description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
COPYRIGHT MATERIAL
The disclosure of this patent contains material which is the subject of copyright protection. Reproduction of the patent document as it appears in the Patent and Trademark Office is permitted in furtherance of the United States Patent Laws (Title 35 United States Code). The copyright owner reserves all other rights under the United States Copyright Laws (Title 17 United States Code).
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is a reflective, magneto-optic spatial light modulator (MOSLM™) assembly that protects an electrically addressable chip, which is formed from a structurally fragile magneto-optic material, against damage resulting from excessive mechanical shock and temperature excursions.
2. Description of the Related Art
The recent developments in magneto-optic display assemblies now provide a two-dimensional array of electronically programmable light shutters or valves that can be used to enter information into data processing systems, such as optical correlators, at very high rates. (For an example of one magneto-optic display assembly, see William E. Ross' U.S. Pat. No. 4,550,983 which is assigned to the same assignee.) Coherent, polarized light is used for information processing and can either pass through or be reflected by these magneto-optic light valves where the light is rotated and analyzed in accordance with either the Faraday or the Kerr effects, respectively.
These electrically addressable, such as by coincident current select, magneto-optic light valves are sometimes also identified as a spatial light modulator (SLM) chip. One such SLM chip known in the industry as a LIGHT-MOD™ chip is available from the Data Systems Division of Litton Systems, Inc. at Agoura Hills, Calif. This LIGHT-MOD chip has at its heart a magneto-optic active area having a square side dimension of 0.128 inch (0.325 centimeter) that is structured into a plurality of individual mesas or pixels which are arranged in a 128×128 array. This array is electrically addressable through the use of complementary X- and Y-address conductors so that selected and non-selected pixels function as light valves having visually different and distinct illumination characteristics.
Physically, the SLM chip is an electromagnetic device. The SLM chip is temperature dependent since it loses desirable electromagnetic functions when the chip temperature reaches the Curie point of the particular magneto-optic material which forms the chip. Further, like all semiconductor wafer materials, the magneto-optic chip exhibits extreme fragility. Therefore, the chip can be subject to unwanted cracking or fracturing, even physical shattering, under adverse mechanical forces and resultant deformations affected upon at least the chip.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the invention to provide a new and improved reflective magneto-optic spatial light modulator (MOSLM™) assembly having a mechanically and thermally protected spatial light modulator (SLM) chip.
It is an object of the invention to provide a reflective MOSLM assembly that channels the ingress and egress of electromagnetic radiation, such as light, incident to the assembly.
It is an object of the invention to provide a reflective MOSLM assembly having a controlled temperature environment that maintains the SLM chip at a temperature less than its Curie point.
It is an object of the invention to provide a reflective MOSLM assembly that is extremely rugged to withstand adverse mechanical forces imposed upon the assembly.
It is an object of the invention to provide a reflective MOSLM assembly that is readily addressable when used in an operating system.
It is an object of the invention to provide a reflective MOSLM assembly stress the MOSLM assembly through heat expansion of its components.
SUMMARY OF THE INVENTION
Briefly, in accordance with the invention, a reflective magneto-optic spatial light modulator (MOSLM™) assembly is disclosed and claimed having a nonmagnetic protective housing that receives, positions, and protects a spatial light modulator (SLM) chip that is formed from relatively fragile magneto-optic material from deformations caused by mechanical stress and by excessive temperature changes, and the assembly further having a channelled ingress and egress of incident electromagnetic radiation, Such as visible and coherent light, to and from the SLM chip.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, the organization and method of operation, together with further objects, features, and the attending advantages thereof, may best be understood when the following description is read in connection with the accompanying drawing(s).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the relflective magneto-optic spatial light modulator (MOSLM™) assembly of the invention.
FIG. 2 is an exploded, perspective view of the reflective MOSLM assembly of FIG. 1.
FIG. 3 is a cross section view of the reflective MOSLM assembly of FIG. 1 along the line 3--3.
FIG. 4 is an end or bottom view of the reflective MOSLM assembly of FIG. 3.
FIG. 5 is a perspective view of the reflective MOSLM assembly of FIG. 1 ready for use in an operating system.
DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 3, a preferred embodiment of the reflective magneto-optic spatial light modulator (MOSLM™) assembly 10 of the invention includes a nonmagnetic case or housing 12, which can be formed from an epoxy glass, that has a singular, outer case wall 14 with an inner wall surface 16 which defines or develops an inner chamber 18 having a predetermined or selected chamber volume.
The inner chamber 18 as shown by FIGS. 2 and 3, is adapted to receive and contain the following subcomponents. A heat dissipater 20, which can be formed from aluminum nitride, for the dissipation heat energy. A diamond substrate heat spreader or transfer layer 22 that is spaced apart from the reverse surface of the dissipator body by a gap 23 which can be filled with a conventional thermally conductive fluid. During initial alignment of the assembly 10, a conventional shim member sized to the desired gap dimension can be used to set and maintain the gap 23. A spatial light modulator (SLM) chip 24, as described above with reference to the LIGHT-MOD™ chip, positioned adjacent to the transfer layer 22 and surrounded in a common plane by an electromagnetic coil 26. The coil 26 is also positioned in relatively close proximity to a conventional thermal sensor chip 28. Both the coil 26 and thermal sensor chip 28 have a conventional electrical connector 25 (see FIG. 5) that provides the desired electrical interface with operational control devices (not shown) external to the reflective MOSLM assembly 10.
The obverse surface of the heat dissipater 20 is bounded by a thermoelectric cooler 30, which is a conventional Peltier effect device for the dissipation of heat energy, that closes the complementary obverse, open end of the inner chamber 18 defined within housing 12 and is in direct, heat transfer contact with heat dissipater 20.
In the assembled arrangement the reflective MOSLM assembly 10 as shown by FIGS. 1 and 3, a heat transfer path is established for the dissipation of heat energy from the SLM chip 24 through the heat transfer layer 22, gap 23 and the conductive fluid therein, to the heat dissipater 20 where thermoelectric cooler 30 accomplishes the desired primary cooling of the SLM chip 24 as one source of heat energy, and secondary cooling of the other sources of heat energy, e.g., the coil 26 which is selectively pulsed during operaton of the SLM chip 24 within the inner chamber 18 of case 12.
This assembly of subcomponents within the nonmagnetic case 12 is guided into proper final assembly with a carrier plate 32, which can be formed from alumina, through the cooperative relationship of a pair of similar guide pins 34 (only one guide pin is shown by FIG. 2) that mate with complementary clear holes 35 formed in the carrier plate. Case 12 can be temporarily joined to the carrier plate 32 by one or more similar conventional fasteners 36 which are removed after alignment of the final reflective MOSLM assembly 10. The entire reflective MOSLM assembly 10 is preferably joined together with adhesives for final use in its operative mode.
A conventional planar flex connector cable 38 as shown by FIGS. 2 and 5 is sandwiched between the case 12 and the carrier plate 32. This connector cable 38, which can be formed of Kapton (a registered trademark material of DuPont), has a plurality of electrical conductors therein that are connected to electrically address one or more pixels in the magneto-optic pixel array of the SLM chip 24.
Referring now in particular to FIGS. 3 and 4, the carrier plate 32 contains an aperture 40 which complements an aperture 42 formed in flex cable 38. These complementary channel apertures 40 and 42 expose the SLM chip 24 to active incident electromagnetic radiation, such as visible light. For example, one visible light can be the coherent light produced by a laser source which has been suitably collimated, filtered and polarized as an optical light beam with or without information content.
An SLM "lens" or mask 44, which can be formed from alumina, is sized to complement the carrier plate aperture 40. This mask 44 has a central aperture 46 that functions as a clean, channel guide for the controlled entrance or ingress, as well as egress, of the optical light beam into the reflective MOSLM assembly 10 so that the light beam is constrained both to "paint the optimum pattern or picture" onto the active, working pixel array of the SLM chip 24 and to reflect the resultant pattern or picture from the chip. Mask 44 is preferably positioned within the carrier plate aperture 40 in a common plane with proper alignment of the complementary apertures 40 and 42. Mask 44 can be attached to the SLM chip 24 with an adhesive after final alignment is made.
Lastly, the completed reflective MOSLM assembly 10 is shown by FIG. 5 as a useable component for an optical information processing system; for example, a reflective optical correlator system.
As will be evidenced from the foregoing description, certain aspects of the invention are not limited to the particular details of construction and of function as illustrated and described. It is contemplated that modifications and other applications will occur to those skilled in this art. However, it is intended that the appended claims shall cover such modifications and applications which do not depart from the true spirit and scope of the present invention. | A reflective magneto-optic spatial light modulator (MOSLM™) assembly has a nonmagnetic protective housing that receives, positions, and protects a spatial light modulator (SLM) chip that is formed from relatively fragile magneto-optic material from deformations caused by mechanical stress and by excessive temperature changes. The assembly further has a channelled ingress and egress of incident electromagnetic radiation, such as visible and coherent light, to and from the SLM chip. | 6 |
CLAIM OF PRIORITY
The present application claims priority from Japanese patent application serial no. 2007-303317, filed on Nov. 22, 2007, the content of which is hereby incorporated by reference into this application.
BACKGROUND
The present invention relates to an optical transmission system and an optical node, and more particularly to an optical transmission system and an optical node capable of receiving a transmitted signal at plural nodes. The rapid increase in data traffic, typically over the Internet, is pushing ahead the expansion of transmission capacities of communication networks. Capacity expansion is achieved by converting transmit signals into optical signals and utilizing time division multiplexing or optical wavelength division multiplexing. A transmission device whose capacity is 10 gigabits per second per channel is now available for practical use. A point-to-point wavelength division multiplexing transmission device, which is capable of transmission for a long distance of over hundreds of kilometers by wavelength-multiplexing a few channels to dozens of channels into a single optical fiber using an optical amplifier, regenerator or the like, is now also available for practical use. To meet the increase in demand for greater transmission capacity and the requirements for further economization and service diversification, a ring-shaped optical network annularly connecting communication nodes or a mesh-shaped optical network having meshed connections to increase the flexibility of route selection are under study. The optical transmission system to be used in the ring-shaped optical network is known as an Optical Add-Drop Multiplexer (OADM). The optical transmission system to be used in the mesh-shaped optical network is known as an Optical Cross-Connect (OXC). Such optical networks can be expected to help simplify the operation by the use of a network monitoring and controlling system placing node devices under remote and centralized management or to facilitate end-to-end path management from the start point to the end point of the circuit and increase the speed of path establishment by the mutual linking of the monitoring and controlling units of the node devices.
Further, the use of a configuration in which sophisticated optical transmission technology is used to pass optical signals through nodes as they are, without electrical or optical conversion, enables the whole network to be economically realized. In an optical transmission systems used in such an optical network, one-to-one bi-directional communication is usually accomplished. In OADM and OXC, optical switches are used for the selection of add-drop/through processing or route changing-over of optical signals. At present, known optical switches for such purposes include semiconductor switches and LiNO3 switches utilizing variations in refractive index caused by applying an electric field to the material, Planar Lightwave Circuit (PLC) type switches utilizing variations in refractive index caused by applying heat to the material, movable optical switches in which the position of the optical fiber or the lens is shifted by using an electromagnet, and Micro-Electro-Mechanical Systems (MEMS) type switches in which a micro-mirror fabricated by semiconductor technology utilizing electrostatic power is controlled. There is also known a Wavelength Selective Switch (WSS) which is provided with not only a switch-over function but also a wavelength division multiplexing function using MEMS or liquid crystal technology. WSS is also capable of performing a bridging function to output signals of the same wavelength to two output ports (also known as a drop-and-continue function). A WSS having the bridging function is described in S. Frisken et al. “High performance ‘Drop and Continue’ functionality in a Wavelength Selective Switch”, OFCNFOEC2006 postdeadline PDP14. On the other hand, audiovisual content delivery is discussed as an aspect of increasingly diverse communication services. In delivering audiovisual contents, reception of optical signals transmitted from a given node by N (N>1) nodes can be more economical than audiovisual content delivery using a router. A transmission managing device and a transmission managing method for such one-to-N type communication is disclosed in JP-A No. 2000-031969. According to the invention disclosed in JP-A No. 2000-031969, each of the one-to-N type paths is managed as one of N mutually independent virtual paths. In one-to-one type communication, bi-directional communication in which signals flow in two directions is frequently used, and in that case the type of path used is a bi-directional path. In one-to-N type communication on the other hand, the direction from “1” to “N” being supposed to be the downlink and that from “N” to “1”, the uplink, it is considered that there is a state of one-way communication or traffic transmitted from “1” and received by “N” in which the downlink is heavier. If one-to-N type communication can be achieved with an optical transmission system performing one-to-one type communication as stated above, an efficient network can be architected because paths of different types can be covered by a transmission system of only one type. However, this is regarded as involving the following problem. Namely, since it is possible for optical signals which would otherwise be on the uplink to disappear, an unexpected alarm would be issued. Moreover, pass management is made more complex by the mixed presence of one-to-one type paths and one-to-N type paths.
SUMMARY
The problem noted above can be addressed by an optical transmission system including plural optical nodes capable of dropping or adding optical signals and a monitoring and controlling device that monitors and controls these optical nodes, wherein each of the optical nodes is provided with an optical transceiver and an optical add-drop unit that sends out optical signal from the optical transceiver to a transmission line or guides optical signal from the transmission line to the optical transceiver; the optical add-drop unit, regarding add signals, selects optical signals from the optical transceiver of an own node thereof or optical signals from a second transmission line for optical signals to be sent out to a first transmission line, and regarding drop signals, drops signals from the first transmission line to the own node thereof and at the same time sends out the same to the second transmission line or blocks the same to the second transmission line; and an alarm inhibiting device is further provided that, regarding transmit signals from a first optical transceiver of a first optical node, inhibits any unexpected alarm from being issued by the first optical transceiver when selection is made by the optical add-drop unit of a second optical node to drop the signals to the own node thereof and to send the same out to a transmission line in a downlink direction. The problem can also be addressed by an optical node including an optical transceiver and an optical add-drop unit that sends out optical signal from the optical transceiver to a transmission line or guides optical signal from the transmission line to the optical transceiver, wherein when the optical add-drop unit, regarding drop signals, drops signals from a first transmission line to the own node thereof and sends out the same to a second transmission line, the optical add-drop unit, regarding add signals, selects optical signals from the optical transceiver of the own node thereof as optical signals to be sent out to the first transmission line and blocks receive signals from the second transmission line.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described in conjunction with the accompanying drawings, in which:
FIGS. 1A to 1C are block diagrams illustrating network forms;
FIG. 2 is a block diagram of an optical transmission system;
FIG. 3 is a block diagram of an optical node;
FIGS. 4A and 4B are block diagrams illustrating possible configurations of a WDM optical switch;
FIGS. 5A and 5B are block diagrams illustrating the configuration of a wavelength selective switch;
FIG. 6 is a block diagram illustrating the flows of main signals and the states of dropping and addition in an optical transmission system;
FIG. 7 illustrates a screen displaying a list of paths;
FIG. 8 illustrates the control of dropping and addition when a receiving node is to be added to the optical transmission system; and
FIG. 9 lists the states of drop function parts and of add function parts in the WDM optical switches.
DETAILED DESCRIPTION
Modes of implementing the present invention will be described below with reference to preferred embodiments thereof in conjunction with the accompanying drawings. Herein, FIGS. 1 A to 1 C are block diagrams illustrating network forms; FIG. 2 is a block diagram of an optical transmission system; FIG. 3 is a block diagram of an optical node; FIGS. 4A and 4B are block diagrams illustrating possible configurations of a WDM optical switch; FIGS. 5A and 5B are block diagrams illustrating the configuration of a wavelength selective switch; FIG. 6 is a block diagram illustrating the flows of main signals and the states of dropping and addition in an optical transmission system; FIG. 7 illustrates a screen displaying a list of paths; FIG. 8 illustrates the control of dropping and addition when a receiving node is to be added to the optical transmission system; and FIG. 9 lists the states of drop function parts and of add function parts in the WDM optical switches.
Embodiment 1
Network forms will be described with reference to FIGS. 1A to 1C . FIG. 1A shows a configuration having two offices 20 -A and 20 -B at the terminal points and office 20 -C between office 20 -A and office 20 -B, which are connected to one another by transmission line fibers. It is a linear-shaped network in which at least part of signals added at office 20 -A or office 20 -B can be dropped at office 20 -C and other signals can be added at office 20 -C. Solid lines here indicate that paths are set between office 20 -A and office 20 -B, between office 20 -A and office 20 -C, and between office 20 -C and office 20 -B.
FIG. 1B shows a ring-shaped network. In the ring-shaped network, office 20 -A, office 20 -B, office 20 -C and office 20 -D are connected to the respectively adjoining offices 20 by transmission line fibers. As the network constitutes a ring, even if a fiber runs into fault in one position, the network can be protected by transmission in the reverse way. Moreover, the network can be operated with relative ease. Solid lines here indicate that paths are set among office 20 -B, office 20 -A and office 20 -C, between office 20 -C and office 20 -D, and between office 20 -B and office 20 -D. A mesh-shaped network shown in FIG. 1C is a network in which office 20 -A, office 20 -B, office 20 -C, office 20 -D and other offices 20 not shown are connected by transmission line fibers in a mesh shape. Solid lines here indicate that paths are set between office 20 -A and office 20 -B, between office 20 -A and office 20 -D, among office 20 -A, office 20 -C and office 20 -D, and between office 20 -B and office 20 -D. A mesh-shaped network, though more difficult to operate and manage than a ring-shaped one, is more flexible in many respects, such as permitting rerouting of paths or load balancing according to conditions. Next, the configuration of an optical transmission system will be described with reference to FIG. 2 . An optical transmission system 10 includes optical nodes 20 , transmission line fibers 70 connecting the optical nodes, an integrated monitoring and controlling unit 90 , a monitoring and controlling network 100 for delivering and receiving monitoring and controlling signals between the integrated monitoring and controlling unit 90 and the optical nodes 20 , and a repeater 110 disposed between the transmission line fibers 70 . The integrated monitoring and controlling unit 90 performs configuration management, fault management, bandwidth management, performance management, security management and so forth of the network. The integrated monitoring and controlling unit 90 , in order to secure a communication bandwidth sufficient for meeting the demand between any combination of optical nodes 20 , references configuration management information and fault management information to select resources available to the pertinent optical nodes 20 and a fault-free path, and sets a communication channel or path by controlling plural optical nodes including the pertinent optical nodes.
Between the optical nodes 20 , the repeater 110 which performs linear repeating to extend the transmission distance is disposed. The repeater 110 includes a linear repeating device 111 which amplifies optical signals from another transmission line fiber and transmits them to still another transmission line fiber and a repeater monitoring and controlling unit 116 for monitoring the linear repeating device 111 . For the repeater 110 , an item having appropriate functions and performance features for maintaining a prescribed main signal quality standard according to the transmission distance, the fiber type and the position of office building is selected. The main signal quality standard is so set as to keep the bit error rate at no more than 10^-12 (10 −12 ). Plural repeaters 110 may be disposed between the optical nodes 20 . The linear repeating device 111 collectively amplifies wavelength multiplexed signals with an optical fiber amplifier using Erbium-doped fibers or the like, and monitors the optical power and wavelength. A regenerator may be applied in place of the linear repeating device 111 . The regenerator once converts optical signals having traveled over the transmission line into electric signals, and performs waveform reshaping, retiming, regenerating and digital quality monitoring, including in specific terms bit error monitoring by a method known as Bit Interleaved Parity (BIP). Each of the optical nodes 20 includes plural interfaces (IFs) 60 connected to client devices, optical amplifiers (OAs) 50 connected to the transmission line fibers 70 , a WDM optical switching unit 40 connected to the IFs 60 and the OAs 50 , and a node monitoring and controlling unit 30 which monitors the constituent elements 40 through 60 and is connected to the integrated monitoring and controlling unit 90 via the monitoring and controlling network 100 . Further details of the optical nodes 20 will be described with reference to FIG. 3 .
The integrated monitoring and controlling unit 90 may use a centralized control system by a single server or redundant servers. Alternatively, a distributed control system in which device monitoring and controlling units communicate with each other to exchange network status information or route calculation, or a combination of these systems may be used as well. Where a distributed control system is used, the integrated monitoring and controlling unit may be either dispensed with or simplified. Available inter-device communication control techniques for distributed control systems include a group of protocols of Generalized Multi Protocol Label Switching (GMPLS) prescribed by RFC3471-3473 and so forth of The Internet Engineering Task Force (IETF). The optical amplifiers may be optical semiconductor amplifiers instead of optical fiber amplifiers. The repeater 110 may be an optical 2R or optical 3R repeater which has effects to reshape the waveform and to improve the signal-to-noise ratio by utilizing the nonlinear effects and the like in fibers or semiconductors without having to convert optical signals into electric signals as long as it has a function to extend the transmission distance. The repeater may have a configuration in which only the desired line out of plural lines is dropped or added by using an optical multiplexer/demultiplexer filter or an optical switch. A device which accomplishes this dropping/adding without converting optical signals into electric signals is known as an OADM. Next, the configuration of the optical node will be described with reference to FIG. 3 . Each of the optical nodes 20 includes the node monitoring and controlling unit 30 , the WDM optical switching unit 40 which changes over between wavelength division multiplexing and demultiplexing and the main signals, the interfaces (IFs) 60 which perform overhead processing, main signal quality monitoring using the BIP, accommodate signals from a client device 80 and convert them into the wavelength outputted to the transmission line, and the optical amplifier (OA) 50 which, with respect to signals from plural IFs 60 , amplifies signals wavelength-multiplexed via the WDM optical switch as optical signals and delivers them to transmission line fibers. The IFs 60 may process error correction as set forth in the ITU-T Recommendation G. 709 to compensate for quality deterioration resulting from such factors as an extension of the transmission distance, seasonal fluctuations of fibers, loss fluctuations due to any external physical force and deterioration of parts over time. The IFs 60 accommodate signals from the client device 80 which are interfaced by STM-16 (2.5 Gbit/s), STM-64 (10 Gbit/s) and STM-256 (40 Gbit/s). The IFs 60 convert them into signals of OTU-1 (2.7 Gbit/s), OTU-2 (10.7 Gbit/s) and OTU-3 (42.8 Gbit/s) each prescribed by ITU-T G.709 OTN and having a wavelength prescribed by ITU-T, and outputs the converted signals to the WDM optical switching unit 40 . The IFs 60 also convert signals from the WDM optical switching unit 40 in the reverse way to the foregoing. The IFs 60 may further have a function to regenerate and repeat signals transferred from one transmission line to another transmission line into signals of OTU-n (n=1, 2, 3).
As client signals, GbE (1 Gbit/s) prescribed by IEEE 802.3z and 10GbE (10.3 Gbit/s) prescribed by IEEE 802.3ae are also accommodated. The speed of interfacing with the WDM optical switching unit 40 involves the addition of the proportion of error correcting codes, about 7% to 25%, to the speed of the applicable one of these signals. The WDM optical switching unit 40 selects the output destination routes of signals from the IFs and performs wavelength division multiplexing. The WDM optical switching unit 40 includes a WDM optical switch 41 , a CPU 42 , a switching state table 43 , a performance information table 44 , a fault information table 45 and a driving control unit 46 , all connected to the CPU 42 by internal communication lines, and a communication control unit 47 connected to the CPU 42 and to the node monitoring and controlling unit 30 . The node monitoring and controlling unit 30 includes a CPU 31 , a configuration management information storage unit 32 , a fault management information storage unit 33 , a performance management information storage unit 34 and a switching management information storage unit 35 , all connected to the CPU 31 by internal communication lines, and a communication control unit 36 connected to the CPU 31 , the integrated monitoring and controlling unit 90 , the WDM optical switching unit 40 , the IFs 60 and the OAs 50 . The OA 50 amplifies signals from the WDM optical switching unit 40 and delivers the amplified signals to the transmission line fiber 70 . The OA 50 also amplifies wavelength-multiplexed signals from the transmission line fiber 70 and delivers the amplified signals to the WDM optical switching unit 40 . Further, the OA 50 multiplexes/demultiplexes signals for monitoring and control. The optical power of delivery to the transmission line fiber is determined with account taken of the number of wavelengths, losses on transmission lines between optical nodes, the Optical Signal-to-Noise Ratio (OSNR) due to the noise figure of the optical amplifier, and the waveform deterioration or noise increase due to nonlinear effects, chromatic dispersion or polarization mode dispersion in the fibers. Known nonlinear effects include Self Phase Modulation (SPM), Cross Phase Modulation (XPM) and Four Wave Mixing (FWM). The extent of waveform deterioration is dependent on the number of wavelengths, the dispersion of fibers, a nonlinear constant, input power to the fibers and losses on optical fibers and so forth. The dispersion of fibers and nonlinear constant differs whether the fibers are single mode fibers (SMF) or dispersion-shifted fibers (DSF). Even DSFs of the same kind may differ from one product to another. The output power of the amplifier before delivering signals to the IF 60 is determined with account taken of the loss of the WDM optical switching unit 40 , OSNR at the ends of the path, and the dynamic range of the receiver and receiver sensitivity. A dispensation compensation function to cancel waveform distortion by wavelength dispersion may be built into the OA 50 or the IF 60 . Commercially available means for realizing dispensation compensation function include a dispensation compensation fiber different in sign from the transmission line fibers, fiber diffraction grating, optical lens, resonator and what uses electric signal processing. As the wavelengths to be outputted from the IFs 60 , wavelengths on the wavelength grid prescribed by the ITU-T Recommendations G694.1 and G694.2 can be used. By setting appropriate transmitting conditions, the number of wavelengths can be selected from a wide variety including 8, 16, 20, 40, 64, 80, 128 and 160. Next, the configuration of the WDM optical switch will be described with reference to FIGS. 4A and 4B . The optical node 20 includes the WDM optical switching unit 40 and the OAs 50 . As the description here concerns the WDM optical switching unit, the IFs and other constituent elements whose description is dispensable will not be touched upon.
A number of ways are conceivable for the configuration of the WDM optical switching unit 40 . As shown in FIG. 4A , it may include a multiplexer/demultiplexer 180 , a drop function unit 140 and an add function unit 150 . Or wavelength selective switches 160 and 160 A may be applied as shown in FIG. 4B .
The multiplexer/demultiplexer 180 in FIG. 4A uses a PLC type element known as Arrayed Waveguide Grating (AWG). The drop function unit 140 uses an optical splitter. The add function unit 150 uses a 1×2 optical switch. The choice is not limited to the foregoing. The 1×2 optical switch may be what is formed by integrating plural channels. Next, the wavelength selective switch will be described with reference to FIGS. 5A and 5B . In FIG. 5A , a wavelength selective switch 160 includes a splitter 161 and a wavelength selector 166 . The splitter 161 splits each of input wavelength-multiplexed signals of λ 1 to λm into two wavelength-multiplexed signals of λ 1 to λm and outputs the split signals through two ports. The wavelength selector 166 , by receiving inputting of m wavelength-multiplexed signals of λ 1 , λ 2 , λ 3 , . . . , λm through Port_c and inputting a prescribed control signal, outputs one or plural desired wavelengths through any desired output port. The wavelength selector 166 is shown here in a case in which λ 1 and λ 5 are outputted through Port_ 1 , λ 2 , λ 7 and λm through Port_ 2 and λ 4 , λ 6 , λ 8 , . . . , λm-1 through Port_k. It is also possible here to effect such control as let no wavelength be outputted through a certain port. Further, control is so effected as to block λ 3 from being outputted through any output port. It is also permissible to call the wavelength selector the wavelength selective switch. FIG. 5B shows functional blocks of the wavelength selector. When a wavelength-multiplexed signal is inputted to the wavelength selector 166 through Port_c, it is demultiplexed by a demultiplexer 167 into the constituent wavelengths, and these wavelengths are inputted to optical switches 168 , one of which is made available for each wavelength. The lights differing in wavelengths inputted to the optical switches 168 are inputted to multiplexers 169 , one of which is made available for each output port, in response to a control signal. The multiplexers 169 wavelength-multiplex the lights differing in wavelength inputted from the optical switches, and output the multiplexed signals. It is possible in this way to input wavelength-multiplexed signals and take out from any desired output port lights of any desired number and wavelength. It is possible to realize a bridge in the drop function unit with a WSS described in S. Frisken et al. “High performance ‘Drop and Continue’ functionality in a Wavelength Selective Switch”, OFCNFOEC2006 postdeadline PDP14 or a WSS of the configuration described here and apply it to one-to-N type optical paths. Whereas the drop function unit was described with reference to FIGS. 5A and 5B , it is obvious to persons skilled in the art that, if the multiplexers 169 are caused to operate as demultiplexers and the demultiplexers 167 , as multiplexers, it will operate as the wavelength selective switch 160 A shown in FIG. 4B .
Next, the flow of main signals and the state of dropping/addition in the optical transmission system will be described with reference to FIG. 6 . The optical transmission system 10 includes the integrated monitoring and controlling unit 90 , the monitoring and controlling network 100 , an optical node office A 20 - 1 , an optical node office B 20 - 2 , an optical node office C 20 - 3 , an optical node office D 20 - 4 , the repeater 110 and the transmission line fibers 70 . Each of the optical nodes 20 includes the node monitoring and controlling unit 30 , the OAs 50 , the WDM optical switching unit 40 and the IF 60 .
In the case described below, a one-to-N type optical path is set from office A to offices B, C and D. On a usual one-to-one type optical path, as bi-directional communication takes place, there also are optical signals in the direction from office D to office A (hereinafter also expressed as “uplink”) together with optical signals in the direction from office A to office D (hereinafter also expressed as “downlink”). However, on a one-to-N type path, sometimes there may be only signals in the downlink direction, there can be an absence of receive signals at the IF 60 - 1 of office A. On a usual one-to-one type optical path, the IF 60 - 1 detects the absence of receive signals as an alarm, and notifies the fact to the integrated monitoring and controlling unit 90 via the node monitoring and controlling unit 30 - 1 . In the optical transmission system 10 of this embodiment in which one-to-one type optical paths and one-to-N type optical paths are used in mixture, IFs 60 of the same kind are used in common by the one-to-one type optical paths and the one-to-N type optical paths. Where IFs 60 are shared, in one-to-N type optical path setting, the IF 60 - 1 tries to issue an alarm because of the absence of receive signals. However, the integrated monitoring and controlling unit 90 issues a control signal to inhibit alarming by the receiver on the transmission line side of the IF 60 - 1 for use on the pertinent one-to-N type optical path of office A in setting the one-to-N type optical path. This enables, even after the setting of the one-to-N type optical path, any unexpected alarm from the IF 60 - 1 to be inhibited and unnecessary confusion of maintenance and operation to be prevented. Although the signal to inhibit alarming is supposed to be issued at the time of setting the one-to-N type optical path in the foregoing description, other methods are also available. Thus, when no optical path is set, alarming is inhibited and, when any one-to-one type optical path is to be set, the alarming inhibition is lifted. On the other hand, when any one-to-N type optical path is to be set, the alarm inhibition is maintained only for the receiver on the transmission line side of the IF 60 - 1 . A screen displaying a list of paths will now be described with reference to FIG. 7 . FIG. 7 shows a screen displaying a list of paths, which constitutes a user interface of the integrated monitoring and controlling unit 90 . A path listing screen 200 shows items including a path type 210 , a path name 220 , and the respective node names and IF mounting positions of the start point 230 and the end point 240 of each optical path. In this illustration, the items of one-to-one type optical paths 120 - 1 and 120 - 5 are displayed. Also, one-to-N type optical paths are displayed to which related path names 220 are assigned, each individually displayed with respect to the receiving node. Three path names are assigned to one-to-N type optical paths 120 - 2 through 120 - 4 each having three receiving nodes. The path name of each include signs of the start point node, end point node, route direction, optical path type such as one-to-one or one-to-N, presence or absence of redundancy, wavelength number and serial number. Regarding the optical path type, one-to-N type optical paths having the same transmitting node can be related to one another as a one-to-N type optical path group and managed collectively by assigning the same sign and number. More specifically, in the path name “A-B-W-M1-N-003-00002” of the one-to-N type optical path 120 - 2 , “A” represents the start point node; “B”, the end point node; “W”, from West to East; “M1” the first group of one-to-N type paths; “N”, no redundancy; “003”, the wavelength number; and “00002”, the serial number. Similarly, in the path name “B-A-E-U-P-012-00005” of the one-to-one type optical path 120 - 5 , “E” represents from East to West; “U”, the one-to-one type path; and “P”, 1+1 redundancy. In this embodiment, one-to-N type optical paths are assigned different but related names, and placed under individual management for each receiving node. As a result, stopping of an individual one out of the plural receiving nodes or the addition of a new receiving node is facilitated by referring group number of one-to-N type paths and so forth. Also, collective deletion of a set of one-to-N type optical paths having the same transmitting node or the same group number is facilitated. Further, when searching for or filtering one-to-N type optical paths having the same transmitting node or the same group number or related alarms or performance information, the efficiency can be enhanced, and spotting any fault or confirmation of the affected range can be facilitated.
Embodiment 2
Control of dropping and addition when a receiving node is to be added to the optical transmission system will be described with reference to FIG. 8 and FIG. 9 . In FIG. 8 , it is supposed that a one-to-N type optical path having office A as the transmitting node and offices B and C as the receiving nodes is set in the optical transmission system 10 . The flow of signals in this state is represented by thick solid lines. The states of the drop function unit 140 and the add function unit 150 in the WDM optical switching unit 40 are stated in the “Before addition” line in FIG. 9 . In FIG. 9 , the drop function unit is expressed as “D” and the add function unit, as “A”. In the list, “D.C.” means irrelevant and “DITTO”, the same as above. As the add function unit, a 2×1 optical switch or WSS can be used, and this unit is functionally a selector. Referring back to FIG. 8 , addition of office D as a receiving node to the one-to-N type optical path of the optical transmission system 10 will be described. The multicast path to be added is represented by a thick broken line. The states of the drop function unit 140 and the add function unit 150 of the WDM optical switching unit 40 then are stated in the “After addition” line in FIG. 9 . Thus, the downlink drop function unit of office D is placed in the drop state, and the uplink add function unit of office D, in the add state. The downlink drop function unit of office C is placed in a bridge state, in which the bridge state may be confirmed by an optical splitter 160 before addition, the downlink add function unit, in a through state, and the uplink drop function unit, in a through state. In this way, it is made possible to add office D as a receiving node without affecting the signals received by existing offices B and C.
Another way to inhibit alarming will be described with further reference to FIG. 8 . When a one-to-N type optical path is set from office A to offices B and C, control is effected not only on the drop function unit/add function unit in the downlink direction but also to have transmission signals on the dummy transmission line side to be transmitted from the IF 60 - 2 of office B and the IF 60 - 3 of office C as shown in FIG. 8 . It also controls the drop function unit/add function unit of office B and office C in the uplink direction. The numbers of wavelengths that pass the uplink/downlink optical amplifiers can be thereby kept equal. As a result, any unexpected alarm related to the number of waveforms, such as inconsistency in the number of wavelengths to detect any difference between the registered number of wavelengths and the number of wavelengths in actual use, can be inhibited. When information on the number of wavelengths is to be notified to each node via the supervisory signal, the numbers of wavelengths are the same between uplink and downlink at normal states. Namely, when it is to make distinction between normal and abnormal states regarding the number of wavelengths, the same handling is made possible as between one-to-one type optical paths and one-to-N type optical paths.
Although the foregoing description included a part which might give an impression that the drop function unit would be bridged in setting the one-to-N type optical path, this is a merely functional description. Actually, when signals are to be bridged by using an optical splitter as described above, even if a control signal is set on the device side, there will be no change in the real state of the optical signals. It is self-evident that the effect of this embodiment would be no different in this case either. As described so far, the optical transmission system of this embodiment allows no unexpected alarm to be issued even in the mixed presence of one-to-one type optical paths and one-to-N type optical paths. Therefore, it is considered extremely effective in having an optical transmission system perform audiovisual content delivery or the like. The optical transmission system according to the present invention allows no unexpected alarm to be issued even in the mixed presence of one-to-one type optical paths and one-to-N type optical paths and facilitates easy management of paths. | Where an integrated monitoring and controlling unit is to control an optical add-drop unit so as to cause transmit signals from the optical transceiver of a first optical node to be received by the optical transceivers of plural different optical nodes, this purpose can be achieved by an optical transmission system provided with an alarm inhibiting device that can inhibit the optical transceiver, which is a source of transmission, from issuing any unexpected alarm. | 7 |
This is a division of application Ser. No. 090,985, filed Nov. 5, 1979 now U.S. Pat. No. 4,369,093.
BACKGROUND AND FIELD OF THE INVENTION
In the paper-making industry, machines called "pulp machines" or "pulpers" prepare the paper pulp by breaking down cellulose materials which can be totally or partly materials to be recycled, such as old papers, boxes etc. In order to achieve this, the pulping machine is made of a fixed, open tub having a rotor in the form of a turbine. This tube is filled with water and with a certain amount of cellulose materials, and the rotor is then started up. The rotor causes energetic stirring of the water and the disintegration of the cellulose material which occurs in the form of dispersion or of a suspension and is discharged through perforations provided in the bottom of the tub.
In the standard kind of pulping machines, the concentration of dry cellulose materials has to remain quite weak, below 7% and generally about 5%, since otherwise the suspension is not liquid enough to be able to flow away and be discharged through the perforated sheet of metal forming the grating which usually surrounds the turbine.
In spite of this dilution, the discharge grating gradually becomes blocked up, as much by foreign bodies which are mixed with the cellulose material (clips, iron wires, string, etc) as by pieces of cellulose which have still not been broken down. Thus it is necessary to stop the pulping machine and to empty it, which involves a break in the production and a great loss of material, as well as being a source of pollution resulting from the disposal of these remnants.
In practice, the pulping machine is started up and it is interrupted when the flow of the discharged suspension falls below a certain value. The pulping machine is then half empty, which for a pulping machine of 30 m 3 represents 15 m 3 of the suspension with 5% of dry material, that is about 750 kg of dry material containing about 10% to 15% of impurities and 85% of good fibre. If the pulping machine is stopped and emptied three times in 24 hours, this means a loss of 1.3 tons of good fibre for 200 kg of impurities.
These figures explain the existing interest in trying to recover this fibre and avoid the pollution which results by its rejection.
SUMMARY OF THE INVENTION
The subject of the invention is a process and a device for resolving these problems.
The process according to the invention consists in regularly taking out a determined volume of the pulp filled with impurities contained within the pulping machine, stirring this pulp while progressively diluting it and at the same time extracting the fibre suspension which is recycled in the pulping machine, in order finally to empty the said volume when its fibre content is below a chosen value, up to the point where there only remains an impurity residue which is rejected.
This pulp transfer is preferably carried out in an enclosed volume of which the capacity does not exceed one tenth of that of the pulping machine and the discharge of this volume is brought about by introducing compressed air.
The device according to the invention consists of an enclosed volume annexed to the pulping machine, having a lateral stirring means and means for separation and of recycling by the pulping machine of the suspension of fibres, a pulp inlet controlled by a valve and connected to the lower part of the pulping machine, a bottom outlet for reject material, as well as a water inlet and a compressed air inlet.
Separation is preferably ensured by arranging the disc of the rotor set back with regard to the surface of the enclosed volume on which it is assembled, so as to define an extraction gap.
The enclosed volume is preferably in the general shape of a surface of revolution about a horizontal axis or an axis slightly inclined to the horizontal, terminated by two flat vertical sides or almost vertical sides, at the lower part of one of these is assembled the rotor of the enclosed volume.
Behind the rotor of the enclosed volume there is an impervious box which communicates with the pulping machine.
The axis of the enclosed volume is slightly inclined towards this rotor and the outlet of the impurities is arranged at the lower part of the enclosed volume near the rotor in order to make a receptacle for the impurities.
Means are provided to ensure in a cyclic fashion the communication of the pulping machine and of the enclosed volume, the introduction of the water, the emptying of the enclosed volume and the extraction of the impurities.
The rotor has bars which cooperate with the grooves carried by the opening which is provided in the side on which is assembled the rotor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of an axial vertical section of a device according to the invention;
FIG. 2 is a similar partial view of an embodiment of the rotor;
FIG. 3 is a partial plan view of the rotor of FIG. 2;
FIG. 4 is a partial plan view of the annulus 18a of FIG. 2;
FIG. 5 is a schematic top view of the device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a tub 1 of a standard type of pulping machine, working while open, with an average concentration of from 2 to 7% of dry material. The rotor of the pulping machine is in simplified form in FIG. 2.
The rotor 2 is in known manner, surrounded with a perforated grating 3 which is connected with a receptacle 30 which is provided with a discharge 32 for the fibre suspension constituting the pulp which is finally accepted. These parts are not shown in detail since they are known.
On the other hand, according to the invention, the tub 1 has an outlet 4 combined with a valve 5 and situated at the lower part of the pulping machine. This outlet 4 leads to a volume 6 which is an entirely enclosed volume and is small compared to the volume of the tub 1.
This volume has, in addition to the inlet 4 which is controlled by the valve 5, a low outlet 7 for rejected material, which is controlled by a valve 20, a water inlet 8, a compressed air inlet 9, and a gas outlet 10, these last two mentioned communicating with the volume 6 either separately or via a common channel 11. The volume 6 also has a rotor 12 with blades 13 driven by a motor 14, an impervious box 15 behind the rotor 12, and an outlet 16 at the lower part of the box 15, communicating with the tub 1.
The rotor 12 is made from a plate provided with blades or vanes 13, the surface of the plate 12 being set back in relation to the surface 18 of the volume 6 so as to define a gap 31, of predetermined dimensions, for the passage of the fibre suspension. The opening 17 of the side 18 of the volume 6 has a diameter which is substantially equal to that of the plate 12 and the gap 31 is approximately in the range of from 5 to 10 mm in thickness.
The process according to the invention is as follows. The tub 1 is filled with water and with cellulose materials in the usual proportions (about 5% of dry cellulose materials) and the rotor 2 is put into operation.
At the end of an interval of time during which the pulp is disintegrated and discharged through discharge 32, the openings of the grating 3 begin to become congested and the discharge flow in receptacle 30 and discharge 32 diminishes.
The valve 5 is then opened and, the motor 14 at this stage being in operation, the volume 6 fills up, via the outlet 4 with a fibre suspension filled with impurities. This moving of the impurities which have accumulated on the grating 3 is ensured by the centrifugal effect of the rotor 2 at the bottom of the pulping machine 1 and by the suction of the rotor 12 which acts like a pump.
The suspension which penetrates thus into the volume 6 undergoes a violent mixing and separation, the impurities remaining in the volume 6, while the decontaminated suspension penetrates, by the action of the rotor 12 and by the gap 31, into the box 15 to be returned to the tub 1.
After some time, which can be in the range of some minutes, it is established that the gap 31 is beginning to become congested and the rate of the extraction of the suspension drops. The valve 5 is then closed and the water inlet 8 is opened, which causes a progressive dilution of the pulp situated in the volume 6.
This phase can last for from 5 to 15 minutes, although these figures are not given by way of limitation. The phase is interrupted when the concentration of cellulose materials in the water which leaves through outlet 16 falls to the region of 1%.
Next the gas outlet 10 is closed and the compressed air inlet 9 is opened. Volume 6 empties by the action of the compressed air up to a point where its level reaches the lower part of the opening 17.
During this phase, the very diluted suspension contained in the volume 6 is continually thrown by the rotor 12 on to the sides of the latter which are washed in this way, and the impurities accumulate in the outlet 7.
After this phase, which likewise lasts a few minutes, the compressed air inlet 9 is closed, the rejection valve 20 is opened and the impurities are rejected.
A new cycle such as the one described above can then be started up.
Using this process and this arrangement, the following results are obtained. The impurities discharged past outlet 7 contain practically no fibres and are made up of pieces of plastic, glass, wood, metal, string etc. This decreases the pollution considerably and indicates a high degree of recovery of fibres.
The operating of the pulping machine is not interrupted. The tub 1 is replenished either continuously or discontinuously. The process and the device practically only use up the power of the motor, and the dilution water discharged into the volume 6 can be recycled water, commonly referred to as production water, which results from the draining or the concentration of the pulp. This water contains charges, paste, fibrils, dye etc., which do not spoil the process.
The power consumption of the motor is compensated for by the recovery of cellulose materials and by the economy which results from the avoidance of interruptions.
For an effective operation of the device and of the process, a certain number of arrangements and complementary means are provided:
(a) Volume 6 is preferably in the shape of a section of a cylinder or a cone with its axis slightly inclined to the horizontal in the direction of the rotor 12.
(b) The rotor 12 is situated in the lower zone of one level side 18 which terminates volume 6.
(c) The end and opposite side 19 makes an open dihedral with the side 18 towards the bottom.
(d) The side 18 is approximately vertical and the side 19 approximately perpendicular to the axis of volume 6.
(e) The outlet 7 is situated so that it constitutes a cavity or a receptacle above the valve 20 which controls it.
(f) The outlet 16 is at a lower level at the lower part of the opening 17.
The objective and the advantages of these arrangements are as follows:
While the rotor 12 turns, it produces a stirring of the suspension which involves a general rotation movement around the axis of volume 6 and a movement according to the arrows F. The rotation movement ensures a continuous washing of the lateral side of volume 6, a washing which is very efficient when this side is a surface of revolution. The movement according to the arrows F ensures the cleaning of the higher parts of volume 6, notably during the emptying phase of the latter, the water being thrown violently onto the sides and notably onto the high angles. The trapezium shape of the vertical section of volume 6 ensures a better cleaning of the high angles.
The feature of the bottom of volume 6 being slightly inclined towards the rotor ensures a better back flow of the impurities towards the rotor 12 and the outlet 7.
The impurities are thrown by the rotor 12 against the side of volume 6; the arrangement of the outlet 7 in the shape of a receptacle in the lower part near the rotor, forms a kind of trap for the impurities, which accumulate and are wedged in the receptacle and do not move in spite of the violent movement of the water. Moreover, behind the rotor 12, blades 21 have been provided which ensure excess pressure in the box 15 and by this, ensure the back flow of the suspension via the outlet 16 towards the tub 1, the rotor 12 functioning as a pump.
The rotor 12 can be produced in different ways. In the example of FIG. 1, it is a single component made of a plate carrying radial vanes 13.
The assembly of rotor 12, box 15, and motor 14 forms a unit assembled on the side 18, this assembly having an annular sheet of metal 18a in which the opening 17 is made. Thus, this assembly can be removed as a unit. Moreover, the gap between the rotor plate and sheet 18a is adjustable or regulatable, which enables it to be adapted to the materials which are to be treated. The edge of the opening 17 is chamfered.
In the variation of FIGS. 2, 3, and 4 the rotor plate carries centrifugal blades 23 which can be of soft steel and terminal vanes 24 made of a metal which is more resistant to wear. The vanes 24 bear terminal edges 25 which project into the opening 17. Besides this, certain vanes bear bars 26 of a very hard material, such as tool steel or tungsten carbide, these bars being fixed parallel to the annular sheet 18a with a very small clearance, preferably less than 1 mm. The bars 26 cooperate with grooves 22 in the shape of hollow fissures in the annular sheet 18a of the side 18 which surrounds the opening 17.
The fissures 22 can be radial or inclined so as to make an angle with the vanes 24.
The effect of this arrangement is as follows: When the rotor 12 turns, the impurities in the form of strips, such as pieces of plastic, shreds of string etc. arrive in the gap between the rotor plate and the opening 17, on both sides of the edge of this opening and they tend to remain stationary in this position. The clearance between the bars 26 and the grooves 22, pushes these impurities into the grooves 22 where they are cut up by a scissor effect. Some of the impurities thus reach the box 15 and they are recycled in the main pulping machine. They are thus gradually eliminated and do not pass into the pulp suspension extracted from the tub 1.
Another arrangement of the invention consists in providing a water inlet 27 near the rotor 12 in order to ensure the cleaning of the latter. This water inlet can be used when the volume 6 is empty or nearly empty to ensure the elimination of the impurities on the surface of the rotor 12 and in the gap 31. It can also be used while the volume 6 is still full if the force of the jet is sufficient to ensure this washing.
As indicated above, the pulping machine can be used for continuous or discontinuous operation.
In the case of a continuous operation, the tub 1 is constantly refilled with water and with cellulose materials and when the valve 5 is opened the hydrostatic pressure is relatively high. To avoid a sudden spattering of impurities on the rotor 12, it is preferable to fill the volume 6 with water before opening the valve 5. The suction effect of rotor 12 and the centrifugal effect of rotor 2 is sufficient to cause the introduction of the pulp charged with impurities into the volume 6.
With a discontinuous operation, it is possible on the other hand to open the valve 5 while volume 6 is empty. In fact in this type of operation, the tub 1 is half empty at least when the grating 3 begins to become obstructed, and the opening of valve 5 does not involve any risk of causing a too sudden spattering of impurities on the rotor 12. It has been stated that volume 6 is small relative to the volume of the tub 1. This point is a feature of the process and of the device of the invention.
It is possible to adapt the assembly constituted by the volume 6, the rotor 12 and their attachments on tubs 1 to very different volumes. The volume 6 will be, for example, in the region of 1 m 3 for the tubs 1 ranging from 10 m 3 to 60 m 3 . In all these cases, the ratio of volume 6 to the volume of the tub 1 is in the range of at least 1:10. Thus the filling cycle of volume 6 and the extraction cycle of the impurities causes only a very small decrease of the level of tub 1 and it is with a continuous succession of partial purifications that the pulping machine is progressively cleared of its impurities.
To take an example, if the opening phase of the valve 5 is six minutes, the phase of dilution with water by the inlet 8 after closing the valve 5 is ten minutes, the emptying phase by compressed air arising in 9 is 5 minutes and the cleansing of the impurities lasts 2 minutes, the total cycle of the process lasts 23 minutes and it can thus be repeated more than twice per hour.
Thus the process of the invention consists in putting into operation a partial extraction of pulp charged with impurities from the pulping machine, transferring it into an enclosed volume where it is stirred with the addition of water and pulp suspension extracted therefrom by a separation device until the pulp suspension is diluted to a concentration in the range of up to 1% of dry materials. The process then consists in emptying this volume, for example, by the action of compressed air, of substantially the whole suspension and finally extracting the impurities, the suspension being returned to the pulping machine.
The arrangement of the invention can be adapted to the existing pulping machines. In fact it suffices to make an opening in the bottom of the tub 1 for the association of volume 6 and of its attachments, including the channeling 16 ensuring the back flow to the tub 1. The pulper, its rotor 2 and the grating 3 are known standard devices whose construction has not been modified.
The operation in cycles can obviously be automated. An assembly of arrangements of automatic control of valves controlling the channels 4,7,8,9, 10 and 27, with the necessary time delays, as well as the operation of the motor 14 or of the arrangement for the compression of the air arriving in 9, allows an automatic cyclic operation to be ensured.
The air pressure necessary for emptying the volume 6 is low, in the range of 500 gr/cm 2 , and can be ensured by a simple ventilator.
Different variations can be adopted in the carrying out of the invention, notably concerning the shape of volume 6 and the arrangement of rotor 12. The extraction of the suspension by the rotor 12 can be obtained by an annular, perforated side around the rotor instead of extraction through the annular gap 31 although this solution is preferred.
Nevertheless, the arrangement shown is the preferred arrangement, notably concerning the arrangement of the rotor 12 at the lower part of a nearly vertical side in relation to an outlet 7 forming the receptacle for impurities. This arrangement in fact allows the blocking of the impurities in the outlet receptacle in the course of emptying volume 6 while ensuring the cleaning of the latter by spatterings of liquid due to the operation of the rotor.
The velocities of the rotors 2 and 12 can vary greatly. They are generally in the range of from 16 to 18 m/per second at the periphery of the turbine disc. | A process is provided for the removal from paper pulp of impurities, the pulp being contained in a pulping machine. Some of the pulp is periodically transferred into an enclosed chamber annexed to the pulping machine, the chamber having a volume which is small compared to the volume of the pulping machine. The pulp in the chamber is stirred and separated by a rotor, and fibre suspension is returned to the pulping machine, dilution water being introduced into this chamber. The chamber is emptied and impurities thereafter discharged. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of PPA No. 61/713,824, filed Oct. 15, 2012 by the present inventor. EFS ID 13984828
FEDERALLY SPONSORED RESEARCH
[0002] None
SEQUENCE LISTING
[0003] None
BACKGROUND OF THE INVENTION
[0004] This invention relates to an adjustable electrical box screw extender which may be attached to a conventional electrical junction box, a mud ring or can be used alone to enable positioning on the place, where the fixing screws of the electrical devices are inserted, at selectable distances from the junction box or mud ring.
[0005] Because of various state and federal codes, the wiring of a building today requires the use of metal conduits for holding electrical wires, and so-called electrical junction boxes on which may be mounted a variety of electrical switches or plugs for access by the users of the building. Such conduits and junction boxes are mounted within the walls of the building, with openings provided in the walls for access to the junction boxes. These junction boxes are closed on all sides except where joined to conduits and except for the fronts of the boxes which face the openings in the walls.
[0006] It is desirable that the open front of a junction box or the insertion point for the fixing screws of the electrical devices be positioned adjacent to the surface of the wall so that when a switch or plug is mounted in the junction box, the front of the switch or plug will be substantially flush with the surface of the wall. However, because of the wide variety of types of walls in which the conduit and electrical junction boxes are installed, and because the junction boxes are typically installed before the wall surfaces are applied to studs or the like, it is difficult to estimate the proper location of the junction box to ensure that the front of the switch or plug will be flush with the wall surface. If the junction box protrudes out from the wall surface, then the switch or plug will appear unsightly, whereas if the junction box is recessed too far from the wall surface, then the switch or plug to be mounted therein may not be adequately protected from spark or other electrical hazards reaching surrounding combustible materials. Also, if the junction box is too far recessed from the wall surface, it may not even be possible to mount the switch or plug therein.
[0007] A number of adjustable electrical outlet boxes have been proposed to allow mounting a switch or plug so that it is substantially flush with a wall surface. Among these are those disclosed in U.S. Pat. Nos. 1,875,101; 2,048,611; 3,433,886; 4,634,015; 5,098,046; 5,114,105; 5,253,831; 5,289,934; 5,931,325; 6,369,322; 7,002,076; 7,462,775 and 8,245,862. These arrangements all show a combination of a specialized junction box and a slid able element for holding a switch or plug and as such require installation of the specialized junction box everywhere the device is to be used. That is, the device cannot be used with conventional junction boxes and so if the device is going to be used it must be installed at the beginning. This may result in an unnecessary expense since a conventional junction box might have been just as suitable, but such determination is often difficult before the building is constructed.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide an adjustable electrical screw extender attachment which may be mounted on a conventional electrical junction box, mud ring or to be used alone and in which may be installed a conventional electrical switch, outlet or any kind of electrical or communication devices.
[0009] It is another object of the invention to provide such electrical screw extender which may be installed after a building wall or other supporting structure is constructed.
[0010] It is another object of the invention to provide electrical box, electrical mud ring and electrical box extender with a system incorporated to accept the assembly of the electrical screw extender.
[0011] It is an additional object of the invention to provide such electrical screw extender in which intimate electrical and mechanical contact is maintained between an installed electrical device and the conventional junction box or mud ring.
[0012] It is a further object of the present invention to provide such electrical screw extender wherein the disposition of the outlet or switch relative to the junction box may be manually adjusted so that the front edge of said outlet or switch can be positioned substantially flush with a wall surface in which said outlet or switch is installed.
[0013] It is a further object of the present invention to provide electrical junction box, electrical mud ring and electrical box extender with an incorporated system to accept the easy assembly of the electrical screw extender.
[0014] It is also an object of the invention to provide such electrical screw extender wherein no fasteners or other implements project into the installed junction box.
[0015] It is also an object of the invention to use only standard bolts sizes, readily available bolts sizes which enable the installer to make use of them.
[0016] It is also an object of the invention to simplify the way of manufacturing and the use of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:
[0018] FIG. 1 is a perspective view of all the system, including the electrical box, the mud ring, the electrical screw extender and the electrical box extender.
[0019] FIG. 2 is a perspective view of an electrical screw extender and how the fixed portion of said electrical screw extender is placed inside a 2 gang electrical box.
[0020] FIG. 3 is a perspective view of an electrical screw extender and how the fixed portion of said electrical screw extender is placed inside a 2 gang mud ring.
[0021] FIG. 4 is a perspective view of a 2 gang electrical box extender with a circular plastic duct to mount said electrical box extender at the electrical screw extender.
[0022] FIG. 5 is a perspective view of an electrical screw extender and its fixed base.
[0023] FIG. 6 is a lateral view of an electrical screw extender and its fixed base.
[0024] FIG. 7 is a perspective view of an electrical screw extender used with a regular switch.
[0025] FIG. 8 is a top perspective view of a 2 gang electrical box extender.
[0026] FIG. 9 is a front view of a 2 gang electrical box extender.
[0027] FIG. 10 is a perspective view of an electrical screw extender and a regular screw of the electrical devices.
DETAILED DESCRIPTION
[0028] FIG. 1 is a perspective view which also shows the system that can be used with the electrical screw extender. First is a 2 gang electrical box 21 with its different knockouts 19 , two treated internally threaded holes 28 and the fixed bases 71 with the internal thread 24 and the covered back 20 . Next we see a mud ring 32 with its flat base 29 and location slots 30 . For guiding hexagonal part 26 of the electrical screw extender, it is desirable that the upper and lower edges of said mud ring 32 must have four displacement openings 31 which enable with a nut driver. Next we see four electrical screw extenders with the external thread 25 and the internal thread 23 , the hexagonal part 26 and the regulation nut 27 . And last we see the two gang electrical box extender 83 with two ducts 82 ; two tabs 86 with two slots 85 and the border 81 .
[0029] FIG. 2 is a perspective view which shows the electrical screw extender used in electrical box 21 with its different knockouts 19 with two internally threaded holes 28 and the covered back 20 . The various component parts of the electrical screw extender and its fixed base 71 are shown where said fixed base 71 is inside and fixed to said electrical box 21 . Said fixed bases 71 are observed with their respective internal threads 24 into which external threads or male screws 25 from electrical screw extender may be located to vary the distance from the final position. In the part of said external thread or male screw 25 of said electrical screw extender, locknuts 27 are observed, which serve as a means of fixing the selected distances. The hexagonal portion 26 of the electrical screw extenders must have a regular size, can be guided with a nut driver and also has at its center a treated internal thread 23 where the screws of any standard electrical devices can be placed. The sizes of these internal threads 23 are the standard 6/32 in the case of USA but they could be of another size in order to standardize the measures to those of regular use in other countries. For convenience so that the electrical screw extender can be used directly on the threads of the devices that mud rings have, external threads or male screws 25 of said electrical screw extender and female screws or internal threads 23 which are in the hexagonal part of this electrical screw extender must be both the same measure and standardized to the countries where they are used. By extension the inner threaded portion 24 which is located on the fixed base 71 also must be of the same measure as 6/32 is in the case of USA.
[0030] FIG. 3 is a perspective view showing a regular mud ring 32 with its flat base 29 and location slots 30 . The internal threads 24 which are on said bases 71 should be spaced such that the separation from that it is located in the upper edge and that it is located in the lower edge is the same as the separation that exists among fixing screws in electrical devices like outlets or switches. Like it happens to the electrical boxes, It is also recommended that in the initial location, the outer edge of hexagonal portion 26 of said electrical screw extender and its internal thread 23 are completely flush with the outer edge of the mud ring 32 , whether all portion of the outer thread or male screw 25 of said electrical screw extender is fully inside the inner thread 24 of the fixed base 22 including the width of the locknut 27 . For guiding hexagonal part 26 of this electrical screw extender, it is desirable that the upper and lower edges of the mud ring 32 have four displacement openings 31 which enable with a nut driver, the proper and flush placement with the walls of said different hexagonal parts 26 of electrical screw extenders.
[0031] FIG. 4 is a perspective view showing a two gang electrical box extender 83 which has two ducts 82 to mount said electrical box extender 83 in the hexagonal part 26 of the electrical screw extender. The tab 86 has a slot 85 to insert the device's screws in the female thread 23 of the electrical screw extender. Border 81 does not have to be wide because this box extender 83 is not supported by walls.
[0032] FIG. 5 is a perspective view showing the electrical screw extender with all of its parts and the fixed base 71 with its internal thread 24 which is capable of accepting the full length of male external thread 25 of said electrical screw extender. The lower parts of the fixed base 71 must be flat for easy fastening of said fixed part 71 in the electrical box 21 or mud ring 32 . The locknut 27 can be displaced along the length of the outer or male thread 25 of the electrical screw extender. The hexagonal part of the electrical screw extender 26 and its internal thread 23 is capable of accepting the screws of electrical devices like outlets or switches that can be sized smaller than the screw of said electrical device in which case a cut of the length of the fixing screw of electrical devices must be made or it must be replaced by a smaller one or even the electric screw extender manufacturer could provide an appropriately sized screw for the electrical devices. Said hexagonal part 26 can be too circular or any other geometric shape with some slot to be guided with a screwdriver. As previously stated, the length of said electrical screw extender and its hexagonal part can be variable depending on the width of the electrical box or mud ring where they are located. Also if these electrical screw extenders are to be used in existing buildings to provide the appropriate location of electrical devices, they may have different sizes so that they help us measure walls or work circumstances where they can be used.
[0033] FIG. 6 shows a lateral view of the electrical screw extender with its fixed base 71 where the internal thread 24 is located which can accept the outer or male thread 25 of the electrical screw extender. The lock nut 27 is movable over said male or external thread 25 and the hexagonal part 26 has an internal thread 23 which can accept screws from electrical devices. Said hexagonal part 26 can be circular, octagonal or any other geometric shape with some slot to be guided by a screwdriver.
[0034] FIG. 7 shows a side view where an electrical switch 51 can be located properly flush with a new wall of tiles 44 that was located with the adhesive 43 on the sheet rock wall 42 . As usual, the electrical box 21 is fixed on one side in the wood beam 41 and the device mounting bolts 33 are placed into the internal thread 23 of the hexagonal part 26 of the electrical screw extender. The fastening nut 27 is tightened against the fixed base 71 after the portion of the outer or male thread 25 of the electrical screw extender has reached the correct distance in its displacement within the inner thread 24 of said flat base 71 . As an extra safety measure to avoid a possible displacement of the external or male thread 25 of the electrical screw extender on the thread of the locknut 27 and the internal thread 24 of the flat base 71 , said outer or male thread 25 may be damaged by any tool at the exact point that coincides with the outer edge of said security thread 27 . The cables 34 are those normally connected to any electrical switch.
[0035] FIG. 8 is a top perspective view for an electrical box extender 83 with one gang showing the duct 82 , the border 81 the tab 86 with the slot 85 .
[0036] FIG. 9 is a frontal view of the same one gang electrical box extender 83 shown in FIG. 8 with the same parts like duct 82 , border 81 , tab 86 and the slot 86 .
[0037] FIG. 10 is a perspective view showing the electrical screw extender and its different parts, such as the external or male thread 25 , the lock nut 27 , and the exterior hexagonal part 26 with which the exact location of the electrical screw extender is achieved using a nut driver and the internal thread 23 of said hexagonal part 26 , which is able to accept the screws from electrical devices 33 . As a reminder, in the U.S., thread sizes are 6/32 for screws of electrical devices 33 , too for the male or external thread 25 of the electrical screw extender, for the inner thread 23 of the hexagonal portion 26 of said electrical screw extender and the internal thread 24 of the fixed base 72 , but this measure may be another if we use these electrical screw extenders in other countries.
[0038] It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and, the appended claims are intended to cover such modifications and arrangements. | The objective of the present invention is to provide electrical boxes, electrical mud rings and electrical box extenders with a cheap and efficient way to achieve the correct location of electrical devices with respect to the levels of the walls where they are located. With this electrical screw extender, a mechanical/electrical connection is still safe and lasting too. This electrical screw extender has among its advantages that can be placed in different models of electrical boxes and in mud rings, plus it can be used independently in the already existing constructions to extend the points of connection of devices to the correct levels. Besides, these electrical screw extenders can have different sizes or lengths to suit the different depths of the existing electrical boxes or mud rings, as well as are very comfortable and accurate in their use. | 7 |
RELATED APPLICATION
[0001] This application is a divisional application that claims priority to and the benefit of co-pending U.S. patent application Ser. No. 11/857,256, entitled “Compound Relief Tap,” which was filed on Sep. 18, 2007, the disclosure of which is incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is directed toward a compound relief tap, and more specifically, to a compound relief tap with domains made of a plurality of consecutive threads where each domain has different properties associated with variable thread parameters and variable geometrical arrangements such a variation of a taper angle and relief angles for a different portions of domain threads or between domains.
BACKGROUND OF THE INVENTION
[0003] Threads are used to convert torque into linear force between two elements. The first element has male threads on its outer surface and it is screwed into a second element with female threads on the inner surface of an opening, or vice versa. To form threads on the inner surface of an opening, a hole is generally drilled using a drill bit. The drill bit, because of its rapid speed of rotation, leaves the surface of the hole flat. Threads must be added to the surface in a second step using a tap.
[0004] Taps are cutting tools used to create screw threads in solid substances including but not limited to metal, wood, or plastic by shaving away thread shapes on the inner surface of a cylindrical hole. Male taps (i.e., taps capable of forming female threads inside of holes) are generally sold in the form of a long cylindrical tool body tool with a threaded length and a shank often equipped with an end portion for positioning the tap in a torque creating support. A user attaches the tap inside the torque support, places the tap on the hole, and screws the tap into the hole to create threads. Taps often include flute openings made longitudinally along the thread length and define lands with threaded surfaces where chips of removed material from the surface of the hole are pushed for removal. FIG. 4 shows a tap 100 placed inside a torque creating support 36 operated by a user 40 and stabilized in a grip 38 .
[0005] In one device from the prior art shown in FIG. 1 , the tap has a series of regularly spaced and identically shaped threads along the entire thread length. As a result, the user must place a very high level of torque in the first couple of threads where all of the metal is shaved away from the hole. Over time, the high torque placed upon the first few threads dulls the tap's cutting edges and results in a tap where the torque needed to operate the tool increases substantially. Other taps have tried with some level of success to correct this inherent problem.
[0006] FIG. 2 shows a tap where, while the pitch and the minor diameter of each thread remains constant over the thread length, the major diameter (or outside diameter) is progressively increased until the desired thread geometry is reached. Consequently, each thread removes a thinner layer of material and less torque is required to operate the first few threads of the tap. This type of tap creates more problems than it resolves. For example, the user is no longer capable of creating completely formed threads over the entire length of a hole to be threaded. To produce the threads, the tap must be inserted throughout the threaded length. These taps are not capable of threading holes with closed bottoms where threads are needed over the entire length of the hole. In addition, as the tap is inserted, more threads are needed to cut the surface of the material, each cutting at a lesser thickness. As a consequence, a higher torque may be expected based on a greater frictional surface and cutting surface between the tap and the hole.
[0007] FIG. 3 illustrated another unsuccessful attempt at alleviating these problems, where a chamfer angle is created in the first threads to cut threads with the right pitch but where less material is removed by increasing the chamfer angle, the major diameter of the crest of each thread. Efforts to soften chamfer torque and associated heat and wear by modifying threads only results in a greater instability of operations and an inability to operate the tap at different depths.
[0008] What is needed is a tap designed for longer tool life by limiting flank wear and reducing operating heat and torque by selectively placing effective cutting surfaces at the adequate positions while relieving some of the inoperative sections of threads to limit friction associated with torque and heat.
BRIEF SUMMARY OF THE INVENTION
[0009] The present disclosure is directed toward a compound relief tap, and more specifically, to a compound relief tap with domains made of a plurality of consecutive threads where each domain has different properties associated with variable thread parameters and variable geometrical arrangements such a variation of a taper angle and relief angles for a different portions of domain threads or between domains. In a first embodiment, all of the threads in a domain have a given geometrical arrangement. In a second embodiment, several of the threads of the domain possess the geometrical arrangement. In a third embodiment, only the thread of the domain possesses the geometrical arrangement. And in a fourth embodiment, alternative threads in the domain possess the geometrical arrangement. What is also contemplated is a variation in geometrical arrangement between successive domains for any of these threaded domains.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The features of the present disclosure are believed to be novel and are set forth with particularity in the appended claims. The disclosure may best be understood by reference to the following description taken in conjunction with the accompanying drawings, where the figures that employ like reference numerals identify like elements.
[0011] FIG. 1 is side view of a first tap from the prior art.
[0012] FIG. 2 is a side view of a chamfered tap from the prior art with a constant chamfer.
[0013] FIG. 3 is a side view of second chamfered tap from the prior art with variable thread height.
[0014] FIG. 4 is an illustration of a fluted tap with a torque-creating support in a piece secured to a vice grip according to a first embodiment of the present disclosure.
[0015] FIG. 5A is a side view used to illustrate schematically the nomenclature of tap cutting tools.
[0016] FIG. 5B is a detail of one of the lands located between two flutes of the tap cutting tool of FIG. 5A .
[0017] FIG. 5C is a top view of the tap cutting tool of FIG. 5A as seen from the cut line 5 C- 5 C as shown in FIG. 5A .
[0018] FIG. 5D is a sectional view without shading of the tap cutting tool of FIG. 5A as seen from the cut line 5 D- 5 D as shown in FIG. 5A .
[0019] FIG. 6 is a segmented view of a tapered threaded region with domains of a compound relief tap according to a first embodiment of the present disclosure.
[0020] FIG. 7 is a segmented view of a tapered threaded region with domains of a compound relief tap according to another embodiment of the present disclosure.
[0021] FIG. 8 is a volumetric partial section view of a domain of a compound relief tap with major diameter relief according to another embodiment of the present disclosure.
[0022] FIG. 9 is a volumetric partial section view of a domain of a compound relief tap with pitch relief according to another embodiment of the present disclosure.
[0023] FIG. 10 is a volumetric partial section view of a domain of a compound relief tap with negative pitch flank relief according to another embodiment of the present disclosure.
[0024] FIG. 11 is a volumetric partial section view of a domain of a compound relief tap with heel relief according to another embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention is not limited to the particular details of the device depicted and other modifications and applications may be contemplated. Further changes may be made in the above-described device without departing from the true spirit of the scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction should be interpreted as illustrative, not in a limiting sense.
[0026] This disclosure relates to an improvement to a tap 100 designed to improve tool life. Tools are made of metal, and while a hard substance, they present some level of ductility when cutting other, softer metals. A cutting edge pushing into metal may be dulled if abrasion occurs locally and heats up due to local friction associated with cutting speeds, torque, and surface polish of the tool. Tool life depends on a plurality of factors including flank wear, hardness, cutting speed, surface temperature, torque, relief of threads, depth of cut, and feed rate. The relief of surfaces on threads that do not serve to enhance the mechanical operability of the tap 100 only increase friction between the tap 100 and the hole surface to be tapped.
[0027] FIG. 4 illustrates how the tap 100 is operated by a user 40 to cut threads into a hole made in a block of material. The block is held in a vice grip 38 vertically using a torque-creating support 36 , such as a small block with lateral support, movable by rotating two horizontal handles placed on each side of the torque-creating support 36 . A user 40 then applies torque by rotating the handles in the horizontal plane. While a manual torque-creating support 36 is shown, what is contemplated within this disclosure is the use of any type of tap 100 , using any engaging mechanism to rotate the tap and thus activate the cutting edges 150 shown in FIG. 5B about a longitudinal axis 4 as shown in FIG. 5A .
[0028] FIG. 5A illustrates a tap 100 with an overall length 6 that may be separated into a thread length 8 and a shank length 10 of a fixed shank diameter 2 . The ratio of these two lengths is purely illustrative, and it is understood that these lengths vary according to the model and type of tap 100 . The shank length 10 can also include a driving length 28 where the tap 100 is secured to a torque-creating support. This driving length 28 is also of a geometry as shown in FIG. 5C to allow for the coupling of the tap 100 to any needed torque-creating support. While a square attachment 30 is shown, any attachment is contemplated.
[0029] Flutes 18 as shown in FIG. 5D separate lands 22 created in the threaded length 8 between two consecutive flutes 18 . In one embodiment as shown in FIG. 5D , four flutes 18 are positioned at 90 degrees circumferentially around the thread length 8 . Other taps may have flutes 18 of smaller radii, variable curvature, placed around a cylindrical tool body or minor diameter 12 of different size to create a tap 100 with five or more flutes 18 or three or less flutes 18 . What is also shown is a tap 100 with straight flutes 18 as shown in FIG. 5A . What is also contemplated is the use of helical angle, a spiral, or any other type of flute 18 that is not aligned with the longitudinal axis 4 of the tap 100 .
[0030] Returning to FIG. 5A , the threaded length 8 comprises a series of threads shown in V shape having a thread lead angle 26 corresponding to a pitch or average median thread distance between two consecutive threads. In some embodiments, as shown by dashed lines, the tap 100 includes a point 20 . FIG. 5D is a sectional view without shading of the tap cutting tool of FIG. 5A as seen from the cut line 5 D- 5 D as shown in FIG. 5A . This section shows the land width 14 , a section with threads having a minor diameter 156 and a major diameter 155 . FIGS. 5A-5D show that the cylindrical tool body of the tap 100 includes a longitudinal axis 4 rotatable about the longitudinal axis 4 and having successively, a shank of shank length 10 and a threaded length 8 with at least a flute 18 for creating at least a land 22 with a front cutting surface 150 with a cutting edge 140 and a heel 130 as shown in FIG. 8 . Each thread in the threaded length 22 is defined by a minor diameter 156 as the base 96 of a thread a major diameter 155 as the crest 94 of the thread with a leading flank 92 and a trailing flank 131 intersecting at a crest 94 separated by an adjacent thread by a pitch 132 measured at a pitch diameter 133 .
[0031] The threaded length 8 is also divided into a series of successive domains 8 A, 8 B, 8 C, 8 D, etc. as shown in FIG. 6 , each domain having a fixed number of successive threads 70 along the threaded length 8 and each having a geometrical arrangement. While four successive domains 8 A to 8 D are shown, what is contemplated is the use of any number of domains, based on the total length of the threaded length 8 . In one contemplated embodiment, a tap 100 has between 30 and 90 threads and can be divided into any number of domains consisting of at least 2 threads. FIG. 6 also shows a proposed angle of rotation 44 for the threaded length 8 .
[0032] In one embodiment as shown in FIGS. 6 and 7 , the geometrical arrangement is a taper angle Phi (Φ) shown as Φ 1 , Φ 2 , Φ 3 , and Φ 4 . FIG. 6 shows tapered consecutive domains with the same taper angle measured either at the major diameter 50 or the pitch diameter 52 . FIG. 7 shows a tap 100 where each domain has a different taper angle Φ 1 , Φ 2 , Φ 3 , and Φ 4 measured either from the major diameter 54 , 56 , 58 , and 60 , or measured from the pitch diameter 62 , 64 , 66 , and 68 . The taper angle Φ may be a front taper Φ 3 and Φ 4 , a back taper Φ 1 , or no taper Φ 2 for each successive domain. In another embodiment, the taper angle Φ is defined in relation to the minor diameter.
[0033] In another embodiment, shown in FIGS. 5B , and 8 to 11 , the geometrical arrangement is a thread cutting edge relief 32 as shown on FIG. 5B 98 for each of the fixed number of successive threads in each successive domain. FIGS. 5B and 8 show a thread cutting edge relief 32 that may be an eccentric relief 86 , a con-eccentric relief 84 (with concentric margin 88 ), or a concentric relief 82 for each successive domain. As shown in FIG. 8 , the thread cutting edge relief 32 is defined in relation to the major diameter 155 . Dashed lines show the removed relief material from normative threads or threads with concentric relief 82 . In yet another embodiment, the thread cutting edge relief 34 of FIG. 5B is defined in relation to the minor diameter 156 .
[0034] FIGS. 5B and 9 show the thread cutting edge relief 33 as part of leading flank 92 and trailing flank 112 defined as a relief of the pitch diameter 133 . Similarly, the angular value of the taper angle for each successive domain differs and an angular value of the thread cutting edge relief for each successive domain differs. What is shown by dashed lines is the section envelope of the normative thread with a concentric relief on the pitch relief. The figure illustrates a coneccentric relief 104 (with concentric margin 110 ), an eccentric relief 108 , and a concentric relief 106 for the pitch relief at the pitch diameter 133 , respectively.
[0035] In one alternate embodiment, at least a portion of thread for each of the series of successive domains having a geometrical arrangement. In yet another embodiment shown in FIG. 10 , the pitch relief (or the major diameter relief, not shown) is a high negative relief 120 of the leading flank 92 and the trailing flank 112 at the cutting edge for each of the fixed number of successive threads in each successive domain. In yet another embodiment as shown in FIG. 11 , the geometrical arrangement is a double or high positive relief 122 of the leading flank and the trailing flank at the heel of the land for each of the fixed number of successive threads in each successive domain.
[0036] In one contemplated embodiment, the geometrical arrangement of each successive domain is an alternating sequence within each successive domain of a thread of a single land on of the pitch with a variable parameter and the remaining threads of the other land of the pitch without the variable parameter; and yet in another embodiment, a single thread for each of the series of successive domains has a geometrical arrangement as defined herebefore.
[0037] What is also contemplated is any variation, using the principle of domains within a threaded length 8 , of different threads using the above-defined reliefs of threads or any other relief based on another geometrical parameter associated with the art of taps. The above nomenclature, definitions, and associated illustrations correspond to the United States Cutting Tool Institute standards for TAPS GROUND THREAD, which are hereby fully incorporated herein by reference. This standard is also published as the American National Standard for Taps-Cut and Ground Thread, ANSI B94.9 also hereby fully incorporated herein by reference. In the case of conflict between theses definitions, nomenclatures, and associated illustrations, the terms defined within the body of this specification prevail upon the Cutting Tool Institute standard, which in turn prevails upon the ANSI standard.
[0038] It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden. | The present disclosure is directed toward a compound relief tap, and more specifically, to a compound relief tap with domains made of a plurality of consecutive threads where each domain has different properties associated with variable thread parameters and variable geometrical arrangements such a variation of a taper angle and relief angles for different portions of domain threads or between domains. In a first embodiment, all of the threads in a domain have a given geometrical arrangement. In a second embodiment, several of the threads of the domain possess the geometrical arrangement. In a third embodiment, only the thread of the domain possesses the geometrical arrangement. And in a fourth embodiment, alternative threads in the domain possess the geometrical arrangement. What is also contemplated is a variation in geometrical arrangement between successive domains for any of these threaded domains. | 1 |
FIELD OF THE INVENTION
The present invention relates to a device for quickly and easily replacing the pre-existing charge motion control valves within a vehicular air intake system with a charge motion control plate having a higher air flow rate for racing and/or high performance street applications.
BACKGROUND OF THE INVENTION
The versatility and performance of newer muscle cars such as the FORD MUSTANG permit owners to use one vehicle for multiple purposes. Often the same vehicle used to carry groceries home from the supermarket is used for racing applications on the weekend. Owners will often modify their vehicle to make it more competitive in their chosen form of racing. One of the most modified areas of a vehicle for racing applications is the engines air induction system.
Tuning the air induction system can be one of the most critical aspects of getting a vehicle to produce horsepower and torque for either street or racing applications. The basic function of an air induction system is to provide an optimized and evenly distributed flow of fresh air from the air filter to the combustion chamber. The intake manifold is the primary component of the air induction system. In a fuel injected engine the intake manifold includes at least one air intake conduit for each cylinder. The air intake conduit generally extends between the throttle body and the intake port(s) leading to the combustion chamber. In addition to the mere routing of air, today's intake manifolds may also include dynamic supercharging, swirl and tumble control, positive crankcase ventilation and exhaust gas re-circulation.
Charge motion control valves (“CMCVs”) are often used within air induction systems in order to modify the flow of air and fuel into the engine's cylinders. A CMCV is typically and operatively disposed within an air intake conduit of the air induction system “upstream” from a fuel injector. The CMCV is effective to alter the flow of air into the cylinder during certain vehicle operating modes (e.g., during relatively low engine speed and load conditions), and is effective to create turbulence within the cylinder.
One type of CMCV is designed for use in combination with a “Siamese” type intake port which includes an air intake port that splits or “branches” into a pair of separate ports that communicate with one of the engine's cylinders. This type of CMCV is typically and operatively disposed in close proximity to the location where the air intake port splits and is designed to alter the flow of air into each of the port branches. These CMCVs are commonly referred to as “swirl” type CMCVs and are typically designed to substantially “cover” one side of the air intake port, thereby preventing air from entering one of the branches. In this manner, the CMCV provides a “fuel rich” mixture within the covered branch that is subsequently discharged into the cylinder and combusted. Additionally, this type of CMCV covers only a portion of the other side of the main air intake port, effective to allow a substantial amount of air to flow into the other branch and to create a “fuel lean” mixture in that branch that is subsequently discharged into the cylinder and combusted along with the fuel rich mixture. This flow of air into the cylinder creates a swirling effect or turbulence which causes the fuel rich mixture and fuel lean mixture to combine for combustion.
While these prior CMCVs provide emissions benefits, low RPM, and low load engine operation, they suffer some drawbacks which adversely effect the efficiency of the engine during certain operating conditions. For example and without limitation, during cold start operating conditions (i.e., when the vehicle is being started after being exposed to relatively cold temperatures), fuel often condenses on the intake valves due to a lack of heat. Because this type of prior CMCV substantially blocks air from flowing into one of the port branches, condensed fuel often remains on the intake valve within that branch and/or enters the cylinder as a liquid stream and is thus not properly combusted within the cylinder. This undesirably leads to oil degradation, waste fuel, and increased hydrocarbon emissions.
Another prior type of CMCV, commonly referred to as a “tumble” type CMCV, is used to create a “tumbling” flow of air into the cylinders. This type of CMCV provides substantially symmetrical passages for air to flow to each intake valve. Hence, this type of CMCV provides a substantially similar air/fuel mixture and airflow within each branch port. While this type of CMCV prevents condensation from remaining on the intake valves, it substantially restricts air flowing into the combustion chamber. The restriction of air limits the device to use at low engine RPMs and low engine torque requirements.
Another type of CMCV is used to create both tumble and swirl air flow into the cylinders. This type of CMCV provides more air to one intake branch than to the other. This construction prevents some fuel from condensing on the valve receiving the least amount of air and provides a swirl to the combustion chamber via the predominant air flow to the second branch. While this type of CMCV provides some advantages over the other types of CMCVs, because only 10% of the air being supplied to the cylinder is allowed to flow through one branch of the intake, condensed fuel often remains on the intake valve within that branch and/or enters the cylinder as a liquid stream and is thus not properly combusted within the cylinder. This undesirably leads to oil degradation, waste fuel, and increased hydrocarbon emissions.
In addition to the air restriction present in all of the CMCV constructions of the prior art, the devices add substantial complexity to an already complex air induction system. The CMCVs require a pivotally mounted butterfly type valve for each intake branch. The butterfly valves must be coordinated for uniform opening and closing in response to engine speed and torque demands. The coordination requires a combination of solenoids, stepper motors and/or vacuum motors. The motors must be in electrical communication with the on-board computer and a vast array of sensors to cause the CMCVs to open above a predetermined RPM or engine torque requirement to prevent fuel and air starvation. Starving of the engine from fuel and/or air could create dangerous driving situations, as the engine would not respond properly to operator throttle demands.
