defines a single passageway that extends along the axis of rotation of the planetary gear drive, which is adapted or otherwise suitable for passing an electrical or optical cable from the one side the planetary gear to the other side of the planetary gear along its central axis of rotation. The central axis of rotation of the planetary gear is coincident with the central axis of rotation the spool 32 (and hub 44 ), which is indicated by dashed line 69 . A conduit may, therefore, be comprised of one or more structural pieces or segments. The term “conduit” is not intended to imply a single length of pipe. Although not shown, an electrical cable, hydraulic control line, or optical cable (collectively, each a “line”) used for powering or controlling a downhole tool, or transmitting signals from a sensor can be fed through conduit 64 for insertion into one end of coiled tubing (not shown) wrapped around the spool 32 . A conduit 70 may be used to direct the line toward the opposite side of the hub, at which point the line would exit and be fed into the open end of the coiled tubing, which would not be attached to outlet 74 . Alternately, the line can be threaded or inserted through an arrangement (not shown) that attaches to outlet 74 of fluid axle 72 and permits either the line to be fed into, or fluid to be pumped through, the coiled tubing, or both. The line could also be used to power or control devices on the spool 32 such as a valve for closing the connection between the coiled tubing and the fluid axle 72 .
[0022] The other end of hub 44 is attached to fluid axle 72 . The fluid axle is mounted to frame 42 of the stand on flange 73 . Coiled tubing may be attached to outlet 74 of pipe 76 to allow for fluid to be pumped through the coiled tubing. Pipe 76 couples to a swivel joint 78 so that it may rotate with respect to the joint. A source of high pressure fluid outside of the reel is connected to the stationary side of the swivel joint 78 .
[0023] Drive motor 80 is coupled to the input shaft 56 . The drive motor is offset to form the axis of the input shaft 56 , allowing access to opening 66 of conduit 64 . The drive motor is, in this example, coupled to the input shaft by a gear train comprised of gears 82 and 84 . Gear 82 is connected to an output shaft of drive motor 80 , and gear 84 is connected to the input shaft 56 . In this example, the gears form a reduction gear train that reduces speed and increases torque on the input shaft 56 . Optionally, more than one drive motor may be utilized by arranging the drive motors around the input shaft 56 , each placed to one side of the axis of rotation of the input shaft in an arrayed fashion, with each of them coupled to the input shaft through a gear train. The drive motors may be hydraulic and/or electric.
[0024] Rotation of the drive motor turns input shaft 56 , which turns sun gear 58 . Sun gear 58 rotates planetary gears 86 and 88 . The planetary drive may have, optionally, have just one planet gear. It may also have more than two planet gears. In this example, the planetary gears are rotationally mounted on arms of a carrier 90 , which is connected to flange 54 of the frame 42 . Connected, or integrally formed with, sun gear 58 is a carrier with at least two arms 92 and 94 . Planet gears 96 and 98 are mounted, respectively, on the arms 92 and 94 . The planetary gears 86 , 88 , 96 and 98 mesh with an annulus or outer gearing formed on the side of housing 50 , causing it to rotate when the input shaft is rotated. Integrated into the planetary gear drive 48 is a brake 102 . One part of the brake is mounted to input shaft 56 and the other to the stationary carrier 90 .
[0025] The drawing of planetary gear drive 48 is a simplified to show representative elements of a planetary drive. It is just one example of compound planetary gearing. It is intended to be merely representative, and not an limiting example, of planetary gear drives or boxes generally for purposes of illustrating basic principles of operation and a conduit 66 extending through the center of the planetary gearing arrangement to allow passage of a cable or wiring.
[0026] In an alternate embodiment, the reel stand assembly is modified to include a coupling between the spool and the stand to allow for the spool to be removed relatively more quickly from the stand. In such an embodiment, the planetary drive is connected to an outer coupling member (such as an axle) and the hub of the spool being connected to an interior coupling member. An extension of conduit or passageway 66 , which is coaxial with the planetary gearing, extends through both parts of the coupling, along their respective axes of rotation, and into the hub of the spool.
[0027] The foregoing description is of exemplary and preferred embodiments. The invention, as defined by the appended claims, is not limited to the described embodiments. Alterations and modifications to the disclosed embodiments may be made without departing from the invention. The meaning of the terms used in this specification are, unless expressly stated otherwise, intended to have ordinary and customary meaning and are not intended to be limited to the details of the illustrated structures or embodiments. | A modified planetary gear box and arrangement of the gear box with a drive motor permits electrical, optical or other types of cabling or wiring to be passed through the planetary gear box along its axis of rotation. The planetary gear box drives or rotates a reel of coiled tubing. Electrical, hydraulic, optical and other types of line for lowering into a well bore through the coiled tubing is passed through a passageway through the center of the planetary gear box, into one end of a hub of the reel, and then into the coiled tubing, which is injected into the wellbore. The other end of the hub of the reel is able to be connected to a swivel joint that can be connected to a pump for pumping fluid into the coiled tubing. | 4 |
This is a division of application Ser. No 874,655 filed Feb 2, 1978 U.S. Pat. No. 4,188,243.
BACKGROUND OF THE INVENTION
The present invention relates to methods and apparatus for heat treating metallic material, and more particularly the invention relates to a method and apparatus wherein a metallic material to be heat treated, e.g., a long material such as steel pipe, steel bar, shape steel, rail or the like is conveyed in its lengthwise direction at a stable speed, thereby preventing the occurrence of non-uniform heat treatment and ensuring improved heat treating efficiency.
In the past, where a long metallic material such as represented by large diameter steel pipe or the like is subjected to heating treatment over the entire length thereof by continuously conveying the material through a relatively short heating zone, it has been the usual practice to ensure that the material is fed at a constant speed as far as possible so as to prevent non-uniform heating of the parts of the material, that where the heating is effected by induction heating thus causing the ends of the material to tend to be underheated, preliminarily a dummy is joined to each end or excess length for cutting allowance is provided at each end so as to cut off the same after heat treatment, that straightener rolls are provided to remove any distortions produced in the material during the heat treatment, and so on.
In particular, where large diameter steel pipe or the like is heat treated with an induction heating coil, due to the fact that the length of the induction heating coil is extremely small as compared with the length of the metallic material to be heat treated, it is an essential requirement that the metallic material is moved through the coil at a constant speed at all times. In other words, if the travel speed of a metallic material through the coil differs for different positions of the material, this causes the heating time to differ for the different positions of the material with the result that even if the amount of heat supplied per unit time is made constant by the electric heating method. i.e., induction heating (even if the uniform heating of the metallic material in a plane normal to the directon of travel of the material is made easier), the metallic material cannot be heated uniformly in time and consequently the different parts of the material subjected to heating process will be heated to different temperatures, that is, the temperatures of these parts will not be uniform. Of course, this tendency becomes more marked with increase in the preset heating temperature of the coil.
If a metallic material to be subjected to heating treatment is exposed to different heating conditions locally (in the lengthwise direction), the following problems will be caused. In other words, firstly the mechanical properties of the heat treated material will not be the same throughout the material. Secondly, change of shape will be caused by the non-uniform heating. These phenomena will become more marked with increase in heating temperature and increase in the non-uniformity of heating due to the irregularity in the travel speed of the material, and these phenomena also become more marked with increase in the cooling rate for the cooling process following the heating process. As a result, where the material is heated to a relatively high temperature and then cooled rapidly as during a quenching treatment, these phenomena will be still more marked. Up to date, the following conveying methods have been used in connection with the heat treatment by induction heating of such metallic material as large diameter steel pipe.
(i) Roller conveyor method
In this method, metal material, e.g., steel pipe is placed on a roller conveyor and the material is conveyed by means of one or a plurality of drive rolls. While this method is suited for fast feeding purposes, where is a disadvantage that in the case of a treatment, e.g., heat treatment where the feeding speed is low (several tens to several hundreds milli per minute), it is difficult to maintain the feeding speed constant with the result that the conveying speed is made unstable due to slip between the material and the roll surface and consequently the heat treatment is effected non-uniformly.
(ii) Pinch roll method
In this method, metallic material such as steel pipe is conveyed while the material is being held between a pair of top and bottom pinch rolls or between the rolls of a plurality of such pinch roll units which are arranged at a spacing. While this method is advantageous over the first-mentioned method in that the feeding speed is maintained constant, in the case of a metallic material having a circular section, for example, even if the rotational speed of the pinch rolls is maintained constant, there is the difference between the peripheral speeds at the center and marginal portions of the rolls and a slip will be caused between the metallic material and the rolls at some circumferential points of the material. As a result, if the shape of the metallic material is changed even a bit, the contact points between the pinch rolls and the material will be changed, thus changing the feeding speed. On the other hand, where the material is moved by the pinch rolls consisting of straightening rolls, a long material is passed between at least one pair of caliber rolls to straighten the bends and at the same time the material is conveyed at a desired speed to the heating zone by the rotation of the straightening rolls. Thus, while the feeding speed can be made relatively constant as compared with the case where the material is conveyed by feeding rolls, if there is any weld bead on the material or the material has been deformed, when the material contacts with the caliber rolls at a different part thereof, the feeding speed of the rolls will be changed at and around that part, thus making the feeding speed unstable and thereby making it impossible to accomplish both the desired straightening and the stabilization of feeding speed simultaneously.
Where the material is conveyed by driving the material feeding rolls and/or the straightening rolls, it is necessary to make the driving of the large number of such rolls to conform with one another throughtout a wide range of conveying conditions. For instance, where the feeding speed of 100 to 600 mm/min is required for feeding the material in one direction for quenching treatment and then the material is fed in the opposite direction at the speed of 50 to 300 mm/min for tempering treatment, the roll speeds have a wide range of 1:12 (50 to 600 mm/min) with the result that a drive system and the associated units must be provided and the driving system becomes extensive and complicated. The driving system will be made more extensive, if the fast feeding necessary for increasing the efficiency of non-treating feeding and the reverse feeding of material is additionally required.
Further, since no material supporting rolls or the like are provided in the heating zone, with the conventional techniques the ends of the material bend downwardly while the material is introduced into and heated in the zone, and this constitutes a cause of non-uniform heating, bending or the like.
(iii) Car transport method
This method is one in which a single car with a drive mechanism is run on the rails so as to convey a metallic material fixedly mounted in places on the car, and this method also has a problem of friction between the rails and the wheels of the car, thus causing a slip and thereby making the feeding unstable.
These are the disadvantages of the material conveying methods known in the art.
On the other hand, while methods are known in the art which are designed to prevent the ends of material from being heated non-uniformly, such as, one in which a dummy is joined by welding or the like to each end of the material so as to cut off the same after the heat treatment, and another in which an excess length is provided at each material end so as to cut off the same after the heat treatment, these methods also have the disadvantage of requiring additional labor and expenses and deteriorating the yield. Where a metallic material is heat treated by the conventional technique without joining any dummy to each material end, when the ends of the material move past the cooling unit, the cooling water, particularly the cooling water on the inner surface of the pipe will be discharged from the material ends and scattered in all directions, thus producing deteriorating effects on the electric equipment, etc., and also deteriorating the working environment.
SUMMARY OF THE INVENTION
The present invention has been made to overcome the above-mentioned deficiencies in the prior art.
It is therefore a principal object of the present invention to convey a metallic material at a steady speed into a heating zone and thereby to stably subject the entire length of the material to heat treatment at the desired feeding speed.
It is another object of the invention to minimize the occurrence of non-uniform heat treatment of material.
It is still another object of the invention to eliminate the need to join a dummy or excess length to each material end and the need to cut off and remove the same after the heat treatment and thereby to ensure improved heat treating efficiency.
Thus, in accordance with the method of heat treating metallic material provided according to the invention, a material to be treated is gripped at its forward and rear ends by two cars which are respectively arranged at the entry and delivery ends of a heat treating zone comprising a heating unit and/or a cooling unit, whereby while supporting the material on a plurality of free rotatable rolls, one of the cars is driven and a braking force is applied by the other car, thus moving the material by the cars and subjecting it to heat treatment. In this case, preferably the material is pushed from behind by the driven car and a braking force is applied to the material by the forward braking car. Also a dummy is preliminarily attached to each of the cars and thus the dummies are pressed against the ends of the material, thereby eliminating the need to preliminarily join a dummy by welding or providing an excess length at each end of a material itself and to cut off and remove the same after the heat treatment.
The cars are supported on the rails by wheels to run over the rails by the turning of the wheels and the brakes which are separately mounted on the cars are directly pressed against the rails for braking. The cars should preferably be driven by pinion gears which engage with the rack gears disposed along the rails, and consequently a drive system including motors and pinion gears is mounted on each car. In another form of the invention, particularly where the distance of travel of the cars is short, the car may be provided with a rack gear which is adapted to engage with a pinion gear rotated by a motor serving as a stationary unit to thereby move the cars. This has the advantage of eliminating the provision of such installations as power cables, trolleys and the like which must be connected to the cars.
The above and other objects, features and advantages of the present invention will become readily apparent from the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a side view of a heat treating line incorporating an embodiment of the present invention, showing the heating and cooling zone and its entry end equipment.
FIG. 1b is a side view similar to FIG. 1a, showing the heating and cooling zone and its delivery end equipment.
FIG. 2 is an enlarged plan view of the entry car 8 shown in FIG. 1.
FIG. 3 is a sectional view taken along the line III--III of FIG. 2.
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 3.
FIG. 5 is a sectional view taken along the line V--V of FIG. 3.
FIG. 6 is a sectional view taken along the line VI--VI of FIG. 3.
FIG. 7 is an enlarged side view of the delivery car 9 shown in FIG. 1.
FIG. 8 is a sectional view taken along the line VIII--VIII of FIG. 7.
FIG. 9 is a sectional view taken along the line IX--IX of FIG. 7.
FIG. 10 is a sectional view taken along the line X--X of FIG. 7.
FIG. 11 is a sectional view taken along the line XI--XI of FIG. 8.
FIG. 12 is an enlarged elevation taken along the line XII--XII of FIG. 1.
FIGS. 13a and 13b are partial sectional showing respectively the manner in which a dummy is fitted on a pipe to be treated.
FIG. 14 is a plan view of the entry equipment of a heat treating line incorporating the cars according to another embodiment of the present invention.
FIG. 15 is a side view of the equipment of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1a and 1b, numeral 1 designates a long metallic material to be heat treated which is in the form of a large diameter steel pipe by way of example. Numeral 3 designates an induction heating coil which is disposed substantially in a horizontal position, and 4 a cooling unit which in this embodiment takes the form of one having two ring nozzles for cooling the material from inner and outer sides. The induction heating coil 3 and the cooling unit 4 constitute a heat treating zone, and it is needless to say that the cooling unit 4 is designed for use only in case of need and that there are cases where the cooling unit 4 is not used, although it is included in the line. In other words, when the material 1 is subjected to quenching treatment, coolant is sprayed from the nozzles of the cooling unit 4. In this case, if the material 1 is a tubular product which is to be subjected to internal quenching or double-side quenching, the spraying of the coolant is effected by reversely inserting the cooling nozzle into the tubular product from the direction of its movement and spraying the coolant against it. Consequently, the coolant must be discharged from the leading end of the tubular product and consequently the entire treating line is inclined to form a suitable slope with respect to the ground line as shown in FIGS. 1a and 1b. This has also been a cause of slipping phenomenon of tubular products encountered in the prior art methods. In view of this fact, with the prior art methods employing a mechanism which simply conveys a tubular product by means of the drive produced by the sticking force of the rolls contacting and supporting the product, there is a disadvantage that due to the treating line being inclined as mentioned previously, a slip will be caused between the product and the rolls supporting it, thus causing the feeding speed to become more non-uniform. In accordance with the conveying method of this invention, a material 1 is gripped from both the entry and delivery ends of a line by two cars one of which is driven by a non-slip car drive mechanism, such as, a rack and pinion mechanism, etc., and the material is conveyed at a desired speed while applying braking by the other car.
Numeral 6 designates feeding roll units, and in accordance with the invention the rolls are driven only for conveying the material to its heat treatment starting position, for conveying the material after the completion of the heat treatment and for non-treating feeding, such as, for feeding the material through the heat treating zone during the periods other than the heat treating period, and the rolls are caused to idle during the periods of heat treatment. Numeral 7 designates straightening roll units whose rolls are used in a similar manner as those of the feeding roll units 6, namely, the rolls are solely used for the purpose of non-treating feeding and the rolls are caused to idle when the material is subjected to straightening during the heat treatment. Numerals 8 and 9 designate entry and delivery cars which are features of the invention, and in accordance with the invention when conveying the material 1 into the heat treating zone for heat treatment, as mentioned previously, the rolls of the feeding roll units 6 and the straightening roll units 7 are not driven to permit free rotation, and a rail mechanism (to be described later) is provided to extend straightly in each of the entry and delivery directions with the heat treating zone being located centrally. Thus, by driving rack gears by pinion gears provided on the car 8, the car 8 can be moved on the rail mechanism, and also the delivery car 9 is provided with an overrun preventing brakes for applying braking. In this way, the material 1 is gripped between the cars 8 and 9 to convey the material 1. Of course, the delivery car 9 is provided with pinion gears so that the car 9 is driven and the car 3 applies the brakes thereon when the material 1 is to be conveyed in the reverse direction. Numerals 10 and 11 designate dummy pipes attached respectively to the entry and delivery cars 8 and 9, and the dummy pipes may be advantageously constructed so as to be fitted on the ends of the material 1 as shown in FIG. 13a or 13b. As will be seen from FIG. 12, each of the straightening roll units 7 should preferably be constructed so that the material 1 can be restrained from all sides by means of its caliber rolls 7a, 7b, 7c and 7d and that the roll 7a is formed with a relatively large groove 70 as shown in the Figure so as to provide a draft for the caliber roll contacting the part of the material 1 having for example a weld bead projection produced during the tube making operation.
Now referring to FIGS. 2 to 11, the car drive systems and the cars 8 and 9 will be described in greater detail. In the Figures, numerals 12a and 12b designate respectively a pair of parallel girders extended straightly in the delivery and entry directions with the heat treating zone being located therebetween, and numerals 12a', 12b' and 12a", 12b" designate respectively a pair of guide rails fixedly mounted in position in parallel to the girders 12a and 12 b. The guide rails 12a', 12b' and 12a", 12 b" are arranged on both sides of the heat treating zone to extend therealong over a distance corresponding to the required material conveying distance of the entry and delivery cars 8 and 9, that is, a distance sufficient to permit the cars 8 and 9 to completely move the material 1 through the centrally located heat treating zone in either the entry or delivery direction. The guide rails are provided to always prevent the cars from being caused to sway sideways when the cars are subjected to unexpected impact during the gripping and feeding operations of the material 1 by the cars 8 and 9. Numerals 13a, 13b and 14a, 14b designate respectively the guide wheels mounted on the cars 8 and 9 to rotate over the surface of the guide rails 12a', 12b' and 12a", 12b" so as to ensure smooth running of the cars. Numerals 15a and 15b designate rack gears provided as one form of the car drive mechanism and disposed to extend over the same distance as the previously mentioned guide rails, that is, the rack gears are fixedly installed to extend over a distance corresponding to the material conveying distance of the cars 8 and 9 in parallel therewith. In this case, the rack gears 15a are mounted on the central surface portions of the guide rails 12a" to project therefrom and the rack gears 15b are also mounted on the central surface portions of the guide rails 12b" to project therefrom. The guide wheels 14a and 14b are each provided with a circumferential groove formed by depressing the central portion of the outer surface to suit the height of the rack gears 15a and 15b. As a result, the guide wheels 14a and 14b are guided by the surfaces of the guide rails 12a" and 12b" and the opposed sides of the rack gears 15a and 15 b to prevent the rolling of the cars in motion. The other wheels 13a and 13b are placed on the girders to contact with the rails so as to hold the rails from the upper and lower sides in association with the wheels 14a and 14b, and consequently the vertical bouncing of the moving car can be prevented by the clamping of the rails by the wheels 13a and 14a or 13 b and 14b. Numerals 16a and 16b designate pinion gears which are respectively mounted on the cars 8 and 9 so as to engage with the rack gears 15a and 15 b and thereby to constitute unitary rack and pinion mechanisms and provide the required drive mechanisms for the cars 8 and 9.
The cars 8 and 9 also equipped with DC motors 17a and 17b, AC motors 18a and 18b and reduction gears 19a and 19b adapted to be respectively selectively connected to these DC and AC motors, and the pinion gears 16a and 16b are rotated by these motors through the reduction gears 19a and 19b, respectively. The cars 8 and 9 are further equipped with hydraulic brakes 20a and 20b whose shoes are adapted to be directly pressed against the rails 12a' and 12b', respectively, and the brakes preferably are alighned with the pinion gears 16a and 16b, respectively.
In FIGS. 2 to 11, numerals 21a and 21b designate electromagnetic clutch brakes respectively connected to the shafts of the DC motors 17a and 17b in normal service, and 22a and 22b dummy pipe mounting devices respectively disposed on the cars 8 and 9, and the dummy pipes described in connection with FIGS. 1a, 1b, 13a 13b are fixedly mounted to the lower portions of the mounting devices 22a and 22b. Numerals 23a and 23b designate supports for supporting the girders 12a and 12b, respectively. The car drive mechanisms are not intended to be limited to the previously mentioned rack and pinion mechanisms, and it is possible to use various other drives excepting the sticking drives by the rotation of wheels, such as, feed screw mechanism, sprocket drive, wire rope pull drive, etc. Also where the rack and pinion mechanism is used, it may be arranged in the manner reverse to that shown in FIGS. 2 to 11, namely, the rack gear may be mounted on the car so as to be driven by the rotation of the pinion gear fixedly mounted on the girders. For example, as shown in FIGS. 14 and 15 as an exemplary form of an entry equipment for the induction heating coil 3, a rack gear 15' may be mounted centrally on the lower surface of a car 8', and a pinion gear 16' which meshes with the rack gear 15' and a motor 17' and a reduction gear 19' for driving the pinion gear 16' may be fixedly mounted on the girders 12a by means of a base mount 24.
With the embodiment shown in FIGS. 1a and 1b and FIGS. 2 to 11, the quenching operation will be described with reference to a case in which the material 1 is conveyed through the heat treating zone from the entry end to the delivery end. With the material 1 gripped by the delivery and entry cars 9 and 8 through suitable means, such as, by fitting the material 1 into the associated ends of the dummy pipes 11 and 10 of the cars 9 and 8 in the manner shown in FIG. 13a or 13b, the brakes 20b of the delivery car 9 are applied to prevent overrunning and the entry car 8 is moved at a desired speed by the above-mentioned rack and pinion mechanism. In this way, with the feeding roll units 6 and the straightening roll units 7 idling, the material 1 is conveyed to the left in FIGS. 1a and 1b and this feeding is continued until the pipe end of the material 1 is moved past the heat treating zone, thus completing the quenching treatment through the induction heating coil 3 and the cooling unit 4. In this case, in the initial condition the dummy pipe 11 of the delivery car 9 is extending through the induction heating coil 3 thus causing its forward end to extend through the coil entry end, and when the material 1 is moved past the heat treating zone thus entering into the final condition the dummy pipe 10 of the entry car 8 extends through the induction heating coil 3 and the cooling unit 4 thus causing its forward end to extend through the delivery end of the cooling unit 4.
The operation of feeding the thusly quenched material 1 in the reverse direction from the delivery end to the entry end and subjecting to tempering treatment, takes place in the following manner. Contrary to the case with the previously mentioned quenching operation, the brakes 20a of the entry car 8 are applied to prevent overrunning and the delivery car 9 is moved at a desired speed by the car drive mechanism. With the rolls of the feeding roll units 6 and the straightening roll units 7 idling, the material 1 is conveyed to the right in FIGS. 1a and 1b and this is continued until the pipe end of the material 1 is moved past the heat treating zone, thus completing the tempering of the material 1 by the induction heating coil 3.
In accordance with the present invention, by virtue of the fact that the constant speed operation of the cars 8 and 9 is accomplished by the non-slip car drive mechanisms, such as, rack and pinion mechanisms, chain drives or winches, it is possible to reciprocate the cars 8 and 9 by simply changing the connections of the clutches and there is also no danger of overrunning by virtue of the fact that the material is conveyed with the brakes on one of the cars being applied. Further, with some caliber rolls of the straightening roll units 7 being provided with the centrally formed grooves 70, there is no danger of causing misalignment of the tubular product due to the contact between the weld bead projections on the outer surface of the material 1 and the caliber rolls and danger of causing non-uniform feeding speed. The straightening roll units 7 are provided so that when the material 1 is deformed in the longitudinal and radial directions under the effect of heating or heating and cooling, the material 1 is straightened under the idling condition. Further, since the material 1 is gripped and conveyed by the cars 8 and 9 for heat treatment and the rolls of the feeding roll units 6 and the straightening roll units 7 are solely driven for non-treating feeding purposes and since both the quenching and tempering treatments can be accomplished by moving the material both ways through the same line, in extreme cases it is only necessary that the entry car governs the speed for quenching, the delivery car governs the speed for tempering and the feeding roll units 6 and the straightening roll units 7 govern the speeds suitable for non-treating feeding and therefore it is necessary to provide only the equipment required for these purposes. Still further, where only the quenching treatment is required or where both the quenching and tempering treatments are accomplished by repeatedly feeding the material in one direction instead of feeding the material both ways, it is only necessary to provide one of the cars with a car drive mechanism and the other car with overrunning preventive brakes, thus ensuring in any way simplification of the required equipment. Moreover, by virtue of the fact that the cars 8 and 9 are provided with the dummy pieces 10 and 11 and the material 1 is gripped between the dummies for conveyance through the heat treating zone, it is possible to prevent non-uniform heating of the ends of the material 1 due to underheating and it is also possible to prevent bending down of the material ends. Still further, since the dummies 10 and 11 are pressed against the material 1, it is possible to restrain the inner cooling water of the material 1 (in the case of quenching treatment) from flowing to the outside and scattering. In this case, since the inner cooling water is introduced from a cantilever mandrel supported at the rear end of the delivery end equipment, it is of course necessary for the dummy 11 of the delivery car 9 to have a sectional shape so that it is clear of the mandrel and its support located in the direction of movement of the dummy 11. | In the heat treatment (quenching treatment, tempering treatment, etc.) of long metallic material, such as, large diameter steel pipe or the like, in order to stabilize the speed of travel of the material through a heat treating zone, i.e., a zone including a heating unit, such as, an induction heating coil or gas burning type heating furnace and a following cooling unit of the type utilizing either one or both of air blast and water cooling, the material is gripped by two cars which are arranged respectively at the entry and delivery ends of the zone and the cars are moved, while supporting the material by a plurality of free rotatable rollers, so as to move the material at a desired speed. In this case, one of the cars is driven and the other car applies a braking force, thus moving the material at the desired speed through the zone. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims all available benefit of U.S. provisional patent application 61/116,308 filed Nov. 20, 2008, the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a hydraulic clutch and more particularly, to a hydraulic clutch assembly that includes a multiple plate friction clutch pack for use in a motor vehicle driveline.
[0004] 2. Background
[0005] Hydraulically actuated clutches are common components that are used in rotary powered transmission systems, such as for example, transfer cases, rear differentials and front differentials. These clutches are controlled through a hydraulic fluid circuit. Conventional hydraulic fluid circuits for clutch actuation are closed systems, which include a fluid reservoir within the driveline assembly to accommodate a loss of fluid due to leakage, and changes in the system due to thermal effects and etc. Over a period of time and from usage of the clutch system, the driveline assembly may lose some of the hydraulic fluid from the hydraulic fluid circuit, such as for example, via leakage of the hydraulic fluid through the seals. Accordingly, the reservoir may need to be accessed externally by a technician or otherwise for replenishing the hydraulic fluid circuit with hydraulic fluid. For many vehicles, however, access to the reservoir which is located within the driveline assembly is difficult because of the tight packaging of driveline components surrounding the reservoir and the corresponding tortuous pathway to the reservoir. Thus, further improvements and enhancements in hydraulic clutch systems for motor vehicle drivelines may be desirable.
BRIEF SUMMARY OF THE INVENTION
[0006] In one embodiment of the present invention, a hydraulic clutch assembly for a motor vehicle driveline is provided. The clutch assembly comprises an input member and an output member. A friction clutch pack is operably disposed between the input and output members for controlling torque transfer between the two members. A first fluid circuit contains a hydraulic based fluid at a first pressure and is in fluid communication with the friction clutch pack for lubricating the clutch pack. In fluid communication with the first fluid circuit is a second fluid circuit which has a reservoir. The first fluid circuit replenishes the reservoir with the hydraulic based fluid at a second pressure that is less than the first pressure. A motor and a gear train are also included. The gear train has an input force, which is driven by the motor, and an output force. In fluid communication with the second fluid circuit is a first piston. The second fluid circuit is for delivering the hydraulic based fluid from the reservoir to the first piston. The first piston is driven by the output force to displace the hydraulic based fluid. A second piston is translated by the displaced hydraulic based fluid to actuate the friction clutch pack.
[0007] In one aspect, the second fluid circuit has a compensation port that is in fluid communication with the reservoir. The motor is a bi-directional electric motor, which includes a rotor, and the gear train has the input force that is driven by the electric motor. An electric brake is for selectively inhibiting rotation of the rotor. A ball screw is driven by the output force. The first piston is in fluid communication with the reservoir via the compensation port for delivery of the hydraulic based fluid and is driven by the ball screw to displace the hydraulic based fluid.