Accordingly, what is needed in the art is a charge motion plate for high-performance applications. The charge motion plate should achieve objectives such as: even distribution of the fuel and air mixture to both branches of a siamese intake port arrangement, reduced airflow restriction for crisper throttle response and increased horsepower, compatibility with original equipment manufacturer “OEM” or aftermarket turbo chargers and superchargers, and compatibility with nitrous oxide injection systems.
In addition, the charge motion plate should be easily manufactured without moving parts to malfunction or adjust. The charge motion plates should include packaging flexibility for installation on various vehicle configurations including retrofitting existing vehicles with minimal modification to the existing air induction system.
SUMMARY OF THE INVENTION
The present invention provides a charge motion plate kit for internal combustion engines. More specifically, the charge motion plate kit permits replacement of the OEM charge motion valves of the prior art for high performance applications. In one embodiment, the charge motion plate kit comprises a single charge motion plate for each bank of cylinders, each charge motion plate includes at least one aperture for each cylinder within the bank. For example, a charge motion plate kit for a four cylinder engine would include one charge motion plate with at least four air flow apertures, and a charge motion plate kit for an eight cylinder engine would include two charge motion plates each including at least four air intake apertures. The plates are constructed to mount juxtaposed to the intake manifold mounting flange and the cylinder head intake manifold mounting surface in a sandwiched configuration.
The pre-existing OEM CMCVs include cast or injection molded plates. Each plate includes an aperture aligned with each cylinder of the engine. An elongated rod extends longitudinally through the center portion of each plate. A stamped sheet metal plate is mounted to the rod within each aperture. A pneumatic or electric motor attaches to the rod to provide rotational movement for opening and closing the sheet metal valves in response to commands from the vehicle's on-board computer.
The instant invention provides a charge motion plate kit which replaces the charge motion control valves of the prior art. The charge motion control plates of the instant invention are preferably constructed of billet aluminum and provide increased air flow when compared to the prior art CMCVs. Each plate includes a first surface and a second surface. The first surface is positionable juxtaposed to the intake surface of the cylinder head while the second surface is positionable juxtaposed to the intake manifold mounting flange. The charge motion control plates include an outer contoured perimeter which allows the plates to be mounted to a broad range of engine configurations without interference from sensors or other engine components. In the preferred embodiment, each charge motion control plate includes an air/fuel flow aperture extending through the plate for each cylinder of one engine cylinder bank. The air/fuel flow apertures are sized and shaped to approximate the size and shape of the engines intake ports. In the case of siamese intake ports, the air/fuel flow apertures are preferably sized and shaped to approximate the size and shape of both siamese ports without a divider rib. However, in some application, the divider rib may be included to further modify the flow characteristics of air entering the cylinder. The charge motion control plates also preferably include a plurality of through holes constructed and arranged to align with existing fastener apertures in the intake manifold and cylinder head for secure attachment of the charge motion control plates. Alternatively, the plates may be constructed and arranged for adhesive attachment to either or both the intake manifold and/or cylinder head.
In one embodiment each air flow aperture within the charge motion control plate(s) includes a threaded aperture extending from an outer surface through to the air flow aperture(s) for attachment of a nitrous oxide manifold. The threaded aperture(s) facilitate easy attachment of a nitrous oxide injection system for additional horsepower production.
Accordingly, it is an objective of the present invention to provide a charge motion control plate kit for vehicles with OEM installed charge motion control valves.
An additional objective of the present invention is to provide a charge motion control plate kit which provides even distribution of the fuel and air mixture to both branches of a siamese intake port arrangement.
It is a further objective of the present invention to provide a charge motion control plate kit that reduces airflow restriction, when compared to the prior art CMCVs, for crisper throttle response and increased horsepower production.
A still further objective of the present invention is to provide a charge motion control plate kit which provides compatibility with OEM or aftermarket turbo chargers, superchargers and nitrous oxide injection systems.
Another objective of the present invention is to provide a charge motion control plate kit for vehicles which is simple to install and which is ideally suited for original equipment and aftermarket installations.
Yet another objective of the present invention is to provide a charge motion control plate kit that can be inexpensively manufactured and which is simple and reliable in operation.
Still another objective of this invention is to provide a charge motion control plate kit that does not require moving parts to malfunction or adjust.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are 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 FIGURES
FIG. 1 is a perspective view of a cylinder of an internal combustion engine illustrating a prior art charge motion control valve;
FIG. 2 is a top view of the cylinder including the prior art charge motion control valve illustrated in FIG. 1 ;
FIG. 3 is a perspective view of the charge motion control plate of the instant invention;
FIG. 4 is a side view of the charge motion control plate of the instant invention;
FIG. 5 is a bottom view of the charge motion control plate of the instant invention;
FIG. 6 is a side view of the charge motion control plate of the instant invention;
FIG. 7 is a section view of the charge motion control plate taken along lines 1 — 1 of FIG. 5 ;
FIG. 8 is a section view of the charge motion control plate taken along lines 2 — 2 of FIG. 4 ;
FIG. 9 is a section view of the charge motion control plate taken along lines 3 — 3 of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Although the invention is described in terms of a preferred specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto.
Referring now to FIGS. 1 and 2 , there is shown a prior art charge motion control valve 10 . The device is adapted for use in combination with an internal combustion engine of the type having at least one cylinder 12 . Cylinder 12 includes a pair of intake valves 14 , 16 , which selectively and respectively allow intake ports 18 , 20 to be fluidly connected to cylinder 12 and to deliver an air and fuel mixture to cylinder 12 . Cylinder 12 further includes at least one exhaust valve 22 which selectively discharges exhaust gasses from the cylinder 12 through discharge port 24 . Cylinder 12 further includes a conventional piston 26 which is slidably disposed within cylinder 12 .
Intake ports 18 and 20 comprise “Siamese” type intake ports which are integrally and fluidly joined to an air intake conduit 28 which splits or “branches” at point 30 , thereby supplying intake ports 18 and 20 . A conventional fuel injector 32 is operatively disposed within port 28 and includes a conventional “split” spray nozzle 34 which is operatively disposed in relative close proximity to point 30 and which is effective to selectively spray a stream of atomized fuel 33 into ports 18 and 20 .
The prior art charge motion control valve (“CMCV”) 10 is made from a relatively thin heat resistant metal material. CMCV 10 is mounted along a rod (not shown) in a typical manner for pivotal movement within port 28 . An electric or vacuum motor (not shown) is secured to the rod for opening and closing the CMCV in response to commands from the on-board computer. In the closed position the nozzle portion 34 of fuel injector 32 extends past valve 10 and discharges fuel slightly “downstream” from valve 10 .
Referring to FIGS. 3–6 , one embodiment of the instant invention charge motion control plate 100 is illustrated. The instant invention provides a charge motion control plate kit which replaces the charge motion control valves 10 ( FIGS. 1 and 2 ) of the prior art. Each plate is generally rectangular in shape and includes a first surface 102 , a second surface 104 , a top surface 114 , a bottom surface 116 and a pair of end surfaces 118 . The first surface is positionable juxtaposed to the intake surface of the cylinder head while the second surface is positionable juxtaposed to the intake manifold mounting flange. Each charge motion control plate 100 includes an outer contoured perimeter 106 which allows the plates to be mounted to a broad range of engine configurations without interference from sensors or other engine components. In the preferred embodiment, each charge motion control plate includes at least one air/fuel flow aperture 108 extending through the plate for each cylinder of each engine cylinder bank. The air/fuel flow apertures 108 are sized and shaped to approximate the size and shape of the engines intake ports 18 and 20 ( FIGS. 1 and 2 ). In the case of siamese intake ports, the air flow apertures are preferably sized and shaped to approximate the size and shape of both siamese ports without a divider rib. However, in some applications a divider rib (not shown) may be included to further modify or control the flow characteristics of air entering the cylinder. In a most preferred embodiment, the air flow aperture 108 includes angled perimeter surfaces 110 which provide a directed air flow into the intake ports. One embodiment of the charge motion control plates 100 also preferably include a plurality of through holes 111 constructed and arranged to align with existing fastener apertures in the intake manifold and cylinder head for secure attachment of the charge motion control plates. The first and/or second surface 102 , 104 may also include a seal constructed and arranged to prevent air from leaking between the mounting surfaces and into the combustion chamber. In a non-limiting embodiment, the preferred seal includes an O-ring groove 112 and a cooperating O-ring (not shown). Alternative seals, which may include, but should not be limited to gaskets, overlapping seals, copper seals, compression seals and suitable combinations thereof may be utilized in place of the O-ring and O-ring groove. Alternatively, the plates may be constructed and arranged for adhesive attachment to either or both the intake manifold and/or cylinder head. Adhesives suitable for attachment of the charge motion control plates are described in, but should not be limited to, U.S. Pat. No. 6,739,302 incorporated herein by reference.
Referring to FIGS. 3 , 5 , 7 – 8 , one embodiment of the charge motion control plates is illustrated. In this embodiment, the bottom surface of the outer contoured perimeter includes at least one nitrous oxide injection port 120 for transfer of a nitrous oxide gas into the air flow aperture 108 . The nitrous oxide injection port(s) extends between the outer contoured perimeter and the air flow aperture(s). The nitrous oxide injection ports may be drilled at a suitable angle for ease of attaching the nitrous oxide injection system and preferably include internal threads 122 for attachment of fittings and the like. Alternative means of attaching nitrous oxide injection systems such as snap rings, epoxy, integrally formed fittings and the like may alternatively be utilized without departing from the scope of the invention.
In a most preferred and non-limiting embodiment, the charge motion control plate(s) are constructed of aluminum and are about 1 3/16 inches thick. It should be appreciated that the charge motion control plate(s) may be made thinner or thicker as the space requirements, materials and engine configurations require. The charge motion control plate may alternatively be made from other materials which may include, but should not be limited to steel, titanium, plastic or suitable combinations thereof.
The charge motion plates of the instant invention may be installed on vehicles which include OEM installed CMCVs by simply removing the CMCV from its position between the air conduit and the first and second intake ports and securing the instant invention charge motion control plate(s) between the air conduit and the first and second intake ports. Once the charge motion plates are secured in place, air may be drawn or directed through the air conduit by the engine, wherein the air is divided into substantially equal amounts entering into the first intake port and the second intake port to carry a fuel into the cylinder.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement 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 of the invention and the invention is not to be considered limited to what is shown and described in the specification.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | The present invention provides a charge motion plate kit for internal combustion engines. More specifically, the charge motion plate kit permits replacement of the OEM charge motion valves of the prior art for high performance applications. In one embodiment, the charge motion plate kit comprises a single charge motion plate for each bank of cylinders, each charge motion plate includes at least one aperture for each cylinder within the bank. The plates are constructed to mount juxtaposed to the intake manifold mounting flange and the cylinder head intake manifold mounting surface in a sandwiched configuration. | 8 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with Government support under Contract No. B601996 awarded by the United States Department of Energy. The Government has certain rights in this invention.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the data-processing field, and more particularly, to a method and apparatus for implementing an enhanced, three-dimensional (3D) semiconductor stack.
DESCRIPTION OF THE RELATED ART
[0003] Three-dimensional (3D) semiconductor stacking including 3D semiconductor memory stacking is an emerging technology. A 3D semiconductor memory stack advantageously can include a processor die, also known as the logic die or master die in a stack with a slave die, such as a slave DRAM stack.
[0004] Micron Technology has recently proposed a hybrid memory cube (HMC) in which four to eight dynamic random-access memory (DRAM) die are stacked one above the other using through-silicon-via (TSV) technology. This space- and energy-efficient group of DRAMs is then connected to a controller device, forming either a five-chip or nine-chip stack. A Hybrid Memory Cube Consortium (HMCC) is backed by several major technology companies.
[0005] The HMC is a very-high-bandwidth device, and promises to be a compelling technology, although it is a low-memory-capacity replacement for a hub-chip memory, Dual Inline Memory Module (DIMM) with a controlled module, for example IBM's SuperNova DIMM.
[0006] A High-Bandwidth DRAM (HBM) is a similar stack of DRAMs being developed at JEDEC, an independent semiconductor engineering trade organization and standardization body. Although high bandwidth, the HBM is also a low-memory-capacity replacement for a buffered DIMM, or DIMM with address, data, and clock redrive.
[0007] Both the HMC and the HBM are expected to be placed adjacent to a processor on a substrate having the capacity for high-density wiring. Both approaches to 3D stacking of memory require a high-wiring-density substrate between the data storage DRAM and the data processing, to carry the many signals expected between the processor and memory stack.
[0008] U.S. Pat. No. 8,343,804, issued Jan. 1, 2013 to Paul W. Coteus et al. and assigned to the present assignee, discloses a method and structure for implementing multiple different types of dies for memory stacking. In FIGS. 1A , and 1 B, a master-slave structure comprises a printed circuit board (PCB), a master die, and a plurality of slave dies. For example, in the illustrated prior-art master-slave, only the bottom die, labeled “master” in the stacked package, communicates to the outside of the package, thereby to save standby power by allowing the shutting down of circuitry in other dies that are not required to operate. FIG. 1B illustrates the bottom master die, which includes a plurality of arrays and a periphery segment centrally located between the arrays. Multiple through-silicon-vias (TSVs) are placed within the periphery segment.
[0009] U.S. Pat. No. 8,343,804, issued Aug. 20, 2013 to Paul W. Coteus et al. and assigned to the present assignee, discloses a method and circuit for implementing stacking to distribute a logical function over multiple dies in through-silicon-via stacked semiconductor devices. Each die in the die stack includes predefined functional logic for implementing a respective predefined function. The respective predefined function is executed in each respective die and a respective functional result is provided to an adjacent die in the die stack. Each die in the die stack includes logic for providing die identification. An operational die signature is formed by combining a plurality of selected signals on each die. A die signature is coupled to an adjacent die using TSV interconnections where it is combined with that die signature.
[0010] A need exists for an efficient and effective method and apparatus for implementing an enhanced three dimensional (3D) semiconductor stack. It is desirable that a master die be connected directly to a chip-carrier substrate that provides power and carries interface signals. It is desirable to provide such a 3D semiconductor stack structure that preserves a simple stacked DRAM without needing to pass power connections, signal connections, or heat from an associated master die through the DRAM stack, or to impose area or power limitations on the master die.
SUMMARY OF THE INVENTION
[0011] A principal aspect of the present invention is to provide a method and apparatus for implementing an enhanced three dimensional (3D) semiconductor stack. Other important aspects of the present invention are to provide such method and apparatus substantially without negative effects, and that overcome many of the disadvantages of prior-art arrangements.
[0012] In brief, a method and apparatus are provided for implementing an enhanced, three-dimensional (3D) semiconductor stack. A chip carrier has an aperture of a first length and first width. A first chip has at least one of a second length greater than the first length or a second width greater than the first width; a second chip attached to the first chip, the second chip having at least one of a third length less than the first length or a third width less than the first width; the first chip attached to the chip carrier by connections in an overlap region defined by at least one of the first and second lengths or the first and second widths; the second chip extending into the aperture; and a heat spreader attached to the chip carrier and in thermal contact with the first chip for dissipating heat from both the first chip and second chip.
[0013] In accordance with features of the invention, the first chip includes a master die of an inverted master-slave 3D semiconductor stack. A processor or master die is connected directly to the chip carrier substrate that provides power and carries interface signals to a slave DRAM stack.
[0014] In accordance with features of the invention, the master die is placed on a wiring substrate of the chip carrier, which provides the power and all signal connections.
[0015] In accordance with features of the invention, the second chip extending through a hole in the chip carrier includes a DRAM stack that is attached directly to the master die. A thermal path exists between the master die and DRAM stack, and the DRAM stack is effectively cooled through the master die.
[0016] In accordance with features of the invention, the chip carrier aperture optionally includes a blind hole with the DRAM stack attached directly to the master die before assembly with the chip carrier. The DRAM stack is set in the blind hole cavity in the chip carrier which protects it. This also allows the lower wiring layers of the chip carrier to carry signals to an area array of contacts covering substantially the entire bottom surface thereof.
[0017] In accordance with features of the invention, the 3D semiconductor stack includes the master die, which is oversized on all four sides, thereby eliminating the need for through-silicon-vias.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the preferred embodiments of the invention illustrated in the drawings, wherein:
[0019] FIG. 1 is an exploded perspective view not to scale of example structures for implementing an enhanced three dimensional (3D) semiconductor stack in accordance with preferred embodiments;
[0020] FIGS. 2A , 2 B, 2 C, and 2 D show an example assembly sequence for implementing the example enhanced three dimensional (3D) semiconductor stack of FIG. 1 in accordance with preferred embodiments;
[0021] FIGS. 3A , 3 B, 3 C, and 3 D show another example assembly sequence for implementing the example enhanced three dimensional (3D) semiconductor stack of FIG. 1 in accordance with preferred embodiments;
[0022] FIG. 4 is an exploded perspective view not to scale of example structures for implementing a second enhanced three dimensional (3D) semiconductor stack in accordance with preferred embodiments;
[0023] FIGS. 5A , 5 B, 5 C, 5 D, and 5 E show an example assembly sequence for implementing the example second enhanced three dimensional (3D) semiconductor stack of FIG. 4 in accordance with preferred embodiments; and
[0024] FIG. 6 illustrates a temperature distribution of example enhanced three dimensional (3D) semiconductor stacks in accordance with preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] In the following detailed description of embodiments of the invention, reference is made to the accompanying drawings, which illustrate example embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention.
[0026] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0027] In accordance with features of the invention, a method, and structures are provided for implementing enhanced three dimensional (3D) semiconductor stacks.
[0028] Having reference now to the drawings, FIG. 1 is an exploded perspective view not to scale of example structures for implementing an enhanced three dimensional (3D) semiconductor stack generally designated by the reference character 100 in accordance with preferred embodiments. As shown, an imaginary Cartesian coordinate system 102 defines x, y, and z directions.
[0029] The 3D semiconductor stack 100 includes a lid or heat spreader 104 , a processor die 106 that is also called a logic die or a master die, a chip carrier or substrate 108 having a through hole 112 , and a DRAM stack 110 . Chip carrier 108 , which provides all power and signal connections, may be a conventional, low-cost, thin-core or coreless organic substrate with additive wiring layers, a known technology, such as practiced by Kyocera.
[0030] Through hole 112 in chip carrier 108 is slightly larger in the x and y directions than DRAM stack 110 , so that DRAM stack 110 may nest in through-hole 112 . Through-hole 112 optionally includes one or more corner reliefs 114 to minimize stress concentration.
[0031] Master die 106 is not thinned in the z direction, thereby eliminating the cost of a thinning process. In the x and y directions, master die 106 is provided intentionally larger than the through hole 112 , so that the periphery of master die 106 may engage arrays 116 , 118 , 120 , and 122 of connection elements that are fabricated on the positive-z-facing surface of chip carrier substrate 108 , around the edges of through-hole 112 . The positive-z-facing surface of chip carrier 108 comprises a plurality of arrays of connection elements around the periphery of through-hole 112 , such as connection arrays 116 , 118 , 120 , and 122 , to which master die 106 will be attached.
[0032] Decoupling capacitors 124 will also be attached to chip carrier 108 , using pads (not shown). The positive-z-facing surface of DRAM stack 110 comprises an array of connection elements 126 that is used to attach DRAM stack 110 to the negative-z-facing surface of master die 106 .
[0033] Referring to FIGS. 2A , 2 B, 2 C, and 2 D, there is shown an example assembly sequence for implementing the example enhanced three dimensional (3D) semiconductor stack 100 of FIG. 1 in accordance with preferred embodiments.
[0034] Referring now to FIG. 2A , the 3D semiconductor stack 100 is shown in a different view illustrating additional features generally designated by the reference character 200 . As shown in FIG. 2A , a plurality of arrays 202 , 204 , 206 , and 208 of connection elements are fabricated on the periphery of negative-z-facing surface of master die 106 , which includes a central area 210 . The negative-z-facing surface of heat spreader 104 comprises a central area 212 in which master die 106 and decoupling capacitors 122 nest, and a peripheral area 214 that will, in the assembly process shown presently, be attached to the positive-z-facing surface of chip carrier 108 .
[0035] The negative-z-facing surface of the chip carrier substrate 108 comprises an array of connection elements 211 , such as gold-plated pads for use with a land-grid-array connector that connects the package 100 to a main circuit board (not shown). The thickness of chip carrier 108 must be large enough so that, after assembly, the negative-z-facing surface 216 of DRAM stack 110 does not protrude beyond the negative-z-facing surface of chip carrier 108 .
[0036] Referring now to FIG. 2B , a first step generally designated by the reference character 220 in the first assembly sequence of the 3D semiconductor stack 100 is shown. The first step 220 in the first assembly sequence is to solder-attach the master die 106 and the decoupling capacitors 122 to the chip carrier substrate 108 . Specifically, the arrays 116 , 118 , 120 , and 122 of connection elements on the positive-z-facing surface of chip carrier substrate 108 are solder-attached to the corresponding arrays 202 , 204 , 206 , and 208 of connection elements on the negative-z-facing surface of master die 106 .
[0037] Referring now to FIG. 2C , a second step generally designated by the reference character 230 in the first assembly sequence of the 3D semiconductor stack 100 is shown. The second step 230 of the first assembly sequence is to solder-attach the DRAM stack 110 to the master die 106 , as shown in FIG. 2C , with the array 126 of connection elements on the plus-z-facing surface of the DRAM stack 110 (see FIG. 1 ) being solder-attached to the array 211 of connections elements on the negative-z-facing surface of the master die 106 .
[0038] Referring now to FIG. 2D , there is shown a next or final step generally designated by the reference character 240 in the first assembly sequence of the 3D semiconductor stack 100 . The final step 240 of the first assembly sequence is to attach the heat spreader 104 to the chip carrier 108 , by conventional techniques well known in the art.
[0039] Referring to FIGS. 3A , 3 B, 3 C, and 3 D, there is shown a second example assembly sequence for implementing the example enhanced three dimensional (3D) semiconductor stack of FIG. 1 in accordance with preferred embodiments. As compared to the first assembly sequence of FIGS. 2A , 2 B, 2 C, and 2 D, the second assembly sequence reverses the order of the first and second steps.
[0040] Referring now to FIG. 3A , the 3D semiconductor stack 100 is shown in an exploded view starting position generally designated by the reference character 300 for the example second assembly sequence.
[0041] Referring now to FIG. 3B , there is shown a first step generally designated by the reference character 310 in the second assembly sequence of the 3D semiconductor stack 100 . The first step 310 in the second assembly sequence is to solder-attach DRAM stack 110 to master die 106 . Specifically, array 126 of connection elements on the plus-z-facing surface of DRAM stack 110 (see FIG. 1 ) is solder-attached to array 210 of connections elements on the negative-z-facing surface of the master die 106 . This step 310 creates a master-die/DRAM assembly, as shown in FIG. 3B .
[0042] Referring now to FIG. 3C , there is shown a second step generally designated by the reference character 330 in the second assembly sequence of the 3D semiconductor stack 100 . The second step in the second assembly sequence is to solder-attach the master-die/DRAM assembly to chip carrier 108 . Specifically, arrays 116 , 118 , 120 , and 122 of connection elements, located on the positive-z-facing surface of chip carrier 108 , visible in FIG. 3B , are solder-attached to the corresponding arrays 202 , 204 , 206 , and 208 of connection elements located on the negative-z-facing surface of master die 106 .
[0043] Referring now to FIG. 3D , there is shown a final step generally designated by the reference character 340 in the second assembly sequence of the 3D semiconductor stack 100 . The final step 340 of the second assembly sequence is to attach heat spreader 104 to chip carrier 108 , where the result is identical to that shown in FIG. 2D .
[0044] Referring now to FIG. 4 , there is shown a second enhanced three dimensional (3D) semiconductor stack generally designated by the reference character 400 in accordance with preferred embodiments. In FIG. 4 and FIGS. 5A , 5 B, 5 C, 5 D, and 5 E the same reference numbers are used for substantially similar or identical components of the second enhanced 3D semiconductor stack 400 as compared to the enhanced 3D semiconductor stack 100 .
[0045] As shown in FIG. 4 , the second enhanced 3D semiconductor stack 400 as compared to the enhanced 3D semiconductor stack 100 includes a chip carrier 402 having a blind-hole cavity 404 , instead of the chip carrier 108 having the through-hole 112 . For example, the blind-hole cavity 404 is drilled, milled or reamed to a set depth without breaking through to the other side of chip carrier 402 .
[0046] Referring also to FIGS. 5A , 5 B, 5 C, 5 D, and 5 E, a second example assembly sequence for implementing the example second enhanced three dimensional (3D) semiconductor stack 400 in accordance with preferred embodiments. Because the chip carrier 402 comprises blind hole 404 rather than through hole 112 , the first assembly sequence described with respect to FIGS. 2A , 2 B, 2 C, and 2 D for the first 3D semiconductor stack 100 is not possible for the second first 3D semiconductor stack 400 .
[0047] Referring to FIG. 5A , the 3D semiconductor stack 400 is shown in an exploded view starting position generally designated by the reference character 500 for the example second assembly sequence. The negative-z-facing surface of substrate 402 advantageously, but optionally, is populated with a full rectangular array of connections elements 502 , whereas the first 3D semiconductor stack 100 may be populated with only a partial array of connections elements 210 , due to the presence of the through hole 112 , for example as shown in FIG. 2A . All other components are identical in the 3D semiconductor stack 100 and the 3D semiconductor stack 400 .
[0048] Referring now to FIGS. 5B and 5C , there are shown two perspective views of a first step in the second assembly sequence of the 3D semiconductor stack 100 , the first step being generally designated by the reference character 510 . The first step 510 in the second assembly sequence is to solder-attach the DRAM stack 110 to the master die 106 . This step 510 creates a master-die/DRAM assembly, visible in FIG. 5B .
[0049] Referring now to FIG. 5D , there is shown a second step generally designated by the reference character 540 in the second assembly sequence of the 3D semiconductor stack 100 . The second step 540 in the second assembly sequence is to solder-attach the master-die/DRAM assembly to chip carrier 402 . Specifically, arrays 116 , 118 , 120 , and 122 of connection elements on the positive-z-facing surface of chip carrier 402 , visible in FIG. 5C , are solder-attached to the corresponding arrays 202 , 204 , 206 , and 208 of connection elements on the negative-z-facing surface of master die 106 , visible in FIG. 5B .
[0050] Referring now to FIG. 5E , there is shown a final step generally designated by the reference character 550 in the second assembly sequence of the 3D semiconductor stack 100 . The final step 550 of the second assembly sequence is to attach heat spreader 104 to chip carrier 402 .
[0051] Although the second 3D semiconductor stack 400 rules out the first assembly sequence, the 3D semiconductor stack 400 has two advantages over the first 3D semiconductor stack 100 . First, blind hole 404 protects the rear surface of DRAM stack 106 ; and second, the full array 502 of connections elements in semiconductor stack 400 comprises a greater number of connections elements than the partial array 210 of connection elements in the 3D semiconductor stack 100 . Such a large number of connection elements may be required to carry a large number of signals to and from the semiconductor stack 400 . Consequently, if the second assembly sequence is viable, then the second 3D semiconductor stack 400 is preferred. However, if the second assembly sequence is not viable, then the first 3D semiconductor stack 100 is preferred.
[0052] In the first and second enhanced three dimensional (3D) semiconductor stack 100 , 400 , power enters the chip stack through the peripheral portion of the master die that overhangs the through-hole 112 or blind-hole 402 . Consequently, power to DRAM stack 110 and any logic of master die 106 under DRAM stack 110 is fed horizontally, parallel to the plane of master die 106 , which adds undesirable inductance and resistance to the wiring. The power-delivery problem has two potential solutions. The first solution makes use of so-called thick metal layers on master die 106 . Although thick wiring layers are usually not employed on the DRAM layers, thick metal layers can be used on master die 106 for power distribution. Such thick metal layers are sufficient to deliver sufficient power to the interior of the stack 100 , 400 to power both significant master die logic, as well as the DRAM stack 110 . The second solution makes use of on-die voltage-regulation techniques, such as that used in IBM's Power7 processor. Such on-die voltage-regulation techniques create a very well-regulated voltage, offsetting the undesirable effects of the lateral wiring inductance and resistance.
[0053] Both the first enhanced 3D semiconductor stack 100 and the second enhanced 3D semiconductor stack 400 allow for the backside of master die 106 to be connected directly to heat spreader 104 or other cooling means, such that heat generated in the DRAM stack 110 travels through master die 106 to the cooling means. This cooling arrangement is preferred to the opposite situation in the prior art, where heat generated in the master die travels through the DRAM stack to the cooling means, because the master die generates more power than the DRAM stack. Consequently, thermal performance is better for the 3D semiconductor stack 100 and the 3D semiconductor stack 400 , as illustrated by the thermal simulation illustrated in FIG. 6 . Although DRAM temperature is slightly increased as compared to prior-art arrangements, the master-die temperature is dramatically reduced.
[0054] Referring to FIG. 6 there is shown an example temperature distribution for the 3D semiconductor stack 100 and the 3D semiconductor stack 400 in accordance with preferred embodiments. Effective thermal performance is provided, as illustrated by the temperature distribution 600 for the 3D semiconductor stack 100 and the 3D semiconductor stack 400 , providing improvement over the prior-art cooling arrangements.
[0055] While the present invention has been described with reference to the details of the embodiments of the invention shown in the drawing, these details are not intended to limit the scope of the invention as claimed in the appended claims. | A method and apparatus are provided for implementing an enhanced three dimensional (3D) semiconductor stack. A chip carrier has an aperture of a first length and first width. A first chip has at least one of a second length greater than the first length or a second width greater than the first width; a second chip attached to the first chip, the second chip having at least one of a third length less than the first length or a third width less than the first width; the first chip attached to the chip carrier by connections in an overlap region defined by at least one of the first and second lengths or the first and second widths; the second chip extending into the aperture; and a heat spreader attached to the chip carrier and in thermal contact with the first chip for dissipating heat from both the first chip and second chip. | 7 |
FIELD OF THE INVENTION
This invention relates to an electrical connector which allows for rotational movement of a part of the connector to accommodate different orientations of electrical outlets or different desired positions of electrical appliances attached to the connector. The invention is described in the context of, but is not limited to, a lighting appliance such as a night light.
BACKGROUND OF THE INVENTION
Rotatable electrical connectors which permit movement of one side of the connector with respect to the other side of the connector are known in the art. Typically, such connectors allow for 360 degree rotation of the two sides by the use of concentric annular coaxial contact surfaces and are designed to prevent twisting of cords connected thereto. For example, U.S. Pat. No. 4,583,798 discloses the use of a series of contact rings in alignment with contact elements, all disposed within a shell having an openended cylindrical bore. The contact rings are disposed on a barrel within the bore. The barrel is free to rotate about the bore as the cords attached to either end of the connector exhibit rotational movement, thereby preventing the cords from being twisted and kinked. Electrical contact is continuously maintained between the contact rings and the contact elements throughout the rotational movement.
U.S. Pat. No. 4,753,600 discloses a similar concept employing inner and outer copper circular rings. A pair of opposing plates are rotatably joined together by an axle around which the plates rotate so that during rotation, electrical current passes through both plates without interruption. Thus, for example, a tool being directed in a circular motion can be attached to the connector and can then be used continuously without concern of twisting or effective shortening of the electrical supply cord.
U.S. Pat. No. 4,026,618 discloses an electrical plug which is designed to be mounted to a wall socket. The electrical cord connected to the plug may be rotated to any point around a 360 degree path. Such a plug allows for a low profile (i.e., the plug extends outward a very short distance away from the wall socket) thereby allowing objects such as furniture to be positioned very close to the wall. If an electrical appliance is connected to the plug through the electrical cord, such a design allows the electrical cord to be turned around the plug as the orientation of the electrical appliance to the plug changes. These results are achieved by the use of a rotatable disk plate with concentric annular conductive ridges.
All of these patents have in common the fact that they are designed to allow free movement along a 360 degree path and are not designed to be set or held at any particular angular position.
The problem often arises that the orientation of the plug end of an electrical appliance prevents the use of an adjacent plug within the same electrical box. For example, the most common form of electrical outlet comes in pairs. A rotational feature allows for an electrical appliance such as a night light to make advantageous use of multiple plug electrical outlets, regardless of their original orientation against a wall or along an extension cord. However, in the prior art described above, the lack of a tight frictional contact between the two parts which rotate with respect to one another will not allow the electrical connector to remain in a desired fixed position. Also, any twisting of cords attached to the connector would provide sufficient force to change the connector's orientation. If an electrical appliance were directly attached to the connector, the resting position of the appliance in the outlet would depend upon gravitational forces instead of a desired functionally useful position (e.g., one that does not block other outlets or cause electrical cord to hang over other outlets) or an aesthetically pleasing position.
Certain types of plug-in appliances, such as clocks and lighting fixtures, have a required or preferred orientation but typically are furnished with an electrical plug whose orientation is fixed with respect to the appliance. Electrical wiring codes vary in different parts of the country. Some codes require outlets in the same electrical box to be positioned horizontally with respect to one another while other codes require outlets in the same electrical box to be positioned vertically with respect to one another. Such appliances are readily accommodated by an outlet of a given orientation but are not suitable for use with outlets oriented at 90 degrees from the given orientation.
There is still a need for a rotatable electrical connector which allows for movement between a limited angular range to accommodate different orientations of electrical plugs and outlets, which will stay fixed in a desired position unless physically moved and which can achieve these goals through a design that is simple to fabricate. The present invention fills that need.
SUMMARY OF THE INVENTION
The present invention defines an electrical connector formed from two pairs of electrical contacts. One pair of contacts is rotatable with respect to the other pair of contacts. A first pair of contacts have arcuate electrically conductive contact surfaces and are symmetrically arranged with respect to an axis of rotation. The first pair of contacts are in opposed relation to one another and are separated at each end by a non-conductive space. The second pair is meant to be connected to an electrical appliance. The two pairs of contacts are kept in frictional and electrical contact throughout a preselected degree of angular rotation. One of the pairs is connected to male prongs.
In another embodiment, the invention provides an electrical connector formed from two pairs of electrical contacts. One pair of contacts is rotatable with respect to the other pair of contacts. The two pairs of contacts are kept in frictional and electrical contact throughout a 90 degree rotation. Stops are employed to limit rotation to 90 degrees. One of the pairs is connected to male prongs.
The invention also provides an electrical connector formed from two pairs of electrical contacts, one pair of contacts being rotatable with respect to the other pair of contacts. A first pair of contacts have arcuate electrically conductive contact surfaces and are symmetrically arranged with respect to an axis of rotation. The first pair of contacts are in opposed relation to one another and are separated at each end by a non-conductive space. This first pair is connected to male electrical prongs. The second pair is mounted on a support and is connected to an electrical appliance. The two pairs of contacts are kept in frictional and electrical contact throughout a preselected degree of rotation. In this embodiment, the first pair of contacts and the electrical prongs attached thereto are fastened to a nonconductive disk which is seated into a groove in a disk holder. The nonconductive disk rotates within the groove to change the orientation of the electrical prongs with respect to the support.
The invention also provides for a frictional force sufficient to inhibit undesired spontaneous movement of the two sets of electrical contacts with respect to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is perspective view of one preferred form of a rotatable electrical connector in accordance with the present invention as viewed attached to a night light.
FIG. 2 is a sectional view of the night light taken along axis line 2--2 of FIG. 1.
FIG. 3 is an exploded isometric view of one preferred form of a rotatable electrical connector in accordance with the present invention as viewed attached to the night light.
FIG. 4 is an enlarged transverse sectional view of parts of the connector including a disk placed within a rotatable disk holder taken along axis line 4--4 of FIG. 1.
FIG. 5 is an enlarged side elevation view of the disk from its side.
FIG. 6 is an exploded isometric view of the disk and the disk holder.
FIG. 7 is a sectional view of the night light taken along axis line 7--7 in FIG. 2 depicting details of the light's on-off switch.
FIG. 8 is a perspective view of a sensor-activated night light.
FIG. 9 is a sectional view of the circuitry related to the sensoractivated night light embodiment, taken along axis line 9--9 of FIG. 8.
FIG. 10 is a sectional view of the night light taken along axis line 10--10 of FIG. 9.
FIG. 11 is a perspective view of the night light when viewed with blades facing outward.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Apparatus depicting the preferred embodiments of the novel rotatable electrical connector are illustrated in the drawings.
FIG. 1 shows a perspective view of an exemplary end product, a night light, which incorporates therein the novel rotatable electrical connector. The night light is plugged into an electrical outlet by blades 10 (only one blade is visible in the isometric view) and controlled by on/off switch 12 of the rocker type. This view also shows countersunk screw holes 14 which receive screws that connect support 16 to disk holder 18, as described below.
FIG. 2 shows a sectional view of the back side of support 16 taken along axis line 2--2 of FIG. 1. Conductive contacts 20 protrude through to the back side of support 16 and are attached to an electrical conductor, electrical cord, or directly to whatever electrical appliance is desired to be operated. In this embodiment, the conductive contacts 20 are connected through switch 12 (shown in its "off" position) to a light bulb socket 22.
Turning now to FIG. 3, the components of assembly 24 will be described herein. Each of blades 10 are attached at one end to a respective conductive plate 26. Disk 28 is disposed between the conductive plates 26 and the blades 10. In the preferred embodiment, each blade 10 extends through disk 28 and is attached to one end of the conductive plate 26 on the inner facing side of the disk 28. Disk 28 is constructed of a nonconducting material, such as plastic. In the preferred embodiment, blade 10 and conductive plate 26 are formed of a single electrical conductor, bent at right angles to form a blade and plate portion. Each conductive plate 26 is adhered to the disk 28 by fasteners 30 on either side of the plate. Two tabs 32 extend radially outward at diametrically opposed locations on disk 28.
The conductive plates 26 lie flush against the inward facing side of the disk 28, i.e., the side of disk 28 which faces support 16. Conductive plates 26 preferably have an arcuate shape, are symmetrically arranged with respect to the center of disk 28, and are in opposed relation to one another. The ends of the plates are separated by a space so as to avoid creating an electrical short between the two blades.
Blades 10, plates 26 and disk 28 form a discrete subassembly 34. The entire blade/plate/disk subassembly 34 fits into circular groove 36 formed in disk holder 18. Groove 36 includes two oppositely disposed sections 38 (only one section is visible in the perspective view) having an arcuate recess 39 and two stop sections 40 at each end of arcuate recess 39. The diameter of the groove between oppositely disposed sections 38 is slightly larger than the diameter between the outer edges of tabs 32 on disk 28, as will be further described below. Disk holder 18 also includes threaded screw holes 46 at its corners.
FIG. 3 also depicts support 16 which provides a mounting structure for conductive contacts 20. These conductive contacts 20 lead to an electrical appliance such as bulb 42 screwed into socket 22. (The internal leads are not shown in this view.) Support 16 also includes screw holes 44 which line up with threaded screw holes 46 of disk holder 18 when fully assembled.
Assembly consists of placing the blade/plate/disk subassembly 34 into circular groove 36 so that tabs 32 lie flush against the oppositely disposed sections 38 of the groove. Then, disk holder 18 is fastened to support 16 by screws which are inserted into the back of the support 16 (depicted in FIG. 1 as screw holes 14) and which extend through hollow holes 44 and into threaded holes 46. After the screws are tightened, each conductive plate 26 will be in tight frictional contact with a respective conductive contact 20.
In operation, blades 10 are plugged into an electrical outlet. Thereafter, disk holder 18 and conductive contacts 46 mounted on support 16 are rotatable with respect to the blade/plate/disk subassembly 34. The arcuate shape of conductive plates 26 allows for their continuous electrical contact with respective contacts 20 throughout a limited rotational distance. As noted above, the rotational distance is limited by stop sections 40 within groove 36.
In the preferred embodiment, a 90 degree rotation is possible. When the orientation of the plug end of an electrical appliance prevents the use of an adjacent plug within the same electrical box, this 90 degree rotation feature allows for an electrical appliance such as a night light or an AC-DC transformer with blades at its output to make advantageous use of such outlets, regardless of the outlet's original orientation against a wall or on an extension cord. The assembled disk holder/support portion is merely rotated, if necessary, so as to not interfere with the use of an adjacent outlet. The stop sections ensure that the new orientation will be approximately 90 degrees from the old orientation so that if the holder/support portion is rectangular, it will always be at an aesthetically pleasing angle. The tight frictional contact also ensures that once placed in a desired position, the holder/support portion will not move on its own accord as it would in the prior art schemes described above. Even if the conductive contacts 20 were only connected to a cord, twisting of the cord would not provide enough force to move the orientation of the holder/support portion with respect to subassembly 34. In the prior art described above, such movement would result in potentially disadvantageous swiveling or rotating of the electrical connector.
FIG. 4 shows an enlarged sectional view of disk holder 18 with a disk 28 placed within the disk holder's groove. In this position, tabs 32 of the disk 28 abut stop sections 40. Blade/plate/disk subassembly 34 is free to rotate 90 degrees within the groove until the tabs 32 abut against respective oppositely facing stop sections 40.
FIG. 4, in combination with FIGS. 5-7, more clearly depicts the structure of disk 28 and the manner in which disk 28 fits into disk holder 18. The disk and disk holder are defined by portions having diameters D 1 through D 6 .
FIG. 4 shows diameter D 2 , which is the maximum diameter of groove 36 (only section 38 is visible), and diameter D 6 which is the maximum diameter of disk 28 (as taken between tabs 32). D 2 is slightly larger than D 6 so as to allow the disk to move within the groove. FIG. 4 also shows diameter D 5 , which is the maximum diameter of disk 28 without tabs 32, and diameter D 3 which is the diameter of groove 36 measured between stop sections 40. D 3 is slightly larger than D 5 so as to allow the disk to move within the groove. Stop section 40 is defined by D 2 being larger than D 3 .
FIG. 5 shows disk 28 in side elevation such that tabs 32 are not visible. The disk 28 has two portions, each defined by their own diameter. An upper portion 28a is defined by diameter D 4 , while a lower portion 28b is defined by diameter D 5 . D 4 is less than D 5 . This defines a shoulder 29 circumferentially around disk 28 to help seat disk 28 in the opening in disk holder 18, as will be now described.
FIG. 6 shows diameter D 4 associated with the upper portion 28a of disk 28 and diameter D 5 associated with the lower portion 28b of the disk. (In FIG. 4, only diameter D 5 associated with lower portion 28b is visible.) FIG. 6 also shows surface 18a, side wall 18b, and circular opening 19 of disk holder 18. Circular opening 19 has a diameter D 1 which is slightly larger than D 4 . It should also be appreciated that D 1 must be less than D 6 so as to prevent the disk from slipping through opening 19 and is preferably, but not necessarily, less than D 5 .
When disk 28 is placed within disk holder 18, only upper portion 28a is visible from the surface 18a of the disk holder 18. The upper portion 28a preferably lies flush with the surface 18a and the lower portion 28b lies within groove 36. Thus, after disk 28 is placed in disk holder 18, the lower portion 28b will be hidden from view, from the perspective of FIG. 6.
FIG. 7 shows a sectional view of the exemplary night light embodiment taken along axis line 7--7 in FIG. 2 and more clearly depicts the internal operation of on-off switch 12 shown in FIG. 1. The construction and operation of the on-off switch is not unique to the present invention and, for that reason, need not be described in detail. FIG. 7 also shows surface 18a and side wall 18b of disk holder 18 and shows diameters D 1 , D 2 , D 4 and D 5 as they appear in cross-section.
FIG. 8 shows a perspective view of the exemplary night light embodiment similar to FIG. 1, except for the replacement of on-off switch 12 by photocell 48.
FIG. 9 shows a sectional view of the circuitry related to photocell 48 shown in FIG. 8, taken along axis line 9--9 of FIG. 8. Circuitry comprising resistor 50 and transistor 52 are connected to the photocell 48 (depicted in FIG. 8) and cause selective activation and deactivation of power to socket 22 in accordance with the amount of light impinging upon the photocell.
FIG. 10 shows a sectional view of the exemplary night light embodiment taken along axis line 10--10 of FIG. 9.
FIG. 11 shows a perspective view of the exemplary night light embodiment when viewed with blades 10 facing outward from disk holder 18. The blade/plate/disk subassembly 34 can be oriented with respect to the remaining elements around a 90 degree range of position from a first position (as shown) to a second position (shown in phantom). In operation, a decorative or ornamental shade (not shown) can be placed around the socket 22 and bulb 42 area and attached to the night light. The shade can have partly opaque and partly translucent portions. The rotatable feature allows the light to be positioned in the preferred orientation. For example, if there is lettering or other printed matter on the shade, the shade can be oriented so that the lettering or other printed matter is properly oriented.
Although the preferred embodiments show the use of the invention for a night light, it should be understood that the invention is usable for connecting any electrical appliance to an electrical outlet. It should also be recognized that the blades 10 can be replaced by any male-type conductive connector that fits into a mating female socket. Thus, the invention is not limited to use with 110-120 V AC-type appliances.
Although the preferred embodiment discloses that blade 10 and conductive plate 26 are formed of a single electrical conductor, it should be recognized that single fabrication is not necessary. It is only required that blade 10 be electrically connected by some manner, and at some point, to plate 26.
It should also be appreciated that the respective positions of the conductive plates and conductive contacts could be easily reversed. Thus, the conductive contacts could be formed on the inside facing surface of disk 28 and the plates could be placed on support 16. Also, stop sections 40 which limit the rotation to 90 degrees need not be formed inside groove 36. The groove 36 could be formed with only a single depth and protrusions extending out from support 16 could butt against tabs 32, thereby the rotational distance. Alternatively, a single depth groove could be used and tabs 32 could extend outward from disk 28. In this embodiment, protrusions extending out from support 16 would, likewise, limit the rotational distance.
Lastly, it should be realized that the various parts of the electrical connector need not be held together by screws. Instead, glue or snap-together parts may be employed.
The novel rotatable electrical connector described above provides significant advantages not contemplated by prior art rotatable electrical connectors. The ability to maintain the connector at a desired rotational position provides functional and aesthetic advantages not available with freely rotating (360 degree) connectors. Also, the fabrication of conductive surfaces from simple shapes reduces the manufacturing complexity as compared to the use of annular rings of interengaging conductive material.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | An electrical connector is formed from two pairs of contacts. One pair of contacts is rotatable with respect to the other pair of contacts. Both pairs are in conductive and frictional engagement throughout a 90 degree rotational distance. One pair of contacts have an arcuate conductive contact surface, each contact being symmetrically arranged with respect to the axis of rotation, in opposed relation to one another and separated at each end by a non-conductive space. One pair of contacts are attached to a pair of male electrical prongs. The other pair of contacts are attached to an electrical appliance. The one pair of contacts and the attached pair of male electrical prongs are themselves attached to a nonconductive disk. The nonconductive disk is disposed in a circular groove in a disk holder. The nonconductive disk and the pair of contacts and electrical prongs attached thereto are rotatable within the circular groove. Stops are employed to limit the rotational distance to 90 degree. The electrical connector allows an electrical appliance, such as a night light, attached to the connector to be oriented in a desired direction regardless of whether an outlet is vertically or horizontally disposed. | 5 |
FIELD OF THE INVENTION
The present invention relates generally to the field of auxiliary power transmissions, and more particularly concerns a two-speed auxiliary power transmission having multiple countershafts.
BACKGROUND AND SUMMARY OF THE INVENTION
In a vehicle transmission, it is often desirable to have an auxiliary transmission interposed between the primary transmission and the drive shaft of the vehicle. Such auxiliary transmission will normally provide two gear ranges for the vehicle. For example, in a small truck, it may be desirable to provide a higher than normal drive gear range to maximize gas mileage for highway driving. In a jeep or the like, a lower than normal drive gear range may be convenient for off-road operation.
An important design criteria for such auxiliary transmission is size. The transmission must be small so that it will fit in the vehicle in addition to the principal transmission and will not add excessive weight to the vehicle or unduly reduce other compartment sizes in the vehicle. In many cases, the verticle dimension or height of the auxiliary transmission is one critical size dimension because this dimension is limited below by the required ground clearance and above by limitations on intruding into the engine, primary transmission, and passenger space.
In the present invention, the size and weight criteria for an auxiliary transmission are met by the provision of a transmission having multiple countershafts. In accordance with one form of the invention, an auxiliary power transmission has first and second power shafts with first and second sun gears for being rotatably interconnected with the power shafts. The first and second sun gears have differing diameters, and a shift mechanism mechanically interconnects the first and second power shafts and shifts between engagement with the first sun gear and the second sun gear. A transmission housing is dimensioned to house and support the auxiliary power transmission, and first and second main bearings are provided in the housing for rotatably supporting the first and second power shafts, respectively. There are at least three first planet gears disposed about and continuously intermeshed with the first sun gears, and three second planet gears are disposed about and continuously intermeshed with the second sun gear. Three countershafts are provided with each shaft carrying one of the first planet gears on one of its ends and carrying one of the second planet gears on the other of its ends so that each of the three countershafts and the carried first and second planet gears form at least three planet gears sets that transmit power between the first and second sun gears. A plurality of countershaft bearings in the housing rotatably support the countershafts and the planet gear sets are positioned to entrap and at least partially support the first and second sun gears so that the countershaft bearings help support the first and second power shafts. The first and second main bearings are dimensioned according to the support of the first and second power shafts provided by the countershaft bearings. The planet gears sets are unequally spaced apart, one from the other, about the first and second sun gears to form at least one space between the planet gear sets that is large relative to at least one of the other spaces between the planet gear sets.
The large spacing between the planet gear sets provides a good access to the interior of the auxiliary transmission. In most cases, a shift mechanism will be located within the planet gear sets, and the large spacing will allow a shift fork to have easy access to the shift mechanism. Thus, the unequal spacing of the planet gear sets facilitates the shifting of the transmission.
Also, since the planet gear sets are unequally spaced, the housing may also be constructed with one or more flat sides which occurs at the larger spacing between the planet gear sets. One transverse dimension of the auxiliary transmission is, thus, reduced and the transmission may be mounted so that this reduced dimension is oriented to provide a minimized height for the auxiliary transmission. Since the height of the auxiliary transmission is often a critical dimension for such transmissions, the unequal spacing of the planet gear sets on the present invention provides a structure particularly suited for this type of transmission.
An additional advantage to unequal spacing is the total number of available gear ratios when not restricted to the conventional requirements for assembly of equally spaced planets, i.e., this non-conventional establishment of angular position of planets allows the use of any tooth combination of suns and planets and therefore just as many overall ratios to select from.
As used herein, the terms sun gear and planet gear are used in a broad descriptive sense to mean that the planet gears are positioned around the sun gears. By use of the term planet gear, it is not intended to imply that the planet gears must rotate about the sun gear and it is not meant to imply that the planet gears must be mounted in some type of carrier that could allow rotation of the planet gears about the sun gears. In the embodiment of the invention described herein, the planet gears are part of a countershaft set whose position (axis of rotation) is fixed with respect to the position (axis of rotation) of the sun gears.
In accordance with another aspect of the invention, it is important that the planet gear sets be located at alignment positions relative to the other planet gear sets in order to provide load sharing between countershafts in the auxiliary transmission. An alignment position is an angular position on the input and output sun gears where the teeth of the two sun gears may be aligned. By definition, a tooth of one sun gear at an alignment position will be aligned with a tooth of the other sun gear at least once during each revolution of the planet gears. When teeth are aligned, a plane passing through the center of a tooth and the center of one sun gear will pass through the center of a tooth on the other sun gear.
Also, in order to provide load sharing in the auxiliary transmission of the present invention, it has been found that the planet gear set should be machined from a single piece of stock with the two planet gears of the planet gear set having at least one pair of aligned tooth spaces. That is, at least one tooth space of one planet gear is aligned with a tooth space on the other planet gear in the set. Each aligned tooth space on one planet gear of a planet gear set must be marked as being aligned with a tooth space on the other planet gear and preferably the tooth alignment is held to within a tolerance of 0.0002 inches. In this construction, with the planet gear sets being machined from a single piece of stock and with the planet gear sets being carefully located, relative to one another, at alignment positions, a strong, smooth operating auxiliary transmission is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be understood by reference to the Detailed Description of a preferred embodiment when considered in conjunction with the Drawings in which:
FIG. 1 is a cross-sectional view of a transmission unit showing one form of the present invention;
FIG. 2 is a cross-sectional view of the transmission unit depicting the shift collar and shift lever with the planet gear sets removed for purposes of better illustrating the structure of the shift mechanism;
FIG. 3 is an end view of the transmission housing as viewed from the end on which the input power shaft would extend from the unit with the first planet gears shown with phantom lines; and
FIG. 4 is an end view of the transmission unit viewed from the end on which the output power shaft would extend from the unit with the second planet gears and countershafts shown in phantom lines.
DETAILED DESCRIPTION
In the drawings there is illustrated a two-speed auxiliary transmission that is particularly adapted for use as an "overdrive" transmission. However, the principles of the invention may be applied to any other transmission which includes meshing gears, one of which is selectively engaged in the drive train.
Referring now to the drawings in which like reference characters designate like or corresponding parts throughout the several views, as is shown by the cross-sectional view in FIG. 1, the transmission includes a housing 10 and tail housing 11 which is adapted to support the transmission mechanism. The transmission mechanism illustrated is connected to the primary transmission of the vehicle (not shown), by means of an input power shaft 12 on which is mounted an input sun gear 14. A splined socket 16 receives the input power shaft 12 and assists in further interlocking the input power shaft 12 with the input sun gear 14. As an interlocked unit, the input sun gear 14 and the input power shaft 12 are supported for rotation in a bearing 18 which is mounted on the housing 10, and a first seal 20, for preventing the loss of lubricating fluids and for preventing debris from collecting inside the transmission unit, is mounted on the housing 10 between the input sun gear 14 and the housing 10.
The input sun gear 14 is in continuous mesh with a plurality of substantially coplanar first planet gears 24, each of which is located near the end of a countershaft 26. Near the opposite end of each countershaft 26, a second planet gear 28 is located, and together with the first planet gear 24 and the countershaft 26, makes up a planet gear set 29. Each planet gear set 29 is machined from one piece of stock, and whenever the input sun gear 14 turns the first planet gears 24, the second planet gears 28 are also turned. The planet gear sets 29 are supported for rotation in roller bearings 30 and 31 and by thrust bearings 32 and 33. In this manner, the planet gear sets 29 transmit power from the input sun gear 14 to the output sun gear 34.
Each planet gear set 29 is constructed with at least one tooth space 25 of the first planet gear 24 in alignment with at least one tooth space 27 of the second planet gear 28 so that a plane defined by the center axis of the countershaft 26 and the tooth space 25 will pass through the tooth space 27 in the same manner and position as with tooth space 25.
The output sun gear 34 is mounted for selectively free rotation on the output power shaft 36 by means of roller bearings 38, and an output drive spline 40, which is fixedly mounted on the end of the output power shaft 36, is disposed between the output sun gear 34 and the input sun gear 14. A shift collar 58 is meshed with the output drive spline 40 and is operable to slide on the drive spline to place the transmission in neutral, direct drive or overdrive. When not engaged with the output drive spline 40, the output sun gear 34 spins freely on the output power shaft 36, but when the shift collar 58 engages the output drive spline 40 with the output sun gear 34, they turn as an interlocked unit with the rotation of the output power shaft 36 being derived from the planet gear sets 29. So engaged, the transmission is in the "overdrive" position.
Because the shift collar 58 is also capable of sliding coaxially in an opposite direction, it can selectively engage the output drive spline 40 with the input drive gear 14 and cause these two elements to act as an interlocked unit. When in this position, the output power shaft 36 is rotatably driven directly by the input power shaft 12, and the transmission is said to be in "direct drive". A third position, referred to as "neutral" is obtained when the shift collar 58 is substantially coplanar with the output drive gear 40 with neither of the sun gears 14 and 34 being engaged.
The position of the shift collar 58 is selectively determined by manipulation of the shift control arm 62 (shown in FIG. 2) which is mounted on the housings 10 and 10A and connected to the shift linkage of the vehicle (not shown). A shift fork 60 (partially shown in FIG. 1 and best shown in FIG. 2) extends between the countershafts 26 and connects the shift collar 58 with the shift control arm 62. It can be appreciated that the placement of the planet gear sets 29 about the central drive train provides a space sufficient for a shift fork 60 of adequate size to reach between the counter shafts 26 to the shift collar 58.
The output power shaft 36 is supported for rotation in a ball bearing 46 which is mounted on the housing 10 and by a bushing 56, also mounted on the housing 10. Thrust bearings 42 disposed between the output shaft 36 and the input sun gear 14 facilitate rotation, and seals 20 and 54 help prevent the loss of lubricants. A speedometer gear 50 is mounted on and rotates with the output power shaft 36 and is in continuous mesh with a take-off gear 52 for the purpose of monitoring vehicle speed.
In the preferred embodiment, the transmission includes four countershafts 26 arranged about the two sun gears 14 and 34 with an angular spacing of less than 180° degrees between any two adjacent countershafts 26. In this construction the input planet gears 24 trap and partially support the input sun gear 14, and the output planet gears trap and partially support the output sun gear 34. Hence, the countershaft bearings 30 and 31 at least partially support the input power shaft 12 and the output power shaft 36 through the planet gears 24 and 28 and the sun gears 14 and 34. In view of this support, the size of the bearings 18, 46 and bushing 56 supporting the power shafts 12 and 36 may be reduced in size accordingly. That is, the bearings 18 and 46 may be sized to be smaller than the bearing size that would be required under normal design conditions in a transmission where the sun gears 14 and 34 were not trapped and supported. In the specific embodiment disclosed herein the bearings 18 and 46 carry no perceptable radial load and bearings 22, 42 and 46 accept a thrust load only if helical gears are used. However, it will be understood that in other configurations and modifications of the invention, the bearing size and load distribution between the main bearings 18 and 46 and the countershaft bearings 30 and 31 will change. Also safety factors of design will change with varying applications for the transmission which will change the permissible amount of size reduction at bearings 18 and 46.
In operation, the primary transmission of the vehicle (not shown) drives the input power shaft 12 and input sun gear 14 which continuously turn the planet gear sets 29. When the shift collar 58 is positioned for "overdrive", it interlocks the output sun gear 34 with the output drive spline 40, and the planet gear sets 29 transmit power between the input power shaft 12 and the output power shaft 36. While in overdrive, the planet gear sets 29 share a substantially equal load.
When the shift collar 58 is positioned for "direct drive", the input sun gear 14 and the output drive spline 40 are interlocked and power is transferred from the input power shaft 12 and input sun gear 14 through the shift collar 58 to the output drive spline 40 and output power shaft 36. While in direct drive, the output sun gear 34 spins freely on the output power shaft 36. In "neutral" the output sun gear 34 spins freely on the output power shaft 36, and the input sun gear 14 is also not engaged with the shift collar 58.
Referring now to FIG. 2 there is shown a cross-sectional view of the transmission unit depicting the shift collar 58 and shift fork 60 with the planet gear sets 29 removed for purposes of better illustrating the structure of the shift mechanism. In the illustrated embodiment, the shift control arm 62 is "notched" by grooves 68 and a tensioned spring detent 64 is mounted on the housing 10 so that the detent 64 holds the shift control arm 62 in place by exerting pressure to it perpendicularly. A seal 66 is mounted on the housing 10 and circumferentially surrounds the control arm 62 to prevent the movement of lubricants and debris while the shift control arm 62 moves from one notched position 68 to another. The shift fork 60, which is fixedly attached to the shift control arm 62, extends between the countershafts 26 through the large space (see FIGS. 3 and 4) to the shift collar 58 and connencts the shift collar 58 to the shift control arm 62. It can be appreciated that the unequal arrangement of the countershafts 26 plays a significant role in providing enough space through which a shift fork 60 with sufficient leverage can pass to manipulate the shift collar 58. In the operation of the embodiment depicted, the position of the shift collar 58 is selected when the vehicle is not in motion because a synchronization mechanism is not used. Of course, this embodiment could be readily modified to use synchronization mechanisms.
Referring now to FIG. 3, there is shown an end view of the transmission unit as viewed from the end on which the input power shaft 12 would extend. The placement of the first planet gears 24 is depicted by phantom lines, and the large space 70 through which the shift fork 60 extends, is illustrated by an open bracket. Also depicted in FIG. 3 are points determining the cross-sectional lines from which the cross-sectional views in FIGS. 1 and 2 are derived.
The cross-sectional view depicted in FIG. 1 is taken along a line 1--1 (which includes one angle) that extends through the center of two opposing planet gears 24 and then by a line extending from the axis of rotation of the planet gear 24 nearest the bottom of FIG. 3 through the access plate 72 in a substantially perpendicular direction to the plate 72.
The cross-sectional view depicted in FIG. 2 is taken through a line 2--2 which runs through the axis of rotation of the input power shaft 12 and the center of the control arm 62.
In FIG. 4 there is shown an end view of the transmission unit from the end on which the output power shaft 36 would extend. The relative placement of the second planet gears 28 is depicted by phantom lines.
By reference to FIGS. 3 and 4, it can be appreciated that the relative placement of the planet gear sets 29 allows for easy access to the internal shift collar 58 without a substantial increase in the overall size of the transmission unit.
As previously mentioned, the planet gear sets 29 are located about the sun gears at alignment positions. These positions vary depending on the diameter and toothing of the respective gears. In FIGS. 3 and 4, each first planet gear 24 has 17 teeth, an addendum diameter of 2.03 inches, a dedendum diameter of 1.55 inches and a pitch diameter of 1.822 inches. Each second planet gear 28 has 19 teeth, an addendum diameter of 2.30 inches, a dedendum diameter of 1.82 inches and a pitch diameter of 2.080 inches and one tooth space of the first planet gear 24 is aligned with a tooth space of the second planet gear 28. The input sun gear 14 has 39 teeth and a pitch diameter of 4.180 inches, while the output sun gear 34 has 35 teeth and a pitch diameter of 3.832 inches. In this construction, alignment positions occur at angular distances of about 125 degrees and about 55 degrees, amoung others, between the countershafts 29 relative to the center of the input power shaft 12 (or the output power shaft 36).
These alignment positions are best shown in FIG. 3. As illustrated in FIG. 3, starting at the axis of rotation of the power shafts 12 and 36 (designated point 100), four phantom radii 101, 102, 103 and 104 are shown. Each radius passes through the axis of rotation of a planet gear set 29 and the point 100 so that the radii, in this preferred embodiment form two sets of identical angles. The identical angles between radii 101 and 102 and between radii 103 and 104 are larger than the identical angles between radii 101 and 103 and between radii 102 and 104. In this embodiment, the larger identical angles are about 125 degrees, and the smaller identical angles are about 55 degrees. The alignment positions lie along the radii so described.
The assembly of the transmission is accomplished by first aligning two teeth of the two sun gears 14 and 34 at the position of one of the planet gear sets 29. The aligned gear spaces of the planet gear set 29 are then meshed with the aligned sun gear teeth. The sun gears 14 and 34 are then rotated along with the first gear set until the two sun gears have aligned teeth at a position spaced 55° away from the first sun gear set. The aligned tooth spaces of a second gear set 29 are then meshed with the aligned sun gear teeth. The remaining two planet gear sets 29 are mounted in like manner at 125° and 55° spacings. In each instance, the sun and planet gears are rotated until aligned sun gear teeth appear at the positions of the planet gear sets and the marked aligned tooth spaces of the planet gear sets are meshed with the aligned sun gear teeth. It will be understood that the alignment positions will differ for different sun and planet gears, but the alignment positions may be found by mounting one planet gear set, rotating the sun gears and visually finding the alignment positions.
In this construction, it is apparent that the transmission has a long transverse dimension and a short one. Referring to FIGS. 3 and 4, if the shift control arm 62 is designated as the top of the transmission, it will be appreciated that the vertical height of the housing 10 has been reduced relative to the housing that would be required in the case of symetric spacing of the planet gears 24 and 28 about the sun gears 14 and 34. This is an advantageous feature when the transmission of the present invention is used on a vehicle requiring minimized height and weight in an auxiliary transmission.
It will be understood that the above description is a preferred embodiment of the invention and that it is capable of numerous modifications, rearrangements and substitutions of parts without departing from the spirit of the invention. While the gear sizing and the angular spacing of 125 and 55 degrees between the countershafts are considered optimum for most automobile or light vehicle applications, other gear sizing and/or other alignment positions may be chosen without departing from the spirit of the invention. | An auxiliary transmission unit having multiple countershafts is disclosed for use in a motor vehicle. The countershafts are disposed about an input sun gear and an output sun gear in such a manner as to provide an opening for a shift fork to reach a central shift mechanism locating the planet gears, one with respect to the other, at angular alignment positions in an unequally spaced manner. A tooth of one sun gear at an alignment position will be aligned with a tooth of the other sun gear at least once during one revolution of a countershaft. The unequal spacing of the countershafts provides reduced height for the auxiliary transmission housing. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed to U.S. provisional patent application Serial No. 60/363,933 filed on Mar. 13, 2002.
BACKGROUND OF THE INVENTION
[0002] The invention relates to the preparation of liquid samples for analysis. In one aspect, the invention relates to a method for diluting the samples while in another aspect, the invention relates to an apparatus in which the samples are diluted. In yet another aspect, the invention relates to the sampling of a chemical-mechanical polishing slurry for the purpose of monitoring one or more properties of the slurry.
[0003] Liquids are used in many processes and applications. Often the composition of the liquid is important to the efficacy of the process or application, and often the composition of the liquid will change with use and/or time. Accordingly, such liquids are often monitored to ensure that their compositions remain within prescribed specifications.
[0004] One common form of monitoring a liquid used in a process involves obtaining a sample of the liquid and performing an off-line analysis upon it. Depending upon the process, the monitoring may require obtaining a plurality of samples either at one time or over a period of time. Depending upon the nature of the liquid and the analysis, and perhaps other factors as well, the liquid sample may or may not require some form of preparation before analysis. One form of preparation is dilution of the liquid sample.
[0005] By way of an example of a liquid that is used in a process and that requires frequent monitoring of its composition, chemical-mechanical polishing (CMP) systems are often employed in the microelectronics industry to planarize and/or polish semiconductor wafers. These systems typically contain and employ a “slurry” which is circulated throughout the system such that the slurry contacts and/or impinges upon the wafers. As the slurry impacts and/or passes over the wafers, the wafers are planarized and polished. One example of a slurry typically used in CMP systems is Semi-Sperse® 12 (SS-12) manufactured by Cabot Corporation of Aurora, Ill.
[0006] In order to maintain the consistency, performance, efficiency, and/or usefulness of the system, the “health” of the slurry must be maintained. Slurry instability, external contamination and/or process conditions (e.g., shear-inducing pressure gradients, flow rates, and exposure to air) may compromise slurry health. Thus, slurry properties (e.g., specific gravity, pH, weight percent solids, ionic contamination level, zeta potential, particle size distribution, etc.) are often closely monitored by a sampling system.
[0007] One such system for monitoring a CMP slurry is the intelligent Slurry Particle Equipment (iSPEQ) system which is described in commonly-owned, co-pending U.S. S No. 60/313,440 filed Aug. 17, 2001 and entitled “Sampling and Measurement System with Multiple Slurry Chemical Manifold”. The iSPEQ typically comprises an AccuSizer 780/OL (manufactured by Particle Sizing Systems of Santa Barbara, Calif.), a multi-port valve manifold, a sample station, one or more system drains and an aspirator. The iSPEQ system uses a unique method for flushing its multi-port manifold. This method is described in commonly-owned, co-pending U.S. S No. 60/313,439 filed Aug. 17, 2001 and entitled “Flushing a Multi-Port Valve Manifold”. In addition, the iSPEQ uses another method for collecting slurry from the sample station using the aspirator and multi-port manifold. This method is described in commonly-owned, co-pending U.S. S No. 60/313,442 filed Aug. 17, 2001 and entitled “Chemical-Mechanical Polishing Sampling System Having Aspirator Drawn Pneumatics.”
[0008] The iSPEQ was primarily designed to measure the particle size distribution (PSD) of CMP slurries. Of all the slurry health parameters, perhaps the most important and frequently measured is the PSD of the bulk or “working” particles and the “large particle tail” of the PSD. Particle size distribution may be graphically represented by the concentration of particles as a function of particle diameter. In slurries such as SS-12, the PSD of the working particles is sufficiently approximated by a Gaussian Distribution where the peak or highest concentration of particles is centered between particles that are roughly 0.05 to 0.5 μm in diameter. Slurries typically contain extremely high concentrations of particles less than 0.5 μm in diameter. The region of the PSD that illustrates the concentration of particles for diameters greater than 0.5 μm is commonly referred to as the “large particle tail” of the PSD.
[0009] In the industry, the large particle tail can be measured using a variety of techniques (e.g. light scattering, light extinction, etc.) and instruments such as sensors, analyzers, and like devices (collectively referred to as sensors), that are commercially available from a host of manufacturers. Many different measurement devices have been tested, compared, and evaluated for their ability to measure PSDs, and optical particle counting is widely accepted as the most sensitive type of measurement technique.
[0010] In general, sensors based upon optical particle counting (these sensors are referred to as “optical particle counters” or “OPCs”) are used to measure the large particle tail of a slurry (those particles larger than about 0.5 μm in diameter). Optical particle counters count individual particles within a diluted slurry (e.g., silica, contaminants, debris, impurities, and the like) as the particles pass through a light beam. The slurry must be diluted enough so that only one detectable particle passes through the light beam at a time.
[0011] To produce a “diluted slurry” or “diluted liquid sample”, a diluent and a slurry are blended and/or mixed together. The diluent can include various grades of water, e.g., deionized, demineralized, ultra-pure, etc., as well as other liquids, e.g., water with a pH adjusted to that of the slurry sample, an organic solvent, etc. Depending upon a variety of factors, e.g., the nature of the slurry, the capabilities of the sensor, etc., proper dilution of the slurry sample for analysis may require several steps, i.e., the slurry sample is diluted to create a first diluted slurry, and then the first diluted slurry is itself diluted to create a second or further diluted slurry. This process can repeat itself as many times as necessary so as to achieve the desired diluted slurry for analysis.
[0012] To repeatedly generate a diluted slurry having an optimum “dilution ratio” (i.e., the ratio of the diluent volume to the slurry sample volume), some OPCs are integrated into an automatic dilution system. An example of a device that contains both a sensor and an “auto-dilution” system is the AccuSizer 780/OL (AccuSizer system). The AccuSizer system, as well as its auto-dilution apparatus, are described in detail in U.S. Pat. No. 4,794,806 (Nicoli, et. al.) and U.S. Pat. No. 5,835,211 (Wells, et. al.). Throughout this disclosure “AccuSizer system” refers to the combination of the auto-dilution apparatus and the sensor, and “AccuSizer sensor” refers to just the sensor component in the AccuSizer system.
[0013] The auto-dilution apparatus of the AccuSizer system and its operation are illustrated in and by FIGS. 1A and 1B. FIG. 1A is a table describing the ten operational steps of the AccuSizer system and the table contains typical times for each step, though the steps are not limited to these times. FIG. 1B is a schematic drawing of the system. The auto-dilution apparatus of the AccuSizer system is available in two formats, single dilution and double dilution. In the single dilution format, a slurry sample is captured in a sample loop, diluted in a mixer, and then the diluted sample is fed to a sensor for analysis. In the double dilution format, a slurry sample is captured in a sample loop, fed to a dilution chamber in which it is mixed with diluent to make a first diluted slurry, the first diluted slurry is then fed to the mixer in which it is mixed with additional diluent to make a second diluted slurry, and then this second slurry is fed to the sensor for analysis. The single dilution format is illustrated in FIG. 1B, and the double dilution format is also illustrated in FIG. 1B but with reference to the inset. The following description of the operation of the AccuSizer system is with respect to the double dilution format, yet the operation of the single dilution format is nearly the same but without reference to the dilution vessel (i.e., chamber).
[0014] The auto-dilution apparatus of the AccuSizer system operates in two stages. In the first stage (Steps 1 - 5 ), slurry sample is captured in a sample loop and diluted, and the sensor is prepared for slurry analysis. In the second stage (Steps 6 - 10 ), the slurry is analyzed and then flushed from the sensor.
[0015] The first stage starts with Step 1 of FIG. 1A, i.e., the simultaneous drawing of a fixed volume of sample (i.e., slurry) into the system and the flushing of dilution chamber 1 of FIG. 1B (i.e., the “vessel” in FIG. 1A). The function of Step 1 is two-fold, i.e., to capture sample for analysis and to ready the vessel to receive the sample.
[0016] During the sample loading sub-step of Step 1 , valve SV 15 is activated (i.e., opened) to capture a pre-determined volume of slurry from slurry port 2 , and syringe pump 3 is off. During the flushing of the dilution chamber (i.e., vessel flushing sub-step of Step 1 ), valves SV 11 and SV 12 are first opened, then valve SV 1 is closed and valve SV 14 is opened. Mass flow controller 4 is operational during the course of Step 1 . Each sub-step of Step 1 takes about 30 seconds to complete but since these sub-steps occur simultaneously, the whole of Step 1 takes only about 30 seconds to complete.
[0017] In Step 2 , mass flow controller 4 transfers deionized water (DI) into the system from DI port 5 , through dilution chamber 1 and static mixer 6 , and into sensor 7 . During this operation, first valves SV 11 and SV 14 are opened, then SV 12 and SV 13 are opened; syringe pump 3 is initialized, and the mass flow controller is operational. Sensor 7 measures the background of the deionized water, which serves as the diluent for the slurry. Step 2 takes about 25 seconds to complete.
[0018] In Steps 3 , 4 and 5 , the slurry is diluted with the deionized and the diluted slurry is transferred to the sensor for analysis. The valve, syringe pump and the mass flow controller operations for these steps are described in FIG. 1A, and the time for each step is about 10, 40 and 0.5 seconds, respectively.
[0019] The second stage of the operation of the AccuSizer system's auto-dilution apparatus commences with Step 6 , the actual analysis (i.e., the “measuring” of FIG. 1A) of the diluted slurry. This step takes about 60 seconds to complete and then in Steps 7 - 10 , the diluted slurry is flushed from the system through exit port 8 . The flush operations of Steps 8 and 9 are relatively long, e.g., about 90 seconds each, due to the need to insure that the sensor is rinsed clean of any residual slurry before the loading of another slurry sample into the system. The background check of Step 10 usually takes about 25 seconds to complete.
[0020] While the AccuSizer system's auto-dilution apparatus and others like it perform the basic task of diluting a slurry sample prior to its analysis by an OPC (or other sensor), it does so in a relatively inefficient manner. Each cycle of the AccuSizer system takes approximately 6 or more minutes to complete, but during this time data, e.g., PSD analysis of the diluted sample, is only collected for 60 seconds. The bottlenecks in this system are many, and they include sample capture, flush steps, background checks and the transfer of the sample to the dilution chamber by a syringe pump. Accordingly, the industry has a continuing interest in a dilution system that allows for more slurry analysis in less time with the concurrent elimination of one or more of the bottlenecks of the present systems. More generally, all industries have a continuing interest in performing efficient monitoring of the liquids used in their processes, and the elimination or moderation of any bottlenecks in these monitoring processes is always welcomed.
SUMMARY OF THE INVENTION
[0021] In one embodiment of this invention, a liquid sample dilution apparatus for producing a diluted liquid sample comprises:
[0022] A. A first mixer manifold comprising:
[0023] 1. An inlet adapted to receive a diluent;
[0024] 2. A plurality of ports, each port adapted to receive a liquid sample;
[0025] 3. A mixing device for blending the liquid sample and the diluent to produce a first diluted liquid sample; and
[0026] 4. A first diluted liquid sample outlet; and
[0027] B. Means for continuously delivering the diluent to the first mixer manifold inlet.
[0028] The means for continuously delivering the diluent includes, for example, a pressurized source and a flow controlling device, e.g., a pump, an orifice, a pipe constriction, etc.
[0029] In another embodiment, the dilution apparatus further comprises a second mixer manifold in fluid communication with the first mixer manifold and adapted to receive the diluted liquid sample from the first mixer manifold and to produce a second or further diluted liquid sample. The second mixer manifold can be of the same or different design as the first mixer manifold. For example, the second mixer manifold does not require one or more ports adapted to receive undiluted liquid sample.
[0030] The function and design of the sensor can vary to interest and in those embodiments in which particle size distribution is the property of interest, the sensor is typically an optical particle counter of any convenient design, e.g., a light scattering sensor, a light extinction sensor, a light scattering and light extinction combination sensor, etc. Each manifold mixer can be in fluid communication with the same sensor, or each manifold mixer can be in fluid communication with a different sensor.
[0031] In another embodiment, the invention is a method of continuously producing a diluted liquid sample for analysis by a sensor, the method comprising:
[0032] Continuously introducing a diluent into a mixer manifold;
[0033] Introducing a liquid sample into the mixer manifold;
[0034] Mixing the diluent and liquid sample in the mixer manifold to produce a diluted liquid sample; and
[0035] Transferring at least a portion of the diluted liquid sample to a sensor for analysis of at least one property of the diluted liquid sample.
[0036] In one variation on this embodiment, one portion of the diluted liquid sample is transferred to a first sensor and another portion of the diluted liquid sample is transferred to a second sensor.
[0037] In another embodiment, the invention is a method of continuously producing a diluted liquid sample for analysis by a sensor, the method comprising:
[0038] Continuously introducing a first diluent into a first mixer manifold;
[0039] Introducing a liquid sample into the first mixer manifold;
[0040] Mixing the diluent and first liquid sample in the first mixer manifold to produce a first diluted liquid sample;
[0041] Transferring at least a portion of the first diluted liquid sample to a second mixer manifold containing a second diluent;
[0042] Mixing the first diluted liquid sample with the second diluent to produce a second diluted liquid sample; and
[0043] Transferring at least a portion of the second diluted liquid sample to a sensor for analysis of at least one property of the second diluted liquid sample.
[0044] While the diluent in these embodiments can be either aqueous or organic, typically the diluent is water, e.g., pH-adjusted, deionized or ultra-pure, and the liquid sample is an aqueous slurry, e.g., a chemical-mechanical polishing slurry. These methods can employ one or more sensors. The sensors can comprise any sensor that requires dilution and is capable of monitoring and/or analyzing the health of a liquid sample, e.g., the large particle tail of a CMP slurry. Suitable sensors are available from a host of different manufacturers, e.g., for CMP slurries the AccuSizer sensor from Particle Sizing Systems (PSS) of Santa Barbara, Calif., the HRLD 150 from Pacific Scientific, and the LiQuilaz-S05 from Particle Measuring Systems of Boulder, Colo. The flow rates of the first and second diluted liquid samples to the sensors can be the same or different. The dilution ratios for each sensor can be the same or different. The sensors can measure any one or more of a number of different properties including particle concentration, mean particle size distribution, zeta potential, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] Embodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in its application to the details of CMP slurries, construction or the arrangement of the components, as illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components throughout the drawings. In the drawings, NO means “normally open”, NC means “normally closed” and C means “common”.
[0046] [0046]FIG. 1A is a table describing the ten operational steps of the AccuSizer system's auto-dilution apparatus.
[0047] [0047]FIG. 1B is a schematic drawing of the AccuSizer system's auto-dilution apparatus.
[0048] [0048]FIG. 2 is a schematic drawing of one embodiment of the dilution apparatus of this invention in combination with at least one sensor.
[0049] [0049]FIG. 3 is a flowchart outlining the steps for continuously producing a CMP diluted slurry using the dilution apparatus of FIG. 2.
[0050] [0050]FIG. 4 is a schematic representation of a test system constructed to compare a first sensor and a second sensor when the dilution apparatus of FIG. 2 is used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Although the invention is described below in the context of slurries used in chemical-mechanical polishing processes, those skilled in the art will recognize that the invention can be employed with, and has applicability to, many other and different processes. “Liquid sample” and similar terms include slurries, colloids, emulsions, solutions, liquids containing gas, and the like, essentially any liquid comprising two or more components and that is amenable to dilution for purposes of analysis for one or more properties related to its composition.
[0052] Various items of equipment, such as fittings, valves, mountings, pipes, monitoring equipment, wiring, and the like have been omitted to simplify the description. However, such conventional equipment and its uses are known to those skilled in the art and can be employed as desired.
[0053] In FIG. 2, both a single-stage and dual-stage dilution apparatus are described. Both apparati comprise diluent-introducing means 4 a and mixer manifold 6 a . The dual stage apparatus also comprises diluent-introducing means 4 b and mixer manifold 6 b.
[0054] Mixer manifold 6 a contains inlet 10 , a plurality of slurry inlet ports 11 a - f (collectively 11 ), outlet 12 , and mixing element 13 . Inlet 10 is adapted to receive the diluent (e.g., deionized water 14 a ), and is typically also adapted to receive a cleaning chemical (e.g., potassium hydroxide 15 ) and a purging fluid (e.g., nitrogen 16 ). Each slurry inlet port 11 is capable of receiving one of a plurality of slurries from one of a plurality of sample points within a CMP system (e.g., a “desired slurry”). The number of slurry inlet ports on the mixer can vary widely and to convenience. Outlet 12 is adapted to expel or otherwise discharge the diluted slurry, and is typically also adapted to expel the cleaning chemical, the purging fluid, and the diluent. Mixing element 13 can include one or more of a variety of devices structured to blend and/or mix one or more fluids and/or other substances together. For ease of design, construction and economic operation, static elements are preferred.
[0055] The diluent-introducing means, e.g., mass flow controller 4 a , is employed to introduce the diluent into mixer manifold 6 a at inlet 10 . The diluent-introducing means (both 4 a and 4 b ) of FIG. 2 is any means or device capable of delivering a constant flow (although not necessarily at a constant flow rate) to the mixers (both 6 a and 6 b ) throughout the liquid sample monitoring operation. These means include pressurized sources of diluent, orifices, pipe constrictions, pumps, etc., with peristaltic pumps or preferred means. Diluent-introducing means 4 a can and usually is used in combination with one or more pressure/flow regulators, pressure indicators, two-way valves, check valves, filters and flow restrictors (none of which are shown).
[0056] Slurry-introducing means (not shown) are employed to introduce a slurry into mixer manifold 6 a at one of the plurality of ports 11 . Slurry-introducing means can include one or more pumps or like devices capable of transporting a fluid through a conduit, pipe, or like structure. In a preferred embodiment, the slurry-introducing means comprises one or more bi-directional, peristaltic pumps. These pumps are capable of providing a broad range of slurry flow rates, and of carefully controlling a slurry flow rate during dilution of the slurry. These pumps are used to control the slurry flow rate so as to achieve an optimal dilution ratio of the slurry for measurement by a sensor. Each slurry will have an optimal dilution ratio. If multiple sensors are used, the optimal dilution ratio will likely be different for each sensor. The peristaltic pumps supply the desired slurry to mixer manifold 6 a at ports 11 . If more than one pump is used, then they are capable of operating simultaneously, sequentially, or individually, as desired.
[0057] Still referring to FIG. 2, the dual-stage embodiment of the dilution apparatus further includes, among other things, second mixer manifold 6 b , second diluent-introducing means 4 b , and an optional slurry-introducing means 17 . Mixer manifold 6 b contains inlet 18 , outlet 19 , and mixing element 20 . Inlet 18 is adapted to receive the diluent and the diluted slurry, and it is typically also adapted to receive a cleaning chemical and a purging fluid. Outlet 19 is structured to expel or otherwise discharge the second diluted slurry, and is typically also adapted to expel the cleaning chemical, the purging fluid, and the diluent. Mixing element 20 , like that of mixing element 13 , can include a variety of devices structured to blend and/or mix one or more fluids and/or other substances together. Like mixer manifold 6 a , diluent can also be introduced into mixer manifold 6 b at inlet 18 by a diluent-introducing means.
[0058] Optional slurry-introducing means 17 is employed to introduce the diluted slurry from mixer 6 a into mixer manifold 6 b at inlet 18 . Slurry-introducing means 17 can include a pump or like device capable of transporting a fluid through a conduit, pipe, or like structure. In a preferred embodiment, slurry-introducing means 17 comprises a bi-directional, peristaltic pump capable of supplying the diluted slurry to mixer manifold 6 b at inlet 18 . In another, less preferred embodiment, slurry-introducing means 17 is eliminated, and the diluted slurry is transferred from mixer 6 a to mixer 6 b simply by the pressure (or vacuum draw) available in the system.
[0059] The dilution apparatus is employed with one or more sensors 7 a - b as shown in FIG. 2. Sensors 7 a - b are capable of operating simultaneously, sequentially, or individually, as desired. In one embodiment, sensors 7 a - b are connected to mixer manifolds 6 a - b by one or more valves (not shown). By-pass of the sensors and removal or discharge from the sensors is accommodated by these valves. The discharge can be collected in one or more drains not shown.
[0060] In a preferred embodiment, operation of sensors 7 a - b (i.e., performance of the sensors) can be monitored by comparing results that are generated by the sensors when each of the sensors measures the same diluted and/or further diluted slurry. Likewise, sensor 7 a can measure a property of the diluted slurry, sensor 7 b can measure a property of the second or further diluted slurry, and the properties of the first diluted slurry and the second diluted slurry can be compared.
[0061] Sensors 7 a - b can, if desired, be produced by the same manufacturer and/or employ the same technique to measure slurry properties. However, sensors 7 a - b can also be different from each other. For example, sensor 7 a can use a light scattering technique to measure a property of a first diluted slurry and/or a second diluted slurry while sensor 7 b can use a light extinction technique to measure a property of a first diluted and/or a second diluted slurry.
[0062] Each of sensors 7 a - b are capable of on-line operation at least about ninety percent (90%) of the time that the dilution apparatus is operating. In an exemplary embodiment, each of sensors 7 a - b are capable of continuous on-line operation. As here used, a sensor is considered to be on-line when the sensor is operating to measure a slurry property.
[0063] The dilution apparatus of this invention can also comprise a chemical introducing means (not shown). The chemical introducing means is selectively operable to introduce one or more cleaning chemicals into the dilution apparatus. The cleaning chemicals (e.g., potassium hydroxide 15 , hydrochloric acid, etc.) can be employed to clean the dilution apparatus and/or remove unwanted slurry. The chemical introducing means can include one or more of, or combination of, a pressure/flow regulator, pressure indicator and valves.
[0064] The dilution apparatus can also comprise a purging fluid introducing means (not shown). The purging fluid introducing means is selectively operable to introduce one or more purging fluids (e.g., nitrogen 16 ) into the dilution apparatus. The purging fluids can be employed to clean the dilution apparatus and/or remove unwanted slurry, water, gases, and the like. The purging fluid introducing means can include one or more of, or combination of, a pressure/flow regulator, pressure indicator and check valves.
[0065] Diluent 14 a from diluent-introducing means 4 a flows through mixer manifold 6 a almost continuously. In a preferred embodiment, diluent 14 a flows through mixer manifold 6 a prior to introduction of slurry into mixer manifold 6 a . The slurry is then diluted as it is introduced into mixer manifold 6 a , and the dilution system does not come into contact with concentrated slurry, which reduces the time required to flush the dilution system between cycles. The operation of mixer 6 b relative to diluent 14 b and diluent-introducing means 4 b is essentially the same for the same reasons.
[0066] In operation, as illustrated in FIG. 3, a procedure 60 for producing a first diluted slurry and a second diluted slurry using the dilution apparatus of FIG. 2 is outlined. When procedure 60 is initiated 62 , the single stage of the dilution apparatus is employed such that diluent begins to flow 63 (or during continuous operation the diluent will already be continuously flowing) and one or more of a plurality of slurries from a plurality of sample points (i.e., a slurry sample) are obtained 64 by the slurry introducing means from one of the plurality of slurry lines 22 a - f . The slurry is then introduced and/or flowed 66 into mixer manifold 6 a by the slurry introducing means.
[0067] After receiving the slurry and the diluent, mixing element 13 within mixer manifold 6 a mixes and/or blends 72 the slurry and the diluent such that a first diluted slurry is created, generated, and/or produced. Since the flow rate of the slurry and the diluent, relative to one another, entering mixer manifold 6 a are known and can be manipulated, a first diluted slurry having a desired and/or optimum dilution ratio can be achieved.
[0068] Optionally, a determination 74 whether to further dilute the diluted slurry is made. If no further dilution is desired, the first diluted slurry can be provided and/or flowed 76 to one or both of sensors 7 a - b such that one or more properties of the diluted slurry can be monitored. Thus, the dilution procedure is completed 78 . If, however, further dilution is favored, the second stage is employed such that the first diluted slurry and additional diluent are introduced and/or flowed 80 into mixer manifold 6 b by optional slurry-introducing means 17 .
[0069] After receiving the first diluted slurry and the additional diluent, mixing device 20 within mixer manifold 6 b mixes and/or blends the first diluted slurry and the additional diluent such that a second or further diluted slurry is created, generated, and/or produced. Since the flow rate of the first diluted slurry and the additional diluent, relative to one other, entering mixer manifold 6 b are or can be known and can be manipulated, a second diluted slurry having a desired and/or optimum dilution ratio can be achieved.
[0070] The second diluted slurry can be provided and/or flowed 84 to one or both of sensors 7 a - b such that one or more properties of the further diluted slurry can be monitored. Thus, the dilution procedure can once again be completed 86 .
[0071] Diluent-introducing means 4 a - b and each of the slurry-introducing means are capable of operating such that the diluent, the slurry, and the first diluted slurry are continuously introduced into mixer manifolds 6 a - b . As a result, the dilution apparatus is capable of continuously producing the first and second diluted slurries. Thus, these diluted slurries can be continuously delivered to, and monitored by, sensors 7 a - b.
[0072] The flow rate of the diluent into one or both of mixer manifolds 6 a - b can be constant, fixed, and/or unchanging and a flow rate of the slurry and/or diluted slurry into one or both of mixer manifolds 6 a - b can be adjustable, variable, and/or non-constant. Thus, the dilution apparatus of this invention, as noted above, can achieve the desired and/or optimum dilution ratios.
[0073] The dilution apparatus of this invention is believed to enhance and/or improve upon one or more qualities of a device such as the AccuSizer system if just the AccuSizer sensor is integrated into the dilution apparatus of this invention. The dilution system of this invention can have diluent constantly coursing through it and as such, the slurry sample is injected directly into the diluent. This means that the dilution system of this invention sees little if any concentrated slurry and this, in turn, makes flushing of the system fast and easy. Furthermore, over a six minute cycle, the dilution system of this invention can collect as much as five or more minutes of data whereas the AccuSizer system typically collects 1 minute of data in a six minute cycle. If measurement of only one slurry is desirable, the sensor and dilution apparatus of this invention could measure slurry continuously (for several weeks) except during times of periodic maintenance.
[0074] Obtaining data as often as possible is desirable for several reasons. One reason is so that any problems with the slurry can be rapidly detected. Slurry must travel through pumps, valves, tubing, filters, etc. before it arrives at a polisher. The slurry is typically circulated through these components in order to prevent settling and/or stagnation. In this arrangement, the polishers are located on slipstreams off of the main slurry loop and the polishers demand slurry only when they require it. However, as the slurry is subjected to multiple passes in the loop, the slurry “health,” in particular the slurry PSD, may detrimentally change. Slurry PSD can change for a variety of reasons such as a failed component like a valve or filter, agglomeration of the slurry particles resulting from recirculation, adding a new tote of slurry with a higher concentration of particles or a water leak into the slurry loop. Therefore, monitoring the slurry PSD as frequently as possible, ensures that slurry problems can be detected quickly and immediate action taken to remedy the problem.
[0075] Another reason for increasing the measurement frequency is to improve the variability of the slurry health parameter measurements. The results of measurements, in which events that occur at random are counted at a definite average rate, can be described by the Poisson distribution. If one counts the occurrences of this type over time and obtains, on average, {overscore (N)} counts, then the uncertainty in the measurement as expressed by the standard deviation is ±{square root}{square root over (N)}. This is sometimes referred to as the “square-root rule.” The standard deviation (σ) of the AccuSizer data, assuming the concentration is invariant, can be approximated by the square-root rule. In the case of the AccuSizer, {overscore (N)} equals the average number of particles counted at a given particle diameter for individual measurements of equal length. The variability (at 3σ) of the AccuSizer data can be calculated as shown in Equation 1. The percent relative standard deviation (%RSTD) can be calculated as shown in Equation 2.
Variability (3σ)=3×Standard Deviation= 3σ=3×{square root}{square root over (N)} (1)
[0076] [0076] % RelativeStandardDeviation = 3 × N _ N _ × 100 % = ± 3 × 100 % N _ ( 2 )
[0077] The abilities of sensors, and systems with sensors integrated into a dilution apparatus, to detect changes in slurry properties can be compared using the %RSTD of particle counts measured by each sensor or system. Equation 2 indicates that as the number of particles counted increases, the %RSTD decreases. Since the %RSTD is a measurement of the “noise,” ideally the %RSTD should be as low as possible so small changes in the slurry PSD can be detected. Increasing the duration of the PSD measurement, results in more particles being counted, which leads to a lower %RSTD, thus lower measurement variability.
[0078] To demonstrate certain benefits of the dilution system of this invention, an AccuSizer system was directly compared to a test system in which an AccuSizer sensor was integrated into the dilution system of this invention. As here used, “test system” refers to the combination of the AccuSizer sensor and the dilution system of this invention.
[0079] The test system is shown in FIG. 4. System 88 generally comprised, among other things, AccuSizer sensor 90 , flow meters 94 a - b , drain 96 , tank 98 , circulation pump 100 , filter 102 , pressure gauge 104 , injection pump 106 , stir plate 108 , static mixer 110 , and lines 112 .
[0080] Test system 88 produced diluted slurry comparably and/or similarly to the dilution apparatus of this invention and, therefore, allowed the AccuSizer system to be compared with the test system. Repeated measurements of Cabot SS-12 slurry were taken with the AccuSizer system and the test system in order to determine the %RSTD of data collected by each system. The same sensor and same lot of Cabot SS-12 slurry were used in both systems, so the only difference between the two systems was the dilution system. The Table summarizes the results obtained from this comparison. The %RSTD for various particle diameters is provided for each system. Notably, the variability of the AccuSizer system was about 4 times larger than the variability of the test system for each of the particle diameters shown. This suggests that the test system can detect smaller changes, approximately one-quarter of the magnitude, than the AccuSizer system.
TABLE Comparison of the AccuSizer System with the Test System Particle Diameter Variability (%RSTD @ 3σ) (μm) AccuSizer system Test system ≧0.5 12.4% 3.4% ≧1.0 28.5% 8.2% ≧2.0 42.0% 12.0% ≧5.0 47.0% 13.5% ≧10.0 60.0% 15.6%
[0081] As test system 88 and the Table confirm, qualities of the AccuSizer sensor were enhanced and/or improved when a dilution apparatus capable of continuously producing diluted slurry, such as the dilution apparatus of this invention, was used in lieu of the auto-dilution apparatus found within the AccuSizer system. Simply put, the test system that included the AccuSizer sensor component was more repeatable and more efficient than the AccuSizer system, thereby allowing smaller changes in slurry health parameters, particularly changes in the large particle tail, to be detected.
[0082] Despite any methods being outlined in a step-by-step sequence, the completion of acts or steps in a particular chronological order is not mandatory. Further, elimination, modification, rearrangement, combination, re-ordering, or the like, of acts or steps is contemplated and considered within the scope of the description and appended claims. Also, while the present invention has been described in terms of the preferred embodiment, equivalents, alternatives and modifications, aside from those expressly stated, are possible and within the scope of the description and appended claims. All U.S. patents and allowed U.S. patent applications cited in this specification are incorporated herein by reference. | A dilution apparatus for continuously producing a diluted liquid sample, e.g., a chemical-mechanical polishing slurry, for analysis, e.g., particle size distribution, comprises a mixer manifold, a diluent-introducing means, e.g., a flow controlling device, for introducing a diluent, e.g., water, into the mixer manifold, and a liquid sample introducing means, e.g., a pump, for introducing the sample into the mixer manifold. The mixer manifold includes a plurality of ports for receiving a plurality of liquid samples from a plurality of sample points. The dilution apparatus can include a second mixer manifold for continuously producing a second diluted liquid sample, and it can be associated with one or more sensors operable to measure sample properties, e.g., an optical particle counter. The sensors can be operated simultaneously, and the measurements of the sensors can be compared. The dilution apparatus is capable of improving accuracy, reliability, repeatability, sensitivity and versatility of the associated sensors, and it is less complex than conventional dilution systems. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of performing two-dimensional electrophoresis.
[0002] Electrophoresis using 2-D PAGE (Two-dimensional PolyAcrylamide Gel Electrophoresis) techniques can separate proteins in a sample according to isoelectric pH (IpH) and molecular weight. Two-Dimensional PAGE generally provides isoelectric focusing electrophoresis in one direction followed by polyacrylamide gel electrophoresis in a second direction, and can be useful in analyzing the protein composition of a sample solution such as a biological sample. For example, gene activity may be studied by analyzing various proteins important to certain cellular functions.
[0003] For example, isoelectric focusing can use Immobilized pH gradient (IPG) strips to separate proteins based on their respective IpH values. An IpH is the pH value at which a protein carries no net charge and will not migrate in an electric field. An IPG strip with zwitter ionic peptides fixed to its surface can establish an identifiable pH gradient when a voltage is applied to electrodes on opposite sides of the IPG strip. Therefore, when a protein sample is applied to an IPG strip, each protein in the sample travels through the IPG strip until it reaches its IpH value on the IPG strip.
[0004] After proteins from the sample are focused on the IPG strip, a buffer, such as a buffer including SDS (sodium dodecyl sulfate), can be applied in preparation for polyacrylamide gel electrophoresis. Sodium dodecyl sulfate is a detergent that can solubize proteins to generate a uniform negative charge. Therefore, the SDS buffer disrupts hydrophobic interactions, increases the solubility of the protein, and leaves the protein molecules negatively charged. As a result, when the proteins are exposed to a polyacrylamide gel to which an electric current is applied, the proteins travel through the polyacrylamide gel and are separated according to their molecular weight. The polyacrylamide gel is typically a flat planar gel slab supported by a cassette housing.
[0005] After completion of the isoelectric focusing in one direction and PAGE in a second direction, the polyacrylamide gel has concentrations of protein deposits that are separated by IpH in one direction and molecular weight in the other direction. In order to view the resulting protein deposits, the polyacrylamide gel can be stained, for example, by removing the gel from its cassette housing and applying a staining reagent such as a silver or ruby protein stain.
[0006] Despite producing highly resolved results, 2-D PAGE presents technical challenges that may result in low reproducibility of results. The number of manual steps involved in 2-D PAGE may require a high level of operator skill to produce reliable 2-D PAGE results. In addition to being a labor-intensive process, many technical difficulties can be caused by operator inconsistencies. For example, the isoelectric focusing steps and the polyacrylamide electrophoresis steps are often carried out using separate devices, which may introduce poor reproducibility due to operator inconsistencies. U.S. Patent Application Publication No. 2002/0100690 to Herbert (hereinafter “Herbert”), disclosure of which is hereby incorporated by reference in its entirety, proposes a method in which the IPG strip and an agarose gel slab are carried on a single cassette. Increased automation of the 2-D PAGE steps may improve reproducibility of results and decrease the need for highly skilled operators.
SUMMARY OF THE INVENTION
[0007] Methods, systems, and devices for electrophoresis are provided that may address some of the challenges discussed above. Embodiments of the present invention provide a device for two-dimensional electrophoresis including a cassette comprising two opposing plates. The two opposing plates form a first elongated portion for receiving a first elongated electrophoretic separation medium and a second portion extending away from the first portion. A second electrophoretic separation medium is on the second portion and between the two opposing plates. A dialysis membrane extends across the second electrophoretic separation medium.
[0008] In some embodiments, the second electrophoretic separation medium can be deposited on one of the plates, and the dialysis membrane can define a void between the dialysis membrane and the other of the two opposing plates. The void can be used to inject fluids onto the electrophoretic separation media without requiring that the electrophoretic separation media be removed from the cassette.
[0009] In other embodiments, a loading chamber for an electrophoresis device is provided comprising a sample chamber having and opening configured to release a sample solution from the sample chamber into an cassette. A hydration chamber is adjacent the sample chamber, and a semi-permeable membrane is between the sample chamber and the hydration chamber. The membrane allows osmotic diffusion of fluid between the sample chamber and the hydration chamber through the membrane. Loading chambers according to embodiments of the present invention can be used to concentrate a protein sample solution prior to electrophoresis.
[0010] In further embodiments, methods for staining an electrophoresis cassette include providing an electrophoresis cassette comprising first and second opposing plates. An electrophoresis medium and a membrane layer on the electrophoresis medium are provided between the first and second opposing plates such that a void is formed between the membrane layer and the first opposing plate. Electrophoresis separation of a sample solution is conducted using the electrophoresis medium. A staining reagent is applied to the electrophoresis medium through the void between the membrane layer and the first opposing plate. A staining solution may be automatically injected into the cassette, and therefore, it may be unnecessary to remove the electrophoresis medium and manually apply the stain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a view of the top side of a 2-D PAGE device according to embodiments of the present invention;
[0012] [0012]FIG. 2 is a cross-sectional view of the 2-D PAGE device of FIG. 1;
[0013] [0013]FIG. 3 is a cross-sectional view of the 2-D PAGE device of FIG. 1 shown illustrating the flow channels for buffer solutions or staining reagents;
[0014] [0014]FIG. 4A-4C is a cross-sectional view of a loading device according to embodiments of the present invention; and
[0015] [0015]FIG. 5 is a cross-sectional view of the 2-D PAGE device of FIG. 1 shown with the loading device of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. This invention, however, should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0017] In the drawings, the relative sizes of elements may be exaggerated for clarity. When an element is described as being on or adjacent another element, the element may be directly on or adjacent the other element, or other elements may be interposed therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. Like reference numerals in the drawings denote like members.
[0018] For ease of discussion, the exemplary embodiments disclosed herein may refer to IPG strip and polyacrylamide gel electrophoresis media. As would be appreciated by those of skill in the art, other electrophoresis media are interchangeable with IPG strips and polyacrylamide gels. Other acrylamide gels that may be used include gel media available from Invitrogen,™ Carlsbad, Calif. (U.S.A.) such as NuPAGE™ Bis-Tris (separation range 1.5 to 300 kDa), NuPAGE™ Tris-Acetate (separation range 30 to 400 kDa), Novex™ Tris-Glycine (separation range 6 to 500 kDa), Tricine (separation range 2 to 200 kDa), and Zymogram (separation range 30 to 200 kDa).
[0019] A 2-D PAGE device 10 is shown in FIGS. 1 and 2. The device 10 includes cassette housing 15 , which supports an IPG strip region 11 and a polyacrylamide gel region 13 . The cassette housing 15 can be about 8 cm long and about 8 cm wide. A sample solution can be introduced into the device 10 through a sample opening 35 and onto the IPG strip region 11 . IPG strips are commercially available under several trade names including BioRad™ from BioRad Laboritories, Hercules, Calif., U.S.A.
[0020] An IPG strip may be inserted into IPG strip region 11 . An IPG strip typically has a shelf life of about one year and should be kept dry and either refrigerated or frozen to increase shelf life. Therefore, it may be advantageous to store IPG strips separately from the cassette housing 10 , and to load and hydrate an IPG strip in the IPG strip region 11 just prior to performing electrophoresis. The IPG electrodes 25 and 26 can be used to apply the current to the IPG strip region 11 such that an IPG strip can perform isoelectric focusing to a sample added to an IPG strip through the sample opening 35 .
[0021] A protein sample may be loaded onto an IPG strip placed in the IPG strip region 11 using a “cup loading” method in which the sample is placed in a cup that interfaces with the hydrated IPG strip. Drip rods may also be used to load the sample as follows. Upon rehydration of the IPG strip, a protein sample may be placed into a drip rod that is then placed on the surface of the IPG strip. The drip rod can contact the IPG strip through the sample openings 35 or buffer openings 31 . The sample may be diluted, for example, by dissolving the sample in one or more of 9.5 M urea, 2-4% non-ionic or zwitterionic detergent, 1% Dithiothreitol (DTT), and 0.8% carrier ampholyte. See O'Farrell PH (1975) “High resolution two-dimensional electrophoresis of proteins.” J Biol Chem 250: 4007-4021. Relatively hydrophobic proteins may be dissolved by a mixure of 2 M thiourea and 7 M urea instead of 9.5 M urea and/or other detergents. See Rabilloud T, Adessi, C, Giraudel A, Lunardi J (1997) “Improvement of the solubilization of proteins in two-dimensional electrophoresis with immobilized pH gradients.” Electro-phoresis 18: 307-316.
[0022] Isoelectric focusing typically requires exposing a sample solution to an IPG strip at about 15 degrees C. for about 12 hours at a constant voltage of about 300 V. Alternatively, various voltages may be applied depending on the IPG strip used and the proteins to be focused. For example, an eleven centimeter IPG strip can be focused for thirty minutes at 250 volts, sixty minutes of slow ramping to 8,000 volts, followed by fifteen to twenty kilovolt hours at 8,000 volts.
[0023] A polyacrylamide gel 47 (FIG. 2), such as Tris-Glycine acrylamide, extends in a substantially flat planer two dimensional slab in the polyacrylamide gel region 13 (FIG. 1). A removable dam 33 separates the IPG region 11 from the polyacrylamide gel region 13 . The removable dam 33 can be plexiglass. In operation, the removable dame 33 can be used to prevent spillage of a high salt content polyacrylamide gel 47 into the IPG strip region 11 while buffers can flush the IPG strip. Preferrably, the total salt concentration should not exceed 300 mM in a sample. The removable dam 33 can be inserted between the opposing plates 41 and 43 of the cassette housing 10 by cutting an incision in the top opposing plate 41 . A plexiglass removable dam 33 can be inserted in the incision and sealed with a high resistance vacuum sealant. The removable dam 33 can be removed prior to performing electrophoresis on the polyacrylamide gel 47 . After removal of the dam 33 , the incision can be sealed, for example, with sequencing tape. However, the removable dam 33 may not be necessary to separate the IPG strip region 11 from the polyacrylamide gel region 13 . For example, the cassette housing 10 may be placed at an angle to prevent a buffer from coming in contact with the polyacrylamide gel 47 . PAGE electrodes 17 and 19 in the form of metal filaments can be used to apply a voltage across the polyacrylamide gel region 13 . After proteins from a sample are focused on an IPG strip placed in the IPG strip region 11 , the protein from the IPG strip can be transferred from the IPG strip to the polyacrylamide gel region 13 . This transfer can be facilitated by a suitable buffer, which can be applied through the buffer openings 29 and 31 . As described above, an SDS/buffer can be used to increase the solubility and to impart a negative charge to the proteins in the solution. Other suitable buffers can be used such as dithiothreitol, tributyl phosphine, a mixture of 6M urea, 0.375 M Tris pH 8.8, 2% SDS, 20% glycerol, or 2% (w/v) Dithiothreitol (DTT), or a mixture of 6M urea, 0.375 M Tris pH 8.8, 2% SDS, 20% glycerol, or 2% (w/v) iodoacetamide. After adding a buffer through buffer openings 29 and 31 , a stopper such as a cylindrical piece of filter paper may be placed in the buffer openings 29 and 31 . Purified water can be added to the filter paper stopper so that the stopper can serve as a salt sink to remove impurities.
[0024] Once the dam 33 is removed and a buffer applied to the sample, an electric current is applied to the PAGE electrodes 17 and 19 so that the proteins that were isoelectrically focused on an IPG strip can travel towards the anode electrode 19 . As a result, the proteins in the sample are separated by their molecular weight in the polyacrylamide gel region 13 . Separation of the proteins in a sample by molecular weight along the polyacrylamide gel typically takes between about 30 and 40 minutes at ambient temperature. As understood by those of skill in the art, bromophenol Blue Dye can be used to determine the length exposure needed.
[0025] The IPG electrodes 25 and 27 can be connected to a current source (not shown) through buffer openings 29 and 31 , and PAGE electrodes 17 and 19 can be connected to current sources through electrode openings 21 and 23 . As will be appreciated by one of skill in the art, buffer openings 29 and 31 , electrode openings 21 and 23 , and sample openings 35 can be placed at other locations around housing 15 . For example, the sample opening 35 is preferably in the center of the IPG strip region 11 , but can also be situated off-center or at one end of the IPG strip region 11 . Although the IPG electrodes 25 and 27 should be placed at opposite ends of the IPG region 11 , additional buffer openings can be placed at various points along the IPG region 11 . The buffer openings 29 and 31 , electrode openings 21 and 23 and the sample opening 35 can be used to introduce various fluids into the cassette such as buffers, hydration solutions, sample solutions and staining reagents. These fluids may be introduced manually or automatically.
[0026] As can be seen in FIG. 2, the cassette housing 15 includes two opposing plates 41 and 43 . Spacers 45 separate opposing plates 41 and 43 . The polyacrylamide gel 47 forms a layer on one of the opposing plates 34 . A semi-permeable dialysis membrane 49 extends over top of the polyacrylamide gel 47 . The semi-permeable membrane 49 encloses and surrounds the polyacrylamide gel 47 to define a void 51 in between the membrane 49 and the other of the opposing plates 41 . The semi-permeable membrane can prevent the polyacrylamide gel 47 from expanding or moving into the void 51 . In certain embodiments, the polyacrylamide gel 47 and the membrane 49 can be chemically crosslinked together.
[0027] The void 51 that is defined by the membrane 49 can provide a space in which fluids may be introduced onto the polyacrylamide gel 47 . For example, as can be seen in FIG. 3, a staining reagent may be introduced by electrode openings 21 and 23 . The staining reagent can flow along arrows 63 across the membrane 49 and onto the polyacrylamide gel 47 . Staining reagents typically require about ninety minutes to stain a polyacrylamide gel. Therefore, embodiments of the present invention can provide staining inside the cassette and may eliminate the need to remove the polyacrylamide gel from the cassette housing 15 for staining. Alternatively, the polyacrylamide gel 47 can be removed from the housing 10 and subsequently stained.
[0028] Many of the steps described herein may be automated, reducing the need for skilled operators to perform the steps manually. For example, staining can be accomplished by automatically adding a staining reagent into the cassette such as with a machine configured to release the staining reagent into the electrode openings 21 and 23 at a predetermined time. As would be understood by those of skill in the art, the application of voltage on an IPG strip or polyacrylamid gel, the application of a buffer, the removal of the dam 33 , and the application of the staining reagent are examples of steps that may each be automated. For example, mechanical systems can be controlled by software and configured using known techniques to apply a solution through a specified opening in the cassette housing 15 , apply a voltage to a specified electrode, or remove the dam 33 , at predetermined times in order to perform 2-D PAGE. Automation of one or more of the steps may produce 2-D PAGE results with higher reproducibility and accuracy and require less intervention from a skilled operator.
[0029] The two opposing plates 41 and 43 and the spacers 45 can be formed of a single unitary member or, alternatively, from a plurality of parts. For example, the opposing plates 41 and 43 may be separately molded pieces that are joined by molded spacers 45 . Preferably the housing 15 is a plastic housing that is heat resistant. However, glass or other suitable materials may also be used. In certain embodiments, the spacers 45 can define an opening that is about 2 mm in height.
[0030] A loading device 110 that can be used to concentrate protein samples is shown in the FIGS. 4A-4C and FIG. 5. The loading device 110 includes a sample chamber 111 and two hydration chambers 113 A and 113 B adjacent the sample chamber 111 . The hydration chambers 113 A and 113 B are separated from the sample chamber 111 by semi-permeable membranes 117 A and 117 B. A sample solution 121 including proteins 123 can be placed in the sample chamber 111 through opening 127 . The sample chamber 111 includes a second opening 115 , which is closed when the sample 121 is placed in the sample chamber 111 in FIG. 4B.
[0031] The hydration chambers 113 A and 113 B are filled with a hypertonic solution 119 in FIG. 4B. The solution 119 is hypertonic with respect to the protein sample solution 121 . Therefore, turgor pressure increases in the hydration chambers 113 A and 113 B when the sample chamber 111 is filled with the protein solution 121 . As a result, electrolytes from the sample solution 121 flow into hydration chambers 113 A and 113 B by way of membranes 117 A and 117 B, and the protein sample solution 121 is concentrated as can be seen in FIG. 4C.
[0032] As shown in FIG. 4A-C, the opening 115 to the sample chamber 111 can be closed to allow concentration of the sample solution (FIGS. 4 A-B), and subsequently opened such that the sample solution 121 can flow into an electrophoresis separation medium, such as an IPG strip 125 (FIG. 4C). As can be seen in FIG. 5, the loading device 110 can be used to load a sample solution 121 into the electrophoresis device 10 . The sample solution 123 follows arrows 61 onto IPG strip 63 through the opening 115 and the sample opening 35 . The loading device 110 can be used to provide automated loading of a concentrated solution into the electrophoresis device 10 .
[0033] In the drawings and specification, there have been disclosed typical illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | A device for two-dimensional electrophoresis includes a cassette comprising two opposing plates. The two opposing plates form a first elongated portion for receiving a first elongated electrophoretic separation medium and a second portion extending away from the first portion. A second electrophoretic separation medium is on the second portion and between the two opposing plates. A dialysis membrane extends across the second electrophoretic separation medium. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to novel polypeptides belonging to the guanosine triphosphate-binding protein coupled receptor (hereinafter, abbreviated as “GPCR”) family, polynucleotides encoding said polypeptides, as well as production and use of the same.
BACKGROUND OF THE INVENTION
[0002] More than 90% of drugs developed by drug industries in the world so far, have targeted interactions in the extracellular spaces, and a majority of these drugs target the GPCRs that comprise seven transmembrane helices (Baldwin J. M., Curr. Opin. Cell Biol. 6: 180-190 (1994); Strader C. D. et al. , FASEB. J. 9: 745-754 (1995); Bockaert J., Pin J. P., EMBO. J. 18: 1723-1729 (1999)). Therefore, GPCRs are one of the most important targets in finding genes for designing drugs. The GPCRs are involved in the signal transduction induced by specific ligands, such as adrenaline and acetylcholine, and characteristics of the binding mechanisms thereof have been actively investigated by conducting experiments (Watson S. & Arkinstrall S., The G-protein Linked receptor Facts Book (Academic Press, London)).
[0003] However, despite the vast data sources, such as cDNAs, ESTs, and microarray analyses, that have been obtained, only a limited number of novel sequences of the family have been discovered (Lee D. K. et al., Brain Res. Mol. Brain Res. 86: 13-22 (2001); Mizushima K. et al., Genomics. 69: 314-321 (2000); Matsumoto M. et al., Gene. 248: 183-189 (2000); Marchese A. et al., Trends Pharmacol. Sci. 20: 447 (1999); Lee D. K., FEBS. Lett. 446: 103-107 (1999); Yonger R. M. et al., Genome Research. 11: 519-530 (2001); Horn F. et al., Nucleic Acids Res. 29: 346-349 (2001)). Even the large-scale classification of known GPCR sequences, such as GPCRdb (Lee D. K. et al., Brain Res. Mol. Brain Res. 86: 13-22 (2001)) and collections by PSI-BLAST (Josefson L. G. , Gene. 239: 333-340 (1999)) , have not led to a broadscale elucidation at the level of the entire genome.
[0004] Therefore, it is important to elucidate the GPCR families as a whole by scanning human genomic sequences, wherein more than 90% of all the sequences thereof have been already determined (International Human Genome Sequencing Consortium. Initial sequencing and analysis of the human genome. Nature 409: 860-921 (2001); Venter J. C. et al., Science 291: 1304-1351 (2001)).
SUMMARY OF THE INVENTION
[0005] This need in the art led to the present invention, and the object of the present invention is to develop an automated technique for efficiently extracting GPCR sequences from the human genome sequences and thereby inclusively identifying novel GPCRs.
[0006] Another object of the present invention is to provide a use for the newly identified GPCRs. As one preferred embodiment of the use of the novel GPCRs, this invention provides for the use of GPCRs to screen drug candidate compounds such as ligands, etc. Moreover, as another preferred embodiment for the use of the novel GPCRs, this invention provides a method for testing disorders based on mutations and expression aberrations of the novel GPCRs as an indicator.
[0007] Furthermore, this invention provides a use for the novel GPCRs or molecules that control the activities thereof, in the treatment of disorders.
[0008] To accomplish the objects described above, first, the present inventors carefully evaluated analytical methods for sequence search (Altschul S. F. et al., Nucleic Acids Res. 25: 3389-3402 (1997)), motif and domain attribution (Bateman A. et al., Nucleic Acids Res. 28: 263-266 (2000); Bairoch A., Nucleic Acids Res. 20 Suppl: 2013-2018 (1992)), and transmembrane helix prediction (Hirokawa T. et al., Bioinformatics, 14: 378-379 (1998)), and then, developed an automated system for identifying GPCR sequences from the whole human genome. This automated system comprises the following three steps.
[0009] The first step is to predict genes. More specifically, translation of the genomic sequences into amino acid sequences. The prediction of a gene can be achieved to a certain extent by resorting to 6-frame development of nucleotide sequences, since most of the known GPCR genes contain no introns. On the other hand, for sequences with multiple exons, it is necessary to predict the entire gene structure using a gene-finding program.
[0010] The second step consists of a three-fold analysis of the amino acid sequences. More specifically, this step comprises: (1) searching for corresponding sequences in known GPCR databases; (2) attributing the motif and domain; and (3) predicting the transmembrane helix (TMH). The former two procedures are used to find closely related GPCR homologues, while the TMH prediction is used to find remote GPCR homologues. Subsequently, candidate sequences are screened by taking the analysis results of the three analyses as a logical sum. In order to maximize the number of candidate sequences at this screening step, the present inventors have used the logical sum of the results of the analyses.
[0011] The third step is to further refine the quality of the candidate genes by eliminating overlapping sequences from the second step, and merging fragmented sequences separated by misprediction.
[0012] According to this automated system, GPCR sequences can be efficiently and inclusively identified. A further great advantage of the automated system is that it can identify even GPCR sequences consisting of multiple exons and remote homologous sequences, which have been difficult to find by conventional methods.
[0013] Using the automated system of the present invention, the inventors have successfully identified 1035 novel GPCR sequences from the whole human genome, such sequences guaranteed with a high confidence to be members of the GPCR family. The discovery of such novel GPCR sequences enables the screening of ligands, antagonists and agonists, which are expected to be useful as drugs. Additionally, GPCRs are thought to have important functions in vivo. Thus, aberrations in the expression and function thereof may be the cause of a variety of disorders. Therefore, it is possible to analyze and evaluate such disorders using as an indicator inappropriate functions or expressions of the identified GPCRs. The identified GPCRs, polynucleotides encoding them, and ligands, antagonists, or agonists of the identified GPCRs may function as preferred therapeutic agents for such disorders.
[0014] Accordingly, the present invention relates to novel GPCRs and genes encoding them, as well as methods for producing and using same. More specifically, the present invention provides the following:
[0015] (1) a polynucleotide encoding a guanosine triphosphate-binding protein coupled receptor selected from the group of:
[0016] (a) a polynucleotide encoding a polypeptide comprising an amino acid sequence of any even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070;
[0017] (b) a polynucleotide comprising a coding region of the nucleotide sequence of any odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069;
[0018] (c) a polynucleotide encoding a polypeptide comprising an amino acid sequence of any even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070 wherein one or more amino acid residues are substituted, deleted, added, and/or inserted; and
[0019] (d) a polynucleotide hybridizing under stringent conditions with a DNA consisting of a nucleotide sequence of any odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069;
[0020] (2) a polynucleotide encoding a fragment of a polypeptide comprising the amino acid sequence of any even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070;
[0021] (3) a vector comprising the polynucleotide of (1) or (2);
[0022] (4) a host cell retaining the polynucleotide of (1) or (2) or the vector of (3);
[0023] (5) a polypeptide encoded by the polynucleotide of (1) or (2);
[0024] (6) a method for producing the polypeptide of (5) , comprising the step of culturing the host cell of (4), and recovering the produced polypeptide from said host cell or culture supernatant thereof;
[0025] (7) an antibody binding to the polypeptide of (5);
[0026] (8) a method of identifying a ligand of the polypeptide of (5), comprising the steps of:
[0027] (a) contacting a candidate compound with the polypeptide of (5) , cell expressing the polypeptide of (5) , or cytoplasmic membrane of the cell; and
[0028] (b) detecting whether the candidate compound binds to the polypeptide of (5), cell expressing the polypeptide of (5), or cytoplasmic membrane thereof;
[0029] (9) a method for identifying an agonist of the polypeptide of (5), comprising the steps of:
[0030] (a) contacting a candidate compound with the cell expressing the polypeptide of (5); and
[0031] (b) detecting whether the candidate compound induces a signal that indicates the activation of the polypeptide of (5);
[0032] (10) a method for identifying an antagonist of the polypeptide of (5), comprising the steps of:
[0033] (a) contacting a cell expressing the polypeptide of (5) with an agonist of the polypeptide of (5) in the presence of a candidate compound; and
[0034] (b) detecting whether the intensity of the signal that indicates the activation of the polypeptide of (5) is reduced or not by comparing with the signal detected in the absence of the candidate compound;
[0035] (11) a ligand identified by the method of (8);
[0036] (12) an agonist identified by the method of (9);
[0037] (13) an antagonist identified by the method of (10);
[0038] (14) a kit for use with the method of any one of (8) to (10) comprising at least one molecule selected from the group:
[0039] (a) the polypeptide of (5); and
[0040] (b) the host cell of (4) or cytoplasmic membrane thereof;
[0041] (15) a pharmaceutical composition for treating a patient, who is in need of increased activity or expression of the polypeptide of (5) , comprising an effective amount of the molecule for the treatment selected from the group of:
[0042] (a) an agonist of the polypeptide of (5);
[0043] (b) the polynucleotide of (1) or (2); and
[0044] (c) the vector of (3);
[0045] (16) a pharmaceutical composition for treating a patient, whose activity or expression of the polypeptide of (5) needs to be suppressed, comprising an effective amount of the molecule for the treatment selected from the group of:
[0046] (a) an antagonist of the polypeptide of (5); and
[0047] (b) a polynucleotide suppressing the expression of a gene encoding the endogenous polypeptide of (5) in vivo;
[0048] (17) a method for testing a disorder associated with the aberration in the expression of a gene encoding the polypeptide of (5) or the aberration in the activity of the polypeptide of (5), comprising the step of detecting a mutation in the gene or in the expression control region thereof in the subject;
[0049] (18) the method of (17), comprising the steps of:
[0050] (a) preparing a DNA sample from a subject;
[0051] (b) isolating from the sample the DNA encoding the polypeptide of (5) or the expression control region thereof;
[0052] (c) determining the nucleotide sequence of the isolated DNA; and
[0053] (d) comparing the nucleotide sequence of DNA determined in step (c) with that of a control;
[0054] (19) the method of (17), comprising the steps of:
[0055] (a) preparing a DNA sample from a subject;
[0056] (b) cleaving the prepared DNA sample with a restriction enzyme;
[0057] (c) separating DNA fragments according to the sizes thereof; and
[0058] (d) comparing the detected sizes of the DNA fragments with those of a control;
[0059] (20) the method of (17), comprising the steps of:
[0060] (a),preparing a DNA sample from a subject;
[0061] (b) amplifying in the sample the DNA encoding the polypeptide of (5) or the expression control region thereof;
[0062] (c) cleaving the amplified DNAs with a restriction enzyme;
[0063] (d) separating the DNA fragments according to the sizes thereof; and
[0064] (e) comparing the detected sizes of the DNA fragments with those of a control;
[0065] (21) the method of (17), comprising the steps of:
[0066] (a) preparing a DNA sample from a subject;
[0067] (b) amplifying in the sample the DNA encoding the polypeptide of (5) or the expression control region thereof;
[0068] (c) dissociating the amplified DNA to single-stranded DNAs;
[0069] (d) separating the dissociated single-stranded DNAs on a non-denaturing gel; and
[0070] (e) comparing the mobility of the separated single-stranded DNAs with that of a control;
[0071] (22) the method of (17), comprising the steps of:
[0072] (a) preparing a DNA sample from a subject;
[0073] (b) amplifying in the sample the DNA encoding the polypeptide of (5) or the expression control region thereof;
[0074] (c) separating the amplified DNAs on a gel with increasing concentration gradient of a DNA denaturant; and
[0075] (d) comparing the mobilities of the separated DNAs with those of a control;
[0076] (23) a method for testing disorders associated with the aberration in the expression of a gene encoding the polypeptide of (5) , comprising the step of detecting the expression level of the gene in the subject;
[0077] (24) the method of (23), comprising the steps of:
[0078] (a) preparing an RNA sample from a subject;
[0079] (b) measuring the amount of RNA encoding the polypeptide of (5) contained in said RNA sample; and
[0080] (c) comparing the amount of measured RNA with that of a control;
[0081] (25) the method of (23), comprising the steps of:
[0082] (a) providing a cDNA sample prepared from a subject, and a basal plate on which nucleotide probes hybridizing to the DNA encoding the polypeptide of (5) are immobilized;
[0083] (b) contacting said cDNA sample with said basal plate;
[0084] (c) measuring the expressed amount of the gene encoding the polypeptide of (5) contained in said cDNA sample by detecting the hybridization intensity between said cDNA sample and the nucleotide probe immobilized on the basal plate; and
[0085] (d) comparing the measured expression amount of the gene encoding the polypeptide of (5) with that of a control;
[0086] (26) the method of (23), comprising the steps of:
[0087] (a) preparing a protein sample from a subject;
[0088] (b) measuring the amount of the polypeptide of (5) contained in said protein sample; and
[0089] (c) comparing the amount of the measured polypeptide with that of a control;
[0090] (27) an oligonucleotide having a chain length of at least 15 nucleotides hybridizing to a DNA encoding the polypeptide of (5) or the expression control region thereof;
[0091] (28) an assay reagent for testing disorders associated with aberration in the expression of the gene encoding the polypeptide of (5) or aberration in the activity of the polypeptide of (5), comprising the oligonucleotide of (27); and
[0092] (29) an assay reagent for testing disorders associated with aberration in the expression of a gene encoding the polypeptide of (5) or aberration in the activity of the polypeptide of (5) comprising the antibody of (7).
[0093] In the following, definitions of terms used herein are described to facilitate understanding of the terms used herein, but it should be understood that they are not described so as to limit the present invention in any way.
[0094] Herein, the term “guanosine triphosphate-binding protein coupled receptor (GPCR)” refers to a cytoplasmic membrane receptor that transmits signals into cells via activation of a GTP-binding protein.
[0095] The term “polynucleotide” as used herein refers to a ribonucleotide or deoxyribonucleotide or a polymer consisting of a plurality of bases or base pairs. Polynucleotides include single-stranded DNAs as well as double-stranded DNAs. Polynucleotides include both unmodified naturally occurring polynucleotides and modified polynucleotides. Tritylated bases and special bases such as inosine are examples of modified bases.
[0096] The term “polypeptide” used herein refers to a polymer comprising a plurality of amino acids. Therefore, oligopeptides and proteins are also included within the concept of polypeptides. Polypeptides include both unmodified naturally occurring polypeptides and modified polypeptides. Examples of polypeptide modifications include acetylation; acylation; ADP-ribosylation; amidation; covalent binding with flavin; covalent binding with heme moieties; covalent binding with nucleotides or nucleotide derivatives; covalent binding with lipids or lipid derivatives; covalent binding with phosphatidylinositols; cross-linkage; cyclization; disulfide bond formation; demethylation; covalent cross linkage formation; cystine formation pyroglutamate formation; formylation; γ-carboxylation; glycosylation; GPI-anchor formation; hydroxylation; iodination; methylation; myristoylation; oxidation; proteolytic treatment; phosphorylation; prenylation; racemization; selenoylation; sulfation; transfer RNA-mediated amino acid addition to a protein such as arginylation; ubiquitination; and such.
[0097] The term “isolation” as used herein refers to a substance (for example, polynucleotide or polypeptide) taken out from the original environment (for example, natural environment for a naturally occurring substance) , and “artificially” changed from the natural state. “Isolated” compound refers to compounds comprising compounds present in samples substantially abundant in subject compound and/or those present in samples wherein the subject compound is partly or substantially purified. Herein, the term “substantially purified” refers to compounds (for example, polynucleotides or polypeptides) that are isolated from the natural environment and which do not contain at least 60%, preferably 75%, and post preferably 90% of the other components associated with the compound in nature.
[0098] The term “mutation” used herein refers to changes of amino acids in an amino acid sequence or changes of bases in a nucleotide sequence (that is, substitution, deletion, addition, or insertion of one or more amino acids or nucleotides). Therefore, the term “mutant” as used herein refers to amino acid sequences wherein one or more amino acid(s) is changed, or nucleotide sequences wherein one or more base(s) is changed. The nucleotide sequence changes in the mutant may either change the amino acid sequence of the polypeptide encoded by the standard polynucleotide or not. The mutant may be one existing in nature, such as an allelic mutant, or one not yet identified in nature. The mutant may be altered conservatively, wherein the substituted amino acid has similar structural or chemical characteristics as that of the original amino acid. Rarely, mutants may be substituted non-conservatively. Guidance to decide which or how many amino acid residues are to be substituted, inserted, or deleted without inhibiting biological or immunological activities can be found using computer programs known in the art, such as the DNA star STAR software.
[0099] “Deletion” is a change either in the amino acid sequence or nucleotide sequence, wherein one or more amino acid residues or nucleotide residues are absent, respectively, as compared with the amino acid sequence of a naturally occurring GPCR and GPCR-associated polypeptide, or the nucleotide sequences encoding same.
[0100] “Insertion” or “addition” is a change either in the amino acid sequence or nucleotide sequence, wherein one or more amino acid residues or nucleotide residues are added, respectively, as compared with the amino acid sequence of a naturally occurring GPCR and GPCR-associated polypeptide, or nucleotide sequences encoding same.
[0101] “Substitution” is a change either in the amino acid sequence or nucleotide sequence, wherein one or more amino acid residues or nucleotide residues are changed for different amino acid residues or nucleotide residues, respectively, as compared with the amino acid sequence of a naturally occurring GPCR and GPCR-associated polypeptide, or nucleotide sequences encoding same.
[0102] The term “hybridize” as used herein refers to a process wherein a nucleic acid chain binds to its complementary chain through the formation of base pairs.
[0103] In general, the term “treatment” as used herein means to achieve pharmacological and/or physiological effects. Such effects may be either a prophylactic effect, preventing disorders or symptoms completely or partially, or a therapeutic effect curing symptoms of disorders completely or partially. The term “treatment” used herein encompasses all treatments of disorders in mammals, in particular, humans. Moreover, this term also includes prophylaxis of the onset of the disease, suppression of progression of the disorder, and amelioration of the disease in subjects with diathesis of disease who have not been diagnosed as being ill.
[0104] The term “ligand” used herein refers to molecules that bind to a polypeptide of the present invention, including both natural and synthetic ligands “Agonist” refers to molecules that bind and activate a polypeptide of the present invention. On the other hand, “antagonist” refers to molecules that inhibit the activation of a polypeptide of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0105] [0105]FIG. 1 is a graph showing the number of pairs between GPCR sequences and other GPCR sequences or non-GPCR sequences, which were plotted with respect to the E-value, detected during the search of known GPCR sequences in an evaluation database including 1,054 of GPCR sequences and 64,154 of non-GPCR sequences.
DETAILED DESCRIPTION OF THE INVENTION
[0106] <Polypeptides>
[0107] The present invention provides novel polypeptides belonging to the GPCR family. Nucleotide sequences of 1035 polynucleotides derived from humans, whose sequences have been identified by the present inventors, are shown in the odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069. Amino acid sequences of polypeptides encoded by said polynucleotides are shown in the even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070. In the nucleotide sequences shown in the odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069, n means a base selected from a, t, c, and g. In the amino acid sequences shown in the even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070, Xaa means any one of amino acids. GPCRs have the activity to transmit signals into the cell through the activation of a G protein by the action of a ligand of GPCR, and are associated with genetic diseases and disorders in great many regions of the body, such as the cranial nervous system, the cardiovascular system, the alimentary system, the immune system, the locomotorial system, the urogenital system, etc. Therefore, the polypeptides of this invention can be used to screen for ligands, agonists, or antagonists that control the functions of the polypeptides, which serves as an important target in the development of drugs for above-described disorders.
[0108] This invention also provides polypeptides functionally equivalent to the polypeptides identified by the present inventors. Herein, the term “functionally equivalent” means that the subject polypeptide has a biological characteristic equivalent to that of a polypeptide identified by the present inventors. Examples of biological characteristics of GPCRs include: binding activity with a ligand; and the activity to transduce signals into cells through the activation of trimeric GTP-binding proteins. The trimeric GTP-binding proteins are classified into following three categories according to the types of the intracellular signal transduction systems activated thereby: (1) Gq type: elevating the Ca 2+ level; (2) Gs type: increasing cAMP; and (3) Gi type: suppressing cAMP (Trends Pharmacol. Sci. (99) 20: 118-124). Therefore, it is possible to assess whether a subjective polypeptide has a biological characteristic equivalent to that of a polypeptide identified by the inventors or not, for example, by detecting the changes in intercellular concentrations of cAMP or calcium caused by the activation.
[0109] A method for introducing mutation(s) into the amino acid sequence of a protein can be mentioned as one embodiment of methods for preparing polypeptides functionally equivalent to the polypeptides identified by the inventors. Such a method includes, for example, the site-directed mutagenesis (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 8.1-8.5). Amino acid mutation in polypeptides may also occur in nature. The present invention includes mutant proteins, regardless whether artificially or naturally produced, comprising amino acid sequences identified by the inventors (i.e., the even-numbered SEQ ID NOs from SEQ ID No: 2 to SEQ ID NO: 2070) wherein one or more amino acid residues are altered by substitution, deletion, insertion, and/or addition, yet which are functionally equivalent to the polypeptides identified by present inventors.
[0110] As for the amino acid residue to be substituted, it is preferable that it be substituted with a different amino acid residue that allows the properties of the amino acid residue to be conserved. For example, Ala, Val, Leu, Ile, Pro, Met, Phe, and Trp are all classified as non-polar amino acids, and are considered to have similar properties to each other. Further, examples of uncharged amino acids are Gly, Ser, Thr, Cys, Tyr, Asn, and Gln. Moreover, examples of acidic amino acids are Asp and Glu, and those of basic amino acids are Lys, Arg, and His.
[0111] There is no limitation in the number and sites of the amino acid mutation in these polypeptides so long as the mutated polypeptide retains the functions of the original polypeptide. The number of mutations may be typically less than 10%, preferably less than 5%, and more preferably less than 1% of the total amino acid residues.
[0112] Other embodiments of the method for preparing polypeptides functionally equivalent to the polypeptides identified by the inventors include methods utilizing hybridization techniques or gene amplification techniques. More specifically, those skilled in the art can obtain polypeptides functionally equivalent to the polypeptides determined by the present inventors by isolating highly homologous DNAs from DNA samples derived from organisms of the same or different species using hybridization techniques (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 6.3-6.4) based on the DNA sequences encoding the polypeptides identified by the inventors (i.e., sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069). Thus, such polypeptides encoded by DNAs hybridizing to the DNAs encoding the polypeptides identified by the inventors, which polypeptides are functionally equivalent to the polypeptides identified by the inventors, are also included in the polypeptides of this invention.
[0113] Examples of organisms to be used for isolating such polypeptides are rats, mice, rabbits, chicken, pigs, cattle, etc., as well as humans, but the present invention is not limited to these organisms.
[0114] The hybridization stringency required to isolate a DNA encoding a functionally equivalent polypeptide to the polypeptides identified by the inventors is normally “1×SSC, 0.1% SDS, 37° C.” or so, a more stringent condition being “0.5×SSC, 0.1% SDS, 42° C.” or so, and a much more stringent condition being “0.2×SSC, 0.1% SDS, 65° C.” or so. As the stringency becomes higher, isolation of a DNA with higher homology to the probe sequence can be expected. However, above-mentioned combinations of conditions of SSC, SDS, and temperature are only an example, and those skilled in the art can achieve the same stringency as described above by appropriately combining above-mentioned factors or others parameters which determine the stringency of the hybridization (for example, probe concentration, probe length, reaction time of hybridization, etc.).
[0115] The polypeptides encoded by the DNA isolated using such hybridization techniques normally are highly homologous in their amino acid sequences to the polypeptides identified by the present inventors. Herein, high homology indicates a sequence identity of at least 40% or more, preferably 60% or more, more preferably 80% or more, still more preferably 90% or more, further still more preferably at least 95% or more, and yet more preferably at least 97% or more (for example, 98% to 99%). Homology of amino acid sequences can be determined, for example, by using the algorithm BLAST according to Karlin and Altschul (Proc. Natl. Acad. Sci. USA 87: 2264-2268 (1990); Proc. Natl. Acad. Sci. USA 90: 5873-5877 (1993)). Based on this algorithm, a program referred to as BLASTX has been developed (Altschul et al., J. Mol. Biol. 215: 403-410 (1990)). When amino acid sequences are analyzed using BLASTX, parameters are set, for example, score=50 and wordlength=3, while in the case of using BLAST and Gapped BLAST programs, default parameters of each program are used. Specific techniques of these analytical methods are well known in the field (See http://www.ncbi.nlm.nih.gov.).
[0116] The gene amplification technique (PCR) (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 6.1-6.4) can be utilized to obtain a polypeptide functionally equivalent to the polypeptides isolated by the present inventors, based on DNA fragments isolated as highly homologous DNAs to the DNA sequences encoding the polypeptides isolated by the present inventors, by designing primers based on a part of the DNA sequences encoding the polypeptides identified by the inventors (sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069).
[0117] Polypeptides of this invention may be in the form of a “mature” protein, or may be also a part of a larger protein, such as fusion proteins. Polypeptides of this invention may contain secretory sequences, namely leader sequences; prosequences; sequences useful for purification, such as multiple histidine residues and such; and additive sequences to secure the stability during recombinant production.
[0118] <Polypeptide Fragments>
[0119] The present invention also provides fragments of the polypeptides of this invention. These fragments are polypeptides having amino acid sequences which are partly, but not entirely, identical to the above polypeptides of this invention. The polypeptide fragments of this invention usually consist of 8 amino acid residues or more, and preferably 12 amino acid residues or more (for example, 15 amino acid residues or more) . Examples of preferred fragments include truncation polypeptides, having amino acid sequences lacking a series of amino acid residues including either the amino terminus or carboxyl terminus, or two series of amino acid residues, one including the amino terminus and the other including the carboxyl terminus. Furthermore, fragments featured by structural or functional characteristics are also preferable, which include those having α-helix and α-helix forming regions, β-sheet and β-sheet forming regions, turn and turn forming regions, coil and coil forming regions, hydrophilic regions, hydrophobic regions, α-amphipathic regions, β-amphipathic regions, variable regions, surface forming regions, substrate-binding regions, and high antigenicity index region. Biologically active fragments are also preferred. Biologically active fragments mediate the activities of the polypeptides of this invention, which fragments include those having similar or improved activities, or reduced undesirable activities. For example, fragments having the activity to transduce signals into cells via binding of a ligand, and furthermore, fragments having antigenicity or immunogenicity in animals, especially humans are included. These polypeptide fragments preferably retain the biological activities of the polypeptides of this invention, which activity includes antigenicity. Mutants of specific sequences or fragments also constitute an aspect of this invention. Preferred mutants are those which are different from the subject polypeptide, due to replacement with conservative amino acids, namely, those in which residue(s) is (are) substituted with other residue(s) having similar properties. Typical substitutions are those between Ala, Val, Leu, and Ile; Ser and Thr; acidic residues Asp and Glu, Asn, and Gln; basic residues Lys and Arg; or aromatic residues Phe and Tyr.
[0120] Alternatively, fragments which bind to ligands without transducing signals into cells may be also useful as competitive inhibitors for the polypeptides of this invention and are included in the present invention.
[0121] <Production of Polypeptides>
[0122] Polypeptides of this invention may be produced by any appropriate method. Such polypeptides include isolated naturally-occurring polypeptides, and polypeptides which are produced by gene recombination, synthesis, or by a combination thereof. Procedures for producing these polypeptides are well known in the art. Recombinant polypeptides may be prepared, for example, by transferring a vector, wherein the polynucleotide of the present invention is inserted, into an appropriate host cell, and purifying the polypeptide expressed within the resulting transformant. On the other hand, naturally occurring polypeptides can be prepared, for example, using affinity columns, wherein antibodies against the polypeptide of this invention (described below) are immobilized (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 16.1-16.19). Antibodies for affinity purification may be either polyclonal or monoclonal antibodies. The polypeptides of this invention may be also prepared by the in vitro translation method (for example, see “On the fidelity of mRNA translation in the nuclease-treated rabbit reticulocyte lysate system.” Dasso, M. C. and Jackson, R. J. (1989) NAR 17: 3129-3144), and so on. Polypeptide fragments of this invention can be produced, for example, by cleaving the polypeptides of the present invention with appropriate peptidases.
[0123] <Polynucleotides>
[0124] The present invention also provides polynucleotides encoding the polypeptides of this invention. The polynucleotides of this invention include: those encoding polypeptides comprising the amino acid sequences of even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070; those comprising the coding regions of the nucleotide sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069; and those comprising different nucleotide sequences from those of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069 due to the degeneracy of genetic codes but still encoding polypeptides comprising amino acid sequences of even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070. Furthermore, the polynucleotides of this invention include those encoding polypeptides functionally equivalent to the polypeptides of the present invention, comprising nucleotide sequences which are homologous to said polynucleotide sequences at least 40% or more, preferably 60% or more, more preferably 80% or more, further more preferably 90% or more, and still preferably 95% or more, and further still more preferably 97% or more (for example, 98% to 99%) in the entire length. Homology of the nucleotide sequences can be determined, for example, using the BLAST algorithm by Karlin and Altschul (Proc. Natl. Acad. Sci. USA 87: 2264-2268 (1990); Proc. Natl. Acad. Sci. USA 90: 5873-5877 (1993)). Based on this algorithm, an algorithm called BLASTN has been developed (Altschul et al. J. Mol. Biol. 215: 403-410 (1990)). When analyzing a nucleotide sequence using the BLASTN program, parameters are set, for example, score=100 and wordlength=12. When using both BLAST and Gapped BLAST programs, default parameters of each program are used. Specific techniques of these analytical methods are well known in the art (http://www.ncbi.nlm.nih.gov.). The polynucleotides of this invention also include polynucleotides having a nucleotide sequences complementary to those of the above-described polynucleotides.
[0125] The polynucleotides of this invention can be obtained for example, from cDNA libraries induced from intracellular mRNAs by standard cloning and screening methods. Moreover, the polynucleotides of this invention can be obtained from natural sources, such as genomic libraries, and also can be synthesized using commercially available techniques known in the art.
[0126] Polynucleotides comprising nucleotide sequences significantly homologous to the polynucleotide sequences identified by the inventors (sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069) can be prepared using, for example, hybridization techniques (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 6.3-6.4) and the gene amplification technique (PCR) (Current Protocols in Molecular Biology, edit. Ausubel et al. (1987) Publish. John Wiley & Sons Section 6.1-6.4). That is, based on the polynucleotide sequences identified by the inventors (sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069) or portions thereof, using hybridization techniques, DNAs highly homologous to these polynucleotides can be isolated from DNA samples derived from the same or different species of organisms. Moreover, polynucleotides highly homologous to the sequences of said polynucleotides can be isolated using the gene amplification technique by designing primers based on portions of the polynucleotide sequences identified by the inventors (sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069). Therefore, the present invention includes polynucleotides hybridizing under stringent conditions to the polynucleotides comprising the nucleotide sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069. The conditions for stringent hybridization are usually “1×SSC, 0.1% SDS, 37° C.” or so, with a more stringent condition being “0.5×SSC, 0.1% SDS, 42° C.” or so, and a furthermore stringent one being “0.2×SSC, 0.1% SDS, 65° C.” or so. The more stringent the hybridization conditions are, the more highly homologous DNAs to the probe sequence can be expected. However, the above-described combinations of conditions of SSC, SDS, and temperature are mere examples, and those skilled in the art may achieve similar stringency as described above by appropriately combining the aforementioned factors or others parameters that determine the hybridization stringency (for example, probe concentration, probe length, reaction time of hybridization, etc.).
[0127] Polynucleotides comprising nucleotide sequences significantly homologous to the sequences of the polynucleotides identified by the inventors can also be prepared by inducing mutations into the nucleotide sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069 (for example, the site-directed mutagenesis) (Current Protocols in Molecular Biology, edit. Ausubel, et al. (1987) Publish. John Wiley & Sons Section 8.1-8.5). Such polynucleotides may be also generated by mutation in nature. The present invention includes polynucleotides encoding polypeptides comprising amino acid sequences of even-numbered SEQ ID NOs from SEQ ID NO: 2 to SEQ ID NO: 2070 wherein one or more amino acid residues are substituted, deleted, inserted, and/or added, due to such mutations of the nucleotide sequences.
[0128] Polynucleotides used for recombinant production of the polypeptide of this invention include the coding sequences of the mature polypeptide or fragments thereof alone; and coding sequences of the mature polypeptide or fragments thereof in the same reading frame with other coding sequences (for example, leader or secretory sequences; pre-, pro-, or preproprotein sequences; or sequence encoding other fusion peptide portions). For example, a marker sequence that facilitates purification of the fusion polypeptide may be encoded in the same reading frame. A preferred embodiment of this invention includes specific marker sequences, such as the hexahistidine peptide or Myc tag provided by the pcDNA3.1/Myc-His vector (Invitrogen), which is described in the literature (Gentz et al., Proc. Natl. Acad. Sci. USA (1989) 86: 821-824). Further, this polynucleotide may comprise a 5′- and 3′-noncoding sequence, for example, transcribed but non-translated sequences; splicing and polyadenylation signals; ribosome-binding sites; and mRNA stabilization sequences.
[0129] <Probe, Primer, Antisense, Ribozyme>
[0130] The present invention provides nucleotides, having a chain length of at least 15 nucleotides, which are complementary to a polynucleotide isolated by the present inventors (a polynucleotide or a complementary strand thereof consisting of the nucleotide sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069) Herein, the term “complementary strand” is defined as one strand of a double strand nucleic acid composed of A:T (A:U in case of RNA) and G:C base pairs to the other strand. Also, “complementary” is defined as not only those completely matching within a continuous region of at least 15 sequential nucleotides, but also those having a homology of at least 70%, preferably at least 80%, more preferably 90%, and most preferably 95% or higher within that region. The homology may be determined using the algorithm described herein. Probe and primers for detection or amplification of the polynucleotides of the present invention are included in these polynucleotides. Typical polynucleotides used as primers have a chain length of 15 to 100 nucleotides, and preferably 15 to 35 nucleotides. Alternatively, polynucleotides used as probes are nucleotides having a chain length of at least 15 nucleotides, preferably at least 30 nucleotides, containing at least a portion or the whole sequence of a DNA of the present invention. Such nucleotides preferably hybridize specifically to a DNA encoding a polypeptide of the present invention. The term “hybridize specifically” defines that it hybridizes under a normal hybridization condition, preferably a stringent condition with a nucleotide identified by the present inventors (sequence shown as odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069) , but not with DNAs encoding other polypeptides.
[0131] These nucleotides can be used for detecting and diagnosing abnormal activities of the polypeptides of the present invention or abnormal expression of genes encoding the polypeptides.
[0132] Further, these nucleotides include polynucleotides that suppress the expression of genes encoding the polypeptides of the present invention. Such polynucleotides include antisense DNAs (DNAs encoding antisense RNAs, which are complementary to transcriptional products of the genes encoding the polypeptides of the present invention) and ribozymes (DNAs encoding RNAs having ribozyme activities to specifically cleave transcriptional products of the genes encoding the polypeptides of the present invention).
[0133] A plurality of factors, such as those described below, arise as a result of actions suppressing the expression of a target gene by an antisense DNA: inhibition of the transcription initiation by the formation of a triple strand; suppression of the transcription through hybridization with a local open loop conformation site formed by an RNA polymerase; inhibition of the transcription by hybridization with RNA, which is in course of synthesis; suppression of the splicing through hybridization at a junction of intron and exon; suppression of the splicing through hybridization with a spliceosome forming site; suppression of the transfer from the nuclei to cytoplasm through hybridization with the mRNAs; suppression of the splicing through hybridization with capping sites or poly(A) addition sites; suppression of the translation initiation through hybridization with a translation initiation factor binding site; suppression of the translation through hybridization with the ribosome binding site near the initiation codon; inhibition of the elongation of the peptide chain through hybridization with the translation regions and polysome binding sites of the mRNAs; suppression of the expression of genes by hybridization with the interaction sites between nucleic acids and proteins; and such. These actions inhibit the processes of transcription, splicing, and/or translation to suppress the expression of a target gene (Hirajima and Inoue, “New Biochemistry Experimental Course No. 2, Nucleic Acid IV, Duplication and Expression of Genes”, Japan Biochemical Society ed., Tokyo Kagaku Doujin, pp. 319-347 (1993)).
[0134] The antisense DNA of the present invention may suppress the expression of the target gene through any of the above-mentioned actions. According to one embodiment, an antisense sequence designed to be complementary to a non-translated region near the 5′-terminus of mRNA of a gene may effectively inhibit the translation of the gene. Additionally, sequences which are complementary to the coding region or the 3′ non-translated region can be also used. As described above, DNA containing antisense sequences not only to the translation region of a gene, but also those to sequences of non-translated regions are included in the antisense DNA of the present invention. The antisense DNAs to be used in the present invention are linked to downstream of an appropriate promoter, and a sequence including a transcriptional termination signal is preferably linked to the 3′-side thereof. The sequence of the antisense DNA is preferably complementary to the target gene or a part thereof; however, so long as the expression of the gene can be effectively inhibited, it does not have to be a completely complementary DNA. The transcribed RNA is preferably 90% or more, more preferably 95% or more, complementary to the transcribed product of the target gene. In order to effectively inhibit the expression of the target gene using an antisense sequence, the antisense DNA has at least a chain length of 15 bp or more, preferably 100 bp, more preferably 500 bp, and usually has a chain length less than 3000 bp, preferably less than 2000 bp to cause an antisense effect.
[0135] Such antisense DNA can be also applied to gene therapy for diseases caused by abnormalities (functional abnormalities or expression abnormalities) of the polypeptides of the present invention, and such. The antisense DNA can be prepared by, for example, the phosphorothionate method (Stein, “Physicochemical properties of phosphorothionate oligodeoxynucleotides.” Nucleic Acids Res. 16, 3209-21 (1988)) and such based on the sequence information of a DNA (for example, sequences of odd-numbered SEQ ID NOs from SEQ ID NO: 1 to SEQ ID NO: 2069)) encoding a polypeptide of the present invention.
[0136] Further, suppression of the expression of endogenous genes can be also achieved utilizing DNAs encoding ribozymes. Ribozymes are RNA molecules having catalytic activity. There exist ribozymes having various activities, and the research of ribozymes as an enzyme for truncating RNA allowed for the design of ribozymes that cleave RNAs in a site-specific manner. There are ribozymes which are larger than 400 nucleotides, such as Group I intron type ribozymes, and M1RNA comprised in RNaseP, and those which have an active domain of about 40 nucleotides, called hammer-head type and a hairpin type ribozymes (Makoto Koizumi and Eiko Ohtsuka, (1990) , Protein Nucleic Acid and Enzyme (PNE) 35:2191).
[0137] For example, the hammer head type ribozyme cleaves the 3′-side of C15 of G13U14C15 within its own sequence. A base pair formation of the U14 with the A at position 9 is important for the activity, and it is shown that the cleavage proceeds even if the C at position 15 is A or U (M. Koizumi et al., (1988) FEBS Lett. 228:225). Restriction enzymatic RNA-truncating ribozymes recognizing sequences of UC, UU, and UA in a target RNA may be generated by designing the substrate binding site of the ribozyme complementary with the RNA sequence near the target site (M. Koizumi, et al., (1988) FEBS Lett. 239:285; Makoto Koizumi and Eiko Ohtsuka, (1990) , Protein Nucleic Acid and Enzyme (PNE) 35:2191); and M. Koizumi et al. (1989), Nucleic Acids Res. 17:7059). A plurality of sites, which can be used as a target, exist among the polynucleotides (having sequence of odd-numbered SEQ ID NOs from SEQ ID NO: 1- to SEQ ID NO: 2069) identified by the present inventors.
[0138] Further, the hairpin type ribozymes are also useful in the context of the present invention. The hairpin type ribozymes are found on, for example, the minus chain of a satellite RNA of tobacco ringspot virus (J. M. Buzayan, Nature 323:349 (1986)). It is also demonstrated that the ribozyme can be designed to cause a target specific RNA truncation (Y. Kikuchi and N. Sasaki, (1991) Nucleic Acids Res. 19:6751; and Y. Kikuchi, (1992) Chemistry and Organism 30:112).
[0139] When the polynucleotides suppressing the expression of the genes encoding the polypeptides of the present invention are used in gene therapy, they may be administered to a patient by the ex vivo method, in vivo method, and such, using, for example, viral vectors such as retroviral vector, adenoviral vector, adeno-associated viral vectors, and such; and non-viral vectors such as liposome; and so on.
[0140] <Production of Vector, Host cell, and Polypeptide>
[0141] Further, the present invention provides methods for producing vectors containing a polynucleotide of the present invention, host cells retaining a polynucleotide of the present invention or said vector, and polypeptides of the present invention utilizing said host cells.
[0142] The vector of the present invention is not limited so long as the DNA inserted in the vector is retained stably. For example, pBluescript vector (Stratagene) is preferable as a cloning vector when using E. coli as the host. When the vector is used for producing a polypeptide of the present invention, an expression vector is particularly useful. The expression vector is not specifically limited so long as it expresses polypeptides in vitro, in E. coli , in cultured cells, and in vivo. However, preferable examples include the pBEST vector (ProMega) for in vitro expression, the pET vector (Invitrogen) for expression in E. coli , the pME18S-FL3 vector (GenBank Accession No. AB009864) for the expression in cultured cells, and the pME18S vector (Mol. Cell Biol. 8:466-472(1988)) for in vitro expression, and soon. The insertion of a DNA of the present invention into a vector can be carried out by conventional methods, for example, by the ligase reaction using restriction enzyme sites (Current Protocols in Molecular Biology, edit. Ausubel, et al., (1987) Publish. John Wiley & Sons, Section 11-4-11.11).
[0143] The host cell to which the vector of the present invention is introduced is not specifically limited, and various host cells can be used according to the objects of the present invention. For example, bacterial cells (e.g. Streptococcus, Staphylococcus, E. coli , Streptomyces, Bacillus subtilis ) , fungal cells (e.g. yeast, Aspergillus), insect cells (e.g. Drosophila S2, Spodoptera SF9), animal cells (e.g. CHO, COS, HeLa, C127, 3T3, BHK, HEK293, Bowes melanoma cell), and plant cells can be exemplified as cells to express polypeptides. The transfection of a vector to a host cell can be carried out by conventional methods, such as the calcium phosphate precipitation method, the electroporation method (Current protocols in Molecular Biology, edit., Ausubel et al., (1987) Publish. John Wiley & Sons, Section 9.1-9.9), the Lipofectamine method (GIBCO-BRL), the microinjection method, and so on.
[0144] Appropriate secretion signals can be incorporated into the polypeptide of interest in order to secrete polypeptides into the lumen of endoplasmic reticulum, into cavity around the cell, or into the extracellular environment by expressing them in a host cell. These signals may be endogenous signals or signals from a different species to the objective polypeptide.
[0145] When a polypeptide of the present invention is secreted into the culture media, the culture media is collected to collect the polypeptide of the present invention. When a polypeptide of the present invention is produced intracellularly, the cells are first lysed, and then, the polypeptides are collected.
[0146] In order to collect and purify a polypeptide of the present invention from a recombinant cell culture, methods known in the art including ammonium sulfate or ethanol precipitation, extraction by acid, anionic or cationic exchange chromatography, phosphocellulose chromatography, hydrophobic interaction chromatography, affinity chromatography, hydroxylapatite chromatography, and lectin chromatography can be used.
[0147] <Test Method>
[0148] The present invention provides a method for testing diseases related to abnormal expression of the genes encoding the polypeptides of the present invention, or abnormal activities of the polypeptides of the present invention. It is considered that GPCR has an important function in vivo, and thus, abnormal expression and function thereof may cause various diseases. Therefore, assay of diseases may be accomplished using inappropriate activities or expression of the polypeptides of the present invention as an index.
[0149] The term “assay of diseases” includes not only tests to draft therapeutic strategy for a subject who exhibits the symptom of a disease, but also tests for preventing diseases by determining whether the subject is susceptible to the disease.
[0150] One embodiment of the test methods of the present invention is a method comprising the step of detecting a mutation in a gene encoding a polypeptide of the present invention or in the expression control regions thereof in a subject.
[0151] More specifically, the test can be accomplished by directly determining the nucleotide sequence of a gene encoding a polypeptide of the present invention or its expression control region in a subject. According to this method, first, a DNA sample is prepared from a subject. The DNA sample can be prepared from chromosomal DNA or RNA extracted from cells of the subject, for example, the biopsy or autopsy specimen of blood, urine, saliva, and tissue. In order to prepare a DNA sample for the present method from a chromosomal DNA, a genomic library may be produced by, for example, digesting the chromosomal DNA with appropriate restriction enzymes, and then cloning the digested DNA to a vector. On the other hand, for example, a cDNA library may be prepared from RNA by using reverse transcriptase to prepare a DNA sample for the present method from RNA. Next, DNA containing a gene encoding a polypeptide of the present invention or the expression control region thereof is isolated according to the present method. The isolation of a DNA can be carried out by screening the genomic library or cDNA library using probes hybridizing with the DNA containing the gene encoding the polypeptide of the present invention or its expression control region. The isolation of a DNA can be also carried out by PCR using the genomic DNA library, cDNA library, and RNA as the template, and primers hybridizing to a DNA containing a gene encoding a polypeptide of the present invention or its expression control region. Then, the nucleotide sequence of the isolated DNA is determined according to the present method. The determination of the nucleotide sequence of selected DNAs can be carried out by methods known to those skilled in the art. According to the present method, the determined nucleotide sequence of the DNA is then compared with that of a control. The “control” herein refers to a nucleotide sequence of DNAs containing a gene encoding a normal (wild type) polypeptide of the present invention or its expression control region. When the nucleotide sequence of a DNA of a subject differs from those of the control as a result of a comparison above, the subject is judged to be afflicted with disease or in danger of the onset of disease.
[0152] According to the test method of the present invention, various methods can be used other than the method directly determining the nucleotide sequence of a DNA, which was derived from the subject, as described above.
[0153] In one embodiment of the method, a DNA sample is first prepared from a subject and is digested with restriction enzymes. Then, the DNA fragments are separated in accordance with their size, followed by comparison of the detected sizes of the DNA fragments with those of a control. Alternatively, in another embodiment, a DNA sample is first prepared from a subject. Then, DNA containing a gene encoding a polypeptide of the present invention or its expression control region is amplified from the sample, and the amplified DNAs are digested with restriction enzymes. After separating the DNA fragments according to their size, the detected sizes of the DNA fragments are compared with those of a control.
[0154] Such methods include, for example, a method utilizing the Restriction Fragment Length Polymorphism/RFLP, the PCR-RFLP method, and such. Specifically, when variations exist for the recognition sites of a restriction enzyme, or when insertion(s) or deletion(s) of base(s) exists in a DNA fragment generated by a restriction enzyme treatment, the sizes of fragments that are generated after the restriction enzyme treatment vary in comparison with those of a control. The portion containing the mutation is amplified by PCR, and then, is treated with respective restriction enzymes to detect these mutations as a difference of the mobility of bands after electrophoresis. Alternatively, the presence or absence of the mutations can be detected by carrying out the Southern blotting with a probe DNA of the present invention after treating the chromosomal DNA with respective restriction enzymes followed by electrophoresis. The restriction enzymes to be used can be appropriately selected in accordance with respective mutations. The Southern blotting can be conducted not only on the genomic DNA but also on cDNAs directly digested with restriction enzymes, wherein the cDNAs are converted by the use of a reverse transcriptase from RNAs prepared from subjects. Alternatively, after amplifying DNAs containing a gene encoding a polypeptide of the present invention or its expression control region by PCR using the cDNA as a template, the cDNAs are digested with restriction enzymes and the difference of mobility on an electrophoresis gel of DNA fragments generated by the digestion are examined.
[0155] In another embodiment of the present method, a DNA sample is first prepared from a subject. Then, a DNA containing a gene encoding a polypeptide of the present invention or its expression control region is amplified. Thereafter, the amplified DNA is dissociated into single strand DNAs, and the single strand DNAs are separated on a non-denaturing gel. The mobility of the separated single strand DNAs on the gel is compared with those of a control.
[0156] Such methods include, for example, the PCR-SSCP (single-strand conformation polymorphism) method (“Cloning and polymerase chain reaction-single-strand conformation polymorphism analysis of anonymous Alu repeats on chromosome 11.” Genomics. Jan. 1, 1992, 12(1): 139-146; “Detection of p53 gene mutations in human brain tumors by single-strand conformation polymorphism analysis of polymerase chain reaction products.” Oncogene. Aug. 1, 1991; 6(8): 1313-1318; “Multiple fluorescence-based PCR-SSCP analysis with postlabelling.” PCR Methods Appl. Apr. 1, 1995; 4(5): 275-282). This method is particularly preferable for screening many DNA samples, since it has advantages such as: comparative simplicity of operation; small amount of a test sample required; and so on. The principle of the method is as follows. A single strand DNA dissociated from a double-strand DNA fragment forms a unique higher conformation depending on respective nucleotide sequence. Complementary single-stranded DNAs having the same chain length of the dissociated DNA strand shift to different positions in accordance with the difference of the respective higher conformations after electrophoresis on a polyacrylamide gel without a denaturant. The higher conformation of a single-stranded DNA changes even by a substitution of one base, which change results in a different mobility by polyacrylamide gel electrophoresis. Accordingly, the presence of a mutation in a DNA fragment due to point mutation, deletion, insertion, and such can be detected by detecting the change of the mobility.
[0157] More specifically, DNA containing a gene encoding a polypeptide of the present invention (or its expression control region) is first amplified by PCR and such. Preferably, a DNA of a length of about 200 bp to 400 bp is amplified. Those skilled in the art can appropriately select the condition and such for the PCR. DNA products amplified by PCR can be labeled by primers, which are labeled with isotopes such as 32 P; fluorescent dyes; biotin; and so on. Alternatively, the amplified DNA products can be also labeled by conducting PCR in a reaction solution containing substrate bases, which are labeled with isotopes such as 32 P; fluorescent dyes; biotin; and so on. Further, the labeling can be also carried out by adding substrate bases, which are labeled with isotope such as 32 P; fluorescent dyes; biotin; and so on, to the amplified DNA fragment using Klenow enzyme and such, after the PCR reaction. Then, the obtained labeled DNA fragments are denatured by heating and such, and electrophoresis is carried out on a polyacrylamide gel without a denaturant such as urea. The condition for the separation of the DNA fragments by this electrophoresis can be improved by adding appropriate amounts (about 5% to 10%) of glycerol to the polyacrylamide gel. Further, although the condition for electrophoresis varies depending on the property of respective DNA fragments, it is usually carried out at room temperature (20° C. to 25° C.). When a preferable separation is not achieved at this temperature, a temperature at which optimum mobility can be achieved is searched from 4° C. to 30° C. The mobility of the DNA fragments is detected by autoradiography with X-ray films, scanner for detecting fluorescence, and such, after the electrophoresis to analyze the result. When a band with different mobility is detected, the presence of a mutation can be confirmed by directly excising the band from the gel, amplifying it again by PCR, and directly sequencing the amplified fragment. Further, the bands can be also detected by staining the gel after electrophoresis with ethidium bromide, silver, and such, without using labeled DNAs.
[0158] In still another method, a DNA sample is first prepared from a subject. DNA containing a gene encoding a polypeptide of the present invention or its expression control region is amplified, and then, the amplified DNAs are separated on a gel with gradient concentration of a DNA denaturant. The mobilities of the separated DNAs on the gel are compared with those of a control.
[0159] For example, the denaturant gradient gel electrophoresis method (DGGE method) and such can be exemplified as such methods. The DGGE method comprises the steps of: (1) electrophoresing the mixture of DNA fragments on a polyacrylamide gel with gradient concentration of denaturant; and (2) separating the DNA fragments in accordance with the difference of instabilities of respective fragments. Unstable DNA fragments containing mismatches dissociated partly to a single-strand near the mismatches because of the instability of the DNA sequence by shifting to a part with a certain concentration of the denaturant on the gel. The mobility of the partly-dissociated DNA fragment becomes remarkably slow, ending in a difference of the mobility with that of perfectly double-stranded DNAs without dissociated parts, which allows separation of these DNAs. Specifically, DNA containing a gene encoding a polypeptide of the present invention or its expression control region is (1) amplified by PCR and such with a primer of the present invention and such; (2) electrophoresed on a polyacrylamide gel with gradient concentration of denaturant such as urea; and (3) the result is compared with that of a control. The presence or absence of a mutation can be detected by detecting the difference of mobility of the DNA fragment due to the extreme slowing down of the mobility speed of the fragment by separation into single-stranded DNAs of a DNA fragment with mutations at parts of the gel where the concentration of the denaturant is lower.
[0160] In addition to the above-mentioned methods, the Allele Specific Oligonucleotide (ASO) hybridization method can be used to detect mutations at only specific sites. An oligonucleotide with a nucleotide sequences contained to have a mutation is prepared, and is subjected to hybridization with a DNA sample. The efficiency of hybridization is reduced by the existence of a mutation. The decrease can be detected by the Southern blotting method; methods which utilize a specific fluorescent reagent that have a characteristic to quench by intercalation into the gap of the hybrid; and such. Further, the detection may be also conducted by the ribonuclease A mismatch truncation method. Specifically, DNA containing a gene encoding a polypeptide of the present invention is amplified by PCR and such, and the amplified DNAs are hybridized with labeled RNAs, which were prepared from a control cDNA and such to incorporate them into a plasmid vector and such. The presence of a mutation can be detected with autoradiography and such, after cleaving those sites that form a single-stranded conformation due to the existence of a mutation with ribonuclease A.