[0008] Further aspects, features, and advantages of the present invention will become apparent from consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view of a motor vehicle driveline including a transfer case in accordance with an embodiment of the present invention;
[0010] FIG. 2 is a sectional view of a motor vehicle transfer case in accordance with one embodiment of the present invention;
[0011] FIG. 3 is a schematic representation of a lubrication fluid circuit in accordance with one embodiment of the present invention;
[0012] FIG. 4 is a schematic representation of a hydraulic clutch assembly including a hydraulic fluid circuit in accordance with one embodiment of the present invention; and
[0013] FIG. 5 is a side sectional view of a fluid reservoir for fluid communication between the lubrication and hydraulic fluid circuits in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Detailed embodiments of the present invention are disclosed herein. It is understood, however, that the disclosed embodiments are merely exemplary of the invention and may be embodied in various and alternative forms. The Figures are not necessarily to scale; some figures may be configured to show the details of a particular component. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a representative bases for the claims and for teaching one skilled in the art to practice the present invention.
[0015] Referring to FIG. 1 , a vehicle driveline system incorporating at least one embodiment of the present invention is illustrated and generally designated by the reference numeral 10 . The vehicle drive system 10 includes an engine 12 which drives a transmission 14 . The transmission 14 may be a manual transmission with a clutch or an automatic transmission. The output of the transmission 14 drives a transfer case assembly 16 . In turn, the transfer case assembly 16 is operably coupled to and drives a rear or primary driveline assembly 20 . The primary driveline 20 has a rear or primary drive shaft 22 which is operably coupled to and drives a rear or primary differential 24 . The primary differential 24 drives a pair of aligned primary or rear axles 26 which are each coupled to a primary or rear tire and wheel assembly 28 .
[0016] The transfer case assembly 16 also provides torque to a front or secondary driveline assembly 30 . The secondary driveline 30 includes a front or secondary drive shaft 32 which in turn drives the front or secondary differential 34 . The secondary differential 34 provides drive torque through a pair of aligned front or secondary axles 36 which are each coupled to a front or secondary tire and wheel assembly 38 .
[0017] In one embodiment, locking hubs 42 are operably disposed between the front or secondary pair of axles 36 and the front tire and wheel assemblies 38 . The locking hubs 42 may be either remotely operated and thus include electrical or pneumatic operators or may be manually activated. Alternatively, front axle disconnects (not illustrated) may be housed within the secondary differential 34 and may be activated or deactivated to couple or uncouple the secondary axles 36 from the output of the secondary differential 34 .
[0018] Both the primary driveline 20 and the secondary driveline 30 include suitable and appropriately disposed universal joints 44 which may be of conventional type or so-called “constant velocity” joints. The universal joints may function in a convention fashion to allow static and dynamic offsets and misalignments between the various shafts and components.
[0019] The system 10 also includes a microcontroller 46 having various programs and sub-routines which receive data from various vehicle sensors. The microcontroller in response to the data provides a control output to achieve the design goals of the present invention which will be more fully described below.
[0020] FIG. 2 is a cross-sectional view of the transfer case assembly 16 incorporating at least one embodiment of the present invention. It should be noted, however, that although various embodiments of the present invention are described herein as being incorporated within the transfer case assembly 16 , it will be readily appreciated by those skilled in the art that various other embodiments of the present invention may be incorporated into other vehicle driveline assemblies, such as for example, the primary and/or secondary differential assemblies 20 and 30 .
[0021] The output drive power from the transmission 14 is provided to the transfer case 16 by an input shaft 18 . The input shaft 18 , the rear output shaft 31 and the front output shaft 33 extend from an outer housing 62 of the transfer case 16 . The rear and front output shafts 31 and 33 are correspondingly coupled to the primary and secondary drive shafts 22 and 32 , e.g. via universal joints 44 .
[0022] In one embodiment, the housing 62 includes two housing halves 64 and 66 secured together by bolts 68 . The housing 62 includes various seals 70 and 71 , recesses, shoulders, flanges, bores, etc. that receive and position the various components and parts of the transfer case 16 discussed herein. The input shaft 18 is coupled to the rear output shaft 31 for AWD and 2-wheel drive. The rear output shaft 31 is rotably mounted on bearings 78 and 79 at opposite ends.
[0023] The front output shaft 33 is rotably mounted within the housing 62 on bearings 80 . The input gear 84 is selectively driven through a clutch 94 by the rear output shaft 31 and is concentric therewith. A front output gear 86 is coupled to the front output shaft 33 and rotates therewith. An idler gear 90 is coupled to the input gear 84 and the front output gear 86 . When the transfer case 16 is in the two-wheel drive mode, the input gear 84 rotates freely on the rear output shaft 31 and thus, no output drive power is applied to the front output shaft 33 .
[0024] To initiate the AWD or 4-WD mode, the clutch 94 is activated to controllably and selectively provide rotational energy to the input gear 84 so that it will provide rotational energy as needed or selected to the front wheels 38 through a series of rotationally coupled parts. In this mode, shafts 22 and 32 ( FIG. 1 ) may be allowed to rotate at different speeds for smooth vehicle handling. When the clutch 94 is fully in the AWD mode, the clutch 94 and the input gear 84 will be more fully coupled and will rotate at the same speed or nearly the same speed with only some slippage. In this mode, the rear and front drive shafts 22 and 32 rotate at or closer to the same speed.
[0025] Referring also to FIG. 4 is one embodiment of a hydraulic clutch assembly 48 , which includes the clutch 94 , in accordance with the present invention. The hydraulic clutch assembly 48 is located within the housing 62 and is operable to actuate the clutch 94 . The clutch assembly 48 includes a hydraulic fluid circuit 49 containing a hydraulic based fluid or hydraulic fluid, e.g., hydrocarbon based oil, synthetic oil, silicone fluid or any other suitable fluid for hydraulic actuation.
[0026] Operating the hydraulic clutch assembly 48 is a bi-directional, fractional horsepower electric motor 50 which is disposed within a suitably sized region of the housing 62 . The electric motor 50 includes an output shaft 52 that may optionally be supported upon suitable bearings (not shown). The drive shaft 52 is coupled with a spur gear 54 and an electric brake 56 . When electric power is provided to the electric motor 50 , the electric motor 50 rotates the output shaft 52 and the spur gear 54 . When electric power to the electric motor 50 is terminated, system forces may attempt to back drive the electric motor 50 . The electric brake 56 inhibits further reverse rotation of the output shaft 52 and thus the spur gear 54 .
[0027] In one embodiment, the spur gear 54 is in constant mesh with a second spur gear 58 . The second spur gear 58 is secured to a second drive shaft 60 that is support by anti-friction bearings such as a roller bearing assembly 72 . The second drive shaft 60 includes a ball screw portion 74 . Between the drive shaft 60 and the ball screw portion 74 is mounted at least one spring or washer 76 that functions as a resilient stop. Disposed about the ball screw portion 74 is a re-circulating ball nut 78 . The re-circulating ball nut 78 includes at least one ball or roller bearing 80 which will re-circulate about a complimentary configured groove 88 in the ball screw 74 and thus, provides a low friction interconnection between the ball screw 74 and the nut 78 . As the shaft 60 bi-directionally rotates in response to bi-directional rotation of the output shaft 52 of the electric motor 50 , the re-circulating ball nut 78 translates to the left and right. The ball screw portion 74 and the re-circulating ball nut 78 thus function as a rotary to linear motion actuator.
[0028] The re-circulating ball nut 78 is coupled to a source piston 92 (e.g. master piston) which translates axially between a retracted position 93 and an extended position 95 within an elongated cylinder 96 . The source piston 92 includes a pair of high-pressure seals 98 which are received in suitable configured circumferential grooves 100 near each end of the piston 92 . The piston 92 in FIG. 4 is shown in a partially retracted position (e.g. between the fully retracted position 93 and the fully extended position 95 ). As the piston 92 is retracted by rotation of the ball screw nut 78 , it passes a compensation port 102 which is in fluid communication with a fluid reservoir 104 . The fluid reservoir 104 is preferably maintained substantially full of the hydraulic based fluid. In the retracted position 93 , the compensation portion 102 is unobstructed by the source piston 92 to advance the hydraulic based fluid into the elongated cylinder 96 .
[0029] Additionally, a secondary port 103 may be provided which is in fluid communication with both the reservoir 104 and the source piston 92 and is positioned along the elongated cylinder 96 to provide lubrication between the source piston 92 and the elongated cylinder 96 with the hydraulic based fluid. In at least one embodiment, the hydraulic based fluid is suitable as both a lubrication fluid and a hydraulic fluid. In one embodiment, a flexible diaphragm/separator 106 within the reservoir 104 may be used to accommodate any changes in volume of the hydraulic based fluid and a metal plate or cap 108 may be used to secure the flexible diaphragm/separator 106 in position. In an alternative embodiment, the reservoir 104 does not include a diaphragm/separator 106 .
[0030] The elongated cylinder 96 narrows to a first fluid passageway 110 . The first fluid passageway 110 communicates with an annular cylinder 126 which includes a pressure plate 128 (e.g. slave or apply piston). In one embodiment, the pressure plate is in the form of a bonded piston with rubber seals bonded onto a monolithic base metal. When the source piston 92 is in the extended position 95 , the hydraulic based fluid is displaced from the elongated cylinder 96 through the first fluid passageway 110 into the annular cylinder 126 . The pressure plate 128 transfers axial motion from the displaced hydraulic based fluid to the clutch 94 , thereby activating or engaging the clutch 94 .
[0031] In one embodiment, a second fluid passageway 130 provides fluid communication between the elongated cylinder 96 and a fluid pressure sensor or transducer 132 . The pressure fluid sensor 132 is preferably a piezoelectric device which provides a signal in a single or multiple conductor cable to a microprocessor 134 regarding the real time hydraulic pressure within the elongated cylinder 96 . Electrical energy is provided to the electric motor 50 through a single or multiple conductor cable to control actuation of the source piston 92 .
[0032] In at least one embodiment of the present invention, the clutch 94 is in the form of a multiple plate friction clutch pack assembly. In the activated or engaged condition, the friction clutch pack assembly 94 is driven by a plurality of male or external splines or teeth 112 disposed on the rear output shaft 31 (e.g. providing input torque) which engages complimentarily configured female splines 114 on the first plurality of smaller diameter friction clutch plates or discs 116 . The first plurality of friction clutch plates or discs 116 are interleaved with a second plurality of larger diameter friction clutch plates or discs 118 . The friction clutch plates or discs 116 and 118 may include suitable clutch paper or friction material in accordance with convention practice.
[0033] Each of the second plurality of larger diameter friction clutch plates or discs 118 include male or external splines 120 which engage and drive complimentary configured female or internal splines 122 formed on the interior of a cylindrical portion of a clutch drum 124 (e.g. receiving output torque). The clutch drum 124 is engaged with the input gear 84 and receives torque from the hydraulic clutch assembly 48 to drive the input gear 84 . Suitable oil seals prevent the ingress of foreign materials and maintain a fluid tight seal between the housing 62 , the rear output shaft 31 and the clutch drum 124 .
[0034] Also referring to FIG. 3 , a lubrication fluid circuit 140 is in fluid communication with the reservoir 104 . The lubrication fluid circuit 140 is provided within the housing 62 and contains the hydraulic based fluid. The hydraulic fluid circuit 49 is open to and receives hydraulic based fluid from the lubrication fluid circuit 140 . Accordingly, any hydraulic based fluid that may have escaped from the hydraulic fluid circuit 49 , e.g., weeping through seals, etc., is preferably replenished by the oil base fluid from the lubrication fluid circuit 140 , thereby minimizing or eliminating the need to externally access the reservoir 104 for replenishing with the hydraulic based fluid.
[0035] In one embodiment, the lubrication fluid circuit 140 is in fluid communication with the clutch assembly 94 (forming a “wet clutch assembly”) and provides a lubricating interface for the clutch assembly 94 and between the clutch assembly 94 and the rear output shaft 31 and/or the clutch drum 124 , e.g., via the clutch lube port 142 .
[0036] A pump 144 (e.g. gerotor pump), which is illustrated in this example as being an off-axis pump, is in fluid communication with the lubrication fluid circuit 140 and is used to pressurize and drive the oil base fluid through the lubrication fluid circuit 140 . In one embodiment, the pressure of the hydraulic based fluid in the lubrication fluid circuit 140 is greater than about 100 psig.
[0037] In the illustrated example, the lubrication fluid circuit 140 is in fluid communication with the hydraulic fluid circuit 49 via an inlet port 146 . The hydraulic based fluid is advanced from the lubrication fluid circuit 140 through the inlet port 146 and into the reservoir 104 for replenishing the hydraulic fluid circuit 49 with the hydraulic based fluid.
[0038] The relatively high pressure of the hydraulic based fluid from the lubrication fluid circuit 140 is reduced prior to being introduced into the reservoir 104 . In one example, the hydraulic based fluid in the reservoir 104 has a pressure that is less than about 20 psig. As illustrated in FIG. 3 , an inlet check valve 148 may be disposed in the inlet port 146 for reducing the pressure of the hydraulic based fluid being advanced into the reservoir 104 . Additionally, a filter 150 may be disposed within the inlet port 146 for removing debris from the hydraulic based fluid, providing a relative clean stream of hydraulic based fluid for replenishing the reservoir 104 . In one example, the filter 150 reduces the pressure of the hydraulic based fluid being delivered to the reservoir 104 .
[0039] Any excess hydraulic based fluid from the reservoir 104 is returned to the lubrication fluid circuit 140 via a return port 154 . A return check valve 156 may be positioned in the return port 154 for controlling the amount of hydraulic based fluid returning to the lubrication fluid circuit 140 . Alternatively, the return port 154 may be open (e.g. without a valve) for returning any excess hydraulic fluid to the lubrication fluid circuit 140 .
[0040] The lubrication fluid circuit 140 includes a sump 158 that is preferably upstream from the pump 144 and is for containing a supply of the hydraulic based fluid. The sump 158 has a filter 160 for capturing any debris in the hydraulic based fluid prior to being advanced through the pump 144 .
[0041] Referring to FIG. 5 is an alternative configuration for replenishing the hydraulic fluid circuit 49 with the hydraulic based fluid from the lubrication fluid circuit 140 . An orifice plug 162 is positioned within the inlet port 146 that feeds the reservoir 104 . A restricted opening 164 (e.g. narrow opening), which is formed through the orifice plug 162 , reduces the pressure of the hydraulic based fluid being delivered to the reservoir 104 . In one example, the hydraulic based fluid is delivered continuously to the reservoir through the restricted opening 154 keeping the reservoir substantially full of the fluid.
[0042] The filter 166 (e.g. a micron filter) is positioned above the main chamber 168 of the reservoir 104 for capturing any debris in the hydraulic based fluid. The main chamber 168 provides the hydraulic based fluid to the source piston 92 via the compensation port 102 and the secondary port 103 as described earlier.
[0043] The return port 154 and the inlet port 146 are preferably positioned adjacent to the diaphragm-filter 106 and 166 and opposite the main chamber 168 . It is believed that this configuration will facilitate removing any excess hydraulic based fluid from the reservoir 104 . That is, the excess hydraulic based fluid may flow directly from the inlet port 146 across the diaphragm-filter 106 and 166 to the return port 154 without descending into the main chamber 168 when the main chamber 168 is substantially full of the hydraulic based fluid. An outlet valve 170 may also be disposed in the return port 154 for controlling the outflow of the hydraulic based fluid from the reservoir 104 . The return port 154 provides a fluid pathway for returning the excess hydraulic based fluid to the lubrication circuit 140 .
[0044] As a person skilled in the art will readily appreciate, the above description is meant as an illustration of the implementation of the principles of this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation, and change, without departing from the spirit of this invention as defined in the following claims. | In at least one embodiment, a hydraulic clutch assembly for a motor vehicle driveline is provided. The clutch assembly comprises an input member, and output member and a friction clutch pack operably disposed therebetween for controlling torque transfer. A first fluid circuit contains hydraulic based fluid at a first pressure and is in fluid communication with the friction clutch pack for lubrication thereof. A second fluid circuit is in fluid communication with the first fluid circuit for replenishing the second fluid circuit with the hydraulic based fluid at a second pressure that is less than the first pressure. The clutch assembly further comprises a motor and a gear train. The gear train has an input force driven by the motor and an output force. A first piston is in fluid communication with the second fluid circuit for delivering the hydraulic based fluid thereto and is operatively driven by the output force to displace the hydraulic based fluid. A second piston is translated by the hydraulic based fluid displaced by the first piston to actuate the friction clutch pack. | 5 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/405,463, filed Sep. 24, 1999, now abandoned, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
A large number of drugs and other medicaments are routinely prepared and administered to patients in a health care facility. Sometimes, two components of a therapeutic composition are required to be mixed immediately prior to administration. One method for mixing therapeutic compositions immediately prior to administration includes mixing two solutions in a mixing vessel, whereupon the mixture is drawn into a syringe, and the resulting mixed composition is then applied to an appropriate site of the patient. However, this process is often cumbersome, a significant amount of the drug may be lost, and the time between the mixing and the application is often too long with sensitive compositions (i.e., compositions that, upon mixing, must be immediately administered).
Another method for mixing therapeutic compositions immediately prior to administration employs two syringes that are clamped together. Output ends of the syringes are inserted into a Y-shaped coupling device having two input openings and a single output opening. Mixing occurs in the Y-shaped coupling device or in a needle connected to the single output end of the Y-shaped coupling device. However, with this type of arrangement, control over the degree of mixing does not exist and the degree of mixing, therefore, may be inadequate.
Another method for mixing therapeutic compositions immediately prior to administration includes coupling two syringes with an independent coupling means, thereby allowing the contents of one syringe to be mixed with the contents of the other coupled syringe. The independent coupling means, however, provides a space where there is very little agitation due to plug flow of the contents. The contents, therefore, do not mix well. Additionally, when the syringes are uncoupled (i.e., disengaged), the contents have to be aspirated out of the independent coupling means or they will be lost. In addition, the independent coupling means must be removed and discarded before attaching a needle to the delivery or injection syringe.
U.S. Pat. No. 4,994,029 (the '029 patent) discloses a syringe mixer and injector device formed of an injector and an adapter having opposed interconnectable nozzles on their facing ends and sockets and a short tubular spike in each socket to penetrate the stopper of a vial when connected to that socket. See, the '029 patent col. 2, 11. 24-31. It is among the additional objects of the invention to provide such a device which can be used with a receiving vial charged with a medicament solid or liquid, and a charging vial charged with a medicament liquid for one-way transfer to the receiving vial for admixing the medicaments therein without retransfer to the charging vial. Id. at col. 2, 11. 38-24 and col. 6, 11. 23-30. The injector inner end has a connection, provided with a nozzle recess containing a tapered, e.g. central, spout defining the inner terminus of pathway 5 and a lock connection formation, such as a luer lock tab, arranged to form a male connection formation for interconnecting releasably with mating parts on adapter 30 . Col. 4, 11. 5-12. Since the '029 patent explicitly discloses that the system is made for one-way transfer, without recharging the charging vial, it would not be suitable for the recombination of materials between two syringes.
Since the system disclosed in the '029 patent was not contemplated for multiple-pass use (i.e., recombination of materials between two syringes), the skilled artisan would not use the '029 patent disclosure for a syringe system wherein multiple-pass use is desired. This is so because a system not contemplated for multiple-pass use, that is nonetheless employed for multiple-pass use, can result in an appreciable amount of sample loss (e.g., leakage). This is especially troublesome when the drug is expensive (e.g. leuprolide acetate). This is also troublesome since the U.S. Food and Drug Administration (FDA) requires that the health care professionals administer an active ingredient in a precise and known amount. Obviously, this requirement cannot be met when there is an appreciable amount of sample loss due to the syringe assembly.
U.S. Pat. No. 6,223,786 (the '786 patent) is directed to devices and methods for mixing medication and filling an ampule of a needle-less injector prior to an injection, which includes a reagent holder and a diluent holder. See, the '786 patent, col. 2, 11. 6-15. The diluent holder includes a plunger which is depressed to load the diluent from the diluent holder into the reagent holder to mix with the reagent to produce a liquid medication for filling the ampule of the needle-less injector. Id. at col. 2, 11. 20-25. In further embodiments, the reagent holder further includes a reagent plunger rod. Id. at col. 2, 11. 24-26. There is no disclosure or suggestion either explicitly or implicitly to include a male or female end forming a fluid tight engagement. In fact, the only engagement disclosed is a thread like engagement without any mention to fluid tightness. Moreover, the engagement disclosed by the '786 cannot be locked, as the threaded engagement has no means of locking.
In the most simplistic embodiment, the '786 patent discloses a four part system: diluent holder, support brushing, reagent holder, and the needleless injector; while the '029 patent discloses a four part system: injector, plunger vial, adaptor and charging vial. The presence of multiple (e.g., four) components increases the likelihood of human error when mixing and administering a drug. Additionally, the presence of multiple components increases the likelihood of an occurrence of sample loss (e.g., leakage).
Thus, there is a need for a syringe system wherein components of a composition can be easily mixed by the end user without losing a significant amount of mixed composition during the mixing process and wherein the mixed composition can be easily and rapidly administered to a patient. Such a syringe system will have a relatively few number of interconnecting parts, to minimize human error and to minimize sample loss. Additionally, the syringe system will effectively mix the contents located therein without sample loss, such that it will be approved by the FDA when used with drugs that must be administered in a known, discrete and precise amount (e.g., leuprolide acetate).
SUMMARY OF THE INVENTION
The present invention provides a syringe system wherein components of a composition can be easily mixed by the end user without losing a significant amount of mixed composition during the mixing process and wherein the mixed composition can be easily and rapidly administered to a patient. The syringe system has a relatively few number of interconnecting parts, to minimize human error and to minimize sample loss. Additionally, the syringe system effectively mixes the contents located therein without sample loss, such that it can be approved by the FDA when used with drugs that must be administered in a known, discrete and precise amount (e.g., leuprolide acetate).
The present invention provides a coupling syringe system for obtaining a mixed composition, a method for forming a mixed composition that employs such a coupling syringe system, and a method for administering a mixed composition to a patient, that employs such a coupling syringe system.
The coupling syringe system includes a first syringe, a first syringe plunger, a second syringe, and a second syringe plunger. The first syringe includes a first syringe barrel having a first syringe open proximal end and a first syringe distal end. The first syringe further includes a first syringe tip with a male end portion, wherein the male end portion has a locking ring and a tip. The first syringe barrel has a first syringe inner surface. The first syringe plunger is slidably disposed within the first syringe barrel. The first syringe plunger is in fluid-tight engagement with the first syringe inner surface. The second syringe includes a second syringe barrel having a second syringe open proximal end and a second syringe distal end. The second syringe further includes a second syringe tip with a female end portion, wherein the female end portion includes one or more exteriorly protruding members adapted to detachably fit the locking ring. The second syringe barrel has a second syringe inner surface. The second syringe plunger is slidably disposed within the second syringe barrel. The second syringe plunger is in fluid-tight engagement with the second syringe inner surface. The female end portion has an opening therein. The opening is sized and configured to receive the tip of the male end portion therein. The locking ring couples the first syringe to the second syringe when the tip of the male end portion is disposed within the female end portion, forming a fluid tight engagement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a coupled syringe system with a mixed composition formed from introducing the composition of the syringe with the male end portion into the syringe with the female end portion.
FIG. 2 illustrates a coupled syringe system with a mixed composition formed from introducing the composition of the syringe with the female end portion into the syringe with the male end portion.
FIG. 3 illustrates a syringe with a female end portion.
FIG. 4 illustrates a syringe with a male end portion.
FIG. 5 illustrates a coupled syringe system with a mixed composition formed from introducing the composition of the syringe with the female end portion into the syringe with the male end portion.
FIG. 6 illustrates a syringe with a male end portion detachably connected to a discharge assembly wherein the discharge assembly includes a needle and wherein a needle cover is removably mounted over the needle cannula.
DETAILED DESCRIPTION OF THE INVENTION
The coupling syringe system of the present invention allows for the effective mixing of compositions immediately prior to administration. The mixing does not result in a significant loss of the composition. In addition, the time between the mixing and the administration of the composition is minimal, such that a sensitive composition (i.e., a composition that, upon mixing, must be immediately administered) is not chemically or physically altered (i.e., there is minimal decomposition). The use of the coupling syringe system of the invention does not result in a plug flow of the contents. In addition, the coupling syringe system can conveniently be disassembled and a needle can conveniently be attached to the syringe which includes a male end portion and a locking ring.
Referring to FIGS. 1-6 , a coupling syringe system of the present invention is identified generally by the numeral 1 . As shown in FIGS. 1 , 2 , and 5 , syringe system 1 includes a first syringe 13 and a second syringe 14 . The first syringe 13 includes a barrel 2 . The barrel 2 has a distal end 3 , an open proximal end 4 , and a generally cylindrical wall 5 extending between the ends to define a fluid receiving chamber 6 . Cylindrical wall 5 of the first syringe barrel defines an outside diameter along much of its length. An outwardly projecting finger flange 7 is defined near proximal end 4 of the first syringe barrel 2 for facilitating digital manipulation of the first syringe. Additionally, as shown in FIG. 4 , distal end 3 of the first syringe barrel 2 is characterized with a tip 8 . Tip 8 is provided with a fluid passage 9 extending therethrough and communicating with fluid receiving chamber 6 . The tip 8 is also provided with a male end portion 10 wherein the male end portion 10 is provided with a locking ring 11 .
The locking ring 11 is configured such that the interior of the locking ring 11 contains threads which are adapted to receive protruding members 12 exteriorly disposed on the female end portion of the second syringe 14 as shown in FIG. 3 . The locking ring 11 is designed to interlock the first syringe 13 (i.e., the syringe including the male end portion) and the second syringe 14 (i.e., the syringe including the female end portion). In addition, the locking ring 11 is configured to detachably connect to a discharge assembly 15 . Specifically, the discharge assembly 15 can include a needle 16 (see FIG. 6 ).
As shown in FIGS. 1 , 2 , and 5 , syringe system 1 also includes a second syringe 14 having a barrel 18 . The barrel 18 has a distal end 19 , an open proximal end 20 , and a generally cylindrical wall 21 extending between the ends to define a fluid receiving chamber 22 . Cylindrical wall 21 of the second syringe barrel defines an outside diameter along much of its length. An outwardly projecting finger flange 23 is defined near proximal end 20 of the second syringe barrel 18 for facilitating digital manipulation of the second syringe 14 . As shown in FIG. 3 , distal end 19 of the second syringe barrel is characterized with a tip 25 . Tip 25 is provided with a fluid passage 26 extending therethrough and communicating with fluid receiving chamber 22 . The tip 25 is also provided with a female end portion 27 wherein the female end portion 27 is configured to detachably connect to the locking ring 11 . The female end portion 27 includes one or more (e.g., 1, 2, 3, or 4) exteriorly protruding members 30 adapted to detachably engage the locking ring 11 . The protruding members 30 are configured such that they can thread into the locking ring 11 .
As shown in FIGS. 1 , 2 , 4 , and 6 , a plunger 40 is disposed in fluid receiving chamber 6 and is in sliding fluid-tight engagement with cylindrical wall 5 of syringe barrel 2 . Sliding movement of plunger 40 in a distal direction causes the composition (i.e., solid, liquid, or mixture thereof) in chamber 6 to be expelled through passage 9 of tip 8 (see FIG. 4 ) and into fluid receiving chamber 22 (see FIGS. 1 , 2 , 3 , and 6 ) thereby mixing the composition (i.e., solid, liquid, or mixture thereof) of chamber 6 with the composition (i.e., solid, liquid, or mixture thereof) of chamber 22 . Conversely, sliding movement of plunger 40 in a proximal direction draws the composition (i.e., solid, liquid, or mixture thereof) in chamber 22 through passage 26 and into fluid receiving chamber 6 thereby mixing the composition (i.e., solid, liquid, or mixture thereof) of chamber 26 with the composition (i.e., solid, liquid, or mixture thereof) of chamber 22 . It is appreciated that those skilled in the art understand that any combination of the above steps can be carried out and repeated until such time as an effective amount of mixing is attained.
As shown in FIGS. 1 , 2 , 3 , and 6 , a plunger 90 is disposed in fluid receiving chamber 22 and is in sliding fluid-tight engagement with cylindrical wall 21 of syringe barrel 18 . Sliding movement of plunger 90 in a distal direction causes the composition (i.e., solid, liquid, or mixture thereof) in chamber 22 to be expelled through passage 26 of tip 25 and into fluid receiving chamber 6 (see FIGS. 1 , 2 , 4 , and 6 ) thereby mixing the composition (i.e., solid, liquid, or mixture thereof) of chamber 22 with the composition (i.e., solid, liquid, or mixture thereof) of chamber 6 . Conversely, sliding movement of plunger 90 in a proximal direction draws the composition (i.e., solid, liquid, or mixture thereof) in chamber 6 through passage 9 and into fluid receiving chamber 22 thereby mixing the composition (i.e., solid, liquid, or mixture thereof) of chamber 6 with the composition (i.e., solid, liquid, or mixture thereof) of chamber 22 . It is appreciated that those skilled in the art understand that any combination of the above steps can be carried out and repeated until such time as an effective amount of mixing is attained.