[0161] Another embodiment of the test method of the present invention is a method comprising the step of detecting the expression level of a gene encoding a polypeptide of the present invention. Herein, transcription and translation are included in the meaning of the term “expression of a gene”. Accordingly, mRNAs and proteins are included in the term “expression product”.
[0162] First, an RNA sample is prepared from a subject according to the method for testing the transcription level of a gene encoding a polypeptide of the present invention. Then, the amount of RNA encoding the polypeptide of the present invention in the RNA sample is measured. Thereafter, the measured amount of the RNA encoding the polypeptide of the invention is compared with that of a control.
[0163] A Northern blotting method using a probe which hybridizes with the polynucleotide encoding a polypeptide of the present invention; an RT-PCR method using a primer which hybridizes with a polynucleotide encoding the polypeptide of the present invention; and such can be exemplified as such methods.
[0164] Further, a DNA array (Masami Muramatsu and Masashi Yamamoto, New Genetic Engineering Handbook pp. 280-284, YODOSHA Co., LTD.) can also be utilized in the test for the transcription level of the gene encoding the polypeptide of the present invention. Specifically, first, a cDNA sample prepared from a subject and a basal plate on which polynucleotide probes hybridizing with the polynucleotides encoding the polypeptides of the present invention are fixed are provided. Plural kinds of polynucleotide probes can be fixed on the basal plate in order to detect plural kinds of polynucleotides encoding the polypeptides of the present invention. Preparation of a cDNA sample from a subject can be carried out by methods well known to those skilled in the art. In a preferable embodiment for the preparation of the cDNA sample, first, total RNAs are extracted from a cell of a subject. Example of cells include cells of the biopsy or autopsy specimen, of blood, urine, saliva, tissue, and such. The extraction of total RNAs can be carried out, for example, as follows. So long as total RNAs with high purity can be prepared, known methods, kits, and such can be used. For example, total RNAs are extracted by using “Isogen” (Nippon Gene) following a pretreatment with “RNA later” (Ambion) Specific procedures of the method may be carried out according to the attached protocol. Then, the cDNA sample is prepared by synthesizing cDNAs with reverse transcriptase using extracted total RNAs as a template. The synthesis of cDNA from total RNAs can be carried out by conventional methods known in the art. The prepared cDNA sample is labeled for detection according to needs. The labeling substance is not specifically limited so long as it can be detected, and include, for example, fluorescent substances, radioactive elements, and so on. The labeling can be carried out by conventional methods (L. Luo et al., “Gene expression profiles of laser-captured adjacent neuronal subtypes”, (1999) Nat. Med. 5: 117-122).
[0165] The term “basal plate” herein refers to a board type material on which polynucleotides can be fixed. So long as polynucleotides can be immobilized on the plate, there is no restriction on the basal plate of the present invention. However, a basal plate that is generally used in the DNA array technique is preferred.
[0166] An advantage of the DNA array technique is that the amount of solution needed for hybridization is very small, and that extremely complicated targets containing cDNA derived from the total RNAs of a cell can be hybridized to the fixed nucleotide probes. In general, a DNA array comprises thousands of nucleotides which are printed on a basal plate at a high density. Usually, DNAs are printed on the surface layer of a non-porous basal plate. The surface layer of the basal plate is usually glass, but a porous film, for example, such as nitrocellulose membrane, can be also used. There are two types for fixation (array) of the nucleotides: one is the array based on polynucleotides developed by Affymetrix Co., Ltd.; and the other is the array of cDNA mainly developed by Stanford University. The polynucleotides are usually synthesized in situ for the array of the polynucleotide. For example, in situ synthesis method of polynucleotides such as the photolithographic technique (Affymetrix) ; and the ink-jet technique (Rosetta Inpharmatics) for fixing a chemical substance; and so on are already known in the art, and any of these techniques can be used for the production of basal plates of the present invention. There is no limitation on the polynucleotide probes to be fixed on the basal plates, so long as it specifically hybridizes with a gene encoding a polypeptide of the present invention. The polynucleotide probe of the present invention includes polynucleotides and cDNAs. Herein, the term “specifically hybridizes” means that a polynucleotide substantially hybridizes with a polynucleotide encoding a polypeptide of the present invention and substantially does not hybridize with other polynucleotides. So long as specific hybridization is possible, the polynucleotide probe does not have to be completely complementary to the nucleotide sequence to be detected. Generally, to immobilize a cDNA on a plate, the length of the polynucleotide probe to be fixed on the basal plate is usually 100 to 4000 bases, preferably 200 to 4000 bases, and more preferably 500 to 4000 bases. On the other hand, to immobilize synthetic polynucleotides, the length of the probes are usually 15 to 500 bases, preferably 30 to 200 bases, and more preferably 50 to 200 bases. The step for fixing of the polynucleotides on the basal plate is also called “printing” in general. Specifically, the printing can be, for example, conducted as follows, but is not limited thereto. Several kinds of polynucleotide probes are printed within an area of 4.5 mm×4.5 mm. According to this step, respective arrays can be printed using one pin. Accordingly, when a tool with 48 pins is used, 48 arrays can be printed repeatedly on one standard slide for microscopes.
[0167] Then, the cDNA sample is contacted with the basal plate according to the present method. The cDNA sample is hybridized with nucleotide probes on the basal plate, which can specifically hybridize with a DNA encoding a polypeptide of the present invention, in this step. Although the reaction solution and the reaction condition for hybridization varies depending on various factors, such as the length of the nucleotide probe fixed on the basal plate, they can be determined according to usual methods well known to those skilled in the art.
[0168] Next, the expression level of the gene encoding the polypeptide of the present invention contained in the cDNA sample is measured by detecting the hybridization intensity of the cDNA sample with the nucleotide probe fixed on the basal plate. Further, the measured expression level of the gene encoding the polypeptide of the present invention is compared with that of the control.
[0169] A cDNA in the cDNA sample hybridizes with the nucleotide probe fixed on the basal plate when such cDNA derived from the gene encoding the polypeptide of the present exists in the cDNA sample. Thus, the expression level of the gene encoding the polypeptide of the present invention can be measured by detecting the intensity of the hybridization of the polynucleotide probe with the cDNA. One skilled in the art can appropriately conduct the detection of the hybridization intensity of the polynucleotide probe with the cDNA depending on the kind of substances used for labeling the cDNA sample. For example, when the cDNA is labeled with a fluorescent substance, it can be detected by reading out the fluorescent signal with a scanner.
[0170] The expression level of the gene encoding the polypeptide of the present invention in cDNA samples derived from a subject and control (normal healthy subject) can be measured simultaneously in one measurement by labeling them with different fluorescent substances according to the method of the present invention. For example, one of the above-mentioned cDNA samples can be labeled with a fluorescent substance, Cy5, and the other with Cy3. The intensity of respective fluorescent signals show the expression level of the gene encoding the polypeptide of the present invention in the subject and the control, respectively (Duggan et al., Nat. Genet. 21:10-14 (1999))
[0171] On the other hand, polypeptide samples are first prepared from subjects in the test for the translational level of a gene encoding a polypeptide of the present invention. Then, the amount of the polypeptide of the present invention contained in the polypeptide sample is measured and compared with that of the control.
[0172] Exemplarily methods include the SDS polyacrylamide electrophoresis method; and methods utilizing antibodies binding to the polypeptides of the invention like the Western blotting method, dot-blotting method, immunoprecipitation method, enzyme-linked immunosorbent assay (ELISA), and immunofluorescence.
[0173] When the expression level of a gene encoding a polypeptide of the present invention is significantly changed in comparison with that of the control, the subject is judged to be infected with a disease related to the expression abnormality of the gene, or to be in danger for the onset of the disease.
[0174] <Test Drug>
[0175] Furthermore, the present invention provides test drugs for diseases related to abnormal expression of a gene encoding a polypeptide of the present invention, or related to abnormal activities of a polypeptide of the present invention.
[0176] An embodiment of a test drug of the present invention contains an oligonucleotide having a chain length of at least 15 nucleotides which hybridizes with a DNA containing a polynucleotide encoding a polypeptide of the present invention or its expression control region as mentioned above. The oligonucleotide can be used in the above-mentioned test method of the present invention as a probe for detecting the gene encoding the polypeptide of the present invention or its expression control region, or as a primer for amplifying the gene encoding the polypeptide of the present invention or its expression control region. The oligonucleotides of the present invention can be prepared, for example, by a commercially available oligonucleotide synthesizing machine. The probes can be also prepared as double-stranded DNA fragments which are obtained by restriction enzyme treatments and such. The oligonucleotides of the present invention are preferably appropriately labeled for the use as a probe. The method of labeling includes, for example, a labeling method using T4 polynucleotide kinase to phosphorylate the 5′-terminus of the oligonucleotide with 32 P; and a method of introducing substrate bases, which are labeled with isotopes such as 32 P, fluorescent dyes, biotin, and so on using random hexamer oligonucleotides and such as primers and DNA polymerase such as Klenow enzyme (the random prime method, etc.).
[0177] Another embodiment of the test drug of the present invention is a test drug containing antibodies which binds to a polypeptide of the present invention described below. The antibodies are used to detect the polypeptide of the present invention in the above-mentioned test method of the present invention. The forms of the antibodies are not limited so long as they can detect the polypeptides of the present invention. Polyclonal antibodies and monoclonal antibodies are included as the antibodies for the test. The antibodies may be labeled according to needs.
[0178] For example, sterilized water, physiological saline, vegetable oils, surfactants, lipids, solubilizers, buffers, protein stabilizers (such as BSA and gelatin) , preservatives, and such may be mixed in the above-mentioned test drugs except the effective ingredient, oligonucleotide and antibody, if necessary.
[0179] <Antibody>
[0180] The present invention provides antibodies that bind to a polypeptide of the present invention. Herein, the term “antibodies” refers to polyclonal antibodies, monoclonal antibodies, chimeric antibodies, single-stranded antibodies, humanized antibodies, and Fab fragments including Fab or other products of the immunoglobulin expression library.
[0181] A polypeptide of the present invention or its fragment, or analogs thereof, or a cell that expresses them can be used as an immunogen for producing antibodies binding to the polypeptide of the present invention. The antibodies are preferably immunospecific to a polypeptide of the present invention. The term “immunospecific” means that the antibody has substantially higher affinity to the polypeptide of the present invention than to other polypeptides.
[0182] The antibodies binding to a polypeptide of the present invention can be prepared by conventional methods. For example, a polyclonal antibody can be obtained as follows. A polypeptide of the present invention or a fusion protein thereof with GST is immunized to small animals such as rabbit to obtain serum. The polyclonal antibody is prepared by purifying the serum through ammonium sulfate precipitation; protein A or protein G column; DEAE ion exchange chromatography; affinity column wherein the polypeptide of the present invention are coupled; and so on. On the other hand, a monoclonal antibody, for example, can be prepared as follows. A polypeptide of the present invention is administered to small animals such as mouse and the spleen is subsequently extirpated from the mouse and ground down to separate cells. Then, the cells are fused with mouse myeloma cells using reagents such as polyethylene glycol, and clones that produce antibodies binding to the polypeptide of the present invention are selected from these fused cells (hybridoma). The obtained hybridoma is then transplanted into the peritoneal cavity of a mouse, and ascites is collected from the mouse. The monoclonal antibodies can be prepared by purifying the ascites using, for example, ammonium sulfate precipitation; protein A or protein G column; DEAE ion exchange chromatography; affinity column wherein the polypeptides of the present invention are coupled; and so on.
[0183] The antibodies of the present invention can be used for the isolation, identification, and purification of the polypeptides of the present invention and cells expressing them. The antibodies binding to a polypeptide of the present invention can be also used for determining the expression level of a polypeptide of the present invention to test for a disease related to abnormal expression of a polypeptide of the present invention.
[0184] <Identification of Ligand, Agonist, or Antagonist>
[0185] The polypeptides of the present invention can be also used to identify ligands, agonists, or antagonists thereof. These object molecules of the identification may be naturally-occurring molecules as well as structural or functional imitated molecules, which are artificially synthesized. The polypeptides of the present invention are related to various biological functions, including many pathologies. Thus, the detection of compounds that activate the polypeptides of the present invention, and compounds that inhibit the activation of the polypeptides of the present invention is expected.
[0186] To identify ligands against the polypeptide of the present invention, a polypeptide of the present invention is first contacted with a candidate compound, and then, it is detected whether or not the candidate compound binds to the polypeptide of the present invention.
[0187] There is no limitation on the sample to be tested and such samples include, for example, various known compounds and peptides whose ligand activity to GPCRs are unknown (for example, those registered in the Chemical File) ; and random peptide groups, which were produced by utilizing the phage-display method (J. Mol. Biol. (1991) 222, 301-310). Further, culture supernatant of microorganism; natural components derived from plants and marine organisms; and so on can be used as the object of the screening. Moreover, extract from biotic tissues such as brain; extracted solutions from cells; expression products of gene libraries; and so on can be also mentioned as samples to be tested, but is not limited thereto.
[0188] According to the present method, binding of the purified polypeptides of the present invention with candidate compounds can be detected. Conventional methods, such as methods purifying compounds binding to a protein of the present invention by contacting a test sample with an affinity column of the polypeptide of the present invention; and the West-Western blotting method, can be utilized to detect binding. Candidate compounds are appropriately labeled according to these methods, and the binding with the polypeptide of the present invention is detected utilizing the label. Further, a method detecting the surface plasmon resonance changes caused by the dissociation of a trimeric-type GTP binding protein due to the binding of a ligand, by preparing cell membranes in which the polypeptide of the present invention is expressed, fixing the membrane on a chip, and detecting the changes of surface plasmon resonance on the chip (Nature Biotechnology (99) 17:1105). Further, the binding activity of a candidate compound and the polypeptide of the present invention can be also detected using signals as an index of activation of the polypeptide of the present invention. Such signal includes, for example, changes of intracellular Ca 2+ level, changes of intracellular cAMP level, changes of intracellular pH, and changes of intracellular adenylate cyclase level, but are not restricted to these examples.
[0189] As an example of the method, a procedure as follows can be conducted: (1) a cell membrane expressing the polypeptide of the present invention is mixed with 400 pM of GTPγS labeled with 35 S in a solution of 20 mM HEPES (pH 7.4) , 100 mM NaCl, 10 mM MgCl 2 , and 50 μM GDP; (2) the reaction solution is incubated in the presence and in the absence of a test sample; (3) the solution is filtrated; and (4) the radioactivity of bound GTPγS is compared.
[0190] Further, the GPCR share a system transmitting a signal into the cell through the activation of the trimeric-type GTP binding protein in common. The trimeric-type GTP binding protein is classified depending on the type of activated intracellular transmission system into 3 types: (1) Gq type, those increasing Ca 2+ ; (2) Gs type, those increasing cAMP; and (3) Gi type, those suppressing cAMP. Positive signals of the ligand screening can be transduced to an increase of the Ca 2+ level, which is the intracellular transmission pathway of Gq, by applying the system. More specifically, it can be transduced to an increase of the Ca 2+ level by forming chimeras of Gq protein α subunit and other G protein α subunits, or by using promiscuous G α protein, G α15 and G α16. The increased Ca 2+ level can be detected using changes of reporter gene systems, comprising TRE (TPA responsive element) or MRE (multiple responsive element) upstream in the system; staining indicators such as Fura-2, Fluo-3; and fluorescent protein, aequorin, and so on as an index. Similarly, the chimerizing the Gs protein α subunit and other G protein α subunit to transduce the positive signals to increased cAMP levels, which is the intracellular transmission pathway of Gs, the ligands, can be detected by using the changes in a reporter gene system including CRE (cAMP-responsive element) upstream as an index (Trends Pharmacol. Sci. (99) 20: 118-124).
[0191] Host cells to express the polypeptides of the present invention in the screening system are not specifically limited, and various host cells can be used in accordance with the object. For example, mammal cells such as COS cell, CHO cell, HEK293 cell; yeast; Drosophila-derived cell; and E. coli cell be mentioned. Vectors containing a promoter positioned upstream of the gene encoding the polypeptide of the present invention, a splice site of RNA, polyadenylation site, transcription termination sequence, origin of replication, and such can be preferably used as vectors for expressing the polypeptides of the present invention in vertebrate animal cells. For example, pSV2dhfr (Mol. Cell. Biol. (1981) 1, 854-864) containing the early promoter of SV40; pEF-BOS (Nucleic Acids Res. (1990) 18, 5322); pCDM8 (Nature (1987) 329, 840-842); pCEP4 (Invitrogen) ; and such are useful vectors for expressing GPCR. The insertion of a DNA encoding a polypeptide of the present invention to a vector can be carried out by a ordinary method utilizing the ligase reaction with restriction enzyme sites (Current protocols in Molecular Biology, edit. Ausubel et al., (1987) Publish. John Wiley & Sons, Section 11.4-11.11). Further, the introduction of a vector to the host cell can be carried out by known methods such as the calcium phosphate precipitation method, the electroporation method (Current protocols in Molecular Biology, edit. , Ausubel et al., (1987) Publish. John Wiley & Sons. Section 9.1-9.9) , the Lipofectamine method (GIBCO-BRL) , the FuGENE6 reagent (Boehringer Mannheim), the microinjection method, and so on.
[0192] To identify agonists of a polypeptide of the present invention, a cell expressing the polypeptide of the present invention is contacted with candidate compounds to detect whether or not the candidate compounds generate a signal, which then works as an index of activation of the polypeptide of the present invention. Namely, compounds are identified which generate a signal indicative of activation of the present polypeptide in the above-described identification method for a ligand using cells expressing the polypeptide of the present invention. Such compounds serve as agonist candidates of the polypeptide of the present invention.
[0193] To identify antagonists of a polypeptide of the present invention, a cell expressing the polypeptide of the present invention is contacted with an agonist for the polypeptide of the present invention in the presence of a candidate compound to detect whether or not the signal, which serves as an index of activation of the polypeptide of the present invention, is reduced in comparison with a case (control) where the detection is conducted in the absence of the candidate compound. Namely, compounds suppressing the generation of the signal, which serves as an index of the activation of the present polypeptide by the agonist excitation, are isolated by acting the agonist as well as the candidate compound in the above-mentioned identification method of a ligand using the cell expressing the polypeptide of the present invention. Such compounds serve as candidates of antagonist of the polypeptide of the present invention. Examples of potent antagonists of the polypeptide of the present invention includes antibodies; in some cases, polypeptides having close relation with the ligand (e.g., a ligand fragment) ; and small molecules which bind to a polypeptide of the present invention but does not induce response (therefore, the activity of the receptor is prevented).
[0194] Further, the present invention provides a kit to be used for the above-mentioned identification method. The kit includes a polypeptide of the present invention, or a cell expressing a polypeptide of the present invention, or cell membranes of the cells. The kit may include compounds serving as candidates for ligands, agonists, and antagonists of GPCR.
[0195] <Pharmaceutical Composition for Treatment of Disease>
[0196] The present invention provides pharmaceutical compositions for treating patients who are in need of an increase in or the suppression of the activity or expression of a polypeptide of the present invention.
[0197] An agonist of the polypeptide of the present invention, a polynucleotide of the present invention, and a vector wherein a polynucleotide of the present invention is inserted can be used as an effective ingredient of the pharmaceutical composition for increasing the activity or expression of the polypeptide of the present invention. On the other hand, an antagonist of a polypeptide of the present invention, a polynucleotide suppressing the expression of the gene encoding the endogenous polypeptide of the present invention in vivo can be used as an effective ingredient of the pharmaceutical composition for suppressing the activity or expression of the polypeptide of the present invention. Antagonists include polypeptides of the present invention in a soluble form, which have the ability to bind to a ligand under a competitive condition with the endogenous polypeptide of the present invention. A typical example of such competitive substance is a fragment of a polypeptide of the present invention. The antisense DNAs and ribozymes mentioned above are also included as polynucleotides suppressing the expression of a gene encoding a polypeptide of the present invention.
[0198] When a therapeutic compound is used as a pharmaceutical agent, it can be administered as a pharmaceutical composition prepared by known pharmaceutical methods, in addition to directly administering the compound itself to a patient. For example, it can be formulated into a form suitable for oral or parenteral administration, such as tablet, pill, powder, granule, capsule, troche, syrup, liquid, emulsion, suspension, injection (such as liquid, and suspension) suppository, inhalant, percutaneous absorbent, eye drop, eye ointment, obtained by mixing the active ingredient with a pharmacologically acceptable support (such as excipient, binder, disintegrator, flavor, corrigent, emulsifier, diluent, solubilizer).
[0199] Administration to a patient can be typically carried out by methods known to those skilled in the art, such as intra-arterial injection, intravenous injection, subcutaneous injection, and such. Although the dosage varies depending on the weight and age of the patient, administration methods, and such, one skilled in the art can appropriately select an appropriate dose. Further, if the compound can be encoded by DNA, gene therapy can be also carried out through introduction of the DNA to a vector for gene therapy.
[0200] The vectors for gene therapy include, for example, viral vectors such as retroviral vectors, adenoviral vectors, adeno-associated viral vectors; and non-viral vectors such as liposomes; and so on. The objective DNA can be administered to a patient by ex vivo methods and in vivo methods utilizing such vectors.
[0201] According to the present invention, novel GPCRs, polynucleotides encoding the polypeptides, vectors containing the polynucleotides, host cells containing the vectors, and methods or producing the polypeptides have been provided. Further, methods of identifying a compound which binds to a polypeptide or modifies its activity have been provided. The polypeptides, polynucleotides, and compounds which bind to a polypeptide of the present invention or modify its activity are expected to be useful in the development of novel preventive and therapeutic drugs for diseases associated with the polypeptides of the present invention. Furthermore, according to the present invention, test methods for diseases comprising the step of detecting mutations and expression of a gene encoding a polypeptide of the present invention have been provided. GPCR is one of the molecules which is most important and remarked in the fields of the development of pharmaceutical agents and medical treatments. Novel GPCRs comprehensively provided in the present invention are expected to make remarkable development in these fields. Thus, the present invention provides valuable information to the researchers of GPCR.
[0202] Any patents, patent applications, and publications cited herein are incorporated by reference.
[0203] The identification of the polypeptides of the present invention is illustrated below in detail by way of Examples.
EXAMPLE 1
[0204] Extraction of Amino Acid Sequences from Human Genome Data
[0205] In the first step for discovering novel GPCR genes (i.e., sequence extraction) , the present inventors selected all candidates of the 6-frame translation sequences (6F development sequence), which exist between the initiation codon and termination codon in human genome sequences. When a plurality of initiation codons (ATG) are found on the same sequence, the initiation codon giving the longest sequence was selected. On the other hand, in order to detect sequences containing plural exons, protein-coding regions (GD sequence) were discovered using the gene discovery program (GeneDecoder) (Asai, K. , et al., Pacific Symposium on Biocomputing 98, pp.228-239 (PSB98, 1998)). Since a GPCR protein contains seven transmembrane helices with a length of about 20 residues, the condition for both sequences was set to comprise 150 residues or more (>20*7).
[0206] 375,412 sequences by 6-frame translation and 95,900 sequences by the GeneDecoder were predicted from human genome draft sequences at NCBI (February 2001.). The sequences predicted by 6-frame translation correspond to sequences without introns, and those by the GeneDecoder are mainly constituted of sequences with plural exons.
[0207] The GeneDecoder is a gene discovery program using a hidden Markov Model (HMM) , as well as information related to sequence homology and distribution of the length of exons. The program was evaluated by using Genset 98 (http://bioinformatics weizmann.ac.il/databases/gensets/Human/), which contains 462 sequences comprising plural exons, and 2,843 exons, and resulted in 97.6% sensitivity and 40.4% selectivity at the nucleotide level. On the other hand, sensitivity and selectivity for detecting a correct exon boundary was 64.2% and 21.3%, respectively.
EXAMPLE 2
[0208] Triple Analysis
[0209] BLASTP (Altschul, S. F. et al., Nucleic Acids Res. 25, 3389-3402 (1997)) for searching sequences; PFAM database (Bateman, A., et al., Nucleic Acids Res. 28, 263-266 (2000)) and PROSITE databases (Bairoch, A., Nucleic Acids Res. 20, Suppl: 2013-2018 (1992)) for assigning domains and motifs; and TMWindows, which is a unique algorithm written by the present inventors, and further, Mitaku method (Hirokawa, T., et al., Bioinformatics. 14, 378-379 (1998)) for predicting TMH were used in the triple analysis. Specifically, the inventors carried out the triple analysis as follows:
[0210] (1) Amino acid sequences (6F development sequences, GD sequences) obtained in the sequence extraction step were searched in SWISSPROT database using BLASTP, and sequences which coincide with known GPCR sequences with an E-value of <10 −10 or 10 −50 were selected.
[0211] (2) Sequences wherein a GPCR-specific domain in PFAM database could be assigned with an E-value of <1.0 or 10 −10 were selected from the 6F development sequences and GD sequences using HMMER program. Simultaneously, sequences wherein a GPCR-specific motif pattern in PROSITE (Bairoch, A. Nucleic Acids Res. 20, Suppl: 2013-2018(1992)) database could be assigned with a P-value of <2×10 −3 or <10 −5 were selected.
[0212] (3) The number of transmembrane helices in 6F development sequences and GD sequences was predicted using the TMWindows and Mitaku method. For example, describing the logical sum of the result obtained by TMWindows as having 7 transmembrane helices and the result obtained by the Mitaku method as having 6 to 8 transmembrane helices as {TMWindows (7) or Mitaku (6-8)}, sequences which were coincided to respective conditions prepared as {TMWindows (7) or Mitaku (6-8)}, {TMWindows (7) or Mitaku (7)}, and {TMWindows (7) and Mitaku (7)} were selected.
[0213] The programs and databases which were used in the analysis above are described in detail. PFAM is a protein domain database which was described by the hidden Markov Model (HMM) , HMMER (Bateman, A., et al. , Nucleic Acids Res. 28, 263-266 (2000)) attributes them to the sequences, and the significance is scored by the E-value. On the other hand, PROSITE is a motif pattern which is described by normal representation. The present inventors used “P-value”, which was obtained by multiplying the appearance probability of respective residues, as an index in order to score the significance of attribution. For example, when the normal representation pattern is A-[T,S]-G, the P-value is P A *{Pt+PS}*P G .
[0214] TMWindows is a unique program written by the present inventors and relates to TMH prediction. Herein, the hydrophobic index of Engelman-Staitz-Goldman (Engelman, D. M., et al., Annual Review of Biophysics and Biophysical Chemistry. 15, 321-353. (1986)) is allotted to every amino acid residue, and all sequences are scanned by nine different window widths (19- to 27 residues). The index was determined as the most suitable index for membrane protein analysis through the comparison of all indices contained in the AAindex database (Tomii, K. & Kanehisa, M. Protein Eng. 9, 27-36 (1996)). Continuous regions having an average hydrophobic index of >2.5 were predicted as transmembrane helices from each window width. The numbers which are predicted by each different window sets indicates a range of the numbers of the helices. On the other hand, the number of helices was predicted by the Mitaku method using physicochemical parameters.
[0215] The thresholds used in these analyses were obtained by the evaluation of respective methods by the present inventors. The reference data set used for evaluation is a sequence set obtained by excluding fragment sequences from SWISSPROT version 39 (Bairoch, A. & Apweiler, R., Nucleic Acids Res. 28, 45-48 (2000)), which contains 1,054 known GPCR sequences and 64,154 non-GPCR sequences. Specific evaluation procedures of the analytical method are shown below.
[0216] (1) 1,054 known GPCR sequences were searched in the data set for evaluation using BLASTP, and the sensitivity and selectivity related to the discrimination of accurate and inaccurate pairs were calculated for each E-value.
[0217] (2) A PFAM domain specific to GPCR was attributed to the sequences of the data set for evaluation using HMMER, and the sensitivity and selectivity of the E-values were calculated for the number of the accurate and inaccurate attribution. On the other hand, the sensitivity and selectivity of P-values were calculated for the number of the accurate and inaccurate attribution with respect to PROSITE pattern.
[0218] (3) In general, the TMH anticipation tool is not so accurate in predicting real number of helices. However, by establishing the number of helix to be predicted widely as 6 to 8, 5 to 9, or 4 to 10, and such, the sensitivity for detecting a real seven transmembrane helix type sequence can be significantly increased. We considered four ranges: 7, 6 to 8, 5 to 9, and 4 to 10, for both TMWindows and the Mitaku method, and calculated the sensitivity and selectivity to detect a real seven transmembrane helix for all of the combinations (16 combinations) for each of them.
[0219] During the evaluation, the present inventors laid emphasis on two thresholds, namely, the best sensitivity threshold and the best selectivity threshold. The former threshold is intended to minimize the false positive to obtain a sensitivity of almost 100%. On the other hand, the latter is intended to minimize the false negative to obtain a selectivity of almost 100%.
[0220] For example, the evaluation of the threshold of BLASTP is shown in FIG. 1. The arrow on the left represents the number of pairs between GPCRs, and the arrow on the right shows the pair between GPCR and non-GPCR sequence. In the region wherein the E-value is less than 10 −50 , almost all of the pairs were formed between GPCR sequences, excluding some unrelated pairs near the boundary region. This corresponds to the best selectivity threshold. Interestingly, these false positives were caused by the correspondence with LDL receptor domains or EGF factor domains, which are characteristic in receptors having only one transmembrane helix. When the E-value is less than 10 −10 , the number of false positives was 115, but almost all of GPCRs were within the range. The boundary region corresponds to the best sensitivity threshold.
[0221] Similarly, as summarized in Table 1, the present inventors evaluated thresholds of respective tools and generated four levels of data sets based on them.
TABLE 1 Level A Level D (Best Selectivity) Level B Level C (Best Sensitivity) BLASTP E <10 −50 E <10 −10 E <10 −10 E <10 −10 (99%, 100%) (100%, 90.1%) (100%, 90.1%) (100%, 90.1%) PFAM E <10 −10 F <1.0 E <1.0 E <1.0 (95%, 99.6%) (100%, 84.3%) (100%, 84.3%) (100%, 84.3%) PROSITE P <10 −5 P <2 × 10 −3 P <2 × 10 −3 P <2 × 10 −3 (90%, 100%) (100%, 95.0%) (100%, 95.0%) (100%, 95.0%) TMH Not used {TMWindows(7) {TMWindows(7) {TMWindows(7) or Prediction and Mitaku(7)} or Mitaku(7)} Mitaku(6-8)} (36.0%, 70.6%) (86.8%, 44.6%) (99.3%, 28.8%)
[0222] Herein, the sensitivity (left) and selectivity (right) obtained by using each threshold are represented in the parentheses under the threshold of each program.
[0223] The most reliable data (level A, the best selectivity data set) was obtained by the logical sum of sequences obtained from the best selectivity thresholds of BLASTP, PFAM, and PROSITE. In addition, in order to discover far-related GPCR sequences, the logical sum of results by three levels (Table 1) of TMH prediction threshold and results by the best sensitivity thresholds of BLASTP, PFAM, and PROSITE was obtained. Then, the most sensitive data set was prepared as the best sensitivity data set (level D). According to the evaluation method used by the present inventors, any of the sequences discovered by the best selectivity data set is a protein having seven transmembrane helices, and the possibility that they are a guanosine triphosphate binding protein-coupling type is extremely high.
EXAMPLE 3
[0224] Accurate Selection of the Number of Genes
[0225] GPCR candidate substances were screened from sequences generated in the first step, using the thresholds shown in Table 1. However, since these sequences contained following duplicated examples, it was required to finally select rigidly the number of candidates.
[0226] Case 1: Perfect Matching or Duplication at a Same Gene Locus.
[0227] These resulted from using two sequence preparation methods: namely, (1) 6-frame translation, and (2) prediction by the GeneDecoder. The present inventors regarded them as same genes.
[0228] Case 2: Many Copies on Different Chromosomes or at Different Positions on a same Chromosome.
[0229] From a biological viewpoint, the present inventors regarded them as different genes. Duplicated genes were most frequently found between chromosome 2 and 11.
[0230] Case 3: Two or More Sequences Partially Corresponding to any Long Known Sequence.
[0231] These were considered to be generated by missplicing by the gene discovery program. The present inventors considered that they should be fused as generally one gene.
[0232] The present inventors first improved the precision of candidate genes by studying above-mentioned cases, respectively. Two sequences, i and j, were regarded as the same gene by using a specific algorithm: C i =C j , F i =F J , n i =n j , and e i −t j <0 (i<j); wherein 50 or more residues are aligned at 99% or more similarity (herein, “C” represents chromosome number; “F” frame number; “R” the position on a genomic sequence; and S (C,F,R) sequence) , (Herein, when n is a contiguous number and t and e are relative positions at the N- and C-terminus on a contiguous sequences, the positions R is R (n, t, e)).
[0233] After the above screening, the present inventors finally obtained the best selectivity and the best sensitivity data sets containing 827 and 2109 sequences, respectively, and also obtained other levels of data sets by considering biological information, using NCBI human draft sequences (both 2001 and 2002 version). The number of GPCR candidates of every chromosome is summarized in Table 2 for each data set.
TABLE 2 Chromosome LEVEL-A LEVEL-B LEVEL-C LEVEL-D 1 85 122 141 18 2 41 75 88 12 3 52 7 91 142 4 13 3 38 62 5 2 51 6 9 6 5 6 7 111 7 3 71 7 98 8 1 2 3 53 9 31 4 5 6 10 12 25 3 6 11 23 31 32 36 12 28 65 7 12 13 1 21 31 5 14 4 5 59 7 15 15 23 34 73 16 13 2 45 7 17 32 43 4 6 18 8 21 25 3 19 54 78 81 10 20 7 1 25 .41 21 0 4 6 9 22 5 9 11 18 X 14 2 2 51 Y 0 0 2 2 Un 1 5 7 15 Total 827 130 151 2109
[0234] The number of GPCR candidates of every chromosome Un means those whose chromosome number is unknown.
[0235] As shown in the table, it was found that chromosome 11 has the maximum number of GPCR candidates in all levels of data sets, and chromosomes 1, 6, and 19 also have many GPCR candidates. On the other hand, chromosomes 21 and Y have extremely few GPCR candidates. Further, this tendency does not have changed, even after updating the data monthly.
[0236] Further analysis concerning the best selectivity data set is summarized in Table 3.
TABLE 3 Data Families Total Acetylchline (muscarinic) receptors 9 Adenosine and adenine nucleotide receptors 18 Adrenergic, Dopamine, Serotonine receptors 37 Angiotensin receptors 5 Bradykinin receptors 3 Cannabinoids receptors 1 Chemokines and chemotactic factors receptors 31 Cholccystokinin/gastrin receptors 2 Endothelin receptors 2 Family 2(B) receptors 18 Family 3(C) receptors 28 Family fz/smo receptors 10 Glycoprotein hormone receptors 5 Histamine receptors 2 Melanocortins receptors 5 Melanotonin receptors 3 Neuropeptide Y receptors 6 Neurotensin receptors 4 No swissprot 7TM 17 Odorant/olfactory and gustatory receptors 507 Opioid peptides receptors 5 Opsins 5 Orphan receptors 68 Other receptors 4 Platelet activating factor receptors 3 Prostanoids receptors 8 Proteinase-activated receptors 5 Releasing hormones receptors 3 Somatostatin receptors 6 Tachykinin receptors 3 Vasopressin/oxytocin receptors 4 Total 827
[0237] The present inventors classified sequences by a sequence similarity of 30%, which is generally considered to be the threshold for an evolutionarily related family. The largest family is the olfactory receptor family, containing 507 members. Major families containing more than 20 members are: the adrenalin, dopamine, and serotonin receptor family (37); the 2B receptor family (18); the 3C receptor family (28); the chemokine and chemoatractant receptor family (31); and the orphan receptor family (68).
EXAMPLE 4
[0238] Extraction of Novel Sequence
[0239] Sequences were searched in UNIGENE (Schuler, G. D., J. Mol. Med. 75, 694-698 (1997)) and nr-aa (ftp://ncbi.nlm.nih.gov/blast/db/README) databases. When at least 100 or more residues in the sequences which were investigated were continuously aligned with known sequences, and when the amino acid identity of that region is 96% or more, the present inventors designated the sequence as a known sequence. Novel GPCR candidates were obtained using this standard. These data sets will be maintained and updated by routine recalculations to the future.
[0240] The present inventors classified the extracted novel sequences into groups A, B, and C (Table 4 to Table 6). The sequences in groups A, B, and C are newly identified sequences, selected based on the search method in UNIGENE and nr-aa database, after the numbers of the sequences were made precise based on the best selectivity data set (level A), the data set at level B, and the data set at level C, respectively, among sequence sets which were obtained by triple analysis.
[0241] Further, the nucleotide sequences and amino acid sequences of the novel gene described in group A are shown in SEQ ID NOs: 1 to 936; those described in group B are shown in SEQ ID NOs: 1 to 1684; and those described in C group are shown in SEQ ID NOs: 1 to 2070.
TABLE 4 Number of novel SEQ Assayed amino acids Assay method genes ID NO: A-1 6F development sequence Homology 241 1-482 search A-2 GD sequence Homology 113 483-708 search A-3 6F development sequence + Motif search 114 709-936 GD sequence Domain search
[0242] A-1 Sequence set obtained through the assay of 6F sequences by homology search (use of the most easy method).
[0243] A-2 The part of amino acid sequence comprising multi exon, increased by use of GD sequence.
[0244] A-3 Sequence set found for the first time by use of motif and domain attribution. Homologous with very little homology, which cannot be found through normal sequence searches, were detected.
TABLE 5 Number of Assayed amino acids Assay method novel genes SEQ ID NO: B-1 6F development sequence Homology search 378 1-482 937-1210 B-2 GD sequence Homology search 180 483-708 1211-1344 B-3 6F development sequence + Motif search 259 709-936 GD sequence Domain search 1345-1634 B-4 6F development sequence + Transmembrance helix 25 1635-1684 GD sequence prediction
[0245] B-1 Sequence set obtained through the assay of 6F sequences by homology search (use of the most easy method).
[0246] B-2 The part of amino acid sequence comprising multi exon, increased by use of GD sequence.
[0247] B-3 Sequence set found for the first time by use of motif and domain attribution. Homologous with very little homology, which cannot be found through normal sequence searches, were detected.
[0248] B-4 Sequence set found for the first time by use of the prediction method for the transmembrane helix. Sequences which cannot be found even through normal homology search, motif and domain attribution were also determined.
TABLE 6 Number of Assayed amino acids Assay method novel genes SEQ ID NO: C-1 6F development sequence Homology search 378 1-482 937-1210 C-2 GD sequence Homology search 180 483-708 1211-1344 C-3 6F development sequence + Motif search 259 709-936 GD sequence Domain search 1345-1634 C-4 6F development sequence + Transmembrane helix 218 1635-2070 GD sequence prediction
[0249] C-1 Sequence set obtained through the assay of 6F sequences by homology search (use of the most easy method).
[0250] C-2 The part of amino acid sequence comprising multi exon, increased by use of GD sequence.
[0251] C-3 Sequence set found for the first time by use of motif and domain attribution. Homologous with very little homology, which cannot be found through normal sequence searches, were detected. C-4 Sequence set found for the first time by use of the prediction method for the transmembrane helix. Sequences which cannot be found even through normal homology search, motif and domain attribution were also determined. | The object of the present invention is to provide a technique for efficiently extracting GPCR sequences from human genome sequences, thereby comprehensively identifying novel GPCRs. An original automatic system for identifying GPCR sequences is disclosed, and 1035 novel GPCRs are successfully identified from the entire human genome by utilizing the system. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation application of PCT/JP2004/019300 filed on Dec. 24, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to an electrodeionization apparatus used for producing deionized water in various fields including semiconductor manufacturing, liquid crystal display manufacturing, pharmaceutical manufacturing, food processing, and the like. More particularly the present invention relates to the electrodeionization apparatus which produces treated water which is improved in resistivity and removing rate of weak electrolyte anions and is suitable to produce highly pure water continuously. Further more, the present invention relates to a method for electrodeionization which employs the electrodeionization apparatus.
BACKGROUND OF THE INVENTION
[0003] The electrodeionization apparatus used for producing the deionized water is employed in various fields including the semiconductor manufacturing plants, the liquid crystal display manufacturing plants, the food processing industry, the electric power plants, household equipments, laboratories and the like. FIG. 6 shows a conventional electrodeionization apparatus in which a plurality of anion exchange membranes 13 and a plurality of cation exchange membranes 14 are alternately arranged between electrodes (anode 11 , cathode 12 ) in such a manner as to alternately form concentrating compartments 15 and desalting compartments 16 , and the desalting compartments 16 are filled with ion exchangers 10 . In FIG. 6 , the reference numeral 17 denotes an anodic compartment and the numeral 18 denotes a cathodic compartment.
[0004] A part of the concentrated water flown out from the concentrating compartment 15 is fed into the anodic compartments 17 and the desalting compartments 18 .
[0005] In an electrodeionization apparatus, H + ions and OH − ions are formed by dissociation of the water to continuously regenerate the ion exchangers filled in the desalting compartments so that the electrodeionization apparatus can efficiently deionize the water without regeneration with using agents which are employed in a conventional ion exchange apparatus which is widely used for desalting water. An electrodeionization apparatus produces highly pure water continuously, so that it is employed widely in a pure water producing apparatus or the like.
[0006] Generally, when the electrodeionization apparatus is applied with the electrical current exceeding the critical current density to deionize, OH − and H + are formed by water dissociation as described above to carry the electric charge. H + ion has mobility of 349.7 cm 2 Ω −1 eq −1 , which is very large in comparison with that of the other ions (30 to 70 cm 2 Ω −1 eq −1 ). Therefore, particularly when the diluting compartment has a large thickness W, the difference of the mobilities between H + and OH − is increased so that H + tends to be quickly discharged to the concentrating compartments and OH − tends to remain in the desalting compartment. Furthermore, Na + and K + also tend to remain in the desalting compartments because these are monovalent and H + ion carries the electrons, while the multi-valent cations and anions including Ca 2+ , Mg 2+ are discharged to the concentrating compartments with relative ease. As the result, the product water tends to include monovalent alkali such as NaOH and KOH so that the product water (deionized water) becomes to contain Na ions at a high concentration (Na leak phenomenon).
[0007] An electrodeionization apparatus in which a desalting compartment is provided with vertical partition ribs for dividing the desalting compartment into cells being long in the vertical direction is disclosed in JP4-72567B. According to this electrodeionization apparatus having the desalting compartment divided into long cells by ribs in which ion exchange resins are filled respectively, the channelizing phenomenon where the flow of water from the inlet to the outlet of the desalting compartment is partially one-sided is prevented and the compression and the ion exchange resins in the desalting compartment is prevented from being compressed or moved.
[0008] The desalting compartments are filled with an equal amount of anion exchange resins and cation exchange resins so that the volume ratio of the anion exchange resins is 50 vol. %.
[0009] In the electrodeionization apparatus of JP4-72567B, the number of the cells is limited because the cells are formed by dividing the desalting compartment in the vertical direction. That is a large number of cells can not be formed in the apparatus. Further, the flow of the water in a lateral direction is blocked by the ribs, so that the contact efficiency between the water and the ion exchange resins is poor. In addition, the ion exchange resins are compressed at lower portions of the cells so that the cells have a vacancy at upper portions thereof, whereby the rate of filling the ion exchange resins tends to be poor.
[0010] The applicant disclosed, in JP2001-25647A, an electrodeionization apparatus which overcomes problems described above, which has high contact efficiency between water and ion exchanger, and which has high filling density of the ion exchanger. The applicant also disclosed, in JP2003-126862A, that this type of electrodeionization apparatus is improved in a desalting-efficiency when it has 60 to 80 vol. % of a volume ratio of anion exchange resins in the desalting compartments.
[0011] These electrodeionization apparatuses have desalting compartments, each of which is divided into a plurality of cells by a partition member, and ion exchange resins are filled in the respective cells. At least a part of the partition member facing the cell is inclined relative to an average flow direction of the water in the desalting compartment. The inclined part of the partition member allows permeation of the water, but prevents the ion exchanger to pass therethrough. Therefore, at least a part of the water flowing into the desalting compartment should flow obliquely relative to the average flow direction of water, so that the water is dispersed overall the desalting compartment, thereby improving the contact efficiency between water and ion exchanger and improving the deionization property.
[0012] When a plurality of cells are arranged along the membrane surface both in the average flow direction of water and a direction perpendicular to the average flow direction, (for example, when the apparatus has a large number of cells which are arranged vertically and laterally), the contact efficiency between water and ion exchanger becomes extremely high. Since the height of each cell is low, the ion exchanger is scarcely compressed. A vacancy is not formed at an upper portion in the cell, and the cell is filled evenly with the ion exchanger.
[0013] Generally, in an electrodeionization apparatus, ions contained in water to be treated move from a desalting compartment to a concentrating compartment depending on a potential difference between electrodes. Therefore, weak electrolytes including carbonic acid, silica and the like are hard to be removed from the water to be treated. For example, in an electrodeionization apparatus in which the anion exchange resin ratio is 50 volume % as described in JP4-72567B, the removal rate of silica is as low as about 70 to 90%.
[0014] JP2003-126862A above referred discloses the electrodeionization apparatus in which partition members are provided in a desalting compartment to divide the desalting compartment into a plurality of cells surrounded by the partition members and a cation exchange membrane and an anion exchange membrane, and the cells are filled with a mixture containing an anion exchange resin and a cation exchange resin at a mixing ratio of the anion exchange resin to the total amount of the anion exchange resin and the cation exchange resin is 60 to 80 volume %, in order to improve the removal rate of weak electrolytes.
[0015] The ratio of the anion exchange resin is made high in this Japanese publication due to the following reason:
[0016] Carbonic acid (CO 2 ) as a weak electrolyte changes to bicarbonate ion by ionization reaction with hydroxide ion (OH − ) (CO 2 +OH − →HCO 3 − ).
[0017] The bicarbonate ion moves from the desalting compartment to the concentrating compartment through the anion exchange membrane. Therefore, it is important for removal of carbonic acid first to promote the ionization reaction, and secondly to improve the mobility of the bicarbonate ion. In order to promote the ionization reaction of carbonic acid (formation of bicarbonate ion), OH − ion is required to be fed, and it is brought by dissociation of water (H 2 O→H + +OH − ).
[0018] The water dissociates between the ion exchange resins and between the ion exchange resin and the ion exchange membrane. The hydrogen ion and the hydroxide ion produced between the ion exchange resins have a short lifetime because they associate with each other again in the desalting compartment. Therefore, the OH − ions produced between the ion exchange resin and the ion exchange membrane, especially between the cation exchange membrane and anion exchange membrane are effective for ionizing carbonic acid. As the amount ratio of the anion exchange resin is made higher, the contact ratio of the anion exchange resin to the cation exchange membrane becomes higher, thereby the amount of the OH − ions to be produced increases. As a result, the ionization-reaction of carbonic acid is promoted.
[0019] As the amount ratio of the anion exchange resin increases, the amount of OH − ions to be produced also increases, but the removing rate of Na + ions is deteriorated because the amount of H + ions decreases, thereby the treated water is deteriorated in resistivity.
[0020] In JP2003-126862A, Na leakage is prevented by adopting the structure of the electrodeionization apparatus in JP2001-25647A above referred (in which a desalting compartment is divided into a plurality of cells), which is superior in the deionizing property.
[0021] [Patent Reference 1] JP4-72567B
[0022] [Patent Reference 2] JP2001-25647A
[0023] [Patent Reference 3] JP2003-126862A
[0024] As the concentration of carbonic acid increases in water, the equivalent electrical conductance also increases in accordance thereto whereby the current density required for deionization becomes higher than that in conventional apparatuses. When the anion exchange resin is filled in a desalting compartment in a large amount ratio, a voltage applied between the electrodes should be higher than when the anion exchange resin is filled therein with an amount ratio of 50%, in order to make the current density high. When the anion exchange resin is filled in the desalting compartment in an increased amount ratio, the cation resin is filled therein in a decreased amount ratio. When the volume ratio of the anion exchange resin in the desalting compartment is increased from 60% to 70%, pathway of ions via the anion exchange resin increases by about three times, but pathway of ions via the cation exchange resin decreases to one tenth due to reduction of cation exchange resin ratio from 40% to 30%.
[0025] As described above, as the current density becomes higher, the amount of H + ions produced by the dissociation of water increases. Both Na + ions and H + ions move competitively via the cation exchange resin having the reduced pathway, but the pathway is occupied by H + ions with priority due to a very large mobility thereof. As a result thereof, Na + ions become hard to move the pathway, electrical resistance increases and voltage applied to the electrodes is increased.
[0026] In case that anion exchange resin is filled in a desalting compartment merely in a large amount ratio like as JP2003-126862, the current density is not increased, resulting that carbonic acid can not be removed sufficiently and that resistivity of treated water increases. Since the rise of voltage leads to the rise of electric power consumption, it is uneconomical.
SUMMARY OF THE INVENTION
[0027] An object of the present invention is to provide an electrodeionization apparatus and an electrodeionization method which provide treated water having extremely high purity and low concentration of weak electrolytic anion with sufficient current density even when a voltage applied thereto is low.
[0028] An electrodeionization apparatus of a first aspect of the invention has a plurality of cation exchange membranes and a plurality of anion exchange membranes which are alternately arranged between electrodes in such a manner as to alternately form desalting compartments and concentrating compartments and the desalting compartments, the desalting compartments being filled with ion exchange resins, water to be treated being introduced into the desalting compartments, concentrated water being introduced into the concentrating compartments, and the ion exchange resins being a mixture of an anion exchange resin and a cation exchange resin, wherein a mixing ratio of the anion exchange resin to the total amount of the anion exchange resin and the cation exchange resin is 66 to 80 volume % at an upper stream zone in each desalting compartment and 50 to 65 volume % at a lower stream zone in each desalting compartment.
[0029] An electrodeionization apparatus of a second aspect of the invention has a plurality of cation exchange membranes and a plurality of anion exchange membranes which are alternately arranged between electrodes in such a manner as to alternately form desalting compartments and concentrating compartments and the desalting compartments, the desalting compartments being filled with ion exchange resins, water to be treated being introduced into the desalting compartments, concentrated water being introduced into the concentrating compartments, and the ion exchange resins being a mixture of an anion exchange resin and a cation exchange resin, wherein a mixing ratio of the anion exchange resin to the total amount of the anion exchange resin and the cation exchange resin is 50 to 65 volume % at an upper stream zone in each desalting compartment and 66 to 80 volume % at a lower stream zone in each desalting compartment.
[0030] An electrodeionization method of a third aspect of the invention employs the electrodeionization apparatus of either the first aspect or the second aspect, and the apparatus is operated at a current density of 300 mA/dm 2 or more.
[0031] An electrodeionization method of a fourth aspect of the invention employs the electrodeionization apparatus of either the first aspect or the second aspect, and the apparatus desalts water to be treated having a Na ion concentration of 300 ppb or more.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is an exploded perspective view showing the structure of a desalting compartment according to an embodiment;
[0033] FIG. 2 is a perspective view showing a main part of a partition member;
[0034] FIG. 3 is an exploded perspective view of the partition member;
[0035] FIG. 4 is a front view illustrating the water flowing condition of the partition member;
[0036] FIG. 5 a and 5 b are perspective views showing a ratio of anion exchange resin in a desalting compartment;
[0037] FIG. 6 is an exploded perspective view showing an electrodeionization apparatus according to the conventional one.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] When an electrodeionization apparatus has an area in which a ratio of anion exchange resin is 66 to 80 volume % in an upper stream zone or a lower stream zone in a desalting compartment, weak electrolytes are sufficiently removed in this area.
[0039] The electrodeionization apparatus of the first aspect has the desalting compartment filled with the ion exchange resin. The lower stream zone near the exit of the desalting compartment is filled with the ion exchange resins, 50 to 65 volume % of which is anion exchange resin. In this lower stream zone, water is easily dissociated (hereinafter sometimes referred to “split”). Cation exchange resin in this zone has enough pathway to sufficiently move both H ions and Na ions produced by split in the first aspect, so that Na leakage is prevented and current density is increased without voltage rise.
[0040] The electrodeionization apparatus of the second aspect has the desalting compartment filled with the ion exchange resin. The upper stream zone near the inlet of the desalting compartment is filled with the ion exchange resins, 50 to 65 volume % of which is anion exchange resin. In this upper stream zone, Na ions are removed at a high rate so that the amount of Na ions flowing down to the lower stream zone is reduced. Hence, Na leakage is prevented, moving load of Na ions is reduced, and current density is increased without voltage rise.
[0041] Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. FIG. 1 is an exploded perspective view showing the structure of a desalting compartment according to an embodiment, FIG. 2 is a perspective view showing a main part of a partition member, FIG. 3 is an exploded perspective view of the partition member, and FIG. 4 is a front view illustrating the water flowing condition of the partition member.
[0042] The desalting compartment has a rectangular frame 20 , a partition member 21 and disposed in the frame 20 preferably having conductivity, an ion exchange resin 23 filled in cells 22 formed by the partition member 21 , an anion exchange membrane 24 and a cation exchange membrane 25 which are disposed to sandwich the frame 20 .
[0043] The frame 20 is provided with a flow inlet 26 for introducing raw water to be treated and a flow inlet 27 for concentrated water in an upper portion thereof and with a flow outlet 28 for desalted water and a flow outlet 29 for concentrated water formed in a lower portion thereof. The flow inlet 26 and the flow outlet 28 are connected to the inside of the frame 20 through a notch-like channels 26 a, 28 a, respectively.
[0044] Though only one channel 26 a is illustrated to communicate with only the left top cell in FIG. 1 , actually a plurality of channels 26 a are formed in the upper portion of the frame 20 to-uniformly distribute the raw water into the respective top cells aligned in the lateral direction, that is, the channels 26 a directly communicate with the respective top cells. In the same manner, though only one channel 28 a is illustrated to communicate with only the right bottom cell in FIG. 1 , actually a plurality of channels 28 a are formed in the lower portion of the frame 20 so as to directly communicate with the respective bottom cells.
[0045] The partition member 21 according to this embodiment is in a honeycomb form of a hexagonal shape in which a large number of cells are arranged in vertical and lateral directions in such a manner that a pair of sides of each cell 22 extend in the longitudinal direction of the frame 20 , i.e. in the vertical direction.
[0046] The partition member 21 may be previously formed as an integral part or may be formed by combining a plurality parts. For example, as shown in FIG. 3 , the partition member 21 may be formed by connecting vertical surfaces 31 of zigzag plates 30 as shown in FIG. 3 . Each zigzag plate 30 comprises inclined surfaces 32 , 33 which are connected at an angle of 120° with the vertical surfaces 31 . To connect the vertical surfaces 31 , adhesives may be employed. The zigzag plate 30 is made of material which is permeable to water but not permeable to ion exchanger, e.g. woven fabric, non-woven fabric, mesh, and porous material. The zigzag plate 30 is preferably formed to have rigidity by using synthetic resin or metal having acid resistance and alkali resistance. The vertical surfaces 31 may be permeable or not permeable to water.
[0047] The partition member 21 may be fitted in the frame 20 . The frame 20 may be provided with a water permeable sheet or a mesh attached to one side thereof and the partition member 21 may be bonded to the sheet or the mesh.
[0048] The other structure of the electrodeionization apparatus according to the embodiment is the same as that of the aforementioned conventional one of FIG. 6 .
[0049] When the desalting operation is conducted by passing raw water through this electrodeionization apparatus, the raw water introduced into the desalting compartment flows through the partition member 21 surrounding each cell 22 so as to flow into adjacent cells 22 and thus gradually flows downwardly. During this, the water is deionized. Finally, the water reaches the bottom of the desalting compartment and flows out to the flow outlet 28 through the channels 28 a. Through the flow outlet 28 , the water is took out from the electrodeionization apparatus as the desalted water.
[0050] The general direction of water in the desalting compartment is a downward vertical direction because the channels 26 a for introducing raw water exist at the top of the frame 20 and the channels 28 a for taking out the desalted water exist at the bottom of the frame 20 . The partition member 21 at upper portions and lower portions of the respective cells is inclined relative to the general direction of water, so that the water flows obliquely and downwardly from one cell 22 into the lower left cell 22 and the lower right cell 22 . Therefore, the water flows substantially uniformly to all cells 22 , thereby improving the contact efficiency between the water and the ion exchanger.
[0051] In this desalting compartment, since the cells 22 are relatively small, the downward pressure applied to the ion exchange resin in each cell by the self weight of the ion exchange resin and water pressure is low. Therefore, the ion exchange resin is not compressed in any of the cells 22 , thereby preventing the ion exchange resin from being partially compressed at the lower portion of the cells.
[0052] Employed as the ion exchanger to be filled in the cells 22 is a mixture of an anion exchange resin and, a cation exchange resin. The desalting compartment has a first zone containing anion exchange resin at an extremely high ratio and a second zone containing anion exchange resin at an equal or slightly high ratio, so that the first zone is sometimes referred to “highly excessive zone” of anion exchange resin, and the second zone “slightly excessive zone” of anion exchange resin hereinafter. The highly excessive zone has a mixing ratio of the anion exchange resin to the total amount of the anion exchange resin and the cation exchange resin of 66 to 80 volume %, preferably 70 to 80%, and the slightly excessive zone has a mixing ratio of the anion exchange resin to the total amount of the anion exchange resin and the cation exchange resin of 50 to 65 volume %.
[0053] In the first aspect, as shown in FIG. 5 a, the highly excessive zone is located in the upstream side in the desalting compartment, and the slightly excessive zone is located in the downstream side in the desalting compartment.
[0054] In the second aspect, as shown in FIG. 5 b , the slightly excessive zone is located in the upstream side in the desalting compartment, and the highly excessive zone is located in the downstream side in the desalting compartment.
[0055] In both aspects of FIGS. 5 a and 5 b, the boundary B between the highly excessive zone and the slightly excessive zone is preferably located in the range of 25 to 75%, especially 40 to 60% away from the inlet of the desalting compartment in an average flow direction in the desalting compartment (in a direction from the top to the bottom in FIGS. 5 a and 5 b ).
[0056] When the ratio of anion exchange resin in the highly excessive zone is lower than 66 volume %, the amount of OH − ions produced by water dissociation is insufficient and carbonic acid is ionized to bicarbonate ion at an insufficient rate, thereby removal rate of the carbonic acid is decreased. When the ratio of anion exchange resin in the highly excessive zone is higher than 80 volume %, removal rate of cations including Na + ions decreases, thereby the concentration of Na + ion and the like in the treated water is increased. When the ratio of anion exchange resin is in the range of 66 to 80 volume % in the highly excessive zone, carbonic acid, Na + ion and the like are sufficiently removed, and further ionization of silica, which is a weak acid, is promoted so that removal rate of silica is increased. When the ratio of anion exchange resin in the slightly excessive zone is lower than 50 volume %, anions tend to leak from this zone. When the ratio of anion exchange resin is higher than 65 volume % in the slightly excessive zone, cations tend to leak from this zone, thereby the effect of the invention can not be obtained.
[0057] The desalting compartment may-have, between the highly excessive zone and the slightly excessive zone, a moderately excessive zone where a ratio of the anion exchange resin is between those in the highly excessive zone and the slightly excessive zone. The ratio of the anion exchange resin may vary within the above range in both the highly excessive zone and the slightly excessive zone. The ratio may be increased or decreased continuously from the upstream side to the downstream side in each zone within the above range.
[0058] The apparatus according to the invention can be operated at a current density of 300 mA/dm 2 or more, for example, 300 to 120 mA/dm 2 , so that treated water having a high resistivity of 10M Ω·cm or higher can be produced even when raw water to be treated has a Na ion concentration of 300 ppb or more, for example, 300 to 2000 ppb.
[0059] Though the cells are hexagonal in FIGS. 1 through 4 , the cells may be quadrangular e.g. rhombic. The partition member may be a triangle-type partition member composed of triangular cell. The partition member may form cells having other shapes. The apparatus may have no cells, wherein the apparatus has no partition member.
[0060] In the electrodeionization apparatus of the present invention, the projected area to the ion exchange membrane of the cells is preferably 1 to 100 cm 2 , particularly 5 to 80 cm 2 , more particularly 10 to 50 cm 2 . The distance between a pair of the anion exchange membrane and the cation exchange membrane via the desalting compartment i.e. the thickness of the desalting compartment is preferably 1.5 to 15 mm, particularly 3 to 10 mm. As the size of the cells is reduced, the amount of the ion exchanger to be filled in one cell is reduced so that the fluidization of the ion exchanger is restrained. In addition, the strength of the partition member and the strength of the desalting compartment are increased. However, the pressure loss of the water flowing in the desalting compartment is increased.
[0061] The concentrating compartment in one aspect may have a thickness of 0.3 to 1 mm and may be provided with a spacer of 20 to 60 meshes therein.
[0062] The particle diameter of the ion exchange resin is preferably 0.1 to 1 mm, particularly 0.2 to 0.6 mm. According to a preferable way of filling the ion exchanger, the ion exchange resin corresponding to 100 to 140% of the volume of the cells are introduced into the cells and, after that, the cells are sandwiched between the ion exchange membranes so as to precisely fill the ion exchange resin in the cells.
[0063] According to another way of filling the ion exchange resin in the cells, after the ion exchange resin is filled in the cells and the ion exchange membranes are disposed on the opposite sides of the desalting compartment, raw water is supplied to swell the ion exchanger inside the cells and, after that, the frames and the membranes are tightened up such that the volume ratio becomes 100 to 102%.
[0064] The concentrating compartment in another aspect may be filled with ion exchange resin. The concentrating compartment filled with an ion exchange resin allows electric current to easily pass the inside thereof and intensifies turbulence of water inside thereof, thus improving the efficiency of electric current. As the same manner in the desalting compartment, a partition member may be arranged in the concentrating compartment to form a plurality of cells therein and an ion exchange resin may be filled in the respective cells.
[0065] Normally, acid anode water passed through the anodic compartment is introduced to the cathodic compartment and neutralized therein, because the cathodic compartment is generally alkaline. The neutralization lowers the conductivity and partially increase the voltage of the cathodic compartment, so that scales are easy to form. Therefore, it is preferable to employ as the cathode a mesh electrode, a non-woven fabric electrode, or a combination thereof because such an electrode has a large electrode area, thereby lowering the current density on the electrode surface and thus preventing precipitation of scales.
[0066] For operating the electrodeionization apparatus of the present invention, it is preferable to circulate concentrated water and to control the circulated water so as to have an ion concentration 5 to 40 times higher than the feed water. In this case, it is preferable to electrically separate and discharge hardness i.e. scale ingredients in the concentrated water so as to make the Langelier Index in the circulated water negative. A weak acid ion exchange resin may be used for removing hardness elements.
EXAMPLES AND COMPARATIVE EXAMPLES
[0067] Hereinafter, Examples 1 and 2, Referential Examples 1 and 2, and Comparative Examples 1 and 2 will be described.
[0068] An electrodeionization apparatus used in Examples and Comparative Examples has desalting compartments having a structure as shown in FIGS. 1 to 4 , and concentrating compartments having three ribs extending vertically therein, respectively.
[0069] The desalting compartments and the concentrating compartments have a width of 130 mm and a height of 400 mm, respectively. The desalting compartments have a thickness of 5 mm, and the concentrating compartments have a thickness of 2.5 mm.
[0070] The apparatus has three desalting compartments and four desalting compartments, and they are alternately arranged as shown in FIG. 6 . As shown in FIG. 6 , electrode compartments are located on the outsides of both the concentrating compartments which are located at the outest sides, respectively. Raw water is introduced into each concentrating compartment to flow therethrough as concentrated water. The water counterflows in each concentrating compartment relative to each desalting compartment by one pass.
[0071] Cells in the desalting compartment are hexagonal as shown in FIGS. 1 to 4 . The length of one side of each hexagon is 16.1 mm. The vertical wall portions of the partition member forming each cell are made of polypropylene, and the slantwise mesh portions thereof are made of polyester.
[0072] The cells of each desalting compartment was filled with a mixture of an anion exchange resin and a cation exchange resin. Mixing ratios of the anion exchange resin and the cation exchange resin were as follows. In Examples 1 and 2, the boundary B was located at the middle of the desalting compartment in the vertical direction. In Comparative Examples 1 and 2, and Referential Examples 1 and 2, the mixing ratio of the anion exchange resin and the cation exchange resin was uniform throughout the desalting compartment.
Example 1
[0073] Upper stream zone:75% lower stream zone:60%
Example 2
[0074] Upper stream zone:60% lower stream zone:75%
Comparative Example 1
Referential Examples 1 and 2
[0075] 70%
Comparative Example 2
[0076] 60%
[0077] Each concentrating compartment was filled with a mixture of the anion exchange resin and the cation exchange resin in which the mixing volume ratio was 4: 6. Each electrode compartment was filled with the cation exchange resin.
[0078] Other operation conditions were as follows:
[0079] Raw water: Water prepared by treating city water with a reverse osmosis membrane, having a concentration of carbonic acid of 18 mgCO 2 /L, a concentration of Na ion of 760 ppb (110 ppb in Referential Example 1) and a conductivity of 10 μS/cm (1 μS/cm in Referential Example 1).
[0080] Flow rate in the desalting compartment :190 L/h
[0081] Flow rate in the concentrating compartment :40 L/h
[0082] Voltage: 20V
[0083] Current: 4 A
[0084] Current density: 800 mA/dm 2 (200 mA/dm 2 in
[0085] Referential Example 2)
[0086] Current efficiency: 20%
[0087] The qualities of treated water thus obtained are shown in Table 1. According to Table 1, by providing a highly excessive zone of the anion exchange resin in the upper zone or the lower zone of the desalting compartment and a slightly excessive zone of the anion exchange resin in the opposite zone of the same desalting compartment, carbonic acid was removed without increasing voltage even when the apparatuses were operated at a current density of 800 mA/dm 2 to treat the raw water having a concentration of Na ion of 300 ppb or more.
[0088] According to Referential Example 1 in which the raw water had a low concentration of Na ion, the raw water having a good condition did not cause increase of voltage. According to Referential Example 2, in which the current density was low when the treatment was executed, the low current density did not cause increase of voltage.
TABLE 1 Ratio of Anion exchange resin Concentration Current upper lower of Na ion density Increase of Resistivity No. 20 cm 20 cm total [ppb] [mA/dm 2 ] Voltage [MΩ · cm] Example 1 75% 60% 68% 760 800 none 12.8 Example 2 60% 75% 68% 760 800 none 14.5 Comparative 70% 70% 70% 760 800 increase 14.7 Example 1 Referential 70% 70% 70% 110 800 none 15.2 Example 1 Referential 70% 70% 70% 760 200 none 7.8 Example 2 Comparative 60% 60% 60% 760 800 none 3.4 Example 2 | An electric deionization device capable of sufficiently removing weak electrolyte components and producing processed desalting chamber having rectangular-parallelepiped frame 20, a compartment member 21 disposed in the frame 20 and, desirably, having conductivity, an ion exchange resin 23 filled in small chambes 22 formed by the compartment member 21, and an anion exchange membrane 24 and a cation exchange membrane 25 disposed so as to hold the frame 20. The compartment member 21 is formed in a hexagonal honeycomb shape. The ion exchange membrane 23 is the mixture of an anion exchange resin with a cation exchange resin, and its mixing ratio on the upstream side is different from that on the downstream side. | 1 |
CROSS REFERENCE TO RELATED APPLICATON
The present invention is an improvement of the air purification unit disclosed in copending application Ser. No. 147,819, filed Jan. 25, 1988, of Donald L. Clark and entitled Air Purification Method and Apparatus.
BACKGROUND OF THE INVENTION
The present invention relates to an improved air purification unit.
In copending application Ser. No. 147,819 an air purification unit is disclosed which utilizes a conventional centrifugal blower having a transition chamber associated therewith for converting the velocity of the blower output to static pressure. It is with an improved air moving construction utilized in apparatus of the foregoing type that the present invention is concerned.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide an improved air moving structure for an air purification unit which does not require a transition chamber to convert air velocity to static pressure and thus simplifies the structure of the unit.
Another object of the present invention is to provide an improved air moving construction for an air purification unit which permits the housing of the unit to be divided into substantially equal inlet and outlet chambers, thereby providing relatively high efficiency of air flow through a relatively small housing.
A further object of the present invention is to provide an improved air moving construction in an air purification unit which occupies a relatively small volume within the housing, thereby permitting the unit to be of a relatively small size.
Yet another object of the present invention is to provide an improved air purification unit having a construction in which the outlet air is propelled substantially by pressure from an air outlet chamber within the unit, thereby contributing to extremely efficient and silent operation. Other objects and attendant advantages of the present invention will readily be perceived hereafter.
The present invention relates to an air purification unit comprising a housing including a top side and a front side, an air inlet in said housing, an air outlet in said housing, a partition in said housing dividing said housing into an air inlet chamber in communication with said air inlet and an air outlet chamber in communication with said air outlet, filter means on said housing for purifying air passing therethrough, and a motorized impeller effectively mounted on said partition for moving air from said inlet chamber to said outlet chamber and pressurizing air in said outlet chamber and forcing air from said outlet chamber.
The various aspects of the present invention will be more fully understood when the following portions of the specification are read in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the improved air purifier of the present invention;
FIG. 2 is an exploded view of the air purifier of the present invention;
FIG. 3 is a cross sectional view taken substantially along line 3--3 of FIG. 1;
FIG. 4 is a cross sectional view taken substantially along line 4--4 of FIG. 1;
FIG. 5 is a cross sectional view taken substantially along line 5--5 of FIG. 1;
FIG. 5a is a fragmentary enlarged cross sectional view taken along line 5a--5a of FIG. 5;
FIG. 5b is a cross sectional view taken substantially along line 5b--5b of FIG. 5a;
FIG. 6 is a fragmentary enlarged cross sectional view taken substantially along line 3--3 of FIG. 1;
FIG. 7 is an enlarged fragmentary cross sectional view taken substantially along line 7--7 of FIG. 1;
FIG. 8 is an enlarged fragmentary cross sectional view taken substantially along line 4--4 of FIG. 1;
FIG. 9 is a schematic side elevational view of an occupied room with the improved air purifier of the present invention mounted on a wall thereof;
FIG. 10 is a schematic plan view of the room of FIG. 9 with the occupants removed;
FIG. 11 is a diagrammatic plan view showing how a plurality of improved air purifiers can be mounted within a room;
FIG. 12 is a diagrammatic plan view of a room of the same size of the room of FIG. 11 but showing an alternate mounting arrangement for a plurality of air purifiers;
FIG. 13 is a diagrammatic plan view of a room which is larger than that of FIGS. 11 and 12 and showing how a plurality of improved air purifiers can be mounted within the room;
FIG. 14 is a diagrammatic plan view of a still larger room and showing how a plurality of air purifiers can be mounted therein; and
FIG. 15 is a schematic diagram of air flow through the outlet grill.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The improved air purifier 10 of the present invention includes a housing 11 having a bottom wall 12, a top wall 13, a rear wall 14 and opposed side walls 15 which are lined with sound absorbing sheet material 12', 13', 14' and 15', respectively.
An air moving unit, which is known as a motorized impeller 16, includes electric motor 17 and an impeller 18. Motor housing portion 16' is mounted on bracket 19 having its opposite ends 20' suitably secured, as by welding, to partition plate 21' which extends diagonally across the housing 11 between side walls 15 (FIGS. 3 and 6) and thus divides the housing into two chambers of substantially equal size. More specifically, a flange 22' at the lower end of plate 21' lies on top of insulation 12' (FIG. 3) and a flange 23' lies along flange 62a of filter-receiving frame 56 which is described in detail hereafter.
Motorized impeller 16 also includes a rotatable housing portion 39' (FIG. 5a) to which impeller wheel 18 is attached by welding. Impeller blades 40' have their opposite sides fastened between plates 41' and 42'. Plate 41' has an annular flange 43' welded to rotatable motor housing portion 39'. Plate 42' is in the nature of an annular shroud, and its edge 44' is contiguous to stationary annular shroud or inlet ring 45' which is fixedly secured to plate 21' by screws 47' and defines circular inlet opening 49'. Inlet ring 45' induces air smoothly from chamber 51 into the rotating impeller 18 as it rotates in the direction of arrow 38 in FIG. 5b, and this is known as backward rotation. Motorized impeller 16 is commercially available and forms no part of the present invention except for the manner in which it coacts with the remainder of the structure of the air purifier 10.
An air inlet opening 20 (FIG. 2) is formed in top wall 13. A frame 21 defines the periphery of opening 20. More specifically, frame 21 includes a plurality of sides in the shape of an S or a Z, depending on how they are viewed in cross section. Frame side 22 (FIGS. 3 and 6) extends substantially the entire distance between side walls 15 and it includes a bottom shelf portion 23 (FIG. 6), a vertical side 24 and an upper flange 25 which is suitably secured to the underside of bent-over portion 14" of rear wall 14, as by welding. Sides 26 (FIGS. 4 and 8) of frame 21 extend along side walls 15 and include lower shelf portions 27, vertical portions 29, and upper flange portions 30 which are secured to the undersides 15" of bent-over side walls 15, as by welding. Frame member 31 (FIG. 6) extends substantially the entire distance between side walls 15 and includes a vertical portion 32 which is a continuation of top wall 13. A horizontal shelf 33 is formed as a continuation of vertical wall 32. Horizontal shelves 23, 27 and 33 have upper surfaces which lie in the same horizontal plane.
A plurality of items are mounted within frame 21. First of all, a removable tray 35 has a perforated bottom 36, the outer edges of which rest on horizontal shelves 23, 27 and 33. Tray 35 also has upstanding pairs of sides 37 and 39 which confine pelletized material 40 within the tray. The pelletized material comprises a second stage filter consisting preferably of activated charcoal and alumina with potassium permanganate for removing gaseous pollutants from the air passing therethrough. A removable prefilter 41 consists of two layers of polyester fabric material 42 and 43 suitably secured to each other and mounted on a rectangular wire frame 44. Filter 41 consists of loose webbonded material, and it functions as a prefilter for removing particulate matter in excess of 1 micron from the air passing therethrough. The underside of filter 41 rests on the upper peripheral horizontal flange 45 of tray 35 and thus also functions to confine the particulate matter 40 within tray 35. A grill 46 fits on top of prefilter 41 and is held in position by tabs or clips 47 which are secured to flanges 15" (FIG. 8) by screws 49. Thus, when motorized impeller 16 is in operation, air will be taken in to housing 11 through grill 46 and it will pass through prefilter 41 and through particulate matter 40 and into inlet chamber 51 and inlet 49' of motorized impeller 16. The prefilter 41 performs the additional function of diffusing the air passing through the particulate bed 40 so that good gas-solid interchange is obtained. The filters 36 and 41 also attenuate any noise from the impeller.
The air being discharged radially outwardly from impeller 18 pressurizes outlet chamber 50 after the air is centrifugally drawn through motorized impeller 16 from chamber 51 on the opposite side of plate 21' from chamber 50. The use of the specific type of motorized impeller 16 eliminates the need for an expansion duct and thus simplifies the construction of unit 10. Furthermore, it has been found that the pressurization of chamber 50 by motorized impeller 16 causes the air to diffuse through the outlet in the direction of arrows 52 (FIG. 3) in a uniformly distributed manner across the entire final filter, thus causing efficient and quiet air flow. The fact that chambers 51 and 50 are of substantially equal size enhances the efficiency of air flow through housing 11. In this respect, if one chamber was smaller than the other, it would have a restrictive effect on the air flow. In addition, the motorized impeller 16 functions to pressurize the air in chamber 50 and thus forces the air uniformly through the outlet substantially by pressure, thereby producing relatively silent operation. In the specific embodiment shown in the drawings, plate 21' is inclined to the horizontal at less than 45°, but any reasonable variation from 45°, either above or below, is acceptable. The impeller 18 may be plastic or metal, and it rotates backwardly with respect to blades 40' to induce air from chamber 51 into chamber 50. The direction of rotation is depicted by arrow 58' in FIG. 5b. Motorized impeller 16 is commercially available from ebm Elektrobau Mulfingen GmbH & Co.
A filter-receiving frame 56 is suitably secured within housing 11, as by welding. More specifically, frame 56 includes sides 59, 60, 61 and 62 having flanges 59a, 60a, 61a and 62a, respectively. The opposite ends of frame sides 59, 60, 61 and 62 are formed into flanges 59b, 60b, 61b and 62b, respectively, which are secured, as by welding, to flanges 15a, 15b, 12a and 13a of housing walls 15, 15, 12 and 13, respectively.
A corrugated high efficiency particulate filter element 63 is permanently mounted within a frame 64 which is removably received within frame 56 with a telescopic fit. Thus frame 64 with filter 63 therein are replaceable as a unit within frame 56, as required. A rectangular gasket 58 is located between frame 64 and frame 56, as shown. High efficiency particulate filter 63 traps submicron particles of a size less than 1 micron. This location of filter 63 also further attenuates the air and impeller noise. Essentially, the motorized impeller 16 is placed between two filter banks oriented at a 90° angle to each other by being mounted on partition plate 21' which is at an angle oriented at plus or minus 45°.
An air outlet grill 65 also fits within frame 56 and is retained therein by clips or tabs 66 which are secured to the housing by screws 67. Outlet grille 65 has horizontal dividers or vanes 90 (FIG. 6) and vertical dividers or vanes 91 (FIG. 7). Vanes 90 have perfectly horizontal sides and vanes 91 have perfectly vertical sides to thereby cause the discharged air to approximate a stream of primary air defined by the dotted lines in FIGS. 9 and 10 which induces air into it from the lower occupied zone A (FIG. 9). The flow of primary air from grille 65 is schematically shown in FIG. 15. Stated otherwise, the straight vanes 90 and 91 on the discharge grille prevent the primary air stream from being directed into the lower occupied zone A. The air stream also flows perpendicularly to the room wall (FIGS. 9 and 10), and smoke and odors in the secondary air in lower zone A are drawn up and induced into the purified primary air stream.
A speed control knob 92 is mounted on wall 15 and it functions in conjunction with structure of motor 17 to provide speed control of motorized impeller 16. Thus the speed of motorized impeller 16 can be varied from very low speeds to very high speeds to meet various pollution conditions. In this respect, when there is very little pollution, the motorized impeller 16 can be run at low speed, and when there is high pollution, it can be run at high speed. The use of a speed control is optional.
To install unit 10 on a wall, an angle bracket 18, as shown in phantom in FIG. 3, is normally used. Bracket 18 extends substantially the entire distance between side walls 15. Screws (not shown) extend through the vertical leg of the angle bracket and into a room wall to hold housing side 14 in abutting relationship therewith.
The above described air purifier unit is used to practice the method of air purification described hereafter. One basic way of practicing the method is to install unit 10 on a wall 70 of a room with its rear wall 14 against wall 70 (FIGS. 9 and 10). The bottom wall 12 of the unit should be at least one foot above the highest level of the zone of occupancy, that is, if the highest level a person may reach is 61/2 feet above the floor, then the bottom 12 of the housing should be about 71/2 feet above the floor. This serves the dual purpose of avoiding direct aiming of the air outlet current at the occupants and also causing the air outlet stream 71 (FIG. 15) to be directed into the upper zone B of the room which may contain smoke particles and other odorous matter which rise into this zone. The discharge is preferably at a velocity of 300 to 500 feet per minute into a room such as depicted in FIGS. 9 and 10. The discharged purified air from outlet grill 65, which constitutes a primary air stream, substantially in the shape of a column, is schematically shown within the parallel dotted-lines emanating from the unit 10 in FIGS. 9 and 10. This column is directed into the upper zone B, and it performs a plurality of functions. In this respect, it induces secondary yet uncleaned air from the lower occupied zone A into the primary clean air stream in upper room zone B, as depicted by arrows 74 in FIG. 9, and it displaces and disperses the secondary air mass in zone B, as schematically depicted by the arrows in FIG. 10, thereby performing a constant removal of polluted air rising and induced from lower zone A without creating an appreciable draft therein.
The air which is returned to unit 10 is depicted by arrows 75, and this air enters unit 10 through inlet grill 46 which is facing the ceiling 76. The inlet grill should be spaced at least about 6 inches from ceiling 76 to permit removal and replacement of the first stage filter 41 and the second stage filter 36. The fact that the air inlet grill faces the ceiling, thus directs impeller noise in this direction and away from the occupants. Furthermore, the motorized impeller noise is attenuated because of the muffling action of the first and second stage filters. Furthermore, the sound insulation 12', 13', 14' and 15' also absorbs the motorized impeller noise.
The first stage filter 41, as noted above, is fabricated of non-woven polyester material, or other suitable filter media, and it traps particulate matter above the 1.0 micron range. The second stage filter consists of pelletized material in tray 35, as noted above, and it may be an activated carbon or alumina and potassium permanganate blend or other combinations of adsorbents and absorbents for removing odorous and gaseous contaminants which include but are not limited to gaseous chemicals found in smoke, body odors, food odors, chemical odors and the like which are normally experienced in occupied rooms such as commercial gathering places, offices, banquet rooms, board rooms, cafeterias, laboratories, and other places where tobacco smoke and other odors are generated.
The partially purified air which has thus passed through the first and second stage filters for the above-described purification steps, is then induced into motorized impeller 16 from which it passes into chamber 50 and is forced through third stage filter 63 which is a corrugated high efficiency particulate filter which traps submicron particles below the 1 micron size. This filter may have other efficiency ratings and should be selected for the particular need. This filter also aids in attenuating the impeller noise. Generally a HEPA filter is used which removes at least 95% of all particles 0.3 microns in size. However, filters of less efficiency may be used.
The purified air which is thus discharged from outlet grill 65 as depicted at 71, thus causes the above-described cycle to be repeated. Considering, for example, that the unit 10 purifies approximately 1,000 cubic feet per minute in a room such as depicted in FIGS. 9 and 10 having 10,000 cubic feet, it can readily be seen that the entire air volume within the room is passed through the air purifier in 10 minutes in this case. The unit 10 is capable of removing approximately 95% of all contaminants in the air passing therethrough, and thus a relatively high degree of air purification is achieved.
In FIG. 11 the placement of a plurality of units 10 having the above capacity are depicted on wall 77 of a room which may have 2,000 square feet and 20,000 cubic feet and contain up to about 80 people. An alternate arrangement for a room of the size depicted in FIG. 11 is shown in FIG. 12 wherein a unit 10 is mounted on each of two opposing walls 79 and 80. FIG. 13 depicts the placement of a plurality of units 10 in a room which may contain 3,000 square feet and 30,000 cubic feet and have up to about 120 people therein. In a room of this size two units 10 may be placed on one wall 81 to direct their output toward opposing wall 82. The two units 10 on wall 81 are spaced in such a manner so that the unit 10 on wall 82 directs its air to the midpoint between the units 10 on wall 81. In FIG. 14 an arrangement of units 10 is shown for a room which may contain 4,000 square feet and 40,000 cubic feet and be occupied by up to about 160 people. In a room of this size, two units 10 may be mounted on wall 83 and two units 10 may be mounted on opposite wall 84 and have their outputs directed toward wall 83, as shown. It will be appreciated that purifier units of different capacities than unit 10 described above can be used in different quantities and/or in different placement arrangements. The purifier units can be built in different sizes to match specific capacity requirements.
While in the above description the tray of pelletized material has been shown as removable from the top of the housing, it will be appreciated that the housing can be modified to permit installation and removal of the tray from the front or the side.