As shown in FIG. 6 , a discharge assembly 15 can be connected to the locking ring 11 of the first syringe 13 . More particularly, the discharge assembly 15 includes needle cannula 50 having a proximal end 51 , a sharp distal end 52 and a lumen 55 extending therebetween. A hub 75 joined to the cannula so that the lumen 55 is in fluid communication with the hub 75 . Tip 8 fits into hub 75 and frictionally engages the hub 75 so that the lumen 55 of needle cannula communicates with passage through tip 8 and further communicates with fluid receiving chamber 6 of syringe barrel 2 . In this embodiment, needle assembly 77 is removably mounted to tip 8 . However, it is within the purview of the present invention to include a needle cannula that is directly and permanently mounted to the syringe tip.
As shown in FIG. 6 , a needle cover 60 can be removably mounted over needle cannula 50 to prevent accidental sticks prior to use of syringe assembly 70 . Needle cover 60 can be removed from syringe assembly 70 immediately prior to use.
In an alternative embodiment, a first securing device can conveniently be mounted on the interior surface of barrel 2 or on the inside of barrel 18 . The first securing device, upon engaging with a second securing device mounted on the external surface of plunger 40 or plunger 90 , respectively, can prohibit the plunger 40 or the plunger 90 from disengaging from barrel 2 or the barrel 18 , respectively.
The first syringe and the second syringe can conveniently be manufactured from any suitable material. Typically, both the first syringe and the second syringe are each independently manufactured from glass or plastic (e.g., polypropylene, polyethylene, polycarbonate, polystyrene, and the like).
The size of both the first syringe and second syringe can independently be any suitable size. Suitable sizes include a syringe barrel of about 0.01 to about 100 cc, about 0.1 cc to about 50 cc, about 0.1 cc to about 25 cc, or about 0.5 cc to about 10 cc.
The first syringe 13 (i.e., the syringe including the male end portion and locking ring) can conveniently be manufactured by any suitable process. The first syringe can conveniently be manufactured by an injecting molding process where the entire syringe is made as one unit. Alternatively, the first syringe can be manufactured by independently molding the syringe and locking ring and then mounting (i.e., attaching) the locking ring and first syringe. Preferably, the locking ring is permanently attached to the first syringe. Although the ring can also be mounted coaxially and rotably with tip 8 by a flange and seal configuration. In this configuration, the ring can be rotated around the tip. Typically, the locking ring is permanently attached to the first syringe by welding the two pieces together.
The second syringe 14 (i.e., the syringe including the female end portion) can conveniently be manufactured by any suitable process. The second syringe can be manufactured by an injecting molding process where the entire syringe is made as one unit.
Each composition to be combined with a syringe can independently be a solid, liquid, or mixture thereof. In addition, the solid can be a powder or crystalline material. As used herein, a mixture of a solid and a liquid can be a heterogeneous phase (e.g., an emulsion or a colloidal suspension). Alternatively, a mixture of a solid and a liquid can be a homogeneous phase (i.e., a solid completely dissolved in a liquid).
Each composition can independently include one or more (e.g., 1, 2, or 3) compounds. In addition, the compound of the composition can be a drug delivery system, a drug (i.e., pharmaceutical) or a pharmaceutically acceptable salt thereof, a liquid carrier, a liquid, a lipid formulation, or a vaccine.
Any suitable drug delivery system can be employed. A suitable drug delivery system includes, but is not limited to, is the Atrigel® delivery system mixed with doxycycline or leuprolide acetate. The Atrigel® system is described in U.S. Pat. No. 5,278,201, the disclosure of which is incorporated herein by reference.
Any suitable drug (i.e., pharmaceutical) or pharmaceutically acceptable salt thereof can be employed. Suitable classes of drugs include antibiotics, peptides, hormones, analgesics, growth factors, and any agent described in U.S. Pat. No. 4,938,763B1, the disclosure of which is incorporated herein by reference. The drug can exist as a solid (e.g., crystal or powder), an oil, or as a liquid. In addition, the drug may exist in a microcapsule containing the drug or as a microparticle.
Any suitable liquid carrier can be employed. Suitable liquid carriers include a collagen solution, a sterile aqueous solution, a sterile saline solution, an alcoholic solution, or any suitable mixture thereof. In addition, the liquid carrier can be an emulsion formed from a mixture of an oil or lipid with a sterile aqueous solution or a sterile saline solution.
Specifically, the liquid drug delivery system can be the Atrigel® system mixed with a powder drug (e.g., doxycycline or leuprolide acetate).
Specifically, the drug can be an antibiotic or growth factor.
Specifically, the liquid carrier can be a collagen solution and a powder drug.
Specifically, the liquid carrier can be a sterile aqueous or a sterile saline solution and a powder drug.
Specifically, the liquid can be an alcohol and a drug mixed with a sterile saline or a sterile aqueous solution.
Specifically, the lipid formulation can be mixed with a sterile aqueous solution or a sterile saline solution to form an emulsion.
Specifically, the liquid carrier (e.g., a sterile aqueous solution or a sterile saline solution) can be mixed with a microcapsule or a microparticle containing drug.
Specifically, the vaccine solution can be mixed with an oil to form an emulsion.
Any suitable method of administration can be employed. Typically, the mixed composition can be administered to a patient by intravenous, intramuscular, intraperitoneal, or subcutaneous routes.
EXAMPLES
Both the amount of drug and the drug content, delivered from a syringe system of the present invention, is relatively uniform. Additionally, there is relatively low sample loss when delivering a drug from syringe system of the present invention.
Example 1
The LA-2575 30.0 mg drug product when injected subcutaneously forms a biodegradable implant that delivers 30.0 mg of leuprolide acetate (LA) over a four-month period. The drug product is composed of two separate syringes. Syringe A with a female Luer Lok fitting contains the drug delivery vehicle, and Syringe B with a male Luer Lok fitting contains lyophilized LA. To constitute the product for injection, Syringe A and Syringe B are connected, and the contents are passed back and forth until blended. After mixing, the two syringes are separated, a hypodermic needle is attached to Syringe B, and the constituted drug product is administered subcutaneously to the patient.
A fraction of the constituted drug product is trapped in the hub of Syringe A after the mixing process and in the hub and needle of Syringe B after injection. To meet the targeted delivery values, this retained drug product must be accounted for when calculating the fill weights for both syringes. Also, the amount of material and drug delivered from the mixed syringe must be consistent in quantity to meet strict FDA rules for administered drug. To determine whether the amount of material and drug administered was consistent, an experiment was performed with the following supplies:
Syringe A, a 1.2 ml syringe (UltraTek) molded with a female Luer-Lok® fitting, contains the vehicle 75:25 Poly (D,L-lactide-co-glycolide) (PLG) dissolved in a biocompatible solvent N-methyl 2-pyrrolidone (NMP). The fill weight was 560 mg vehicle. Syringe B, a 1.0 mL syringe (Becton-Dickinson) molded with a male Luer-Lok® fitting, contains lyophilized LA. The fill weight was 35.8 mg of lyophilized LA.
Each of three lab analysts constituted 10 replicate units using 30 mixing cycles and determined delivered mass and % LA content. The data given in the table show that the delivered mass was consistent with a delivered mass of 504.4±6.55 mg and the mixing was uniform with a drug content of 5.6±0.19%. These data show that the syringe coupling system gives uniform mixing of the contents and reproducible delivery of the mixed mass.
30 Cycles
Del.
Analyst
Sample
Mass (mg)
LA (%)
1 (ST)
1
508.6
5.7%
2
517.3
5.7%
3
512.8
5.8%
4
514.9
5.7%
5
508.7
5.7%
6
505.9
5.5%
7
504.4
5.8%
8
506.2
5.7%
9
512.6
5.8%
10
503.6
5.7%
2 (SV)
1
508.8
5.7%
2
504.2
5.7%
3
511.7
5.6%
4
509.9
5.6%
5
501.0
5.7%
6
502.3
5.5%
7
500.1
5.6%
8
499.7
5.7%
9
505.1
5.7%
10
505.0
5.7%
3 (RM)
1
494.9
5.1%
2
499.4
5.4%
3
501.6
5.7%
4
506.0
5.7%
5
497.9
5.6%
6
505.3
5.7%
7
501.0
5.4%
8
502.8
5.0%
9
485.8
5.2%
10
494.5
5.6%
Mean
504.4
5.6%
SD
6.55
0.19%
% RSD
1.3%
3.5%
Example 2
The 6-Month ELIGARD 45.0 mg drug product when injected subcutaneously forms a biodegradable implant that delivers 45.0 mg of leuprolide acetate (LA) over a six-month period. The drug product is composed of two separate syringes. Syringe A with a female Luer Lok fitting contains the drug delivery vehicle, and Syringe B with a male Luer Lok fitting contains lyophilized LA. To constitute the product for injection, Syringe A and Syringe B are connected, and the contents are passed back and forth until blended. After mixing, the two syringes are separated, a hypodermic needle is attached to Syringe B, and the constituted drug product is administered subcutaneously to the patient.
A fraction of the constituted drug product is trapped in the hub of Syringe A after the mixing process and in the hub and needle of Syringe B after injection. To meet the targeted delivery values, this retained drug product must be accounted for when calculating the fill weights for both syringes. An experiment was conducted to determine the amount of total mass delivered, the amount of drug, and the drug content when the two syringes were mixed. The following supplies were used in this experiment:
Syringe A, a 1.2 ml syringe (UltraTek) molded with a female Luer-Lok® fitting, contains the vehicle 85:15 Poly (D,L-lactide-co-glycolide) (PLG) dissolved in a biocompatible solvent N-methyl 2-pyrrolidone (NMP). The fill weight of the polymer vehicle was 410±2 mg. Syringe B, a 3.0 mL syringe (Becton-Dickinson) molded with a male Luer-Lok® fitting, contains lyophilized LA. The fill weight of this syringe was 56.3 mg of LA.
Each of three lab analysts constituted six replicate units using 60 mixing cycles and determined delivered mass and % LA content. The results given in the table show that the delivered mass was consistent with 371.4±4.5 mg, the amount of drug delivered at 45.5±0.8 mg, and the drug content at 12.3±0.2%. These data show that the unique syringe coupling system gives both uniform mixing of the contents and reproducible delivery of the mixed mass.
60 Cycles
Analyst
Sample
Del. Mass (mg)
LA Rev (mg)
LA Recov (%)
1 (ST)
1
376.8
46.0
12.2%
2
376.0
46.3
12.3%
3
360.8
43.6
12.1%
4
373.2
45.7
12.2%
5
378.3
46.2
12.2%
6
372.8
46.9
12.6%
2 (SK)
1
376.6
45.2
12.0%
2
372.4
45.4
12.2%
3
365.1
44.7
12.2%
4
368.1
45.5
12.4%
5
373.5
45.8
12.3%
6
372.9
46.5
12.5%
3 (MA)
1
372.1
44.4
11.9%
2
370.4
44.7
12.1%
3
366.5
45.4
12.4%
4
367.1
45.5
12.4%
5
371.1
45.9
12.4%
6
370.6
45.4
12.3%
Mean
371.4
45.5
12.3%
Std. Dev
4.5
0.8
0.2%
% RSD
1.2%
1.8%
1.3% | The present invention relates generally to medical devices for mixing, preparing and administering therapeutic compositions, and more particularly to a system comprising two syringes and a locking ring wherein two compositions are mixed between the two syringes immediately prior to administration. | 0 |
BACKGROUND OF THE INVENTION
It is common to utilize sprinkler heads in buildings for the purpose of enabling water to be applied automatically to a fire in the building. Most sprinkleer heads incorporate a heat sensitive member formed of eutectic material which liquifies upon reaching a predetermined critical temperature. In most conventional sprinkler head constructions, the eutectic material forms part of a link or strut which normally precludes the discharge of water from the head, but which, upon reaching its predetermined temperature, liquifies and effects collapsing of the link or strut, thereby enabling a value to open and water to be sprayed from the head. Examples of such prior constructions are illustrated in U.S. Pat. Nos. 241,937; 1,315,079; 1,584,719; 2,129,012; and 2,664,956.
One of the difficulties with conventional sprinkler heads is the time required to raise the temperature of the eutectic material to that at which it liquifies. It is not uncommon for the temperature within a building to rise to a level corresponding to or above the critical temperature of the eutectic material and to remain at such elevated temperature for an unduly long period of time before the sprinkler is actuated. This is believed to be due, in large part, to the fact that, in such prior constructions, heat is absorbed not only by the eutectic material, but by all parts of the sprinkler head. Thus, although the ambient temperature is at or higher than the critical temperature, some time is required for the eutectic material to absorb sufficient heat to raise it to its critical temperature. In those instances in which heat must be transmitted via other parts of the sprinkler head to the eutectic material, therefore, the necessity of raising the temperature of such other parts to the critical temperature actually results in a time lag in sprinkler head operation. Such time lag in some cases may mean the difference between losing and saving the building and its contents.
SUMMARY OF THE INVENTION
A principal objective of the present invention is to provide an automatic sprinkler head construction in which the actuation of the sprinkler system depends upon the liquification of a heat sensitive, eutectic material and wherein the construction is such as to concentrate the heat to which the eutectic material is exposed. This objective is accomplished by sandwiching the eutectic material between a pair of thermally insulating members which, together with the eutectic material, constitute the actuating mechanism for the sprinkler head. In addition, a heat collector of highly thermally conductive material encircles the insulating members and engages the eutectic material. Inasmuch as the thermally insulating parts of the actuating mechanism do not drain heat from the collector, the heat collected by the collector will be concentrated at the zone at which it engages the eutectic material, thereby accelerating the transfer of heat from the collector to the eutectic material.
Another object of the invention is the provision of a sprinkler head which is more economical to produce than currently available sprinkler heads.
DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages of the invention will be pointed out specifically or will become apparent from the following description when it is considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a view partly in section and partly in elevation of a sprinkler head constructed in accordance with one preferred embodiment of the invention and coupled to a sprinkling system;
FIG. 2 is an enlarged, elevational view of the actuating mechanism shown in FIG. 1;
FIG. 3 is a sectional view taken on the line 3--3 of FIG. 2;
FIG. 4 is a plan view of a blank adapted to form a part of the sprinkler head;
FIG. 5 is a fragmentary view of a modified form of the invention; and
FIG. 6 is a plan view of a portion of the apparatus shown in FIG. 5.
DETAILED DESCRIPTION
Apparatus constructed in accordance with the invention is adapted for use in a sprinkler system having a plurality of water pipes, one of which is shown at 1 in FIG. 1 and which is provided at intervals with interiorly threaded fittings 2 each of which surrounds an outlet opening 3 in the pipe. Adapted for accommodation in the fitting 2 is a coupling 4 having a threaded end 5 for reception within the fitting 2 and having a passage 6 extending therethrogh in register with the opening 3. The opposite end of the coupling 4 has a flat face 7. Adjacent the face 7 the coupling is formed with a pair of opposed grooves 8 and corresponding ribs 9 for a purpose presently to be explained.
A sprinkler head constructed according to the invention includes a frame F formed from a metal shaped to form a generally circular deflector 10 from which extends a pair of mounting legs 11. Each leg preferably has an elongate opening 12 therein, and each leg terminates at its free end in an offset mounting foot of such size as snugly to be accommodated in the groove 8. After forming, the blank is shaped so that the deflector plate 10 has a concavo-convex configuration, as shown in FIG. 1, and the center of the plate is provided with a tapped opening 14 for the accommodation of an adjustable set screw 15. Alternatively, the plate 10 may have a spherical dimple in lieu of the set screw. The plate 10 is fitted to the coupling 4 by inserting the mounting feet 11 in the grooves 8, following which the ribs 9 are deformed to engage and interlock with the feet.
The passage 6 normally is sealed by a valve or plug 16 of such size as to be accommodated in the passage. An O-ring 17 carried by the valve 16 forms a seal. The valve 16 also includes a flange 18 which normally overlies and rests upon the face 7 of the fitting 4.
Although the valve 16 normally seals the passage 6, it is capable of being unseated by the pressure of water in the line 1 and in the passage 6. It is necessary, therefore, to provide means for holding the valve in its passage-sealing position until such time as the passage should be opened. Such holding means comprises a strut assembly 20 composed of a pair of members 21 and 22 arranged end-to-end but spaced by a gap G in which is sandwiched a wafer 23 formed of eutectic material. The members 21 and 22 are formed of thermally insulating material, such as Bakelite, epoxy, and the like, whereas the wafer 23 is formed of a eutectic material having excellent heat transfer properties, such as an alloy of bismuth, tin, and lead. The material from which the wafer is made has a predetermined critical temperature at which it liquifies. Typically, such wafers liquify at temperatures of between 135° F. and 500° F.
The member 21 has a reduced diameter shank 24 which forms a shoulder 25. Encircling the insulating member 22, the shank 24, and spanning the gap G is a heat collecting sleeve 26 formed of a material, such as brass, bronze, and the like that is highly heat conductive and resistant to corrosion. Preferably, the outer surface of the sleeve 26 is provided with fins 27 to increase the external surface area of the sleeve.
The diameter of the shank 24 corresponds substantially to the internal diameter of the sleeve, and the diameter of the wafer 23 also corresponds to the internal diameter of the sleeve so as to enable the wafer 23 to fit snugly within and in engagement with the sleeve. The diameter of the member 22, however, necessarily is less than the internal diameter of the sleeve, thereby ensuring free movement of the member 22 axially of the sleeve and providing an annular passageway or space 28 for a purpose to be explained presently.
When the parts of the strut are assembled, the insulating members 21 and 22 bear upon the wafer 23 and project beyond opposite ends of the sleeve 26. The outer end of the member 21 is provided with a rounded protrusion 29 that is adapted to be seated in a dimple (not shown) formed in the set screw 15 or in the plate 10. The outer end of the insulating member 22 has a rounded surface 30 that is adapted to be accommodated in a complementally shaped recess 31 formed in the upper surface of the valve 16. In assembled relation, the strut 20 spans the distance between the set screw 15 and the valve 16 and forcibly maintains the latter in sealing relation within the passage 6.
The apparatus preferably includes ejecting means 32 for accelerating removal of the strut 20 from between the fittings 4 and the deflector 10. The ejector comprises a U-shaped spring having parallel legs 33 joined at one end by a bight 34 which is adapted to be accommodated in a slot 35 formed in the member 21. The free ends of the legs 33 are accommodated in sockets 36 formed in the upper surface of the valve 16. The legs 33 are prestressed in such manner that they constantly exert a force on the strut 20 tending to move the lower end of the latter to the left, as viewed in FIG. 3, but such biasing force normally is overcome by the accommodation of the rounded ends 29 and 30 of the members 21 and 22 in their associated dimples.
The embodiment illustrated in FIGS. 5 and 6 differs from the earlier described embodiment in two ways. First, the ejector 32 is not required, although it may be used if desired. Second, the valve 16 is replaced by a valve 37 having a retainer 38 formed of soft metal, such as copper, or bronze, and within which is retained a disc 39 of harder metal. The disc has a dimple 40 in one surface thereof for the accommodation of the strut member 22. The retainer 38 also includes a laterally projecting tongue 41 having a lip 42 at its free end. In this embodiment, the coupling 4 has an upstanding valve seat 43 surrounding the passage 6 and on which the valve 37 seats.
When the parts of the apparatus are assembled in the manner as shown in FIGS. 1-3, the valve 16 will be maintained firmly in its passage-sealing relation by means of the strut 20, and the entire assembly will be exposed to ambient temperature. Should the temperature rise, as would be the case in the event of a fire, the thermally conductive sleeve 26 will absorb heat. Since the members 21 and 22 are formed of thermally insulating material, there will be little heat transfer to such members from the sleeve. The eutectic wafer 23, however, is highly heat conductive. Accordingly, heat from the sleeve 26 rapidly will be transmitted to the wafer 23 to raise its temperature. When the temperature of the wafer 23 reaches a predetermined, critical temperature, such as 165° F., the eutectic material will liquify and flow out the gap G into the annular passageway 28, thereby making possible movement of the member 22 toward the member 21. When the member 22 has moved toward member 21 a sufficient distance, the force of the ejector 32 will cause the nose 30 of the member 22 to slide out of the dimple 31 and displace the entire strut assembly from between the legs 11 with a snap action, thereby enabling water to issue from the passage 6 amd impinge upon the deflector 10.
The operation of the embodiment shown in FIGS. 5 and 6 corresponds to that of the earlier described embodiment with the exception that displacement of the member 22 toward the member 21 enables water to flow out of the passage 6 more quickly. Water issuing from the passage 6 will impinge upon the tongue 41 and upon the lip 42, thereby creating an unbalanced condition which ensures rapid removal of the valve 37 from the path of water issuing from the passage 6.
In each of the disclosed embodiments it is possible to accelerate, to a certain extent, the transfer of heat from the collecting sleeve 26 to the eutectic wafer 23. This may be accomplished by interposing between the wafer and the member 21 a thin disc 44 of material having excellent heat conductive properties, such as copper. The periphery of the disc 44 should be in engagement with the inner surface of the sleeve 26 and, if desired, the disc may have a peripheral flange 45 to increase the surface engagement. If the disc is used, it conducts heat inwardly from the sleeve 26 and transfers such heat to the surface of the wafer, thereby accelerating raising of the temperature of the wafer inwardly of the sleeve 26.
Although it is preferred to provide space for flow of the liquified eutectic material by the simple expedient of forming the member 22 to a diameter less then that of the sleeve 26, it is possible to achieve the same result in other ways. For example, the member 22 could be configured so that it tapers toward its free end, or its free end could be provided with a recess, or the sleeve 26 could be apertured adjacent the gap G.
The disclosed embodiments are representative of presently preferred forms of the invention, but are intended to be illustrative rather than definitive thereof. The invention is defind in the claims. | A fire extinguisher sprinkler head construction has a fitting adapted to be coupled to a water line and having a passage therein through which water may flow and impinge upon a deflector. The water passage normally is sealed by a closure and a collapsible strut, the latter including a eutectic member which liquifies upon reaching a predetermined temperature. The eutectic member is sandwiched between a pair of thermally insulating members, also forming part of the strut, and is engaged by a thermally conductive member which functions as a heat collector. | 5 |
FIELD OF THE INVENTION
This invention relates to molded plastic hangers for garments and, more particularly, to such hangers specifically designed for slacks, pants and the like.
BACKGROUND OF THE INVENTION
It has become conventional practice to utilize garment hangers not only for display of garments at the retail level but also to utilize the garments as a means of transport such as from the factory to the wholesaler or the retailer. In some cases the garment is placed on a hanger and will remain with that hanger and will ultimately be given to the final purchaser. In order to be satisfactory for this purpose, the hanger should have certain important functional characteristics. These characteristics include ease of placing the garment on the hanger and ease of removal of the garment from the hanger. Particularly is this latter characteristic desirable at the retail level where the garment may be removed from the hanger several times for purpose of display or determining the fit. It is also important that the hanger be capable of positively holding the garment during transport. In doing so, it must hold the garment against sliding off the hanger and it must also prevent the garment from sliding toward one end of the hanger and becoming bunched at that end which will result in creasing or otherwise marking the garment. It is particularly important from the point of view of the retailer that whatever means the hanger provides to grip the garment against inadvertent release or sliding to one end, not so tightly clamp or hold the garment that it will crease it because a creased garment has to be pressed before the customer will take it and this is an expensive operation. It is also important that the hanger be inexpensive and be so simple and quick to operate that its use is not a labor intensive operation. In the past, hangers have been developed which have a pair of bars, one of which can be separated or at least spread apart from the other to permit a garment to be draped over it and then the bars brought together to clamp or hold the garment. The bars or rods of this type of hanger are hinged together at one end. For this purpose a number of hinge constructions have been developed including a hinge which is molded integral with both of the bars. The hinges have proved to be a source of difficulty from several standpoints. Among these is that if they are so made that they are not readily subject to fatigue, they have insufficient resilience to be readily usable. If they are so designed that they can withstand frequent usage without fatiguing, they are too stiff to be readily operable. This invention provides a solution to such problems as well as others.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a one-piece integral molded plastic hanger having an upper bar and a lower bar integral with each other at one end by means of a hinge. The hinge is so shaped it has a downwardly inclined portion when the hanger is open with the upper bar pivoted into an upwardly inclined position. However, when the bar is pivoted to the closed position parallel to the lower bar, the hinge itself shifts into a position which is substantially parallel with the bars. In so doing, the hinge provides the required resistance or stiffness to the respositioning of the upper bar and is able to accomplish this without distortion of the plastic forming the hinge that will result in breakage and fatigue. The construction of the hinge does not add significantly to the cost of the hanger but, at the same time, it does improve the operating characteristics of the hanger when the upper bar has to be manipulated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of the hanger in its as-molded condition;
FIG. 2 is an end view of the hanger as viewed from the latch end;
FIG. 3 is an enlarged, fragmentary front elevation view of the hinge for the hanger in open position;
FIG. 4 is a view similar to FIG. 3 but showing the hinge in the closed position;
FIG. 5 is a fragmentary sectional view taken along the plane V--V of FIG. 3;
FIG. 6 is a fragmentary end view taken along the plane VI--VI of FIG. 3;
FIG. 7 is an enlarged sectional view taken along the plane VII--VII of FIG. 3;
FIG. 8 is a fragmentary oblique view of the latch end of the upper bar;
FIG. 9 is an enlarged sectional view taken along the plane IX--IX of FIG. 8;
FIG. 10 is an enlarged, exploded sectional view of the latch;
FIG. 11 is a fragmentary front view of the hanger closed and with a garment draped over the upper bar; and
FIG. 12 is a sectional view taken along the plane XII--XII of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the numeral 10 refers to a hanger having an upper bar 11 and a lower bar 12 integrally joined at one end by a hinge 13. The other ends of the bars, when the hanger is closed, are connected by a latch 14 having a keeper 51 and a strike 16. Intermediate the ends of the lower bar 12, preferably centered between its ends, is a hook 17. As will be seen from FIG. 2, the lower portion of the hook is offset at 18 whereby the upper bar can be pressed around the hook and into a position where it is parallel to and vertically aligned with the lower bar 12. The upper portion of the hook is offset in the opposite direction so that it will be centered above the center of the load applied to the hanger when the hanger is occupied by a garment draped over the upper bar. The upper bar, the lower bar, the latch assembly 14, the hook 17 and the hinge 13 are all molded as a single integral structure thereby eliminating all assembly operations and thus materially reducing the labor content of the manufacturing cost of the hanger. The position of the upper bar 11 as the hanger is removed from the mold is that illustrated in FIGS. 1 and 2. This creates a bias in the hinge structure which will return the upper bar to this position whenever it is released to assume its normal position. The upper and lower bars are each of I-beam cross section giving them rigidity with minimal use of material. At the base of the hook, the lower bar or beam is reinforced by struts 19 to distribute the load between the upper and lower flanges of the lower bar.
The hinge 13 is formed by shaping the upper flange 30 of the upper bar 11 into a somewhat V-shaped loop so that it becomes the lower flange 31 of the lower bar 12 and, in a similar manner, forming the lower flange 32 of the upper bar 11 so that it becomes the upper flange 33 of the lower bar. In the area of the hinge, the central web 34 of the I-beam construction is eliminated leaving an elongated generally V-shaped aperture 35. This construction provides the hinge with inner and outer spring members 36 and 37, respectively. The inner spring member 36 forms a rounded apex 38 which becomes the pivot about which the hinge rotates when the hanger is opened and closed. The outer spring 37 extends substantially beyond the apex of the inner spring and within the loop formed by the outer spring a web similar to web 39 occupies the outer portion of the loop. The inner wall of the web 39 is curved on an arc that is generally concentric with the rounded apex of the inner spring. When the bar 11 is in its released position as illustrated in FIG. 1, the spacing between the inner edge of the web 39 and the adjacent apex 38 of the inner spring 36 is somewhat wider than the remainder of the aperture 35. However, when the hanger is closed and the bar 11 moved to a position parallel with the lower bar 12, this portion of the aperture narrows so that there is general uniformity of width throughout the length of the aperture. The web 39 provides resistance to the closing of the hinge and thus is a stiffener giving the hinge a substantial spring action when the hanger is opened and closed.
Because of this construction, when the hanger is in released position as illustrated in FIG. 1, the hinge is inclined downwardly at an acute angle from the plane of the lower bar 12. In a preferred construction, this downward inclination is approximately 40 degrees. However, when the upper bar 11 is pivoted to the closed position generally parallel to the lower bar 12, the entire hinge structure pivots upwardly until it is almost aligned with the bars. This results from the fact that as the upper bar is moved to the closed position, the apex 38 of the inner spring 36 shifts a very short distance outwardly and pivots upwardly. At the same time, due to the presence of the stiffening web 39, the outer spring is forced to rotate about the apex of the inner spring and rotates upwardly a substantially greater distance and substantially eliminates the curvature which is built into both the inner and outer springs. In so doing, the outer spring is placed under a substantial tension load because its outer apex is unable to deflect. The rigidity of the web transfers the deformation required to close the hinge to that portion of the outer spring which extends from the inner end of the stiffening web 39 to the inner end of the aperture 35 in both the upper and lower bars.
It is also significant to the function of the hinge 13 that the aperture 35 extends a substantial distance along both the upper and lower bars and between the ends of the hinge and the ends of the aperture 35, the upper and lower bars are curved away from each other to form a V, the sides of which are curved outwardly. This is important in providing a zone where the inner spring member acts in compression and the outer spring member acts in tension when the hanger is opened and closed.
At the apex of the outer spring, the outer surface is flattened to form a panel 40. The panel 40 is non-functional so far as the spring is concerned but does serve as a surface on which indicia can be mounted to provide information concerning what is on the hanger such as size, etc. It will be noted from FIG. 3 that in order to provide the panel 40 the outer end of the apex of the outer spring is flattened and the lower portion of the spring adjacent the apex is curved more sharply in a downwardly direction. These arrangements have been embodied in the spring structure so that the panel 40 will remain in a highly visible position when the spring is closed as is indicated in FIG. 4. However, if the panel is eliminated, the outer spring could be redesigned with a smoothly rounded apex similar to the apex of the inner spring without in any way affecting the function of the spring.
To utilize the hanger, the operator can grasp the hanger by the lower bar or the hook in one hand and tilt it until the upper bar 11 is substantially horizontal. At that point the operator with the other hand can drape a garment such as pants or slacks over the bar 11 and, by a combination of closing the bar forcefully and the weight of the garment, the upper bar 11 can be pivoted downwardly while being pivoted laterally to pass around the hook 17 until the bars are parallel. In so doing, the inner leg of the garment is forced to pass around the back side of the upper bar, under the upper bar and between it and the lower bar and then, with the other leg, hang downwardly against the front face of the lower bar as illustrated in FIG. 12. At this point the strike 50 of the upper bar is passed over the top of the keeper 51 of the lower bar until the strike can be seated within the pocket 52 of the lower bar (FIG. 10). By virtue of the fact that a portion of the garment is pressed between the upper and lower bars as illustrated in FIG. 12, the garment provides a bias pulling the strike 50 of the upper bar into the pocket 52 of the latch 51 on the lower bar. At the same time, the garment also reinforces the upward pivotal bias of the upper bar so that the strike hooks upwardly as well as inwardly into the keeper 51. To remove the garment from the hanger, it is only necessary to disengage the latch and allow the upper bar to swing slightly laterally so the garment can be removed endwise from the upper bar. The pressure generated by the garment, as illustrated in FIG. 11, while adequate to hold the latch in positive engagement, even during handling and transport of the hanger and garment, need not be of a magnitude that will crease or otherwise leave any mark on the garment when it is removed. This is important in maintaining the garment in acceptable condition for prospective customers. At the same time, the grip the hanger exerts on the garment is sufficiently positive that the garment will remain on the hanger even though subjected to vibration, impact and other forces which are adequate with many hanger constructions to cause the garment to be inadvertently released. At the same time, the hanger's construction is such that it may be repeatedly used without fatigue at the hinge. In this connection it must be kept in mind that not only does the hinge have to withstand vertical movement as it is opened and closed but it also must be able to sustain repeated lateral twisting in order to permit the upper bar to pass around the upper portion of the hook 17. This problem is accentuated by the fact that the upper portion of the hook must be offset toward the front of the hanger so that it will be basically centered with respect to the hanger as loaded. The center of loading of the hanger is forced to the front of the hanger by the fact that the major portion of the garment is offset to the front side of the bars as they are closed as is indicated in FIG. 11. The fact that the aperture 35 is relatively long and the outer portion of the outer spring is reinforced by the web 39 and the inner portions of both the inner and outer springs are relatively long, permits this lateral deflection or twisting to occur over a sufficient length of material that no portion of the material is strained to the point of fatiguing. Thus, the hanger, while inexpensive and compact, is effective, not only for transportation and display purposes, but also may be repeatedly reused because it has an exceptionally long life.
Having described a preferred embodiment of the invention, it will be understood that various modifications of the invention can be made without departing from the principles of the invention. Such modifications are to be considered as included in the hereinafter appended claims unless these claims, by their language, expressly state otherwise. | A one-piece molded plastic garment hanger has upper and lower bars connected at one end by a hinge. The hanger has a support hook generally centered between the ends of the hanger and integral with the lower bar. The hinge is designed with inner and outer spaced spring members separated by a gap with the inner spring member serving as the pivot and the outer one having a rigid web in its apex serving as a stiffener. The entire hinge in open position being inclined downwardly at an acute angle to the axis of the lower bar. When the hanger is closed and the bars generally parallel, the hinge is pivoted upwardly into substantial alignment with the lower bar axis. | 0 |
This application is a continuation of U.S. application Ser. No. 10/099,950, filed Mar. 19, 2002, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to a semiconductor power converting apparatus with employment of semiconductor elements and the like. More specifically, the present invention is directed to a semiconductor power converting apparatus capable of suppressing an occurrence of an overvoltage while a switching operation is carried out.
As disclosed in IPEC2000 S-17-3 “Development of IEGT series and Parallel Connection Technology for High Power Converters”, each of the arms of a power converter is constituted by a series connection of MOS control semiconductor devices such as IGBTs (insulated-gate bipolar transistors), so that a MOS control semiconductor power converter for outputting a high AC voltage and a high DC voltage can be realized. Since the MOS control semiconductor elements which are series-connected to each other and constitute each of these arms are turned ON or OFF at the same time in response to a pulse signal controlled by either the PWM (pulse width modulation) control or the PAM (pulse-amplitude modulation) control, the DC voltage may be converted into the AC voltage and/or the AC voltage may be converted into the DC voltage.
On the other hand, in another known technique, there are disclosed MOS control semiconductors series-connected to each other, which constitute the respective arms, that may be protected from overvoltages. The published abstract of the Japanese Electric Society Industrial Application Department Meeting in 1999, vol. 2, entitled “Switching Test of Flat-pack IGBTs connected in Series”, pp. 119-120 describes the following protection technique. That is, the avalanche element is connected between the gate and the collector of the IGBT and is brought into the conductive state when this avalanche element exceeds a predetermined voltage and thus avalanches. The voltage of the avalanche element is also increased in connection with the increase of the collector voltage the IGBT. When this voltage of the avalanche element exceeds the avalanche voltage of the avalanche element, the current is supplied from the collector of the IGBT to the gate thereof via this avalanche element, so that the gate voltage of the IGBT is increased and, correspondingly, the impedance of the IGBT is reduced. As a result, the collector voltage of the IGBT is suppressed in order that the IGBT can be protected from the element destruction (breakdown) due to an overvoltage. Also, this publication, entitled “Switching Test for Series-Connection of Planar IGBTs”, in vol. 2 (1999) of the lecture on Japanese Electric Society Industrial Application Department discloses that the MOS control semiconductors can be protected in such a manner that the gate voltage is increased so as to increase the saturated current value.
SUMMARY OF THE INVENTION
However, in the above-described publication entitled “Switching Test for Series-Connection of Planar IGBTs” in the published abstract of Japanese Electric Society Industrial Application Department Meeting in 1999, vol. 2, in such a case that an overcurrent is supplied to an arm under an ON state, among the arms which constitute the MOS control semiconductor converter, the MOS control semiconductor having the lowest saturated current selected amongst the series-connected MOS control semiconductors (e.g., IGBTs) of that arm limits this overcurrent to the saturated current value of that IGBT. As a consequence, since the MOS control semiconductor having the lowest saturated current limits the current, the impedance thereof is increased and the voltage sharing of this MOS control semiconductor is increased. Thus, the semiconductor element may be destroyed due to the application of the overvoltage.
Further, in the above-described publication entitled “Switching Test for Series-Connection of Planar IGBTs” in the published abstract of Japanese Electric Society Industrial Application Department Meeting in 1999, vol. 2, an additionally expensive semiconductor element having a high-voltage withstanding avalanche voltage equivalent to that of such an IGBT to be protected is also required.
The present invention has an object to provide a semiconductor power converting apparatus containing such a circuit capable of preventing an application of an overvoltage. That is, in order to protect MOS control semiconductor devices from the overvoltage, when an overcurrent flows through these MOS control semiconductor devices, this circuit can avoid such an operation that the overvoltage is applied to such an MOS control semiconductor having a minimum saturated current among the series-connected MOS control semiconductor devices, while such a semiconductor element having an avalanche voltage equal to the high withstand voltage is not employed.
According to one aspect of a semiconductor power converting apparatus of the present invention, while a current is supplied to a gate of an IGBT from a gate driver of a MOS control semiconductor, a gate voltage of such an MOS control semiconductor which has reached a saturated current is increased to a voltage higher than a gate voltage obtained under steady ON state, and thus, the saturated current value of this MOS control semiconductor element is increased.
In general, such a relationship as shown in FIG. 2 is established between a collector-to-emitter voltage (will be referred to as a “collector voltage” hereinafter) of an MOS control semiconductor such as an IGBT, and a collector current of this MOS control semiconductor. When the collector voltage is increased at an arbitrary gate-to-emitter voltage (will be referred to as a “gate voltage” hereinafter), the collector current is also increased in connection with this operation. When this increased collector current reaches a certain current value, this collector current does not exceed this reached current value. This maximum current value is referred to as a “saturated current value.” As shown by FIG. 2, when the gate voltage becomes increased, the larger the saturated current value also becomes increased.
As shown in FIG. 3, MOS control semiconductors 11 to 14 such as IGBTs having different saturated current values from each other are series-connected to each other and the series-connected MOS control semiconductors are connected to a voltage source 21 . Also, it is assumed that saturated current values of the respective IGBTs (namely, saturated current value at gate voltages under steady ON states) are defined by IGBT 11 <IGBT 12 <IGBT 13 <IGBT 14 . In the case that all of the series-connected IGBTs are brought into ON states, a current may flow through this IGBT series-connection at a current increased rate which is determined based upon both a leakage impedance 23 of a wiring line and the voltage source 21 . Generally speaking, since a gate voltage of an IGBT is controlled in such a manner that this gate voltage may become a certain gate voltage higher than a threshold value, the IGBT is transferred from an OFF state into an ON state. In this connection, “a certain gate voltage higher than a threshold value” will be referred to as a “steady ON gate voltage” hereinafter in this specification.
In the case that a current flowing through the IGBT series-connection indicated in FIG. 3 reaches the saturated current value during the steady ON gate voltage of the IGBT 11 having the lowest saturated current, this IGBT 11 , having the lowest saturated current, limits this current. As a consequence, since the IGBT 11 limits the current, the impedance thereof is increased. Since a voltage applied to a certain element is equal to a product between an impedance of this element and a current flowing through this element, the collector voltage of the IGBT 11 is increased while the impedance is increased.
However, when the collector voltage of the IGBT under ON state exceeds a previously set value, if the gate circuit functions such that when the collector voltage increases, the gate voltage of the IGBT also increases, then the gate voltage of the IGBT 11 becomes higher than the steady ON gate voltage in connection with an increase of the collector voltage of the IGBT 11 , so that the saturated current value of the IGBT 11 can be increased up to the saturated current value of the IGBT 12 at the steady ON gate voltage. It should be noted that the previously set value is set within a range defined from the steady OFF voltage and the withstanding voltage of the semiconductor element. When the saturated current value of the IGBT 11 reaches the saturated current value of the IGBT 12 , both the IGBT 11 and the IGBT 12 may limit the current, so that the voltage sharing by the IGBT 11 can be reduced by ½. As a result, in the case that the voltage of the DC voltage source 21 is smaller than the summed value of the IGBT 11 and the IGBT 12 , it is possible to avoid such an operation that the semiconductor elements are destroyed, or brought into the breakdown state due to the overvoltage applied to the IGBT.
On the other hand, In such a case that the voltage of the DC voltage source 21 is higher than a total value of the element withstanding voltages of both the IGBT 11 and the IGBT 12 , the collector voltages of both the IGBT 11 and the IGBT 12 are further increased. In connection to this collector voltage increase, the gate voltages of both the IGBT 11 and the IGBT 12 are further increased, so that the saturated current values of the IGBT 11 and the IGBT 12 can reach the saturated current value of the IGBT 13 at the steady ON gate voltage. When the saturated current values of both the IGBT 11 and the IGBT 12 reach the saturated current of the IGBT 13 , the voltage of the DC power source 21 can be shared by three sets of IGBTs, namely the IGBT 11 , the IGBT 12 , and the IGBT 13 . As a result, if the voltage of the DC power source 21 is lower than the element withstanding voltages of the IGBT 11 , the IGBT 12 , and the IGBT 13 , then it is possible to avoid the element breakdown caused by the application of the overvoltage.
Also, in such a case that the voltage of the DC voltage source 21 is higher than a total value of the element withstanding voltages of the IGBT 11 , the IGBT 12 , and the IGBT 13 , the collector voltages of the IGBT 11 , the IGBT 11 , and the IGBT 13 are further increased. In connection to this collector voltage increase, the gate voltages of the IGBT 11 , the IGBT 12 , and the IGBT 13 are further increased, so that the saturated current values of the IGBT 11 , the IGBT 12 , and the IGBT 13 are reached to the saturated current value of the IGBT 14 . When the saturated current values of the IGBT 11 , IGBT 12 , the IGBT 13 and the IGBT 14 are equal to each other, the voltage of the DC voltage source 21 can be shared by four sets of the IGBTs, namely, the IGBT 11 , the IGBT 12 , the IGBT 13 , and the IGBT 14 .
On the other hand, since the series-connection of the IGBT 11 to the IGBT 14 may block the voltage of the voltage source 21 under OFF state, a total value of the element withstanding voltages of the series-connection constructed of the IGBT 11 to the IGBT 14 necessarily exceeds the voltage of the voltage source 21 . As a consequence, if the saturated currents of the IGBT 11 , the IGBT 12 , the IGBT 13 , and the IGBT 14 are equal to each other, then the voltage of the DC voltage source 21 can be shared by four sets of the IGBTs, namely, the IGBT 11 , the IGBT 12 , the IGBT 13 , and the IGBT 14 . As a result, it is possible to prevent the semiconductor elements from being destroyed due to the application of the overvoltage.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram schematically showing a major unit of one arm of a power converter according to an embodiment 1 of the present invention.
FIG. 2 is a graph for graphically indicating a characteristic of an IGBT employed in a semiconductor power converting apparatus of the present invention.
FIG. 3 is an explanatory diagram for explaining a series-connection of MOS control semiconductors having different saturated currents from each other.
FIG. 4 is a schematic diagram for indicating a major unit of a power converter to which the present invention is applied.
FIG. 5 is a circuit diagram for indicating a major unit of one arm of a power converter according to the embodiment 1 of the present invention.
FIG. 6 is a circuit diagram for representing another major unit of one arm of the power converter according to the embodiment 1 of the present invention.
FIG. 7 is a circuit diagram for showing a major unit of one arm of a power converter according to an embodiment 2 of the present invention.
FIG. 8 is a circuit diagram for indicating a major unit of one arm of a power converter according to an embodiment 3 of the present invention.
FIG. 9 is a circuit diagram for showing a major unit of one arm of a power converter according to an embodiment 4 of the present invention.
FIG. 10 is a circuit diagram for indicating a major unit of one arm of a power converter according to an embodiment 5 of the present invention.
FIG. 11 is a circuit diagram for showing a major unit of one arm of a power converter according to an embodiment 6 of the present invention.
FIG. 12 is a circuit diagram for indicating a major unit of one arm of a power converter according to an embodiment 7 of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now to drawings, various embodiments of the present invention will be described in detail. It should be understood that the same reference numerals will be employed as those for indicating the circuit elements having the same functions in the respective embodiments. It should also be noted that potentials appearing at the respective terminals of each of the IGBTs such as from an IGBT 11 to an IGBT 14 , and also potentials within the respective gate circuits are defined in terms of an emitter potential which is used as a reference with respect to each of those IGBTs. In other words, it is so assumed that a collector potential of the IGBT 11 corresponds to a collector-to-emitter voltage of the IGBT 11 , whereas a collector potential of the IGBT 12 corresponds to a collector-to-emitter voltage of the IGBT 12 . It should also be noted that even when an IGBT is replaced by another MOS control semiconductor device such as an MOSFET, a similar effect to that of the below-mentioned embodiment may be achieved.
Embodiment 1
An arrangement of a semiconductor power converting apparatus according to this embodiment 1 of the present invention will now be described with reference to FIG. 1 and FIG. 4 . FIG. 4 schematically shows a major unit of the semiconductor power converting apparatus according to this embodiment 1, and FIG. 1 schematically represents an arm 20 of the major unit shown in FIG. 4 . In the power converting apparatus of FIG. 4, three sets of two series-connected arms 20 are connected in a parallel manner, and these arms 20 are connected to a DC voltage source 21 . Each of neutral points of the paired arms is connected to a load 22 .
A structure of an arm is given as follows: That is, in each arm, IGBTs are series-connected to each other, and a flywheel diode 2 is in an inverse-parallel connection with each of these series-connected IGBTs. Also, a gate circuit 100 is connected to each of the IGBTs. While the present invention is not necessarily limited to a specific series-connection number of IGBTs, four sets of IGBTs (namely, IGBT 11 , IGBT 12 , IGBT 13 , and IGBT 14 ) are series-connected to each other in the example of FIG. 1 . The gate circuit 100 is connected to a gate G and an emitter E of each of the IGBT 11 , the IGBT 12 , the IGBT 13 , and the IGBT 14 . Also, the diode 2 is in an inverse-parallel connection with each of the four IGBTs.
The gate circuit 100 is formed by employing the below-mentioned circuit arrangement. A description will now be made by exemplifying such a gate circuit 100 connected to the IGBT 11 . While a voltage source 131 is connected to the emitter of the IGBT 11 , electric power required for driving a pulse generator 7 is supplied from this voltage source 131 to this pulse generator 7 .
As shown in FIG. 5, while the voltage source 131 is series-connected to another voltage source 132 , and also a center point between these voltage sources 131 and 132 is connected to the emitter of the IGBT 11 , the electric power required for driving the pulse generator 7 may be supplied from both the voltage source 131 and the voltage source 132 . In this alternative case, a terminal of a high voltage side of the voltage source 131 is connected to a power supply line 13 P, and a terminal of a low voltage side of the voltage source 132 is connected to another power supply line 13 N. An output of the pulse generator 7 is connected to one input 1 of a comparator 750 . Another input 2 of the comparator 750 is connected to a voltage dividing point at which a collector-to-emitter voltage of the IGBT 11 is sub-divided by both a resistor 3 and a resistor 4 . This connection point of the input 2 of the comparator 750 need not be selected to the voltage dividing point, but may be connected to any point in which while the collector potential of this IGBT 11 is increased, the potential of this connection point may be increased. The comparator 750 compares potentials of these two inputs thereof to output a higher potential. The output of the comparator 750 is connected to the gate of this IGST 11 , and the gate potential of the IGBT 11 is controlled to the output potential of the comparator 750 .
As shown in FIG. 6, such an amplifying circuit as a buffer circuit 650 may be connected between the comparator 750 and the gate of the IGBT 11 . In this alternative case, the output of the comparator 750 is connected to an input of the buffer circuit 650 , and an output of this buffer circuit 650 is connected to the gate of the IGBT 11 . With the addition of the buffer circuit 650 , the gate potential of the IGBT 11 may be controlled in a high speed.
Next, operations of the power converting apparatus will now be explained. While electric power required for driving the pulse generator 7 is supplied from the voltage source 131 , a pulse signal which is controlled by way of either the PWM control or the PAM control is outputted from the pulse generator 7 . Normally, the pulse signal which is controlled by way of either the PWM control or the PAM control is transmitted from another upper-graded circuit (not shown) to the pulse generators 7 of the respective gate circuits 100 of the IGBT 11 through the IGBT 14 , which are series-connected to each other. In response to the transmitted signals, the pulse generators 7 generate such pulse signals which are controlled by way of either the PWM control or the PAW control. The generated pulse signal is supplied via the comparator 750 to the gate of the IGBT 11 so as to turn ON, or OFF this IGBT 11 . In the present invention, such a potential obtained when the IGBT 11 is turned ON and then the gate potential thereof is brought into a steady state is defined as a steady ON-gate voltage. Since the IGBT 11 , the IGBT 12 , the IGBT 13 , and the IGBT 14 are switched at the same time, the arm 20 is turned ON/OFF so as to produce an AC voltage, so that this AC voltage is applied to the load 22 . Under normal condition, both an arm 20 (N) and another arm 20 (P) are alternately ON/OFF-controlled, and the paired arms are not turned ON at the same time. In other words, both the arm 20 (P) and the arm 20 (N) are not turned ON at the same time. Such a voltage produced by dividing the voltage of the DC voltage source 21 by a total series-connection number of the IGBTs employed in each of the arms corresponds to a steady voltage of an IGBT under OFF connection. This voltage will be referred to as “steady OFF voltage” thereinafter in this specification.
In this case, an attention is paid to such a time instant when a drive signal to the arm 20 (P) is brought into an ON state and the arm 20 (N) is brought into an OFF state in the power converter of FIG. 4 . When the arm 20 (P) is brought into the ON state, a current flows through such a path from the DC voltage source 21 to the arm 20 (P) and the inductance load 22 . At this time, in the case that the arm 20 (N) is erroneously turned ON, or shortcircuited due to some reason, a current will flow through such a path defined from the DC voltage source 21 via the arm 20 (P) and the arm 20 (N) to the DC voltage source 21 . Since both the arm 20 (P) and the arm 20 (N) become low impedances at the same time, a large current may flow through this arm 20 .
Operations of the power converting apparatus will now be explained by exemplifying such a case that the arm 20 (N) is shortcircuited. In accordance with the present invention, when a value of a current is reached to a saturated current value of the IGBT 11 having the lowest saturated voltage, this IGBT 11 limits this current and then a collector potential of this IGBT 11 is increased. Since the collector potential of the IGBT 11 is increased, the potential at the voltage dividing point 9 is increased. When the potential at the voltage dividing point 9 exceeds the potential of the pulse generator 7 , the comparator 750 outputs the potential of this voltage dividing point (or node) 9 so as to control the gate potential of the IGBT 11 to the gate potential of the voltage dividing point. Normally, both a resistance value of a voltage-dividing resistor 3 and a resistance value of a voltage-dividing resistor 4 are set in such a manner that when a collector potential of an IGBT exceeds the steady OFF voltage, a potential of the voltage dividing point 9 may exceed a potential of the pulse generator 7 .
When a collector potential of the IGBT 11 exceeds the steady OFF voltage, the gate potential of the IGBT 11 is increased, so that the saturated current value of this IGBT 11 is increased. While the saturated current value is increased, such a current which passes through the arm 20 (P) is also increased. In the case that the current is increased and then is reached to a saturated current value of the IGBT 12 whose saturated current value is the second lowest current value, the IGBT 12 having the second lowest current value limits the current, so that the collector potential of this IGBT 12 is increased. Since the IGBT 12 also shares the voltage of the DC voltage source, the increase of the collector potential of the IGBT 11 is once relaxed.
However, since both the IGBT 11 and the IGBT 12 limit the current, impedances thereof are increased, so that both the collector potential of the IGBT 11 and the collector potential of the IGBT 12 are increased. Since the collector potential of the IGBT 11 is further increased, the gate potential of this IGBT 11 is increased. Similar to both the operation of the gate circuit 100 connected to the IGBT 11 and the operation of this IGBT 11 , since the collector potential of the IGBT 12 is increased, the gate potential of the IGBT 12 is also increased, and thus, both the saturated current values of the IGBT 11 and the IGBT 12 are increased. The saturated current values of both the IGBT 11 and the IGBT 12 are increased, and also, the current flowing through the arm 20 (P) is similarly increased. When this flowing current is reached to a saturated current value of the IGBT 13 , the IGBT 13 subsequently limits the current, so that the corrector potential thereof is increased.
On the other hand, the potential increases of both the IGBT 11 and the IGBT 12 are once relaxed. However, since the IGBT 11 , the IGBT 12 , and the IGBT 13 may commonly limit the current, the impedances thereof are increased, so that the collector potentials of the IGBT 11 , the IGBT 12 , and the IGBT 13 are further increased. While the collector potentials are increased, the gate potentials of the IGBT 11 , the IGBT 12 , and the IGBT 13 are increased, and then, the current is reached to a saturated current value of the IGBT 14 . Since the voltage of the DC voltage source 21 can be shared by the four sets of IGBTs (namely, IGBT 11 , IGBT 12 , IGBT 13 , and IGBT 14 ), the element destruction caused by the overvoltage can be prevented. As a result, such an effect of this embodiment 1 can be achieved. That is, even when the overcurrent may flow through the MOS control semiconductors, these MOS control semiconductors such as IGBTs can be protected from the overvoltage.
Embodiment 2
As indicated in FIG. 7, a semiconductor power converting apparatus according to an embodiment 2 of the present invention is arranged such that the comparator 750 of the above-described embodiment 1 is constituted by connecting a pnp transistor 72 and an npn transistor 71 in a complementary manner, the npn transistor 71 is connected to a power supply line 13 PP having a higher potential than that of the power supply line 13 P for driving the pulse generator 7 .
A collector of the pnp transistor 72 is connected to the voltage dividing point 9 , and a collector of the npn transistor 71 is connected to the power supply line 13 PP. The pulse generator 7 is driven by both the voltage source 131 and the voltage source 132 . When the IGBT is set to an ON state, the pulse generator 7 outputs the potential of the power supply line 13 P, whereas when the IGBT is set to an OFF state, the pulse generator 7 outputs the potential of the power supply line 13 N. The potential of the power supply line 13 PP is higher than the potential of the power supply line 13 P by such a voltage difference of the voltage source 133 .
While the IGBT 11 is exemplified, a description will now be made of operations in which when the collector potential of the IGBT is increased under the ON state of this IGBT, the gate potential is increased so as to increase the saturated current value. When the collector potential of the IGBT 11 is increased, the potential of the voltage dividing point 9 is increased. Since the ON state of this IGBT is supposed, the pulse generator 7 outputs the potential of the power supply line 13 P. The comparator 750 outputs the potential of the pulse generator 7 , received via resistor 74 , until the potential of the voltage dividing point 9 is reached to the output potential of the pulse generator 750 , namely, reached to the potential of the power supply line 13 P. When the potential of the voltage dividing point 9 becomes higher than the output potential of the pulse generator 7 , a current will flow from the collector of the pnp transistor 72 to the base thereof, and thus, a base potential of the npn transistor 71 becomes higher than a base potential of the pnp transistor 72 , so that this npn transistor 71 is brought into the ON state. Since the potential of the power supply line 13 PP to which the collector of the npn transistor 71 is connected is higher than a maximum output potential of the pulse generator 7 , the potential of the emitter of the npn transistor 71 , namely, the output potential of the comparator 750 , can be increased.
As a consequence, also in this embodiment 2, since the gate potential of the IGBT 11 can be increased higher than the gate voltage under the steady ON state and, also, the saturated current value of the IGBT can be increased similar to the embodiment 1, the IGBT can be protected from the overvoltage in a manner similar to that of the embodiment 1. It should also be noted that it is practically difficult to increase the gate potential of the IGBT 11 higher than a summed voltage of the voltage source 131 and the voltage source 132 . As a consequence, the voltage of the voltage source 132 is set in such a manner that when the gate voltage of the IGBT 11 is equal to the summed voltage between the voltage source 131 and the voltage source 132 , a saturated current value becomes higher than the saturated current value during the steady ON gate voltage of the IGBT 14 .
Embodiment 3
In a semiconductor power converting apparatus of an embodiment 3 according to the present invention, as indicated in FIG. 8, in which a buffer circuit 650 is connected between the comparator 750 of the embodiment 3 and a gate of an IGBT, this buffer circuit 650 is arranged by connecting an npn transistor 61 and a pnp transistor 62 in a complementary manner. The buffer circuit 650 transmits a potential of the comparator 750 to the gate of the IGBT 11 . As a consequence, similar to the above-described embodiment 1, since the gate potential of the IGBT 11 is increased to a level higher than the gate voltage of the steady ON state, in order to increase a saturated current value of the IGBT in this embodiment 3, this IGBT can be protected from the overvoltage in a similar manner to that of the above-described embodiment 1. Since the buffer circuit amplifies a current used to charge the gate of the IGBT, the gate potential of the IGBT can be quickly controlled to become the potential of the voltage dividing point 9 , and also the IGBT can be more firmly protected from the overvoltage.
Embodiment 4
As indicated in FIG. 9, in a semiconductor power converting apparatus of an embodiment 4 according to the present invention, a diode 73 is in an inverse-parallel connection with the pnp transistor 72 of the embodiment 3. When a potential of the voltage dividing point 9 exceeds an output potential of the pulse generator 7 , the output of the voltage dividing point 9 is outputted via the diode 73 to the output of the comparator 750 , the output of the comparator 750 can be quickly controlled to become the potential of the voltage dividing point 9 .
As a consequence, similar to the above-described embodiment 1, since the gate potential of the IGBT 11 is increased to a level higher than the gate voltage of the steady ON, state in order to increase a saturated current value of the IGBT in this embodiment 4, shown in FIG. 9, this IGBT can be protected from the overvoltage in a similar manner to that of the above-described embodiment 1. In accordance with this embodiment 4, the output of the comparator 750 can be quickly controlled to become the potential of the voltage dividing point 9 , and thus the IGBT can be more securely protected from the overvoltage.