It can thus be seen that the improved method and apparatus for effecting purification of contaminated air in a room is manifestly capable of achieving the above-described objects, and while preferred embodiments have been disclosed, it will be appreciated that the present invention is not limited thereto but may be otherwise embodied within the scope of the following claims. | An air purification unit including a housing of substantially rectangular solid configuration and having an inlet and an outlet, a diagonal partition in the housing dividing it into substantially equal inlet and outlet chambers, first filters in communication with the inlet chamber for removing gases and particulate matter entering the inlet chamber, second filters in communication with the outlet chamber for removing submicron particles, and a specialized motorized impeller mounted on the diagonal partition for moving air from the inlet chamber to the outlet chamber, the motorized impeller including a stationary inlet ring secured to the partition, a stationary motor housing portion fixed relative to the partition and a rotatable motor housing portion carrying a backwardly rotatable impeller wheel for drawing air through the center of the impeller wheel as it rotates and forcing it radially outwardly through the impeller wheel to thereby pressurize air in the outlet chamber. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a temporary heat-proof apparatus for repairs of a gate and vicinity thereof of a coke oven chamber. As well known, even when the gate and vicinity of a specific coke oven of a coking battery under operation is in need of repairs, operation of other chambers should be maintained continuously for technical, economical and other reasons. However, hot air blowing off the interior of the chamber makes repair operations very difficult. Thus, a heat-proof apparatus capable of completely preventing such inner hot air from blowing off the chamber has long been desired.
Accordingly, it is the object of this invention to provide such a heat-proof apparatus that is simple in construction, easy to operate and yet hardly damaged in use.
SUMMARY OF THE INVENTION
In accordance with the present invention, a temporary heat-proof apparatus generally comprises in combination a heat proof unit capable of completely preventing inner hot air from blowing off the chamber, and a charging unit therefor. Constructions of the heat-proof unit and charging unit will be described in greater detail hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings;
FIG. 1 is a vertical sectional view of a temporary heat-proof apparatus constructed in accordance with the invention, shown in combination with a charging unit and a door lifter apparatus and inserted into a coke oven chamber;
FIG. 2A is a fragmentary cross-sectional view of the heat-proof apparatus and charging unit of FIG. 1, taken along the line 2A--2A;
FIG. 2B is a fragmentary cross-sectional view of the heat-proof apparatus and charging unit of FIG. 1, taken along the line 2B--2B;
FIG. 3 is a further cross-sectional view of the heat-proof apparatus of FIG. 1 in a condition of full expansion against the walls of the oven chamber;
FIG. 4 is a front view of the charging unit illustrated in FIG. 1;
FIG. 5 is a front view of a slide frame of the heat-proof apparatus shown in FIG. 1;
FIG. 6 is a vertical section of the structure shown in FIG. 5; and
FIG. 7 is a referential view showing an example of actuation of the charging unit.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, particularly to FIGS. 1, 2A, 2B and 3, there are illustrated a pair of vertical channel members 1 and 1' substantially C-shaped in cross-section and arranged opposite each other, and a vertical backplate 2 welded at both ends to the channel members 1 and 1' to form a vertical frame 3. Onto the backplate 2 is fastened with bolts 6 a plate 5 which is provided with pairs of brackets 4 and 4' extending rearwardly therefrom. There is also illustrated a vertical heat-proof plate 7 of substantially C-shaped cross-section which is provided with pairs of brackets 8 and 8' extending forwardly for respective connection with the above-mentioned brackets 4 and 4'. The brackets 4 and 4' are joined to the corresponding brackets 8 and 8' by pins 9 inserted through fitting holes. On the outside of the heat-proof plate 7 is fitted an adiabatic member 10. Between the channels 1 and 1' are arranged upper and lower slide frames 13 and 14. As shown in FIGS. 6 and 7, the upper slide frame 13 is provided with a pair of upper and lower hooks 15 and 15' of box shape in front view and connected by vertical rods 16. On the lowermost vertical rod 16 is formed a worm-screw along which a bevel gear 17 is driven to cause the former to move up and down. The bevel gear 17 engages another bevel gear 17' which drives the former. The bevel gear 17' is fixed on one end of a gear shaft which has an eye at the other end for receiving a drive means (not shown).
On the top of the upper slide frame 13 is mounted an adiabatic member 19 for pressure-contacting the ceiling of the coke oven, and on the lower end of the lower slide frame 14 is mounted an adiabatic member 20 for pressure-contacting the bottom of the coke oven. On the vertical rod 16' is also formed a worm-screw along which a bevel gear 21 is driven to cause the vertical rod 16' to move up and down. The bevel gear 21 engages another bevel gear 21' which drives the former. The bevel gear 21' is also fixed on one end of a gear shaft (not identified) intersecting the rod 16' at right angles. The other end of the gear shaft is provided with an eye 22 to insert a drive means thereinto for driving the bevel gear.
As shown in FIGS. 1 and 3, between both side walls of the heat-proof plate 7 and in front of the vertical frame 3, there are mounted upper and lower expander devices 23 capable of causing the adiabatic member 10 to pressure-contact both side walls of the coke oven to produce a complete seal. Each of the expander devices 23 comprises a shaft 25 having a worm-screwed portion on one end, an eye 24 on the other end and pairs of links 26 and 27 connected to the heat-proof plate 7. Both inner ends of the links 26 are pivotally connected to a bearing of the shaft 25, while the inner ends of the links 27 are pivotably connected to a female member meshing with the worm-screw portion of the shaft 25. Further, as shown in FIGS. 1, 2 and 3, an air-cooling duct 28 is arranged between the brackets 4 and 4'. The position of the air-cooling duct is not critical.
Now, referring to FIGS. 1, 4 and 7, there is illustrated a charging unit for the above heat-proof unit. The charging unit comprises a pair of vertical frames 31 provided with both upper and lower locking bar devices 32 and 32' and lug pieces 33 and 33'. The unit further comprises a rotatable shaft 35 with normal and reverse screw threads 34 and 34' and provided with upper and lower supporting arms 36 and 36' which are pivotably connected to female members (not identified). On the lower end of the shaft 35 is mounted a bevel gear 41 which meshes with another bevel gear 42. On the other end of a shaft 43 of the bevel gear 42 is formed a square hole for receiving a drive means (not shown) to drive the bevel gear 42. Upper and lower auxiliary arms 44 and 44' are arranged each with one end pivotably connected with the center portion of the corresponding support arm 36 or 36' and the other end pivotably connected with a bracket extending from the locking bar device 32 to guide the supporting arm. In the drawings, the following referential numerals designate respectively; 37, a locking bar; 38, a bar housing; 39, a coil spring; 40, a spring holding plate; 45, a stopper; and 46, a suspending roller.
In operation, when any specific oven gate and vicinity at a pusher- or coke-side of a coke oven chamber 51 is in need of repairs, the heat-proof apparatus of this invention which has been so far hung up in a depository is now carried together with the charging unit from the depository to the front of the coke oven chamber by a door lifter 55 per se mounted, for example, on a pusher or a coke guide car. When it has been carried to the front of the chamber and the upper and lower stopper plates 45 of the charging unit abut against a door sealing frame 47 to stop the door lifter 55, a drive means (not shown) is put into the square hole 43 of the bevel gear shaft of the charging unit to rotate the rotatable shaft 35 through the bevel gears 42 and 41. Rotation of the shaft 35 causes the upper and lower female screw members connected to the arms 36 and 36' to move up and down, respectively. This results in advancement of the front ends of the arms 36 and 36', as shown in FIG. 7, and allows the heat-proof unit to be charged deep into the coke oven chamber 51. A drive means (not shown) is then inserted into the eyes 18, 22 and 24 in order that the bevel gears 17' 17, 21' 21, the shafts 25 and the female screw members meshing with the shafts are respectively driven to actuate the upper and lower slide frames 13 and 14 and the expander devices 23. Thereby, the upper and lower adiabatic members 19 and 20 and both ends of the side walls of the adiabatic member 10 are caused to pressure contact the respective coke oven chamber walls to prevent interior hot air from blowing off the oven chamber.
Since the heat-proof unit can now stand independently in this condition as shown in FIG. 1, and both upper and lower hooks 15 and 15' are freed from the arms 36 and 36' in the process of elevating the slide frame 13, the charging unit now can be removed and returned to its original location by the door lifter 55.
The oven gate and vicinity thus separated from the hot interior air of the oven by the above-described heat-proof apparatus can be repaired under very good conditions, and if desired, the conditions can be further improved by cool air from the air-cooling duct 28. After completion of the repairs, the charging unit is again carried to the front of the coke oven chamber by the door lifter 55 and both supporting arms 36 and 36' are advanced, if necessary, by driving the bevel gears 42 and 41. The bevel gears 17' and 17 are then driven in reverse by a drive means inserted into the eye 18 until the upper adiabatic member 19 leaves the ceiling of the oven chamber and the hooks 15 and 15' engage the ends of the supporting arms 36 and 36'. After restoring the expander devices 23 and the lower adiabatic member 20 to the original condition by driving the eyes 24 and 22 respectively, the heat-proof apparatus is carried together with the charging unit from the coke oven chamber to the original place by the door lifter 55. | When repairing a gate and vicinity of a coke oven chamber during operation, hot air blowing off the interior of the chamber makes repairs impossible or almost difficult. Disclosed is a temporary heat-proof apparatus capable of preventing such hot air from blowing off the chamber, which generally comprises two units in combination, viz. a heat-proof unit and a charging unit therefor. Both front end portions of the heat-proof unit are expandable toward side walls of the oven chamber, while upper and lower slide frames are arranged respectively to pressure-contact the ceiling and bottom of the chamber. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cartridge type liquid feeding container having a cartridge for housing a liquid such as cosmetic ink, writing ink, correction liquid, etc, and capable of feeding out the liquid inside the cartridge.
2. Description of the Related Art
Conventionally, as a container housing a liquid of this kind and capable of feeding the liquid, there is the one described in, for example, Japanese Utility Model Publication No. 6-14844. The liquid container described in this Official Gazette is comprised of a barrel body in which a coating liquid storing portion is formed, a threaded bar projectingly provided at a piston slidably fitted in the storing portion, and a rotary cylinder integrally connecting an inner cylinder member and an outer cylinder member. The outer cylinder member has a ring protruded rib and an engaging claw capable of being resilient in an axial direction in a tip end portion of the outer cylinder so that the ring protruded rib is press-fitted into a ring groove at the rear end of the barrel body to rotatably connect the rotary cylinder to the barrel body, and the engaging claw of the outer cylinder member is elastically meshed with a ratchet tooth integrally formed in a circumferential direction in the barrel body to construct a ratchet mechanism. A threaded hole is provided in the inner cylinder member of the rotary cylinder to be screwed onto the threaded bar. Two plane portions formed on both sides over the entire length of the threaded bar are slidably fitted into a slide hole formed in a partition wall of the rear end of the storing portion of the barrel body, and the threaded bar is advanced without being rotated by the rotation of the rotary cylinder to press the piston in the axial direction to supply a coating liquid.
When the rotary cylinder is rotated with respect to the barrel body, relative rotation occurs between the inner cylinder member of the rotary cylinder and the threaded bar because the threaded bar is slidably fitted in the slide hole formed in the partition wall of the rear end portion of the storing portion of the barrel body, and the threaded bar advances by thread engagement between the threaded bar and the threaded hole of the rotary cylinder to press the piston in the axial direction to make it possible to supply a coating liquid to a tip end of the barrel body.
However, with the liquid container described in this Official Gazette, when the liquid stored in the coating liquid storing portion is used up, the liquid container itself cannot be reused, and is thrown away after only one use, which is a waste of resources. When the content of the liquid is desired to be replaced and used temporarily, there is no other way but to use another liquid container.
The liquid container described in Japanese Patent Laid-Open No. 2001-299442 has the same problems as Japanese Utility Model Publication No. 6-14844.
SUMMARY OF THE INVENTION
The present invention is made in view of the above problems, and its object is to provide a cartridge type liquid feeding container which is a cartridge type capable of being used by refilling or replacing the liquid instead of throwing away the container itself after only one use, and is capable of feeding out the liquid inside the cartridge. Another object of the present invention is to provide a cartridge type liquid feeding container which makes it possible to perform the operation easily when the liquid is refilled or replaced.
In order to achieve the object, a cartridge type liquid feeding container according to the present invention comprises a body, a manipulating body capable of being manipulated from an outside, a cartridge which is loaded into the body so as to be attachable and detachable, and has a cartridge case, a tank portion located inside the cartridge case for housing a liquid, and a piston which slidably moves in the tank portion, a liquid supplying body for supplying the liquid inside the tank portion to the outside, a piston rod which is workable on the piston to press the piston of the cartridge forward, and is movable inside the cartridge case and body, and a conversion mechanism for converting a manipulating force applied to the manipulating body into forward movement of the piston rod.
The conversion mechanism may be a thread engagement between the piston rod and the cartridge case, for screwing the piston rod into the cartridge case, and moving the piston rod forward by relative rotation between the manipulating body and the body.
The piston rod may be biased in a direction to go away from the cartridge, inside the body and the thread engagement may screw the piston rod into the cartridge case when the cartridge is located in a mounting position inside the body, whereas when the cartridge is out of the mounting position inside the body, the thread engagement may loosen the screwing of the piston rod and the cartridge case.
The thread engagement may comprise a male thread formed on an outer peripheral surface of the piston rod and a female thread provided on the cartridge case, the female thread may be capable of expanding and contracting in a radial direction, and when the female thread is located in the mounting position inside the body, the female thread may contract in a diameter and be screwed onto the male thread.
Preferably, the liquid supplying body may be separable from the body.
The liquid supplying body may be provided on a leading tool, the cartridge may be attachably and detachably connected to the leading tool, and the leading tool may be attachably and detachably mounted to the body.
According to the present invention, by manipulating the manipulating body, the conversion mechanism converts the manipulating force applied to the manipulating body into the forward movement of the piston rod, the piston rod works on the piston of the cartridge and moves inside the cartridge case and inside the body to press the piston forward. The piston slides in the tank portion to push the liquid inside the tank portion forward, and therefore the liquid can be supplied to the outside from the liquid supplying body. When the liquid inside the tank portion becomes scarce, the cartridge is removed from the body, and is replaced with a new cartridge, whereby the liquid can be supplied again. At this time, the piston rod is separable from the piston, and therefore the cartridge can be easily replaced.
In this manner, the body, the piston rod, and the manipulating body can be used continuously without being thrown away after only one use, and the resources can be utilized effectively.
On replacement of the cartridge, when the cartridge is removed from the mounting position inside the body, the screwing of the piston rod and the cartridge case is loosened, and thereby the cartridge can be released from the piston rod and easily removed. Then, the piston rod can be automatically returned to the position where the piston rod is separated from the cartridge.
If the liquid supplying body of the cartridge is replaced, different kinds of liquid can be supplied with the same liquid feeding container.
The present disclosure relates to subject manner contained in Japanese Patent Application No. 2004-12326, filed on Jan. 20, 2004, which is expressly incorporated herein by reference in its entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall longitudinal cross-sectional view showing a cartridge type liquid feeding container of a first embodiment of the present invention;
FIG. 2 is an overall longitudinal cross sectional view showing a state when a cartridge of the cartridge type liquid feeding container of the first embodiment is loaded;
FIG. 3 is an overall longitudinal cross-sectional view showing a state in which a piston rod of the cartridge type liquid feeding container of the first embodiment moves forward;
FIG. 4A is a plan view, FIG. 4B is a longitudinal cross-sectional view of a manipulating body, and FIG. 4C is a sectional view taken along the c—c line in FIG. 4B ;
FIG. 5A is a plan view, and FIG. 5B is a longitudinal cross-sectional view of the cartridge;
FIG. 6A is a longitudinal cross-sectional view of a chuck, and FIG. 6B is a view seen along the line 6 B in FIG. 6A ;
FIG. 7A is a plan view, and FIG. 7B is a longitudinal cross-sectional view of a piston;
FIG. 8 is an overall longitudinal cross-sectional view showing a cartridge type liquid feeding container of a second embodiment of the present invention;
FIG. 9 is an overall longitudinal cross-sectional view showing a state when a cartridge of the cartridge type liquid feeding container of the second embodiment is loaded;
FIG. 10A is a plan view and FIG. 10B is a longitudinal cross-sectional view of the cartridge of the second embodiment;
FIG. 11A is a longitudinal cross-sectional view of a chuck, and FIG. 11B is a view seen along the line 11 B in FIG. 11A , of the second embodiment;
FIG. 12 is an overall longitudinal cross-sectional view of a cartridge type liquid feeding container of a third embodiment of the present invention; and
FIG. 13 is an overall longitudinal cross-sectional view showing a state when a cartridge of the cartridge type liquid feeding container of the third embodiment is loaded.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, an embodiment of the present invention will be explained by referring the drawings.
FIG. 1 to FIG. 3 are views showing a cartridge type liquid feeding container of a first embodiment of the present invention.
In the drawings, a cartridge type liquid feeding container 10 generally has a leading tool 12 including a liquid supplying body, a body 13 , a manipulating body 14 , a cartridge 16 , a piston rod 17 , a spring 18 for biasing the piston rod 17 rearward and a cap 19 .
The leading tool 12 is provided with a brush 24 which is a liquid supplying body for coating the liquid, a tip end pipe 26 for flowing the liquid to the brush 24 , and a pipe holder 28 which is fixed inside the leading tool 12 , and also fixes the brush 24 and a tip end pipe 26 to the leading tool 12 . Further, on an inner peripheral surface of the leading tool 12 , a plurality of longitudinal ribs 12 a (see FIG. 1 ) extending in an axial direction are formed behind the pipe holder 28 . However, instead of the longitudinal ribs 12 a , the inner peripheral surface of the leading tool 12 may be in a polygonal shape.
A rear end portion of the leading tool 12 is inserted into a tip end portion of the body 13 and is screwed into the tip end portion of the body 13 to be attachable and detachable. After being screwed, the leading tool 12 and the body 13 are integrally connected. An annular step portion 13 a expanded in an inner diameter direction is formed in a central portion inside the body 13 , and the piston rod 17 penetrates through a center hole of the annular step portion 13 a . A portion in the front from the annular step portion 13 a inside the body 13 is a space into which the cartridge 16 is inserted. A portion just in front of the annular step portion 13 a is a small diameter portion 13 b , and the small diameter portion 13 b has a smaller inner diameter than the portion on the front side from the small diameter portion 13 b . An annular rib 13 d is formed on an inner peripheral surface of the rear end portion of the body 13 .
A manipulating body 14 is mounted to a rear end portion of the body 13 to be capable of relatively rotating manipulation with respect to the body 13 . Namely, as shown in FIGS. 4A , 4 B and 4 C, the manipulating body 14 is formed with a large diameter portion 14 a and a small diameter portion 14 b . An annular rib 14 c is formed on an outer peripheral surface of the small diameter portion 14 b , and the annular rib 14 c is fitted in the annular rib 13 d . A plurality of longitudinal ribs 14 e extending in an axial direction are formed on an inner peripheral surface of the manipulating body 14 .
The cartridge 16 is attached into the body 13 so as to be attachable and detachable, and as shown in FIGS. 5A and 5B , the cartridge 16 has a cartridge case 30 , a tank portion 32 defined inside the cartridge case 30 and housing the liquid, and a piston 34 which moves slidably in the tank portion 32 and serves as a bottom lid. A liquid L which is housed in the tank portion 32 can be, for example, a correction liquid, writing ink, cosmetic ink and the like, and the viscosity does not matter. A tip end of the cartridge case 30 is connected to the pipe holder 28 , a tip end opening 32 a of the tank portion 32 which is formed at a tip end of the cartridge case 30 communicates with the brush 24 via the pipe holder 28 and the tip end pipe 26 . Longitudinal grooves 30 c fitted on the longitudinal ribs 12 a of the leading tool 12 are formed on an outer peripheral surface of the tip end portion of the cartridge case 30 . Thus, the cartridge 16 rotates integrally with the leading tool 12 . If the inner peripheral surface of the leading tool 12 is in a polygonal shape, the outer peripheral surface of the tip end portion of the cartridge case 30 should be formed into the polygonal shape fitted into the inner peripheral surface of the leading tool 12 .
A tip plug 35 is enclosed in a tip end opening 32 a of the tank portion 32 to prevent leakage of the liquid L when the viscosity of the liquid L is small in the unused state of the cartridge, and when the cartridge 16 is connected to the pipe holder 28 when used, the pipe holder 28 pushes the tip plug 35 into the tank portion 32 and opens the tip end opening 32 a . However, when the viscosity of the liquid L is large, the tip plug 35 is not always needed, and instead of the tip plug 35 , a cap for preventing the entrance of dust and the like may be provided. The tip plug 35 may be formed into any shape besides the spherical shape as shown in the drawing.
A chuck 36 is provided at a rear end of the cartridge case 30 . The chuck 36 is a vertical chuck, and as shown in FIGS. 6A and 6B , its engaging protrusion 36 a is engaged to an engaging hole 30 a formed on an outer peripheral surface of the rear end portion of the cartridge case 30 , and a pair of upper and lower protrusions 36 b which are formed at the rear end of the chuck 36 and project in an outer diameter direction are fitted into a pair of upper and lower notches 30 b formed at the rear end of the cartridge case 30 . At the rear end of the chuck 36 , notches 36 c are formed in a portion where the protrusions 36 b are not formed, and on an inner peripheral surface at the rear end of the chuck 36 , a female thread 36 d is formed in a portion where the notches 36 c are not formed. As a result that the notches 36 c are compressed, the female thread 36 d of the chuck 36 is capable of reducing in the diameter in a radial direction.
The piston 34 is constructed by a material elastically in contact with the inner peripheral surface of the cartridge case 30 , and as shown in FIGS. 7A and 7B , a receiving recessed portion 34 a opened to the rear is formed at a rear end portion of the piston 34 .
In the piston rod 17 , its tip end portion is capable of being fitted into the receiving recessed portion 34 a of the piston 34 to be attachable and detachable. A male thread 17 a is formed on an outer peripheral surface of the piston rod 17 . A plurality of longitudinal ribs 17 b which are fitted in the longitudinal ribs 14 e of the manipulating body 14 are formed at the rear end portion of the piton rod 17 . Thus, the piston rod 17 rotates integrally with the manipulating body 14 . The inner peripheral surface of the manipulating body 14 may be in the polygonal shape, and the outer peripheral surface of the rear end portion of the piston rod 17 may be in the polygonal shape fitted in the inner peripheral surface of the manipulating body 14 .
The piston rod 17 and the chuck 36 provided at the cartridge case 30 are capable of being screwed, and a thread engagement of the male thread 17 a of the piston rod 17 and the female thread 36 d of the chuck 36 construct a conversion mechanism for moving the piston rod 17 forward. When the tip end portion of the piston rod 17 is fitted into the receiving recessed portion 34 a of the piston 34 , the tip end portion of the piston rod 17 is workable on the piston 34 , and the forward moving force of the piston rod 17 can be transmitted to the piston 34 . In this example, the piston rod 17 directly comes into contact with the piston 34 and is capable of pressing operation, but the present invention is not limited to this, and the piston 34 may be made capable of pressing operation via an additional member.
In the cartridge type liquid feeding container 10 constructed as above, the operation will be explained. First, the cartridge 16 is loaded into the body 13 . Loading is performed by releasing the screwing of the body 13 and the leading tool 12 , and after connecting the cartridge case 30 to the pipe holder 28 of the leading tool 12 , inserting the cartridge 16 into the body 13 from the opening at the tip end of the body 13 , which is opened, and screwing the leading tool 12 into the body 13 again (see FIG. 2 ). On the occasion of this screwing, the cartridge 16 is inserted until it abuts to the annular step portion 13 a of the body 13 as the cartridge 16 is rotating with the leading tool 12 . The chuck 36 provided at the cartridge case 30 is inserted into the small diameter portion 13 b of the body 13 , the protrusions 36 b of the chuck 36 are pressed by the small diameter portion 13 b and compress the notches 36 c to reduce the inner diameter of the rear end portion of the chuck 36 . While the chuck 36 is rotating, its female thread 36 d is screwed into the male thread 17 a of the piston rod 17 .
When the cartridge type liquid feeding container 10 is used, the cap 19 is removed, and the liquid can be applied on a desired portion with the brush 24 . When the amount of liquid supplied from the brush 24 becomes scarce, the manipulating body 14 is rotated in a predetermined direction with respect to the body 13 . Then, the piston rod 17 integrally rotating with the manipulating body 14 rotates, and the cartridge 16 is integrated with the body 13 , whereby the piston rod 17 screwed into the chuck 36 of the cartridge 16 moves forward inside the body 13 . The tip end portion of the piston rod 17 is fitted into the receiving recessed portion 34 a of the piston 34 to push the piston 34 forward, whereby the liquid L inside the tank portion 32 is pushed out to the brush 24 via the pipe holder 28 , and is applied onto the surface to be coated from the brush 24 .
In this manner, as the liquid is used, the piston rod 17 moves forward in the cartridge case 30 and in the body 13 , and the piston 34 slides forward inside the tank portion 32 (see FIG. 3 ). When the liquid is used and the liquid inside the tank portion 32 becomes scarce, and it becomes necessary to replace the cartridge 16 , screwing of the leading tool 12 and the body 13 is released again. When the leading tool 12 is rotated to release the screwing, the cartridge 16 also moves forward while rotating. At this time, the female thread 36 d of the chuck 36 rotates with respect to the male thread 17 a of the piston rod 17 . However, when the protrusions 36 b of the chuck 36 disengage from the small diameter portion 13 b , the inner diameter of the rear end portion of the chuck 36 returns to the original natural state. Therefore, the female thread 36 d is not screwed onto the male thread 17 a any more, the screwing is loosened, the piston rod 17 is released from the cartridge 16 , and therefore the piston rod 17 is returned rearward by the spring force of the spring 18 to return automatically to the initial state.
After the leading tool 12 and the body 13 are separated from each other, the old cartridge 16 is removed from the leading tool 12 , then a new cartridge 16 is connected to the leading tool 12 , and this new cartridge 16 is loaded into the body 13 again, whereby the new cartridge can be used similarly to the above. In this manner, the liquid can be refilled or replaced-without throwing away the components of the liquid feeding container 10 such as the leading tool 12 , the body 13 , the manipulating body 14 and the like other than the cartridge.
Not only the cartridge 16 but also the leading tool 12 can be replaced. For example, when the kind of the liquid is changed, the cartridge inclusive the leading tool 12 is replaced, whereby the leading tool 12 including the brush 24 can be replaced.
FIG. 8 is a view showing a second embodiment of the present invention. In the drawing, the same members as in the first embodiment are given the same reference numerals and characters, and the detailed explanation thereof will be omitted.
This embodiment differs from the first embodiment in the point that a C-type chuck is used in this embodiment instead of the vertical type chuck used as a chuck in the first embodiment, and in the other points than this, the second embodiment is approximately the same as the first embodiment.
As shown in FIGS. 10A and 10B and FIGS. 11A and 11B , a pair of upper and lower protrusions 38 b formed at a rear end of the C-type chuck 38 to project in an outer diameter direction are fitted into a pair of upper and lower notches 30 b formed at the rear end of the cartridge case 30 and locked. On the peripheral surface of the chuck 38 , a slit 38 c extending in the axial direction is formed in a portion where the protrusions 38 b are not formed, and thus the cross-section of the chuck 38 is formed into the C-shape. On an inner peripheral surface of the rear end portion of the chuck 38 , a female thread 38 d is formed at a portion where the slit 38 c is not formed. The slit 38 c is compressed, whereby the female thread 38 d of the chuck 38 is capable of being reduced in the diameter in the radial direction. The outline of the chuck 38 including the slit 38 c is not limited to a circular shape, but may be an elliptical shape.
A thread engagement of the male thread 17 a of the piston rod 17 and the female thread 38 d of the chuck 38 constructs a conversion mechanism for advancing the piston rod 17 .
In the case of the cartridge 16 provided with such a chuck 38 , when the cartridge 16 is loaded into the body 13 (see FIG. 9 ), the chuck 38 is inserted into the small diameter portion 13 b of the body 13 , the protrusions 38 b of the chuck 38 are pressed by the small diameter portion 13 b to compress the slit 38 c , the inner diameter of the chuck 38 is reduced, and the female thread 38 d is screwed onto the male thread 17 a of the piston rod 17 while the chuck 38 is rotating ( FIG. 8 ).
On the other hand, when it is necessary to replace the cartridge 16 , then the screwing of the leading tool 12 and the body 13 is released, and the leading tool 12 is rotated, the cartridge 16 also moves forward while rotating. At this time, the female thread 38 d of the chuck 38 is rotated with respect to the male thread 17 a of the piston rod 17 , but when the protrusions 38 b of the chuck 38 are disengaged from the small diameter portion 13 b , the inner diameter of the rear end portion of the chuck 36 returns into the original natural state, and therefore the female thread 38 d is not screwed onto the male thread 17 a any more, thus loosening the screwing, and releasing the piston rod 17 from the cartridge 16 . Therefore, the piston rod 17 is returned rearward by the spring force of the spring 18 and automatically returns into the initial state.
Thus, the second embodiment can be operated similarly to the first embodiment.
FIG. 12 is a view showing a third embodiment of the present invention. In the drawing, the same members as in the first embodiment are given the same reference numerals and characters, and the detailed explanation will be omitted.
This embodiment differs from the previous embodiments in the point that the manipulating body is not mounted to the rear end portion of the body, but a leading tool 42 mounted to a tip end portion of a body 43 serves as the manipulating body.
Namely, the leading tool 42 is provided with the brush 24 as the liquid supplying body for coating the liquid, the tip end pipe 26 for flowing the liquid to the brush 24 , the pipe holder 28 which is fixed inside the leading tool 42 and fixes the brush 24 and the tip end pipe 26 to the leading tool 42 . Further, on an inner peripheral surface of the leading tool 42 , a plurality of longitudinal ribs 12 a (see FIG. 12 ) extending in the axial direction are formed at the rear from the pipe holder 28 .
A rear end portion of the leading tool 42 is inserted into and fitted into a tip end portion of the body 43 to be attachable and detachable. After fitting, the leading tool 42 and the body 43 are connected to each other to be relatively rotatable. A stopper 44 is fixed in a central portion inside the body 43 , and the piston rod 17 penetrates through a center hole of the stopper 44 . A portion inside the body 43 , which is in the front from the stopper 44 becomes the space into which the cartridge 16 is inserted. The portion of the body 43 just in front of the stopper 44 becomes a small diameter portion 43 b , and the small diameter portion 43 b has the smaller inner diameter than the portion on the front side from the small diameter portion 43 b . At the rear portion from the stopper 44 of the body 43 , a plurality of longitudinal ribs 43 a extending in the axial direction are formed on its inner peripheral surface, the longitudinal ribs 17 b are fitted in between the longitudinal ribs 43 a , and thereby the piston rod 17 rotates integrally with the body 43 . An inner peripheral surface inside the body 43 may be in the polygonal shape, and the rear end portion of the piston rod 17 may be in a polygonal shape fitted to this.
In the cartridge type liquid feeding container 10 constructed as above, an operation thereof will be explained. First, the cartridge 16 is loaded into the body 43 . Loading is performed by releasing the connection of the body 43 and the leading tool 42 , and after connecting the cartridge case 30 to the pipe holder 28 of the leading tool 42 , inserting the cartridge 16 into the body 43 from the opening at the opened tip end of the body 43 and connecting the leading tool 42 to the body 43 again (see FIG. 13 ). At this time, the cartridge 16 is inserted until the cartridge 16 abuts to the stopper 44 fixed in the body 43 . The chuck 36 provided on the cartridge case 30 is inserted into the small diameter portion 43 b of the body 43 , the protrusions 36 b of the chuck 36 are pressed by the small diameter portion 43 b to compress the notches 36 c and the inner diameter of the rear end portion of the chuck 36 is reduced. The female thread 36 d is screwed into the male thread 17 a of the piston rod 17 while the leading tool 42 and the chuck 36 are being rotated.
When the cartridge type liquid feeding container 10 is used, the cap 19 is removed, and the liquid can be applied on a desired portion with the brush 24 . When the liquid supplied from the brush 24 becomes scarce, the leading tool 42 is rotated in a predetermined direction with respect to the body 43 . Then, the cartridge 16 which rotates integrally with the leading tool 42 rotates, while the piston rod 17 is incapable of rotating with respect to the body 43 , and therefore the piston rod 17 moves forward inside the body 43 while being screwed into the chuck 36 of the cartridge 16 . The tip end portion of the piston rod 17 is fitted into the receiving recessed portion 34 a of the piston 34 to push out the piston 34 forward, and therefore the liquid inside the tank portion 32 is pushed out to the brush 24 via the pipe holder 28 to be coated on the surface to be coated from the brush 24 .
In this manner, as the liquid is used, the piston rod 17 moves forward in the cartridge case 30 and the body 43 , and the piston 34 slides forward in the tank portion 32 . When the liquid is used up and the liquid inside the tank portion 32 has run out, and it is necessary to replace the cartridge 16 , the connection of the leading tool 42 and the body 43 is released again. On releasing the connection, when the leading tool 42 is pulled out while rotating, the cartridge 16 also moves forward while rotating. At this time, the female screw 36 d of the chuck 36 rotates with respect to the male screw 17 a of the piston rod 17 , but when the protrusions 36 b of the chuck 36 disengage from the small diameter portion 43 b , the inner diameter of the rear end portion of the chuck 36 returns to the original natural state. Therefore, the female thread 36 d is not screwed onto the male thread 17 a , screwing is loosened, the piston rod 17 is released from the cartridge 16 , and therefore the piston rod 17 is returned rearward by the spring force of the spring 18 and automatically returns into the initial state.
After the leading tool 42 and the body 43 are separated from each other, the old cartridge 16 is disengaged from the leading tool 42 , a new cartridge 16 is connected to the leading tool 42 , and the new cartridge 16 is loaded into the body 43 , whereby the liquid feeding container can be used similarly to the above. In this manner, the liquid can be refilled or replaced without throwing away the components of the liquid feeding container 10 such as the leading tool 42 and the body 43 other than the cartridge.
Not only the cartridge 16 , but also the leading tool 42 can be replaced. For example, when the kind of the liquid is changed, if the leading tool 42 including the cartridge 16 is replaced, the leading tool 42 including the brush 24 can be replaced.
In each of the above embodiments, the member constructed by the single member can be constructed by a plurality of members, and the member constructed by a plurality of members can be constructed by a single member.
While the principles of the invention have been described above in connection with specific embodiments, and particular modifications thereof, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of invention. | A cartridge type liquid feeding container is capable of being used by refilling or replacing a liquid instead of throwing away the container itself, and can feed out the liquid inside the cartridge.
The liquid feeding container includes a body, a manipulating body which is mounted movable with respect to the body and is made capable of being manipulated from an outside, a cartridge which is loaded into the body so as to be attachable and detachable, a liquid supplying body for supplying the liquid inside the tank portion to the outside, a piston rod which is workable on the piston to press the piston of the cartridge forward, and movable inside the cartridge case and body, and a conversion mechanism for converting a manipulating force applied to the manipulating body into forward movement of the piston rod. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to devices and methods for facilitating intravenous access, and in particular to such devices and methods utilizing various combinations of vacuum, heat and tactile stimulation to dilate peripheral veins and thereby to facilitate their identification for blood sampling or cannulation. Other applications of the present invention, however, are also possible, and are within the scope of what the inventor regards as his invention.
2. Related Background Art
Peripheral intravenous access plays an integral role in treatment of patients with both critical and non-critical conditions. It is routinely accomplished by application of a tourniquet to an extremity with enough pressure to occlude venous drainage, but not arterial inflow, thereby causing dilation of veins distal to the tourniquet. Once a dilated vessel is identified, a cannula is inserted percutaneously. Not infrequently, underlying physiologic states including, but not limited to, dehydration, shock from blood loss or redistribution of blood volume, hypothermia, and even anxiety cause peripheral vasoconstriction by neuroendocrine pathways. This vasoconstriction often impedes the normal venous dilation when a tourniquet is applied, making intravenous access problematic. At this point, medical specialists will often apply heat or tactile stimulation, or place the extremity lower than the heart in an attempt to improve peripheral blood flow and overcome vasoconstriction. More central access, with its greater inherent risk to the patient, is often needed if these efforts fail.
Various efforts have been made to ameliorate these problems. U.S. Pat. No. 4,299,219 (Norris, Jr.) relates to a device to dilate peripheral veins at the site of application of the device. Suction from the device is created by an operator-activated plunger. The utility of the device appears to be limited by at least two factors: (1) its usefulness presupposes that a target vein can be identified prior to application of the device; and (2) the device only causes a small area of venodilation, which will rapidly collapse on needle entry.
U.S. Pat. No. 4,747,409 (Silen) relates to a sleeve with heating elements used to enwrap a distal extremity for the purpose of warming, thereby enhancing arterial blood flow. This device would seem to have limited ability to counteract vasoconstriction on the venous side of the circulation.
U.S. Pat. No. 5,074,285 (Wright) relates to one of a number of known devices for applying a thermal environment to an extremity in the hope of achieving various therapeutic effects. An extremity is placed within a stocking that has pockets placed along its length. Thermal elements are then placed in one or more of the pockets, with the intent of applying heat or cold at one or more specified sites along the extremity. This device also incorporates a series of compartments placed along the length of a tubular body that encases the extremity and stocking with the purpose of applying a pressure gradient along the length of the tubular body. The sequenced pressure gradient is used primarily in treating lymphatic or venous stasis problems in extremities requiring thermal therapy.
U.S. Pat. No. 5,441,477 (Hargest) relates to an apparatus combining electrotherapy and the massaging action of a thermally energized fluidized bed for treating injured extremities. (Other patents also relate to the use of a fluidized bed for massaging a part of a body, with or without heating or cooling, e.g., U.S. Pat. No. 4,214,576 (Henley).)
U.S. Pat. No. 5,683,438 (Grahn) relates to a device that combines a heat source with a sustained vacuum to dilate superficial capillary beds with the intent of treating hypothermia.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide a device and method that enable reliable dilation of veins and their subsequent identification and access for venipuncture or the like.
According to one aspect of the present invention, this object is attained by providing a device which includes a chamber having an interior for receiving a portion of a body, and having at least one inlet for admitting a fluid into the chamber. A fluid supply is connected to the inlet to enable the fluid to be admitted into the chamber. A heater is positioned so as to be able to heat the fluid being supplied to the chamber by the fluid supply. A suction source is connected to the chamber in such manner as to enable application of suction to the interior of the chamber. The chamber may contain particulate matter such that supply of the fluid into the chamber produces a fluidized bed. The chamber preferably contains a partition or sleeve that divides the chamber into two portions, one of which receives an extremity of a patient's body while the other receives the fluid.
Another aspect of the invention is a method of vasodilation, in which a portion of a body is heated (for example, by means of a fluidized bed), and a vacuum is applied to the portion of the body for a period of time after performance of the heating step. In one embodiment, the heating step may also include massaging of the portion of the body.
These and other objects, features and advantages of the present invention will be more fully appreciated from a consideration of the following detailed description of the preferred embodiments, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a preferred embodiment of an apparatus according to the present invention.
FIG. 2 is a schematic view of the embodiment of FIG. 1, showing more clearly the functional relation of its components.
FIG. 3 is a cross-sectional view of a portion of the embodiment of FIG. 1 .
FIG. 4 is a flowchart illustrating a method of using the embodiment of FIG. 1, in accordance with the invention.
FIG. 5 is a view, partly in section, of another preferred embodiment of an apparatus according to the present invention.
FIG. 6 is a flowchart illustrating a method of using the embodiment of FIG. 5, in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the embodiment shown in FIG. 1, apparatus 100 includes a cabinet 102 mounted on a cart 104 for mobility (in the version illustrated, the cart 104 is a platform on wheels or castors). Also disposed on the cart 104 is a tubular assembly 106 , which is shown as being mounted on the side of the cabinet 102 . A control panel 108 is on the top of the cabinet 102 .
As shown in detail in FIGS. 2 and 3, the tubular assembly 106 has a cylindrical housing or outer shell 110 , and a cuff 112 of latex rubber mounted airtightly at the upper end of the housing 110 . The upper end 114 of the cuff 112 is open, and is of a size suitable for receiving a portion of a patient's body, typically an arm or a leg. The upper, free end 114 of the cuff 112 is provided with a tourniquet arrangement 116 or the like that permits the formation and maintenance of an airtight seal about the periphery of the portion of the patient's body extending into the chamber defined by the interior of the housing 110 . In the embodiment shown, the cuff 112 is attached to the cylindrical housing 110 by a clamp assembly 118 . The clamp assembly 118 also airtightly secures a tubular plastic barrier or partition 120 in the form of a sleeve, closed at its lower end 122 , which is disposed inside the cylindrical housing 110 , and open at its upper end 124 . In use, the interior of this sleeve or barrier 120 receives a portion of the patient's body.
The tubular housing 110 also may contain a mass of particulate material 126 , such as plastic or glass beads, capable of being made into a fluidized bed by the introduction of a sufficient stream of a gas. This particulate material 126 is between the tubular housing 110 and the sleeve 120 , and is separated by the latter from the open end of the housing 110 . At the bottom end of the tubular housing 110 is a fixture 128 via which a gas, such as air, can be introduced to fluidize the particulate material 126 .
In addition, the tubular housing 110 is provided in this embodiment with a suitable number of (one or more) one-way ventholes or valves 130 , which can advantageously be perforations in the sleeve 120 , each covered with its own small flap of material (which may advantageously be similar or identical to the material of the sleeve itself). These valves permit fluid to leave the tubular housing 110 during fluidization of the particulate matter 126 .
As can be seen from FIG. 2, the gas supply fixture 128 at the bottom of the tubular housing 110 is connected to both a blower and a vacuum pump. (These can be the same element 132 , as illustrated, since neither the quantity or force of the stream of blown air, nor the suction required to operate the apparatus in the intended manner, is particularly great, and it is not necessary to produce a vacuum at the same time as a stream of blown air is being provided; even though a single pneumatic unit of this type is shown, and is within the scope of the invention, however, reference will be made herein to a “blower” and a “vacuum pump”, for simplicity.) When the blower 132 is operating to supply air to the tubular housing 110 to fluidize the particulate matter 126 , the control unit 134 receives a signal from a heat sensor, preferably a thermistor (not shown), located at an appropriate position, and uses a feedback loop to control a heating element 136 located in the gas supply line 138 leading from the blower 132 to the tubular housing 110 , to maintain the blown air at a desired temperature. Preferably, this temperature can be selected by the physician within some limits.
The operation of this apparatus according to the method of the present invention is as follows.
A portion of a patient's body, such as an arm or a leg, is inserted through the open end 114 of the cuff 112 into the interior of the sleeve 120 , and the tourniquet assembly 116 is used to seal the cuff 112 airtightly against the patient's skin. The blower 132 is actuated, as is the heating element 136 in the gas supply line 138 , thus providing a flow of warmed gas (air, in the embodiment of FIG. 1) into the tubular housing 110 . This supply of gas is delivered under conditions suitable to fluidize the particulate material 126 (if any) in the tubular housing 110 , producing (in such case) a fluidized bed in the latter. Motion of the particles in the fluidized bed is transmitted through the sleeve 120 to the patient's skin, providing a massaging action to the latter (in the absence of particulate material, there is simply a pressure on the skin due to the inflow of the gas). At the same time, the warmth of the gas heats the patient's limb.
After a predetermined length of time, the control unit 134 turns off both the heating element 136 and the blower 132 , and actuates the vacuum pump 132 . (Where, as shown, the blower and vacuum pump are the same element 132 , this action involves simply the deactivation of the heating element 136 and the reversal of direction of the action of the pneumatic unit 132 ). A weak vacuum is then drawn on the interior of the tubular housing 110 . This suction forces the one-way valve(s) 130 closed. Because of this, and because the patient's limb is airtightly sealed in the opening of the cuff by the tourniquet assembly 116 , the air pressure in the interior of the sleeve 120 is also reduced below ambient atmospheric pressure, thus applying a mild suction to the patient's skin. The fluidized bed action (if provided) suffices to drive some air our through the cuff 112 even through the otherwise airtight seal. (It is nonetheless within the scope of the invention for the sleeve 120 to be elastic enough to distend in response to the drop in pressure, rather than air being forced out through the seal.) The inventor has found that this combination of mild pressurization with heating, followed by mild suction, produces an advantageous and unexpectedly effective vasodilation in the portion of the patient's body so treated. In the case where a fluidized bed is used, the massaging action also contributes to this effect.
The exact length of time for each phase can be controlled automatically, or can be varied by the attending physician as deemed appropriate for the particular patient. A time of a few minutes for each phase may be appropriate. The air may usefully be heated to about 102-104° F. during the heating and massaging phase, and the vacuum drawn during the following phase may be on the order of 2 psi, although this value may be suitably varied by as much as 50% in either direction.
One manner of operation of the embodiment of FIGS. 1-3 is illustrated in the flowchart of FIG. 4 . As is shown there, in step S 101 , the portion of the patient's body to be treated (for example, an arm) is placed in the chamber inside the sleeve 120 , and an airtight seal between the cuff 112 and the arm is effected. Then, in step S 102 , the heater 136 and the blower 132 are activated, resulting in the fluidization of the particles 126 (if such are provided) in the housing 110 , and in the delivery of both pressure and heat to the arm, with a massaging effect if particles 126 are used. After the passage of a predetermined amount of time during which the arm is subjected to this action, the heater 136 is turned off and the direction of action of the blower 132 is reversed (step S 103 ), to pull a slight vacuum on the air in the housing 110 . Since this reduces the air pressure in the sleeve 120 as well, the arm is also subjected to the slight vacuum. This condition is also maintained for a predetermined length of time, which may or may not be the same length as the duration of the warming treatment, and is then terminated. After this, the patient's arm may be withdrawn from the apparatus to see if an appropriate site for venipuncture now exists. If the attending physician deems it appropriate, the process, including steps S 101 -S 103 , may be repeated.
FIG. 5 illustrates a second preferred embodiment 200 of the invention, in which the fluidized bed optionally provided in of the first embodiment 100 is eliminated. In this embodiment, a rigid or semi-rigid outer shell 202 is provided, which contains a flexible, heat-permeable inner liner 204 and has a flexible flange 206 at one end. Gaskets (not shown) attach the flange 206 and the inner liner 204 airtightly to the shell 202 . The shell 202 is sufficiently rigid to maintain its shape even in the presence of a small pressure differential across its thickness, such as a differential of 2 psi. The inner liner 204 , in contrast, is preferably so light that it will collapse under any significant pressure differential at all (many plastics may be suitable for use as the liner).
The shell 202 has an inlet 208 and an outlet 210 for a fluid, which in this preferred embodiment is water. A pressure-relief valve 212 is provided in one wall of the shell 202 , and is constructed to open to allow ambient air into the shell 202 whenever the pressure inside the shell 20 is less than ambient pressure by more than a predetermined amount (say, 80 mm of Hg). Also, toward the top of the shell 202 is provided a fluid-level detector 214 , to detect when the level of water in the shell 202 has reached the position of the detector 214 , and to send a signal to that effect to a control unit 216 in response to such detection. One simple construction (not shown) of such a detector may be a wire cage provided on the interior of the shell 202 , with an electrically conductive float that, upon the water level rising sufficiently, moves into conductive contact with two electrical terminals or contacts to complete an electrical circuit, thereby to allow emission of an electrical signal to the control unit. Other constructions, within the reach of those of ordinary skill, can be used instead. The power for such signal may be provided either by battery at the shell 202 , or be supplied from elsewhere.
A reservoir 218 of water is provided, the interior of which communicates via two lines 220 and 222 with two pumps 224 and 226 , which may preferably be roller pumps. Each of these pumps 224 and 226 communicates via a respective second line 228 and 230 with either the inlet 208 or the outlet 210 , respectively, at the shell 202 . Each pump 224 and 226 is controlled by a respective pump regulator 232 and 234 .
The control unit 216 is preferably located in a cabinet 236 together with the pumps 224 and 226 and the water reservoir 218 . Also, a heating device 238 is provided in the reservoir 218 , under control of a temperature regulator such as a thermostat 240 , to maintain the contents of the reservoir 218 at a desired temperature.
In operation, the second embodiment 200 of the invention is used as follows. First, the portion of the patient's body to be treated, for example, an arm, is placed through the flexible flange 206 and into the flexible liner 204 (step S 201 ), and an airtight seal against the skin is achieved. The inflow pump 224 is then started, under control of the control unit 216 (step S 202 ). (More exactly, the operator actuates an external switch, responsive to which the control unit 216 emits necessary signals to activate the inflow pump 224 .) Preheated water from the reservoir 218 is pumped through the inflow conduit 228 , through the inlet 208 and into the space 242 between the shell 202 and the liner 204 . Ordinarily, at the beginning of the process, the liner 204 should preferably lie very close against the inner wall of the shell 202 , and consequently, the water is being pumped into a space 242 containing little or no air. As this occurs, the pressure due to the presence of the heated water raises the air pressure in the liner 204 sufficiently to force air out of the liner 204 , passing between the arm and the flange 206 (naturally, the seal of the flange against the patient's skin must not be so tight as to prevent this). Alternatively, if desired, a one-way valve could be provided for this purpose, but is not believed to be necessary as a practical matter. As the water rises, it eventually activates the level detector 214 , which emits a signal that causes the control unit 216 to activate the outflow pump 226 as well (step S 203 ).
Thus, in this portion of the process, the arm is subjected to a slightly elevated pressure, and is warmed by the heated water.
Once both pumps 224 and 226 are working, the water is pumped in and out of the shell 202 at a constant rate, maintaining the arm or other portion of the body in a steady condition for a predetermined time, under control of the control unit 216 . (Alternatively, the duration of this portion of the process could be left to manual control by the operator.) Then, the inflow pump 224 is stopped, while the outflow pump 226 continues to operate, and evacuates the water from between the shell 202 and the liner 204 (step S 204 ). This evacuation of the water reduces the pressure of the air remaining inside the liner 204 . The relief valve 212 , however, ensures that the pressure inside the shell 202 (and inside the liner 204 ) does not fall more than a preset amount below ambient atmospheric pressure. In this preferred embodiment, this preset amount or limit is equal to 80 mm of Hg.
This reduction of pressure also results in the flexible flange 206 being forced, by atmospheric pressure, still more tightly against the arm. (If desired, a strap with Velcro (TM) or other fasteners can be used to make this seal still tighter.) At the proper time, the outflow pump 226 is stopped (step S 205 ). Again, this time can be preset in the control unit 216 , or the operation of the outflow pump 226 can be stopped by the operator manually. A tourniquet is now placed on the arm, the seal of the flange 206 around the arm is broken, and the patient's arm is removed for venipuncture, intravenous access or the like.
Many variations of the foregoing methods and apparatus are possible without departing from the scope of what the inventors consider to be their invention, broadly construed. For instance, in the first embodiment, instead of one-way valves on the surface of the sleeve or barrier, such valves may instead be provided in a portion (or all) of the lateral surface of the tubular housing. In such case, the heating of the patient's skin is achieved by the conduction of heat through the material of the sleeve, whereas in the arrangement shown, the warming of the skin is partly the result of convection. Also, in all embodiments, the sleeve that receives the limb or other portion of the patient's body may be disposable if for any reason that is desirable. Again, while it is contemplated to provide such sleeve (whether disposable or not), the benefits of the invention may be derived even if no such sleeve is present (at least where no particulate material is used to generate a fluidized bed).
Again, particularly (but not only) in the second embodiment, the inflow pump could be controlled in such fashion as to provide a pulsating action, to provide the limb with a massaging action, as in the first embodiment. Such pulsation could be delivered during part or all of the treatment.
Also, the arrangement of the components on and in the cart 104 may be varied in any convenient manner. One useful variation may be to mount the tubular housing such that its position and orientation can be varied according to convenience. Again, the apparatus need not be mounted on a cart at all. For example, it could be mounted on the wall of a room, or mounted to the interior of an ambulance or the like, or could be constructed to be detachably mountable to a bed, or could be provided without a permanent mounting.
It is also to be understood that the method of the invention, although described above with reference to two preferred embodiments of the apparatus of the invention, could be performed with other, quite different apparatus. Such use of other apparatus to perform the method of the invention, as set out hereafter in the claims, is also within the scope of the invention, with whatever apparatus it may be performed.
As discussed above, with regard to the first embodiment, the blower and suction unit can be separate units or a combined unit having both functions. As a further variation, it is contemplated to use separate units for the blower and the suction source, and in particular to use as the blower a unit such as those conventionally used to provide heated air to a patient covered with a plastic blanket (such arrangements are used conventionally to prevent hypothermia during or after surgery, for example). In this variation, an adapter is provided to fit such blower, the suction source and the tubular assembly containing the chamber to which both suction and blown air are applied. One example of a structure for such an adapter might be a three-way connector made of polyvinyl chloride tubing, or the like. In this variation, or embodiment, also, the tubular assembly can if desired contain particulate matter, so as to utilize a fluidized bed as in the first embodiment, or the particulate material can be omitted. In any event, the successive steps involving the supply of heated fluid (in this case, air) to the chamber followed by application of suction after termination of the supply of heated fluid, may be performed as with the other structures described herein.
Again, while it is most preferably conceived that the invention will be used by insertion of a limb of a patient into the sleeve, the apparatus may be constructed on any scale desired. For example, the sleeve could be constructed large enough to receive the entire lower portion of a patient's body, including part or even the entire torso, and used to stimulate blood flow over a large portion of the body.
Finally, while it is contemplated that the present invention will be used with human patients, veterinary use is also within the scope of the invention.
While the present invention has been described with specific reference to the presently preferred embodiments and variations thereof, which constitute the inventor's best contemplated mode of practicing the invention, many additional modifications and variations thereof will now be readily apparent to those of skill in the art. Accordingly, it is to be understood that the scope of the present invention is to be limited, not by the details of the foregoing illustrative embodiments, but only by the terms of the appended claims. | A device suitable for vein dilation includes a chamber having an interior for receiving a portion of a body, and having at least one inlet for admitting a fluid into the chamber. A fluid supply is connected to that inlet to enable the fluid to be admitted into the chamber. A suction source is connected to the chamber such as to be able to apply suction to the interior of the chamber, and a heater is positioned to be able to heat the fluid being supplied to the chamber by the fluid supply. In use, a portion of a body may be massaged and heated (one possibility is to use a fluidized bed formed in the chamber while the body portion is in the chamber), and a vacuum is applied to the portion of the body after performance of the massaging and heating step. Alternatively, the massaging may be omitted, and the body portion heated first and then subjected to a period of suction. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates generally to a perfectly registered substrate product and its novel method of manufacture. Specifically, this invention relates to a novel cutting method used to create advertising, media, and other products made out of different substrate materials that have registered color and graphics, and the resulting products. More specifically, this invention relates to a novel method for processing a continuous web or individual sheets of substrate using “kiss cutting” to generate multiple page advertising brochures, magazine inserts, direct mail pieces, fliers, games, and the like, and the products generated by the method.
BACKGROUND OF THE INVENTION
[0002] Advertising brochures and fliers are well-established media for advertising goods and services. An essential attribute of such media is that it must attract and hold a viewing person's attention. These printed publications must therefore be visually attractive and aesthetically appealing.
[0003] One particular type of advertising brochure, sometimes called a gatefold, has one or more pages that can be opened by the viewer, in the manner of book pages, to reveal printed matter inside, previously covered by the pages and therefore unseen. The unopened pages may also have printed matter on their top-side, and a cut, allowing the pages to be opened. To ensure visual attractiveness this top-side printed matter must be properly “registered” on both sides of the cut. Any misalignment or change of color from one side of the cut to the other will detract from the aesthetic appeal of the brochure, thereby diminishing its advertising effectiveness.
[0004] A solution to this registration problem is to first complete the printing or other patterning of a substrate material, such as paper, MYLAR®, plastic, plastic film, foil or fabric, and then form the openable pages through a combination of folding the substrate, attaching one segment of the substrate to another segment, and cutting some layers of the substrate, with the cut or cuts slicing through the patterning. If the various pieces of the substrate formed by the cuts cannot move relative to each other after the cuts are made, then the desired registration across the cuts is guaranteed by construction.
[0005] Different pieces of the substrate remain fixed relative to each other if the cuts are carefully made only in some layers of the substrate and not in others. One method for accomplishing this is known as “kiss cutting.” In this method, the substrate is configured as a stack of sheets on top of each other, and only the sheet or sheets nearest one side of the stack are cut, leaving other sheets above or below them uncut. This type of cutting can be accomplished, for example, mechanically or optically. Mechanical kiss cutting is done by a die, slitting wheel, knife, or other device or devices with one or more sharp edges. Optical kiss cutting is performed using a laser or other optical device.
[0006] Current systems use kiss-cutting in processes for cutting smaller paper or substrate pieces out of larger sections of paper or substrate. For example, European patent EP 0 525 530 B1 to Bootman discloses a method of making perfume-containing pouches for inclusion in magazine advertisements. The individual pouches are separated from a web by kiss-cutting. The pouches can be decorated with artwork designed to match already existing artwork on the magazine page. The kiss-cutting, however, plays no role in this matching other than to define the individual pouches. U.S. Pat. No. 5,953,885 to Berman et al discloses a method of making multiple cosmetic samplers from a web of substrate material. The method involves folding the web and kiss-cutting to define the individual samplers. U.S. Patent Application Publication US 2002/0096241 A1 to Instance discloses a method of producing self-adhesive labels. The labels are separated on a web by cutting only through a top substrate layer, leaving a bottom backing layer uncut.
[0007] An object of the present invention is the novel application of kiss-cutting to the mass production of patterned substrates for the purpose of maintaining registration of the pattern across the cut or cuts, as described above. A further object of the present invention is to simplify the separation of the web into the individual products.
[0008] Previously known methods of producing such properly registered substrates tend to be more cumbersome, time-consuming, and wasteful of material; hence potentially more expensive. For example, U.S. Pat. Nos. 5,769,773 and 5,938,243 to DeSanto disclose a method for manufacturing advertising brochures from a continuous paper web and the resulting paper products. DeSanto's method provides for cutting the web longitudinally at designated intervals, then folding the web over to create brochures with a continuous back page and a front page with a slit in it, such that consumers may open the brochure to access the advertising material inside. The folding step occurs after the slitting step, which may increase the risk of misaligning the top pages of the resulting product brochures and affect the printing registration.
[0009] In addition, this and other existing methods for creating advertising and other media paper products make only intermittent cuts to create the gatefold products, thereby leaving “margins” on the individual products that must be cut off. This adds additional steps and machinery to the methods, increasing manufacturing time and expense. In the DeSanto patents, for example, while the web is still substantially intact, the individual paper products are, by mechanical necessity, joined by uncut strips at the top and bottom, extending across the entire width of the web. In order to complete and properly separate the individual products along the web, these strips must be completely removed; otherwise the pages cannot be opened. This requires at least two carefully positioned transverse cuts by at least two independent knives, and creates wasted substrate material.
[0010] By contrast, the kiss cuts of the present invention are made after the folding step, and are therefore more likely to preserve the alignment of the pattern across these cuts. Furthermore, these kiss cuts are continuous along substantially the entire length of the web or individual sheets of substrate, but not through the entire thickness of the substrate. The substrate therefore remains intact without the need for top and bottom margins. The individual products can then be separated with one transverse cut at the top and at the bottom using a single knife or other cutting device—according to this embodiment of the present invention, the process is simplified and the amount of wasted substrate material is reduced. Alternatively, two or more knives can be used if additional material must be removed between each product, or at the top and/or bottom of each product, in order to meet customer demands.
SUMMARY
[0011] The present invention provides a novel method of manufacturing advertising brochures, magazine inserts, and other related paper products from a continuous web, or one or more individual sheets of substrate, using kiss-cutting to create multiple advertising or printed surfaces. The method eliminates the problem of imperfect registration, thereby providing a product with the highest standard of printing quality for advertising, marketing, direct mail, and other printed materials.
[0012] According to one aspect of the present invention, a continuous web or one or more individual sheets of substrate is printed, on one or both sides. The substrate is any material capable of receiving and retaining print, and the print can be either in color or black and white or a combination thereof. Substrates according to the present invention include paper, MYLAR®, plastic, plastic film, fabric, and metal foils. The substrate is also optionally coated with one or more coatings, including but not limited to fragrances, including fragrance oils, varnish, latex, including latex “scratch-off” materials, sublimation and other inks, and cosmetics, such as eye shadow, blush, lip gloss, lipstick, etc. It will be obvious to one of skill in the art that many types of substrates can be printed upon and are therefore contemplated by the present invention and many different coatings can be applied to various substrates, such that the present invention is therefore not limited to the previous lists.
[0013] The substrate, whether in continuous web or individual sheet form, is mechanically displaced in one or more places to create two or multiple layers, the layers sitting on top of one bottom layer. Mechanical displacement can be folding, ribboning, or any other method of displacing a segment of the substrate to create two or more layers. One or several of the top layer(s) of the substrate is then longitudinally “kiss cut” in the same direction that the substrate is traveling as it is being processed. As many layers as are required are cut through, leaving at least the bottom layer uncut. The process can be adjusted so that the required number of layers are “kiss cut” according to customer specifications for the final desired substrate product. Mechanical displacement can occur before or after any desired coatings are applied to the substrate.
[0014] Importantly, the “kiss cut” method slits at least one layer of substrate after the substrate has been printed upon and after the paper has been displaced into the required format for the final product. According to an alternative embodiment, additional mechanical displacement of one or more segments of the substrate may occur after the substrate has been kiss cut. The “kiss cut” advantageously provides perfect or near-perfect registration of printing color and graphics.
[0015] According to an aspect of the present invention, “kiss cutting” occurs by mechanical or optical cutting. Mechanical cutting can occur by a die, slitting wheel, knife, or other mechanical cutting method known to those of skill in the art. Optical cutting can occur by laser or other optical cutting method known to those of skill in the art.
[0016] The longitudinal “kiss cut” extends substantially continuously throughout the entire length of the substrate. After the substrate is “kiss cut”, when the substrate is in the form of a continuous web, it can be optionally further processed by transversely cutting the web into individual products at designated intervals. Importantly, each resulting product is free from any “extra” segment or margin due to the fact that the longitudinal “kiss cut” extends substantially the entire length of the web. Thus, the individual products have freely openable segments that provide additional advertising space, and that are created immediately upon transversely cutting the web into individual products without the need to further remove any “extra” segments or margins. Only one transverse cutting device is required to separate the individual products from each other but more than one transverse cutting device can be used.
[0017] According to an alternative embodiment, segments of substrate are removed from one or both ends of each individual product, in order to meet customer specifications, for example, to maintain uncommon bleed color at opposite ends of each product, or to create a particular sized product. In those instances, more than one transverse cutting knife or other device can be used to remove the necessary segment or segments from the individual products.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 depicts the continuous process of the present invention performed on a web of substrate to generate a single gatefold product.
[0019] FIG. 2 depicts the continuous process performed on a web of substrate to generate a double gatefold product.
[0020] FIG. 3 depicts the continuous process performed on a web of substrate to generate a ribboned kiss cut product.
[0021] FIGS. 4A and 4B provide an example of a single gatefold product generated by the claimed method.
[0022] FIGS. 5A and 5B provide an example of a double gatefold product generated by the claimed method.
[0023] FIG. 6 depicts a flow chart of steps of the present invention using individual sheets of substrate to create a single gatefold product.
[0024] FIG. 7 depicts a flow chart of steps of the present invention using individual sheets of substrate to create a double gatefold product.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The product of the present method is generated by the novel “kiss cut” method of the present invention. Frequently, the resulting kiss cut product is an advertising brochure, magazine insert, or other media/informational paper product. Customers requiring improved registration of printing and graphics on their products will select the product and method of the present invention over others that do not provide sufficient registration.
[0026] FIG. 1 illustrates one embodiment of the present invention, using a continuous web 10 of substrate to generate a kiss cut, single gatefold product 50 , which product is illustrated on FIGS. 4A and 4B . It is to be understood that the embodiment illustrated in FIG. 1 and described in the following paragraphs is but one possible embodiment of the invention and is not to be regarded as limiting.
[0027] Referring to FIG. 1 , the substrate issues as a web 10 from a roll 11 . The substrate has graphic areas such as text and/or illustrations, on one or both of the top side 13 and bottom side 15 , respectively, of the web 10 . These graphic areas repeat periodically along substantially the entire length of the web 10 and are created in a pattern-generating process such as printing.
[0028] Referring to FIG. 1 , areas of adhesive 14 (indicated by shading) are applied to the substrate by a roller 16 . These areas of adhesive may be spots, lines, or large areas depending on the nature of the final product. The roller 16 for application of adhesive is only one example of a device contemplated by the present invention for dispensing adhesive. It will be understood by one ordinarily skilled in the art that other devices that dispense adhesive in the necessary quantity and location on the substrate fall within the scope of this invention. Another embodiment, for example, is illustrated on FIG. 2 , which illustrates using a continuous web 10 of substrate to generate kiss cut, double gate fold products 55 , which products are illustrated in FIGS. 5A and 5B . As shown on FIG. 2 , areas of adhesive 14 are dispensed onto one edge of the top side 13 of the substrate using a tubular dispenser 21 .
[0029] As illustrated on both FIGS. 1 and 2 , a segment 18 of the web 10 is displaced transversely and attached to an undisplaced segment 20 . The displaced segment 18 is secured to the undisplaced segment 20 by means of the areas of adhesive 14 . Once secure in this manner, the two segments may be regarded as a top layer, 22 , and a bottom layer, 24 , the displaced segment 18 being joined with at least one other point on the top side 13 of the substrate. FIG. 1 , for example, illustrates joining the displaced segment 18 with the top side 13 over a broad area, as indicated by the use of a wide swath of adhesive 14 on the top side 13 . FIG. 2 , on the other hand, illustrates joining the displaced segment 18 at only a small portion of the top side 13 near one edge 17 such that the edges 17 and 19 of the substrate are joined, as indicated by the use of a smaller swath of adhesive 14 on the substrate.
[0030] Displacement of the substrate occurs mechanically, and the displacement may be in the form of a single fold, as illustrated in FIGS. 1 and 2 , or a “ribbon” of the substrate, as illustrated in FIG. 3 . It will be understood by those ordinarily skilled in the art that mechanical displacement of a web or individual sheets of substrate according to the present invention is not limited to the examples set forth herein, and that the mechanical displacement is carried out by any mechanical device suited to displace the substrate.
[0031] For example, as shown in FIG. 3 , a cutting device 30 continuously cuts the substrate, which subsequently is ribboned using bars 32 that roll the substrate over at least one time to bring the ribboned, displaced segment 34 of the web 10 onto the top side 13 of the substrate. The ribboning cut is performed at any point between the two edges 17 and 19 of the substrate such that the ribboned, displaced segment 34 , which is comprised of one or more segments of substrate, according to this embodiment can be smaller than the top side 13 of the substrate.
[0032] Referring back to FIGS. 1 and 2 , the next step in the process is the selective cutting of the substrate layers, sometimes called a “kiss cut.” In the embodiment illustrated here a cutting device 26 cuts through only the top layer 22 , leaving the bottom layer 24 uncut and fully intact. It is to be understood that the invention is not limited by the number of layers, and that the kiss cut can be made through any number of layers, starting with a layer either on the top side 13 or bottom side 15 of the web 10 . The resulting cut 28 is made continuously through the length of the substrate, in this case, a continuous web. The transverse dotted lines on FIGS. 1 and 2 illustrate the potential size of the final individual products generated according to the present method, such as brochures or other advertising media, however, the resulting cut 28 completely spans the length of each product.
[0033] In the embodiments illustrated in FIGS. 1 and 2 , the cutting device 26 is shown as a die, however it is to be understood that the cutting device 26 is not limited to a die and may also be a rotary cutter, a knife, or an optical cutting device such as a laser. Further, more than one cutting device 26 is contemplated in the current invention, for example, two or more knives in tandem may be used to create the continuous longitudinal slit 28 and two or more cutting devices can be used to create multiple longitudinal slits. An advantage to the use of a cutting die or laser is that the cut may be given an arbitrary shape, thereby allowing a greater variety in the possible forms of the final product. Since the kiss cut or cuts are made only after the substrate has been printed upon, precise registration of the patterns on the left side 36 and the right side 38 of each cut 28 is guaranteed by construction. A support bar, roller or other device 29 is optimally located beneath the web 10 at the location where the web 10 is longitudinally cut, to prevent buckling of the web 10 during this step.
[0034] Referring to FIG. 3 , the kiss cut for the ribboned web is performed using a cutting device 26 such as the die shown in FIG. 3 , and the ribboned, displaced segment 34 is kiss cut, leaving the bottom layer 24 uncut. This enables the design of products different from those illustrated in FIGS. 4A, 4B , 5 A, and 5 B, that can have multiple gatefolds at different locations, for added flexibility and creativity in advertising and media.
[0035] Referring now to FIGS. 1, 2 , and 3 , one or more coatings 25 are optionally applied to the substrate, such as fragrance, latex, varnish, ink, and/or cosmetic products, using an applicator 27 . Ink coatings include various types of ink, such as sublimation, or tattoo ink. Cosmetic products include a wide variety of products such as, but not limited to, eye shadow, eye liner, lip gloss, lipstick, blush, and concealer. The coatings 25 are applied to the substrate in the form of compositions, which are made up of the coatings alone or the coatings subsumed in a binder or other mixture, as necessary for the application of the coatings. For example, fragrance may be applied to the substrate in the form of an oil, to market the fragrance to consumers. Different types of compositions as required for the application of various coatings will be understood by those of ordinary skill in the art to be part of this invention.
[0036] The coating applicator 27 contemplated by the current invention is any type of application device that will apply the required amount of coating(s) to the substrate, depending on the type of substrate and quantity of coating necessary to meet customer specifications. It will be understood by those skilled in the art that the applicator 27 is not limited to the “bottle” or “tube” example depicted in FIGS. 1, 2 , and 3 .
[0037] Referring to any of FIGS. 1, 2 , or 3 , the web 10 can be separated into the individual products. According to this embodiment, a series of single transverse cuts 40 are made through the top layer 22 and the bottom layer 24 , extending completely across the width of the web 10 . These cuts 40 can be made at any location along the web 10 , based on the desired final product. The transverse dotted lines which indicate locations of transverse cuts 40 are exemplary only and do not limit the size or shape of the final product contemplated by the current invention. These cuts 40 are generally made with the same periodicity as that of the graphic patterns printed on the substrate, thus producing a plurality of identical products. In this embodiment these transverse cuts 40 are made by a cutting device such as a die, slitting wheel, knife, or optical cutting device such as a laser. More than one cutting device used in tandem is also contemplated by the current invention. Additionally, this separation of the web 10 need not occur as part of the process illustrated here. Instead, following the kiss cut the processed web may be collected in some manner, such as a roll, and shipped elsewhere for separation.
[0038] FIGS. 4A and 4B illustrate one example of a final product contemplated by the present invention, a single gatefold product 50 . The right side of the brochure is a single openable page 52 , formed by the kiss cut according to the method of the present invention, and is shown in a closed position in FIG. 4A and an open position in FIG. 4B . A coating composition 25 , such as fragrance, which was applied according to the method of the present invention as indicated in FIG. 1 , is present under the single openable page 52 .
[0039] FIGS. 5A and 5B illustrate another example of a final product contemplated by the present invention, a double gatefold product 55 . The two openable pages, 56 and 58, are formed by the kiss cut according to the method of the present invention. FIG. 5A shows the pages 56 and 58 in their closed position, separated by the kiss cut 28 running the entire length of the brochure 55 . FIG. 5B shows the pages in their open position. A coating composition 25 lies under the right page 56 , applied during the method of the present invention as indicated in FIG. 2 .
[0040] The present invention also contemplates processing individual sheets of substrate, as illustrated in FIGS. 6 and 7 . These figures provide flow diagrams for processing individual sheets 60 of substrate. According to the present invention, sheets 60 of substrate are continuously processed in the same manner as the web 10 in FIGS. 1, 2 and 3 , but without the need for tranverse cuts to separate the finished products.
[0041] As shown in FIGS. 6 and 7 , areas of adhesive 14 and optionally a coating composition 25 is applied to each individual sheet 60 of substrate, which has been printed with graphic areas such as text and/or illustrations, on one or both of the top and bottom sides of each sheet 60 . Each sheet is then mechanically displaced, such as by folding 62 , and kiss cut 28 to generate a single 50 or double 55 gatefold product.
[0042] The foregoing illustrations of embodiments of the present invention are offered for the purposes of illustration and not limitation. It will be readily apparent to those skilled in the art that the embodiments described herein may be modified or revised in various ways without departing from the spirit and scope of the invention. The scope of the invention is to be measured by the appended claims. | A method of processing a continuous web of a sheetlike substrate and the resulting article of manufacture are presented. The resulting article comprises multiple layers of the substrate with at least some of the layers decorated with graphical patterns. Outer layers are cut so that they may be lifted, as in opening the pages of a book, thereby revealing graphical patterns on the inner layers. Precise registration of the graphical patterns across these cuts, a necessity for highest visual aesthetic appeal, is achieved by first patterning the substrate and then making the cuts only through the outermost layers. This method of cutting insures that the web as a whole remains intact during processing. The cuts are continuous along essentially the entire length of the web, eliminating waste of material when the web is separated into the individual articles. | 1 |
FIELD OF THE INVENTION
The present invention concerns a method for improving the conservation of a photographic product with a cellulose ester type support.
BACKGROUND OF THE INVENTION
The preservation of cinematographic films with a support of the cellulose ester type is an important criterion for producers, directors and institutions keen to safeguard their heritage. Different types of cellulose ester have been used, such as cellulose acetate butyrate, cellulose acetate propionate and cellulose triacetate. These types of support offer a certain advantage over cellulose nitrate, which was abandoned in the 1950s owing to its instability and the danger that it represented. However, archiving film of the cellulose ester type, exposed and developed, is made very difficult by the decomposition of the support, which is accompanied by a release of acetic acid, and hence the name "vinegar syndrome" given to this phenomenon described in the literature, see for example Adelstein, PZ et al, SMPTE Journal 1995, May, 281, or Ram, T et al, J. Imag. Sci. 1994, 38(3), 249.
Certain chemical compounds required in the processing of film, along with atmospheric contaminants (hydrogen peroxide, sulphur dioxide, ozone, nitrogen oxide, etc) also contribute to the deterioration of the images contained on film with a triacetate support.
U.S. Pat. No. 5,215,192 describes a method which improves the archiving of a photographic product which has been exposed and developed. This patent describes the use of zeolite-based molecular sieves having the ability to absorb moisture, acetic acid and residual solvents. These molecular sieves are packaged in sachets placed inside archive canisters.
However, since most of the gaseous releases take place in the area where the film is winding between the reels (see U.S. Pat. No. 5,215,192 column 4, lines 36-41), the aforementioned technique does not inhibit deterioration sufficiently. This is why the present invention recommends a treatment applied directly to the film to be archived, which enables the level of acetic acid, moisture and residual solvents to be controlled, while leaving a transparent protective layer which preserves the quality of the image.
The applicant recently described a fibrous inorganic polymer of aluminium and silicon and a method for synthesising it in the international patent application PCT/EP 95/04165, filed on 24 Oct. 1995, entitled "Alumino-silicate polymer and method for preparing it".
The present invention has as its object the use of a composition of the aforementioned fibrous inorganic polymer to improve the conservation of a photographic product with a cellulose ester type support.
SUMMARY OF THE INVENTION
The composition used according to the invention is a film-forming aqueous composition which comprises a fibrous alumino-silicate polymer of formula Al x Si y O z in which x:y is between 1 and 3, and z is between 2 and 6.
According to one embodiment, the composition also comprises a water-soluble polymer binder.
According to the present invention, the polymer binder, when there is one, is water-soluble, that is to say it can be mixed with water in proportions enabling a person skilled in the art to obtain a composition which is homogeneous and optically clear to the naked eye, in a temperature range between room temperature and 75°. The binder must enable a transparent composition to be produced which is applicable in a layer using the usual techniques (see Research Disclosure, publication 17643, December 1978, chapter XVA, page 27). A person skilled in the art will be able to adjust the concentrations of the components so as to obtain a composition whose viscosity falls within a range of between 4 and 20 centipoise.
Useful polymer binders comprise proteinaceous binders, for example deionised gelatine, gelatine derivatives, hydrophilic cellulosic substances such as methylcellulose, polyalkylene glycols such as polyethylene glycols, with a molecular mass between 103 and 106, polyvinyl alcohol, polyethylene oxides and polyacrylamides.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the composition according to the invention, the alumino-silicate is a fibrous substance, described in the aforementioned international patent application PCT/EP 95/04165. According to this patent application, the alumino-silicate is obtained by means of a method comprising the following main steps:
(a) a mixed alcoxide of aluminium and silicon or a precursor of such an alcoxide is mixed with an aqueous alkali, at a pH between 4 and 6.5 and advantageously between 4.6 and 5.6, keeping the aluminium concentration between 5×10-4M and 10-2M,
(b) the mixture obtained in (a) is heated at a temperature below 100° C. in the presence of a silanol group, for example in the form of divided silica, for a sufficient period to obtain a complete reaction resulting in the formation of a polymer, and
(c) the ions are eliminated from the reactional mixture obtained in (b). The reaction in step (b) is considered to be complete when the reactional medium no longer contains any cations other then those of the alkali, that is to say when the Al and Si ions have been consumed.
According to one embodiment, the initial product, at step (a), is a precursor which is the product of the hydrolysis reaction of an aluminium salt, for example aluminium chloride, and a silicon alcoxide.
The composition according to the invention has a viscosity which is such that it can be layered easily. This viscosity will be between 4 and 20 centipoise. The composition according to the invention can contain different additives normally used in compositions of this type and designed to improve the characteristics which assist layering, or the stability of layers, for example thickeners, wetting agents, surfactants or preservatives. The alumino-silicate content of the composition will be adjusted by persons skilled in the art so as to obtain a layer after drying which has an Al+Si content between 50 and 100 mg/m2 (per treated face), and ideally between 70 and 90 mg/m2 (per treated face).
The alumino-silicate polymer can be used in several ways. The cellulose ester support can be treated before the application of the photographic layers (as a substratum or under-layer), or after the application of the photographic layers (as a top layer), by means of a film-forming aqueous composition as described according to the invention. It is also possible to treat an exposed, developed film by passing it through a bath with such a composition or spraying such a composition onto its surface.
In particular, the film to be treated can be either immersed in an extra bath, at the end of the photographic processing line, with a temperature between room temperature and 40° C., or coated onto both faces by means of a top layer based on the said composition using normal techniques (see Research Disclosure, publication 17643, December 1978, chapter XV-A, page 27). The layer obtained, after drying, has a thickness of at least 1 μm. In general terms, the binder used is not initially cross-linked, so that an optimum mixture with the alumino-silicate polymer is promoted, but the layer can, nonetheless, be tanned during a subsequent step, by means of the tanning agents normally used in the preparation of photographic products (see Research Disclosure, publication 36544, September 1994, chapter II-B, page 508).
Where the binder is gelatine or a gelatine derivative, it is necessary to adjust the pH of the alumino-silicate polymer solution to a value below the isoelectric point of gelatine to avoid precipitation.
The inside of the storage canisters for the reels can also be treated by coating with a top layer of the said composition. The reels can be stored in canisters made of plastic (polyethylene, polypropylene, polycarbonate, etc) or metal.
In order to evaluate the efficacy of the method according to the invention, a method of accelerated ageing is used which is described in the literature, see for example Adelstein, PZ et al, SMPTE Journal 1995, May, 281, or Ram, T et al, J. Imag. Sci. 1994, 38(3), 249.
The following examples illustrate the invention.
EXAMPLE 1
An alumino-silicate polymer is prepared according to the method in Example 2 of the aforementioned patent application PCT/EP 95/04165. This alumino-silicate comprises 3.88 g of Al+Si/l, with an Al:Si molar ratio of 2. For a mixture of 1031 g of this alumino-silicate (4.0 g Al+Si), 0.18% by weight of Tween 80™ non-ionic surfactant is added with respect to the Al+Si weight. While stirring, the above composition is mixed with 400 g of an aqueous solution of Type IV photographic gelatine containing 1% by weight of dry gelatine while keeping the temperature at 40° C. The volume is adjusted to 1600 ml using water to obtain an Al+Si content of 2.5 g/l. The stirring of the mixture is continued for 1 hour 30 minutes while keeping the temperature at 40° C. This composition is applied to both faces of a film with an exposed and developed cellulose triacetate support.
The covering on this film after drying is around 80 mg/m2 per face. The control film (film B), which is identical except that it does not include a layer of the composition and which comes from the same sample as film A, is placed in a second airtight metal canister identical to the preceding one. The two canisters are placed in the same oven at 80° C. for 21 days. The relative humidity level within the canisters is around 50%. This test simulates an accelerated ageing of the film.
EXAMPLE 2
An alumino-silicate polymer is prepared according to the method in Example 2 of the aforementioned international patent application PCT/EP 95/04165. This alumino-silicate comprises 2.5 g Al+Si/l, with an Al:Si molar ratio of 2. This composition is applied directly to both faces of a film with an exposed and developed cellulose triacetate support. The covering of Al+Si on the top layer is around 80 mg/m2 per face after drying. The treated film (film C) is placed in an airtight metal canister. A control film (Film D) which is identical except that it does not have a top layer of the composition and which comes from the same sample as film C, is placed in a second airtight canister identical to the preceding one. The two canisters are placed in the same oven at 80° C. for 21 days. The relative humidity level within the canisters is around 50%. This test simulates an accelerated aging of the film.
Results
Following the treatments in Examples 1 and 2, the quality of the films A, B, C and D is assessed visually according to the following criteria:
A=the support shows no sign of deterioration and the quality of the image is excellent;
B=the support shows no sign of deterioration and the quality of the image is acceptable;
C=the support has deteriorated and the quality of the image is unacceptable;
The results obtained are shown in the following table:
______________________________________Quality of support and image______________________________________Example 1 Film A B Film B CExample 2 Film C B Film D C______________________________________
These results show that exposed, developed photographic films with a support of the cellulose ester type, which have undergone a treatment according to the invention, exhibit, after an accelerated ageing test, a quality of support and image which are much higher than the same films when untreated.
In order to assess the ability of the protective top layer to adsorb acetic acid, a sample of blank cellulose triacetate is treated with a composition, according to the method in Example 2, having an alumino-silicate content expressed in terms of Al+Si of 5.87 g/l. The covering with Al+Si of the layer obtained after drying is around 200 mg/m2 per face. This treated support is placed in an airtight metal canister. A control sample of blank cellulose triacetate, untreated and identical to the previous one, is placed in a sealed canister identical to the previous one.
These two canisters are placed in the same oven at 80° C. for 21 days. The relative humidity level within the canisters is around 50%. After heating, the treated support has an acceptable physical appearance while the untreated support has deteriorated. By scraping the treated support with a razor blade, a sample of the layer of alumino-silicate is obtained in the form of powder. A sample of the untreated support is prepared in powder form. These two samples are analysed by mass spectroscopy (Nermag R-10-100 model) under the following operating conditions:
vacuum=10-5 torr
starting temperature=30° C.
heating: 20°/min
maximum temperature=300° C.
introduction of the sample=direct mode.