Embodiment 5
As indicated in FIG. 10, in a semiconductor power converting apparatus of an embodiment 5 according to the present invention, the input 1 of the comparator 750 is connected to the voltage dividing point 9 , and also the input 2 of the comparator 750 is connected to the output of the pulse generator 7 , in comparison with the power converting apparatus of the embodiment 4 in which the input 1 of the comparator 750 is connected to the output of the pulse generator 7 , and the input 2 of the comparator 750 is connected to the voltage dividing point 9 of the series connected resistors 3 and 4 . Since the comparator 750 outputs a higher potential selected from the potentials of the input 1 and the input 2 , a similar effect to that of the embodiment 4 may be achieved.
Embodiment 6
As indicated in FIG. 11, a semiconductor power converting apparatus according to an embodiment 6 of the present invention is arranged in such a manner that while both the pnp transistor 72 and the npn transistor 71 are eliminated from the circuit arrangement of the comparator 750 of the embodiment 4, the npn transistor 61 is connected to the power supply line 13 PP having the higher potential than that of the power supply line 13 P which drives the pulse generator 7 .
The collector of the pnp transistor 62 is connected to the center point of series-connected voltage sources 131 and 132 , the collector of IGBT 11 is connected to the dividing point 9 via resistor 3 , and the collector of the npn transistor 61 is connected to the power supply line 13 PP having a higher potential than the output potential of the pulse generator 7 , while both the pnp transistor 62 and the npn transistor 61 constitute the buffer circuit 650 . The pulse generator 7 is driven by both the voltage source 131 and the voltage source 132 . When an IGBT is set to an ON state, the pulse generator 7 outputs the potential of the power supply line 13 P, whereas when the IGBT is set to an OFF state, the pulse generator 7 outputs the potential of the power supply line 13 N. The potential of the power supply line 13 PP is higher than the potential of the power supply line 13 P by such a voltage difference of the voltage source 133 .
While the IGBT 11 is exemplified, a description will now be made of operations in which when the collector potential of the IGBT is increased under the ON state of this IGBT, the gate potential is increased so as to increase the saturated current value. When the collector potential of the IGBT 11 is increased, the potential of the voltage dividing point 9 is increased. Since the ON state of this IGBT is supposed, the pulse generator 7 outputs the potential of the power supply line 13 P. The comparator 750 outputs the potential of the pulse generator 7 until the potential of the voltage dividing point 9 reaches the output potential of the pulse generator 750 , namely, reached to the potential of the power supply line 13 P, since an anode potential of a diode 73 is lower than a cathode potential thereof, and thus, this diode 73 becomes a high impedance.
When a potential of the voltage dividing point 9 is increased to a level higher than the output potential of the pulse generator 7 , the diode 73 becomes a low impedance, so that the output of the comparator 750 can output the potential of the voltage dividing point 9 . Since the collector of the npn transistor 61 is connected to the power supply line 13 PP having the higher potential than the output potential of the pulse generator 7 , the output potential of the pnp transistor 62 can be increased higher than a maximum output potential of the pulse generator 7 , and also the gate potential of the IGBT 11 can be increased higher than the steady ON gate voltage.
As a consequence, also in this arrangement of the embodiment 6 shown in FIG. 7, since the gate potential of the IGBT 11 is increased to a level higher than the gate voltage under the steady ON state and, also, the saturated current value of the IGBT is increased similar to the embodiment 4, the IGBT can be protected from the overvoltage in a manner similar to that of the embodiment 4.
Embodiment 7
As shown in FIG. 12, in a semiconductor power converting apparatus according to an embodiment 7 of the present invention, while both an output of the pulse generator 7 and a potential of the voltage dividing point 9 are inputted to an adder 850 . This adder 850 controls a gate potential applied to an IGBT by adding the potential of the voltage dividing point 9 to the potential of the pulse generator 7 .
When the collector potential of the IGBT 11 is increased, the potential of the voltage dividing point 9 is increased. Since the gate of the IGBT 11 is controlled in accordance with a potential obtained by adding the output potential of the pulse generator 7 to the potential at the voltage dividing point 9 , the gate potential of the IGBT is also increased, so that the saturated current value of the IGBT 11 can be increased. As a result, similar to the embodiment 1, the IGBT can be protected from the overvoltage also in this embodiment 7.
According to the above-described embodiments of the present invention, in order to protect the MOS control semiconductor devices from the overvoltage, when the overcurrent flows through the MOS control semiconductor devices, it is possible to avoid such an operation that the overvoltage is applied to such an MOS control semiconductor having the minimum saturated current among the series-connected MOS control semiconductor devices, while such a semiconductor element having an avalanche voltage equal to the high withstand voltage is not employed.
It should be further understood by those skilled in the art that the foregoing description has been made on embodiments of the invention and that various changes and modifications may be made in the invention without departing from the spirit of the invention and the scope of the appended claims. | A semiconductor power converting apparatus including at least one series arrangement of MOS control semiconductor devices such as Insulator-gate Bipolar Transistors (IGBTs) or metal oxide MOS transistors which are respectively applied with a gate voltage under the control of corresponding a driver. The driver contains a supply line having a higher potential than a gate voltage of an IGBT coupled thereto when the IGBT is in a steady ON state, and is such that is causes an increase of the gate voltage of the IGBT in accordance with the current of the supply line when a potential difference between the power supply line and an emitter of the IGBT is constant and the collector voltage thereof exceeds a predetermined value under an ON state of the IGBT. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of copending International Application PCT/DE98/00511, filed Feb. 20, 1998, which designated the United States, published as WO 98/37386 on Aug. 27, 1998.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method of setting switching points in a system driven by a sensor configuration for any fixed ratio between the signal peaks in the output signal of a sensor.
The use of sensors to record the movement or the angular position of rotating parts is well known. Examples of this are crankshaft, camshaft, transmission, and ABS sensors in automobiles.
The sensors used in such cases are preferably Hall sensors, which sense the change in a magnetic field. For example, a permanent magnet is mounted on a part, which is in a fixed location, in order to produce a magnetic field. The magnetic field is then modulated by a gearwheel or other ferromagnetic pick-up, which is attached to the rotating part, according to position. In that configuration, the Hall sensor is preferably located between the permanent magnet and the gearwheel or pick-up, and is thus able to detect fluctuations in the magnetic field. If, for example, a tooth of the gearwheel is in the magnetic field, a “high” output signal is supplied, whereas a gap between the teeth produces a “low” output signal. In this way, the signal output by the Hall sensor can be used to infer the position or setting of a rotating part.
The signal supplied by a sensor is influenced considerably by the operating conditions under which the sensor is used. These operating conditions include unavoidable imponderablities, such as operating temperature or size of the air gap, etc. Despite the fluctuations caused by the operating conditions, the sensor should supply an output signal which is as well defined as possible. This means that the output signal should have a well defined waveform, irrespective of the fluctuations caused by the operating conditions. The reason for this is as follows:
If a sensor configuration supplies a sinusoidal signal, for example, then a well-defined response can be obtained from a system controlled by the sensor configuration if switching processes in the system, which depend on the output signal of the sensor, are carried out at the zero crossings of the signal. This is because these zero crossings are independent of the respective signal amplitude and, furthermore, have very steep edges.
Of course, in other signal waveforms of the output signal of the sensor, a switching point other than a zero crossing or the signal center may possibly also be advantageous.
Hence, when evaluating the output signal of a sensor for switching a system controlled by means of this sensor, a switching point should be maintained irrespective of the signal amplitude of the output signal of the sensor, and this applies even for very slow signals.
VDI Reports 1287, 1996, pages 583-611, “Eine neue Generation von ‘Hall-Effect’-Zahnradsensoren: Vorteile durch die Ver-bindung von BIMos Technologie und neuen Verpackungsrezepten” [A new generation of Hall-effect gearwheel sensors: advantages as a result of the combination of BIMos technology and new packing formulations], describes a sensor configuration in which the amplitude of the output signal of a sensor is initially normalized, possibly using an analog/digital (A/D) converter. Two further A/D and D/A converters are then used to record the signal peak values. From these, a switching threshold is then derived and defined. Finally, in this manner, it is possible to obtain a system response which is essentially independent of temperature fluctuations and the width of the air gap. That sensor configuration requires a relatively large outlay, however, since gain matching and numerous A/D converters are necessary.
German published patent application DE 32 01 811 A1 describes a device for recording rotational speed, angle, position and the like. In that configuration, the signal from a sensor is passed to switching means which monitor the amplitude and/or amplitude fluctuations. To do this, the amplitude is recorded by a peak value meter and passed to a threshold stage. This marks a permissible range for fluctuations in the signal amplitude. If the range is not adhered to, the signal from the sensor is switched off, which ensures that no distorted signals are output. According to that method, the signal output by the sensor is not corrected, i.e. there is no retrospective action by the threshold stage on the output signal, in other words the output signal is monitored only passively.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for setting the switching points of a sensor output signal, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and whereby, with a small outlay, switching processes in a system driven by means of an output signal of a sensor are carried out reliably at selected points in the output signal of the sensor. In particular, the switching points should be maintained irrespective of the amplitude of the output signal.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method of setting switching points in a system driven by a sensor configuration with a sensor generating an output signal having upper and lower signal peaks, which comprises the following steps:
determining switching points for a selectable ratio between an upper reference value and a lower reference value;
comparing the upper and lower reference values with upper and lower signal peaks in the output signal of the sensor;
fixing a ratio between the signal peaks of the output signal by readjusting an offset of the output signal whenever an asymmetrical signal position is detected;
simultaneously postadjusting the reference values to the upper and lower signal peaks equally quickly and in opposite directions whenever the upper and lower reference values are situated between the signal peaks or the signal peaks are situated between the upper and lower reference values; and
continually repeating the comparing, fixing and postadjusting steps.
In accordance with a concomitant feature of the invention, the sensor output signal is a sinusoidal output signal and the switching points are set at the zero crossings of the output signal.
In order to carry out the method, an offset is set in the output circuit using an offset D/A converter, whilst a detector circuit comprising a current divider and a current mirror is used to record signal peaks in the output signal of the sensor, and resistors are used to set a previously determined switching point.
Subsequently, previously determined switching points remain constant irrespective of the amplitude of the output signal and hence, for example, irrespective of the width of the air gap.
Between the offset D/A converter and the detector circuit there is a calibration logic unit which is driven by comparators supplied, on the one hand, with the output signals of the current divider and the current mirror and, on the other hand, with the output signal of the sensor.
The switching points for a sinusoidal output signal are preferably set at the zero crossings of the output signal. This variant of the method has the advantage of very steep edges at the switching points.
The method according to the invention is extremely simple and precludes additional sources of error, such as are caused by additional switching means connected intermediately, for example a PGA.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method of setting switching points for a sensor output signal, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of the self-calibrating sensor configuration; and
FIG. 2 is a graphical illustration of how the method according to the invention works.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a Hall probe 1 that supplies an output signal via an amplifier 2 to an output circuit 3 containing a resistor R 1 which converts a current output as output signal into a voltage.
The circuit may, of course, also be designed differently, for instance where the output signal is a voltage output supplied to a voltage summing amplifier.
Finally, an output signal is supplied to an output terminal 4 via a first comparator K 1 . For purposes of noise suppression, the comparator K 1 preferably exhibits hysteresis.
A calibration configuration comprising, in particular, an offset D/A converter 5 driven by a calibration logic unit 6 is used to set the offset or the displacement of the output signal of the amplifier 2 such that the predetermined switching point falls precisely at a reference voltage, for example ground. This predetermined switching point, that is to say, for example, the signal center, as explained in the introduction, is set by means of a voltage divider comprising resistors R 2 and R 3 . This ensures that the switching point remains constant irrespective of the signal amplitude or the width of the air gap. The circuitry of the output circuit 3 is extremely simple, which means that additional sources of error, causing noise or signal distortions, for example, are precluded as far as possible.
The output signal of the Hall probe 1 and of the amplifier 2 is tapped off via a line 7 in the output circuit 3 and supplied to inputs of comparators K 2 and K 3 , the other inputs of which receive voltages ref+ and ref− from a transistor auxiliary circuit comprising a current divider and a current mirror 8 . The currents supplied to the resistors R 2 and R 3 are therefore equal. The ratio of the resistance values of the resistors R 2 and R 3 can then be used to set a reference-ground potential for any desired ratio between the voltages ref+ and ref−. This is because if the resistance values of the resistors R 2 and R 3 and the currents I 2 and I 3 flowing there in each case, for example, are of equal magnitude, the voltages ref+ and ref− are symmetrical about the reference-ground potential, which is ground in the present case. Hence, the switching point is then in the signal center.
If, for example, the following relationship is true for the resistance values of the resistors R 2 and R 3 : R 2 =2×R 3 and I 2 =I 3 , then the voltage ref+ is twice as far from the reference-ground potential as the voltage ref−. In this case, the switching point is then at ⅓ of the signal swing.
In addition, the current divider and the current mirror also have transistors 9 , 10 , 11 , 12 , the base of the transistor 9 receiving a bias voltage, and the emitters of the transistors 11 and 12 being connected to a voltage source.
The calibration logic unit 6 now operates as follows:
If the output signal of the amplifier 2 in the output circuit 3 provides neither the switching threshold of the comparator K 2 nor the switching threshold of the comparator K 3 , a small signal is obviously present. In this case, the current is reduced by a peak value D/A converter 13 situated at the output of the calibration logic unit 6 , said peak value D/A converter having a current output connected to the emitters of the transistors 9 , 10 . The current through the resistors R 2 and R 3 is therefore reduced. As a result, the voltages ref+ and ref− are approximated to the reference-ground potential equally quickly from opposite directions. The switching thresholds of the comparators K 2 and K 3 are therefore brought to the signal peaks in the output signal.
If, in contrast, both the switching threshold of the comparator K 2 and the switching threshold of the comparator K 3 are exceeded by the output signal in the output circuit 3 , then the signal is large, which means that the current through the gain D/A converter 13 must be increased. Consequently, the increased current through the resistors R 2 and R 3 causes the voltages ref+ and ref− to change equally quickly and in opposite directions away from the reference-ground potential. Consequently, the switching thresholds of the comparators K 2 and K 3 are in turn brought to the signal peaks in the output signal, this time directed away from the reference-ground potential.
Finally, if only one of the two comparators K 2 and K 3 responds to the output signal in the output circuit 3 , then the signal position is asymmetrical and the offset D/A converter 5 must be readjusted.
In the steady state of the sensor configuration, the position of the voltages ref+ and ref− is such that they reflect the signal peaks in the output signal of the amplifier 2 in the output circuit 3 . In addition, the offset of the output signal is adjusted such that the distinguished switching point falls precisely at the reference-ground potential, for example ground.
FIG. 2 again illustrates how the method according to the invention works. The reference-ground potential ref 0 is set to be in between the two voltages ref+ and ref−. For a large output signal 1 , the voltages ref+ and ref− are brought outward to the signal peaks, as indicated by the large arrows. For a small output signal 2 , the voltages ref+ and ref− are brought inward to the signal peaks, as illustrated by the small arrows.
It should also be noted that any changes occurring in the gain matching, that is to say in the gain D/A converter 13 , do not have any influence on the switching point, as this signal path is decoupled from the latter. This ensures that the output signal is highly reproducible, which is particularly important for crankshaft sensors.
The clock signal for the calibration logic unit 6 can be derived from the output signal in the output circuit 3 . This is possible provided that the sensor configuration is generally calibrated, or at least the starting values of the sensor configuration produce regular, even if not precise, operation. If appropriate, an auxiliary clock signal may be supplied in a starting phase, said auxiliary clock signal shifting the offset from the offset D/A converter until a signal appears at the output circuit 3 , the system then changing over to “normal” operation. This makes startup possible even with relatively ill-suited starting values.
If appropriate, the output circuit 3 may be additionally provided with a parallel path which defines the response in the uncalibrated state. In addition, it is also conceivable for calibration values which have been determined once to be stored in a permanent memory, such as an EEPROM or a fuse, and for these values then to be used for renewed startup of the sensor configuration when there is no calibration. | The sensor configuration has a sensor and a calibration circuit, which self-calibrates the system by setting its switching points. The calibration circuit is located in the output circuit of the sensor. The method utilizes the calibration circuit to set an offset in the output circuit using an offset D/A converter in such a way that the switching points coincide with reference values. The offset D/A converter is driven with a calibration logic unit. | 6 |
FIELD OF THE INVENTION
The present invention relates to a low-pass filter for a wireless communication system; and, more particularly, to a HTS low-pass filter for suppressing broadband harmonics.
DESCRIPTION OF THE PRIOR ART
Recently, as various wireless communication systems and services are developed intensively, the considerable performance improvement such as small insertion loss, high selectivity, high sensitivity and small size are needed in development of communication components for a cellular phone and a personal communication system. In order to satisfy these demands, the development of materials, design (circuits) and fabrication (processes) technologies are essential for the communication devices.
Since low-pass filter (LPF) is a frequency selective and passive device with low levels of attenuation, LPF is widely used to reject harmonics or spurious signals in a integrated mixer, a voltage controlled oscillator (VCO) and so on. But an open-stub type low-pass filter and a step-impedance type low pass filter have a narrow stopband (about 3 times of cutoff frequency in case of a conventional LPF).
FIGS. 1A and 1B show an equivalent circuit diagram and a schematic diagram of a conventional microstrip low-pass filter.
FIG. 1A shows the equivalent circuit diagram of the lumped-element low-pass filter designed through the transformation of impedance level and frequency scale from the prototype low-pass filter (not shown). The lumped-element low-pass filter (or π-type low-pass filter) includes an inductance L 2 corresponded to the microstrip transmission line, a first shunt capacitance C 1 and a second shunt capacitance C 2 corresponded to the two parallel microstrip open-stubs (in this case: C 1 =C 2 ).
Referring to FIG. 1B, the conventional microstrip low-pass filter includes a crystalline substrate 180 (hereinafter, referred to as “an MgO substrate”), a signal transmission input port 150 and a signal transmission output port 160 , two parallel stripe lines 170 of a microstrip open-stub type, a microstrip line 140 and a ground plane 190 .
The signal transmission input port 150 and the signal transmission output port 160 are fabricated on both edges of the top face of the MgO substrate 180 . Two parallel microstrip open-stubs 170 between the signal transmission input port 150 and the signal transmission output port 160 are perpendicular to a signal propagation direction. Therefore, the microstrip line 140 is perpendicular to two parallel microstrip open-subs 170 . The groundplane (e.g., Au or Ag film) 190 is coated at the bottom (backside) of the MgO substrate 180 .
In general, there are some problems in the conventional low-pass filter as described above. Since the conventional low-pass filter has a narrow stopband range in frequency domain, an interference occurred by the adjacent wireless communication systems and a noise generated by the communication system itself are quite serious.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a low-pass filter having a high-efficiency broad stopband characteristics, in which attenuation poles and a frequency range of the stopband can be controlled easily.
In accordance with an aspect of the present invention, there is provided a low-pass filter comprising: a circuit pattern having at least one or more units, wherein the circuit pattern includes a coupled line section having a pair of parallel stripe lines and a transmission line section having a pair of parallel straight lines whose two ports of one side are opened and whose two ports of the other side are connected to each other, each port of one side of the pair of the parallel straight lines being connected with each port of one side of the coupled line section.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and aspects of the invention will become apparent from the following description of the embodiments with reference to the accompanying drawings, in which:
FIGS. 1A and 1B show an equivalent circuit diagram and a schematic diagram of a conventional microstrip low-pass filter, respectively;
FIGS. 2A to 2 C illustrate a schematic diagram, a basic circuit diagram and an equivalent circuit diagram of a high-temperature superconductor (HTS) coupled line low-pass filter in accordance with the present invention, respectively;
FIGS. 3A to 3 C illustrate a schematic diagram, a basic circuit diagram and an equivalent circuit diagram of a seventh-order coupled line low-pass filter in accordance with the present invention, respectively;
FIGS. 4A and 4B are graphs illustrating simulated results of the seventh-order coupled line low-pass filter shown in FIG. 3A;
FIGS. 5A to 5 F are cross-sectional views illustrating sequential steps associated with a method for fabricating the seventh-order coupled line low-pass filter; and
FIG. 6 shows comparison of the simulated and measured results of the seventh-order HTS coupled line low-pass filter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2A shows a microstrip circuit of a high-temperature superconductor (HTS) low-pass filter (LPF) in accordance with an embodiment of the present invention. Referring to FIG. 2A, the HTS low-pass filter includes a transmission line section 241 and a coupled line section 242 . The transmission line section 241 includes a microstripe line 243 and the coupled line section 242 includes a pair of parallel stripe lines 244 and 245 .
The pair of the parallel stripe lines 244 and 245 are stacked on a HTS epitaxial thin film (not shown). A first lead line 246 is extended from the first parallel stripe line 244 to a signal transmission input port. A second lead line 247 is extended from the second parallel stripe line 245 to a signal transmission output port. The microstripe line 243 connects the first and the second parallel stripe lines 244 and 245 . The microstripe line 243 is more slender and longer than the first and the second lead lines 246 and 247 .
At this time, an electrical length ratio of the coupled line section to the transmission line section is approximately 1:2, and a distance from the first parallel stripe line 244 to the second parallel wire 245 is less than 10 μm. A width of the microstripe line 243 is less than that of the first and the second lead lines 246 and 247 .
FIG. 2B shows an equivalent circuit of the high-temperature superconductor low-pass filter in FIG. 2 A.
As shown in FIG. 2B, the HTS high-temperature superconductor low-pass filter includes a first π type equivalent circuit portion 235 corresponding to the transmission line section 241 and a second π type equivalent circuit portion 234 corresponding to the coupled line section 242 .
Compared with the conventional low-pass filter shown in FIG. 1B, the high-temperature superconductor low-pass filter in accordance with the present invention further includes a third capacitor C R . That is, an inductor L R is disposed between the signal transmission input port and the signal transmission output port. A first capacitor C P1 is connected between the signal transmission input port and a ground, and a second capacitor C P2 is connected between the signal transmission output port and the ground. The third capacitor C R is connected in parallel with the inductor LR between the first and the second capacitors C P1 and CP 2 . The first and the second capacitors C P1 and C P2 are constituted with capacitors C C1 and C C2 which are physically isolated, respectively.
FIG. 2C shows an equivalent circuit of the high-temperature superconductor low-pass filter shown in FIG. 2 B. As shown in FIG. 2C, the equivalent circuit diagram includes an inductor L 1 disposed between the signal transmission input port and the signal transmission output port, a first capacitor C 1 connected between the signal transmission input port and the ground, and a second capacitor C 2 connected between the signal transmission output port and the ground.
Such a low-pass filter has three attenuation poles due to the electrical length φ of the transmission line section and the coupled line section. Two attenuation poles are positioned at two points where a susceptance of a serial element becomes zero and one attenuation pole is positioned at a point where a susceptance of parallel elements becomes infinite.
FIGS. 3A to 3 C illustrate a schematic diagram, a basic circuit diagram and an equivalent circuit diagram of a seventh-order low-pass filter in accordance with the present invention, respectively.
Referring to FIG. 3A, the seventh-order low-pass filter includes a transmission line section 360 having three stripe lines and a coupled line section 370 having three pair of parallel stripe lines. Each stripe line is connected to each pair of the parallel stripe lines.
Compared with the high-temperature superconductor low-pass filter shown in FIG. 2A, three circuit patterns are serially connected between the signal transmission input port and the signal transmission output port.
FIG. 3B shows an equivalent circuit of the seventh-order low-pass filter in FIG. 3 A. As shown, the seventh-order low-pass filter includes a first π type equivalent circuit portion 340 corresponding to the transmission line section 360 and a second π type equivalent circuit portion 350 corresponding to the coupled line section 370 . Three circuit patterns 310 , 320 and 330 are serially connected between the signal transmission input port and the signal transmission output port.
FIG. 3C shows an equivalent circuit of the seventh-order low-pass filter in FIG. 3 B. Compared with the low-pass filter shown in FIG. 2C, the seventh-order low-pass filter includes three circuit patterns which are connected in series. Each circuit pattern includes an inductor L 1 disposed between the signal transmission input port and the signal transmission output port, a first capacitor C 1 connected between the signal transmission input port and the ground, and a second capacitor C 2 connected between the signal transmission output port and the ground.
According to a filter design of the present invention, respective parameters of the π type equivalent circuit are expressed as follows: jω 0 C 1 = jω 0 C c + jω 0 C p ( Eq . 1 ) jω 0 L 2 = 1 jω 0 C r + 1 jω 0 L r ( Eq . 2 )
where, jω o C r =j (Y oo −Y oe )/2*tanφ, jω o L r =jZ o sin 2φ. Here, ω 0 denotes a cutoff frequency of the proposed low-pass filter, C capacitance of low-pass filter, L inductance of low-pass filter, Y 00 an odd mode admittance of a coupled line, Y oe an even mode admittance of the coupled line, Y o a characteristic admittance and φ an electrical length of a coupled line.
Using a transmission line and coupled line theory together with the equations 1 and 2, a susceptance (an imaginary number portion of an admittance in relation to a conductivity) is expressed as follows: 1 jω 0 L n = j Y 00 - Y o e 2 tan φ - j Y 0 c s c2 φ ( Eq . 3 ) jω 0 C n = j Y o e tan φ + j Y 0 tan φ 2 ( Eq . 4 )
The low-pass filter expressed as these physical parameters has three attenuation poles due to the electrical length φ of the transmission line section and the coupled line section. Two attenuation poles are positioned at two points where the susceptance of serial elements in the equation 3 becomes zero and one attenuation pole is positioned at a point where a susceptance of parallel elements in the equation 4 becomes infinite.
Since the attenuation poles are dispersedly positioned at the stopband of the low-pass filter, the frequency range of the stopband is expanded up to ten times of the cutoff frequency. Also, a device size can be scaled down remarkably. That is, the positions and the number of the attenuation poles are controlled adjusting the electrical length of the transmission line section and the coupled line section, so that it is possible to implement the low-pass filter having a broad stopband.
FIG. 4A is a graph illustrating simulation results of the seventh-order low-pass filter which is designed to have five attenuation poles. A cutoff frequency of the seventh-order low-pass filter is 900 MHz with a ripple level of 0.01 dB. FIG. 4B is a graph illustrating simulation results obtained using an EM simulator in order to design actually the low-pass filter based on the simulation results.
As shown, the seventh-order low-pass filter in accordance with the present invention has a symmetrically elliptic low-pass characteristic at the center of 4 GHz. The attenuation poles are positioned at 1.5 GHz, 2.4 GHz, 3.8 GHz, 4.4 GHz and 6.1 GHz. The seventh-order low-pass filter exhibits an improved characteristic stopband in the range from 1 to 7 GHz at the cutoff frequency of 1 GHz.
FIGS. 5A to 5 F are cross-sectional views illustrating sequential steps associated with a method for fabricating the seventh-order low-pass filter.
Referring to FIG. 5A, a high-temperature superconductor (HTS) YBa 2 Cu 3 O 7−x (YBCO) epitaxial thin film 520 is grown on an MgO substrate 510 in a C-axis direction. Then, an Au/Cr film 530 is formed on the HTS YBCO epitaxial thin film 520 .
Referring to FIG. 5B, a photoresist 540 is formed on an entire structure using a spin coating method.
Referring to FIG. 5C, a predetermined portion of the photoresist 540 is removed through an exposure of an ultraviolet (UV) source to thereby form a photoresist pattern 550 and mask aligner to form a photoresist pattern 550 .
Referring to FIG. 5D, the HTS YBCO epitaxial thin film 520 with metal films 530 and photoresist pattern 550 is formed through the standard photolithographic and ion-milling etching processes.
Referring to FIG. 5E, after the photoresist pattern 550 is removed by acetone, an Au/Cr pad 530 is formed by using a lift-off method to good contact with a K-connector.
Referring to FIG. 5F, the groundplane 560 is fabricated by sputtering of the metal film (Cr/Ag film).
FIG. 6 shows comparison of the simulated and measured results of the seventh-order HTS coupled line low-pass filter. The measured results are identical to the EM simulations.
The HTS coupled line low-pass is fabricated using the HTS YBCO thin film grown on MgO substrate through surface treatment (polishing). Even if the HTS coupled line low-pass filters are fabricated as microstrip type, the microwave losses can be reduced considerably due to a very low surface resistance of HTS epitaxial films.
The planar type HTS coupled line low-pass filter for suppression of harmonics and spurious signals can be applied to the various wireless communication systems for the remarkable improvement of a skirt characteristic as well as a broadband harmonics rejection characteristic, and reduction of interferences and noises.
Although the preferred embodiments of the invention have been disclosed 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. | Disclosed is a high-temperature superconductor low-pass filter for removing broadband harmonics in a wireless communication system. The high-temperature superconductor low-pass filter includes a coupled line section and a transmission line section, in which the coupled line section is connected in parallel with the transmission line section. The coupled line section has two microstrip open-stub type parallel stripe lines stacked on a high-temperature superconductor, and the transmission line section has one stripe line. Since the high-temperature superconductor low-pass filter has attenuation poles at a stopband, it has stopband characteristics to 7-8 times wider than a cutoff frequency. The high-temperature superconductor low-pass filter can easily remove sub-harmonics which are inevitably occurred in the wireless communication system. | 8 |
BACKGROUND OF THE INVENTION
The extrusion of molten polymers and copolymers onto a moving substrate web is well known. The coating is usually accomplished by melting the polymer in an extruder, extruding the molten polymer through a slit-die to form a molten film and passing the web substrate, for example, a paper web and the extruded film simultaneously between two pressure rolls and thereby bonding the hot polymer film to the paper. Various polymers have been found to be suitable for such a procedure including polyethylene, copolymers of ethylene and propylene and various ethylene-acrylic acid copolymers. In the case of polypropylene and ethylene-propylene copolymers, although the high-temperature resistance is sufficient for extrusion coating application, the resultant films are not sufficiently rigid for some applications. On the other hand, polystyrene exhibits similar high-temperature resistance properties yet is so brittle that when extruded it tends to crack and exhibits poor adhesion to the substrate. The polymers are normally incompatible for blend purposes.
OBJECTS OF THE INVENTION
It is a primary object of this invention to provide an extrudable blend of polypropylene-polystyrene that is suitable for extrusion coating.
It is a further object of this invention to provide extrusion coatings of polypropylene/polystyrene, which may be pigmented or unpigmented, and which combine the flexibility properties of polypropylene with the rigidity properties of polystyrene.
It is yet another object of this invention to provide coated substrates having good coating to substrate adhesion characterized by an exceptional aesthetical appeal by virtue of unique pearlescent appearance obtained under conditions particularly suitable for high-speed commercial production.
SUMMARY OF THE INVENTION
These and other objects will become apparent from the following description of the invention which are achieved by providing an extrudable polypropylene material exhibiting certain parameters of viscosity as measured by its melt flow rate and a polystyrene material compatible therewith, blending said materials, heating the resultant blend to a molten state and extruding the molten blend through a heated slot-type die onto a substrate employing conventional extrusion coating techniques and apparatus, the extrudable melt exhibiting highly satisfactory melt curtain stability at melt temperatures between about 475° F. to about 575° F.
DETAILED DESCRIPTION OF THE INVENTION
The above objects are accomplished when employing polypropylene/polystyrene blends, as more particularly defined hereinbelow, in an extrusion coating technique wherein the melt temperature is within the range of about 475° F. to about 575° F. employing blend ratios of polypropylene to polystyrene in the range of 5:1 to 2:1, preferably comprising 50 to 70% by weight of polypropylene, 10 to 30% by weight of polystyrene and, if desired, up to about 10% of an inorganic pigment or 5 to 30% of a concentrate of pigment in a polymeric carrier.
As used further herein, the following terms have the following meanings:
Melt curtain is the molten plastic web that is formed when the plastic resin pellets are melted and extruded through a narrow, for example 0.030 inch, linear die opening.
Melt flow rate is a measure of the viscosity of the polypropylene expressed in grams, per ten minutes as determined by ASTM method D1238-Condition G. Such method covers extrusion of molten resins through a die of a specified length and diameter under prescribed conditions of temperature, load and piston position in a piston plastometer and empirically defines parameters critically influenced by the physical properties and molecular structure of the polymer. The melt flow rate of the polypropylene is critical herein as discussed further hereinbelow.
Melt performance is evaluated as the ability of the extrudate exiting the die to be drawn down to film thicknesses in the range of about 0.3 to 1 mil, preferably about 0.4 to 0.5 mil, extrusion coatings without tearing or streaking and without necking-in or otherwise exhibiting deformation at the melt curtain edges.
Satisfactory melt performance in accordance with the invention is a critical condition herein as discussed further hereinbelow.
Any combination of polypropylene and polystyrene capable of exhibiting the melt performance standard under the process conditions set forth hereinabove may be utilized in accordance with this invention.
The selection of suitable polystyrenes is determined primarily by the ability of the particular resin to withstand elevated extrusion temperatures without degradation into monomer and compatibility with the polypropylene component of the blend. Polystyrenes that degrade at the 475°-575° F. melt temperature, as evidenced by the emission of excessive smoke or burnt odor, are not satisfactory for use herein. It has been found that in general such polymers having average molecular weights greater than 200,000, preferably in the range of 250,000 to 325,000, and having low initial monomer levels, are suitable for use herein. Particularly suitable resins may be illustrated by high temperature resistant-low monomer content resins such as "Dow XP60690326w", "Dow 666u" and "Dow 685D", each commercially available from Dow Chemical Co., Midland, Mich.
Selection of the polypropylene resin suitable for use is likewise determined by the ability of the resin to withstand melt temperatures within the range of 475°-575° F. without degradation and compatibility with the polystyrene component of the blend. A suitable resin is a polypropylene homopolymer having a melt flow rate at 230° C. of about 30 to about 40 grams per ten minutes available commercially from Hercules, Inc. as "PD-131". The polypropylenes in general may have molecular weights in the range of 100,000 to about 150,000 and include the homopolymer and copolymers of propylene and ethylene. However, as indicated hereinabove, the critical parameter of a melt flow rate between about 30 and about 40 grams per ten minutes is more definitive of operable polymers since it reflects more the molecular structure and processing history of the polymer. It has been found that polypropylene homopolymers and copolymers with ethylene that do not exhibit the prescribed melt flow rate likewise do not exhibit the melt performance or compatibility properties necessary for operability in accordance with this invention.
It will be evident from the description of this invention that there are several related and interdependent factors of criticality necessary to the successful operation of this invention; namely, the melt temperature of the molten blend; the ratio of the components of the blend; the melt flow rate of the polypropylene polymer; and the high temperature stability of the polystyrene. It should be understood however that these parameters are to be evaluated in terms of the coating line speeds to which they relate. As used herein, satisfactory properties are evaluated at line speeds of about 500 to 1,000 feet per minute.
It has been found that melt temperatures lower than 475° F. result in melt curtains that are too viscous to be drawn down to suitable coating thicknesses while temperatures in excess of 575° F. seriously degrade the polystyrene resin component as evidenced by dense smoke coming off the melt curtain. At the same time, blends having a higher ratio than 5:1 of polypropylene to polystyrene result in severe neck-in of the melt curtain, i.e. instability at the edges of the melt curtain resulting in progressive narrowing and non-uniform coating.
The criticality of the melt flow rate may best be understood by the following examples in which a conventional extrusion coating line is employed except that the temperature of the chill roll is at 120° F. to aid in adhesion and to avoid loss of crystalline properties of the polypropylene. In general, temperatures of the chill roll should be maintained within the range of about 120° to 200° F. to obtain satisfactory results. A typical extrusion coating line will otherwise comprise supplying a substrate, electrostatically treated if desired to improve adhesion, from a suitable supply roll, with the running web passing under the extruder. Molten extrudate is continuously discharged from said extruder onto the running substrate web as a thin film through the extruder die gap. Immediately upon being applied to the surface of the substrate, the polymer is adhered to the surface of the substrate by passing the coated substrate between the nip of counter-rotating pressure rolls, designated herein as chill rolls. Due to the fact that the chill rolls are operating at a linear speed substantially in excess of that at which the molten polymer exits the dies, the extrudate is "drawn down" from the die gap thickness, for example 30 mils to a coating thickness, e.g. 0.30 mils.
EXAMPLE 1
The following polypropylenes and/or propylene/ethylene copolymers were physically blended with polystyrene available commercially as Dow 666u, (Dow Chemical Co.) and extrusion coated onto paperboard at a coating weight of approximately 1 mil. The blend ratio of polypropylene to polystyrene was 4:1. The blend was extruded through a 1" extruder having a 30 mils die gap and was examined for melt performance of the blend. The results obtained were as indicated in the Table which follows wherein: PP indicates polypropylene; Grade refers to whether the polypropylene is film or extrusion grade. Polypropylenes are divided into such grades because of the different viscosity requirements needed for cast film vs. extrusion coating. Casting requires a high viscosity melt curtain while extrusion coating requires a lower viscosity to enable draw down to target coating weights. Melt flow rate refers to the flow rate of the polypropylene as measured by ASTM method D1238-Condition G.
Table______________________________________ Melt Melt PerformancePP Grade Flow Rate of Blend______________________________________(1) "SA-861" Film 8 Tear off underhomopolymer .sup.1 MD tension(2) "9670 BZ" Film 8 Tear off underhomopolymer .sup.2 MD tension(3) "PB 784" Film 9 Tear off underhomopolymer .sup.2 MD tension(4) "4018" Film 10 Tear off underhomopolymer .sup.3 MD tension(5) "PD-131" Coating 30 Good stabilityhomopolymer .sup.1 under tension(6) "P7673-499P" Coating 45 Streaks & filmethylene propylene splitting undercopolymer .sup.4 tension(7) "4G7DP" Coating 60 Streaks in film,ethylene propylene separates undercopolymer .sup.4 MD tension______________________________________ .sup.1 Hercules, Inc., Wilmington, Del. .sup.2 Diamond Shamrock Corp., Morristown, N.J. .sup.3 Amoco Chemicals, Inc., Naperville, Ill. .sup.4 Eastman Chemical Products, Inc., Kingston, Tenn.
It will be apparent from the table, that the melt flow rate of the polypropylene is a critical parameter herein since homopolymers and copolymers exhibiting melt flow rates outside the proscribed value are not satisfactory, the resulting blend either tearing under the process tension or resulting in streaking and/or film splitting under tension. When process conditions were varied, i.e. lower melt temperatures, different die gaps, etc. the poor performance blends could not be improved sufficiently to make them suitable for extrusion coating and comparable results were obtained.
The polypropylene defined is believed to be a highly unique homopolymer which by itself is unsuitable for use under the process conditions herein described because of unstable melt curtain edges. While at present a wide selection of such unique polymers does not appear to be commercially available, it will be understood that the invention contemplates substituting for the illustrated homopolymer any equivalent homopolymer or copolymer exhibiting the required melt flow rate and melt performance.
Various additives including pigments and anti-oxidants may be added to the polymer blends without detriment.
Anti-oxidants can be added to the polystyrenes to inhibit thermal degradation and prevent undesirable formation of monomer during processing of the melt. Suitable anti-oxidants include octadecyl-3-(3',5'-ditertiary butyl-4'-hydroxy phenyl) n-propionate and tetrakis [methylene 3-(3',5'-ditertiary butyl-4'-hydroxy phenyl) n-propionate] methane, available commercially as Irganox 1076 and Irganox 1010 (CIBA-GEIGY).
Various pigments and colorants may also be incorporated if desired to impart color and/or opacity. Pigments such as TiO 2 and carbon black may be added to the polymer blends per se or may be more conveniently dispersed in a carrier resin such as polyethylene which does not adversely affect the melt performance of the blend.
It has been found that when using mineral pigments such as TiO 2 or carbon black per se, amounts in excess of 10% by weight are to be avoided since higher concentrations result in dispersion and suspension problems of the pigment in the resin blend. Higher amounts of loading however may be realized with pigment concentrates, i.e. dispersions thereof in a polymeric carrier.
Particularly suitable are such pigment dispersions in extrusion-grade polyethylene having a melt index of about 7 to 8 grams per ten minutes and density of about 0.918 which are commercially available as concentrates. Such pigment concentrates are well known in the art and are usually prepared by heating the polymeric carrier to a sufficiently liquified state and mixing the colorant and resin particles until all elements are uniformly dispersed. Such concentrates are readily available commercially, a suitable example being "Ampacet 11171" white color concentrate (Ampacet Corp., Mt. Vernon, N.Y.). When the pigment concentrate is employed, amounts of from 5 to 30% by weight may be employed. It should be understood that the particular pigment employed should be compatible with the polymer blend and should not cause either an undesirable increase in viscosity or incompatibility with the blend or severe melt performance problems causing voids, web tear, etc. when extruded at the high melt temperatures herein.
EXAMPLE 2
(A) The procedure of Example 1 was repeated employing a blend comprising 60% polypropylene having a melt flow rate of 30 grams/10 mins., 30% polystyrene (Dow 685D) and 10% by weight TiO 2 .
(B) The procedure of Example 1 was repeated employing a blend comprising 55% PD-131 polypropylene, 25% Dow 685D polystyrene and 20% of a concentrate comprising TiO 2 in a polyethylene carrier.
The blends of (A) and (B) were extruded at a melt temperature of 540° F. and drawn down to a coating thickness of 0.5 mil on paperboard producing a white pearlescent coated paperboard substrate. Melt performance and processing conditions were excellent at line speeds in excess of 1000 fpm. When the blend of (B) were reformulated to incorporate up to 10% of pigment concentrates employing ethylene-ethyl-acrylate or ethylene methylacrylate copolymers, the pigments were found to be incompatible with the polystyrene/polypropylene blends resulting in severe melt curtain problems such as voids and web tear at the melt temperature employed.
The blends of the invention and the extruded film produced therefrom are particularly useful in the extrusion coating of paperboard. The resultant substrate has increased rigidity over polyethylene extrusion coatings which permits use of lighter weight paperboard resulting in a savings in the amount of paperboard consumed in producing such items as paper cups thereby resulting in a more economical manufacturing process.
Additionally, the films are non-blocking, have a non-slippery feel and a highly attractive textured, pearlescent appearance. The films may be pigmented as desired to further enhance the aesthetic appearance of the coatings and final end products such as paper cups.
While the above description has been primarily directed to the extrusion coating of paperboard, the blends are equally suitable for use in extrusion coating of plastic films such as cellophane, polyesters, and polyolefin films.
It is thought that the invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the matter of the ingredients and identity and proportions without departing from the scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred embodiment thereof. | Melt extrudable polypropylene-polystyrene compositions are provided which are particularly suitable for use in extrusion coating. Substrates coated with such compositions as well as methods of producing such coated substrates are also provided. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to the field of hair curlers made of a self-gripping tape or fabric.
Hair curlers made of a self-gripping tape or fabric of the Velcro® type are well-known. For example, U.S. Pat. No. 3,123,080 discloses a band of fabric which is glued, welded, hooked or sewn to a cylindrical body which can be rigid or deformable plastic foam. According to U.S. Pat. No. 3,267,942, a fabric cylinder is made self supporting by insertion of reinforcement rings.
U.S. Pat. No. 3,438,382 discloses a hair curler in which the fabric is secured to a hollow curler of body by passing the end of the strips of fabric through slots in the curler body.
U.S. Pat. No. 5,660,192 discloses a hair curler having a foam plastic roller on which a self-gripping tape is seated. The tape may be bonded to the roller with adhesive.
U.S. Pat. No. 5,799,670 discloses a curler having a Velcro type surface which is used in conjunction with a control wand. The curler includes an aperture which is identical in shape and width to the control wand so that the curler can slide along the wand. The wand includes a release stop means enabling the curler to be secured on and removed from the wand.
While the use of a wand enables easier application of the curler, the configuration of the curler increases both its weight and the likelihood that an additional means will be required to secure the curler to the hair. While the combination of the fabric and foam provides a lighter curler, the foam required nevertheless increases of both the size of each curler and its cost.
SUMMARY OF THE INVENTION
It is therefore in an object of the invention to provide a hair curler which is very light in weight.
Is a further object of the invention to provide a lightweight hair curler utilizing a separate applicator for easy application.
To achieve these and other objects, the invention provides a combination of hair curler and applicator in which the hair curler is formed from a cylinder of a Velcro®-type fabric or tape, in which the exterior surface is covered with fastening elements. In this manner, the hair curler maintains a very light weight that enhances the self fastening effect. The lightness provides more stability to keep the curler in place more effectively, in contrast to heavier curlers that may wobble, requiring reinforcement with a net or clips. Because the hair curler of the invention is deliberately flimsy, it requires a rigid applicator to facilitate the rolling process.
In a first embodiment, where the curler is to be applied by a hair dresser, the applicator can be a rigid cylinder of plastic of diameter slightly less than the curler and length slightly greater than the curler, and which includes means on each end to assist the hair dresser in gripping the applicator.
In another embodiment, where the curler is to be applied to the user's own hair, the applicator is formed of a rigid, deformable material such as a hard rubber, and includes a handle. When the curler is wound around the hair, the applicator may be removed from the curler by application of pressure to lines of deformation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of a curler according to the invention;
FIG. 2 is an enlarged, cross-sectional view of a material used to form a curler;
FIG. 3 is a plan view of a curler in combination with an applicator of a first type;
FIG. 4 is a cut away, interior view of the applicator shown in FIG. 3;
FIG. 5 is a plan view of an applicator of a different type;
FIG. 6 shows the applicator of FIG. 5 in combination with a curler; and
FIGS. 7-10 are plan views of variations of the applicator shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic curler 10 of the invention, shown in FIG. 1, includes a fabric strip 12 having hook-shaped protrusions 14, wound into a cylindrical shape and secured along a line 16 with stitching, adhesive or any other commonly used means of securing. It is understood that the fabric strip 12 is any fabric or tape which grips the hair. This fabric of tape is generally described as being of the Velcro®-type, having either closed or open loops, or monofilament threads, straight or with bulbous ends. The hooks and loops may be singular or arranged in pairs about 1 mm apart, or in vertical rows, parallel to each other, about 2 mm apart. The curler may have a combination of the two types of filaments. Where the fabric 12 is a sufficiently heavy, no reinforcement will be needed.
If the fabric 12 is considered excessively flimsy for its purpose, a reinforced material as shown in FIG. 2 will be used. The material of FIG. 2 includes hooks or loops 22 secured in fabric or tape 24 which is secured to a reinforcing layer 26 by an adhesive layer 28; alternatively, the layers can be sewn together. Regardless of whether one or two layers are used, the curler should be extremely light in weight and entirely flexible, i.e. not rigidified. The end of the curler may be left flat, or may be rolled on itself, as shown in FIG. 2, to form an end portion 30 about 1 mm in thickness.
Although the curler will generally have filaments protruding from the entirety of its external surface, this is not required, and the filaments may protrude from only a portion of the external surface, in any desired pattern.
The hair curler can be provided in a variety of lengths and diameters as is known in the art. In a typical configuration, the curler will be about 30 mm in diameter and about 60 mm in length.
FIG. 3 shows the curler of FIG. 1 in combination with an applicator used by a hair dresser. Applicator 40 is a rigid plastic cylinder about 1.5 to 2 mm smaller in diameter than the curler; assuming the above dimensions for the curler, the diameter of the applicator is about 28 mm. The applicator must have a wall of sufficient thickness that it is rigid, and will typically be about 2 mm in thickness, although this should not be considered limiting as lesser and greater thicknesses may also be acceptable. The applicator should be at least as long as the curler, and will typically be at least 5 mm longer in order to make it easier to grip.
The ends of the applicator should be provided with a means to make the applicator easier to grip. As shown in FIG. 3, the exterior surface of the applicator is provided with a series of longitudinal ranges about 1 mm in thickness and about 1-1.5 cm in length.
The internal surface on the applicator is shown in FIG. 4. In order to aid gripping, the internal surface is provided with a series of transverse ridges about 1 mm in thickness and about 2 millimeters apart.
The curler 10 is inserted onto the applicator 40 prior to curling the hair. With the roller inside the curler, the hair dresser winds the curler with a first hand until it is self-anchored in the hair, after which the roller is detached by sliding it out as follows: with the opposite hand, the hair dresser's forefinger presses on the inner surface of the roller, and the thumb presses on the outer surface. The roller and the anchored hair are thus pressed between the thumb and forefinger. Using the pressure on the roller and a simultaneous pulling motion by the forefinger against the thumb, the roller slides out. Halfway along the detachment of the roller, the thumb lifts off to hold the roller with the forefinger. The thumb and forefinger of the first hand continue to hold the curler in place until the applicator is completely removed.
Where the curlers are to be applied to the users own hair, an applicator 50 as shown in FIG. 5 and FIG. 6 is used. Applicator 50 is typically formed from a hollow cylinder of hard rubber or resilient plastic at least about 2 mm in thickness and is divided into two portions, a roller portion 52 and a handle portion 54, divided by a transverse ridge 56. The roller portion is about the same length as the curler 10, but may be slightly longer, about 1 mm. The diameter of the roller portion is slightly less than that of the curler, about 0.3 to 1 mm less.
A pair of opposed longitudinal depressions or ridges 58 are formed in the surface of the roller, these depressions or ridges extending throughout the length of the roller portion into the handle portion, and terminating toward the end of the handle portion. These depressions or ridges are about to 2-10 mm wide; the depressions are about 0.5 mm deep, the ridges up to about 1.0 mm thick, preferably 0.5-1 mm.
In order to aid gripping of the handle, a plurality of ridges 60 may be provided thereupon. As shown in the figures, the ridges may be transverse, but could also be longitudinal as shown in FIG. 3.
As shown in FIGS. 5 and 6, the handle is merely a continuation of the roller portion. Alternatively, as shown in FIGS. 7-10, the handle may be of various other shapes especially shapes intended to be distinctive or attractive. The handle should be at least six centimeters in length.
This applicator is used as follows: with one hand, the thumb and another finger grasp the opposed depressions on the handle portion and squeeze the applicator, thereby reducing its diameter. The roller portion is then inserted into the curler, the pressure is removed from the depressions and the hair is wound around the curler. The applicator can then be detached by applying pressure to the depressions, thus reducing the diameter of the roller portion. Once again, the fingers of the opposite hand hold the hair and curler until the roller is completely detached. | A hair curler and an applicator therefor, the hair curler formed from a hollow cylinder of a Velcro®-type material having a plurality of filaments protruding from its external surface. Where the applicator is to be used by a hair dresser, it is a hollow cylinder of rigid material, freely slidable within the hair curler. Where the curler is to be applied by the user, the applicator is formed with a handle portion and a roller portion, and is formed of a resilient material which can be reduced in diameter upon application of pressure. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a lighting device for vehicles.
More particularly, it relates to a lighting device for vehicles, which has at least one light source and a holder formed for supporting the light source and provided with at least one electrical contact element.
Such a lighting device is disclosed by DE-A 21 24 930. The lighting device is designed in the form of a lamp and has a reflector into which a light source can be inserted. For the light source a holder is provided, into which the light source can be inserted and which can be fastened in an opening in the reflector vertex. The holder has electrical contact elements, on which the light source comes to rest and which can be connected to at least one electrical lead for connecting to a voltage source. The electrical lead is led in from the outside to the holder and requires a seal on the holder. the holder has a covering in the form of a cap made of electrically insulating material. At the point of connection of the holder to the reflector, a seal is likewise necessary. Since the holder is always connected to the electrical lead, manipulation of the holder for the assembly or disassembly of the light source is made more difficult.
In the case of lighting devices for vehicles, it is an aim to keep the number of separate electrical leads necessary for them small and to combine the latter in one single cable loom. In addition, it is an aim to provide as few connection points as possible for the electrical leads on the lighting device. These requirements cannot be fulfilled in the case of the known lighting device.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a lighting device for vehicles, which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a lighting device of the above mentioned general type which has a plug part of a plug connection for connecting to at least one electrical lead arranged in part of the lighting device, and the at least one electrical connecting element of the holder connected to the plug part is arranged on the one part on the lighting device, and the connecting element is bringable to rest on the at least one contact element on the holder under the action of a spring force in a built-in position of the holder on the lighting device.
When the lighting device is designed in accordance with the present invention, it has the advantage, in contrast, that the holder itself is not directly connected to the at least one electrical lead and its manipulation is hence significantly simplified. Furthermore, only one seal is necessary on the lighting device at the point of connection to the holder.
In accordance with another feature of the present invention, the housing device has an opening for passing a section of the holder, and the opening has a plurality of radial cutouts at its edge, so that the section of the holder passing through the opening has a plurality of corresponding radial projections with shoulder pointing axially in a direction opposite to the insertion direction of the holder. The shoulders engage on the inside of the housing during rotation of the holder in a fastening direction. With this construction a simple and reliably operating fastening of the holder is achieved.
In accordance with a further feature of the present invention a reflector is arranged in the housing and has an opening arranged at least approximately coaxially to the opening of the housing. Both openings have in each case a plurality of radial cutouts at their edge, and the section of the holder passing through the openings correspondingly has a plurality of radial projections with shoulders pointing axially in a direction opposite to the insertion direction. The shoulders engage on the inside of the reflector during rotation of the holder in the fastening direction. The fastening of the holder in accordance with these features offers the advantage that the light source is aligned particularly accurately with reference to the reflector.
A collar can be arranged on the housing at least approximately coaxially surrounding the opening, so as to stick out to the outside. The covering of the holder can have a section at least approximately coaxially surrounding the collar toward the outside of the housing, and the section cooperates with the collar for sealing the opening. These features provide a simple and reliable operating sealing of the point of connection between the holder and the housing.
The connecting element can project outwards inside the collar. The section of the covering can be radially elastically deformable, and the collar can be designed tapering away from the housing on its outer surface. Therefore a secure seal can be achieved without an additional component, such as for example a sealing ring.
In accordance with still a further feature of the present invention, an additional collar can surround the first mentioned collar and the section of the covering and stick out to the outside. In this way a protection is formed against splash water.
Finally, at least one electrical lead device for contacting a light source of the headlight can be additionally connected to the plug part. Therefore only one plug part is necessary on the lighting device, via which all the light sources of the lighting device can be connected to the voltage source.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a lighting device for vehicles in a horizontal longitudinal section;
FIG. 2 shows a section, designated by II, of the lighting device from FIG. 1, in an enlarged representation;
FIG. 3 shows an elevation of the lighting device of FIG. 2 in the direction of the arrow III in FIG. 2; without inserted light source;
FIG. 4 shows a partial elevation in the direction of the arrow IV in FIG. 3;
FIG. 5 shows a partial section along line V--V in FIG. 3; and
FIG. 6 shows a partial section through the lighting device along line VI--VI in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A lighting device for vehicles, especially motor vehicles, shown in FIGS. 1 to 6, comprises a headlight 10 and a lamp 12 arranged alongside the latter, which are arranged in a common housing 14 consisting, for example, of plastic. The headlight 10 has a reflector 16 which is arranged so as to be adjustable in the housing 14. A light source 18 is inserted into the reflector 16. The housing 14 has, in its rear wall 15 in the region of the headlight 10, an opening 20, through which the light source 18 is accessible and which can be closed by a cap 22. The light exit opening of the housing 14 is covered with a covering pane 24 which is transparent to light. A plug 26 is arranged on the rear wall 15 of the housing 14. Inside the housing 14, electrical leads 28 lead off from the plug 26 to the light source 18. A plug part 30 can be connected to the plug part 26 and is connected to electrical leads 32 which lead to a voltage source via a light switch.
The lamp 12 has a reflector 34 arranged inside the housing 14. The reflector can be designed in one piece with the rear wall 15 of the housing 14 or as a separate part. As shown in FIG. 3, the reflector 34 has, in its vertex arranged toward the rear wall of the housing 14, an approximately circular opening 36, through which a light source 38 can be introduced. The vertex of the reflector 34 rests at least in part on the inside of the rear wall 15 of the housing 14. The housing 14 has, in its rear wall 15, a further approximately circular opening 40, which is arranged at least approximately coaxially to the opening 36 of the reflector 34. The two openings 36 and 40 each have at their edge a plurality, for example three, of radial cutouts 42. The cutouts 42 of the two openings 36 and 40 are arranged in alignment. From the rear wall 15 of the housing 14 a collar 44 sticks out in one piece to the outside. The collar is designed such that it at least approximately coaxially surround the opening 40. The collar 44, at its outer surface pointing radially away from the opening 40, is designed to be approximately conically tapering away from the rear wall 15, at least in its region arranged close to the rear wall 15. A further collar 46, at least approximately coaxially surrounding the collar 44, sticks out in one piece to the outside from the rear wall 15.
Arranged alongside the edge of the opening 40, on the inside of the rear wall 15 of the housing 14, there is a plurality, for example two, of electrical connecting elements 48. They can be designed, for example, as flat-pin connectors. In FIG. 2, only one of the connecting elements 48 can be seen, while in FIG. 3 both connecting elements 48 are shown. The connecting elements 48 are arranged distributed on a somewhat larger diameter than the diameter of the opening 40 and project outward through corresponding openings in the rear wall 15 to the rear side of the housing 14. Inside the housing 14, the connecting elements 48 are connected to electrical leads 49, which are in turn connected to the plug part 26. The connecting elements 48 are fastened on the inside of the ear wall 15, for example by being hooked onto the rear wall 15 by means of hooks 47 brought out from the said elements.
The light source 38 of the lamp 12 can be inserted into a holder 50 which is shown in FIG. 2. The holder 50 has a covering 52 made of electrically insulating material, for example plastic. The covering 52 has an essentially circular-cylindrical main body 54 having a longitudinal axis 53 and is designed smaller in cross-section than the opening 40 in the housing rear wall 15 and the opening 36 in the reflector 34. Integrally molded on the main body 54 there is a flange 55 sticking outward radially to the longitudinal axis 53. A further essentially circular-cylindrical section 56 is integrally molded on the flange, on the outside of the rear wall 15 and approximately coaxial to the main body 54. The section 56 is designed widening conically on its inner surface to its free end region and can be expanded in a radial elastic manner. In the region of the flange 55, a closed bottom 57 is integrally molded on the main body 54, radially inward to the longitudinal axis 53. Thereby a depression 58 open only to the interior of the housing 14 is formed on the main body 54.