The sample from the treated support clearly shows the presence of acetic acid, while the sample from the untreated support does not exhibit this characteristic. The layer of alumino-silicate polymer adsorbs the acetic acid and acts as a barrier against the release of acetic acid, which stabilise the cellulose ester type support.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | The present invention improves the conservation of a photographic product with a cellulose ester type support. The present invention involves coating on the support or the photographic product with a transparent film-forming aqueous composition. The composition is a fibrous alumino-silicate polymer of formula Al x Si y O z in which x:y is between 1 and 3, and z is between 2 and 6. The support can be treated before the application of the photographic layers (as a substratum or under-layer) or after the application of the photographic layers (as a top layer). It is also possible to treat an exposed, developed film by applying a top layer of the said composition. | 8 |
FIELD OF THE INVENTION
The present invention relates to a technological process for the preparation of lower olefins with stress on ethylene by conversion of hydrocarbons.
BACKGROUND ARTS
Research on the production of ethylene by the pyrolysis of heavy oils has been very active in recent years both in china and abroad, for example, the QC (quick contact) reaction system developed by Stone & Webster Eng Co. of USA (U.S. Pat. No. 4,663,019, ZL88102644.1 and EP 0381870A etc.): this technology uses a downward tubular reactor and a feeding mode of a single feed oil. The steam pyrolysis technology developed by British Petroleum Ltd. (U.S. Pat. No. 4,087,350): this technology uses a tubular fixed bed catalytic reactor. The technology developed by Tokyo Science and Technology Co. of Japan for producing olefins using coke particles as a heat carrier (U.S. Pat. No. 4,259,177): this technology uses a fluidized bed reactor of the reaction-regeneration type. The HCC (Heavy-oil contact cracking) technology developed by SINOPEC Loyang Petro-Chemical Engineering Co. (ZL 92105507.2): this technology uses an up flow or down flow tubular piston flow reactor and a feeding mode of a single feed oil. The above technologies are all able to produce ethylene from heavy oils. But in the flow sheets of the above technologies, only the case of feeding a single fresh feed oil is considered. American patent U.S. Pat. No. 5,348,644 is patent for an invention relating to the improvement of the feeding equipment and technological process of a lift pipe catalytic cracking device. The fluidization state of the catalyst in the lift pipe is optimized by installation of special equipment in the pre-lift section of the lift pipe and thereby the contact state of the catalyst and the feed oil for the catalytic cracking in the lift pipe is improved and more ideal product distribution of the catalytic cracking is obtained. Chinese patent ZL 8910052, U.S. Pat. No. 5,264,115 and U.S. Pat. No. 5,506,365 provide a fluidized bed process and device for converting hydrocarbons which consists of a steam pyrolysis section for light hydrocarbon fractions at the upstream of a reaction zone and a catalytic cracking section for heavy hydrocarbon fractions at the downstream of said reaction zone in a tubular reaction zone with an upstream or downstream flow in the presence of the catalyst particles in a fluidized phase. The applied catalyst belongs to the type of catalytic cracking. The purpose is to obtain a propylene yield slightly higher than the conventional catalytic cracking while raising the yields of gasoline and diesel oil in the product. The major characteristic is to separate C 2 components from the product and then introduce them into an oligomerization reactor to proceed the oligomerization reaction; the remained C 2 components and the oligomerization products are returned to the lift pipe to proceed the steam cracking reaction so that the purpose of raising the yields of fuel oils and propylene is achieved. It can be seen from the example that the yields of the C 2 olefin, C 3 olefin in this technology are both lower than 7.0% by weight.
In order to solve the problems of simultaneous feeding of multiple feed oils and/or re-refining of some pyrolyzed by-products (e.g etheane, propane etc) in the technology of heavy oil pyrolysis to prepare ethylene, the present invention is to provide an effective method which allows different feed conduct the proylsis under different process conditions so that optimizing the reaction conditions and product structure, raising the yield of ethylene and saving the capital and operation costs can be realized.
The major characteristic of the present invention is the multiple feed accompanied by ethane re-refining for the purpose of producing more ethylene. In the technological process for conversion of hydrocarbons to prepare gaseous olifins by bringing them into contact with solid catalyst particles, the feed hydrocarbons are not only one and the desired pyrolysis conditions for various hydrocarbons are not completely the same. For example, the optimal reaction temperature for ethane is higher than that for naphtha and the optimal reaction temperature for naphtha is highter than that for vacuum distillates, and so on. In order to pyrolyze various feed hydrocarbons under their respective optimal conditions as far as possible, separate heaters are used in the tubular heater pyrolysis technology. For example, there must be one or two ethane pyrolysis heaters to proceed pyrolysis for re-refining ethane in the plant that uses naphtha or light diesel oil as a feed. In the technology of the catalytic pyrolysis for ethylene preparation, it is impossible to pyrolyze the feeds with different properties in separate heaters because there is only one reactor. The optimal pyrolysis conditions can not be met for various hydrocarbons if they are mixed and then fed. Taking the simultaneous pyrolysis of an atmospheric residue and ethane as an example, the optimal pyrolysis temperature for the atmospheric residue (at the outlet) is 650-750° C., but the pyrolysis rate of ethane in this temperature range can not meet the need of industrial production; if the pyrolysis temperature is raised to above 800° C. to meet the conditions for ethane pyrolysis, the pyrolysis extent of the atmospheric residue can not be controlled. In the above case, it is possible to feed the atmospheric residue and ethane separately and attain desired pyrolysis extents for various feeds by using the method of the multiple feed at separate points of the present invention.
SUMMERY OF THE INVENTION
One aspect of the present invention is therefore to provide a process for catalytic pyrolysis of hydrocarbon feeds to produce lower olefins with stress on ethylene and co-produce light aromatics, which is to bring the hydrocarbon feeds into contact with a solid granular catalyst in a piston flow reactor to proceed catalytic pyrolysis, the hydrocarbon feeds include two or more hydrocarbons having different physicochemical properties, the feed hydrocarbons are mixed with steam and introduced, the general reaction conditions in the reaction zone are: temperature 600-900° C., pressure 0.13-0.40 MPa (absolute), total steam/hydrocarbon ratio 0.1-1.0, total catalyst/oil ratio 5-100 and the catalyst/oil contact time 0.02-5 s; the oil gas after reaction is separated quickly from the catalyst and quenched, the catalyst is recycled for reuse after regeneration, different feeds are introduced from different positions, hydrocarbons difficult to pyrolyze are first introduced into the reactor and brought into contact with the catalyst of high temperatures and high activities from the regenerator and the pyrolysis takes place, meanwhile, the catalyst cools down and deactivates; then other hydrocarbons easier to pyrolyze are introduced in sequence from the upstream to downstream of the reaction zone, the hydrocarbons introduced later play a role of quenching those introduced earlier, the temperature of the reaction zone and the activity of the catalyst are lowered step by step from the upstream to the downstream; the positions from which various hydrocarbons enter the reactor are determined as such that the residence times of various hydrocarbons in the reactor are gradually decreased in the sequence from difficulty to ease in pyrolysis, the differences in the residence times of every adjacent two hydrocarbon feeds in the reactor are 0.01-3 s.
Another aspect of the present invention is to provide a process for direct conversion of heavy hydrocarbons to produce lower olefins with stress on ethylene and co-produce light aromatics, which is to bring the hydrocarbon feeds into contact with a solid granular catalyst in a piston flow reactor to proceed catalytic pyrolysis, the feed hydrocarbons are mixed with steam and introduced, the general reaction conditions in the reaction zone are: temperature 600-900° C., pressure 0.13-0.40 MPa (absolute), total steam/hydrocarbon ratio 0.1-1.0, total catalyst/oil ratio 5-100 and the catalyst/oil contact time 0.02-5 s; the oil gas after reaction is separated quickly from the catalyst and quenched, the catalyst is recycled for reuse after regeneration; the oil gas enters a fractionation and separation system to proceed the separation, a product gas mainly containing ethylene, the by-product ethane, and a liquid product rich in aromatics can be obtained, the highly pure by-product ethane from the separation system and/or the gases containing ethane from other sources return to the pyrolysis reactor of the piston flow type from the upstream inlet of the reactor and come into contact with the catalyst of high temperatures and high activities, fast pyrolysis takes place at temperatures higher than 780° C. to produce ethylene and meanwhile, the catalyst cools down and deactivates, steam is introduced at the same time when ethane feed is introduced from the upstream inlet of the reactor; heavy hydrocarbon feeds are introduced at position certain distance from downstream of the inlet for ethane, the hydrocarbons introduced later play a role of quenching those introduced earlier, the reaction temperature at this moment is lowered to 680-800° C.; the feeding positions of the by-product ethane and the heavy hydrocarbons are determined as such that the residence time of ethane, which is difficult to pyrolyze, is long, while that of heavy hydrocarbons, which are easy to pyrolyze, is short, the differences in the residence times of ethane and heavy hydrocarbons in the reactor are 0.01-3 s.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE—Schematic diagram of the lift pipe reactor of the present invention as an example
1 -Lift pipe
2 -Pre-lift gas
3 -Subsider
4 -Regenerated catalyst
5 -Pipeline for stripping steam
6 -Outlet of the pyrolyzed gas
I, II, III, IV are all the feed inlets
DETAILED DESCRIPTION OF THE INVENTION
Hydrocarbons entering the reactor from different inlets are subjected to different reaction conditions, for light hydrocarbons, which are difficult to pyrolyze, the pyrolysis temperature is higher and the pyrolysis time is longer, while for heavy hydrocarbons, which are difficult to pyrolyze, the reaction temperature is lower and the pyrolysis time is shorter. Hydrocarbons with different properties are fed to the reactor in sequence and the differences in the residence times in the reactor of adjacent hydrocarbons are 0.0-3 s. Hydrocarbons hard to pyrolyze are first fed to the reactor and brought into contact with the catalyst of high temperatures and high activities from the regenerator and the pyrolysis reaction takes place, at the same time, the catalyst cools down and deactivates and then other hydrocarbon feeds easy to pyrolyze are fed in sequence, the hydrocarbons fed later play a role of quenching those fed earlier.
This method is usable for the technology in which one or multiple hydrocarbon oil(s) are used as the feed(s), said hydrocarbons include ethane, propane, butane, light hydrocarbons and heavy hydrocarbons. Said heavy hydrocarbons are referred to the hydrocarbons with a distillation range higher than 350° C., including straight run heavy hydrocarbons and secondary processing heavy hydrocarbons, i.e., various straight run wax oils, coker wax oils, straight run vacuum gas oils, atmospheric residues, coker gas oils, thermal cracking heavy oils, solvent-deasphalted oils and various solvent extraction residues of heavy hydrocarbons; said light hydrocarbons are referred to hydrocarbons with a distillation range lower than 350° C., such as LPG, refinery petroleum gases, oil field gases, oil field light hydrocarbons, naphtha and light diesel oil.
Citing a lift pipe reactor as an example, the particular process is described as follows (see The FIGURE): the regenerated catalyst 4 from the regenerator enters the lift pipe 1 , and then flows upward under the driving of the pre-lifting steam and pre-lifting dry gas introduced from the bottom of the lift pipe; the pre-lifting dry gas is highly pure ethane from the separation zone of the pyrolyzed gas and/or light hydrocarbon gases of other sources containing ethane, steam is added at the same time; ethane quickly pyrolyzes under the action of the hot catalyst at 780-900° C., ethane may also be sprayed from inlet I. A mixture of propane and/or butane from the separation zone and/or other sources and a certain amount of steam is atomized and sprayed from feed inlet II into the lift pipe, where the mixture comes into contact with the mixed stream of the catalyst and the ethane reactant at about 780-850° C. and the catalytic pyrolysis reaction takes place. A mixture of the light hydrocarbons having a distillation range lower than 350° C. and a certain amount of steam is atomized and sprayed from feed inlet II into the lift pipe, where the mixture comes into contact with the mixture of the catalyst and the upstream reactants at 720-830° C. and the catalytic pyrolysis reaction takes place. A mixture of heavy hydrocarbons having a distillation range higher than 350° C. and a certain amount of steam is atomized and sprayed from feed inlet IV into the lift pipe, where the mixture comes into contact with the mixture of the catalyst and the upstream reaction stream at about 680-800° C. and the catalytic pyrolysis reaction takes place. The distances among the feed inlets for various hydrocarbons are calculated to allow the differences in the residence time of the adjacent hydrocarbons introduced into the reactor in sequence to be 0.0-3 s. Heavier feed oils are sprayed in sequence into the lift pipe at the inlets above the inlets from which the lighter feed oils are sprayed and may play a role of quenching the pyrolyzed stream of lighter feed oils so that the secondary reactions of the pyrolyzed stream of the lighter feed oils are quickly stopped or slowed down. The mixture of the catalyst and the reaction stream of the hydrocarbon feeds in the lift pipe flows upward and enters the subsider 3 , wherein fast separation of gas/solid stream is performed. The reaction stream is removed from the outlet 6 at the top of the subsider, while the deactivated catalyst drops down along the subsider and is stripped by the stripping steam sprayed from the pipeline 5 . The stripped catalyst to be regenerated goes down and enters the regenerator, wherein the coke-burning regeneration reaction is carried out, the regeneration temperature being 700-950° C. During the coke-burning regeneration, the catalyst absorbs a great amount of heat and its temperature rises to 800-900° C. After steam stripping in the transfer pipeline, the high temperature regenerated catalyst is recycled back to the pre-lift section of the lift pipe along the regeneration inclined pipe for reuse. After quenching, the reaction stream removed from exit 6 enters the fractionation system and separates into pyrolyzed gas and a liquid product rich in aromatics, the pyrolyzed gas is then separated in the separation system into highly pure individual hydrocarbons (CH 4 , C 2 H 4 , C 2 H 6 , C 3 H 6 , C 3 H 8 , C 4 H 8 , C 4 H 6 , C 4 H 10 ), wherein the highly pure ethane returns to be bottom of the lift pipe for pyrolysis or is delivered to the ethane pyrolysis heater for pyrolysis.
The components of the special catalyst (LCM) used for the catalytic pyrolysis can be selected from SiO 2 , Al 2 O 3 and oxides of alkali metals, alkali earth metals and transition metals or mixtures thereof, aluminum silicate modified with oxides of alkali or alkali earth metals can also be used, and optionally, a part of molecular sieves are added.
If the feed hydrocarbon to be pyrolyzed are two or more in the scope of ethane, propane, butane, light hydrocarbons having a distillation range lower than 350° C. and heavy hydrocarbons having a distillation range higher than 350° C., different feeds can enter the device from different positions according to the above method to realize the optimization of the pyrolysis conditions.
The effect of the present invention. Realization of the pyrolysis of the feeds with different properties under different process conditions results in the optimization of the reaction conditions and product structure, e.g., the yield of ethylene attains 23.76 wt % or higher, as well as savings of capital and operating costs.
EXAMPLE 1
This example is the pyrolysis results using an atmospheric residue and ethane as a co-feed. The pyrolysis test is carried out on a high-low parallel lift pipe pilot-scale device with a total length of the lift pipe being 15.42 m, its internal diameter being 19 mm and a capacity being 0.24 t/d. Ethane, which is difficult to pyrolyze, is first introduced into the lift pipe from the bottom of the lift pipe and brought into contact with the hot and active regenerated catalyst so that reaction takes place, the temperature of the regenerated catalyst at this moment is 820° C., the temperature of the hydrocarbon/catalyst mixture after introducing ethane is 810° C. The inlet of the atmospheric residue is located 4.2 m above the inlet of ethane. The residence time of ethane from the bottom to this point is 0.45 s. The temperature of the mixed stream after introducing the atmospheric residue is 740° C., the temperature at the outlet of the lift pipe is 710° C. The catalyst used in this example is numbered as LCM-A, its properties and composition are shown in Table 1. The process conditions and the material balance in a pilot-scale test of the lift pipe are shown in Table 2. For comparison, the result of the pilot-scale test is also shown when the atmospheric residue and ethane is mixed and fed from the same inlet.
The results in Table 2 show that, in the technology of ethylene production from atmospheric residues with ethane re-refining, rather optimal pyrolysis conditions for both the atmospheric residue and ethane are realized and the conversions are appropriate when the method of multiple feed at separate point of the present invention are adopted. The yield of ethylene from the individual pyrolysis of the atmospheric residue is 22.36 wt %, while that after the re-refining of 4.56% of ethane attains 25.63 wt %.
It can also be seen from Table 2 that when the pyrolyzed ethane from the atmospheric residue is not re-refined and additional 6.5 wt % ethane is added, if ethane and the heavy oil are fed from the same feed inlet and the temperature of catalyst/oil mixture is 740° C., the yield of ethylene is only 21.30%; if ethane and the heavy oil are fed into the device from different feed inlets, i.e., the temperature at the inlet for ethane is 810° C. and that for the residue is 740° C., the yield of ethylene is 23.76%. Moreover, the aromatic content in the pyrolyzed gasoline is greater than 86 wt %, that in the pyrolyzed liquid product having a distillation range higher than 200° C. is greater than 89 wt %.
EXAMPLE 2
This example is the pyrolysis results using an atmospheric residue and a straight run gasoline as a co-feed, the process conditions and the material balance in a pilot-scale test of the lift pipe are shown in Table 3. The straight run gasoline is introduced into the device from the bottom of the lift pipe, the number of the catalyst used is LCM-B, its propertied and composition are seen in Table 1. The temperature of the catalyst/oil mixture is 780° C., the atmospheric residue is sprayed at the position 4.2 m above the inlet of the straight run gasoline, the residence time of the straight run gasoline from the bottom to this point is 0.6 s, and the temperature of the mixed stream after spraying the atmospheric reside is 700° C., the temperature at the outlet of the lift pipe is 660° C.
The results in Table 3 show that, by using the method of mixed feed of the atmospheric residue and the straight run gasoline, the total pyrolysis extent of the mixed feed is rather low when the optimal conditions for the pyrolysis of the atmospheric residue are ensured, in the total material balance, the yields of ethylene and propylene are 21.84% and 12.93%, respectively, either of them is lower than that when only the atmospheric reside is pyrolyzed, indicating that the pyrolysis extent of the straight run gasoline is not high; rather high pyrolysis extent of the straight run gasoline is attained while ensuring that the pyrolysis of the atmospheric residue proceeds under the optimal conditions by using the method of the multiple feed at separate point of the present invention: in the total material balance of the mixed feed, the yield of ethylene reaches 24.50%, that of propylene reaches 14.51%, either of them exceeds that when only the atmospheric residue is pyrolyzed.
TABLE 1
Properties and composition of the catalyst
Catalyst LCM-A
Catalyst LCM-B
Item
Alkali
Transition metal
Type of the active component
earth metal Oxides
oxides
Chemical
composition
Al 2 O 3 , wt %
40
42
Na 2 O, wt %
<0.3
<0.3
Fe 2 O 3 , wt %
0.8
0.8
Active component, wt %
8.2
6.5
Specific surface, m 2 /g
58
65
Porosity, ml/g
0.12
0.13
Bulk density, g/ml
0.85
0.85
Sieve composition, wt %
0-20 μ
2.6
3.2
20-40 μ
19.4
20.2
40-60 μ
31.5
32.1
60-80 μ
24.7
23.9
>80 μ
21.8
20.6
TABLE 2
Pyrolysis result using ethane and an atmospheric residue
Material balance
Material balance
for the pyrolysis
for the pyrolysis
of the atmospheric
of the atmospheric
Item
residue
residue and ethane
Feeding mode
Single
Separate*
Mixed
Separate
Whether ethane is refined
No
Yes
No
No
Ethane content in feed, wt %
0.0
0.0
6.5
6.5
Temp. of regeneration
820
820
820
820
bed, ° C.
Temp. of stripping steam for
400
400
400
400
regenerated catalyst, ° C.
Stream temp. after spraying
/
810
740
810
ethane, ° C.
Stream temp. after spraying
740
740
740
740
atmospheric residue, ° C.
Temp. at the outlet of lift
710
710
710
710
pipe, ° C.
Temp. after quenching, ° C.
600
600
600
600
Catalyst type
A
A
A
A
Steam/hydrocarbon ratio,
0.23
0.23
0.23
0.23
wt/wt
Catalyst/oil ratio, wt/wt
18.0
18.0
18.0
10
Yield of major products, wt %
Hydrogen
0.87
1.09
0.84
1.03
Methane
11.44
11.81
10.76
11.13
Ethylene
22.36
25.63
21.30
23.76
Ethane
4.56
/
10.20
6.79
Propylene
12.86
13.25
12.05
12.21
Propane
0.71
0.72
0.67
0.68
Butane
0.22
0.22
0.21
0.21
Butylene
3.04
3.10
2.85
2.90
Butadiene
1.87
1.91
1.75
1.76
Pyrolyzed gasoline (<200° C.)
12.46
12.76
11.68
11.85
Pyrolyzed middle distillate
5.23
5.24
4.94
4.89
Pyrolyzed heavy oil
9.86
9.88
9.30
9.22
(>300° C.)
Coke
13.23
13.27
12.40
12.37
Loss
1.29
1.12
1.05
1.21
Where: (1) Aromatic content
88.12
87.75
86.54
87.87
in pyrolyzed gasoline
(2) Aromatic content in the
90.13
89.89
90.10
91.39
pyrolyzed product having a
distillation range higher than
200° C.
*Ethane in the pyrolyzed product from the atmospheric residue is returned back to the lift pipe for re-refining.
TABLE 3
Pyrolysis result using straight run gasoline and an atmospheric residue
Material balance
Material balance
Material balance for
for the pyrolysis
for pyrolysis of
pyrolysis of
of atmospheric
straight run
atmospheric residue and
Item
residue
gasoline
straight run gasoline
Feeding mode
Single
Single
Mixed
Separate
Gasoline proportion in feed, wt %
0.0
100
20
20
Temp. of regeneration bed, ° C.
800
/
800
800
Temp. of stripping steam for regenerated
400
/
400
400
catalyst, ° C.
Stream temp. after spraying gasoline, ° C.
/
780
700
780
Stream temp. after spraying atmospheric residue, ° C.
700
700
700
700
Temp. at the outlet of the lift pipe, ° C.
660
660
660
660
Temp. after quenching, ° C.
600
600
600
600
Catalyst type
B
B
B
B
Steam/hydrocarbon ratio, wt/wt
0.25
/
0.25
0.25
Catalyst/oil ratio, wt/wt
18.6
/
19.2
19.0
Yield of major products, wt %
Ethylene
23.05
30.30
21.84
24.50
Propylene
14.01
16.51
12.93
14.51
C 4 olefins
6.73
8.48
6.24
7.08
Pyrolyzed gasoline (<200° C.)
13.45
19.20
23.16
14.60
Pyrolyzed middle distillate
6.60
2.00
5.50
5.68
Pyrolyzed heavy oil (>300° C.)
9.31
0.01
7.45
7.45
Coke plus loss
9.00
0.50
7.30
7.30
Where: (1) Aromatic content in pyrolyzed
88.44
92.30
78.52
89.10
gasoline
(2) Aromatic content in the pyrolyzed product
92.65
/
92.50
93.76
having a distillation range higher than 200° C. | A process for hydrocarbon conversion to prepare lower olefins such as ethylene, propylene, etc., and light aromatics by bringing hydrocarbons into contact with a solid granular catalyst. In order to optimize the reaction conditions and product structure and save the capital and operating costs, a piston flow reactor is used in this process and multiple groups of feed inlets, which allow hydrocarbons with different properties to enter the device from different feed inlets and proceed pyrolysis under different operation conditions, are set on the reactor. This process is usable for individual pyrolysis or co-feed pyrolysis of hydrocarbons from refinery gases, liquid hydrocarbons, to heavy residues. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] Many different types of wind turbines have been built that can efficiently convert wind energy into electrical energy. For large scale power generation, a typical configuration is a wind farm consisting of three bladed horizontal axis turbines. These turbines are very large with blades of 50-100 feet or more built upon large steel towers and are pointed into the wind. Alternatively, vertical axis wind turbines do not need to be pointed into the wind and have been built in many different designs. Many wind turbines have problems operating or starting up in low wind speed conditions, require complex mechanisms to adjust to wind conditions and can have problems with noise and vibration. Existing models are rarely suitable for congested urban conditions or portability and are not always suitable to be manufactured from low cost materials.
[0004] This invention is of a lightweight wind turbine that can be mounted either vertically or horizontally and is lightweight and portable. This wind generator utilizes an airfoil on the leading edge that is twisted into a three dimensional shape and consists of stackable units. Each unit can be inexpensively manufactured from lightweight materials, for example injection molded plastic or inflatable rubber. The units then connect together in a stack with the assembly held together by a central pole or cable. This design solves the problem of portability but retains the ability to provide for significant power generation when multiple units are stacked in series. One embodiment is of an efficient wind turbine that utilizes uniquely shaped three dimensional airfoil blades with opposing pitches of a helix twist angles to create beneficial wind flow during both low and high wind speed conditions. Other embodiments of this invention include methods of operation including multiple mounting configurations and the use of the turbine to generate power underwater.
[0005] Several typical examples of turbines for wind power will be described, however none have the same characteristics as those of this invention. These examples represent the state of the art or the closest examples to this invention. In U.S. Pat. No. 7,362,004 B2, Becker describes a wind turbine made of straight outer airfoil blades and inner helical wing blades supported within a cage structure. As with many other wind turbines, a protective cage structure is required that adds expense, complexity and significant weight. In another example of a wind generator, Stephens describes a wind driven generator including a rotor comprised of blades in a cylindrical duct in U.S. Pat. No. 7,365,448 B2. This design is compact and much like a paddle wheel enclosed within a cylindrical housing. It also uses cams to put the blades into the wind.
[0006] There are several commercial examples of portable wind generators. The Magenn Power Air Rotor System is a cylindrical turbine structure that is floated from 200-1,000 feet above ground transmitting energy through a tether. It is a lighter than air system that could be portable, but it is a complex design that is inherently costly to produce. The Quietrevolution QR5 has a helical design with three helical blades. Carbon fiber is used to manufacture the blades, which is a commonly used material for turbine blades. However, carbon fiber blades are costly and typically manufactured in small lots by hand. One example of a turbine that utilizes low cost plastic is Oregon Wind Corp.'s Urban Turbine™. This design uses a helical blade on a central pole that is encaged in a steel or aluminum bracket.
[0007] One type of wind turbine that has some similar features is the giromill or cycloturbine variety of vertical axis wind turbine. These are typically powered by three vertical airfoils attached by radial arms to a central rotating mast and were first described in U.S. Pat. No. 1,835,018 By Darrieus. Since radial airfoils are most effective at higher wind speeds, the cycloturbine variation alters the pitch of the airfoils to create drag for starting and then to generate greater lift to accelerate rotation. In a further evolution, Darrieus type vertical turbines have been built with helically twisted airfoil blades. The Quietrevolution and Turby brand commercial products have three vertical blades, each with a 60 degree helical twist. Start up for these models is typically achieved by using the generator as a motor. In U.S. Pat. No. 6,253,700 Gorlov teaches a helical turbine assembly that has primarily been used as a hydrofoil, producing energy from flowing water and works under the same principles as the Darrieus wind turbines. Savonius type wind turbines use scoops to create drag to turn a central shaft. Combinations of Darrieus and Savonius type units have been built with radial airfoils and cups attached to the central shaft to facilitate starting have been developed such as that in U.S. Pat. No. 3,918,839. In this design, starter rotors are used to only harness drag and facilitate rotation of the main shaft such that the exterior airfoil blades can then efficiently capture the wind energy.
BRIEF SUMMARY OF THE INVENTION
[0008] It is an object of this invention to provide for an improved wind energy generator. This invention is a wind turbine that utilizes airfoils in a unique design that are made of lightweight materials. Further, the turbine is manufactured as relatively small units by low cost production methods, and these portable units could be stacked in series to provide for significant power harvesting. It is a further object of this invention to provide a wind turbine made from a three dimensional twisted airfoil. The airfoil can contain two, three or four blades.
[0009] It is a further object of this invention to provide a wind turbine comprised of airfoil blades made from a flexible material such that the blades bend towards the center of the turbine upon their return into the wind. This effectively reduces negative drag to further increase efficiency.
[0010] It is a further object of this invention to provide for airfoils in which the twisted blades contain cut-outs, or hollow sections in blades. These hollow sections provide for a decreased weight of the turbine while not reducing its efficiency.
[0011] It is a further object of this invention to provide a wind turbine that could be assembled from portable unit pieces to the desired length. It is a further object of this invention to provide a wind turbine that is lightweight and portable and requires minimum external support.
[0012] It is a further object of this invention to provide a wind turbine constructed from inflatable airfoils. It is a further object of this invention to provide a wind turbine that could be easily mounted on a roof, a pole, or a horizontal cable. It is a further object of this invention to provide a wind turbine that is portable and could be transported and then mounted on a vehicle, or on a cable between two vehicles. It is a further objective of this invention to provide an inflatable wind generator with a swivel joint. This allows the inflatable design of the airfoil to be mounted between trucks, buildings, or other structures. It is a further object of this invention to provide for an airfoil generator system in which multiple airfoil units are mounted horizontally on wheel hubs. It is a further object of this invention to provide a turbine unit that can be used underwater to generate hydro power. The hollow plastic airfoil units of this invention could be filled with foam or another substance to increase rigidity for underwater use.
[0013] It is a further object of this invention to provide for a double airfoil turbine that has an interior twisted airfoil and an outer airfoil.
[0014] It is a further object of this invention to provide for airfoil wind turbines that provide better efficiency by utilizing airfoil segments with opposing pitches.
[0015] It is a further object of this invention to provide an air turbine that is comprised of a central airfoil that is highly efficient at low wind speeds, and a plurality of circumferential airfoils to provide greater efficiency at higher wind speeds. Preferably, the assembly consists of three circumferential airfoils, although there can be fewer or greater than three. The spin of the air turbine rotates a central shaft that powers a generator. It is a further object of this invention to provide for an air turbine with a central airfoil and a plurality of circumferential airfoils in which said central airfoil is of a multiple bladed inverted helix. Preferably, said central airfoil consists of three blades although there can be fewer or greater than three blades. More preferably, the central airfoil is comprised of two joined parts; one half with a clockwise helix and one half with a counterclockwise helix.
[0016] It is a further object of this invention to attach, via a spoked hub, a plurality of circumferential airfoils to the central twisted helix airfoil. The circumferential airfoils are single blades and can either be a flat or bent, or be comprised of two conjoined twisted segments of opposite pitch. In each case, said spoked hub must have arms long enough so that the central airfoil can spin without interference from the circumferential airfoils.
[0017] It is a further object of this invention to provide for an improved energy generator in which a plurality of airfoils are positioned circumferentially around a central rotating shaft to power a generator. In this design, the circumferential airfoils taught previously are attached to each other via spoked hubs and no central airfoil is necessary. In a preferred embodiment, the circumferential airfoils are of a single bladed helical configuration. Further preferred is that multiple assemblies of these airfoils, connected by spoked hubs, be stacked with the pitch of the adjoining airfoil blades alternating between clockwise and counterclockwise. There can be any number of these blades. In another embodiment, some of the spoked hubs are removed and instead the circumferential pitched airfoil blades are connected to each other by means of integral tabs. For these configurations, the V-shaped counterclockwise and clockwise helix airfoil turbine can be asymmetrical or symmetrical or a combination of both in a helix profile.
[0018] It is a further object of this invention to provide for an improved energy generator in which a plurality of circumferential airfoils are attached via a hub to a central rotating shaft. In this embodiment, the helical airfoils are wing tipped and the tipped ends are not attached to a hub. This type of configuration prevents roll off at the end of the airfoil for better efficiency.
[0019] It is a further object of this invention to provide for a collapsible energy generator in which a plurality of hinged airfoil blades are mounted circumferentially to spoked hub on a rotating shaft. The blades are preferably of opposing pitches with a hinge in the middle and at the spoke connection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] To improve the understanding of this invention, figures are provided to better describe examples of design and operation. These drawings represent examples of preferred embodiments but additional designs and operational conditions may also be included in this invention. While each example is described as a wind powered device comprised of airfoils, it is also possible to be utilized as a water powered device comprised of hydrofoils.
[0021] FIG. 1 shows multiple airfoil units stacked together and mounted on a central pole.
[0022] FIG. 2 shows two individual units of a twisted airfoil design with end caps.
[0023] FIG. 3 shows the end view of a three vane airfoil.
[0024] FIG. 4 is a flexible three vane airfoil.
[0025] FIG. 5 is a four vane airfoil built from a stack of individual units.
[0026] FIG. 6 shows a stack of airfoils with a hollow cutaway manufactured in the side of each blade.
[0027] FIG. 7 shows the details of how a clockwise pitched airfoil is stacked upon a counter-clockwise pitched airfoil.
[0028] FIG. 8 details a counter-clockwise pitched airfoil stacked upon a clockwise pitched airfoil.
[0029] FIG. 9 shows multiple inflatable airfoil units tethered to a ground unit spool.
[0030] FIG. 10 shows multiple airfoils mounted on a hub.
[0031] FIG. 11 is an airfoil assembly with an attached swivel joint.
[0032] FIG. 12 is an assembly with a twisted inner airfoil and outer airfoil.
[0033] FIG. 13 is a wind turbine with an inverted clockwise and counterclockwise helical three bladed central airfoil and three circumferential bent airfoils.
[0034] FIG. 14 is a wind turbine with an inverted clockwise and counterclockwise helical three bladed central airfoil and three circumferential inverted clockwise and counterclockwise helical airfoils.
[0035] FIG. 15 is a wind turbine with three inverted clockwise and counterclockwise helical airfoils.
[0036] FIG. 16 shows a stack of multiple airfoil wind turbines.
[0037] FIG. 17 illustrates a collapsible airfoil assembly in which each of the airfoil blades is hinged.
DETAILED DESCRIPTION OF THE INVENTION
[0038] An assembly, built of multiple individual airfoil units 1 is shown in FIG. 1 . This assembly is mounted on a center pole 2 that is attached to a frame 3 to which a generator 4 is attached. This design is a true airfoil design and thus it is always exposed to the wind regardless of wind direction. The airfoil of this invention provide a leading edge like an airplane wing and thus provides separation of the airflow between the top and bottom sections of the airfoil in such a manner that it generates lift in addition to being pushed. The combination of lift and push is not typical for conventional wind turbines and provides for improved efficiency.
[0039] The twisted airfoil, shown in FIG. 2 , is comprised of multiple units that stack upon each other until the desired size is formed. Shown are the individual unit 5 , and the manner in which these units attach to each other 6 . Also shown are optional metal end caps 7 that fit into the bosses on both ends and provide a strong attachment point. Typically, wind turbines require a large size to produce significant power but large blades or turbine components made of the requisite lightweight materials require expensive hand made manufacturing whereas the stackable units of this invention could be manufactured by low cost processes including plastic injection molding. The design of the individual units is unique in that it includes both mechanical interconnects on the ends of each unit and a hollow square central section, in which a pole or cable runs, that acts as a keyway. For larger units, metal end caps could be inserted between sections to provide additional strength. Having individual units lowers manufacturing costs as well as transportation costs over having a one piece large turbine.
[0040] FIG. 3 is an end view of a three blade twisted airfoil unit 8 . The airfoil blades are designed such that the wind 9 provides both push 10 and lift 11 . FIG. 4 shows this airfoil unit constructed of a flexible material such that the blade tips 12 are pushed towards the center thus reducing the negative drag as the wind 13 contacts the uncapped side of the airfoil 14 .
[0041] FIG. 5 shows a four-bladed airfoil 15 with the blades tilted at the optimum 33-degree angle from normal 16 . While this angle is believed to be the optimum for efficiency, it is understood that different angles of the airfoil into the wind will also be effective.
[0042] FIG. 6 is a stack of twisted airfoil units in which a portion of the center of each blade is removed 17 to reduce the weight of the structure. Since the leading edge 18 is a true airfoil, the wind is deflected both over and under the blade and thus the center part of the blade is not needed to obtain the desired turbine effect. Note that this concept of hollowing the blade center could be done in other shapes and could be used on three- and four-bladed airfoils as well.
[0043] FIG. 7 shows a configuration of how two airfoil units could be stacked together. A three blade airfoil unit with a clockwise spiral 19 is attached to a three blade airfoil unit with a counter-clockwise spiral 20 . In this configuration, the leading edge 21 directs the wind into the center of the turbine 22 and sets up the direction of spin with the curve of the airfoils 23 . The mid section of the airfoil 24 acts like a wing while the leading edge 25 is an airfoil can create both push and lift creating this spin. The section 26 is bent over to reduce drag as it rotates forward into the funnel zone.
[0044] FIG. 8 shows a configuration in which a three blade counter-clockwise spiral airfoil 27 is attached to a three blade clockwise-spiral airfoil 28 . In this configuration the air stream converges towards the center foil 29 such that the force is concentrated increasing the efficiency of the system. The spirals also tend to direct the air outward in the opposite direction on the back side of the turbine.
[0045] Although the helical turbines described herein could be mounted horizontally or vertically FIG. 9 shows another operation mode in which lighter than air inflatable gangs of airfoils 30 are tethered by a cable 31 to a spool 32 that is mounted on a vehicle or on the ground. The inflatable airfoil is made of a rubber-like material and can be mounted inside a fabric cover to which cables could be attached. The hollow airfoil could be filled with lighter than air gas and floated on a cable tether into the atmosphere where the wind currents are strong.
[0046] Another operation mode is shown in FIG. 10 where gangs of airfoils 33 are mounted to common hubs 34 such that the cumulative mechanical energy is captured by the hub mounted generator 35 . The hubs are attached to a bracket 36 that is mounted on a swivel 37 that can rotate the entire assembly into the wind. There can be different variations of this configuration including designs in which each twisted airfoil assembly powers an individual generator.
[0047] Another operation mode is shown in FIG. 11 where the turbine 38 is mounted horizontally on a pole 39 that is attached to a plurality of cables on one side 40 and to a swivel joint 41 connected to a cable 42 on the other. The swivel joint prevents tangling of the cable, while the generator 43 captures the mechanical energy from the spinning pole. The twisted airfoil of this invention simply needs a pole or cable running through the center to support it, perhaps with metal end caps between individual sections. Most other turbines require a large heavy aluminum or steel cage structure with welded bracket hubs to hold it together. This increases the weight of this other system significantly. In addition to stationary structures, it is an objective of this invention to provide a wind turbine that can be easily mounted to mobile structures, such as trucks and boats.
[0048] FIG. 12 shows yet another operational mode in which the built up twisted airfoil turbine 44 is combined with an outer airfoil 45 . This configuration improves efficiency in that the inside foil spins better at low wind speeds while the outer foil can better utilize higher wind speeds.
[0049] FIG. 13 shows an example of a wind turbine comprised of a three dimensional inverted clockwise and counterclockwise central helical airfoil with three circumferential airfoils. The central airfoil is comprised of two separate three bladed winged airfoils, one winged helical airfoil in the counterclockwise direction 46 and the other winged helical airfoil in the clockwise direction 47 , that are joined together. They can also be molded as one continuous part. When a clockwise rotated airfoil is attached to a counter-clockwise rotated airfoil, the spinning action of this system in the wind will create a vacuum where the two halves meet. This effective pushing of the air into the center, while pushing it away from the center on the backside is not found in standard turbines. The wind turbine of this example also is comprised of three Darrieus type circumferential airfoils 48 that are bent outward to allow for the central airfoil to spin freely. The central airfoil is attached to a three spoke hub 49 on the top and the bottom; the spokes of which are attached to the three circumferential airfoils. The central airfoil is very efficient in low wind speed conditions and the three circumferential airfoils are very efficient at high wind speeds. Also visible is the mounting hub 50 and the central rotating shaft 51 that the turbine is attached to and powers the generator. Note that the circumferential airfoils are optional and can be omitted or can be configured differently, such as straight blades, with corresponding changes in the spokes. Although the central and circumferential airfoils may spin independently of each other, it is preferred that they are fixed in position relative to each other such that they spin together. In this way the central airfoil can effectively be used to start up the assembly in low wind conditions and the circumferential airfoils can impart greater efficiency once the turbine is spinning. While any number of circumferential airfoils can be utilized, three are used in the preferred embodiment.
[0050] The central three bladed airfoil in the example shown in FIG. 14 is the same as the central airfoil used in the previous figures with a counterclockwise helix half 52 joined to a clockwise helix half 53 . In this example the three circumferential airfoils are also comprised of a counterclockwise helix half 54 joined to a clockwise helix half 55 . The central and circumferential airfoils are all connected to a three spoke central hub 56 on each end. The leading edge of the two counterclockwise and clockwise airfoils direct the air outward while the back side of these two helices directs the fluid inwards. A vacuum is created by the air moving outward, and the air is rapidly pulled into the center leading to a very high efficiency. This wing shaped turbine airfoil design can self start in low wind conditions and work efficiently in high winds without the need for an interior drag foil. The improved three dimensional helical wing shape effectively produces drag in low winds and lift in high winds across the leading edge airfoil shape not found on conventional helix designs. This contrasts with the single Darrieus helix designs that have difficulty starting in low winds.
[0051] FIG. 15 represents a similar wind turbine as the previous examples, except that the central airfoil is absent. Instead there are three circumferential airfoils, each with half of the airfoil helix clockwise 57 and half helix counterclockwise 58 joined by a three spoke hub 59 at the top, middle and bottom. Through the center of the assembly a rotating shaft 60 is attached to each of the three spoked hubs.
[0052] FIG. 16 is an example of a similar multiple helix airfoil wind turbine to FIG. 15 in which two units are stacked to provide for a larger more powerful unit. However in this example, the ends of each helical airfoil have a tab such that they could be connected directly to the next twisted airfoil. As shown, the central three spoked hub of FIG. 15 is no longer necessary in this configuration. Visible is the circumferential airfoil blade segment with a clockwise helix 61 and a segment with a counterclockwise helix 62 . The circumferential airfoils are connected by three spoke hubs 63 and a central rotating shaft 64 powers the generator.
[0053] An example of the type of wind generator described by this invention in a collapsible configuration is shown in FIG. 17 . In this model, the counterclockwise helical half of the airfoil 65 is connected to the clockwise helical half 66 by a hinge 67 . Hinges 68 and 69 connect the airfoils to spoked hubs 70 and 71 that are attached to the central rotating shaft 72 . This entire assembly can collapse for a very portable energy generator. This configuration still provides for the improved efficiency of the opposed pitched blade combination, yet in a portable design. | An improved wind energy generator is described. This invention is a wind turbine that utilizes airfoils in unique designs that are made of lightweight materials. The turbine is manufactured by low cost production methods as portable units that are stacked in series to provide for significant power harvesting. The use of three dimensional twisted airfoils enable high efficiency and easy start up. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of hypodermic syringes and needles. More particularly, the present invention is directed to a disposable hypodermic syringe and needle combination which has a retractable sheath to prevent accidents and abuse of the syringe and needle combination.
2. Brief Description of the Prior Art
Disposable hypodermic syringes and needles have been known in the art for a long time.
Hypodermic syringes and needles are often used for administering medication to patients suffering from infectious diseases. Therefore, it has been considered of great importance in the art to avoid accidents where doctors, nurses, or other persons are wounded by used hypodermic needles. Presently, the safe disposal of used syringes and needles is considered a serious problem in the art, particularly in light of the recent spread of acquired immunodeficiency syndrome (AIDS), and of the widespread abuse of syringes and needles by addicts for administering illicit drugs.
In order to solve or ameliorate the foregoing problems, the prior art has provided rigid, puncture resistant disposable plastic containers into which doctors or nurses are expected to deposit disposable hypodermic syringes and needles immediately after their use. The containers, filled with the discarded syringes and needles, are then sealed and eventually disposed of. The disposal is ideally conducted in a manner which does not permit access to unauthorized persons desiring to obtain the syringes and needles for illegal or like abusive purposes. In spite of the foregoing and other precautions, accidents still occur with used hypodermic needles, sometimes with tragic consequences. Moreover, discarded syringes and needles are still often misappropriated for illegal, or drug abuse, purposes.
The foregoing problems remain especially acute in connection with syringes and needles used by paramedics, because paramedics often are unable to carry the specialized plastic containers required for safe disposal. Moreover, personnel working in housekeeping duties in hospitals presently are still often exposed to improperly discarded hypodermic syringes and needles. The present invention is designed to solve or substantially ameliorate the above-described problems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a disposable hypodermic syringe and needle combination wherein the needle is protected before and after use, to prevent accidents involving the used needle.
It is another object of the present invention to provide a disposable hypodermic syringe and needle combination wherein the needle is protected before use, and wherein the needle is permanently and irreversibly concealed after use so as to prevent abuse by users of illicit drugs.
The foregoing and other objects and advantages are attained by a hypodermic syringe and needle combination having a sheath mounted to the barrel in a first position wherein the sheath extends and conceals the needle. The sheath is movable on the barrel to occupy a second position wherein the needle is at least partially exposed. The needle and syringe combination is normally used to fill the syringe with medication and inject it into the patient in the second position of the sheath. The sheath is also movable to a third position on the barrel wherein the sheath again conceals the needle. The sheath is preferably irreversibly locked into the third position for disposal so that the combination cannot be retrieved and used for illegal or unauthorized purposes.
The features of the present invention can be best understood together with further objects and advantages by reference to the following description, taken in connection with the accompanying drawings, wherein like numerals indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first preferred embodiment of the hypodermic syringe and needle combination of the present invention, the view showing a protective sheath extended to cover and conceal the needle;
FIG. 2 is another perspective view of the first preferred embodiment, the view showing a protective sheath retracted, thereby exposing the needle;
FIG. 3 is still another perspective view of the first preferred embodiment, the view showing the protective sheath again extended and locked into position after the combination has been used;
FIG. 4 is a cross-sectional view taken on lines 4,4 of FIG. 1;
FIG. 5 is a cross-sectional view taken on lines 5,5 of FIG. 2;
FIG. 6 is a cross-sectional view taken on lines 6,6 of FIG. 3;
FIG. 7 is a partially exploded side view of the first preferred embodiment;
FIG. 8 is a side view of the first preferred embodiment with a portion of the protective sheath broken away, the view showing the protective sheath in its extended position covering the needle;
FIG. 9 is a partial side view of the first preferred embodiment, with a portion of the protective sheath broken away, the view showing the protective sheath in its retracted position wherein the needle is exposed;
FIG. 10 is another partial side view of the first preferred embodiment, with a portion of the protective sheath broken away, the view showing the protective sheath in its extended locked position covering the needle;
FIG. 11 is a cross-sectional view, the cross-section being taken on lines 11,11 of FIG. 8;
FIG. 12 is a perspective view of a second preferred embodiment of the hypodermic syringe and needle combination of the present invention, the view showing a protective sheath extended to cover the needle;
FIG. 13 is a side view of the second preferred embodiment, partly in cross-section, the side view showing the protective sheath extended to cover the needle;
FIG. 14 is a partial side view of the second preferred embodiment, partly in cross-section, the view showing the protective sheath retracted to expose the needle;
FIG. 15 is a cross-sectional view of the second preferred embodiment, the cross-section being taken on lines 15,15 of FIG. 13;
FIG. 16 is a partial cross-sectional view of the second preferred embodiment, the cross-section being taken on lines 16,16 of FIG. 15;
FIG. 17 is a partial cross-sectional view of a third preferred embodiment of the hypodermic syringe and needle combination of the present invention, the view corresponding to an extended position of a protective sheath to cover the needle;
FIG. 18 is another partial cross-sectional view of the third preferred embodiment, the view corresponding to an extended and irreversibly locked position of the protective sheath to cover the needle;
FIG. 19 is a side view, partly in cross-section, of a fourth preferred embodiment of the hypodermic syringe and needle combination of the present invention, the view showing a protective sheath extended to cover the needle;
FIG. 20 is another side view, partly in cross-section, of the fourth preferred embodiment, the view showing a protective sheath retracted to cover the needle;
FIG. 21 is a cross-sectional view taken on lines 21,21 of FIG. 19;
FIG. 22 is a cross-sectional view taken on lines 22,22 of FIG. 21, the view corresponding to an extended position of the protective sheath to cover the needle;
FIG. 23 is another cross-sectional view of the fourth preferred embodiment, the view corresponding to a locked position of the protective sheath to cover the needle, and C
FIG. 24 is a cross-sectional view taken on lines 24,24 of FIG. 23.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following specification taken in conjunction with the drawings sets forth the preferred embodiments of the present invention. The embodiments of the invention disclosed herein are the best modes contemplated by the inventor for carrying out her invention in a commercial environment, although it should be understood that several modifications can be accomplished within the scope of the present invention.
Referring now to FIGS. 1 through 11 of the appended drawings, a first preferred embodiment 30 of the hypodermic syringe and needle combination of the present invention is disclosed. The first preferred embodiment 30 includes a syringe barrel 32 and a plunger 34 mounted into the barrel 32 at its first end 36. A hypodermic needle 38 is mounted in a conventional manner to the second end 40 of the barrel 32.
As an important novel feature, a sheath 42 is mounted to the barrel 32 at the same end 40 of the barrel 32 where the needle 38 is mounted. As is best shown on the perspective view of FIG. 1, in its normal or first position, the sheath 42 is disposed to conceal and cover the needle 38. The combination of the first preferred embodiment 30 is assembled during manufacture, and is kept, during shipping, storage, and preliminary preparation for administration of medication (not shown) to a patient (not shown), with the sheath 42 in its extended first position. To insure sterility, the sheath 42 is preferably sealed to the barrel with an airtight flexible plastic wrap (not shown). The flexible wrap (not shown) also serves as a tamper indicator.
The end 44 of the sheath 42, which is remote from the barrel 32, is tapered in the first preferred embodiment 30, and bears a friction fitted plastic cap or cover 46. The cap or cover 46 is shown on FIGS. 1 and 8.
As is apparent from FIGS. 1 through 11, the sheath 42 can be moved on the barrel 32 to expose the needle 38 when it is desired to fill the barrel 32 with medication (not shown) and administer the medication (not shown) to a patient (not shown). More particularly, the sheath 42 is locked in its first position to the barrel 32, but can be dislodged from the first position to be moved to a second position to expose the needle 38. The second position is shown on FIG. 2. Still a third position of the sheath 42 relative to the barrel 32 and needle 38 is shown on FIG. 3. In the third position, into which the sheath 42 is placed for disposal of the hypodermic syringe and needle combination 30, the sheath 42 is substantially irreversibly locked to cover and conceal the needle 38. Consequently, in its "disposal state", the hypodermic syringe and needle combination 30 cannot be accidentally reused, and the needle 38 is prevented from accidentally wounding someone, thereby potentially spreading dangerous infectious disease. As an added safety feature, after the sheath 42 is locked into the third position shown on FIG. 3, but before final discarding, the cap or cover 46 is preferably refitted to the sheath 42.
The above-described functions of the preferred embodiment 30 are accomplished by the structure illustrated in FIGS. 1-11. More particularly, the surface of the barrel 32 includes a channel or groove having two interconnected elongated parallel portions, which respectively bear the reference numerals 48 and 50 on the drawing Figures. The interior surface of the sheath 42 includes a protrusion or boss 52 which fits into and is guided in the channels 48 and 50. The channels or grooves 48 and 50 are approximately 0.008" to 0.012" deep.
The partial cross-sectional view of FIG. 4 shows the boss 52 placed into the channel 48 in the first position of the sheath 42 (in which the combination 30 is normally kept prior to use).
In order to reversibly lock the sheath 42 in this position the guide channel 48 has a depression or cavity 54 in a location corresponding to the location of the boss 52 in the first position of the sheath 42. The cavity 54 includes a camming surface 56 comprising a slope or a radius, which permits the substantially square-shaped boss 52 to ride out of the cavity 54 in one direction only. FIG. 4 also shows a slope or camming surface 58 at the end 40 of the barrel 32, which permits the initial mounting of the sheath 42 on the barrel 32 without serious interference by the boss 52. FIG. 7 shows well the interconnecting guide channels 48 and 50, and also shows the sheath 42 before it is initially mounted to the barrel 32. The configuration of the cavity 54 shown on FIG. 4 renders it substantially impossible to remove the sheath 42 from the barrel 32 without breaking or damaging the boss 52 and thereby the entire combination 30. In addition to FIG. 4, FIGS. 8 and 11 also show the sheath 42 mounted to the barrel 32 in the first position wherein the boss 52 engages the cavity 54 in the guide channel 48.
FIGS. 2, 5, and 9 indicate the second position of the sheath 42 relative to the barrel 32. In this position, the boss 52 of the sheath 42 engages a second depression or cavity 60, which is located almost at the upper end of the guide channel 48. The shape or configuration of the second cavity 60 is similar to that of the first cavity 54, so that the boss 52 can ride out of the second cavity 60 in the upwardly direction only.
FIGS. 6 and 10 show the boss 52 of the sheath 42 engaging, in the third position of the sheath 42, a third depression or cavity 62 located substantially at the lower end of the guide channel 50. The third cavity 62 has no slope or camming surface; rather it has straight walls 64 designed to capture the boss 52, and thereby irreversibly lock the sheath 42 in the position concealing the needle 38. It is apparent from an inspection of FIG. 6 that the sheath 42 can be moved out of the third position only by breaking or substantially damaging the boss 52.
All components of the above-described combination 30, with the exception of the metal body of the needle 38, can be manufactured by injection molding from plastic materials of the type ordinarily used for the manufacture of hypodermic syringes. The sheath 42, however, can be made of a lower non-medical grade of plastic because it does not come into contact with medication. In fact, as an additional novel and optional feature of the present invention, the sheath 42 is made of a plastic material which melts at substantially lower temperature than the medical grade plastic of the syringe barrel 32 and plunger 34, and which does not withstand the temperatures required for heat sterilization of syringes. Consequently, if one were to attempt to heat sterilize the hypodermic syringe and needle combination of the present invention for reuse, the sheath 42 would melt and render the combination 30 unusable. This, of course, is in addition to the locking feature of the sheath 42 or the barrel 32 for disposal. The just-described feature clearly reduces even further the potential for abuse of the hypodermic syringe and needle combination of the present invention.
Although the manner of using the first preferred embodiment 30 of the novel hypodermic syringe and needle combination of the present invention is apparent from the foregoing description and drawing figures, for the sake of further clarity and full disclosure, the steps are summarized as follows.
Just before use, the tamper evident wrapping seal (not shown) is removed by a doctor (not shown), nurse (not shown), or patient (not shown) from the hypodermic syringe and needle combination 30 of the invention. Thereafter, the cap 46 is removed from the end 44 of the sheath 42, and the sheath 42 is moved upward on the barrel 32, first by dislodging the boss 52 from the first cavity 54 and thereafter by sliding the boss 52 in the guide channel 48. Just before the boss 52 reaches the end of the guide channel 48, it snaps into the cavity 60, indicating that the sheath 42 has reached its second position relative to the barrel 32 and needle 38. The hypodermic syringe and needle combination 30 is used in this configuration to fill the barrel 32 with a drug or medication (not shown) and to administer the medication (not shown) into the patient (not shown). After administration of the medication, the sheath 42 is moved slightly upward, turned, and thereafter moved downward relative to the barrel 32 by riding the boss 52 in the guide channel 50, until the boss 52 is captured in the third cavity 62. This locks the sheath 42 in its final position adapted for safe disposal of the combination 30. Optionally, just before the combination 30 is discarded and as an added safety feature, the cap 46 may be placed back on the end 44 of the sheath 42.
Apparent advantages of the above-described embodiment 30 include the excellent protection it affords against accidentally wounding the hands of doctors, nurses, or other personnel handling the syringe and needle combination 30, before, and especially after administration of a drug (not shown) to a patient (not shown), and the built-in safeguard against abuse or misuse of the syringe and needle combination.
Referring now to FIGS. 12 through 16, a second preferred embodiment 66 of the invention is shown. The second preferred embodiment 66 is similar in many respects to the above-described first preferred embodiment 30, and is therefore described here in less detail. Thus, the second preferred embodiment 66 of the syringe and needle combination of the invention also includes a sheath 42 which is mounted to the syringe barrel 32 for relative motion thereon.
The sheath 42 of the second preferred embodiment 66 includes, on its upper portion, a plurality of circumferentially and substantially evenly spaced fingers 68. As is best shown on FIG. 12, the fingers 68 are defined by the axially disposed slots 70 located in the upper portion of the sheath 42. Each finger 68 includes an inwardly directed boss or protrusion 52. The barrel 32 of the second preferred embodiment 66 includes two circumferential slots or grooves which bear the reference numerals 72 and 74, respectively.
In the second embodiment 66, the sheath 42 has two principal positions relative to the barrel 32 and needle 38. In the first position, shown on FIGS. 13, the bosses 52 of the fingers 68 engage the lower circumferential groove 72, and the needle 38 is protected by the sheath 42. In the second position of the sheath 42, the bosses 52 of the fingers 68 engage the upper circumferential groove 74, and the needle 38 is exposed. After the hypodermic syringe and needle combination of the second preferred embodiment 66 has been used for administering medication, the sheath 42 is again placed into the first position wherein it covers the needle 38.
FIGS. 17 and 18 disclose a third preferred embodiment 76 which is similar in construction to the second embodiment 66, but, after the combination has been used for its intended purpose, permits permanent locking of the sheath 42 in the position where the needle 38 is covered. This is accomplished by providing two circumferential grooves 72 and 78 on the lower portion of the barrel 32. Before use, the camming bosses 52 of the fingers 68 rest in the circumferential groove 72 from which they are removed when the sheath 42 is moved upwardly on the barrel 32 to expose the needle 38. Before the third preferred embodiment 76 is used, additional square bosses 80 of the fingers 68 rest on the barrel 32, as is shown on FIG. 17. After use, the sheath 42 is locked into its position to cover the needle 38 by pushing the sheath 42 on the barrel 32 slightly below its original first position, whereby the square bosses 80 engage and lock into the groove 72, and the camming bosses 52 are simply accommodated in the circumferential groove 78.
FIGS. 19 through 23 disclose yet a fourth preferred embodiment 82 of the hypodermic syringe and needle combination of the present invention. The fourth embodiment 82 is similar in many respects to the first preferred embodiment 30 in that an inwardly directed boss 52 of the sheath 42 is guided in a guide channel 84 to accomplish the hereinafter-described functions. More particularly, in the first position of the sheath 42 it covers and protects the needle 38. In this position, the boss 52 is disposed in a side arm 86 of the guide channel 84. In order to prepare the syringe and needle combination 82 for use, the cap 46 is removed and the sheath 42 is slightly turned relative to the barrel 32 until the boss 52 is located in the main guide channel 84. The sheath 42 is then moved upward on the barrel 32 to expose the needle 38. After administration of a drug (not shown) by the combination 82, the sheath 42 is moved downwardly on the barrel 32, and is thereafter turned so as to guide the boss 52 into the second side arm 88 of the guide channel 84. After a slight upward pull, the boss 52 engages and locks into the cavity 90, thereby locking the sheath 42 into its final position for disposal. In this position the needle 38 is covered by the sheath 42, but for added safety the cap 46 is also replaced on the sheath 42.
What has been described above is a novel hypodermic syringe and needle combination having a movably mounted protective sheath to cover the needle before and after the use of the syringe and needle for administering drugs to patients, or in the course of veterinary medicine, drugs to animals. The novel combination of the present invention offers the advantages of safety, substantially eliminates the dangers of accidental wounding and infection of persons by used needles, and significantly reduces the danger for abuse or misuse of disposable syringes and needles.
Inasmuch as many modifications of the present invention may become readily apparent to those skilled in the art in light of the foregoing disclosure, the scope of the present invention should be interpreted solely from the following claims. | A disposable combination of a hypodermic syringe and needle has a sheath movably mounted on the syringe barrel to normally occupy a first position wherein the sheath extends to cover and protect the needle. Substantially axial guide channels are provided in the exterior surface of the barrel to accept an inwardly pointed boss of the sheath to guide the sheath into a second position and a third position. In the second position of the sheath, relative to the barrel and needle, the needle is at least partially exposed. In the third position of the sheath, which is used for disposal of the syringe and needle combination, the needle is again covered by the sheath and preferably the sheath is irreversibly locked whereby abuse or misuse of the syringe and needle combination is substantially prevented. In alternative embodiments, instead of axial guide channels, the bosses of the sheath may be engaged in appropriately formed circumferential grooves or depressions formed in the outer surface of the barrel. | 0 |
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to European Patent Application No. 09157726.2 filed in Europe on Apr. 9, 2009, the entire content of which is hereby incorporated by reference in its entirety.
FIELD
[0002] The disclosure relates to axial compressor blades and design methods thereof. For example, the disclosure relates to blades without shrouds and design methods that provide or produce unshrouded blades in stages 18 - 22 of axial compressors resilient to tip corner cracking.
BACKGROUND INFORMATION
[0003] Detailed design simulation may not eliminate all axial compressor blade failures as some of these failures can be a result of interaction between different components and therefore difficult to predict. One such failure mode is tip corner cracking that occurs towards the trailing edge of a blade due to Chord-Wise bending mode excitation. It is understood that the failure may be a result of resonance of the vanes passing frequency, which is the frequency of the vanes' wakes impacting an adjacent blade, and the chord-wise bending, which relates to a particular blade's Eigen-frequency. This can be characterised by a local bending of the tip of the blade in a direction perpendicular to the blade's chord. Another assumed failure cause can be a forced excitation resulting from rubbing of the blade's tip against the compressor casing. This rubbing can occur wherever new blades are mounted in a compressor.
[0004] Known solutions to tip corner cracking can include increasing the number of vanes. While this can be effective in eliminating a particular resonance, the solution can increase manufacturing cost and reduces stage efficiency and further does not address the problem of rubbing.
[0005] Another solution can involve increasing the blade's clearances at the tip, thereby reducing the rubbing potential. This however can reduce stage efficiency and may negatively affect the surge limit.
[0006] A further solution can involve changing the blade design by introducing squealer tips or abrasive coating, for example as described in U.S. Pat. No. 6,478,537 B2 as it relates to turbine blades, and/or using a hardened material on the blade's tip, as described in U.S. Patent Application Publication No. 2008/0263865 A1.
[0007] In each case disclosed above, manufacturing costs can be increased. In addition, the foregoing solutions do not always address tip corner cracking.
SUMMARY
[0008] A blade for a multi-stage axial compressor, for use in any one of stages eighteen to twenty one of the axial compressor, including a base and an airfoil, extending radially from the base, having a suction face and a pressure face, a second end radially distal from the base, a chord length, a camber line, a thickness defined by a distance, perpendicular to the camber line, between the suction face and the pressure face, a plurality of relative thicknesses, defined as the thickness divided by the chord length, an airfoil height, defined as a distance between the base and the second end, and a relative height, defined as a height point, extending in the radial direction from the base, divided by the airfoil height, at a first division starting from the base, the relative airfoil height is 0.000000 and a maximum relative thickness at that height is 0.1200, at a second division starting from the base, the relative airfoil height is 0.305181 and a maximum relative thickness at that height is 0.1139,at a third division starting from the base, the relative airfoil height is 0.553382 and a maximum relative thickness at that height is 0.1089, at a fourth division starting from the base, the relative airfoil height is 0.745602 and a maximum relative thickness at that height is 0.1050, at a fifth division starting from the base, the relative airfoil height is 0.884467 and a maximum relative thickness at that height is 0.1023, at a sixth division starting from the base, the relative airfoil height is 0.973731 and a maximum relative thickness at that height is 0.1005, and at a seventh division starting from the base, the relative airfoil height is 1.0000 and a maximum relative thickness at that height is 0.1000, each maximum relative thickness has a tolerance of +/−0.3%, and is carried to four decimal places and each relative height is carried to six decimal places.
[0009] A stage twenty-two blade for a multi-stage axial compressor including a base, and an airfoil, extending radially from the base, having a suction face and a pressure face, a second end radially distal from the base, a chord length, a thickness defined by a distance between the suction face and the pressure face, a plurality of relative thicknesses defined as the thickness divided by the chord length, an airfoil height defined as a distance between the base and second end, and a relative height defined as a height point, extending in the radial direction from the base, divided by the airfoil height, at a first division starting from the base, the relative airfoil height is 0.000000 and a maximum relative thickness at that height is 0.1100, at a second division starting from the base, the relative airfoil height is 0.276215 and a maximum relative thickness at that height is 0.1027, at a third division starting from the base, the relative airfoil height is 0.503836 and a maximum relative thickness at that height is 0.0967, at a four division starting from the base, the relative airfoil height is 0.690537 and a maximum relative thickness at that height is 0.0920,at a fifth division starting from the base, the relative airfoil height is 0.835465 and a maximum relative thickness at that height is 0.0885, at a sixth division starting from the base, the relative airfoil height is 0.947997 and a maximum relative thickness at that height is 0.0860, and at a seventh division starting from the base, the relative airfoil height is 1.0000 and a maximum relative thickness at that height is 0.0850, each maximum relative thickness has a tolerance of +/−0.3%, and is carried to four decimal places and each relative height is carried to six decimal places.
[0010] A method for manufacturing a modified airfoil of a blade for a multistage axial compressor based on a pre-modified airfoil of a blade wherein the blade includes a base and an airfoil that has a pressure face, a suction face, and a thickness defined as the distance between the pressure face and the suction face. The method includes: a) checking, by simulation, a stress level of the pre-modified airfoil of a blade in response to a perfect impulse using force response analysis; b) thickening, by simulation, of the airfoil in a way that shifts a natural frequency of the pre-modified airfoil to a higher frequency and reduces a stress in the pre-modified airfoil in response to a multi frequency impulse; c) checking, by simulation, a stress level of the modified airfoil in response to a perfect impulse by force response analysis, and when the stress level is less than 50% of the stress level of a) repeat from b); and d) manufacturing a blade with the modified airfoil of b).
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Exemplary embodiments of the present disclosure are described more fully hereinafter with reference to the accompanying drawings, in which:
[0012] FIG. 1 is a cross sectional view along the longitudinal axis of a portion of an axial compressor section that includes exemplary blades;
[0013] FIG. 2 is a top view of a prior art airfoil of an exemplary stage 18 - 22 stage blade of FIG. 1 ;
[0014] FIG. 3 is a top view of an airfoil of the exemplary blade shown in FIG. 1 ; and
[0015] FIG. 4 is a side view of the exemplary blade shown in FIG. 1 showing airfoil features.
[0016] In the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosure. It may be evident, however, that the disclosure may be practiced without these specific details.
DETAILED DESCRIPTION
[0017] An exemplary embodiment provides a blade for a multi-stage axial compressor. The exemplary blade can include an airfoil, extending from a base, with a plurality of maximum relative thicknesses at a plurality of relative heights at a plurality of divisions. At a first division starting from the base, the relative airfoil height can be, for example, 0.000000 and the maximum relative thickness at that height can be, for example, 0.1200. At a second division starting from the base, the relative airfoil height can be, for example, 0.305181 and the maximum relative thickness at that height can be, for example, 0.1139. At a third division starting from the base, the relative airfoil height can be, for example, 0.553382 and the maximum relative thickness at that height can be, for example, 0.1089. At a fourth division starting from the base, the relative airfoil height can be, for example, 0.745602 and the maximum relative thickness at that height can be, for example, 0.1050. At a fifth division starting from the base, the relative airfoil height can be, for example, 0.884467 and the maximum relative thickness at that height can be, for example, 0.1023. At a sixth division starting from the base, the relative airfoil height can be, for example, 0.973731 and the maximum relative thickness at that height can be, for example, 0.1005. At a seventh division starting from the base, the relative airfoil height can be, for example, 1.0000 and the maximum relative thickness at that height can be, for example, 0.1000,
[0018] Another exemplary embodiment provides a blade for a multi stage axial compressor. The exemplary blade includes an airfoil, extending from a base, with a plurality of maximum relative thicknesses at a plurality of relative heights at a plurality of divisions. At a first division starting from the base, the relative airfoil height can be, for example, 0.000000 and the maximum relative thickness at that height can be, for example, 0.1100. At a second division starting from the base, the relative airfoil height can be, for example, 0.276215 and the maximum relative thickness at that height can be, for example, 0.1027. At a third division starting from the base, the relative airfoil height can be, for example, 0.503836 and the maximum relative thickness at that height can be, for example, 0.0967. At a four division starting from the base, the relative airfoil height can be, for example, 0.690537 and the maximum relative thickness at that height can be, for example, 0.0920. At a fifth division starting from the base, the relative airfoil height can be, for example, 0.835465 and the maximum relative thickness at that height can be, for example, 0.0885. At a sixth division starting from the base, the relative airfoil height can be, for example, 0.947997 and the maximum relative thickness at that height can be, for example, 0.0860. At a seventh division starting from the base, the relative airfoil height can be, for example, 1.0000 and the maximum relative thickness at that height can be, for example, 0.0850
[0019] Referring to FIG. 1 , a portion of an exemplary multi-stage compressor 1 is illustrated. Each stage 5 of the axial compressor 1 includes a plurality of circumferentially spaced blades 6 mounted on a rotor 7 and a plurality of circumferentially spaced vanes 8 , downstream of the blade 6 along the longitudinal axis LA of the axial compressor 1 , mounted on a stator 9 . For illustration purposes only the first twenty-two stages 5 are shown in FIG. 1 . Each of the different stages 5 of the axial compressor 1 has a vane 8 and a blade 6 each having a uniquely shaped airfoil 10 .
[0020] FIG. 3 is a top view of an exemplary airfoil 10 b configured to be an airfoil 10 of a blade 6 of any one of compressor stages eighteen to twenty-two 15 , shown in FIG. 1 . The airfoil 10 b has a pressure side 22 , a suction side 20 and a camber line CL. The camber line CL is the mean line of the airfoil profile extending from the leading edge LE to the trailing edge TE equidistant from the pressure side 22 and the suction side 20 . The airfoil 10 has a thickness TH, which is defined as the distance between the pressure side 22 and the suction side 20 of the airfoil 10 measured perpendicular to the camber line CL. The maximum thickness TH is the point across the airfoil 10 where the pressure side 22 and suction side 20 are furthest apart. The chord length CD of the airfoil 10 , as shown in FIG. 2 , is the perpendicular projection of the airfoil profile onto the chord line CL.
[0021] Airfoils 10 of exemplary embodiments have a maximum airfoil thickness TH profile in the radial direction RD that can be expressed in relative terms. For example, the maximum relative thickness RTH can be the maximum thickness TH divided by the chord length CD for a given airfoil height point.
[0022] As shown in FIG. 4 , the airfoil height point, measured in the radial direction RD, is a reference point along the airfoil height AH wherein the airfoil height AH is the distance between the airfoil base A and a radially distal end of the airfoil 10 . In this disclosure airfoil height points can be referenced from the airfoil base A and expressed as relative height RAH defined as an airfoil height point divided by airfoil height AH.
[0023] FIG. 4 further shows the general location of the tip region TR of the airfoil, which is the region of the airfoil 10 furthest from its base A. This region can be further subdivided in to a corner tip region TETR, which, in this disclosure, is taken to be the corner region of the tip TR that is proximal to and includes the trailing edge TE.
[0024] Exemplary embodiments of airfoils 10 of blades 6 suitable for an axial compressor 1 will now be described, by way of example, with reference to the dimensional characteristics defined in FIG. 3 , at various relative airfoil heights RAH.
[0025] An exemplary embodiment, suitable for an axial compressor eighteenth stage 5 , blade 6 , as shown in FIG. 1 , has a maximum relative thickness RTH, taken to four decimal places, at various relative airfoil heights RAH, taken to six decimal places, as set forth in Table 1.
[0000]
TABLE 1
Maximum relative
Relative height
thickness RTH
RAH
0.12
0
0.1139
0.305740
0.1089
0.557395
0.105
0.752759
0.1022
0.891832
0.1005
0.977925
0.1
1
[0026] An exemplary embodiment, suitable for an axial compressor nineteenth stage 5 , blade 6 , as shown in FIG. 1 , has a maximum relative thickness RTH, taken to four decimal places, at various relative airfoil heights RAH, taken to six decimal places, as set forth in Table 2.
[0000]
TABLE 2
Maximum relative
Relative height
thickness RTH
RAH
0.12
0
0.1139
0.304813
0.1089
0.556150
0.105
0.749733
0.1022
0.886631
0.1005
0.973262
0.1
1
[0027] An exemplary embodiment, suitable for an axial compressor twentieth stage 5 , blade 6 , as shown in FIG. 1 , has a maximum relative thickness RTH, taken to four decimal places, at various relative airfoil heights RAH, taken to six decimal places as set forth in Table 3.
[0000]
TABLE 3
Maximum relative
Relative height
thickness RTH
RAH
0.12
0
0.1138
0.304622
0.1088
0.549370
0.105
0.738445
0.1023
0.877101
0.1005
0.969538
0.1
1
[0028] An exemplary embodiment, suitable for an axial compressor twenty first stage 5 , blade 6 , as shown in FIG. 1 , has a maximum relative thickness RTH, taken to four decimal places, at various relative airfoil heights RAH, taken to six decimal places, as set forth in Table 4.
[0000]
TABLE 4
Maximum relative
Relative height
thickness RTH
RAH
0.12
0
0.1138
0.310969
0.1088
0.560170
0.105
0.750799
0.1023
0.888179
0.1005
0.976571
0.1
1
[0029] An exemplary embodiment, suitable for any one of stages eighteen to twenty one of an axial compressor as shown in FIG. 1 , has a maximum thickness with a tolerance of +/−0.3%, at various relative airfoil heights RAH, taken to six decimal places, as set forth in Table 5.
[0000]
TABLE 5
Maximum relative
Relative height
thickness RTH
RAH
0.12
0
0.1139
0.305181
0.1089
0.553382
0.105
0.745602
0.1023
0.884467
0.1005
0.973731
0.1
1
[0030] An exemplary embodiment, suitable for an axial compressor twenty second stage 5 , blade 6 , as shown in FIG. 1 , has a maximum relative thickness RTH, taken to four decimal places, with a tolerance of +/−0.3%, at various relative airfoil heights RAH, taken to six decimal places, as set forth in Table 6.
[0000]
TABLE 6
Maximum relative
Relative height
thickness RTH
RAH
0.11
0
0.1027
0.276215
0.0967
0.503836
0.092
0.690537
0.0885
0.835465
0.086
0.947997
0.085
1
[0031] An exemplary design method for modifying an axial compressor airfoil 10 susceptible, in use, to tip corner cracking in the tip corner region TRTE, shall now be described. An example of such an airfoil 10 a , referred to as a pre-modified airfoil 10 a , is shown in FIG. 2 . First a baseline measurement of the pre-modified airfoil 10 a is established. This involves, for example, checking the stress level of an airfoil 10 a , by simulation, using force response analysis, in response to an impulse force. The check can be done by the known method of finite element analysis, wherein the impulse can be a so called perfect impulse defined by being a broad spectrum frequency impulse so as to simulate a multi-frequency impulse imparted to an airfoil typically by the action of rubbing.
[0032] The check can further include, or be the measurement of, the frequency of the chord wise bending mode, using known techniques, of the pre-modified airfoil 10 a for later comparison with a modified airfoil 10 b so as to address failures resulting from chord wise bending mode excitation. The determination of the final modification, ready for blade manufacture, is, in an exemplary embodiment, determined by simulation.
[0033] After establishing, by simulation, a baseline, a simulated modification of the airfoil 10 , in an exemplary embodiment, involves thickening of the pre-modified airfoil 10 a in order to shift the natural frequency of the airfoil 10 to a higher frequency so as to reduce stress in response to a broad frequency pulse in the modified airfoil 10 b . The thickening also can increase stiffness. In an exemplary embodiment, the tip region TR can be preferentially thickened so as to minimise changes to the aerodynamic behaviour of the airfoil 10 . In a further exemplary embodiment the thickening can be greatest in a region proximal and adjacent to the trailing edge TE so as to provide increased resilience of the modified airfoil 10 b to tip corner cracking.
[0034] Next the impulse force response and the resulting stress level changed by the simulated thickening of the airfoil 10 is checked by simulation. In order to get a good comparison, the impulse force can be the same perfect impulse used to check the pre-modified airfoil 10 a , and the same force response analysis method can be used.
[0035] To ensure resilience to tip corner cracking the changes in performance of the airfoil 10 must be significant. Therefore, if the stress level in the thickened blade 6 is greater than 50% of the pre-modified airfoil 10 a , and/or in a further exemplary embodiment, the difference in the ratio of the frequency of the chord wise bending mode of the pre-modified 10 a and modified airfoil 10 b is less than 1.4:1, then the simulated thickening step can be repeated, otherwise the design steps are considered complete and the blade, with the modified airfoil 10 b , can be ready for manufacture.
[0036] Although the disclosure has been herein shown and described in what is conceived to be the most practical exemplary embodiment, it will be appreciated by those skilled in the art that the present disclosure can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the disclosure is indicated by the appended claims rather that the foregoing description and all changes that come within the meaning and range and equivalences thereof are intended to be embraced therein.
REFERENCE NUMBERS
[0000]
1 Axial compressor
5 Stage
6 Blade
7 Rotor
8 Vane
9 Stator
10 Airfoil
10 a Pre-modified airfoil
10 b Modified airfoil
15 Stages 18 to 22
20 Suction face
22 Pressure face
A Airfoil base
AH Airfoil height
CD Chord length
CL Camber line
LA Longitudinal axis
LE Leading edge
RAH Relative airfoil height
RD Radial direction
RTH Relative airfoil thickness
TH Airfoil thickness
TE Trailing edge
TR Tip Region
TRTE Corner tip region | The disclosure provides blades, and the modification thereof, for stages 18 - 22 of an axial compressor wherein the blades have reduced susceptibility to tip cracking. The blades and blades manufactured by the provided method have a thickened profile that results in reduced stress in response to multi frequency impulses and can have increased frequency response of the chord wise bending mode. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 12/400,497, filed Mar. 9, 2009, which is a non-provisional patent application of U.S. Provisional Patent Application Ser. No. 61/046,118, filed Apr. 18, 2008, each of which is incorporated herein by reference.
[0002] Priority of U.S. Provisional Patent Application Ser. No. 61/046,118, filed Apr. 18, 2008, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to continuous batch washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g. clothing, linen, etc.) in a continuous batch tunnel washer wherein the textiles are moved sequentially from one module or zone to the next module or zone including initial pre-wash zones, a plurality of main wash and pre-rinse zones, and then transferred to an extractor that removes water. More particularly, the present invention relates to an improved method of washing textiles in a continuous batch tunnel washer wherein a counter flow of wash liquor from one module or zone to the next module or zone is stopped, allowing for a standing bath. Chemicals are then added to separate soil from the goods and suspend the soil in the wash liquor. After a period of time, counter flow is commenced again to remove the suspended soil. The pre-rinsed goods are spray rinsed during extraction of excess water so that soil is not redeposited eliminated graying of the goods.
[0007] 2. General Background of the Invention
[0008] Currently, washing in a commercial environment is conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g. U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone. Commercial continuous batch washing machines utilize a constant counter flow of liquor and a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquid with the goods throughout the particular zone or zones.
[0009] Currently, a counter flow is used during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness. Additionally, while the bath liquor is being heated, this thermal energy is partially carried away by the counter flow thus wasting energy while a desired temperature value is achieved.
[0010] A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract.
[0011] Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples.
[0000]
TABLE
PAT. NO.
TITLE
ISSUE DATE
4,236,393
Continuous tunnel batch washer
Dec. 02, 1980
4,485,509
Continuous batch type washing
Dec. 04, 1984
machine and method for operating
same
4,522,046
Continuous batch laundry system
Jun. 11, 1985
5,211,039
Continuous batch type washing
May 18, 1993
machine
5,454,237
Continuous batch type washing
Oct. 03,1995
machine
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention improves the current art by reducing water consumption, improving rinsing capability, reducing the number of components required to perform the function of laundering fabric articles or textiles, and saving valuable floor space in the laundry.
[0013] The present invention reduces and/or combines zones, sectors, or modules and improves the method of processing the textiles. Rinsing is done in two zones, first in the continuous batch washer itself in an intermediate rinse zone after each main wash zone(s) and a pre-rinse in the last zone(s). A final rinse is then done in a mechanical water removal machine such as a centrifugal extractor or mechanical press.
[0014] When the goods are initially transferred into the main wash modules, the counter flow of wash liquor into the modules is stopped allowing for a standing bath. Chemicals are added to separate the soil from the goods and suspend the soil in the wash liquor. If needed, the wash liquor to the separate module bath is raised in temperature to facilitate the release of soil from the goods and activate the chemicals.
[0015] Once the soil has been released from the textiles, there is no more work for the chemicals to perform. At this time, the process can be described as “chemical equilibrium”. At this point, water by counter flow is commenced to remove the suspended soil. This rinsing is termed “intermediate rinse” in the wash zone(s) and a pre-rinse after the last wash zone. A final rinse can be performed in a centrifugal extractor or mechanical press.
[0016] The process of the present invention uses fresh water that can be supplied through an atomizing nozzle while the goods are being extracted. Because the free soil has already been removed in the pre-rinse zone, the spray rinse while extracting will not re-deposit soil on the linen thereby reducing or eliminating graying of the goods. It is not necessary to centrifuge (and drain at a low speed) the soil laden water before the final extract. With the present invention the process time is reduced. The amount of fresh water required compared with conventional processes is reduced.
[0017] The method of the present invention uses less water than in current art because the counter flow is stopped for part of the cycle. The spray rinse in the centrifugal extractor or mechanical press is more effective than the current practice of draining the free water from the linen and then refilling.
[0018] The method of the present invention preserves the washing effectiveness of current counter flow washers to wash heavy soil classifications because the amount of soil dilution is the same even though there are less zones, stages, or modules. The present invention provides a higher effective rinsing provided by the spray rinse in the centrifugal extractor because of the pre-rinse.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0020] FIG. 1 is a schematic diagram showing the preferred embodiment of the apparatus of the present invention;
[0021] FIG. 2 is a schematic diagram showing the preferred embodiment of the apparatus of the present invention;
[0022] FIG. 3 is a schematic diagram showing the preferred embodiment of the apparatus of the present invention;
[0023] FIG. 4 is a schematic diagram of an alternate embodiment of the apparatus of the present invention;
[0024] FIG. 5 is a schematic diagram of the alternate embodiment of the apparatus of the present invention;
[0025] FIG. 6 is a partial perspective view of the alternate embodiment of the apparatus of the present invention;
[0026] FIG. 7 is a partial perspective view of the preferred embodiment of the apparatus of the present invention;
[0027] FIG. 8 is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube;
[0028] FIG. 9 is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube; and
[0029] FIG. 10 is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube.
DETAILED DESCRIPTION OF THE INVENTION
[0030] FIGS. 1-3 shows a schematic diagram of the textile washing apparatus of the present invention, designated generally by the numeral 10 . Textile washing apparatus 10 provides a tunnel washer 11 having an inlet end portion 12 and an outlet end portion 13 . In FIG. 1 , tunnel washer 11 provides a number of modules 14 - 18 . These modules 14 - 18 can include a first module 14 and a second module 15 which can be pre-wash modules. The plurality of modules 14 - 18 can also include modules 16 , 17 and 18 which are main wash and pre-rinse modules.