A first electrical contact element 59 is inserted into the depression 58 of the main body 54. The contact element consists of sheet metal and rests on the bottom 57 with a planar section 60. It has a contact arm 61 which sticks out from the bottom 57, is approximately V-shaped and can be elastically deformed toward the bottom 57. A further section 62 of the contact element 59 is, as shown in FIG. 6, bent over on the planar section 60 and runs approximately parallel to the wall of the main body 54, away from the bottom 57. Inside the main body 54, proceeding from the bottom 57 in sections, a wall 63 is designed, which runs approximately parallel to the wall of the main body 54, along the longitudinal axis 53, but does not reach as far as the main body 54. The section 62 of the contact element 59 rungs between the wall 63 and the main body 54 and is hooked in there by means of one or more hooks 64 brought out from the said section, so that the contact element 59 is held. The end region of the section 62 projects in the direction of the longitudinal axis 53 beyond the wall 63 and is bent over radially outward. Thereby it projects radially beyond the main body 54 but is still arranged inside the cylindrical section 56 of the covering 52. The end 65 of the section 62 is designed bent in a U-shape in a plane at right angles to the longitudinal axis 53, as can be seen in FIG. 3.
In addition, a second contact element 70 in the form of a lamp carrier is inserted into the main body 54. The lamp carrier can consist of sheet metal. The lamp carrier 70 has an annular planar section 71, which can best be seen in FIG. 3. It is arranged approximately at right angles to the longitudinal axis 53 and, for example, three tongues stick out from it radially outward. They engage in corresponding depressions or openings 73 for fastening the lamp carrier 70 to the main body 54, as is shown in FIG. 2. For example, three arms 74 are bent over on the outer edge of the annular section 71, pointing away from the bottom 57, approximately parallel to the longitudinal axis 53. The free end regions 75 of the arms are in turn bent over in such a way that they run approximately in a plane at right angles to the longitudinal axis 53. Shoulders 76 pointing toward the bottom 57 are formed on the free end regions 75, and one end of the end regions 75 is bent over away from the bottom 57. The arms 74 are arranged in corresponding recesses 77 in the main body 54. The recesses extend, proceeding from the end of the main body 54 pointing away from the bottom 57, as far as the annular section 71. The arms 74, at their ends arranged on the annular section 71, rest on the bottom of the recesses 77 and thereby the position of the lamp carrier 70 in the direction of the longitudinal axis 53 is determined. The end regions 75 of the arms 74 project radially outward beyond the main body 54 but are arranged on a smaller diameter than the internal diameter of the cylindrical section 56 of the covering 52. In the direction of the longitudinal axis 53, the end regions 75 are arranged approximately at the level of the end of the main body 54. In addition, on the outer edge of the annular section 71, a carrier 78 is bent over, extending approximately parallel to the longitudinal axis 53 toward the bottom 57, as is shown in FIG. 2. The free end region 79 of the carrier 78 is designed bent in a U-shape in a plane at right angles to the longitudinal axis 53, as shown in FIG. 3. The end region 79 is arranged between the main body 54 and the cylindrical section 56 of the covering 52. The end region 79 is arranged in the same direction as the end region 65 of the contact element 59, that is to say the free ends of the limbs of the end regions 65 and 79 point around the longitudinal axis 53 in the same peripheral direction. On the inner edge of the annular section 61, distributed at a distance from each other around its periphery, two feet 80 shown in FIGS. 3 and 4 are bent over, extending approximately parallel to the longitudinal axis 53 toward the bottom 57. The feet are, for example, arranged on the periphery at the same locations as two of the tongues 72. The feet 80 are curved in such a manner that they at least approximately form sections of generatrices of a circular cylinder. The ends of the feet 80 pointing toward the bottom 57 each have a depression 81 designed away from the bottom 57. The depression 81 is limited on both sides by means of an edge in each case. The edge of one side of the depression 81 is lower than the edge on the other side of the depression 81. The annular section 71 is provided on its inner edge in the peripheral direction with a radial recess 82 next to each of the feet 80. It is also possible to arrange a recess 82 on both sides respectively of one foot 80.
In the following, the assembly of the holder 50 will be explained in more detail. Firstly, the first contact element 59 is inserted into the holder 50 along the longitudinal axis 53, until its planar section 60 comes to rest on the bottom 57. The first contact element 59 is held in the holder 50 by means of the hooks 64 hooking into the latter. Subsequently, the lamp carrier 70 is inserted into the holder 50 along the longitudinal axis 53, until the said lamp carrier 70 comes to rest with the ends of its arms 74 on the bottom of the recesses 77. In this position, the tongues 72 engage in the openings 73, with the result that the lamp carrier 70 is held in the holder 50. As shown in FIG. 1, the light source 38 which can be inserted into the lamp carrier 70 has an approximately circular cylindrical base 85, on whose end is arranged an electrical contact 86 which is used for connecting the light source 38 to the positive terminal of a voltage source. Two pins 87 project radially outward from the periphery of the base 85 at a spacing from each other, at least one of the said pins 87 being used as electrical contact for connecting the light source 38 to ground. In the course of inserting the light source 38 into the holder 50, its base 85 is introduced through the annular section 71 of the lamp carrier 70, specifically in a rotational position in which its pins 87 can penetrate through the recesses 82 next to the feet 80. After a specific insertion path of the light source 38 in the direction of the longitudinal axis 53, its contact 86 comes to rest on the contact arm 61 of the contact element 59 and, on further inserting the light source 38, the said contact arm 61 is bent resiliently toward the bottom 57. Following further insertion of the light source 38 over a specific distance, the latter can be rotated in the lamp carrier 70 about the longitudinal axis 53, its pins 87 then being able to slide over the lower edge of the depression 81 into the depression 81. Further rotation of the light source 38 beyond the depression 81 is then prevented by the higher edge of the depression 81 on the other side. By means of the restoring force of the contact arm 61, the light source 38 is pressed away from the bottom 57, with the result that its pins 87 are held in the contact position in the depression 81 and the electrical connection of the pins 87 to the lamp carrier 70 is ensured.
For fastening the holder 50 to the housing 14 and to the reflector 34, respectively, the light source 38 inserted in the former is introduced through the opening 40 in the housing rear wall 15 and the opening 36 in the reflector 34 in the direction of arrow 90. The holder 50 is in this case located in a rotational position in which the end regions 75 of the arms 74 of the lamp carrier 70 can pass through the radial cutouts 42 of the openings 36 and 40. The main body 54 of the covering 52 likewise passes through the openings 36 and 40, while the cylindrical section 56 is arranged outside the opening 40 and outside the housing 14. After a specific insertion distance of the holder 50 in the direction of arrow 90, the section 56 with its conical inner surface comes to rest on the conical outer surface of the collar 44 and, on further insertion, the section 56 is radially resiliently expanded somewhat. After a further insertion distance, the end regions 75 of the arms 74 of the lamp carrier 70 pass through the opening 36 into the reflector 34, with the result that the holder 50 can be rotated about the longitudinal axis 53 in the direction of arrow 91 into a locking position. In so doing, the end regions 75 come alongside the radial cutouts 42 of the opening 36 and engage, as shown in FIG. 5 on the inside of the reflector 34 with their shoulders 76, so that the holder 50 can no longer be pulled out along its longitudinal axis 53 in the direction opposite to arrow 90. The U-shaped sections 65 and 79 of the contact element 59 or of the lamp carrier 70, respectively, point with their free limbs in the direction of rotation 91 and, in the rotational position of the holder 50 in which the latter is introduced through the openings 36 and 40, are arranged in a direction opposite to the direction of rotation 91 next to the connecting elements 48 projecting outward through the housing rear wall 15. Upon rotating the holder 50 in the direction of arrow 91 into the locking position, the U-shaped sections 65 and 79 are simultaneously rotated, one of the connecting elements 48 in each case entering between the limbs of the said sections 65, while resiliently bending up the same. Thus, during fitting of the holder 50, the connection of the contact elements 59 and 70 to the connecting elements 48 on the housing 14 is sealed by means of that section 56 of the covering 52 which rests with its inner surface on the outer surface of the collar 44. The section 56 is surrounded by the further collar 46, which additionally forms a protection against splash water and thus improved the sealing of the opening 40.
On the side of the covering 52 pointing away from the housing 14, a projection 92 can stick out and can be engaged for manipulating the holder 50. The projection 92 can have any desired shape in cross-section at right angles to the longitudinal axis 43, for example that of a hexagon, and can be provided with a fluting.
The lamp 12 does not necessarily need to have the reflector 34, and then the end regions 75 of the arm 74 of the lamp carrier 70 engage on the inside of the housing rear wall 15 for fastening the holder 50. The light source 38 can also have a plurality of contacts 86, and separate contact elements 59 then are provided in the holder 50, corresponding to the number of contacts 86, and a plurality of connecting elements 48 then are provided on the housing 14 in a corresponding fashion.
All the electrical connections of the lighting device can be produced via the plug part 26, for further light sources and also for electrical adjusting devices of the headlight 10 for adjusting the headlight range.
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.
While the invention has been illustrated and described as embodied in a lighting device for vehicles, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A lighting device for vehicles has a housing, at least one light source, and a holder fastenable to the housing and formed so that the at least one light source is insertable in the holder. The holder is provided with at least one electrical contact element on which the light source comes to rest. At least one electrical lead is connected with the at least one electrical contact and connectable to a voltage source. The holder has a covering composed of an electrically insulating material. A plug includes a plug part, and at least one electrical connecting element connected with the plug part is arranged on one part of the housing. The connecting element is bringable to rest at the contact element of the holder under the action of a spring force in built-in position of the holder in the housing. | 5 |
BACKGROUND OF THE INVENTION
A known wire electrode member and apparatus for electrical discharge machining is described in U.S. Pat. No. 4,287,404 wherein the electrically conductive metal wire is provided with an active surface comprising at least 50 percent by weight of a metal or alloy selected from a group consisting of zinc, cadmium, tin, lead, antimony and bismuth. In the preferred apparatus, said active surface coating is provided by electrolytic plating on the exterior surface of a conventional metal wire in a continuous manner during the machining operation. Such continuous replenishment of the active surface while the workpiece is being machined understandably renders the equipment more complex to build and operate. Cutting speeds for said prior art wire electrode member is said to be optimum when the core metal is copper or brass since a steel core member is said to require coating with copper or silver for improved electrical conductance. Accordingly, desirable mechanical strength for this electrode member is obtained at some sacrifice in the electrical conductance unless added costs are incurred with utilization of the disclosed higher conductivity inner layer. A low vaporization temperature for the active surface coating on said prior art electrode member is also said to be needed in order to avoid rupturing said electrode member in the machining zone.
It remains desirable, therefore, to overcome the above mentioned drawbacks with an electrode member suitable for electrical discharge machining as well as increase the cutting speeds in said type machining operation.
A further desirable objective is to simplify the process and equipment needed to carry out electrical discharge machining insofar as attributable to the wire electrode member being utilized.
These and other objectives of the present invention will be apparent from the following detailed description.
SUMMARY OF THE INVENTION
It is now been found, surprisingly, that a particular active surface coating of carbon improves the cutting speeds of electrical discharge machining especially at smaller diameters of the wire electrode member thereby enabling a more precise machining operation to be carried out. In the latter respect, the surface finish of a machined metal object can also be improved since higher cutting speeds are customarily utilized with larger diameter wire electrode members. Accordingly, a carbon coating as thin as 1.0 micron and which is adherently bonded to the surface of an electrically conductive metal wire length provides this improvement when coated on a variety of metal containing substrates. A particularly useful metal containing substrate for the desired adherent carbon coating consists of an oxide surface formed on the metal or metal alloy wire core by various known techniques. For example, the "black" tungsten or molybdenum wire which is obtained by drawing such wire through dies, as described in the text "Tungsten" by C. J. Smithells, Chapman and Hall (1952), provides a preferred wire electrode member according to the present invention. The composite electrode member obtained in this manner will consist of a refractory metal core exhibiting both a relatively high mechanical strength and a relatively high melting point, a metal containing inner layer of the selected refractory metal oxide exhibiting a lower melting point being bonded to the metal substrate, and a discontinuous surface coating of graphite which is bonded to the porous oxide inner layer.
A different preferred wire electrode member according to the present invention utilizes a modified form of ferrous alloy metal core wire, such as Dumet or Cumet, both commercial products of General Electric Company, and which have had the copper clad surfaces oxidized for adherent bonding of the active carbon surface layer thereto. A wire electrode member of this type having representive 0.004-0.010 diameter can be prepared by thermally oxidizing the copper clad wire by conventional means, thereafter coating the oxidized wire with a carbon lubricant surface coating, and finally reducing the diameter of said carbon coated wire with dies in the same manner as above described for black refractory metal wire except that said wire drawing is carried out at ordinary ambient temperatures. A still different means contemplated is secure the adherent carbon surface coating to an electrically conductive metal containing substrate in accordance with the present invention consists of known chemical vapor deposition techniques whereby the metal substrate is first coated with carbon and thereafter reduced in diameter as previously described.
Carrying out the electrical discharge machining process according to the present invention generally comprises moving the electrically charged wire electrode member in close proximity to a metal workpiece so as to cause a spark discharge therebetween, said wire electrode member comprising a conductive metal wire length having an adherent carbon surface coating, contacting the gap space between said workpiece surface and the moving wire electrode member with a moving dielectric liquid, removing metal from the workpiece and carbon from the wire electrode member with said spark discharge, and displacing the removed metal and carbon from the gap space in the moving dielectric fluid. In accordance with said modified process, a conventional EDM machine, such as the commercially available ELOX equipment, is supplied with a spool of the present wire electrode material for a single pass mode of operation. The surface graphite layer is volatilized during such operation with the volatilized by-products providing effective flushing of the gap space at high removal rates because of the intensive energy transfer taking place. When such mode of operation is conducted with a preferred black molybdenum wire electrode, constructed as above described, the once used wire can again be recoated with a replacement grapite coating for reuse in the machining operation. Thus, a reusable wire electrode member can be provided according to the present invention which has understandable cost advantages to the EDM equipment manufacturers and users. The presently improved wire electrode member provides still further advantages in the operation of already commercial EDM equipment. More particularly, said wire electrode member is generally transported in said equipment by use of guide means, such as rollers, pulleys and the like, and which further serve to position said electrode member at the working or gap space location. A pair of said guide members are generally oriented vertically or horizontally at said location with the workpiece being located therebetween for longitudinal or lateral machining, respectively, and the moving prior art electrode members having been observed to vibrate in said gap space disturbing the desired machining step. A greater rigidity imparted by the aforemention black molybednum wire electrode member of the present invention reduces such vibration especially when the machining takes place along a diagonal direction wherein said spaced apart guide members are laterally displaced with respect to each other. Moreover, greater lubricity is provided by the present carbon surface coating thereby reducing friction in the EDM equipment which is a further advantage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view depicting the major component parts of an improved EDM apparatus accordng to the present invention;
FIG. 2 is a perspective view for a preferred wire electrode member illustrating its three part composite construction;
FIG. 3 is a photomicrograph depicting the condition of a machined workpiece surface as produced with a brass wire electrode member; and
FIG. 4 is a photomicrograph for said workpiece surface when machined with the presently improved wire electrode member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown a fragmentary view depicting the present wire electrode member 10 while being used in the operation of anotherwise conventional EDM machine. Said wire electrode member 10 is suspended between a pair of guide rollers 12 and 14 to travel downwardly in a vertical direction and produce a spark discharge (not shown) causing the machining step to take place. The metal workpiece 16 being machined in said manner is positioned in close proximity to said moving electrode wire member at a distance producing the spark discharge therebetween when said wire electrode member and workpiece are properly interconnected in a conventional EDM electrical circuit. More particularly, said electrical circuit employs a pair of brush contacts 18 and 20 to contact said electrode member and which are suitably further connected by conductors 24 and 26, respectively, to a conventional EDM power source 22. Electrical connection of said EDM power source by a further conductor 28 completes the required electrical circuit. A supply of moving dielectric fluid 17 such as deionized water is also provided at the gap space location to remove the metal particulates caused by action of the spark discharge on the workpiece along with the carbon particulates being volatilized from the present wire electrode member during such use.
A comparison is provided in the following Table for cutting speeds measured with prior art brass and molybdenum wire electrodes as compared with the presently improved carbon coated electrode members. In said comparison test, the workpiece consisted of a one inch thick hardened tool steel plate being machined in the above described manner with a commercial ELOX machine and which utilized wire electrode members having a diameter as listed in said Table. Voltage and current measurements are also reported in said Table for the various electrode members during use which serve to indicate that excessive electrical power utilization does not occur with the present improvement.
TABLE______________________________________ Cutting Gap GapType Electrode Speed Voltage Current(material-dia.) (in.sup.2 /hr) (volts) (amperes)______________________________________brass - .006 in. 5.4 50 3.0molybdenum (bare) - .006 in. 3.6 50 --molybdenum (black) - .006 in. 4.8 50 --Dumet (graphite coated) - 3.3 50 3.0.006 in.brass - .004 in. 3.9 50 3.0molybdenum (bare) - .004 in. 3.0 50 3.0molybdenum (black) - .004 in. 4.2 45 3.5molybdenum (black) - .004 in. 4.0 45 3.4______________________________________
The above Table results clearly evidence the superiority in cutting speeds for a preferred black molybdenum electrode member of the present invention at the small wire diameter now employed for precise machining. Moreover, the 0.004 inch diameter brass electrode tested for comparison purposes also produced an unstable cutting result as further evidence of its lack of suitability at this wire diameter. On the other hand, the above demonstrated lower comparative cutting speeds for a carbon coated Dumet electrode member may simply illustrate a lack of sufficient graphite coating thickness having been deposited to achieve the desired improvement.
In FIG. 2, there is shown in perspective the composite construction of a representative wire electrode member according to the present invention. Specifically, said wire electrode member 10 consists of an electrically conductive metal core 30, having particular oxidized inner layer 32 formed at its surface which can serve to provide a metallurgical bond for the surface carbon coating 34 deposited thereon. The particular copper oxide found useful in this manner is cuprous oxide which is an electrically semiconductive material after determining that electrically insulative cupric oxide does not serve as an effective bonding medium for the carbon surface layer when the wire electrode member is in use. While such a metallurgical bond is not being critical to achieving the improved metal removal mechanism according to the present invention such a bond should serve to enhance the mechanical integrity of the present composite electrode member and possibly further enhance the deposition thereon of carbon surface coatings having increased thickness for still more rapid metal removal from the workpiece. In this regard, the oxidation of a copper clad Dumet or Cumet wire to form a porous oxide surface deposit to which is adherently bonded a graphite coating has improved cutting speeds in the above described test procedure by at least 20 percent.
FIGS. 3-4 photomicrographs represent SEM views of the above described machined steel rod surface at 500×magnification. The FIG. 3 view illustrates the work surface obtained with a 0.004 inch diameter brass wire electrode member whereas FIG. 4 is the same view obtained upon machining said workpiece with a 0.004 inch diameter black molybdenum wire electrode member of the present invention. A much smoother surface finish in FIG. 4 as compared with FIG. 3 evidences still another benefit attributable to the present invention. A still different benefit to users of the improved EDM apparatus is an ability found to machine steel workpieces to a much greater depth with said black molybdenum electrode member than was found possible with said brass electrode member without risking mechanical breakage of the electrode member. In said latter regard, the penetration depth achieved with said molybdenum electrode member was at least twice that achieved with the brass electrode member.
It will be apparent from the foregoing description that a generally useful electrical discharge machining electrode has been provided along with modifications to the otherwise conventional process and apparatus for its use. It will be apparent to those skilled in the art, however, that compositional variations can be made in the core metals as well as any intermediate layers deposited thereon for the purpose of satisfactorily adhering the carbon surface coating thereto than above specifically disclosed without departing from the spirit and scope of the present invention. For example, it is contemplated that said intermediate bonding layers can be formed with still other low melting point metals and non-metals which also exhibit relatively high vapor pressures when heated by the spark discharge in providing a suitable bonding and carrier substrate for the active carbon surface of said electrode member. Accordingly, it is intended to limit the scope of the present invention only by the scope of the following claims: | An improved electrical discharge machining electrode permitting increased cutting speed of the metal workpiece being machined and which improves the operation of the electrical discharge machining equipment in other respects. The improvement is atrributable to an adherent carbon surface coating deposited on an electrically conductive metal wire length which serves to transfer energy efficiently to the workpiece from the spark discharge as well as enhance the flushing of materials removed by said discharge during the machining operation. The method and apparatus for employment of said improved electrode is also described. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed toward apparatus and methods for servicing equipment such as air conditioning systems, refrigeration systems, engines, transmissions, and tires. More particularly, invention is directed toward a system for safely transferring precisely measured quantities of a variety of liquids and gases to the serviced item using essentially a single work station apparatus. This invention is suitable for many market segments such as commercial, industrial, marine, utility, and the like. Government, military, public and private sectors of the economy will benefit from the use of this invention.
2. Background of the Art
The service industry is one of the largest industries in the United States, and likewise is one of the largest and fastest growing industries in the world. This area spans a tremendously wide range of sectors, with two of the largest sector being the automobile service industry and the air conditioning service industry.
Attention is first drawn to the automobile service industry, which more precisely should be referred to as vehicle service industry, since this sector generally includes servicing of other types of vehicles such as buses, light trucks, heavy trucks and the like. It goes without saying that the number of vehicles is growing faster than the general population. These vehicles, and peripheral system used by these vehicles, require repair and routine preventive maintenance. Service generates a significant portion of the total revenue generated by the automobile industry. A recent study conducted in the United States found that in 1995, vehicle service generated 45 percent of the revenue of automobile dealers, while only 8 percent of the revenue was generated by the sale of new vehicles. The remainder of the dealership revenue was generated by the sale of used cars, and the leasing of new cars. With this brief overview of the vehicle service industry, it is apparent that the efficiency of service apparatus and methods used in servicing any and all types of vehicles have a tremendous financial impact on the service industry sector. This service sector involves lubricants and solvents which are environmentally hazardous, and therefore the handling of these materials is highly regulated. Apparatus which improves environmental safety without compromising efficiency also significantly impacts the finances of the vehicle service industry.
Attention is next directed toward the air conditioning and refrigeration industry. Refrigeration is used in all areas of the United States, and in most areas of the world, as a primary means for preserving the food supply. During the last half of the twentieth century, the population distribution of the United States has tended to move south toward warmer regions which are commonly referred to as the "sun belt" states. Although winters are relatively mild, summers are relatively hot. The hot summers in the sun belt, and the shifting population to this region, have resulted in a tremendous increase in the use of air conditioning equipment. Essentially all large shopping malls, and the majority of homes, are air conditioned. Furthermore, essentially all passenger vehicles in use in the sun belt states, and in use in all but the most temperate climate regions, are air conditioned. Refrigeration and air conditioning units require scheduled and unscheduled service, and like the automobile industry, the service sector is a major generator of revenue. Refrigerants and oils used in the refrigeration and air conditioning equipment are also controlled as potentially environmentally hazardous materials. As in the case of the automobile service industry, any apparatus and methodology which increases the efficiency of servicing cooling equipment, and the handling of materials used in the servicing and operation of this type of equipment, significantly affects the finances of the industry.
Initially, the servicing of vehicle engines or other components, air conditioning units, and other such equipment involving the transfer of fluid, was performed with dedicated equipment. As an example, oil was added to an engine by literally pouring it from a can into the engine, or transferring it from a drum by means of a dedicated pump and service flow line. Using the latter, bulk method, the metering of the correct amount of oil required presented a problem. Adding (and removing) other fluids such as transmission fluid, differential oil and the like, was done serially with dedicated reservoirs and flow lines, with dubiously accurate metering devices. As a further example, air and possibly sealants were added to pneumatic tires using dedicated sources of compressed air and sealant, respectively, and often delivered with dedicated service hoses and fittings.
Traditional servicing of air conditioning units has also required dedicated systems. Refrigerant and oil is typically removed with one system. The system is leak tested with another dedicated system. The system is evacuated with a dedicated vacuum pump and associated service lines or hoses. Refrigerant and oil are added with still additional dedicated systems. It is very important to note that leak testing with nitrogen as a pressurization medium is not new to the petrochemical industry. For many years, the industry has used the method for testing its pressure vessels, such as heat exchangers, piping and the like. However, the method is new in its application to the mobile and stationary air conditioning and refrigeration industries, though only occasionally used by some enlightened technicians as stand-alone equipment to flush and leak test. Furthermore, because there is no widespread understanding of its value within those markets, service equipment is not currently available to accommodate the use of a compressed gas into the now popular "recovery" machine, or dual function "recovery-recycle" machine, as an embodiment of their operation. None has integrated the concept of the invention to be disclosed into their designs.
The importance of integrating compressed gas into air conditioning and refrigeration service equipment is now addressed. Although modern recovery and recycling equipment includes a degree of similarity to the present invention, none has incorporated compressed gas leak test capabilities. This feature is important because, as refrigerant compressor oil circulates throughout an air condition or refrigeration system, it coats the inside of all hoses, tubes, fittings and system components. The oil coating becomes a seal against leaks, making small leaks difficult to detect.
A recent automobile air conditioning trade association survey reported that the national average of success in finding air conditioning system leaks the first time, with today's technology, is only 75%. This means that 25% of all leaks on automobile air conditioning systems are not being found the first time, which translates into many repair jobs which must be reworked and thereby costing extra manpower, lost revenue and customer dissatisfaction.
Examples of modern leak detectors include ultraviolet fluorescent dyes, electronic leak detectors (corona discharge and heated diode technology), and the like.
The failure of non-compressed gas leak testing methodology has occurred because it focuses entirely on the "sensing" or "visual observation" of leaks at ambient pressures. But, the hard-to-find leaks like to "hide" underneath oil and sludge which coats the inside of the system components. Therefore, when technicians use their modern leak detectors, they are failing to locate 25% of the leaks because they have no way to duplicate the conditions in which leaks will fester through the oil and sludge coating. Leaks tend to temporarily seal off when the system is turned off. Thus, even the best leak sensing devices are rendered useless. Probably the biggest single reason why technicians are not finding leaks 25% of the time is that they focus on the "sensing" of leaks before they fester and they fail to understand the importance of first "displacing" system oil and sludge. Locating slow leaks is a "process", not a one-shot test. Therefore, if the coating of refrigerant oil/sludge is not removed from the inside of components of the air conditioning system, a leak detector will not sense some leaks because they are not active during testing. The conditions conducive to leak occurrence have not been reproduced as a prerequisite for the test, namely to create "static" conditions which most closely duplicate the "dynamic" conditions of an operating system. Basically, this invention provides a method for the injection of the three main ingredients which are essential to duplicating those operating conditions:
(1) Trace elements for the leak detector to sense.
(2) Oil/sludge displacement elements.
(3) Nitrogen or some other acceptable compressed gas which acts upon the trace elements to force them through the oil/sludge barrier and in an amount that is easier to detect because of greater than ambient pressures.
The injection of compressed gas into a system must be performed under static conditions where the compressor is not operating and the system is turned off. This must be specifically stated even though it is widely understood that no type of leak test should be performed while the system is operating. The only known exception to this practice is the use of dye as a leak detection method, where dye is injected into the system, the system is operated, and then shut off to visually observe where dye has penetrated or leached through leaks in the system. The present invention, as will be disclosed, is directed toward setting up conditions to activate dormant leaks so that a service person can use prior art leak detection devices to sense and locate the leaks.
Many other service functions currently use dedicated equipment. As a further example of such dedicated equipment and the inventive effort expended upon such dedicated equipment, three references directed toward filling a pneumatic tire with sealant will be cited. U.S. Pat. No. 1,307,173 to Anthony teaches the connection of one end of a rubber hose to a pneumatic tire and the other end of the hose to a container containing a sealant, wherein the hose as a means of injecting sealant from the container into the tire. Anthony does not disclose any means for inserting a known or metered amount of sealant, does not discloses any means for inserting metered quantities of a plurality of materials using a single apparatus, and discloses no closed loop system for transferring and recovering materials. U.S. Pat. No. 5,070,917 to Ferris et al discloses apparatus and methods for charging a pneumatic tire with a gas containing a sealant, and also states that the invention can be used in an alternate embodiment to charge a system with refrigerant. Ferris discloses no recovery system for the refrigerant, and discloses no accurate metering technique. U.S. Pat. No. 5,403,417 to Dudley et al discloses the charging of a tire and sealant material with CO 2 , wherein the charge is supplied by an aerosol or by a pump operated from power obtained from the cigarette lighter of the vehicle. No recovery system, no accurate metering system, and no multipurpose fluid handling system for other materials such as lubricants, is taught by Dudley et al.
The foregoing discussion and examples illustrate that traditional servicing of vehicles and refrigeration equipment is performed using equipment dedicated to each specific service task. Purchase and maintenance of numerous sets of service equipment dedicated to a specific service task, and operational inefficiencies introduced by using numerous sets of service equipment, contributed significantly to the costs of the services performed. Attempts have been made in the prior art to combine, at least to some extent, service equipment in order to reduce equipment cost and to increase service efficiency. An example is the numerous small commercial establishment for "quick lube" servicing of vehicles such as changing engine oil, adding transmission fluid, lubricant to grease fittings, and adding brake, differential and cooling fluids. Some liquids such as engine oil and grease are dispensed from remote bulk storage through dedicated service lines. Other fluids, such as brake fluid, are typically dispensed from small containers by hand. The metering of the bulk liquids, such as engine oil, is at best crude. The system for dispensing specified quantities of engine oil may result in an actually delivered quantity which varies by perhaps ±10% from the specified quantity. Equipment for automated handling of bulk, gaseous fluids are not available in these establishments.