[0031] The total number of modules 14 - 18 can be more or less than the five (5) shown in FIG. 1 . FIG. 2 shows an alternate arrangement that employs a tunnel washer 11 having eight (8) modules 14 - 18 and 35 - 37 . FIG. 3 shows an alternate arrangement that employs a tunnel washer 11 having ten (10) modules 14 - 18 and 35 - 39 . In FIG. 2 , the modules 14 , 15 can be pre-wash modules. In FIG. 3 , modules 14 , 15 , 16 can be pre-wash modules. In FIG. 2 , the modules 16 , 17 , 18 and 35 , 36 , 37 can be main wash and pre-rinse modules. In FIG. 3 , the modules 17 , 18 and 35 , 36 , 37 , 38 , 39 can be main wash and pre-rinse modules. Instead of a two (2) or three (3) module pre-wash section (see FIGS. 1 , 2 , 3 ), a single module 14 could be provided as an alternate option for the pre-wash section.
[0032] Inlet end portion 12 can provide a hopper 19 that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, goods to be washed can include clothing, linens, towels, and the like. An extractor 20 is positioned next to the outlet end portion 13 of tunnel washer 11 . Flow lines 21 , 25 , 26 , 27 , 27 A are provided for adding water and/or chemicals to tunnel washer 11 as will be described more fully hereinafter.
[0033] When the fabric articles, goods, linens are initially transferred into the main wash modules 16 , 17 , 18 , a counter flow of wash liquor into these modules 16 , 17 , 18 is reduced, preferably stopped allowing for a standing bath. Chemicals are then added as indicated by arrows 26 , 27 to the modules 16 , 17 and/or 18 . In FIG. 2 , chemicals are added as indicated by arrows 26 , 27 , 27 A to the modules 16 , 17 , 18 , 35 , 36 and/or 37 . In FIG. 3 , chemicals are added to the modules 16 - 18 and 35 - 39 as indicated by the arrows 26 , 27 , 27 A. In FIGS. 1-3 , these chemicals separate the soil from the goods, linens, textiles and suspend the soil in the wash liquor. During this step of the method of the present invention, the wash liquor temperature can be elevated if needed to facilitate the release of soil from the goods, fabric articles or linens and activate the chemicals.
[0034] Once the maximum soil has been released from the textiles or fabric articles, there is no more work for the chemicals to perform. At this time, the process can be described as chemical equilibrium. The flow of water is stopped for a time period sufficient to release soil from the goods such as for example between about 20 seconds and one hundred twenty (120) seconds. However, this time interval can be between about ten (10) and three hundred (300) seconds.
[0035] After this time interval of having no counter flow, water by counter flow is commenced to remove the suspended soil. This rinsing can be termed pre-rinse. A final rinse is then performed in a centrifugal extractor or mechanical press 20 . The process of the present invention uses fresh water that can be supplied through an atomizing nozzle for example while the goods are being extracted using the extractor 20 . The process of the present invention uses fresh water in the extractor that can be supplied through an atomizing nozzle for example while the goods are being extracted at high speed (e.g. between about 200 and 1,000 g's) using the extractor 20 .
[0036] Flow line 21 transmits water to hopper 19 as indicated by arrow 22 . Flow line 21 also carries water to pre-wash module 15 as indicated by arrow 23 . Arrow 24 indicates a flow of water from module 14 to module 15 as part of the pre-wash.
[0037] In FIG. 1 , flow line 25 adds water for counter flow pre-rinse to module 18 . Such water added via flow line 25 to module 18 flows in counter flow fashion from module 18 to module 17 to module 16 (see arrow 25 A). Arrows 26 and indicate chemical addition to modules 16 and 17 respectively. Chemicals to be added to modules 16 and 17 can include for example detergent, alkalaii, and/or oxidizing agents.
[0038] In FIG. 2 , flow line 25 adds water for counter flow pre-rinse to module 37 . Such water added via flow line 25 to module 37 flows in counter flow fashion from module 38 to module 37 , then 36 , then 35 , then 18 , then to module 17 (see arrow 25 B).
[0039] In FIG. 3 , flow line 25 adds water for counter flow pre-rinse to module 38 . Such water added via flow line 25 to module 38 flows in counter flow fashion from module 38 to module 37 , module 36 , module 35 , module 18 , and module (see arrow 25 C).
[0040] In FIG. 1 , textiles or fabric articles that are pre-washed, washed, and then pre-rinsed in tunnel washer 11 are transferred from module 18 to extractor 20 as indicated schematically by arrow 28 . In FIG. 2 , the textiles or fabric articles that are pre-washed, washed, and then pre-rinsed in tunnel washer 11 are transferred from module 37 to extractor 20 as indicated schematically by arrow 28 . In FIG. 3 , textiles or fabric articles that are pre-washed, washed, intermediately rinsed and then pre-rinsed in tunnel washer 11 are transferred from module 39 to extractor 20 as indicated schematically by arrow 28 .
[0041] The method of the present invention thus conducts rinsing in two zones. Rinsing is first conducted in the tunnel washer 11 in a pre-rinse zone which occurs after the main wash. In FIG. 1 , pre-wash zones can be 14 , 5 . The pre-rinse zone and main wash zone can be modules 16 , 17 , 18 . In FIG. 2 , the pre-wash zone can be modules 14 and 15 while the main wash and pre-rinse zones can be modules 16 , 17 , 18 , 35 , 36 and 37 . In FIG. 3 , the pre-wash zone can be modules 14 and 15 while the main wash and pre-rinse zones can be modules 16 , 17 , 18 , 35 , 36 , 37 , 38 and 39 . The second rinse zone is the final rinse, which is conducted in the extractor 20 or other mechanical water removal machine such as a mechanical press.
[0042] Because the free soil has already been removed in the pre-rinse zone at modules 16 , 17 , 18 of FIG. 1 (or 16 - 18 , 35 - 37 of FIG. 2 or 16 - 18 , 35 - 39 of FIG. 3 ) as part of the method of the present invention, the spray rinse while extracting will not redeposit soil on the linen thereby reducing or eliminating graying of the goods. With the present invention it is not necessary to centrifuge (and drain at a low speed) the soil laden water before the final extract at 20 . With the present invention, the process time is thus reduced. The amount of fresh water required compared with conventional processes is reduced. The spray rinse and the centrifugal extractor 20 or mechanical press is more effective than the current practice of draining the free water from the linen and then refilling the extractor 20 .
[0043] An additional benefit of the pre-rinse concept of the present invention is to permit the mechanical press or extractor to have more time extracting the free water. This result follows because the effect of the pre-rinse is to remove most of the suspended soil. The amount of fresh water required for final rinse is thus greatly reduced. The time for rinsing is reduced, allowing this saved cycle time for water removal.
[0044] The method of the present invention preserves the washing effectiveness of current counter flow washers 11 to wash heavy soil classifications because the amount of soil dilution is the same even though there are fewer zones or stages or modules.
[0045] The present invention provides a higher effective rinsing provided by the spray rinse 30 and the centrifugal extractor 20 because of the pre-rinse that is conducted in the modules 16 , 17 , 18 as discussed above.
[0046] FIGS. 4-10 show an alternate embodiment of the apparatus of the present invention, designated generally by the numeral 40 . The textile washing apparatus 40 of the alternate embodiment can provide the same tunnel washer 11 of the preferred embodiment having the modules 14 - 18 , 35 - 39 provided in any one of the embodiments of FIG. 1 , 2 or 3 . FIG. 4 shows the embodiment of FIG. 1 having a specially configured starch spray arrangement.
[0047] In FIG. 4 , a starch tank 41 contains starch that is to be injected into the linen, fabric articles, or clothing contained in extractor 20 . Starch for the table linen, clothing, fabric articles is pumped in the first phase of the cycle through a spray nozzle 60 (see FIGS. 8-10 ). Controlled flow metering can be achieved for example using an inverter controlled flow metering device. The precise amount of starch is thus injected into the linen, fabric articles, clothing or the like while in extractor 20 . Excess starch can be removed in a separate tank indicated as starch recovery tank 52 in FIG. 4 . Flow line 53 enables recovered starch in tank 52 to be transferred to starch tank 41 .
[0048] Starch tank 41 contains starch that is to be pumped via flow line 42 to nozzle 60 and then to extractor 20 . Fresh water tank 43 can also be used to pipe fresh water to extractor 20 , flowing through valve 45 to nozzle 60 . Valves 44 , 45 and 46 are provided for controlling the flow of either starch or fresh water or a combination thereof to nozzle 60 as shown in FIG. 4 .
[0049] Flow line 49 is a flow line that carries extracted water to tank 51 as it is purged from the fabric articles, clothing or linens contained in extractor 20 . Starch can be recovered via flow lines 49 , 50 to starch recovery tank 52 . Valves 44 , 47 are provided for valving the flow of starch from tank 41 to extractor 20 via flow line 42 . Valve 48 enables tank 41 to be emptied for cleaning or adding new starch.
[0050] In FIGS. 8-10 , starch spray nozzle 60 is shown in more detail. The spray nozzle 60 can provide an elongated section of conduit or pipe 61 . Spray nozzle 60 has an influent end 62 and a discharge end portion 63 . Conduit 61 provides an open ended bore 64 for conveying starch from flow line 42 to nozzle 60 . Influent end 62 provides a connection 80 for attaching conduit 61 to flow line 42 .
[0051] FIGS. 5-7 illustrate the spray pattern 76 that strikes the wall of drum 57 of extractor 20 as emitted by nozzle 60 . In FIGS. 6 and 7 , extractor 20 provides a drum 57 that provides a chamber 55 having an inlet 56 . Clothes, textiles, linens to be sprayed are discharged from tunnel washer 11 via chute 79 into the chamber 55 of extractor 20 . The extractor 20 is preferably movable between a loading and discharging position. The loading position is shown in FIGS. 5 and 6 . In the loading position, clothes transfer from the tunnel washer 11 to the chamber 55 via chute 79 . Pumps 54 can be used to aid in the transfer of water from tank 43 or starch from tank 41 into chamber 55 via nozzle 60 . The spray nozzle 60 produces a spray pattern 76 that extends substantially across the cylindrical wall 58 of drum 57 as shown in FIGS. 6 and 7 . Drum 57 thus provides an inlet 56 for enabling clothing, textiles, or other fabric articles to be added to the drum 57 interior 55 and a rear circular wall 59 . Notice in FIGS. 6 and 7 that the spray pattern 76 extends generally from inlet 56 to circular wall 59 , thus extending substantially across cylindric wall 58 as shown in FIGS. 6 and 7 . Arrow 77 in FIG. 7 illustrates the width of spray pattern 76 which can be about 16 degrees as an example along cylindrical drum wall 58 .
[0052] A mounting plate 65 can be provided having one or more openings 66 for attaching (for example, bolting) spray nozzle 60 to extractor 20 or to a frame that supports extractor 20 .
[0053] The discharge end portion 63 of spray nozzle 60 provides a nozzle tip 67 . The nozzle tip 67 provides a nozzle outlet 70 formed by side plates 71 , 72 , upper plate 73 and lower plate 74 . Atomizing water nozzle 68 , 69 are provided next to nozzle outlet 70 . The atomizing water nozzle 68 is mounted to upper plate 73 . The atomizing water nozzle 69 is mounted to lower plate 74 as shown in FIGS. 8-10 . Spray nozzle 60 can be equipped with aerating or atomizing nozzles 68 , 69 to control the consistency of the starch in the nozzle 60 , thus preventing starch build-up which might eventually plug of the nozzle 60 .
[0054] As part of the method of the present invention, all starch flow lines 42 , 60 can be purged with hot water from fresh water tank via flow line 75 .
[0055] The following is a list of parts and materials suitable for use in the present invention.
[0000]
PARTS LIST
Part
Number
Description
10
textile washing apparatus
11
tunnel washer
12
inlet end portion
13
outlet end portion
14
module
15
module
16
module
17
module
18
module
19
hopper
20
extractor
21
flow line
22
arrow
23
arrow
24
arrow
25
flow line
25A
arrow
25B
arrow
25C
arrow
26
arrow-chemical addition
27
arrow-chemical addition
27A
arrow-chemical addition
28
arrow-textile transfer
29
spray rinse flow line
30
arrow
31
extractor water
32
flow line
33
outlet valve
34
arrow
35
module
36
module
37
module
38
module
39
module
40
textile washing apparatus
41
starch tank
42
flow line
43
fresh water tank
44
valve
45
valve
46
valve
47
valve
48
valve
49
flow line
50
flow line
51
extracted water tank
52
starch recovery tank
53
flow line
54
pump
55
chamber
56
inlet
57
drum
58
cylindrical drum wall
59
circular drum wall
60
spray nozzle
61
conduit
62
influent end
63
discharge end
64
bore
65
mounting plate
66
opening
67
nozzle tip
68
atomizing water nozzle
69
atomizing water nozzle
70
nozzle outlet
71
side plate
72
side plate
73
upper plate
74
lower plate
75
flow line
76
spray pattern
77
arrow
78
drum moving mechanism
79
chute
[0056] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0057] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method of washing fabric articles in a tunnel washer includes moving the fabric articles from the intake of the washer to the discharge of the washer through first and second sectors that are a pre-wash zone. In the pre-wash zone, liquid is counter flowed in the wash interior along a flow path that is generally opposite the direction of travel of the fabric articles. The fabric articles are transferred to a main wash zone, and a washing chemical is added to the main wash zone. At about the same time, counter flow is reduced or stopped. The main wash zone can be heated as an option. After a period of time (for example, between about 20 and 120 seconds) counter flow is resumed or increased. In the wash zone, this is considered an intermediate rinse. After the wash zone(s), the increased counter flow after chemical treatment amounts to a pre-rinse. This pre-rinse ensures that the fabric articles are substantially free of soil or the majority of any soil and substantially free of chemicals when they are transferred to an extractor for final removal of excess water. A final rinse (second rinse) is conducted during extraction of excess water. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a passage structure for an air compressor and particularly to a structure that can increase heat dissipation efficiency and reduce noise during operation of the air compressors.
[0003] 2. Description of the Prior Art
[0004] The rapid progress of society mainly results from people's constantly pursuing a better quality of life. Many new products have been developed and introduced to meet this requirement. Compressor is one of such products. The constant innovation of people has greatly expanded the application scope of the compressor.
[0005] The conventional compressor still has problems during operation, such as generating high air temperature and noise. During compression process of air, the pressure provided by the compressor usually is greater than the upper compressible limit of the air. To reach balance, the air temperature has to rise. But excessive high temperature tends to accelerate wearing of facilities and shorten service life. If the air is to be used by human being, people will feel uncomfortable. On the other hand, not only the machine generates a noise during operation, but also the air compression dose. The noise makes users uncomfortable and reduces the quality of using the machine.
[0006] In short, to satisfy the rapid change pace of the modern society, the problems of the compressor have to be resolved. The present invention aims to practice this issue.
SUMMARY OF THE INVENTION
[0007] The primary object of the present invention is to provide a passage structure for an air compressor so that air and casing have a larger contact area and the casing has a plurality of cooling fins and a trough to increase total heat dissipation efficiency.
[0008] Another object of the invention is to provide a second space in the casing for guiding compressed air flow and a trough to increase the housing space thereby to reduce noise during air compression operation of the compressor.
[0009] The passage structure for an air compressor of the invention is fastened to a compressing unit. The heat dissipation structure includes a upper casing and a lower casing, two spaces located in the casing to form a first space and a second space, and four ports formed on the casing, namely a first port, a second port, a third port and a fourth port. The first port and the second port are communicated through the first space. The first space communicates with the exterior through the first port and the second port. The third port and the fourth port are communicated through the second space, and the second space communicates with the exterior through the third port and the fourth port. A trough for housing is formed in the lower casing by extending an inner surface thereof. The trough communicates with the second space. A plurality of cooling fins are formed by extending the outer surface of the trough to increase heat dissipation efficiency and reduce noise.
[0010] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded view of a first embodiment of the invention;
[0012] FIG. 2 is a perspective view of the first embodiment of the invention; and
[0013] FIG. 3 is an exploded view of a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Refer to FIGS. 1 and 2 for a first embodiment of the invention. The passage structure for an air compressor of the invention is fastened to a compressing unit 10 . The passage structure includes a casing 20 , two spaces including a first space 30 and a second space 32 , four ports including a first port 40 , a second port 42 , a third port 44 and a fourth port 46 , a trough 50 and a plurality of cooling fins 52 .
[0015] The compressing unit 10 has a compression chamber 12 , communicated with the exterior through an air suction port 14 and an air discharging port 16 . The casing 20 includes an upper casing 22 and a lower casing 24 interposed by a washer 60 to form an airtight sealing effect to prevent air from flowing out through the gap between the upper casing 22 and the lower casing 24 . The washer 60 has a plurality of vents 62 to allow the second space 32 formed between the upper casing 22 and the lower casing 24 to become communicable. The first space 30 and second space 32 are formed in the casing 20 in a ditch and/or trough manner on the upper casing 22 and/or lower casing 24 . The first port 40 and the second port 42 are formed respectively on the upper casing 22 and the lower casing 24 , and are communicated through the first space 30 . Thereby the first space 30 also can communicate with the exterior. The third port 44 and the fourth port 46 are formed respectively on the lower casing 24 and the upper casing 22 , and are communicated through the second space 32 . Thereby the second space 32 also can communicate with the exterior. The air suction port 14 corresponds to the second port 42 . The air discharging port 16 corresponds to the third port 44 . A check valve (not shown in the drawings) may be interposed between the air suction port 14 and the second port 42 , and between the air discharging port 16 and the third port 44 . The trough 50 is formed by extending the outer surface of the lower casing 24 and communicates with the second space 32 . Namely the space formed by the trough 50 is a portion of the second space 32 . The cooling fins 52 are extended from the outer surface of the trough 50 .
[0016] When the compressor starts operation, it sucks external air and compress the air to a selected location. The air enters through the first port 40 into the first space 30 . Meanwhile the check valve prevents the air from entering through the air discharging port 16 to the compression chamber 12 . Then the air flows through the second port 42 which communicates with the first space 30 and the air suction port 14 abutting the second port 42 , and enters the compression chamber 12 of the compressing unit 10 to be compressed. The compressed air is discharged through the air discharging port 16 outside the compression chamber 12 . The check valve also prevents the air from discharging through the air suction port 14 outside the compression chamber 12 . Next, the air passes through the third port 44 abutting the air discharging port 16 and enters the second space 32 , and passes through the fourth port 46 and flows out through the second space 32 . When the air is compressed, its temperature rises. The air flow contacts with the inner surface of the second space 32 to transfer heat to the exterior. The second space has a larger air housing capacity due to the trough 50 , and can increase the contact area with the air. The enlarged air housing space also can reduce pulse noise during the air compression, and also enable the compressed air to be discharged more smoothly. Increasing of the air contact area also can improve heat dissipation efficiency. The cooling fins 52 extended from the outer surface of the trough 50 can further enhance heat dissipation effect.
[0017] Refer to FIG. 3 for a second embodiment of the invention. It differs from the previous embodiment by having only one vent 62 on the washer 60 . The vent 62 corresponds to a distal end of the second space 32 on the lower casing 24 . The air flow path of this embodiment is as follow: first, the air enters the second space 32 of the lower casing 24 and flows to the distal end thereof; next enters the second space 32 of the upper casing 22 through the vent 62 of the washer 60 and flows to the distal end; finally the air is discharged through the fourth port 46 . Thus the air has a higher probability to be in contact with the surface of the second space 32 to absorb more heat. Therefore the air temperature discharged through the fourth port 46 is not too high. Compared with the first embodiment, it has a higher efficiency.
[0018] In short, the invention provides a heat dissipation structure for a air compressor. During operation of the compressor the heat dissipation structure not only can increase heat dissipation efficiency, also provide a greater air housing capacity in a limited space of the compressor. Noise generated during operation of the compressor also can be reduced. It offers a significant improvement over the conventional techniques.
[0019] While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention. | A passage structure for an air compressor mainly has a trough extended from inside of a casing that communicates with a second space to increase the contact area of air and the casing. The trough has an outer surface with a plurality of cooling fins located thereon to enhance total heat dissipation effect. The trough forms an additional space to increase air capacity and can reduce noise during compression operation. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to circuit interconnections and, more particularly, to multiple-conductor circuit interconnections in which a pattern of connection pads is provided on a substrate such as a printed circuit board, especially where there is a lack of precise dimensional control as is typically the case with flexible printed circuit substrates.
A particular application of the invention is the manufacture of ultrasound probes for medical applications. As the number of transducer elements in typical ultrasound probes increases and the desired size of the probe handle and other packaging decreases, there is a need to increase the density of electrical connections between the transducer elements and the probe cable. For reasons of manufacturability and economics, the transducer pallet and cable are usually built and tested as separate subassemblies, then joined. If the pallet and cable each terminate in a flexible printed circuit, then the preferred joint is a flex-to-flex bond. Such a bond comprises one or more rows of metallized connection pads on the transducer pallet flex circuit, similar row(s) of pads on the cable flex circuit, and an anisotropic conductive adhesive which, under heat and pressure, forms an electrical and mechanical bond between corresponding connection pads of the two flex circuits.
Flexible printed circuit substrates are typically made of a polyimide, such as Kapton® (a DuPont product), with a typical thickness within the range of 25 to 75 microns. Another flexible printed circuit substrate material conventionally employed is polyester.
A factor that limits the achievable density of a flex-to-flex bond is the need to allow for variations in the pad pitch between the two flexible printed circuits. Typically there is a lack of precise dimensional control during manufacture of flexible printed circuits. Dimensional variations, due to temperature, humidity, flex circuit shrinkage, and other manufacturing variables, constrain both the minimum pad width (to achieve electrical contact at all pads) and the minimum space between pads (to avoid short circuits). Design of a flex-to-flex bond becomes a tradeoff between desire for high density and good yield, and the cost of tight tolerances for the flexible printed circuits.
Electrical connection bonds between two flex circuits or between a flex circuit and a rigid circuit board are used in various situations and products, not just during the manufacture of ultrasound arrays. A major application is electrical connection to flat panel (LCD) displays for appliances, computers, and aircraft. Another application is the fabrication of multilayer flex circuits by lamination of two or more single-layer circuits with anisotropic conductive adhesive. Yet another application is the mounting of integrated circuit packages to a circuit board substrate employing surface mount technology. Tradeoffs between density, yield, and cost occur in the design of all of these products.
Conventionally these problems are addressed by attempting to compensate for dimensional variations. The initial artwork defining the connection pads is made slightly over- or under-size to compensate for the anticipated shrinkage or swelling of the parts during manufacturing. A problem with this approach is that the shrinkage varies slightly from one process run to another or from one batch of material to another, making it nearly impossible to predetermine the exact shrinkage. In any event, the pitch of the interconnection pads must be large enough to accommodate the residual variation in the dimensions of the parts.
SUMMARY OF THE INVENTION
The invention provides accurate alignment between respective arrays of connection pads which are electrically interconnected, so as to avoid need to increase the pitch of the interconnection pads to accommodate residual variation in the dimensions of two parts being interconnected through these arrays, and achieves a high connection density when making these electrical interconnections.
Briefly, in accordance with the invention, connection pads are formed in fanout arrays, with the longitudinal axes of individual pads aligned on radial lines extending from a common origin, allowing significant variations in the dimensions of the respective substrates being electrically connected to be accommodated.
In one form, a connection pad array of the invention formed on a substrate, such as a flexible printed circuit substrate where precise dimensional control is difficult, includes a set of elongated electrical connection pads arranged in a fanout array within a generally trapezoidal array area. The trapezoidal array area has two generally parallel opposite sides extending generally along respective parallel chords of a circle, such that the generally parallel opposite sides define narrower and wider sides of the fanout array. Each one of the pads extends longitudinally between the narrower and wider sides of the fanout array generally along a respective radial line extending from the center of the circle. Typically, the fanout array is symmetrical about a midpoint line extending from the center of the circle and perpendicular to the sides of the fanout array.
In a more general case, applicable where the substrate is anisotropic (meaning the shrinkage or expansion is not the same in all directions), the connection pads are on curved pad-locating lines which follow a power law relationship defined by the equation y=Ax.sup.β, where the circle center is located at (x,y)=(0,0), A is a proportionality constant for the respective pad-locating line, and β is an anisotropy factor.
The line equation y=Ax.sup.β, for the anisotropic case simplifies to the line equation y=Ax for the isotropic case when the anisotropy factor β=1.
In other embodiments, multiple-row connection pad arrays are provided. A multiple-row connection pad array includes a plurality of sets of elongated electrical connection pads arranged in respective fanout arrays as summarized hereinabove. Each of the array areas has two generally parallel opposite sides extending generally along respective parallel chords of a circle, the generally parallel opposite sides defining narrower and wider sides of the particular fanout array. In one form, the fanout arrays are parallel to each other, and positioned at different distances from the center of the circle. Typically, all of the fanout arrays are symmetrical about a single midpoint line extending from the center of the circle and perpendicular to the sides of the fanout arrays.
In another multiple-row connection pad array configuration, the fanout arrays are arranged around, and positioned at equal distances from, the center of the circle, generally forming a square, rectangle, or other polygon.
In accordance with another aspect of the invention, a multiple-conductor interconnect system includes a pair of substrates with respective circuits and respective corresponding connection pad arrays for electrically connecting the respective circuits when joined. Each of the connection pad arrays takes the form of a set of elongated electrical connection pads arranged in a fanout array within a generally trapezoidal array area as summarized hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view depicting a prior art interconnect system showing a pair of substrates supporting respective parallel pad connection pad arrays to be interconnected;
FIG. 2 is a plan view depicting the prior art substrates of FIG. 1 when joined;
FIG. 3 is a side elevational view taken along line 3--3 of FIG. 2;
FIG. 4 is an enlarged view of area 4--4 of FIG. 2, illustrating lateral misalignment near the ends of the prior art parallel pad connection pad arrays;
FIG. 5 is a geometrical representation depicting the manner in which fanout connection pads of the invention extend along radial lines from a common origin;
FIG. 6 is a plan view depicting a pair of substrates supporting respective fanout connection pad arrays for electrically connecting respective circuits on the substrates in accordance with the invention;
FIG. 7 is a plan view depicting the substrates and connection pad arrays of FIG. 6 when joined;
FIG. 8 is a side elevational view taken along line 8--8 of FIG. 7;
FIG. 9 is an enlarged view of area 9--9 of FIG. 7, depicting the manner in which dimensional variations are accommodated at the ends of fanout connection pad arrays in accordance with the invention;
FIG. 10 illustrates a design procedure for a multiple-conductor interconnect system in accordance with the invention;
FIG. 11 depicts an unacceptable result which would occur if a similarly-spaced arrangement of prior art parallel pads were subjected to the same percentage of dimensional variation accommodated by the invention as depicted in FIG. 10;
FIG. 12 is an illustration of how the parallel pads of FIG. 11 would have to be redesigned in order to maintain at least a minimum electrical contact area and a minimum spacing between electrical connection pads;
FIG. 13 depicts one form of a multiple-row connection pad array in accordance with the invention;
FIG. 14 depicts another form of a multiple-row connection pad array in accordance with the invention; and
FIG. 15 depicts a fanout connection pad array for use when the substrate is subject to anisotropic shrinkage or expansion.
DETAILED DESCRIPTION
FIG. 1 illustrates a pair of substrates 20 and 22 having ends 24 and 25 supporting arrays 26 and 28 of prior art parallel connection pads 30 and 32. Circuits on substrates 20 and 22 to be electrically interconnected are represented by conductors 34 and 36 connected to pads 30 and 32, respectively. Typically, substrates 20 and 22 are flexible printed circuit board substrates, made of a suitable polyimide or polyester and are subject to shrinkage or swelling during manufacture. Illustratively, upper printed circuit board substrate 20, as a result of manufacturing processing, is relatively wider than lower substrate 22, and individual connection pads 30 of array 26 are spaced farther apart than individual connection pads 32 of array 28.
FIG. 2 depicts individual substrates 20 and 22 and corresponding arrays 26 and 28 overlapped for electrical connection through individual pads 30 of array 26 and corresponding individual pads 32 of array 28. The side elevational view of FIG. 3 represents the relative positions of substrates 24 and 26.
Due to manufacturing variations, the pitch of pads 32 of array 28 in this example is less than the pitch of pads 30 of array 26. As the two connection pad arrays 26 and 28 are brought together for bonding (FIG. 2), the principal alignment axis is right and left movement, illustrated by directional arrow 38. Thus, during assembly, the relative lateral position of the two substrates 20 and 22 is adjusted to minimize the offset between the outer pads, as is best seen in the enlarged view, FIG. 4, of the ends of arrays 26 and 28 in area 4--4. It will be appreciated that the situation at the opposite ends of arrays 26 and 28 is a mirror image.
In FIG. 4, the design spacing between adjacent pads is represented by distance 44, while the actual spacing 46 achieved near the ends of arrays 26 and 28 is substantially less. Pad overlap occurs in region 48.
Thus, as distance from the center of arrays 26 and 28 increases, actual spacing 46 between adjacent bonded pads becomes smaller, increasing the probability of short circuits. Overlap 48 between corresponding mating pads also decreases, reducing reliability of the connection of the outer pads.
With the arrangement of parallel pads shown in FIGS. 1 and 2, the center pads retain 100% overlap, but overlap of the outer pads is reduced by N times the size difference, where N is the number of pads in the row. As one example, for a row of 100 pads and for flex circuits which differ by 0.5%, overlap of the outer pads is reduced by 50%, assuming the pad width is half the pad pitch.
As shown in FIGS. 5-9, the invention employs a fanout pad arrangement wherein the connection pads of each array are longitudinally aligned along radial lines, such as, for example, representative radial lines 50, 52 and 54 in FIG. 5, extending from the center 56 of a circle represented in partial form as an arc 58. As shown in FIG. 5, a fanout array 60 of individual elongated pads 62 is contained within a generally trapezoidal array area 64 having two generally parallel opposite sides extending generally along respective parallel chords 66 and 68 of circle 58. Line 66 defines a relatively wider side of trapezoidal fanout array 60, and line 68 defines a relatively narrower side of fanout array 60. Each pad 62 extends longitudinally between wider 66 and narrower 68 sides generally along a respective radial. Individual pads 62 have a width w and are spaced from each other by a spacing distance s such that pitch p=w+s.
Preferably, fanout array 60 is symmetrical about a midpoint line which, in FIG. 5, is radial line 52, extending from center 56 of circle 58 perpendicular to sides 66 and 68 of fanout array 60. Although midpoint line 52 is shown intersecting one of pads 62, symmetry can also be maintained in alternative arrangements where midpoint line 52 extends between two pads 62, with no connection pad actually aligned on midpoint line 52.
A practical application of fanout array 60 is represented in FIGS. 6-9. A pair of substrates 70 and 72, which typically are flexible printed circuit substrates characterized by a lack of dimensional control during manufacture, have respective ends 74 and 76 and support respective arrays 78 and 80 of individual connection pads 82 and 84 for establishing electrical connections between respective circuits represented by conductors 86 on substrate 70 and conductors 88 on substrate 72. Due to process variations, substrate 70 illustratively is wider than substrate 72, and pads 82 of array 78 accordingly are spaced farther apart than pads 84 of array 80.
It will be appreciated that conventional standard practices for routing traces to the parallel pads of prior art FIG. 1 are equally applicable to the fanout pads of FIG. 6.
When the printed circuits of FIG. 6 are joined as shown in FIGS. 7 and 8, two alignment axes are available, i.e., lateral and longitudinal, enabling 100% overlap of corresponding pads across the widths of the connection pads. With particular reference to the enlarged view of FIG. 9, connection pad overlap occurs over a distance 96, and the actual space 98 between adjacent pads 84 is the same as the design spacing.
A typical design process for a fanout pad array in accordance with the invention is illustrated in FIG. 10. A single row of N connection pads has a minimum contact area (or bond area) of width w and length l. The minimum space between pads is s. The manufacturing tolerance on the flex circuits is specified as -0,+α, where α is expressed either as a percentage (e.g. 5%) or as a decimal fraction (e.g. 0.05).
In FIG. 10 (which shows only half of the row of connection pads), the narrow end of the fanout array is laid out at a pitch p=w+s and has total width (center-to-center of outer pads) of (N-1)p. If the pads fan out from a center which is at distance R from the narrow end, then the outer pads slant at angle: ##EQU1##
The total width at the broad end of the fanout is: ##EQU2##
The above analysis is an approximation only. For a more rigorous analysis, pad width w and minimum pitch p should be measured not along a horizontal line, but perpendicular to the longitudinal axis of each respective pad. If this is done correctly, and the minimum pitch is strictly adhered to during design, then the actual width of the fanout pad array will be slightly greater than implied by the equations herein. This difference becomes more significant as the fanout angle increases, and is one reason why distance R from the pad array to virtual center 56 should not be too small.
Under worst-case conditions, one flexible substrate circuit has pitch p and the mating circuit has pitch p(1+α). Equivalently, the distances from the narrow end of the fanout to virtual center 56 are R and R(1+α), respectively. When the circuits are aligned, the connection pad overlap is:
(R+l')-R(1+α)=l'-αR.
Since the minimum overlap is specified as l, this sets the actual pad length, l'=l+αR.
Another design parameter is the distance R from the pad array to virtual center 56. Increasing R reduces the fanout angle θ max , and the total width, ##EQU3##
However decreasing R also reduces the pad length l'=l+αR, and reduces the maximum distance αR by which the two flexible circuit substrates may have to be offset in order to obtain alignment.
Thus, increasing R (which tends towards a conventional parallel pad arrangement) beneficially reduces total width by reducing fanout; however, increasing R also disadvantageously increases the required actual length l' of the pads and disadvantageously increases the maximum distance αR by which the two flex circuits may have to be offset in order to obtain alignment. This tradeoff must be resolved by considering the lateral vs. longitudinal constraints of the intended application.
To show the compactness of the fanout arrangement of connection pads, FIGS. 11 and 12 respectively depict an unacceptable result if a similarly-spaced arrangement of prior art parallel connection pads were subjected to the same percentage of dimensional variation accommodated by the invention as depicted in FIG. 10, and how the prior art parallel connection pads would have to be redesigned in order to maintain at least a minimum required contact area and a minimum required spacing between connection pads.
The connection pads ahown in FIG. 11 are of the same size and pitch as those shown in FIG. 10; however, when subjected to the same dimensional mismatch (α=0.05 or 5% in each of FIGS. 10, 11 and 12), the pads at the ends of the row shown in FIG. 11 misalign completely and make no contact.
To meet specification, the parallel connection pad array would have to be redesigned as shown in FIG. 12, where the pad width w' and pitch p' are related as follows: ##EQU4##
This yields a total width of:
(N-1)p'>(N-1)p(1+(N-2)α).
For example, with N=15, α=0.05 or 5%, and R=6l, the fanout design of FIG. 10 has width 2x max ≈17p, whereas the parallel pad design of FIG. 12 has width (N-1)p'=40p.
A multi-row version 90 of the fanout pad array is shown in FIG. 13. Three rows of pads 82a, 82b, 82c, respectively, are employed. If the minimum space between rows of the assembled flexible substrate-to-flexible substrate joint is y, then the circuits must be designed with a gap y' such that, when the circuits are aligned,
R-(R-y')(1+α)≈y'-αR≧y.
This is additional incentive to keep distance R relatively small. However, if R is small and the row pitch l'+y' becomes non-negligible relative to R, then gap y' should be re-calculated for each row. If the row widths are also comparable to R, then the rate of fanout and the number of bond pads which will fit in a given width varies significantly from row to row.
As a specific example, consider a row of N=101 pads with minimum width w=0.15 mm, bond length l=2.0 mm, and space s=0.15 mm. Assume the manufacturing tolerance α=0.003=0.3%. These values are typical of flexible substrate-to-flexible substrate bonds for ultrasound transducers. The nominal pitch is p=w+s=0.3 mm and the total width of the narrow side of the fanout is (N-1)p=30 mm. Setting ##EQU5## which makes the longitudinal alignment (i.e., in a direction parallel to R) of the pads about half as difficult as the lateral alignment. Pad length l'=l+αR≈2.1 mm and the total width of the wider side of the fanout array is ##EQU6##
In the case of a multi-row design with, for example, a minimum gap between connection pad rows of y=2s=0.3 mm, the inter-row gap on each flexible substrate should be y'=y+αR≈0.4 mm.
FIG. 14 depicts another form of multiple-row connection pad array where the pads of respective fanout arrays 92a, 92b, 92c, and 92d are arranged around, and positioned at, equal distances from a center 56, generally forming a square, rectangle or other polygon. The FIG. 14 arrangement is particularly advantageous for connecting integrated circuit packages to underlying printed circuit substrates employing surface mount techniques. Advantageously, conventional circuit routing techniques are still applicable.
The foregoing analyses are based on the assumption that the shrinkage or expansion of flexible and other types of circuit boards during and after manufacture is isotropic, i.e., the same in all directions. Real flexible circuit board materials are slightly anisotropic, although not enough to have a major effect on the connection pad design.
An issue of potentially greater concern is anisotropy introduced by the pattern of metallization (or other processing). If the pattern is made up of many parallel conductors with unmetallized dielectric between them, then shrinkage parallel to the conductors is determined by the combined effects of metal and dielectric, while shrinkage perpendicular to the conductors has a significant contribution from the bare dielectric, unconstrained by metal. It would not be surprising to find an anisotropy of 2:1 or greater in the shrinkage or expansion of such circuit board.
If shrinkage is expected to be anisotropic, then the connection pads are not situated along radial (i.e., straight) lines extending from a center; rather, the connection pads are situated along curved pad-locating lines which follow a power law relationship, as illustrated by an array 80 of connection pads 82 in FIG. 15.
For purposes of analysis center 84 is considered to be at (x,y)=(0,0). In the isotropic example described above with reference to FIGS. 5-10, 13 and 14, each pad is situated along a straight radial line, y=Ax, where each radial line has a different proportionality constant A. In the anisotropic example of FIG. 15, connection pads 82 are situated along pad-locating lines 86 described as y=Ax.sup.β, where A is a constant, different for each respective pad 82, and β is the anisotropy factor. The line equation y=Ax.sup.β for the anisotropic example simplifies to the line equation y=Ax for the isotropic case when β=1, meaning that there is no anisotropy.
In the particular example shown in FIG. 15, connection pads 82 are designed for anisotropic shrinkage described by the scaling x→(1+α)x,y→(1+αβ)y, where the anisotropy factor β=0.5. The constants A for each respective one of the individual y=Ax.sup.β lines 86 are selected so that the pad pitch increases toward the ends of array 80 to maintain a uniform minimum spacing between pads 82. Similar considerations apply to the previously-described embodiments when shrinkage and expansion is anisotropic.
While specific embodiments of the invention have been illustrated and described herein, numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit and scope of the invention. | For providing multiple-conductor circuit interconnections where there is a lack of precise dimensional control, as in manufacturing flexible printed circuits used to make high density electrical interconnections between ultrasonic transducer elements and the probe cable in a medical ultrasound probe, connection pads are formed in fanout arrays, with the longitudinal axes of individual pads extending along radial lines from the center of a circle. The fanout arrays are formed within generally trapezoidal areas, each having two parallel opposite sides extending along respective parallel chords to accommodate significant variation in dimensions of the respective substrates being connected. Multiple-row connection pad arrays may be provided, each with a plurality of fanout arrays of connection pads that may be parallel to each other and positioned at respectively different distances from the center of the circle, or may be arranged around, and positioned at equal distances from, the center of the circle. If the circuit substrate is anisotropic, the connection pads are on curved pad-locating lines defined by y=Ax.sup.β, where (x,y)=(0,0) defines the circle center, A is a proportionality constant for the respective pad-locating line, and β is an anisotropy factor. | 7 |
BACKGROUND OF THE INVENTION
In the food processing and canning industry there has long been a requirement for heating and cooling the canned product. Various types of equipment have long existed for such thermal conditioning of containers, such as cans. Exemplary of such equipment is that shown in U.S. Pat. No. 1,445,196 to Berry and in U.S. Pat. No. 2,043,310 to Thompson. In such prior art equipment are passed along a first helical path within a heating chamber and are then moved to a separate cooling chamber along side the heating chamber. While this equipment performs its designed function, it is bulky and requires considerable space for installation, space which is frequently at a premium in a packing facility. Much of this prior art equipment has also presented difficulties in maintenance and cleaning due to the fixed housing for containing the cooking steam.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus for heating and cooling cylindrical containers that overcomes the disadvantages of the prior art equipment. It is a further object of the invention to provide such apparatus that is rugged and durable and provides for simplified operation and cleaning.
To achieve the foregoing as well as other objects that will become apparent to those skilled in the art, a thermal conditioning system for heating and cooling cylindrical containers is disclosed and includes a container heating apparatus, a heating transport apparatus for supporting movement of the containers through the heating chamber, an introduction conveyor for introducing containers into the heating chamber from outside that chamber, container cooling apparatus positioned generally below the heating chamber, and an exit conveyor for moving the containers from the cooling apparatus to a location outside the heating apparatus and cooling apparatus. The container heating apparatus includes a heating chamber of generally cylindrical configuration with a generally vertical cylindrical axis, with that chamber including a housing enclosing the heating chamber and having a generally cylindrical configuration generally coaxial with the heating chamber axis, and a heating fluid introduced into the chamber for heating the containers within the heating chamber. The heating transport apparatus includes the plurality of generally circular tracks carried by track support and spaced apart from one another along the cylindrical axis, a transport mechanism for moving the containers around those tracks, and a transfer structure for moving the containers from one such track to an adjacent lower such track. The container cooling apparatus includes a cooling fluid spray, and transport apparatus generally coaxial with the heating chamber transport apparatus, with that transport apparatus further including a plurality of generally circular tracks carried by a track support and spaced apart from one another along the cylindrical axis, the first such circular track being positioned directly below the lowermost such heating apparatus track for receiving heated containers therefrom, and further includes a transport mechanism for moving the containers around the tracks, and a transfer structure for moving the containers from one such track to an adjacent lower track.
BRIEF DESCRIPTION OF THE DRAWINGS
To illustrate further the principles of this invention, a preferred embodiment will be described in detail in which:
FIG. 1 is a side elevation of one embodiment of the thermal conditioning apparatus of this invention;
FIG. 2 is a side elevation of the apparatus of FIG. 1 with the housing and introduction conveyor removed to more clearly illustrate the internal structure;
FIG. 3 is a top plan view of the apparatus of FIG. 1 , with the cylindrical heating chamber housing removed;
FIG. 4 is a sectional view of the apparatus of FIGS. 1-3 taken along line 44 of FIG. 3 , with the containers deleted from the transport apparatus to more clearly illustrate the structure;
FIG. 5 is a fragmentary sectional elevation taken along lines 5 — 5 of FIG. 3 ; and
FIG. 6 is top plan view of the apparatus of FIG. 1 with the cylindrical housing removed to illustrate more clearly the introduction of the containers into the heating apparatus transport mechanism and the removal of the containers from that transport apparatus.
DESCRIPTION OF PREFERRED EMBODIMENTS
A particularly preferred embodiment of the thermal conditioning apparatus of this invention is illustrated in the elevational view of FIG. 1 . This apparatus includes a heating chamber 10 of generally cylindrical configuration with a generally vertical cylindrical axis 12 . This heating chamber comprises a housing, which suitably comprises a plurality of axially adjacent sections, such as upper section 14 and lower section 16 , each having a generally cylindrical configuration and being generally coaxial with the heating chamber axis 12 and a generally circular top portion 13 . This heating chamber 10 is further provided with sources for introducing a heated fluid, such as steam, into the chamber. These sources may conveniently be pipes 18 and 20 , which are connected to conventional steam generators (not shown), to provide a supply of this heated fluid for heating the chamber 10 .
The apparatus of this system also includes an introduction conveyor 22 for introducing containers into the heating chamber from outside. The containers to be introduced are preferably of right circular cylindrical configuration, such as cans or canned food products. A ramp 24 , or other suitable structure, brings the containers, preferably with their cylindrical axes generally horizontal, to the introduction conveyor 22 . Conveniently, as shown in the drawings, the ramp 24 and conveyor 22 are configured to provide end-to-end pairs of the cylindrical containers 26 onto the conveyor 22 or, if desired, may provide for introduction of individual containers, or groups of three, four or more containers. The introduction conveyor 22 is of conventional construction and includes a plurality of flights, each spaced apart from the adjacent flight to receive one of the containers 26 , or, in this case, a pair of such containers end-to-end. As shown in FIG. 1 , the introduction conveyor 22 preferably receives the containers 26 on a horizontal portion and then carries them in a generally vertical direction up to a location close to the top of the heating apparatus. As the containers are lifted in the introduction conveyor, they enter a closed channel 28 , which, in this embodiment, first runs vertically and then horizontally adjacent to the top of the apparatus, with the conveyor then returning back down through another vertical portion of the channel to the bottom of the equipment, as shown in FIG. 1 .
FIG. 2 is a side elevation of the apparatus of this invention, with the chamber housing removed to illustrate the structure within. Similarly, FIG. 3 is a top plan view of this apparatus, with the heating chamber housing removed, and FIG. 4 is a sectional elevational view taken along line 44 of FIG. 3 to illustrate the components of the transport apparatus included in that heating chamber. As shown in FIG. 2 , the heating transport apparatus includes a plurality of generally circular tracks 30 , shown in phantom on FIG. 3 , that are carried by track supports 32 (shown most clearly in the fragmentary sectional view of FIG. 5 , taken along line 5 — 5 of FIG. 3 ).
In the sectional elevational view of FIG. 4 is illustrated the transport mechanism for moving the containers around these tracks 30 . The transport mechanism of this embodiment comprises a rotatably mounted cylinder or drum 36 having a generally vertical axis and mounted, suitably by means of a central shaft 38 and conventional bearings 40 , for rotation about this vertical axis. As shown on FIG. 4 , the drum is rotationally driven by conventional means, such as a conventional electric motor or the like 48 , connected to the drum central shaft 38 by conventional means, such as pulleys and belts or chains and sprockets, which are well known to those in the art. Suitably, this drive motor 42 is also used to drive the introduction conveyor 22 , so that rotation of the cylinder 36 is synchronized with movement of the introduction conveyor 22 .
As shown in FIG. 4 and more clearly in the fragmentary sectional view of FIG. 5 , there are attached to the rotating cylinder 36 a plurality of pusher elements 44 extending generally radially outwardly from the rotating cylinder 36 and positioned to engage the cylindrical containers 26 . Thus, rotation of the rotating cylinder 36 about its shaft 38 will urge the containers 26 around the circular track 30 . The radially outer ends of the pusher elements 44 adjacent a given track 30 are connected to a continuous ring 45 , as is shown in FIG. 5 .
As shown on FIG. 2 , each of the circular tracks includes at one point an opening in the track with a ramp 46 extending angularly downwardly from one such track 30 toward the respective subjacent, or next lower track, such that containers moving around each track will, upon encountering the opening and ramp 46 , move down the ramp from the one circular track to the next subjacent track. In this manner the containers 26 that are being moved around the tracks will sequentially move to each lower track, until they are discharged from the entire apparatus.
FIG. 6 is a simplified top view similar to that of FIG. 3 , but with the top cover of the housing removed and the circular track supports removed to illustrate the manner of movement of the containers 26 through the equipment. As the containers 26 are introduced from the ramp 24 onto the horizontal portion of the introduction conveyor 22 , they first move horizontally, and then vertically ( FIG. 1 ) up to a point adjacent to the top of the apparatus, where the conveyer again resumes a horizontal movement that overlaps the top circular track 30 . As described above, this conveyor includes a plurality of flights that push the containers 26 along a track 23 , which preferably has a flat bottom portion with sides extending generally perpendicular to that bottom portion to support the containers as they are moved by the conveyor flights. At the point where the transport conveyor 22 is directly above the topmost circular track, there is provided an opening 48 in that track 23 . That opening 48 permits the containers 26 to drop through that opening onto the immediately subjacent upper circular track, between adjacent pusher elements 44 . As noted above, the movement of the rotating cylinder 36 , and thus the pusher elements 44 , is synchronized with the movement of the flights of the introduction conveyor 22 . Once on this uppermost circular track, the containers 26 then move around that track until they encounter the opening and ramp 46 down to the next lower track, and then proceed through the heating chamber. While in that heating chamber, which is enclosed by the cylindrical segments 14 and 16 , the containers are subject to a heating fluid, such as steam, introduced through the conduits 18 and 20 . The steam effects heating of the interior of the heating chamber, and thus of the containers that are circulating through it.
As shown in FIG. 1 , the heating chamber housing encloses the upper portion of the overall apparatus, with a lower portion, including a number of the circular tracks 30 , outside those cylindrical housings 14 and 16 . The heated fluid, such as steam, is contained in the enclosed portion, because of the heat tending to rise. As the steam may condense on the structures, it may drain to receptacles (not shown) below the apparatus. As the cylindrical containers 26 continue in their process through the apparatus, they ultimately proceed through an opening in one of the tracks at the lowermost portion of the heating chamber housing portion 16 to the next lower track, which is shown in FIG. 1 to be outside that housing portion 16 . This group of cylindrical tracks below the heating chamber housing comprises the transport apparatus of the container cooling apparatus. This apparatus includes the circular tracks and their drive mechanism, including the cylinder 36 and pusher elements 44 , substantially identical to the transport apparatus in the heating chamber, and also a plurality of dispensers 50 dispensing a cooling fluid spray 52 , such as a cool water spray. The cooling fluid is supplied through a conventional conduit from a conventional source (not shown). As shown on FIGS. 1 and 2 , when the containers reach the lowermost track 30 that is within the heating chamber, the openings 48 in that track and at least the next adjacent lower track are positioned close together to facilitate the fast passage of containers from the heating chamber to the cooling apparatus. Subsequent to that passage to the cooling apparatus, the containers then proceed around each adjacent lower track 30 before encountering another ramp 48 downwardly to the next subjacent track, thus maximizing their exposure to cooling sprays. As the containers are moved around the circular tracks between the lowermost portion of the heating chamber housing and the lowermost circular circular track, the application of the cooling fluids spray will cool the containers 26 , suitably to the final temperature required for the process.
The lowermost circular track 30 has its opening and downwardly extending ramp positioned, in this illustrative embodiment, on the side of the apparatus opposite that of the introduction conveyor 22 . An exit conveyor 60 , conveniently of similar structure to the introduction conveyor 22 , is provided and likewise synchronized with the movement of the transport apparatus and the introduction conveyor. This exit conveyor 60 carries the containers to a conventional stacking apparatus, which preferably turns the containers onto their ends for removal for further processing and subsequent distribution.
As shown in FIG. 1 , the heating chamber housing of this embodiment is generally of the shape of a right circular cylinder, and preferably is made up of two axially adjacent sections 14 and 16 . Preferably the upper cylindrical section 14 engages the circular top portion 13 of the heating chamber with a resilient steam seal 15 , suitably formed from a synthetic polymer. Similarly, lower cylindrical section 16 preferably engages the upper section 14 with a similar resilient steam seal 17 . These sections are supported for axial movement by linear actuators 54 and 56 , respectively, which suitably may be pneumatic or hydraulic cylinders. As shown in the broken lines on FIG. 1 , actuation of these cylinders 54 and 56 permits the selective axial displacement of the cylindrical sections 14 and 16 . In a first position, with both these segments raised, the heating chamber is completely enclosed by these two sections. In a second position, with the actuating cylinders extended, the heating chamber sections are selectively lowered, either together, or with the lower section being lowered individually, to expose at least a portion of the heating chamber for maintenance and cleaning, as desired.
While other embodiments of this invention will be readily apparent to those skilled in the art, the foregoing is intended to be descriptive only of the principles of the invention and is not intended to the limitative thereof. Accordingly, the scope of this invention is to be defined set forth below. | A thermal conditioning system for heating and cooling cylindrical containers includes a container heating apparatus with an enclosed heating chamber, transport mechanism for movement of the containers through the heating chamber, a cooling apparatus positioned below the heating chamber, and conveyor systems for introducing containers into the heating chamber and form removing the containers from the cooling apparatus after they have passed through the system. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cavity shaped package having a recessed portion for accommodating electronic parts such as an integrated circuit, hybrid circuits and so on, in particular, a method of forming a package for electronic parts which is made from a metal plate.
2. Description of Related Art
Through the progress of information devices such as personal computers and so on in recent years, electronic parts such as semiconductor IC circuits or hybrid circuits have been advanced into higher density and higher processing speed, and the information devices using these electronic parts are becoming more precise and more miniaturized. On the other hands, higher density and higher processing speed of these electronic parts increases the amount of heat generated therein. Thus, heat sink means having high efficiency of heat radiation is required. However, the problem is that such miniaturized devices incorporating electronic parts cannot secure enough space for heat sink means that have necessary efficiency of heat radiation due to the miniaturization thereof.
In order to solve the problem, a cavity type package comprising a metal plate called “stiffener”, which has a window or a recess at the center for accommodating electronic parts, has been occurred. The package allows the amount of heat generated from the electronic parts to be evacuated by the metal plate of the stiffener. Such package has in one body both functions as a heat spreader and as a stiffener for reinforcing the package. The package made from a metal plate will be an alternative to a conventional package, for example, made from ceramics since the former is superior to the latter in the heat sink function,
FIGS. 7 and 8 show a package of a semiconductor IC circuit as an example applying abovementioned package. The raw materials of the package 1 is selected from one of metal materials, which has a high thermal conductivity required as a heat spreader and for which plastically deforming processing is applicable, such as cupper alloy stainless steel, aluminum and so on.
An approximately rectangular recess portion 2 having a bottom portion 1 c with a predetermined thickness is formed at the center of the surface on one side 1 a of the package 1 . That is, this package 1 is formed in a cavity shape as a whole. A wiring board 4 , which is a TAB or flexible printed board, a usual pointed board, etc., is stuck and secured to the one side 1 a of the package 1 by means of an adhesive. The wiring board 4 may be a layer on which a wiring circuit is formed and by which the wiring circuit is insulated from the package 1 . An opening 4 a having an approximately same size as the recess portion 2 is formed in this wiring board 4 . A terminal portion 4 t having a number of terminals is formed by printed wiring on the periphery of this opening 4 a with a wire width and a pitch of about 37 nm. The terminals of the terminal portion 4 t are electrically connected by printed wiring to externally connecting terminals (not indicated in the figures), which are formed on an outer periphery of the wiring board 4 .
Further a chip 5 of electronic parts such as a semiconductor integrated circuit is accommodated in the recess portion 2 formed on the one side 1 a of the package 1 . The chip 5 is stuck to the bottom portion 1 c of the recess portion 2 by means of an adhesive in a state where a surface of the chip 5 and that of the bottom portion 1 c are tightly fitted. What is important in this sticking using an adhesive is that no bubbles should be produced between the chip 5 and the bottom portion 1 c of the recess portion 2 . This is because the bubbles are expanded and the chip 5 may be thereby peeled off in case where heat is produced during working of the electronic parts in the chip 5 and in case where heat is subjected to the package 1 during its assembling to an apparatus. Thus, the bottom portion 1 c of the recess portion 2 should be formed in such an evenness that warp is smaller than 30 nm.
On the upper surface of the chip 5 there are disposed a number of terminals 5 t with a same wire width and a same pitch as those in the terminal portion 4 t formed on the wiring board 4 . Each of the terminals 5 t of the chip 5 and each terminal of the terminal portion 4 t of the wiring board 4 are electrically connected by bonding wires 7 , as indicated in FIG. 7 . Further sealing agent 8 is injected into the recess portion 2 of the package 1 to seal the chip 5 and the bonding wires 7 .
When the electronic parts such as an integrated circuit packed in the package 1 as described above is mounted onto a circuit board of an electronic apparatus not indicated in the figure, solder balls 9 are placed on the externally connecting terminals formed on an outer periphery of the wiring board 4 and they are melted by heating in a state where the package 1 is provisionary fixed at predetermined position on the circuit board of the electronic apparatus. In this way the electronic parts packed in the package 1 and the circuit board of the electronic apparatus are connected electrically via the wiring board 4 without any damages to the package 1 and its electronic parts due to expanding the bubbles between the chip 5 and the bottom portion 1 c.
On the other hand, when a semiconductor IC circuit is exothermic in operating, the package 1 itself has a function of heat spreader, thereby, heat is conducted the package 1 and is released.
In a forming method of above constituted cavity type package, for example, there is a method that a concave part is pressing processed using a pressing punch by press machine or by chemically etching process, a concave part is formed in a metal plate so that keep a bottom of a thin plate.
However, in a pressing process by press machine metal part of volume of the recess part is pushed into a bottom part and periphery. The periphery metal part is curled, then the flatness of the part is not able to correct state. Thereby, a package acquired necessity flatness has a fatal problem. The chemically etching process takes long time, so there are troublesome that the method is not suited in mass production and takes more cost in necessity. Moreover, precision by limiting to control etching process is worth, there is troublesome that practical use has a limit.
Inventors have proposed in U.S. Pat. No. 6,145,365 a preferred method for forming above mentioned type package made from a metal plate. FIGS. 9 (A) to 9 (D) shows the proposed method in summary. The method will be described herein below.
FIG. 9 (A) shows a metal plate 100 that is positioned with respect to a die 104 of a press machine. FIG. 9 (B) shows a pressing process, where the metal plate 100 is pressed recessed by a punch 105 of the press machine onto one side surface 100 a so that the recessed part 102 is formed. At the same time, a protruding part 103 is formed in ledge shape on another side surface 100 b of the metal plate 100 .
FIGS. 9 (C) and 9 (D) show cutting process, wherein a cutter 106 shaves off the protruding part 103 formed on the surface 100 b so as to form a thin bottom 100 c and to make the surface 100 b flat. In this cutting process, to avoid displacement of the bottom plate 100 c in the direction to the recessed part 102 , the bottom plate 100 c is pressivelly supported by a supporting tool 107 . According to the abovementioned processes, the recessed part 102 for accommodating a chip of electronic parts is formed in the metal plate 100 , which has a bottom plate 100 c having a predetermined comparatively thin thickness as the bottom of the recessed part 102 . Thereby, the recessed part 102 of predetermined depth is formed by pressing and cutting without any damages to the bottom plate 100 c.
In the above methods, it is possible to form the recessed part 102 having a predetermined shape only on one side of the metal plate without giving the metal plate any remarkable stress or changing the composition of the metal plate because metal corresponding to the recessed part 102 is displaced to the protruding part 103 on the other side of the metal plate by plastically deforming processing by means of the press. However, in the cutting process, it is inevitable that the cutter 106 pulls the metal of the protruding part 103 around the cutting line by its movement. Therefore, the metal plate suffers a stress, especially at and around the bottom part 100 c.
Further, into the portion where the cutting by the cutter 106 ends, shown in left side on FIG. 9 (D), a stress of pressure by the movement of the cutter 106 is concentrated. Such stresses provided by cutting process of the protruding part 103 lead to the problems that the dimensions of the package may change over time and that a time-varying warp may occur. Thereby, as mentioned above, in a package of electronic parts that requires such evenness that warp within 30 nm, the time-varying changes of dimensions and evenness become a fatal defect.
SUMMARY OF THE INVENTION
In order to solve such problems, the present invention, a package for accommodating in a recessed part formed one face of a metal plate, in package forming method for electronic parts formed cavity shaped which has thinner bottom part than the metal plate characterized in that, the package is formed the recessed part by pressing press machine or the like from one face of the metal plate and protruding part formed bulgingly in another face of the metal plate, by forming of the recessed part is cut by cutting tool dividedly in more than one and a cutting direction is differed in alternately facing to each other, so stress by cutting is almost cancelled.
Moreover, in the present invention, pressing process for pressing recessed part from one face of the metal plate and cutting process for cutting protruding part of another face of the metal plate are performed repeatedly more than one, and forming in stepwise desired depth of recessed and protruding parts in every forming frequencies a cutting direction may be differed in alternately facing to each other.
Moreover, in the present invention, pressing recessed part of predetermined depth in a face of the metal plate, protruding part of another face (opposite site face) of the metal plate is formed, in every cutting the protruding part dividedly in stepwise, a cutting direction may be differed in alternately facing to each other.
Moreover, in the present invention, when protruding part of another face of the metal plate is formed in every cutting the protruding part dividedly in stepwise, number of times of a cutting direction in alternately facing to each other may be the same.
Furthermore, in the present invention, predetermined recessed part which is shallower than thickness size of the metal plate from a face of the metal plate and the protruding part which is a little small than the recessed part in another face of the metal plate may be formed in every cutting the protruding part dividedly in stepwise, a cutting direction may be differed in alternately facing to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 (A) to 1 (G) are diagrams for explaining a processing procedure of an embodiment of the package forming method according to the present invention;
FIGS. 2 (A) and 2 (B) are plan views showing examples of the cutters and the cutting processing by them according to the present invention;
FIGS. 3 (A) and 3 (B) are diagrams for explaining a processing procedure of another example of cutting the protruding portion in the steps for forming the package according to the present invention;
FIGS. 4 (A) and 4 (B) are diagrams for explaining a processing procedure of another example of cutting the protruding portion by a rotating cutter in the steps for forming the package according to the present invention;
FIGS. 5 (A) and 5 (B) are diagrams for explaining a processing procedure of another example of cutting the protruding portion by a grinder in the steps for forming the package according to the present invention;
FIG. 6 is a drawing showing a processing procedure of the method for forming the package by means of a transfer-processing machine according to the present invention;
FIG. 7 is an exploded perspective view of a package for electronic parts according to the present invention;
FIG. 8 is a cross-sectional view of the package indicated in FIG. 7; and
FIGS. 9 (A) to 9 (D) are diagrams for explaining a processing procedure of the former method for forming a package proposed by the inventor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter the method for forming a package for electronic parts made of a metal plate according to the present invention will be explained in detail, based on a mode of realization indicated in drawings.
FIGS. 1 (A) to 1 (G) shows the first embodiment. FIG. 1 (A) shows metal plate 10 that forms the package 1 shown in FIG. 7 . The metal plate 10 is positioned with respect to a die 11 of a press that has a recess 11 a at a predetermined portion. The raw material for the metal plate 10 is selected from one of cupper alloy, stainless steel and aluminum or the like. As the metal plate 10 , both a sheet cut into a predetermined size and a rolled band like material can be used.
FIG. 1 (B) shows a step of the first pressing processing. After the metal plate 10 is positioned on die 11 , a preliminary recess portion 2 a that is shallower than the recess portion 2 is formed on one side 10 a of the metal plate 10 by means of a punch 12 of the press. An edge of the punch 12 is formed nearly square form in a predetermined size.
At the time of forming the preliminary recess portion 2 a , an amount of metal corresponding to the preliminary recess portion 2 a is displaced to the other side 10 b by the pressure added by the punch 12 . As the result, a protruding portion 3 a protruding from the surface on the other side 10 b of the metal plate 10 is formed so as to have a height h approximately equal to the depth of the preliminary recess portion 2 a . The outer perimeter W 1 of the protruding portion 3 a is slightly smaller in size than the outer perimeter W 2 of the preliminary recess portion 2 a . Also the protruding portion 3 a is analogous in shape to and centered under the preliminary recess portion 2 a . Since such a relation in size is set, the protruding portion 3 a is not cut-off from the metal plate 10 at its edge portion so that it can be always kept joined thereto and that a stress at the cutting processing described later can be minimized. Further, it is desirable to set the height h of the protruding portion 3 a at such a value that it can be shaved off with the minimum stress at the cutting processing. FIGS. 1 (C) and 2 (D) show a first cutting processing, in which the protruding portion 3 a formed on the other side 10 b of the metal plate 10 by the first pressing process is shaved off at its root by means of a cutter 13 so that the cut surface newly obtained by the shaving is coplanar with the other part of the surface of the other side 10 b . The cutter 13 used for the cutting processing has a blade 13 a . As the shape of the blade 13 a , both a straight lined blade whose extremity is straight line as indicated in FIG. 2 (A) and an arrow-shaped blade whose extremity is pointed at the center as indicated in FIG. 2 (B) are acceptable. But the arrow-shaped blade is more preferable than the straight lined blade in order to minimize the stress during the cutting processing. Moreover, the blade 13 a of the cutter 13 is desirable to have a gradient type extremity that is sharp-pointed into the direction of its movement.
The cutter 13 is advanced in the direction indicated by an arrow in FIG. 1 (C), that is to say, form the front end to the rear end. As indicated in FIG. 1 (D), the first cutting processing terminates when the extremity of the blade 13 a has reached to the rear end of the protruding portion 3 a . In this cutting processing it is desirable that a supporting tool 14 which support the bottom of the preliminary recess portion 2 a under pressure is inserted therein in order to prevent the bottom from being displaced inwardly by the cutter 13 . When the cutter 13 cuts the protruding part 3 , the portion of the metal plate 10 where the cutting is executed suffers stress due to concentration of pressure by advancing movement of the cuter 13 toward the rear end and due to tensions pulled by the cutter 13 in the cut surface. Though these kinds of the stresses vary by difference among tenacity of the metal materials, these stresses are dissolved in the second cutting processing described later.
Next FIG. 1 (E) shows a step of the second pressing processing. The second pressing processing is executed by means of the punch 12 and the die 11 of the press so as to make the preliminary recess portion 2 a formed by the first pressing processing deeper, and to form the recess portion 2 having the final depth and shape required as the package 1 . At the same time, a protruding portion 3 whose height is approximately equal to the increased depth of the recess portion, is formed on the other side 10 b of the metal plate 10 , similarly to the first pressing processing. The outer size of this protruding portion 3 is slightly smaller than the inner size of the recess portion 2 and the protruding portion 3 is analogous to the recess portion 2 .
Then a second cutting processing indicated in FIGS. 1 (F) and 1 (G) are executed. The protruding portion 3 formed on the other side 10 b of the metal plate 10 by the second pressing processing is shaved off at its root by means of the cutter 15 so that the cut surface newly obtained by the shaving is coplanar with the remaining part of the surface of the other side 10 b . As indicated by an arrow in FIGS. 1 (F) and 1 (G), the direction that the cutter 15 advances is reversed to that the cutter 13 has advanced though the second cutting processing is similar to the first cutting processing and the cutter 13 used at this second processing is the same as that has used in the first cutting processing. When the cutter 15 has advanced in the inverse direction with respect to that of the cutter 13 , and has reached at the position indicated in FIG. 1 (G), the surface of the other side 10 b of the metal plate 10 is formed flat and a thin bottom plate 10 c is formed in the bottom of the recess portion 2 .
As a result of the second cutting processing, the concentration of stress and stress itself generated in the metal plate 10 at the first cutting processing are almost cancelled or reduced sharply because of the inverse advancing of the cutter 15 with respect to the direction that the cutter 13 has advanced. Also, in the second cutting process, it is desirable that a supporting tool 14 is inserted into the recess portion 3 in order to support the thin bottom plate 10 c under pressure and to prevent the bottom plate 10 c from being displaced inwardly by the cutter 15 .
The cutter 15 used in the second cutting processing is formed as same as the cutter 13 used in the first cutting processing so as to achieve the first and second cutting processing under the same cutting conditions. The cutting condition is so set that the concentration of stress and stress itself may be cancelled. It is another example to accomplish the same cutting condition between the first and second cutting processing that the metal plate 10 is turned horizontally in an inverse direction at each of the first and second cutting processing in order to cut the protruding portions alternately into a regular direction and a counter direction while using one of the cutter 13 and 15 , which moves in one way.
In general, the required flatness for the bottom plate 10 c of the package 1 is warp within 30 nm or less and the required flatness for the package 1 as a whole is warp within 70 nm or less. According to the steps described above, the required flatness of the package 1 can be obtained by canceling the concentration of stress and irregular deformation of the bottom plate 10 c . Moreover the package 1 can be prevented from changes with the passage of time due to small range of the concentration of stress and irregular deformation.
Another Embodiment
FIGS. 3 (A) and (B) show another embodiment of the method for forming a package 1 , in which both the recess portion 2 having a predetermined depth as the package 1 in one side surface 10 a and the protruding portion 3 b protruding onto the other side surface 10 b are formed by one pressing processing. Thereafter the protruding portion 3 b is cut bit by bit repeatedly in a plurality of times. That is as shown in FIG. 3 (A), a first cutting processing is executed in such a way that a part of the thickness of the protruding portion 3 b along a slice line is shaved off by the cutter 13 advancing from right to left in regular direction. Next, a second cutting processing is executed in such a way that the next part of the thickness of the protruding portion 3 b along the next slice line is shaved off by the cutter 15 advancing form left to right in the counter direction. Then, the cutter 13 executes a third cutting processing in the same way as the first cutting processing and the cutter 15 executes a forth cutting processing in the same way as the second cutting processing.
The cutting processing by the cutter 13 and 15 is executed alternately until the remaining part of the protruding portion 3 b is shaved off at its root and the cut surface newly obtained by the cutting becomes coplanar with remaining part of the surface of the other side 10 b . In this way, since the cutting processing is repeated in a plurality of times changing the advancing directions of the cutters alternately in regular direction and in counter direction, the concentration of stress and irregular deformation of the bottom plate 10 c caused by the cutter 13 can be canceled or reduced significantly by the movement of the cutter, and vice versa. Further, since the thickness of the protruding portion 3 b shaved off by one cutting processing sets so small that the infliction of remaining stress and direct stress on the metal plate 10 is prevented and it remains as is, similarly to the example described referring to FIGS. 1 (A) to 1 (G).
As described above, it is preferable that the each number of times of cutting in regular direction and in counter direction finally becomes same when protruding 3 b formed on the surface of the other side 10 b is cut bit by bit in several times. In the example shown in FIG. 3, each number of times in regular direction and in counter direction is two times each but it can be set selectively as desired according to the thickness of a part of the protruding portion 3 b cut in one time. As so set, the concentration of stress and irregular deformation of the package 1 caused by each cutting processing can be canceled by each next cutting processing in the reverse direction.
FIGS. 4 (A) and 4 (B) show another example of the method in which rotating blades 30 of a milling machine is used as cutting tool instead of the cutter used in the first and second cutting processing shown in aforesaid FIGS. 1 (C) and 1 (F). That is, as shown in FIG. 4 (A), after the first pressing processing, the first cutting processing is executed in such way that that the rotating blades 30 cut the protruding part 3 a advancing from right to left in regular direction so that the cut surface newly obtained by the cutting is coplanar with the remaining part of the surface of the other side 10 b . Then, as shown in FIG. 4 (B), in the second cutting processing after the second pressing processing the rotating blades 30 cut the protruding part 3 moving right to left in the counter direction so that the cut surface newly obtained by the cutting becomes coplanar with the remaining part of the surface of the other side 10 b.
Though the method by the rotating blades of a milling machine affects less stress than that by aforementioned cutter 13 or 15 , there causes and remains still some concentration of the stress. But, since the cutting processing is executed in such a way that the rotating blades of a milling machine moves in a plurality of times alternately in regular direction and in counter direction, the concentration of stress and irregular deformation of the bottom plate 10 c caused by the rotating blades can be canceled or reduced significantly.
FIGS. 5 (A) and 5 (B) show modified example of the method shown in FIGS. 4 (A) and 4 (B) in which a grinder is used as cutting tool instead of the cutters or the rotating blades. That is, as shown in FIG. 5 (A), after the first pressing processing, the first cutting processing is executed in such way that that the grinder 31 cut the protruding part 3 a advancing from right to left in regular direction so that the cut surface newly obtained by the cutting is coplanar with the remaining part of the surface of the other side 10 b . Then, as shown in FIG. 5 (B), in the second cutting processing, after the second pressing processing the grinder 31 cut the protruding part 3 moving right to left in the counter direction so that the cut surface newly obtained by the cutting becomes coplanar with the remaining part of the surface of the other side 10 b.
FIG. 6 shows a forming method of a package of electronic parts by means of a transfer-processing machine not shown in the drawing. In this embodiment, a rolled metal band 20 is used as the metal plate, which is, for example, made of cupper alloy, stainless steel and aluminum. First, groove holes 24 defining the outline of the package 1 and pilot holes 26 guiding transfer of the metal band 20 are formed in the metal band. Then, the package 1 and intermediate packages 21 to 23 are formed in such a way that they are connected to each other via connecting portions 25 .
After the processing to form the groove holes 24 and pilot holes 26 , the first press processing is executed so as to form the intermediate package 21 which has a shallow recess portion 2 a in one side surface 20 a of the metal band 20 by applying the first pressing processing as shown in FIG. 1 (B). Then the intermediate package 21 is transferred for the first cutting processing shown in FIGS. 1 (C) and 1 (D), where a cutter 13 shaves off the protruding part (not shown in the drawing) formed on the other side surface of the metal band 20 so forming the intermediate package 22 . Next, the intermediate package 22 is transferred for the second pressing processing shown by FIG. 1 (E) so as to form recess portion 2 having final depth in one side surface 20 a of the metal band 20 , wherein the intermediate package 23 having a protruding portion on the other side surface of the metal band 20 is formed. After the intermediate package 23 is transferred for a final processing, that is to say the second cutting processing as shown in FIGS. 1 (F) and 1 (G), the protruding portion (not shown in the drawing) is shaved off by a cutter 15 so that the final shape of the package 1 is formed. Then, before the package 1 is separated from the metal melt 20 , semiconductor circuit and wiring board are mounted on the package 1 . Finally the package 1 as final product is separated from its intermediates of the metal band by the connecting portions 25 .
In the abovementioned method of forming a package of electronic parts by means of a transfer-processing machine each of the steps of first and second pressing processes and cutting processes is executed to only one of the package 1 and its intermediates 21 to 23 in one time. It is applicable that the each of the steps is executed to the plurality of intermediates grouped as one unit for same processing. In this case, the each step of first and second pressing processes and cutting processes is applied to each of the units.
In before mentioned description of embodiments, a semiconductor IC circuit is an example of electronic parts accommodated in the recess portion of the package but another electronic parts for example hybrid circuit, inductor chip or resistor array may adapt as electronic parts. The present invention is not restricted in these embodiments, which may change in an extent without departing from the scope of the invention.
As described above, in package forming method according to the present invention, the protruding portion, which is formed in ledge shape on one surface of the metal plate opposite to the other surface where the recess portion is formed at the same time, is cut bit by bit repeatedly in a plurality of times changing the advancing directions of the cutting means alternately in regular direction and in counter direction. Thus, the stress and its concentration produced by the cutting in regular direction is cancelled or reduced significantly by the cutting in counter direction, and vice versa. As the result, the package of the electronic parts acquires the required evenness and flatness with little warp. Moreover, reduction of the stress and its concentration on the package prevents the time-varying changes of dimensions and evenness of the package. Accordingly, a high accuracy package for electronic parts can be obtained. | A package for receiving electronic parts is formed with decreased stress and stress concentration to obtain a desired warp and flatness. In particular, according to a cutting protruding part process, a package is accommodated to have a recessed part formed on one face of a metal plate by pressing the face of the metal plate so that a corresponding protruding part is formed bulging from an opposing face of the metal plate. The protruding part is cut by a cutting tool and a bottom which has a cavity shape and is thinner in size than the metal plate is formed at the recessed part. The protruding part is again formed bulging from the metal plate and cut by the cutting tool. The cutting direction is differed in alternately facing directions so that the stress from cutting is almost cancelled. | 1 |
FIELD OF THE INVENTION
This invention relates generally to the manufacture of containers for fluent materials such as cosmetic products. More particularly, the invention is concerned with a technique for providing an annular lip within the container neck, e.g. for use as a wiper for a cosmetic applicator wand.
BACKGROUND OF THE INVENTION
Containers for cosmetic products such as mascara, eyeliner and the like traditionally have a built-in applicator wand, for example in the form of a narrow, elongate brush. Typically, the wand is attached to a closure for the container so that the wand fits within the container when the closure is in place. To apply the cosmetic, the closure is removed from the container, bringing with it the wand and a certain amount of the cosmetic, carried on the wand. An annular lip is provided within the container neck to act as a wiper against which the wand is drawn as it is removed from a container so that excess amounts of the cosmetic are removed from tho wand.
DESCRIPTION OF THE PRIOR ART
Conventional practice is to make the container and wiper as separate plastic mouldings. For example, the container may be a plastic cylinder with a closed lower end and a threaded neck at its upper end. The wiper moulding takes the form of a tapered sleeve that fits within the neck of the container. The sleeve has a flange at its outer end that rests against the top surface of the container neck and the sleeve is of a length selected so that its inner end is located within the container below the threaded neck portion. The sleeve tapers towards its inner end and the sleeve opening at that end is dimensioned so that an appropriate amount of the cosmetic product will be wiped from the wand as it is withdrawn through the sleeve.
Usually, the wiper moulding is inserted into the container neck, after the container has been filled with cosmetic product. However, the wiper moulding can be placed onto the wand and fitted into the container by screwing the closure onto the container neck.
It will be appreciated that formation of the wiper as a separate moulding involves significant capital cost in that a specific mould must be provided for forming the wiper. There is also significant material cost and some cost in assembling the wiper moulding to the container.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved method of forming an annular lip within a container neck which avoids at least some of these costs. A further aim is to provide an improved container/closure combination.
The method of the invention involves providing (a) a container having an annular neck portion with an inner wall and (b) a closure for the neck portion. The closure includes a plug which is adapted to fit within the container neck portion and an outer closure portion which remains external to the container when tho closure is in place. An annular lip-forming member is provided at the inner end of the plug and is joined to the plug by breakable coupling means. The closure is dimensioned with respect to the container neck portion so that the lip-forming member forms an interference fit with the inner wall of the container neck portion when the plug is fully seated within that portion. The coupling means is breakable, for example, by twisting of the closure so that the closure can be removed from the container while leaving the lip-forming member fitted within the container neck portion.
In other words, the lip-forming member initially forms part of the closure and is dimensioned to frictionally jam inside the container neck portion when the closure is fitted to the container and to break away from the closure as the closure is subsequently twisted for removal from the container. Conveniently, the closure is a one-piece plastic moulding which initially includes the lip-forming member only a single mould is then needed to form both the closure and the lip. Where the container is a cosmetic container, the lip of course forms the wiper discussed previously. The wand may also be moulded in one piece with the closure. In this way, the complete container/closure combination can be made using only two moulds. Where the wand is required to include a brush, the brush can be made separate-y and the one-piece closure and wand moulded onto the brush stem as a single operation.
The lip or wiper is installed in the container by simply fitting the closure to the container and then twisting or otherwise manipulating the outer closure portion to break the coupling means between the lip-forming member and the remainder of the closure. The twisting action can be effected immediately after the container has been filled and the closure fitted to the container. Alternatively, the consumer can be provided with instructions to twist the closure before the container is used.
The invention also provides the combination of a container which includes an annular neck portion having an inner wall and a closure for the container, the closure including a plug which fits within the container neck portion, an outer closure portion which remains external to the container, an annular lip-forming member at an inner end of the pug, and breakable coupling means between the lip-forming member and the plug. The closure is dimensioned so that the lip-forming member is an interference fit with the inner wall of the container neck portion when the plug is fully seated within the neck portion so that the lip-forming member can be separated from the closure and remain within the container when the closure is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, reference will now be made to the accompanying drawings which illustrate a particular preferred embodiment of the invention by way of example, and in which:
FIG. 1 is a perspective view of a container for mascara and an associated closure and wand in accordance with the invention, showing the closure and wand positioned above the container prior to insertion therein;
FIG. 2 is a view similar to FIG. 1 showing the closure and container assembled;
FIG. 2a is an enlarged vertical sectional view of the upper part of FIG. 2; and,
FIG. 3 is a view similar to FIG. 1 showing the wand being withdrawn from tho container.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, a mascara container is generally indicated by reference numeral 20 and a closure for the container is indicated at 22. A wand 24 extends downwardly from the closure for insertion into the container as indicated by arrow 26.
Container 20 is an injection moulded, clear plastic cylinder having a closed lower end 28 and an open upper end 30 with a neck portion 32 adjacent end 30. An annular inner wall of neck portion 32 is indicated at 34. A quantity of mascara within the container is shown at 36.
Closure 22 includes a plug 38 that is shaped to fit closely within the container neck portion 32 (as best seen in FIG. 2a), an outer closure portion 40 which remains external to the container when the closure is in place, and an annular lip-forming member 42 at the inner end of the plug 38. These elements (together forming closure 22), and wand 24 are a one-piece plastic moulding 44, as best seen in FIG. 2a. Wand 24 also includes a brush 46 of the type conventionally used for applying mascara. Brush 46 is made up of a wire stem 48 spirally wrapped around an array of bristles 50. Moulding 44 is formed on an exposed inner end portion of stem 48 (see FIG. 1).
Referring now more particularly to FIG. 2a, closure 20 is shown in that view with plug 38 fully seated within the neck portion 32 of container 20. Plug 38 is cylindrical and is shaped to fit closely within the container neck portion 32. The outer end portion 40 of the closure is of tapered cylindrical form and is of slightly larger diameter than the plug 38, defining a shoulder 52 that abuts against the top edge of the container when the closure is fully seated on the container.
Wand 24 is also of tapered cylindrical shape and is in effect formed as a narrower continuation of plug 38, again as best seen in FIG. 2a. Thus, wand 24 adjoins plug 38 at shoulder 54.
When moulding 44 is initially formed, the lip-forming member 42 is moulded as a plastic ring which encircles wand 24 adjacent to plug 38 and which is coupled to the shoulder 54 (FIG. 2a) on plug 38 by breakable coupling means. In the illustrated embodiment, these breakable coupling means take the form of four relatively thin and fragile plastic "gates" or "lands" that extend between lip 42 and shoulder 54. The gates are equally spaced around shoulder 54. Three of the four gates are visible in FIG. 2a and are denoted by reference numeral 56.
Closure 22 is dimensioned with respect to the container neck portion 32 so that the lip-forming member 42 forms an interference fit with the inner wall 34 of the container neck portion 32, when closure 22, and in particular plug 38 are fully seated on the container. More specifically, in accordance with established plastic moulding techniques, container 20 is moulded so that the container side wall tapers slightly towards its bottom end 28. The taper is very slight and is essentially not discernable to the eye, but is necessary in order to permit release from within the container of the mandrel used during the plastic moulding operation to form the inner wall of the container. Closure 22 is then dimensioned precisely so that, as it enters the open end of the container with plug 38, the member 42 will in effect jam against wall 34 when closure 22 reaches its fully seated position. This is the position shown in FIGS. 2 and 2a.
FIG. 1 shows the closure as moulded with member 42 coupled to plug 38. Once the plug has been fully seated within the container as shown in FIGS. 2 and 2a, the closure is twisted by manually turning outer portion 40 causing the coupling gates 56 to break so that member 42 becomes separate from the remainder of the closure. The closure can then be withdrawn, bringing with it the wand 24 as best shown in FIG. 3. Member 42 will remain within the neck portion 32 of the container and will act as a wiper for removing excess mascara from the bristles of the brush 46. It has been found in practice that member 42 remains in the container despite repeated movements of brush 46 back and forth through member 42.
Separation of closure 22 from member 42 is preferably performed by twisting as described, in order to ensure clean separation and avoid the risk of dislodgement of the member. However, it is conceivable that the member and closure could be separated simply by pulling on the closure.
In any event, it will be appreciated that, as compared with the prior art, a container and closure of the form provided by the invention can be manufactured relatively inexpensively using only two plastic moulds and without the need to separately fit a wiper element to the container. Formation of member 42 and gates 56 on closure 22 involves the use of complex movable mould parts but can readily be accomplished by a person skilled in the art.