The accurate dispensing of specified amounts of lubricant, brake fluid, hydraulic fluid, coolant, sealant, coating or other material into an enclosure such as an engine crank case, transmission case, pneumatic tire, or other appropriate receiving enclosure is a serious problem. The amount of added material is typically confirmed by visual inspection by a service person. In the case of adding engine oil, the service person typically uses a dip stick to measure the "level" of the engine oil. In the case of adding brake fluid to a master brake cylinder reservoir, the service person must peer into the recess of the enclosure to verify roughly the desirability of the brake fluid level.
Depending upon the situation and the service being performed, prior art service techniques currently used can be inconvenient. As an example, the interior of the enclosure or recess of the serviced component is usually dark, making visual determination or confirmation of the service step very difficult for the service person. As a more specific example, the power steering reservoirs of most vehicle engines so equipped are notoriously inconvenient to access, and the dip stick is notoriously inaccurate thereby necessitating visual inspection of the reservoir to confirm fluid level. It must be stated that manufacturers have designed reservoirs with service ports having filler caps which must be removed and visually inspected if the reservoir is partially filled, since the amount of liquid to be added is unknown. The present invention is not directed toward preventing individuals from servicing personal equipment, but is directed toward providing means for the service professionals to be more efficient and safer in the way they service fluids. It is also hoped that the present invention will provide incentive to equipment manufacturers to accommodate the use of the disclosed apparatus and methods by improving the serviceability of their equipment.
Prior art service techniques are also inconclusive in that they often result in over filling or under filling of added liquid drawn from uncalibrated containers or reservoirs. An example of this problem is the filling of an automatic transmission unit with hydraulic fluid drawn from an uncalibrated bulk storage container. Although the level of the fill is monitored by reading a dip stick, this indicated level is highly dependent upon the temperature of the hydraulic fluid, and the ease at which the service person can view or "read" the dip stick. Either an over fill or an underfill of 5 percent can be detrimental to the operating life of the transmission.
Prior art servicing techniques can be hazardous in several aspects. As an example, the requirement of a service person into a service port can be a hazard if the contents can spurt up into the service person's eyes. As an additional example, current filling and flushing service methods lead to spillage of liquids or gases which are considered to be harmful to humans, equipment and the environment.
Aerosol methods of injecting materials are commonly used in prior art servicing operations. These are generally hand held containers without immediate liquid and pressure refill capability. They are not designed to deliver bulk volumes, and their small dispenser orifice sizes limit the flow of products.
The prior art also employs one-shot injection devices commonly referred to as "wooshers". These are typically cylinders which must be manually refilled after each use. Operation tends to be inefficient, and they do not contain any type of self contained metering device to gauge the amount of material expelled.
In summary, prior art service techniques used in the automotive industry, air conditioning industry, and any other industry which involves the dispensing, metering, removal and disposal of liquids and gases is riddled with operational, financial and safety problems. Only a few of these problems have been outlined above. Problems seem to be more intense in larger service facilities where many service people are performing services on a variety items using a seemingly endless amount of dedicated service equipment.
An object of the present invention is to provide apparatus and methods with which precise and accurate quantities of fluid can be delivered to an enclosure within a device being serviced. An example of this application would be the delivery of a precise and accurate amount of oil to an automobile air conditioning system.
A further object of the invention is to provide apparatus and methods with which a plurality of fluids can be delivered to serviced equipment using essentially the same service apparatus. Fluids might include lubricant, refrigerant, hydraulic fluid, solvent, coolant, sealant and the like. This feature of the present invention minimizes the need for dedicated service equipment for each service task.
A still further object of the invention is to provide apparatus which is convenient for the service person to use, and which minimizes hazards to the service person by way of contact and exposure, to the equipment being serviced induced by overfills and underfills and the like, and to the environment by way of spills and unwanted vents to the atmosphere.
A further object of the invention is to provide apparatus which can be configured as an "open loop" design, wherein material such as oil is delivered to or removed from the equipment being serviced as a single operation. Such a service operation would include adding engine oil to a crank case or sealant to a pneumatic tire.
A still further object of the invention is to provide apparatus which can also be configured to operate in a "closed loop" design, wherein liquid is continuously exchanged or circulated between the service equipment and the equipment being serviced. Such a closed loop service operation would include the flushing of a radiator of an air conditioning system such as a condenser or evaporator, wherein solvent is continuously circulated through a closed loop, which includes the radiator, for a predetermined length of time.
An additional object of the invention is to provide service apparatus in the form of mobile or portable work stations mounted on service carts, wherein the work station can be easily and conveniently transported to the equipment to be serviced. This feature often, but not necessarily, includes the use of remote reservoirs or pumps, with suitable plumbing to connect the remote elements to the mobile work stations on service carts.
A still further object of the invention is to provide work stations which are adapted for use in relatively large service facilities involving numerous service persons each assigned to a specific service work station. This embodiment of the invention again involves the use of central reservoirs, pressure sources, and vacuum sources which are remote from the work stations, but to which multiple work stations are operationally connected to minimize redundancy of common elements.
There are other objects and applications of the present invention which will become apparent in the disclosure and claims which follows.
SUMMARY OF THE INVENTION
The invention apparatus consists of three basic or "base" components which can be configured and operated to provide the versatility described above in the stated invention objects. The three base components are defined as (1) the calibrated injector chamber component, (2) the reservoir component, and (3) the interaction component. The calibrated injector chamber component, or injector chamber or simply "injector" for brevity, contains a calibrated amount of fluid which is to be injected into a system being serviced. An example of such fluid would be engine oil of a specified amount to be injected into the crank case of an engine being serviced. A second example would be sealant to be injected to a pneumatic vehicle tire at a given pressure. The reservoir component is, as its name implies, a reservoir (such as engine oil or refrigerant oil) to be injected into the equipment being serviced. This reservoir can be remote from the injector component, and can further serve as a reservoir for multiple injector components as will be discussed in detail in a subsequent section of this disclosure. The third base component, defined for brevity as the interaction component, comprises components used to perform the service task at hand and also serves as an "interaction" means between the injector component and the reservoir component. More specifically, the interaction component may comprise a plurality of valves, flow conduits, pumps, compressors, cylinders of gas, or any combination of these sub components. The injector and interaction components are preferably contained within a service cart which is preferably on wheels such that it can be positioned conveniently near the equipment being serviced. The reservoir component can be remote from the service cart, or in some embodiments of the invention, also be mounted on the service cart. Functional relationship between the interaction component, and the reservoir component, will be fully disclosed in the following section.
It is also noted early in this disclosure that the invention can be operated as a "closed loop" system or as an "open loop" system. The mode of operation is determined by the service task at hand, and the arrangement of the sub components or elements of the interaction component. The distinguishing features of the close loop and open loop operation will be disclosed by means of examples.
As an illustration of the basic components of the invention operating as an open loop system, assume that the service task requires the injection of a precise amount of oil into an air conditioning system. For this task, the interaction component uses an injector refill pump and a valve arrangement comprising five valves. There are three modes of operation in performing this service task. Each operational mode will be described briefly. The modes are initiated and terminated preferably by switches which are set by the service person and which are mounted on a control panel preferably affixed to the service cart.
The first mode of operation is the filling of the injector with liquid, which is oil in this example, from the reservoir component. This is accomplished by opening two valves (by means of two switches on the control panel) such that oil is transferred to the injector by the action of the injector refill pump. As the injector is filled, gas displaced from the closed injector chamber is transferred to the liquid reservoir. This prevents any fumes which might be contained in the gas from venting into the atmosphere.
The second mode of operation is the transfer of a specified amount of oil from the injector assembly to the equipment being serviced. The valves opened during the first mode are closed, and two additional valves are opened such that compressed gas from a cylinder or compressor flows into the sealed injector chamber thereby forcing oil through a series of conduits and through a service hose to the equipment being serviced, which is an air conditioning system in the example being discussed. Again, the flow is initiated and terminated by the operation of valves, or valves controlled by switches on the control panel. The injector assembly is constructed with at least a section of transparent material for viewing the level of liquid within. This "sight glass" is also calibrated preferably with a series of inscribed marks which correspond to a given volume of fluid. By use of the calibrated sight glass, the service person can transfer the desired amount of oil into the air conditioning system. When the viewed fluid level drops to a level representative of the desired injection volume, the service person then terminates the second mode by the operation of the same valves or switches on the control panel.
As mentioned above, the second mode is terminated based upon sight glass readings made by the service person. When the desired oil level within the sight glass is reached, this does not mean that all of the oil has reached its final destination, namely the air conditioning system being serviced. A portion of the oil still resides within the conduits in the interaction component and in the service hose. Compressed air or gas is applied to the flow conduits within the interaction component and the service hose to purge this remaining fluid to its final destination, namely to the serviced air conditioning system or alternately to a waste container. This is accomplished by setting a valve or switch on the control panel by the service person. Stated another way, the flow conduits of the system are purged by compressed gas.
It is noted that the function of the compressed air or gas source can be performed by other means. The air conditioning system being discussed also serves to illustrate this option. More specifically, the "high" pressure side of the air conditioning compressor can be used to drive the predetermined volume of oil from the injector into the air conditioning system. Details of this option will be disclosed in a subsequent section.
Upon completion of the third operational mode, the service system is ready to perform another service task. The next task, like the example of the previous service task, can employ the invention using an open loop flow pattern. Other service task that can be performed using this open loop flow pattern include flushing a piece of equipment where the flushing solvent is not recirculated, inflating a pneumatic tire with sealant and gas, filling an engine crank case with lubricating oil, filling a vehicle transmission with hydraulic oil, and the like.
The invention can be operated as a closed loop configuration, as will be illustrated with the following example, where the service task is to flush an air conditioning condenser with solvent, wherein the solvent is repeatedly circulated between the injector component and the condenser.
The first closed loop mode of operation consists of filling the injector with a specified amount of solvent, drawn from the reservoir component, using essentially the same valve settings as described previously in the open loop example. The injector sight glass is again used to determine when the correct amount of solvent has been drawn.
In the second mode of operation, the solvent is circulated from the injector, through the conduit system of the interaction component, through a service tube which connects to the inlet of the radiator, through the radiator, out through a second return service tube, through the interaction component, and back into the injector chamber. Circulation power is provided by the previously described refill pump which also operates as a circulation pump.
After circulating solvent for the desired time period, a the third mode of operation is initiated by setting the appropriate switches on the control panel. As in the previous example, the purpose of this third mode is to purge solvent from the service system, and the radiator being service, using the source of air or gas. This step is similar to the third mode of open loop operation in that the purged solvent is returned to the reservoir component for future use.
The use of the service system in the previously described closed loop mode of operation is by no means restricted to the example of flushing an air conditioning system condenser with solvent. It should be understood that the service system operating in this mode can be used to perform any type of service task which comprises the circulation of fluid within a closed loop.
As mentioned previously, the invention is ideally suited for "field" operation and for operation in facilities requiring numerous service carts. For installations requiring multiple service carts, certain required elements can be supplied to the individual service carts from central sources. As an example, if the invention is used in a service operation which involves the use of a vacuum, vacuum can be supplied by a central vacuum pump wherein vacuum is plumbed to individual service carts by means of hoses which tap off the central vacuum line. A vacuum is usually needed when the service cart is used to evacuate a serviced item, such as an air conditioning unit prior to filling with refrigerant and oil. As a second example, the previously described source of compressed gas or air can be supplied from a central compressor or cylinder, and plumbed to the individual service carts. When the invention is used to service air conditioning and refrigeration equipment, it is desirable to remove and to retain refrigerant and oil prior to servicing, recover the refrigerant from the oil, and reuse the refrigerant and oil if possible. Refrigeration recovery units on each service cart are not practical from the operational and economic viewpoint in service or manufacturing facilities where multiple service operations are in progress simultaneously, because work stoppage or down time would result unless much duplicate equipment were purchased. It is desirable, therefore, to direct recovered refrigerant and oil from individual service carts, into a central flow conduit, and subsequently to a single, central refrigerant recovery system. Recovered refrigerant is likewise returned to individual service carts from the central recovery unit by means of a central refrigerant flow line and plumbing to individual service carts.
There are applications of the invention which require remote and relatively self contained operation. As mentioned previously, it is sometimes preferred that the reservoir component not be a central reservoir which is plumbed to one or more service carts, but rather a reservoir which is actually mounted on the individual service cart. Such a reservoir might be a cylinder of virgin refrigerant.
There are other embodiments and applications of the invention which will be discussed in the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to embodiments thereof which are illustrated in the appended drawings.
FIG. 1 shows the service system operating in an open loop mode while FIG. 1A and 1B show use of the system;
FIG. 2 shows the service system configured to operate in a closed loop mode; and
FIG. 3 shows multiple service carts being supplied with various materials and elements from remote, fixed reservoirs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus and methods of the invention will be disclosed in detail by first describing the apparatus, and thereafter describing the methods of operation of the apparatus in various operational modes to perform various service tasks. Adaptations of basic apparatus and methods will then be disclosed thereby indicating the versatility of the invention.
APPARATUS
The service injection apparatus consists of three basic or "base" components which can be configured and operated to provide the versatility described above in the stated invention objects. Referring to FIG. 1, the three base components are defined as the calibrated injector chamber component 10, the reservoir component 30, and the interaction component whose elements are defined by the broken-line box and identified as a whole by the numeral 60.
Still referring to FIG. 1, the calibrated injector chamber component 10, or "injector chamber" for brevity, will be disclosed in more detail. The shape of the chamber 10 is preferably cylindrical, although other shapes can be used without significantly affecting the basic function of this component. The chamber 10 can be made from a wide variety of materials, including transparent materials so that the material within the chamber can be viewed by a service person operating the apparatus. The chamber 10 is depicted in FIG. 1 as being fabricated with a transparent "sight glass" 13 which is inscribed with calibration marks 15 indicating the volume of liquid 17 within the chamber. The chamber 10 contains two openings or "ports" 18, 16 and a flow conduit 12, which is preferably a tube, and which extends from the top of the chamber 10 to a near the bottom of the chamber. The functions of these elements will be described subsequently as pertaining to a calibrated amount of fluid which is to be injected into a system being serviced.
Again referring to FIG. 1, the reservoir component 30 is, as its name implies, a reservoir of fluid 17 to be injected into equipment being serviced using the service injection apparatus. The reservoir 30 can be remote from the injector chamber component 10, and can further serve as a reservoir for multiple injector components as will be discussed in detail in a subsequent section of this disclosure. The reservoir can be of any convenient shape, contains three "ports" or "openings" designated by the numerals 32, 34 and 36. The port 32 comprises a tube which extends to a location near the bottom of the reservoir 30. The port 34 is a gas intake, exhaust and, if necessary, a liquid overflow vent for the injection chamber 10, so that it effectively acts as a return line from the injector 10 back to the reservoir 30. The port 36 is an atmospheric vent to relieve any pressure within the reservoir 30 and thereby prevent substantial gas pressure buildup inside the reservoir. Functions of these ports will be further explained when the operation of the service apparatus is detailed.
The third base component, defined for brevity as the interaction component, comprises components used to perform the service task at hand and also serve as an "interaction" means between the injector component 10, the reservoir component 30, and the equipment being serviced (not shown). More specifically, the interaction component comprises a plurality of elements including valves, flow conduits or "tubes", pumps, compressors, and cylinders of gas. The interaction component is defined in FIG. 1 by the broken-line box and identified as a whole by the numeral 60. All elements of the interaction component are not shown in FIG. 1 for reasons of brevity. Only those elements needed to operate the service system in the "open loop" when employing the "open loop" flow pattern are shown in FIG. 1. Other elements will be shown in subsequent drawings depicting the service apparatus configured to operate in other modes, and to perform other service tasks. The various elements within the interaction component are controlled by means of valves or switch-operated valves on a control panel 80 which are set by the service person. The control panel is shown as being operationally and functionally connected to the interaction by means of the broken line 82.
The injector 10 and interaction component 60 are preferably contained within a service cart 200 (See FIG. 3) which is preferably on wheels 230 such that it can be positioned conveniently near the equipment being serviced. The reservoir component 30 can be remote from the service cart 200, or in some embodiments of the invention, can also be mounted on the service cart (See FIG. 3). Functional relationship between the interaction component 60, and the reservoir component 30, will be fully disclosed in the following section detailing the operation of the invention.
It was also noted early in this disclosure that the invention can be operated as a "closed loop" system or as an "open loop" system. The mode of operation is determined by the service task at hand, and the arrangement and settings of the elements of the interaction component 60. FIG. 1 illustrates the elements of the interaction component 60 required to operate the apparatus in the open loop mode. All other elements within the interaction component are not used in the open loop mode. These elements will be defined under the discussion of operating the invention in the closed loop flow pattern. The distinguishing features of the close loop and open loop operation will be summarized by examples.
OPERATION USING AN OPEN LOOP FLOW PATTERN
As an illustration of the operation of the service system as an open loop system, attention is again directed to FIG. 1 which shows the system in an open loop configuration. Assume for purposes of discussion that the service task requires the injection of a precise amount of oil into an air conditioning system. For this task, all required active elements within the interaction component are shown. Valves A, B, C, D and E are identified by the numerals 50, 52, 54, 56 and 58, respectively. A series of flow conduits are shown and identified, and these flow conduits will be referred to simply as "tubes" for brevity. It should be understood that these flow paths could comprise pipes, hoses, channels or the like. Initially, all valves are closed. There are three sequences or "modes of operation" required to perform the stated service task. Each of these operational modes will be described in the following paragraphs.
The first mode of operation is the filling of the injector 10 with liquid 17, which is oil in this example, to a level 11 as illustrated in FIG. 1. The liquid 17 is drawn from the reservoir 30 by opening valves 50 and 52. An injector refill pump 63 draws liquid 17 up through the tube 32 in the reservoir 30, through a tube 46 which is connected to the tube 32 by a fitting 32', through a tube 47 through the open valve 50, into the tube 14, and then into the tube 12, which is connected to a tube 14 by means of a fitting 12', thereby deposits this liquid into the chamber 10. As liquid 17 flows into the chamber 10, gas 19 is displaced. This displaced gas flows out through the outlet port 18, through a tube 26 which is connected to the outlet 18 by means of a fitting 18', through the open valve 52, through a tube 45, and into the reservoir chamber 30 through fitting 34' and port 34. As the injector 10 is filled, gas 19 displaced from the closed injector is transferred to the reservoir 30. This prevents any fumes which might be contained in the gas from venting into the atmosphere. This first or "injector fill" mode is initiated by the service person by operating valves or switch operated valves on the control panel 80. For the embodiment being disclosed, it will be assumed that switches are used to operate the valves. More specifically, switch 90 is set "on" to open the valve 50, and switch 91 is set "on" to open the valve 52. These switches are left "on" until the desired amount of liquid 17 flows into the chamber 10 as indicated by the liquid level 11 as read with the sight glass 13 and calibration marks 15.
Once a measured amount of liquid, which is oil in this example, is drawn into the injector chamber 10, the second mode of operation is initiated to transfer this oil from the injector assembly to the equipment being serviced (not shown). The valves 50 and 52 are closed by means of the switches 90 and 91 as illustrated in FIG. 1. Valves 54 and 56 are then opened by setting switches 92 and 93 in the "on" positions, respectively. Compressed gas from a cylinder or compressor source 70 passes through a tube 71, through a tube 72 and open valve 56, through the tube 24 and into the injector chamber 10 through the port 16 and fitting 16' Gas pressure is preferably monitored by the pressure gauge 66. The gas entering the chamber 10 forces the measured amount of liquid up through the tube 12 and through fitting 12' and tube 14, through the open valve 54, through a tube 55 which connects with a service hose 100. This service hose connects with the apparatus being serviced which, in this example, is an air conditioning system which is receiving the measured amount of oil. It should be understood that it is not necessary to inject all liquid within the chamber 10 into the apparatus being serviced. As an alternate, only a metered portion of the total content can be injected by observing the change in liquid level 11 as indicated by the sight glass calibration marks 15. Again, this mode of operation is initiated and terminated by the service person operating switches on the control panel 80.
Even though the a reading of the sight glass 13 indicates that the desired amount of liquid 17 has been driven from the injector chamber 10, a portion of the oil still resides within the conduits in the interaction component 60 and in the service hose 100. The conduit 55 and service hose 100 typically contain most of this residual liquid, since the valves and other components are preferably within the service cart and the other tubes are relatively short. It is desirable, therefore, to purge residual liquid from the tube 55 and service hose 100. This is accomplished by setting the switches on the control panel 80 for the third operational mode as indicated in FIG. 1 More specifically, the switches 90, 91, 92 and 93 are "off", closing their respective valves, and switch 94 is set "on" thereby opening valve 58. Compressed air or gas then flows through tube 71, open valve 58, tube 55 and the service hose 100 thereby purging all residual liquid from these flow paths.
Upon completion of the third operational mode, the service system is ready to perform another service task. The next task, like the example of the previous service task, can employ the invention in the open loop flow pattern. Other service tasks that can be performed using this open loop flow pattern include flushing a piece of equipment where the flushing solvent is not recirculated, servicing a pneumatic tire with sealant (see FIG. 1B) and then inflating the tire with air or gas such as nitrogen, filling an engine crank case (FIG. 1A) with lubricating oil, filling a vehicle transmission with hydraulic oil, and the like as indicated in FIG. 1.
OPERATION USING A CLOSED LOOP FLOW PATTERN
The invention can be operated using a closed loop flow pattern as will be illustrated with the following example, where the service task is to flush an air conditioning condenser with a liquid solvent, wherein the solvent is to be repeatedly circulated between the injector component and the radiator.
Attention is now drawn to FIG. 2 which shows that there are a total of ten two-way valves, whereas the flow paths depicted in FIG. 1 required only five two-way valves. Furthermore, the control panel 80 shown in FIG. 1 has been omitted from FIG. 2 for reasons of simplification and clarity, but it should be understood that the following operational steps are initiated and terminated by a service person operating the appropriate valves or switches on the control panel. As in operations depicted by apparatus in FIG. 1, all control panel valves should be in the closed position before the initiation of any service. Furthermore, all switches should be closed immediately upon completion of that mode, before going to the next mode.
Still referring to FIG. 2, the first mode of operation consists of filling the injector chamber 10 with a specified amount of liquid solvent 17, drawn from the reservoir component 30, by opening the valves by opening valves 312, 306, 300, and 318, and operating the pump 63 as described previously in the open loop example. The injector sight glass 13 is again used to monitor the amount of solvent that is drawn into the injector chamber 10.
Again referring to FIG. 2, in the second mode of closed loop operation comprises continuously circulating the solvent fluid 17. Valves 304, 314, 308 and 302 are opened. The pump 62 now serves as a circulation pump to move liquid out of the injector chamber 10 through the tube 12, the port 12' and the tube 14, through open valve 304 through tube 184 to flush connector inlet 160 which is attached to the inlet of the condenser 199. After the solvent enters the condenser 199, it removes and carries contaminants outward through a flush connector outlet 162 by means of a tube 189, passing through an open valve 314, then through a filter/strainer 23 to remove contaminants before continuing to flow to the pump 62 through a pump inlet 80 After passing through a pump outlet 81, the filtered liquid is ready to be recirculated back to the injector 10 by first passing through an open valve 308, by means of a tube 73, to an open valve 302, through the fitting 16' and into the injector by means of the port 16
After circulating solvent 17 for the desired time period, a the third mode of operation is initiated by setting appropriate valves or switches on the control panel 80 (not shown in FIG. 2). As in the previous example, the purpose of this third mode is to purge solvent from the service system, and the apparatus being service, using the source 70 of air or gas. This step is similar to the third mode of open loop operation in that the purge solvent is returned to the reservoir component 30 for future use. More specifically, compressed air flows from the source 70, through a tube 71, through open valve 310, and then through tubes 72, 74 and 184 to the condenser inlet fitting 160. Residual liquid is thereby forced from the condenser 199 by the air pressure, out through the flush connector outlet 162, through the valve 316 and back into the reservoir 30 by means of the tube 42, the fitting 34' and the port 34.
The use of the service system in the previously described closed loop mode of operation is by no means restricted to the example of flushing an air conditioning radiator with solvent. It should be understood that the service system operating in this mode can be used to perform any type of service task which comprises the circulation of fluid within a closed loop system.
FIELD OPERATIONS
As mentioned previously, the invention is ideally suited for field operation and for operation in facilities requiring numerous service carts. For installations requiring multiple service carts, certain required elements can be supplied to the individual service carts from central sources. Such an installation is shown in FIG. 3 which depicts three service system workstations, mounted on service carts, and denoted by the numeral 200. Each service cart 200 has a set of wheels 230 for ease of movement to the vicinity of the apparatus being serviced.
In FIG. 3, the invention is shown servicing automobiles 210 and, in the enlarged view, the air conditioning unit of the automobile. Flow paths are established between the work station 200 and the air conditioning unit being serviced by flow conduits 254 and 256 which are preferably flexible hoses for convenience. The control panel 80 is shown with several representative functional switches, where some will be specifically discussed in following sections. The injector reservoir 10 and sight glass 13 are shown mounted on the top of the service cart for easy viewing by the service person.
Certain materials or "elements" are supplied to the plurality of service carts 200 from a remote, fixed sources. Four such generic remote sources or "reservoirs" are labeled 400, 401, 403 and 404 in FIG. 3. These elements are delivered to and from the service area as shown by flow arrows preferably by overhead plumbing conduits, such as pipes, identified as a group by the numeral 235. The various elements are supplied to the individual service carts by drops 240 which are tapped into the overhead plumbing pipes 235. As an example, if the cart 200 is used in a service operation which involves the use of a vacuum, the source 400 can comprise a central vacuum pump, and vacuum can be supplied by this central vacuum pump to the service carts by means of the appropriate overhead pipe 235 and corresponding drop lines 240. A vacuum is usually needed when the service cart is used to evacuate a serviced item, such as an air conditioning unit prior to filling with refrigerant and oil. As a second example, the previously described source of compressed gas or air can be supplied from a central compressor or cylinder, identified as the source 404 for purposes of discussion, and plumbed to the individual service carts by means of the corresponding pipe 235 and drops 240. When as a third example the invention is used to service air conditioning and refrigeration equipment, it is desirable to remove and to retain refrigerant and oil prior to servicing, recover the refrigerant from the oil, and reuse the refrigerant and oil if possible. Refrigeration recovery units on each service cart 200 are not practical from an operational and an economic viewpoint. It is desirable, therefore, to direct recovered refrigerant and oil from individual service carts 200, and to transfer this recovered fluid up an appropriate drop line to an overhead pipe 235, and subsequently to a single, central refrigerant recovery system which is defined as remote reservoir unit 403 for purposes of discussion. Such a recovery system comprises an oil-refrigerant separator chamber, an inlet for recovered refrigerant, an outlet for the separated refrigerant, and a drain for the "settled" oil. Recovered refrigerant can then be transferred to the remote reservoir 404 and then returned to the service carts 200 by means of the appropriate overhead pipe 235 and corresponding drops 240. Other materials, such as engine oil, brake fluid, sealant, coolant, specific purge gases such as nitrogen, automatic transmission fluid and the like can effectively be supplied to a plurality of service carts from a single, remote source, such as illustrated in FIG. 3.
There are applications of the invention which require remote and relatively self contained service carts 200. As mentioned previously, it is sometimes preferred that the materials or elements not be supplied from remote source reservoirs which is plumbed to one or more service carts, but rather from one or more reservoirs which are actually mounted on the individual service carts 200. Such a reservoir might be a cylinder 30' of virgin refrigerant as illustrated in FIG. 3. It should be understood that, in principle, each service cart can contain all elements previously discussed, but the system depicted in FIG. 3 is operationally and economically desirable as a delivery system for many elements as discussed in previous sections.
It is noted that the function of the compressed air or gas source can be performed by means other than the air/gas source 70 shown in FIGS. 1 and 2. As an example, if an air conditioning unit is being serviced, the unit itself can be used to perform the functions performed by the air/gas source 70 in previous examples. More specifically, the refrigeration oil can be forced by pressure from the injector reservoir 10 by the "high" pressure side of the air conditioning system while monitoring the amount by visually monitoring the injector chamber sight glass.
SUMMARY
The previous description of apparatus and methods of the invention serve to illustrate the versatility of the invention in performing many service tasks. There are other embodiments and applications of the invention which will be apparent to practitioners of the art.
The invention is essentially a manifold which can be configured for specific applications to "in-source" and "out-source" required elements through an open or closed loop flow pattern, the total embodiment of whose functions comprise the use of three base components which have been fully disclosed herein.
While the foregoing is directed to the preferred embodiments, the scope thereof is determined by the claims which follow. | This invention is directed toward apparatus and methods for servicing equipment such as air conditioning systems, refrigeration systems, engines, transmissions, and tires More particularly, invention is directed toward a system for safely transferring precisely measured quantities of a variety of liquids and gases to the serviced item using essentially a single work station apparatus cooperating with multiple reservoirs of fluids. Furthermore, one or more types of fluids can be supplied, from remote reservoirs, to one or more mobile work stations. Fluids can also be withdrawn from the apparatus being serviced, and reprocessed for future use. Stated another way, the invention eliminates the need for dedicated service equipment to provide each applicable service. This invention is suitable for many market segments such as commercial, industrial, marine, utility, and the like. Government, military, public and private sectors of the economy will benefit from the use of this invention. | 5 |
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