It should also be noted that the preceding description relates to a particular preferred embodiment and that many modifications are possible within the broad scope of the invention. For example, the preceding description relates specifically to a mascara container but there is no limitation to this particular type of container, or indeed to cosmetic containers. For example, the invention could be applied to paint containers in which the wand 24 of tho preferred embodiment might be replaced by a paint brush. In other applications, wand 24 or its equivalent might be omitted entirely. For example, a lip-forming member might be inserted into a container for the purpose of restricting pouring of fluent material from the container.
Closure 22 could be designed to be threaded onto the container rather than being designed as a push-fit.
Broadly speaking, it would be possible to apply the invention to a container other than of cylindrical form. Accordingly, the term "annular" as used herein should be broadly interpreted. | A cosmetic container is provided with an annular lip within the container neck by a method which involves providing a closure for the container which has moulded integrally therewith a lip-forming member. When the closure is fitted to the container, the member forms an interference fit with the inner wall of the container and is retained when the closure is removed. An applicator wand on the closure extends through the annular member and the member acts as a wiper for the wand. | 0 |
This is a continuation of international application Ser. No. PCT/ES93/00012, filed Feb. 24, 1993 and a continuation of application Ser. No. 08/154,011, filed Oct. 22, 1993 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Apparatus especially adapted to the manufacture of carbon filaments (DQ1F.)
Manufacture of carbon fibre from hydrocarbons.
DESCRIPTION OF THE RELATED ART
Carbon fibres are used as a reinforcing element in the manufacture of materials composed of a polymeric, metallic or ceramic matrix. The level of characteristics of the composites depends, aside from other aspects such as amount of reinforcement included, direction of the fibre, etc., on the quality of the fibre, that determines the price thereof.
Consequently, the composites that should be produced at a moderate cost (for inexpensive products and a large market volume, such as seats, frames, etc.) are restricted to the use of only low price fibres, such as fibre glass.
High usage fibres, such as silicon carbide, aramide and carbon fibres are limited to use in those very high usage composites (aerospace industry and Defense industry, that may allow high costs.
Therefore, it is of the utmost interest to achieve the production of high usage fibres at a more affordable price. In this sense a lot of research has been done and, above all, regarding carbon fibre.
The carbon-graphite fibre concept covers a broad range of ceramic fibres of pure graphite from a chemical point of view, but with an ample variation with regard to the degree of graphitization thereof and the structure-properties relationship. Basically there are three big families:
i) ex-PAN carbon-graphite fibre, having such a name as it is manufactured from polyacrylonitrile (PAN) textile thread or rayon textile thread, which is roasted and pyrolized until only the strongly texturized skeleton of the graphite framework of the starting polymer or precursor remains. Basically by the energy consumption that the manufacture thereof implies, it is practically impossible to lower the price thereof; it is the typical fibre of the composites for aeronautics and space vehicles.
ii) ex-PITCH carbon-graphite fibre, having such a name as it is manufactured from pitch or tar, to which additives are added to stimulate the formation of a "mesophase." In a pasty state, the pitch is formed into a thread and then it is subjected to pyrolization treatment such as conventional graphite. The mechanical characteristics thereof are due to the reduced grain size of the graphite processed in this way. There was a time when it was thought that this ex-Pitch fibre was going to be the carbon fibre that was going to replace exPAN fibre due to the lower cost thereof, but the only types of high usage ex-Pitch fibres correspond to Young high modulus fibres and very reduced breakage elongation, thus the potential market thereof is very small.
iii) Unlike the two previous families, which have been available on the free market for quite some time, VGCF (Vapour Growth Carbon Fibres) are still in the laboratory-pilot plant stage and constitute the hopes of industries such as the automobile industry that is never going to be able to afford the cost of ex-PAN and ex-PITCH carbon-graphite fibres.
The production process thereof simply consists of the production of lamp black in which the special necessary precautions are taken so that the product becomes filamentous, just as it has been done in the manufacture of whiskers, no matter how much controversy there is about the physics-chemical mechanisms that control the formation of these fibres. The process consists of using some tiny metallic particles, which acting as seeds, receive all the carbon coming from the decomposition of the hydrocarbon and take on the form of filaments.
The experimental system for growing these fibres is extensively described in the bibliography (see G. G. Tibbetts "Vapour grown carbon fibers," Chapter of the book: J. L. Figueiredo et al. (Editors) "Carbon fibres filaments and composites" Kluwer Academic Publishers (1990) pag. 7394; F. Benissad, P. Gadelle, M. Coulon and L. Bonnetain "Formation de fibres de carbone a partir du methane: i. Croissance catalytique et epaisseissement pyrolytique" Carbon, vol. 26 (1988) pag. 61-69; G. G. Tibbetts "From catalysis to chemical vapor deposition: graphite fibers from natural gas" Paper read at the Graphite Intercalation Compounds Congress organized by The Materials Research Society, Boston (USA) November 1984; M. Endo and H. Ueno "Growth and applications of vapor-grown carbon fibres" Paper read at the Graphite Intercalation Compounds Congress organized by the Materials Research Society, Boston (USA) November 1984.) A quartz tube inside of which, at temperatures slightly above 1000° C. some finely ground transition metal seeds are placed, in an atmosphere of a mixture of hydrogen (that may be accompanied by CO), and a gaseous hydrocarbon, is used. The carbon is adsorbed by the metallic particles and the excess are given off in the form of carbonous filament.
Basically, there are two techniques to produce VGCF, in a fixed bed, wherein the seeds are very still and the only thing that moves is the mixture of reactive gases (the fibres are generated and grown fixed to the substrate or pan), and in a fluidized bed, wherein the seeds are drawn by the gases (just like wind which draws dust particles) while they are growing (M. Endo, A. Katoh, T. Sugiura and M. Shiraishi, "High resolution electromicroscopy on vapour-grown carbon fibres obtained by ultra-fine fluid catalyst" Paper read at the 18th. Biennial American Conference on Carbon. Worchester 1987). The VGCF which both techniques produce, are identical, though generally the fibres coming from the fixed bed have an average length slightly longer than fibres produced in a fluidized bed.
The two big difficulties, not yet overcome, which have hampered manufacturing on an industrial scale of VGCF (despite the large bibliography existing, VGCF have not come onto the free market at a commercial scale), are:
i) very short length
ii) very small amount of fibre produced per operating hour
The matter of fibre length is very restrictive, from the point of view of the short fibre sector market. There are manufacturing processes of composites, that are widely used, which require short fibre, but with a certain minimal length. Thus, for example, the SMC (Sheet Moulding Compound) process, by means of which some many automobile bumpers are manufactured, requires short fibres of approximately 2.5 cm.
In the case of fixed bed systems, which are capable of producing longer VGCF, the bibliography (F. Benissard, P. Gadelle, M. Coulon and L. Bonnetain "Formation de fibres de carbone a partir du methane. TTI: Influence de la nature du precurseur du catalyseur." Carbon, vol. 27 (1989) pag. 585-592; G. G. Tibbets "Length of carbon fibres grown from iron catalyst particles in natural gas" Journal of Crystal Growth, vol. 73 (1985) pag. 431-438) indicates to us that the average length of 1.5 mm. cannot be exceeded. The only document which cites that this fibre length is greatly exceeded is patent (14) the Komaki et al. Japanese Patent No. 60-81318 (see below), wherein the length of 75 mm. is said to be achieved, though there is no explanation as to whether this length refers to the average length of the fibres obtained in a batch, or if (that which is most probable), the length of a few exceptionally long fibres appearing in the substrate or pan is referred to.
Looking for the quickest possible fibre production, the studies seeking the industrial production of VGCF, the fluidized bed systems, which produce fibre lengths of only 500 μm (patent 17), 5 μm 15 mm. are usually chosen. The following list of patents, which we refer to by the numbers in parenthesis, consider these processes:
(1) VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE
Authors: M. Endo, T. Okada, M. Ishioka, K. Nakazato, Y. Okuyama and K. Matsubara
Applicant: Nippon Kokan K.K.
Patent No. at the Patent Office in Tokyo: 01 92425 (89/92425)
Application date: 30 Sep. 1987
Patent application: 87/246178
(2) LOW COST VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE
Author: M. Endo, M. Ishioka, T. Okada, K. Nakazato, Y. Okuyama and K. Matsubara
Patent No. at the Patent Office in Tokyo: 01 92423 (89/92423)
Application date: 30 Sep. 1987
Applicant: Nippon Kokan K.K.
Patent application: 87/246174
(3) LOW COST VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE
Author: M. Endo, T. Okada, M. Ishioka, K. Nakazato, Y. Okuyama and K. Matsubara
Patent No. at the Patent Office in Tokyo: 01 92420 (89/92420)
Application date: 30 Sep. 1987
Patent application: 87/246171
(4) VAPOUR PHASE GROWN ULTRAFINE CARBON FIBRE MANUFACTURE
Author: M. Nakatini and Y. Komatsu
Applicant: Asahi Chemical Industry Co. Ltd.
Patent No. at the Patent Office in Tokyo: 63 282313 (88/282313)
Application date: 15 May 1987
Patent application: 87/116663
(5) VAPOUR PHASE GROWN ULTRAFINE CARBON FIBRE MANUFACTURE
Author: M. Nakatini and Y. Komatsu
Applicant: Asahi Chemical Industry Co. Ltd.
Patent No. at the Patent Office in Tokyo: 62 282020 (87/282020)
Application date: 26 May 1986
Patent application: 86/120789
(6) VAPOUR PHASE GROWN ULTRAFINE CARBON FIBRE MANUFACTURE
Author: A. Furuichi and Y. Komatsu
Applicant: Asahi Chemical Industry Co. Ltd.
Patent No. at the Patent Office in Tokyo: 62 288819 (87/268819)
Application date: 15 May 1986
Patent application: 86/109606
(7) CARBON FIBRE MANUFACTURE
Author: Y. Komatsu and K. Nakamura
Applicant: Asahi Chemical Industry Co. Ltd.
Patent No. at the Patent Office in Tokyo: 61 225321 (86/225321)
Application date: 23 May 1985
Patent application: 85/58812
(8) VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE
Applicant: Showa Denko K.K.
Patent No. at the Patent Office in Tokyo: 61 194223 (86/194223)
Application date: 22 Feb. 1985 Patent application: 85/32817
(9) VAPOUR PHASE GROWN CARBON FIBRES MANUFACTURE
Author: H. Ito and K. Murata
Applicant: Mitsui Engineering and Shipbuilding Co. Ltd.
Patent No. at the Patent Office in Tokyo: 01 104834 (89/104834)
Application date: 15 Oct. 1987 Patent application: 87/260139
(10) VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE USING LASER RADIATION
Author: K. Murata, K. Sato and M. Matsumoto
Applicant: Mitsui Engineering and Shipbuilding Co. Ltd.
Patent No. at the Patent Office in Tokyo: 01 85320 (89/85320)
Application date: 28 Sep. 1987
Patent application: 87/243292
(11) VAPOUR PHASE GROWN CARBON FIBRE MANUFACTURE USING LASER RADIATION
Author: K. Murata, K. Sato and M. Matsumoto
Applicant: Mitsui Engineering and Shipbuilding Co. Ltd.
Patent No. at the Patent Office in Tokyo: 01 85321 (89/85321)
Application date: 28 Sep. 1987
Patent application: 87/243293
(12) CARBON FIBRE MANUFACTURE
Author: M. Murakami and S. Yoshimura
Applicant: Research SS Development Corporation of Japan
Patent No. at the Patent Office in Tokyo: 61 55220 (86/55220)
Application date: 24 Aug. 1984
(13) MANUFACTURING CARBON FIBRES FROM A GASEOUS HYDROCARBON
Author: Y. Komatsu
Applicant: Showa Denko S.A.
European patent No.: 86901499.3 (WO 86/04937) Publication date: 28 Aug. 1986
(14) APPARATUS FOR THE MANUFACTURE OF CARBON FIBRE BY THE THERMAL DECOMPOSITION METHOD
Author: K. Komaki and M. Watanabe
Applicant: Showa Denko S.A.
Patent No. at the Patent Office in Tokyo: 60 8138 Publication date: 9 Jun. 1983
(15) GASEOUS PHASE GROWN CARBON FIBRE MANUFACTURING METHOD
Author: K. Okada et al.
Applicant: Nippon Kokan Kabushiki, Tokyo Patent no. at the Patent Office in Tokyo: 63-12720, application no. 61-150838 Publication date: 20 Jan. 1988
(16) GASEOUS PHASE GROWN ULTRAFINE CARBON FIBRE MANUFACTURE
Author: S. Marimoto
Applicant: Showa Derrico K.K.
Patent No. at the Patent Office in Tokyo: 63 92726 Application date: 1 Oct. 1986
Patent application: 86/233758
(17) GASEOUS PHASE GROWN CARBON FIBRE MANUFACTURING METHOD
Authors: M. Endo, M. Ishioka, K. Nakazato, T. Okada, Y. Okuyama and K. Matsubara
Applicant: Nippon Kokan K.K. Tokyo
Patent No. at the Patent Office in Tokyo: 62-246172
Application date: 30 Sep. 1987
Patent application: 87/246172
(18) PREPARATION OF MICROSCOPIC CARBONATED FIBRES BY A VAPOUR PHASE METHOD
Author: K. Arakawa
Applicant: Nikkiso Co. Ltd. Tokyo
Patent No. at the Patent Office in Tokyo: 60 81138 (EP 84109710.8 and EP 85103297.8)
Application date: 27 Jul. 1984
(19) PROCESS FOR THE MANUFACTURE OF DEPOSITED CARBON FIBRES FROM METHANE
Author: M. Coulon, N. Kanctani-, L. Bonnetain and J. Maire
Applicant: Le Carbon Lorraine
International Patent No.: EP 8505383
Publication date: 5 Dec. 1985
(20) IMPROVED PROCESS FOR GRAPHITE FIBRE GROWTH
Author: J. R. Bradley, J. M. Burkstrand and G. G. Tibbetts
European Patent No.: 83306001.5 (EP 109165)
Application date: 4 Oct. 1983
(21) METHANE PYROLYSIS PROCESS
Author: G. G. Tibbetts and M. G. Devour
Patent Nos.: U.S. Pat. No. 642,574 (20 Aug. 1984), U.S. Pat. No. 685,046 (21 Dec. 1984), ES 546,245 (19 Aug. 1985)
(22) FERRIC NITRATE TREATMENT FOR NUCLEATION OF GRAPHITE FIBRE GROWTH BY MEANS OF METHANE PYROLYSIS
Author: G. G. Tibbetts
Applicant: General Motors Corporation
European Patent No.: 843020243.9 (EP 132909)
Application date: 13 Feb. 1985
(23) STIMULATION BY MEANS OF PRESSURE PULSES OF GRAPHITE FIBRE GROWTH
Author: G. G. Tibbetts
Applicant: General Motors Corporation
European patent no.: 86307589.1 (WO 222492)
Application date: 2 Oct. 1986
On the other hand, there are very few options for the fixed bed (patents (12), (14) and (18)), though they obtain lengths of 100 μm<1<500 μm (in patent (12)), 2 mm<1 <3 mm (in patent 18)), etc.
Therefore, it can be said, that in broad outline, the options of a fluidized bed tend to produce "crashed fibre" (hardly one millimeter long), while the possibilities of manufacturing "short fibre" (longer than 5 mm) are potentially attainable by a fixed bed, but improving with future research the efficiency of the equipment described in the above cited bibliography.
The other key issue, the production speed of VGCF during the manufacturing process, is likewise restrictive. Thus, for example, in patent (13), 6.5. g of fibre are said to be achieved after 5 hours of production in a fluidized bed, while using a fixed bed, in patent (14) 2.5 g are said to be attained in 5 hours of production in a fluidized bed, while using a fixed bed, in patent (14) 2.5 g are said to be attained in 5 hours of production in a fluidized bed, while using a fixed bed, in patent (14) 2.5 g are said to be attained in 5 hours of operation (with the additional remark that in conventional systems, that are not specifically indicated, the production is of 1.8 g. in the same amount of time.)
We understand that the R+D efforts in this technology should be directed towards solving both aspects.
SUMMARY OF THE INVENTION
As is seen in FIG. 1, the obtainment of relatively long ceramic fibres by pyrolysis or reduction of suitable gases (hydrocarbons when carbon fibres are to be obtained, hydrogen-silicon chloride-hydrocarbon mixtures when silicon carbide fibres are to be obtained, etc.), is achieved by passing a gaseous mixture through a substrate (6) (in principle steel wire fabric or mesh) placed frontally to the direction of the gas stream and placed in an oven (4) where the gas reaches a temperature around 1000° C. The device, schematized in cited FIG. 1, consists of the corresponding gas tanks (1) Hydrocarbon tanks and (2) carrier and activator gas or gases, a mixing and preheating chamber (3), the cited oven (4) at % whose outlet (5) the inflammable gases are collected or destroyed and the screen (6) from whose duly activated surface, the carbon fibres grow.
Starting from the fact that stainless steel is indicated in the bibliography as suitable material upon which fibres can grow, in principle (and without this being restrictive) stainless steel can be used to manufacture the substrate, which in accordance with the present invention, and as is shown in FIG. 2, can be
A stainless steel wire metallic mesh with a suitable opening size
An adequately thick steel sheet disk in which suitably sized holes are perforated.
With these substrates it is achieved that the seeds that are formed do so separate from each other. For this purpose a conventional technique consisting of the disks, once they are cleaned, degreased and sickled with diluted hydrochloric acid, are seeded, applying some brush strokes of an alcohol solution of, for example, ferrid nitrate (Fe(NO 3 ) 3 can be used.
The operating conditions of temperature, composition of the mixture and required time, are conventional. The operating temperature is, preferably 1065° C. and the reactive atmosphere 85% hydrogen with 15% methane; the operating time is one hour.
The essential aspect of the invention is that the gas passes through the substrate located frontally to the flow, so that upon this flow (in which turbulences should be avoided) being parallel to the direction of growth of the fibres, the fibres can attain a length of up to 10 to 12 cm. with a thickness of 4 to 15 μm.
In the tips of the fibres, due to the required flow, the gas is renewed from the surroundings of the active end thereof, maintaining it with the entire methane content, that permits the continuity of the growth thereof.
In view of industrial production, it is convenient to reduce the opening size of the mesh (or the size of the holes) until the maximum coverage of the cross-section of the oven is achieved, leaving enough free space such that, without obstructions the stream of reactive gases that will feed the VGCF fibre growth, will pass through. It will also be interesting to place the maximum number possible of pans-substrates, so that in the useful cylindric-tubular space that the reactor-oven constitutes, the largest possible number of fibres are produced simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment thereof, especially when taken in conjunction with the accompanying drawings wherein like reference numerals in the various Figures are utilized to designate like components, and wherein:
FIG. 1 is a schematic view of the reactor according to the present invention;
FIGS. 2a-2d illustrate the substrates according to the present invention;
FIG. 3 shows the basic unit;
FIG. 4 shows another embodiment of the unit illustrated in FIG. 3;
FIG. 5 shows another embodiment of the unit illustrated in FIG. 3;
FIGS. 6a and 6b show a substrate formed by a spiral wound wire;
FIGS. 7a, 7b and 7c show various embodiments of masks;
FIG. 8 shows the dimensions of the unit; and
FIG. 9 shows a reactor according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As it has been indicated in FIG. 1, the device consists of a chamber (3) for preheating and homogenizing the mixture, which though it is not an essential part of the invention, from a practical point of view, it is essential for the purpose of saving energy and reducing the time required to reach the operating temperature.
Neither the geometry of the oven (unless it is tubular) nor the heating system is an essential part of the invention. Due to the easy adjustability thereof, electric heating is advisable. Heating by electric energy consumption allows for two equally valid variants, Joule effect heating and induction heating. In the first case, it takes longer to reach the operating temperature, and in the second case the equipment cost is higher.
The simplest way to eliminate residual gases is done by burning them in a torch when, as usual, operating is done at atmospheric pressure; if there is a desire to vary this pressure, instead of in the torch they would be put in a sealed container with an adjusted pressure escape (pressure higher than atmospheric pressure), or a vacuum pump (pressure lower than atmospheric pressure.) In any case, it is convenient to point out the following:
i) in all that which refers to dimensions, they basically depend on the production capacity provided for. The gas flow must be such that its linear speed (reducing its volume to normal conditions) is between 2 and 16 cm min -1 .
ii) the substrates, which in principle may be the ones indicated in FIG. 2, can, in the strict meaning of the word, be used indistinctly in the Joule effect heating system as well as in the induction heating system. However, this subject will be dealt with hereinafter in greater detail.
iii) an essential improvement lies on the specialization of the supports in substrates and "masks." There is really no clear distinction between both concepts, since the two systems can be included in a single piece as it has been indicated up to now (FIG. 1.) It is simply that some geometries, corresponding to the ones that we associate with the concept of "mask", a word which indicates in an abbreviated form a "passive adjustment mask" consisting of a thin wall, with perforations made for this purpose, which due to their simple location opposite the stream of reactive gases, tends to improve the regularity and laminarity of the flow of gases. These masks play an important role as distributors-uniformers of the flow of gases inside the oven-reactor, having on the other hand very little effectiveness as generating trays of VGCF or fibers of another type of ceramic material, though hereinafter we are going to limit ourselves to VGCF, which are the ones most frequently used. Consequently, a very favorable option is to choose, as in the case of FIG. 4, an input-substrates-substrate "mask and/or output "mask" pan sequence, so that the intermediate sub-produce the maximum VGCF, but this is an advantageous option, not a requirement.
In this sense, in FIG. 3, what we could call the basic unit of the invention is seen. This unit can be repeated a specific number of times as is observed in FIG. 4. At the input of the oven (1) it is very convenient (but not necessary) to have the mask (2) whose basic task is to regularly distribute the gas before it enters the substrate (3) where the carbon fibres are formed. Given that in a unit the hydrocarbon content of the gaseous mixture is not used up, this can pass on to the second unit and from the second unit to the third unit, etc. At the end of the last series of cascaded substrates, it is very convenient that there is a second mask (2) instead of a substrate, so that the turbulences that can be produced in the gas as a result of the strangulation at the output do not affect the laminar flow in the last unit, are avoided.
There is another optional aspect that can be seen by comparing FIGS. 4 and 5. In the first one, length, L, of each unit is the same, while in the second one it is different, reducing in the direction of movement of the gas.
The reason is the following. When the mixture of reactive gases reaches the second substrate (which we will call S2), it is somewhat weakened since part of its carbon potential has been discharged in the feed of the growth of VGCF grown on the first substrate, S1. Consequently, after, for example, twenty minutes of operation, substrate S1 is populated with VGCF with an average length L, while the fibres grown on S2 have an average length shorter than L. Therefore, between the end of the fibres grown on S2 and the subsequent substrate S3 there is wasted space. Therefore, it is logical to place the substrates with a progressively smaller separation.
This does not mean that equidistant substrates can not be used. If, for example, the substrates are placed equidistant at 6 cm., logically a situation in which the VGCF grown on S1 would be reached, as a length of 6 cm. has been attained, their ends would much substrate S2, which would cause their growth to stop. If the operation is now prolonged, the fibres grown on S2 begin to grow more rapidly, since now an atmosphere richer in hydrocarbons reaches them. Once the fibres grown on S2 reach substrate S3, a subsequent prolongation of the operating time permits the fibres grown on S3 to touch substrate S4 and so on.
In other words, one has the liberty to choose between fibres of a single size, which correspond to the situation of equidistant substrates and fibres with some graduated sizes, according to corresponding decreasing values of L. In the first case, the oven can be as long as desired, with an operating time that increases with its length. In the second case, the length of the operation can be minimized.
DESCRIPTION OF THE SUBSTRATES
In the present description the word "substrate" is used to define an object upon which growth of the fibre takes place. The substrate is a support that either due to its own nature or because "seeds" are provided to it (the seeds will be referred to hereinafter) permits said growth.
In FIG. 2 different geometric forms that can be given to the substrates, whose periphery has been drawn circular assuming that it has to adapt to a cylindrical frame has been shown, but they could also have another shape, for example, square. FIG. 6 shows a different type of substrate formed by a spiral wound wire, to which, optionally, a second spiral of finer wire as shown in the bottom part of the Figure may in turn be would around this.
For example, in order to manufacture the latter, a wide range of metallic materials can be used with the sole requirements that they endure the operating temperature (between 600° and 1300° C.) without deteriorating or losing shape (none rust because the oven operates with a reducing atmosphere.) Base alloys Co, No, W and ferro-alloys, heat-resisting steels and stainless-heat-resisting steels are especially appropriate and they can be used in the qualities that are normally used in trade, VITALIUM®, NICHROME®, KHANTAL®, STELLITE®, commercial pure wolfram, etc. VITALIUM is a composition comprising: 0-0.5 C; 0-0.6 Si; 0-0.75 Mn; 5-7 Mo; 28-32 Cr; balance Co.;
NICHROME is a composition comprising: 0.38-0-43 C' 0.7-0.9 Cr; 1.65-2.00 Ni; 0.2-0.3 Mo; balance Fe.;
KHANTAL is a composition comprising: 23.4 Cr; 6.2 Al; 1.9 Co; 0.06 C; balance Fe.;
STELLITE 100, is a composition comprising: 34 Cr; 19 W; 2 C; balance Co.
In order to form the substrates 3 illustrated in FIG. 4, the alloys pointed out for the substrate of FIGS. 6a and 6b can be used, or else any of the graphite board available in commerce for high temperature joints can be used (normal brands CARDBOARD® of the finn Ashland in the USA and PAPYREX® manufactured in Francy by Le Carbonne Lorraine.) The spiral substrate of FIGS. 6a and 6b can comprise a first spiral wound wire about which a second timer wire can be wound. In other words, the first wire acts as a frame about which the second timer wire is wound.
In order to manufacture the substrate of the type of FIG. 2, any quality ceramic material may be used, alumina, mullite, silicon carbide, etc. In this case it is very convenient that the grooves or perforations have toothed edges, that improve the fertility of the substrate since they stimulate the accumulation of the tiny seeds.
The substrates can be used directly, in direct contact with the wall of the oven (which in this case acts as a frame), though it is preferable to use them wrapped in a steel wire tubular element.
MASKS
The mask, as it has already been defined (passive wall with flow adjustment perforations, located frontally to the direction of the flow) constitutes a perforated screen whose task is to provide a redistribution of the flow of gases to make it more uniform and regular and it must be placed, as seen in FIGS. 3, 4 and 5, at the input and output of the gas. Use thereof is very convenient but it is not an essential part of the invention.
In FIGS. 7a, 7b and 7c, different forms of masks with which goods results have been obtained are shown. Of course, these shapes can be varied without this affecting the essence of the invention.
They may be manufactured indistinctly out of the above cited graphite board or any other of the metallic or ceramic materials pointed out above.
Preparation of Seeds and Mixtures for Reactive Gases
The use of certain substances that act as the germ to start the formation of the fibre which is essential for carrying out the invention is not a part of the same. Thus, here we will limit ourselves to gather the information disclosed in the bibliography concerning this subject, some already pointed out, as well as that which refers to mixtures of gases and operating temperatures.
i) Preparation of the seeds--In accordance with the techniques described, the following families of substances can be used as compounds whose reduction give rise to catalytically active seeds for this manufacturing.
i.1) organometallic compounds, especially advisable to form sees that give rise to very fine fibres (thickness <4 μm.)
i.2) inorganic transition metal salts, especially appropriate (iron salts) to form fibres with an intermediate thickness (3 μm<.O slashed.<7 μm), or to form thick fibres (double anion salts) with a thickness of 5 μm<O<20 μm.
Cr and Ni ferrocene, thiocene, metallocene, (Fe, Ni, Cr and Co) oxalates can be cited among organometallic compounds. Among inorganic salts we can indicate nitrates, nitrites, sulfates (and ammonium sulfates) and chlorides (along, mixed and with additions such as potassium and sodium hydroxide.) The same salts of Zr, V, W, Mo, Mn, Pd, Tr and Pt can also be used but less effectively. The dilution margins of each one are very broad and not very significant in their results; as a general rule it can be said that they are used in concentrations between 50% and 80% of the saturation concentration.
ii) Mixture for reactive gases--As to the composition of reactive atmospheres, it is always a mixture of reducing gas and of gaseous hydrocarbon, the latter being in a proportion of 5 to 40%.. Pure hydrogen, which is the best option from a functional point of view, can be used, or to reduce costs, hydrogen with added CO, noble gases, carbon dioxide and SH 2 can be used. Practically all alkanes, such as methane, ethane, propane and butane can be used as hydrocarbons; alkenes, such as ethylene, butadiene, etc.; alkynes, such as acetylene, etc.; aryl hydrocarbons, such as benzene, toluene, styrene, etc.; condensed ring aromatic hydrocarbons, such as indene, naphthalene, phenanthrene, etc.; cycloparaffins, such as cyclopropane, cyclohexane, etc.; cycloolefins such as cyclopentene, cyclohexene, etc.; condensed ring alicyclic hydrocarbons, such as steroids, etc.; sulfurated aliphatic compounds such as methylthiol, methyl-ethylic sulfide, methyl ethyl sulfide, dimethylthioketone, etc.; sulfurated aromatic compounds, such as phenytrol, diphenylsulfide, etc.; sulfurated heterocyclic compounds such as benzothiophenone, thiophenone, etc. A simple kerosene or benzene can be used perfectly, as long as they are adequately vaporized.
The structure and properties of the fibres produced depend very little on the hydrocarbon chosen, thus, the choice tends to be based on costs, degree of toxicity and hazard of use, process time, etc.
iii) Operating temperatures--As to the operating temperatures for the production of VGCF, the recognized margins are 600° to 1300° C., the optimal range being 900° to 1200° C.
EXAMPLES
Example No. 1
The dimensions of the fundamental device are given in FIG. 8.
Example No. 2
The reactor with various compartments of decreasing length in the direction of the flow is shown schematically in FIG. 9. The operating conditions are the following:
Joule effect heating
Input mask, which appears in the top part of FIG. 7, made of graphite board
Output mask, which appears in the bottom left-hand side of FIG. 7, made of 18/8 stainless steel sheet
Four substrates like those of FIG. 6, made (the fine wire as well as the thick wire) of Khanthai A® (CoSi alloy). a very usual material for making electric resistors. The separation distances are furnished in the Figure
All the substrates were seeded coating them with a small brush dipped in al alcohol solution of iron nitrate 60% saturation at room temperature
Operating temperature 1065° C.
Operating cycle. A preheating process was started (only the propane flame of the preheater was used as an energy supply) with only Ar (600 dm 3 /min.) at a temperature increasing to 800° C.; the preheating time lasted 15 minutes. Then, the electric energy control was turned on setting the reference temperature at 1065° C., setting the preheater at 650° C. and cutting off the entry of Ar, introducing hydrogen only for five minutes. Afterwards the operating stage itself takes place for 20 minutes, the atmosphere being 88% H 2 and 12% CH 4 The operation ends with cooling with Ar.
The results are given in TABLE I.
As it can be seen, in the four substrates a similar fibre density is obtained, since the amount of fibres obtained in proportional to the length of the same. If the operating time were extended, longer fibres in the final substrates would have been attained, whereby the production in grams of fibres would have increased a bit.
TABLE I______________________________________ Fibres grown on the substrate S.sub.1 S.sub.2 S.sub.3 S.sub.4______________________________________Average length in cm. 6.1 5.0 3.0 1.5Average thickness in μm 4 a 7 5 a 7 5 a 7 5 a 7Amount produced in g. 0.078 0.058 0.041 0.014Total 0.191 g______________________________________
Example no 3
Just like in the previous example, solely changing the use of a ammonium ferrous sulfate solution as the seed, which gives rise to thicker fibres although they have the same structure. The results obtained are given in TABLE II.
TABLE II______________________________________ Fibres grown on the substrate S.sub.1 S.sub.2 S.sub.3 S.sub.4______________________________________Average length in cm. 6.6 5.0 3.2 1.8Average thickness in μm 5 a 11 5 a 11 5 a 11 5 aAmount produced in g. 0.150 0.103 0.078 0.030Total 0.361 g______________________________________
Example No. 4
The present reactor can be used to obtain ceramic fibres other than carbon fibres. For example, using the mixture of gases and temperatures described by Motojima and Hasegawa (Journal of Crystal Growth, 87, (1988), 311-317), SiC fibres with the lengths and thicknesses described in the above examples for VGCF can be obtained. The operative conditions for this specific case are:
Metal salts are used as seeds.
The deposition temperature is kept between 1030° and 1200° C.
An atmosphere formed by Si 2 Cl 5 , H 2 and Ar with a C/Si ratio of 2 and a minimum of 10% of H 2 and a maximum of Ar of 40% is used.
DESCRIPTION OF THE FIGURES
FIG. 1
General diagram of the device for obtaining fibres
(1) Hydrocarbon tank
(2) Carrier and/or activator gas tank
(3) Mixing and preheating chamber
(4) Oven
(5) Output where the inflammable gases are collected or destroyed
(6) Screen from whose duly activated surface the carbon fibres grow
FIG. 2
Basic types of substrates
(a) 18/8 stainless steel mesh
(b) Rods with broadenings
(c) Smooth rods
(d) Perforated plates
FIG. 3
Diagram of the basic carbon fibre production unit
(1) Frame
(2) Mask
(3) Substrate
FIG. 4
Diagram of a group of units in tandem of an identical length
(1) Frame
(2) Mask
(3) Substrate
L, length the marks the maximum length of the fibre
FIG. 5
Diagram of a group of units in tandem with a decreasing length
(1) Frame
(2) Mask
(3) Substrate
L 1 , L 2 , L n-1 , L n , lengths that mark the maximum fibre length in each unit (L 1 >L 2 >. . . >L n-1 >L n )
FIG. 6
Spiral substrate
In the bottom part of the Figure: Double spiral variant
FIG. 7
Different forms of masks
FIG. 8
Arrangement of the standard reactor
(1) Electric oven
(2) Gas output where they are burned by means of a burner
FIG. 9
Experimental assembly of multichambers of compartments of decreasing size
(1) Electric oven
(2) Gas output where they are burned by means of a burner
(3) Quartz preheated gas intake pipe
(4) Transparent quartz reactor
(5) Wire fabric frame
(6) Substrates
(7) Masks | The production of fibers is carried out by allowing a gas mixture containing a gaseous hydrocarbon or an appropriate gas to pass through a substrate (generally a steel sheet) arranged facing the direction of the gas stream and situated in a furnace wherein the gas reaches a temperature of 1.000° C. approximately. The schematized device is comprised of the corresponding gas reservoirs, that is to say the hydrocarbon gas and the carrying and activating gas, a mixing and preheating chamber, the furnace at the outlet of which are collected or burnt the inflammable gases and the grid from the surface of which, duly activated, the carbon fibers may grow. The gist of the invention is that the gas goes through the substrate situated facing the flow, so that said flow of gas is parallel to the direction of the fiber growth. The maximum length of the fibers is set by the distance between the substrate and a substrate or mask situated at the other extremity of the chamber. | 3 |
[0001] The application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/061,055, filed Jun. 12, 2008, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to ultrasonic surgical devices, and more particularly, to ultrasonic surgical devices useful for removing fibrous, elastic, or tenacious tissue.
[0003] Devices that effectively utilize ultrasonic energy for a variety of applications are well known in a number of diverse arts. One of these devices is an ultrasonic horn used for the removal of tissue. The Ampulla or Gaussian profile was published by Kleesattel as early as 1962, and is employed as a basis for many ultrasonic horns in surgical applications including devices described in U.S. Pat. No. 4,063,557 to Wuchinich, et al, 1977, and U.S. Pat. No. 6,214,017 to Stoddard, et al, 2001 for use in ultrasonic aspiration. The Gaussian profile is used in practice to establish and control the resonance and mechanical gain of horns. A resonator, a connecting body, and the horn act together as a three-body system to provide a mechanical gain, which is defined as the ratio of output stroke amplitude of the distal end of the tip to the input amplitude of the resonator. The mechanical gain is the result of the strain induced in the materials of which the resonator, the connecting body, and the ultrasonic horn are composed.
[0004] A magnetostrictive transducer coupled with the connecting body functions as a first stage of the booster horn with a mechanical gain of about 2:1, due to the reduction in area ratio of the wall of the complex geometry. The major diameter of the horn transitions to the large diameter of the Gaussian segment in a stepped-horn geometry with a gain of as large as about 5:1, again due to reduction in area ratio. The uniform strain along the length of the Gaussian provides multiplicative gain of typically less than 2:1. Thus, the application of ultrasonically vibrating surgical devices used to fragment and remove unwanted tissue with significant precision and safety has led to the development of a number of valuable surgical procedures. Accordingly, the use of ultrasonic aspirators for the fragmentation and surgical removal of tissue from a body has become known. Initially, the technique of surgical aspiration was applied for the fragmentation and removal of cataract tissue. Later, such techniques were applied with significant success to neurosurgery and other surgical specialties where the application of ultrasonic technology through a handheld device for selectively removing tissue on a layer-by-layer basis with precise control has proven feasible.
[0005] Certain devices known in the art characteristically produce continuous vibrations having substantially constant amplitude at a predetermined frequency (i.e. 20-36 kHz). Certain limitations have emerged in attempts to use such devices in a broad spectrum of surgical procedures. For example, the action of a continuously vibrating tip may not have an adequate effect in breaking up certain types of body tissue, more elastic tissue, bone, etc. Because the ultrasonic frequency is limited by the physical characteristics of the handheld device, only the motion available at the tip provides the needed motion to break up a particular tissue. All interaction with the tissue is at the tip, some is purely mechanical, and some is ultrasonic. Some teach in the art that interaction with the tissue at the tip distal and is due only to mechanical interaction. To others, it is clear from experimental results that acoustic power is propagated to the load to aid in tissue fragmentation, emulsification, and aspiration. In any case, the devices have limitations in fragmenting some tissues. The limited focus of such a device may render it ineffective for certain applications due to the vibrations which may be provided by the handheld device. For certain medical procedures, it may be necessary to use multiple hand held devices or it may be necessary to use the same console for powering different handheld devices.
[0006] Certain devices known in the art characteristically produce continuous vibrations having substantially constant amplitude at a frequency of about twenty to about fifty-five kHz. Amplitude of transducer-surgical tip systems decreases with increasing frequency because maximum stress in the material of the horns is proportional to amplitude times frequency, and the material must be maintained to an allowed fraction of its yield strength to support rated life in view of material fatigue limits. For example, U.S. Pat. Nos. 4,063,557, 4,223,676 and 4,425,115 disclose devices suitable for the removal of soft tissue which are particularly adapted for removing highly compliant elastic tissue mixed with blood. Such devices are adapted to be continuously operated when the surgeon wishes to fragment and remove tissue, and generally is operated by a foot switch.
[0007] A known instrument for the ultrasonic fragmentation of tissue at an operation site and aspiration of the tissue particles and fluid away from the site is the CUSA EXcel® Ultrasonic Surgical Aspirator (Integra LifeSciences Corporation, Plainsboro, N.J.). When the longitudinally vibrating tip in such an aspirator is brought into contact with tissue, it gently, selectively, and precisely fragments and removes the tissue. The CUSA® transducer amplitude can be adjusted independently of the frequency and this amplitude can be maintained under load depending on reserve power of the transducer. In simple harmonic motion devices, the frequency is independent of amplitude. Advantages of this unique surgical instrument include minimal damage to healthy tissue in a tumor removal procedure, skeletoning of blood vessels, prompt healing of tissue, minimal heating or tearing of margins of surrounding tissue, minimal pulling of healthy tissue, and excellent tactile feedback for selectively controlled tissue fragmentation and removal.
[0008] In an apparatus that fragments tissue by the ultrasonic vibration of a tool tip, efficiency of energy utilization is optimized when the transducer which provides the ultrasonic vibration operates at resonant frequency. The transducer and surgical tip design establishes the resonant frequency of the system, while the generator tracks the resonant frequency and produces the electrical driving signal to vibrate the transducer at the resonant frequency. However, changes in operational parameters, such as changes in temperature, thermal expansion, and load impedance, result in deviations in the resonant frequency. Accordingly, controlled changes in the frequency of the driving signal are required to track the resonant frequency. This is controlled automatically in the generator.
[0009] Conventional ultrasonic surgical aspirating tips employed in surgery for many years typically present a longitudinally vibrating annular surface with a central channel providing suction or aspiration, which contacts tissue and enables fragmentation via described mechanisms of mechanical impact (momentum), cavitation, and ultrasound propagation. Mechanical impact may be most useful in soft tissue and cavitation clearly contributes to the fragmentation of tenacious and hard tissue in situations where liquids are present and high intensity ultrasound exceeds the cavitation threshold.
[0010] Ultrasound propagation is concerned with the transmission of pressure across the boundary of a surgical tip and tissue, which leads to the propagation of pressure and, perhaps more importantly, particle displacement. Acoustic impedance is the total reaction of a medium to acoustic transmission through it, represented by the complex ratio of the pressure to the effective flux, that is, particle velocity times surface area through the medium. As discussed in the classic text of Krautkramer J. and Krautkramer H, ULTRASONIC TESTING OF MATERIALS , Berlin, Heidelberg, New York, 1983, for the case of a low to high acoustic impedance boundary, it may seem paradoxical that pressure transmitted can exceed 100%, but that is what results from the build-up of pressure from a low to high acoustic impedance boundary. In the case of a high to low acoustic impedance mismatch, such as with a high impedance titanium ultrasonic horn to low impedance fibrous muscle, soft tissue, or water, the pressure transmitted decreases (e.g., less than 15% for titanium to fibrous muscle) and particle displacement increases (e.g., as great as 186% for titanium to muscle).
[0011] Conventional ultrasonic surgical aspirating tips have been found to be efficient in the removal of soft tissue, and with emergent bone tips, applicable to the removal of hard tissue; however, some fibrous, elastic, and tenacious tissues persist in difficulty of removal. It has been found that using such conventional ultrasonic horns and devices that employ only the effects of intensification of ultrasound or sharpened edges to remove bovine fibrous muscle tissue, leaves a fibrous elastic skeleton. Thus, there remains a need for ultrasonic surgical devices with innovative aspiration tips that allow for more effective removal of fibrous tissue via the enhanced utilization of ultrasound fragmentation effects.
[0012] It is known that materials often fail, fracture, tear, or rupture, more readily as a result of a shear force rather than in tension or compression. Common examples include paper, garden bushes, hair, cloth, steel shear bolts or pins, and collagenous materials. A thin fibrous sheet of paper can be pulled or snapped with a greater tension force, but it can much more easily be ripped by the fingers applying light forces in opposite directions (shear). Likewise, scissors readily cut paper by employing a shear force concentrated by opposing edges of the scissors. Studies of mechanical behavior of materials have shown that biologic tissue is viscoelastic material, meaning that it has a time-dependent stress-strain relationship. The effect of the strain rate on the material is critical to causing fragmentation. The ultrasonic horn of the present invention evolved from imagining innovative ways of introducing scissor or shear ultrasonic effects with a surgical aspirating tip.
[0013] Hence, those skilled in the art have recognized a need for an ultrasonic aspiration tip that allows more effective removal of fibrous, elastic, and tenacious tissues. The present invention fulfills this need and others.
SUMMARY OF THE INVENTION
[0014] Briefly and in general terms, the present invention is directed to an apparatus and an associated method of fragmenting and removing of target tissue by the introduction of shear stress and the utilization of high strain rates associated with ultrasound. In more detailed aspects, the invention is directed to an ultrasonic surgical aspirating tip that induces a shear stress field, enabling improved fragmentation and aspiration of fibrous, elastic, and tenacious tissues, such as encountered in some tumors or surgical approaches. In yet more detailed aspects, the tip has an innovative pattern about the contacting annulus of adjacent and alternating lands of opposite angles which promote refracted longitudinal waves propagating in greatly different directions at the interface of the contacted fibrous tissue. Refracted longitudinal waves of different directions produce a shear stress field, especially at the intersection of opposite angled lands, and this shear stress enhances fragmentation and removal rate of fibrous tissue.
[0015] In accordance with aspects of the invention, there is provided an ultrasonic horn configured for use with an ultrasonic surgical handpiece having a resonator that generates ultrasonic waves, the ultrasonic horn comprising an elongated member having a proximal end, a distal end, and a longitudinal axis, the proximal end being adapted to receive ultrasonic waves from the handpiece, a first land member disposed on an annulus at the distal end of the elongated member, the first land member having a first angle with respect to the longitudinal axis, and a second land member disposed on the annulus, the second land member having a second angle with respect to said longitudinal axis, wherein the first and second angles are different. In more detailed aspects, the first and second land members have opposite first and second angles to each other with respect to the longitudinal axis, the opposite first and second angles are equal and opposite, and the first and second land members are located adjacent each other.
[0016] In yet further detailed aspects, the ultrasonic horn further comprises a plurality of land members of different angles alternating around the annulus wherein at least one land member has a blunt edge, whereby cutting is inhibited. The first land member has a first angle of about 10-80°, and the second land member has an opposite second angle of about 10-80° with respect to the longitudinal axis. In another aspect, the first land member has a first angle of about 30-60°, and the second land member has an opposite second angle of about 30-60° with respect to the longitudinal axis. And in yet another aspect, the first land member has a first angle of about 45°, and the second land member has an opposite second angle of about 45° with respect to the longitudinal axis.
[0017] In other aspects, the ultrasonic horn is also configured for use with a suction source, wherein the elongated member is hollow and is connected to the suction source, whereby suction is present at the annulus.
[0018] In accordance with aspects of an associated method, there is provided a method of applying shear stress to tissue, comprising contacting the tissue at a contact surface, applying energy to the tissue at the contact surface at a first angle with a medical device, and applying energy to the tissue at the contact surface with the tissue at a second angle with the medical device simultaneously with applying energy at the first angle, the second angle being different from the first angle, whereby a shear stress field is created in the tissue. In more detailed aspects, the steps of applying energy comprise applying ultrasonic energy to the tissue at first and second angles with the first and second angles being opposite to each other with respect to a longitudinal axis of the medical device. The steps of applying ultrasonic energy comprise applying ultrasonic energy to the tissue at first and second angles with the first and second angles being equal and opposite to each other with respect to a longitudinal axis of the medical device. Yet further, the steps of applying energy at first and second angles comprise applying ultrasonic energy to the tissue at first and second angles located adjacent each other, whereby a shear stress field is formed in the tissue.
[0019] In other method aspects, the steps of applying energy comprise applying ultrasonic energy to the contact surface of the tissue at a plurality of locations at alternating different angles. The steps of applying energy comprise applying ultrasonic energy to the contact surface of the tissue at a first location at an angle of about 45° with respect to a longitudinal axis of the medical device, and applying energy to the contact surface of the tissue at a second location adjacent the first location of the contact surface at about an opposite angle of 45° to the first angle with respect to a longitudinal axis of the medical device. Additionally, the method further comprises applying suction to the tissue at the contact surface to control the position of the tissue during the steps of applying energy to create shear stress.
[0020] Other features and advantages of the present invention will become more apparent from the following detailed description of the invention, when taken in conjunction with the accompanying exemplary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Embodiments of the presently disclosed shear stress ultrasonic horn are described herein with reference to the drawings, in which:
[0022] FIG. 1 is a perspective view of an ultrasonic horn in accordance with aspects of the present invention in which the horn includes an extension member, an elongated member, and a tip distal end having a particular configuration for establishing shear stress in target material, and further includes an adapter at its proximal end for connection with an ultrasonic energy source;
[0023] FIG. 2 presents a perspective view of an ultrasonic horn similar to FIG. 1 but having a curve in its extension member to enable better viewing of target tissue during use, the horn also showing actual connection to an ultrasonic energy generator at its proximal end;
[0024] FIG. 3 shows a cross-sectional view of the horn of FIG. 1 showing the aspiration channel formed completely through the horn, in this embodiment;
[0025] FIG. 4 is a partial cross-sectional view of the horn of FIG. 1 showing further detail of the adapter configuration at the proximal end of the horn;
[0026] FIG. 5 is a perspective, more detailed view of the distal tip annulus at the distal end of the horns of FIGS. 1 and 2 showing a configuration of features used to create shear stress in target tissue, in this case, a plurality of lands set at alternating angles to adjacent lands;
[0027] FIG. 6 is a side view of the distal tip annulus of FIG. 5 showing the relationship of alternate angled lands;
[0028] FIG. 7 is a basic diagram showing the operation of Snell's law at the interface of two different materials, one of which is the material of the ultrasonic horn and the other of which is the material of target tissue;
[0029] FIG. 8 is a schematic diagram showing the refraction of ultrasonic energy from a land formed at the annulus at the tip of the distal end of an ultrasonic horn, the land being oriented at a first angle of +45°;
[0030] FIG. 9 is a schematic diagram showing the refraction of ultrasonic energy from a land formed at the annulus at the tip of the distal end of an ultrasonic horn, the land being oriented at a second angle of −45° (which is opposite the first angle);
[0031] FIG. 10 is an illustration of the propagation of a shear stress field through adjacent cells located about the apex of the land members of FIGS. 8 and 9 that results when the refracted waves of the first land member ( FIG. 8 ) are coupled with the refracted waves of the second and adjacent land member ( FIG. 9 );
[0032] FIG. 11 is a graph of the ultrasonic horn radius versus horn length for a target frequency of 36 kHz, shown in area function of the Gaussian shape;
[0033] FIG. 12 presents a diagram of the shape of an ultrasonic horn; and
[0034] FIG. 13 provides a chart of comparative test data obtained from use of the ultrasonic horn of FIG. 1 compared to the use of ultrasonic horns of more conventional geometries, showing an improvement in results with the horn of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Embodiments of the presently disclosed ultrasonic horn will now be described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “distal” refers to that portion of the instrument, or component thereof which is farther from the user while the term “proximal” refers to that portion of the instrument or component thereof which is closer to the user during normal use. The terms “ultrasonic horn,” “ultrasonic aspirating tip,” “aspirating tip,” “ultrasonic surgical tip,” and “surgical tip” are used herein interchangeably.
[0036] Referring now to FIG. 1 in more detail, there is shown an ultrasonic horn 100 , in accordance with one embodiment of the present disclosure. The ultrasonic horn is adapted for use in an ultrasonic surgical system having an ultrasonic handpiece. An example of such an ultrasonic surgical system is disclosed in U.S. Pat. No. 6,214,017 to Stoddard et al., the entire contents of which are incorporated herein by reference. Alternatively, the ultrasonic horn 100 may be adapted for use with the ultrasonic surgical system disclosed in U.S. Pat. No. 4,063,557 to Wuchinich et al., the entire contents of which are incorporated herein by reference.
[0037] The ultrasonic horn 100 of FIG. 1 includes a proximal end 104 and a distal end 106 . At the proximal end the horn comprises an adapter 102 that includes, extending from the proximal end 104 towards the distal end 106 , a shaft 108 , a threaded member 110 , and a flange 112 terminating at the distal end 106 . The flange 112 includes a leading edge 114 .
[0038] The proximal end 104 of the adapter 102 is configured to connect the ultrasonic horn 100 to an ultrasonic handpiece or resonator. Referring also now to FIG. 2 , the connection of an ultrasonic horn to a resonator 140 is shown. FIG. 2 shows a horn 101 similar to the horn 100 of FIG. 1 with the exception that the horn 101 of FIG. 2 is curved at an angle of approximately 13°. The base designs of such horns include both curved and straight surgical tips, i.e. the profiles may be the same. The surgical curved tips are bent on a mandrel following machining. The bend can be about 13° or less. Curved surgical tips are often preferred because the handpiece is moved out of the field of view of the microscope used by the surgeon viewing the distal end. The curve in the embodiment of FIG. 2 is formed in an extension member 120 of the horn, as described below in further detail.
[0039] The resonator 140 is connected to the adapter 102 of the horn through a connecting body 142 in this embodiment. As used herein, the term “resonator” refers to what is often referred to in the literature as an ultrasonic handpiece. The resonator is typically a laminated core-stack of Permanickel. Those skilled in the art will recognize that the threaded member 110 is identified herein in one embodiment as an externally threaded member for connection to internal threads of the connecting body 142 and/or to an ultrasonic resonator 140 but that other connection types can be implemented to connect to the connecting body and/or ultrasonic resonator. Such connection types include but are not limited to welds, socket couplings, and compression couplings. Because such resonators and connections are well known to those skilled in the art, no further details are provided here.
[0040] The ultrasonic horns 100 and 101 both include an extension member 120 having a proximal end 122 that coincides with the flange 112 of the adapter 102 . The extension member 120 also has a distal end 124 . The horn further comprises an elongated member 130 with a distal tip 132 at the distal end 106 of the horn. The distal end 124 of the extension member terminates in a transition segment 134 to the elongated member 130 . The proximal end 136 of the elongated member is located at the distal side of the transition segment 134 while the distal end of the extension member is located at the proximal side of the transition segment. The distal end of the elongated member 130 is configured as the distal tip 132 .
[0041] The connecting body 142 is configured to connect the resonator 140 to the horn 101 so that ultrasonic energy may be applied to the horn and conducted to a target site. In one embodiment, the resonator 140 includes a magnetostrictive transducer, although other transducer types can be included such as a piezoelectric transducer. The resonator 140 is supplied power from a power generator (not shown) such that the resonator 140 operates at a target frequency, e.g., in the range of about 23,000 Hz (23 kHz), 36 kHz, or other. Utilizing a piezoelectric transducer will provide similar ultrasonic properties and alternate frequencies for higher stroke and power (e.g., 23 kHz and 24 kHz devices). It is important to note that use of alternative transducers or ultrasonic frequencies will not substantially deviate from the innovative principles of the shear stress ultrasonic horn disclosed herein. In one embodiment, the ultrasonic horns 100 and 101 are made of titanium, although other materials such as stainless steel may be used. In a preferred embodiment, the titanium ultrasonic horn is nitride coated to improve hardness and improve wear resistance.
[0042] As best seen in FIG. 3 , which is a longitudinal cross-sectional view of the ultrasonic horn 100 of FIG. 1 , an internal channel 146 is formed longitudinally through the entire horn, i.e., from the distal end 106 to the proximal end 104 . As is known in the art, the channel terminates in the connecting body 102 , and does not continue into the resonator (not shown). In some embodiments, the channel may be coupled to a side port or other device to introduce fluid into the channel or withdraw fluid from the channel by means of suction or vacuum. In some implementations, the central channel supports aspiration or suction of tissue. The internal channel can provide suction when connected with a vacuum source at the console. The suction can be used to control the position of target tissue. For example, suction may be used to draw target tissue to the distal tip of the horn for coupling and contact to the tissue for efficient fragmentation. The internal channel shown and described herein also aids in cooling, where irrigation liquid is caused to flow through the channel.
[0043] The internal channel 146 also affords greater mechanical gain for the horn 100 and 101 because the gain is dependent on the reduction in area ratio of the thin walls. A purpose of the internal channel 146 is to support gain for surgical tips with the contacting annulus distal ends 160 .
[0044] Referring now to FIG. 4 , a top view of the ultrasonic horn 100 of FIG. 3 is shown with the channel 146 shown in phantom lines. The adapter 102 is also shown in partial cross-section. As is clearly shown, the internal channel 146 is also formed within the adapter 102 and throughout the remainder of the horn 100 .
[0045] As a preferred embodiment illustrated in FIG. 5 , the distal end 106 of the ultrasonic horn 100 is shown, and in particular, a contacting annulus 160 disposed at the distal tip of the elongated member 130 is shown in detail. The contacting annulus 160 is formed of a plurality of faces 168 formed at the distal ends of the lands 166 and 167 having differing angles in relation to a longitudinal centerline 162 . In this embodiment, the contacting annulus 160 has twelve lands 166 and 167 , each with a face 168 at the annulus. Although only two lands 166 and 167 are indicated with shading, and only one face 168 is indicated with shading, this is for clarity of illustration purposes only. Each land and each face is meant to be indicated; only a few representative ones were picked for shading.
[0046] The contacting annulus 160 In FIG. 5 has a number of lands 166 having an angle directed toward the longitudinal axis 162 uniformly interspaced with an equal number of lands 167 having an angle directed away from the longitudinal axis 162 . In this embodiment, there are six lands 166 angled towards the center longitudinal axis that are uniformly interspersed with six more lands 167 angled away from the center longitudinal axis. Therefore, each land is located between two lands having the opposite angle (directed toward the axis or away from the axis, as the case may be). In this embodiment, the lands are in contact with adjacent lands and have opposite angles from each other. As an example, in the set of lands angled toward the longitudinal axis, each land has an angle of +45°. The alternating and uniformly interspersed adjacent lands have an angle with regard to that same longitudinal axis of −45°, thereby having an opposite angle. Other angles of alternating lands may be used, fewer or more lands may be used at the contact annulus, the spacing between lands may vary, and different configurations are possible.
[0047] It has been found that adjacent lands of opposite angles promote refracted longitudinal waves propagating in different directions at the interface to the tissue to establish shear forces. Refracted longitudinal waves of different directions produce a shear stress field, especially at the intersection of opposite angled lands 166 and 167 , and this shear stress enhances fragmentation and the removal rate of fibrous tissue. Ultrasound can be further intensified (power per unit area increased) due to the tapering of the adjacent lands, although distal ends or faces 168 are left blunt in one embodiment, so that wear is minimized and tissue is fragmented with ultrasound energy rather than cut, which could cause clogging of the central aspiration channel 146 .
[0048] FIG. 6 presents a side view of the annulus 132 , distal tip 106 , and lands 166 and 167 of FIG. 5 . In particular, portions of two outwardly-extending lands 167 are shown in cross section, one at the top of the figure and one at the bottom. Behind each of these and rotated around the annulus 160 by approximately 30° is a land 166 of opposite angle extending inwardly. The remaining three lands of alternating opposite angles are shown located around the annulus. Also shown is a pre-aspiration aperture 250 through which fluid may be drawn through the internal channel 146 of the horn.
[0049] FIGS. 5 and 6 also show the feature of rounding or blunting 212 the lands 166 and 167 so that sharpness is removed. In this case, the dimension of the blunting is 0.005 inches (0.127 mm). The drawing numeral 212 is only shown in a few places on FIGS. 5 and 6 so as to not lessen clarity of the figure; however, it is meant to apply to the other lands as well.
[0050] It is known that the angle of refraction of the longitudinal wave can be ideally calculated based on Snell's Law, and it is dependent on the incident angle and difference in acoustic velocity of titanium (the material of the horn in one embodiment) and the medium or media encountered at the boundary, e.g., soft tissue, fibrous muscle, water, etc. An illustration of the ultrasonic horn to tissue interface for adjacent lands of opposite angles is provided in FIGS. 7-10 for an assumed dominantly directed extensional wave along the longitudinal axis of the surgical tip. For a +45° and −45° interface of the titanium lands 166 and 167 of opposite angles to tissue 180 , the refracted longitudinal wave angles were calculated for air, water, soft tissue, muscle, and bone employing representative material properties from the literature. Most pertinent, a 13° refracted longitudinal wave angle is calculated for titanium to muscle.
[0051] In FIG. 7 , the basic principle of refraction is illustrated. The ultrasonic energy 172 is propagating in titanium 174 at an angle of θ 1 to the ordinate axis 176 . Upon reaching the boundary 178 (abscissa axis) with fibrous tissue 180 , the ultrasonic energy 172 is refracted by 13°. Therefore θ 2 =±13° as measured from the normal to the interface.
[0052] FIG. 8 presents a diagram of a titanium land 186 having an inner diameter ID and an outer diameter OD. Ultrasonic energy 172 is propagating through the land at an angle of θ 1 =+45° to the centerline 162 through the land. Upon reaching the boundary 186 with fibrous tissue 180 , refraction occurs and the ultrasonic energy then has an angle of θ 2 with the centerline 162 , where θ 1 ≠θ 2 .
[0053] FIG. 9 presents a diagram of a titanium land 190 having the opposite land angle than that of the land 186 in FIG. 7 . The land 190 has an inner diameter ID and an outer diameter OD. Ultrasonic energy 172 is propagating through the land at an angle of θ 1 =−45° to the centerline 192 through the land. Upon reaching the boundary 186 with fibrous tissue 180 , refraction occurs and the ultrasonic energy then has an angle of θ 2 with the centerline 192 , where θ 1 ≠θ 2 .
[0054] FIG. 10 is a drawing showing the land 186 of FIG. 8 in front of the land 190 of FIG. 9 with the refracted ultrasonic energy of each creating a shear stress field 198 . Due to the adjacent lands 186 and 190 being of opposite angles, there will be component waves causing shear 198 . Refracted longitudinal waves of different directions produce a shear stress field, especially at the intersection of opposite angled lands, and this shear stress enhances fragmentation and removal rate of fibrous tissue 180 . Adjacent cells or particles 200 about the intersection of the lands could experience displacement or particle motion with 64° of shear. It is important to note that due to the adjacent lands being of opposite angles (in this case +45° and −45°), there will always be component waves propagating at opposite angles that will subject the fibrous tissue to shear stress.
[0055] In a preferred embodiment, the shear stress tip implementation of adjacent opposite angled lands 186 and 190 does not compress tissue 180 . Ultrasound energy 172 from adjacent opposite angled lands does not cancel due to destructive interference. However, opposing faces would cancel ultrasound energy due to destructive interference and would cause compression of tissue.
[0056] It has been found that although a shear wave component may exist and aid in fragmentation when coupled via solids, refracted longitudinal waves exist and will couple even in liquid, such as water or saline solution supplied as irrigation liquid via the surgical tip flue or channel 146 . Shear waves will not propagate directly in gases and liquids. Shear stress is not wholly or largely dependent on coupling of a shear wave, but rather would be promoted by refracted longitudinal waves of opposite angles.
[0057] Increasing the angle to 60° from 45° between the lands 166 , 167 and the tissue would typically increase shear angle but reduce transmitted particle displacement. Reducing the land angle between the lands 166 , 167 and the tissue from 45° to 30° would reduce shear angle but increase particle displacement. Given that particle displacement calculated exceeds 130% for angles from 30° to 60°, the selection of angle may be dominated by shear angle and ease of manufacturing. Alternative angles could be selected without substantially deviating from the shear stress tip principle of operation.
[0058] Proof of principle was demonstrated with production viable shear stress ultrasonic horns yielding as great as 50% improvement in removal rate of bovine fibrous muscle compared to standard surgical tips and devices with distal-ends that employed only intensification of ultrasound or sharpened edges. Conventional ultrasonic surgical aspirating tips are efficient in removal of soft tissue, and with emergent bone tips, applicable to hard tissue; however, some fibrous, elastic, and tenacious tissues persist in difficulty in removal. A particular advantage of the shear stress ultrasonic horn is that it provides improvement in the removal rate of fibrous tissue via enhanced utilization of ultrasound fragmentation effects.
[0059] FIG. 11 illustrates a shear stress tip profile 230 . Area function of the Gaussian is shown, and it influences the resonant frequency and the mechanical gain. A blend is provided to a short straight section 232 . A flared exponential profile 234 of the horn expands the wall thickness suitably for machining of the distal end of the shear stress tip comprising a plurality of lands as shown in FIGS. 5 and 6 , as one embodiment.
[0060] In FIG. 12 , the elongated member 130 is tapered such that the cross-sectional area S go , is a maximum at the proximal end 136 interfacing with the transition segment 134 and is a minimum S c at the tip 132 . An area function is defined as N where N=S go /S c and is the area ratio of the Gaussian portion, and it establishes gain. The ultrasonic wave is supported by particle motion in the titanium. The particles are vibrating about their neutral position in a longitudinal or extensional wave. The particles do not move along the length of the horn, but only vibrate, just as a cork or bobber shows that a wave passes through water via the liquid. As the horn wall thickness decreases, more strain occurs in the metal as the particles move a greater distance about their neutral position. The displacement of the end of the horn is due to strain along the horn. All the particles supporting the wave are moving at the same resonant frequency. The greater the strain, the greater the velocity of the particles necessary to maintain the same frequency.
[0061] Mechanical gain in the ultrasonic horn 100 is maximized within acceptable stress limits of the titanium with stepped horn, Gaussian horn, blended short straight section, and flared exponential profiles. CUSA® (Integra LifeSciences Corporation, Plainsboro, N.J.) Ampulla (Gaussian) profile affords multiplying the gain of the stepped horn with a uniform distribution of stress, and this profile coupled with a blend to short straight section and flared exponential provide high-gain and forward propagation of ultrasound with minimal errant reflection or standing waves that could limit transmitted ultrasound, increase power requirements, or reduce horn stroke amplitude. These horn profiles promote high mechanical gain, forward propagation of ultrasound, and commensurate surgical tip distal-end stroke.
[0062] Stroke amplitude was not sacrificed in adapting to a larger wall thickness distal end for 36 kHz shear stress tip; in fact, prototype horn stroke exceeded the commercial baseline. This was accomplished with optimization of the Gaussian profile and blend to the straight section. Stroke peak-to-peak of the prototypes was 196 μm (0.0077 in) versus 183 μm (0.0072 in).
[0063] Proof of principle of the ultrasonic horn 100 with the contact annulus exemplified in FIG. 5 was demonstrated with production viable prototypes of about 35.75 kHz yielding as great as a 50% improvement in removal rate of bovine fibrous muscle compared to standard ultrasonic horns and devices that employed only intensification of ultrasound or sharpened edges. Preliminary comparative data are exhibited in FIG. 13 , based on fifteen measurements per surgical tip type. Baseline surgical tips included representative commercial CUSA EXcel® 36 kHz Extended MicroTip™, High-Stroke Extended MicroTip™ (Integra LifeSciences Corporation, Plainsboro, N.J.) and devices with more simply angled, grooved, or beveled ends. The ultrasonic shear stress horns of the present invention are referred to as numeral 240 in the chart. Along with preliminary quantitative data, qualitative observations of removal of bovine muscle indicate elimination of fibrous elastic structure where conventional aspirating tips 242 left a fibrous elastic skeleton. The mean values are printed next to the icons in the chart. The mean values indicated as great as a 50% increase in removal rate for the shear stress horns 240 .
[0064] In one embodiment, pre-aspiration apertures or holes 250 ( FIGS. 1 and 6 ) are formed through opposing sides of the elongated member 130 wall on opposing sides of a straight or constant diameter portion. Pre-aspiration apertures may be employed in conjunction with the internal channel 146 , which, as previously noted, extends from the proximal end 104 to the distal tip 132 . The pre-aspiration holes 250 can be optionally used to suction a portion of the irrigation liquid employed through the channel to aid in cooling the tip. The pre-aspiration holes can also reduce misting caused by cavitation at the distal end of tip, thereby improving viewing via endoscopes or microscopes.
[0065] In terms of applications, the ultrasonic horn 100 is useful for cranial-based surgery, and when performing transsphenoidal or endoscopic-nasal approaches. The ultrasonic horns 100 and 101 of the present disclosure can be combined with irrigation and aspiration systems such as is disclosed in, for example, FIG. 3 of U.S. Pat. No. 6,214,017 B1 to Stoddard et al., which as noted is incorporated by reference herein in its entirety. Irrigation in the internal channel 146 aids in cooling the material of the horn which is in flexure. Pre-aspiration holes may also aid in cooling. The cooling capability can be enhanced by suctioning some portion of the irrigation liquid through the internal channel 146 of the horn 100 or 101 via pre-aspiration.
[0066] As used herein, “vacuum” is meant to include partial vacuum or lowered pressure. The term “angled inwardly” is meant to indicate that the angle is formed on the inside surface of the contact annulus. The term “angled outwardly” is meant to indicate that the angle is formed on the outside surface of the contact annulus. Additionally, the term “lands” is meant to refer to the surface commonly given this name in the art and is also meant to refer to other surfaces that perform the same function.
[0067] The invention may be embodied in other forms without departure from the scope and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the invention. | An ultrasonic horn for use with an ultrasonic surgical hand piece including a resonator comprises a contacting annulus having a plurality of angled lands. The lands are alternated around the annulus such that adjacent lands have opposite angles. As a result of the adjacent angled lands, a shear stress field is developed in contacted tissue due to the promotion of refracted longitudinal ultrasonic waves propagating in different directions at the interface to the coupled tissue. The shear stress field enhances the fragmentation and removal rate of fibrous, elastic, and tenacious tissue. The horn is hollow permitting suction to be applied to the tissue for controlling tissue contact with the lands. | 0 |
FIELD OF THE INVENTION
The invention relates to a container assembly. It relates particularly but not exclusively to a container assembly for maturing wine which includes means for facilitating handling by a forklift truck.
BACKGROUND OF THE INVENTION
International application, now published as WO 2005/052114 A1 (herein incorporated by reference) describes a container assembly for controlling the rate of oxygen transfer from the atmosphere into a liquid stored in the container comprising:
a container with an oxygen permeability of 50 ml to 300 ml of oxygen per square meter of area of wall, for each 1 mm of thickness of said wall, per 24 hour period at room temperature, a floating barrier member for providing a permeable barrier to limit oxygen access from the head space in the container to the surface of the liquid.
Whilst the container assembly described in that application is effective for certain requirements, there is a range of additional requirements which need to be met by developing the basic concept of the original invention further. These include:
increasing the maximum volume, whilst maintaining the correct relationship between surface area of the container and the volume within it, supporting the polyethylene container, so that its shape is maintained, elevating the vessel off the ground, allowing all of the contents to be fully drained through the floor, allowing the vessel to be lifted and tipped to empty solids components of the contents, by means of a forklift with a rotating head, safely stacking the filled vessels vertically, removing the requirement for a floating barrier member when the vessel is filled, providing a convenient means to add and remove oak wood.
Accordingly the following is a description of an invention which facilitates one or more of these improvements.
DISCLOSURE OF THE INVENTION
The invention provides a container assembly for controlling rate of oxygen transfer from the atmosphere into a liquid stored in the container assembly comprising,
a container having a body, the walls of the body having an oxygen permeability within a predetermined range chosen for the liquid being stored, a frame for supporting the container and bracing at least one of the walls of the container against bulging, access opening beneath the frame for allowing entry of the tynes of a forklift, a neck with an open mouth extending from an upper wall of the body, the upper wall being shaped so as to allow all air to flow out of the body through the neck as the container is filled to the level of the bottom of the neck and, an outlet for draining liquid from the container arranged near a bottom wall of the body.
The outlet may comprise a tap or valve. It may be provided at a bottom wall of the container. The bottom wall of the container may slope downwardly towards the outlet to allow substantially all liquid in the container to drain through the outlet when it is opened.
The outlet may be located in a recess of a side wall of the container. The recess may be joined to the side wall by radiused portions which have a radius larger than the depth of the recess. The bottom wall may have a dip at the join with the recess.
A barrier member may be provided in association with the container contents. The barrier member may be arranged to float on the surface of liquid in the body of the container or liquid in the neck of the container. The barrier member may have a peripheral portion which is in sliding contact with the walls of the container so as to separate the liquid surface from the container headspace or neck headspace.
The barrier member may comprise a core of low density material overwrapped and sealed within a plastic film. The plastic film may extend beyond the low density material to form a flexible lip which may abut the sides of the body of the container or the neck to reduce contact with gas in the headspace.
The low density material may comprise a rigid or flexible plastic foam.
The film covering the upper surface of the low density material may be provided with a sealable vent to reduce gas pressure bulging of film with respect to the plastic foam.
Where the container is being used to mature wine, it may comprise a rigid plastics material which allows oxygen to permeate the walls directly from the atmosphere into the liquid in contact with the walls, the rigid plastics material having a permeability measured at a rate of 13 mg to 65 mg of atmospheric oxygen per square meter as measured for a 1 mm thickness during a 24 hour period at room temperature.
In one embodiment, the container assembly may be configured so that the assemblies can be stacked one atop the other.
Preferred aspects of the invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view with partially exploded elements of a container assembly according to the invention;
FIG. 1 a shows an enlarged view of a circled portion of FIG. 1 ;
FIG. 1 b shows an enlarged view of another circled portion of FIG. 1 ;
FIG. 2 shows an isometric view of an alternative container assembly according to the invention;
FIG. 2 a shows an enlarged view of a circled section of FIG. 2 ;
FIG. 2 b shows an enlarged view of a circled section of FIG. 2 ;
FIG. 3 shows a cross-section taken through the container of FIG. 2 ;
FIG. 4 shows an isometric view of a floating element; and
FIG. 5 shows the cross-section Z-Z taken through the floating element of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The various elements identified by numerals in the drawings are listed in the following integer list.
Integer List
1 Container
2 Frame
3 Loop
4 Base valve
5 Oak staves
6 Removable cross member
7 Neck
8 Seal ring
9 Screw lid
10 Rubber bung
11 Variable capacity insert blocking surface
12 Second cylinder
13 Step
14 Locking link
15 Hole
21 PE container
22 External frame
23 Neck
24 Screw lid
25 Screw plug
26 Floating element
27 Roof
28 Tag
29 Valve
31 Foamed core
32 Polyurethane film
33 Wine
34 Peripheral flange
35 Wall
37 Hole
40 Hole
41 Recess
42 Valve
43 Radius
44 Sheet metal base
45 Removable cross member
46 Bottom ring
47 Pillar
48 Openings
49 Dip
50 Opening
One embodiment of the apparatus of our invention is illustrated in FIGS. 1 , 1 a and 1 b , herein. This shown as an optionally thermally insulated polyethylene container of a non-round, preferably flat-sided shape with an opening in the top defined by a round neck ( 7 ) forming part of the tank, which has an internal (or external) screw thread incorporated within it.
This inner container is then fitted within a metal or plastic composite external frame ( 2 ) which, by being in close contact with the walls and engaging on a step in the container wall ( 13 ), supports the weight of the contents and prevents the hydrostatic pressure from excessively bulging the flat side walls of the inner container.
The upper wall of the inner container slopes upwardly towards the neck ( 7 ) to allow air to flow out of the body of the container through the neck as it is filled.
The vertical pillars of the frame of this embodiment are open at both the top and the to bottom. A removable top cross member 6 allows the container ( 1 ) to be fitted into the rigid frame ( 2 ) and is used to restrain each pair of opposed vertical members against the bulge of the vessel under hydrostatic load. This cross member is optionally fitted with upwards projection which can fit into vertical members of another identical vessel stacked on it. By this means the composite vessels can be safely stacked one on the other.
To render the lower vessels more stable, when upper vessels are to be stacked upon them, a side locking link ( 14 ) is fitted to two of the adjacent opposite uprights. A hole ( 15 ) is drilled in the other end of each link. A second identical tank is to be positioned closely beside the first. Subsequently the link of one vertical member is bolted to the vertical member of the next frame.
The rigid frame ( 2 ) is optionally fitted with restraining loops ( 3 ) or additional cross members that will engage with and trap the tines of a forklift truck. By this means the tank can be picked up and moved safely. If the forklift truck is fitted with a rotating head, the vessel may also be tipped in a manner similar to a “Jerry Can” so that the contents within can be freely discharged through the open neck ( 7 ). This enables any solids component in the stored liquid to be easily discharged. Such solid components arise, for example, when red wine is fermented in the vessels and may comprise the skins of the grape and/or the settled yeast lees.
In this embodiment a screw lid ( 9 ) can be screwed into the neck ( 7 ) and sealed by means of an additional seal ring ( 8 ), preferably made of compliant material. The lid is also fitted with a vent in the form of a second cylinder ( 12 ) optionally also fitted with an internal or external screw thread.
The tank can be filled into the second small cylinder ( 12 ) which can then be sealed by means of a silicone or rubber bung ( 10 ), a vented rubber bung (to allow gas to escape from the contents) or a vented or non-vented screw closure or openable valve or especially a one way valve.
An optional base valve ( 4 ) is fitted through the bottom wall forming the base of the tank so as to enable bottom filling or discharge of the tank contents without disturbing sediment that may have settled to the bottom the tank. The bottom wall may slope downwardly to the base valve to facilitate drainage. Where the liquid in the container is wine the walls of the container ( 1 ) neck cylinder ( 7 ) and screw lid ( 9 ) are made from polyethylene preferably with an oxygen permeability in the range between 50 to 300 ml of oxygen per sqm of tank surface per 24 hr per atm for each 1 mm of tank wall thickness at typical storage temperatures of 20-25° C.
The ratio of contained volume to surface area of said container preferably falls within the range 5 to 30 liters per square meter of surface for each 1 mm of thickness, to ensure that an adequate rate of permeation of oxygen is maintained for maturation of wine. Different ratios may apply where other liquids are being matured.
In this embodiment, a pre-assembled pack of oak wood staves ( 5 ) of the desired number, variety and degree of toast is lowered into wine within the tank. That may be fitted with a cord which has a float at the loose end, so that the pack can be retrieved after it has become spent, ie. has given up most of its oak flavour and has become soaked through with liquid, usually sinking.
Should it be desired to partially fill the vessel, a flexible floating element, as described in WO 2005/052114 A1 shaped to match the internal shape of the vessel, can be introduced through the open neck ( 7 ). This element will block most of the free surface area of the contained liquid. At any level of fill within the main body of the vessel, the use of this element enables the stored liquid to see approximately the same amount of oxygen per liter though that part of the walls in contact with the liquid, as well as that area in contact with the floating element. One form of such an element is shown in FIGS. 4 and 5 .
Referring to FIGS. 2 , 2 a , 2 b and 3 to 5 , there is shown a container assembly according to the invention which comprises an optionally thermally insulated polyethylene container ( 21 ) of a flat-sided shape with an opening in the top defined by a neck ( 23 ) in the form of a cylinder extending from a top wall of the container. The neck has an internal (or external) screw thread.
This container is then fitted within a metal external frame ( 22 ) which includes a substantially flat sheet metal base ( 44 ). The cage supports the weight of the contents and is made up of interlocked vertical ( 60 ) and horizontal ( 60 ) steel tubes. By being in close contact with the walls of the inner container, the cage prevents the hydrostatic pressure from excessively bulging the flat side walls of that inner container.
The vertical pillars of the cage of this embodiment are closed at both the top and the bottom. Removable top cross members ( 45 ) allow access for the container ( 21 ) to be fitted into the rigid frame ( 22 ) and are used to restrain each pair of opposed vertical members against the bulge of the vessel under hydrostatic load, as well as to retain the inner container when the tank is tipped.
The sheet metal base ( 44 ) is sized and shaped to nest into the top ring ( 62 ) of the cage on a lower container assembly when stacked on it. By this means the container assemblies can be retained sidewise and thus safely stacked one on the other.
The rigid frame ( 22 ) extends downwardly past the sheet metal base ( 44 ) and is closed with a bottom ring ( 46 ) spaced from the base ( 44 ) by the pillars ( 47 ). That provides access for the tines of a forklift truck through opening ( 48 ). By this means the tank can be picked up and moved. If the forklift truck is fitted with a rotating head, the vessel may also be tipped upside down to discharge through the neck ( 23 ). This enables any solids component in the stored liquid to be easily discharged. Such solid components arise, for example, when red wine is fermented in the vessels and may comprise the skins of the grape and/or the settled yeast lees.
In this embodiment, a screw lid ( 24 ) can be screwed into the neck ( 23 ) and sealed by means of an additional seal ring (not shown), preferably made of compliant material. The lid is also fitted with a screw threaded centre opening ( 50 ). The opening is optionally closed with a screw plug ( 25 ) or fitted with other fittings such as a riser tube with a cap (not shown), a check valve for the venting off of ferment gas, or a hose tail (not shown), to which may be attached the delivery side of a pump that has the suction side attached to an optional base valve ( 43 ), enabling the pumping over the liquid contents.
The container ( 21 ) and neck ( 23 ) are to be made from polyethylene (such as rotationally moulded polyethylene) with an oxygen permeability in the range between 50 to 300 ml of oxygen per sqm of tank surface per 24 hr per atm per 1 mm of tank wall thickness at typical storage temperatures 20-25° C. When the thickness of the tank wall is doubled, it is to be noted that the rate of oxygen transmission per unit of surface area is halved.
The ratio of contained volume to surface area of said container is to fall within the range 5 to 30 liters per square meter of surface for each 1 mm of thickness, to ensure that an adequate rate of permeation of oxygen is maintained for maturation of wine. Different rates may apply where other liquids are being matured.
Unless a riser tube and cap is added to the screw lid ( 24 ) and the wine filled into it, a vessel of this relatively small volume, if filled up into the neck, has a relatively high exposed surface area of wine for the volume. Thus it will be desirable to fit the flexible floating element ( 26 ) which acts as a barrier member as described in WO 2005/052114 A1 sized to match the internal size of the neck ( 23 ).
The floating element ( 26 ) has a foamed plastic core ( 31 ) which floats on top of the wine in the neck of the container. The foamed plastic core ( 31 ) is overwrapped with a polyurethane film overwrap ( 32 ) which comprises two separate layers covering the top and bottom of the foamed plastic core. These two separate layers are laminated together at their edges to form the peripheral flange ( 34 ). The peripheral flange provides a slidable seal with the wall ( 35 ) of the neck so as to substantially reduce the rate of oxygen transfer from the head space of the neck through the surface of the wine and hence limits the growth of undesirable aerobic bacteria.
The floating element is provide with three tags ( 28 ) distributed around its upper surface, each of the tags being formed with a hole or loop ( 37 ). The tags assist with allowing the barrier member to be correctly located in the neck in contact with the wine ( 33 ) initially and to be removed after the container has been emptied.
To reduce oxygen entry it is possible to add carbon dioxide (CO 2 ) gas to the head space above the floating element. That renders the partial pressure of CO 2 near to 1 atmosphere in the head space of the tank, far higher than in air (less than 0.05 atm). Over time this CO 2 gas, which diffuses through polymeric material about 4 to 8 times faster than oxygen and about 12 to 20 times faster than Nitrogen permeates into and can inflate the floating element causing it to bulge at the centre and thus to lift off the wine surface around the edges.
This can come about because CO 2 permeates through and enters the interior of the insert at a far higher rate than the rate at which the initial oxygen and nitrogen within the sealed element can leave. Hence the total pressure in the interior of the element rises and cause it to become inflated. The addition of a valve ( 29 ) is thus desirable for the correct long term functioning of these floating elements.
In use, the valve is left open after the floating element is inserted, so that the internal and external pressure remains balanced and the element prevented from inflating. The valve needs to be re-closeable so that the element can be closed up for washing off after use without wash water entering the interior. The valve also usually needs to be closed during insertion of the element into a tank, to prevent any wine that may be “scooped” up onto the top of the element from entering the interior of that element where it will spoil.
Where the barrier element is to be fitted in the body of the container rather than the neck, it is noted that the element comprising the foamed plastic core and polyurethane film overlap may suitably be formed of flexible materials in order to allow it to be folded so that it may be inserted through the neck of the container during initial setup and to be removed through the neck when the container is emptied.
In this embodiment, there are certain important geometric features that are desirable to enable the tank to function correctly for wine storage use. The upper wall forming the roof ( 27 ) of the tank ( 21 ) rises from its outer edges towards the manhole neck ( 23 ) so that as the tank is filled, substantially all of the head space air above the wine can be discharged through the neck.
To ensure that the contents of the tank can be substantially fully discharged, a further geometric preferment is that the radius ( 43 ) between the side walls and the recess is to be larger than the depth of the recess ( 41 ) in which the valve ( 42 ) is mounted. Furthermore, a dip ( 49 ) is formed in the bottom wall adjoining the recess. In this embodiment, the valve ( 42 ) is attached to the flat face of the recess ( 41 ) by round-head coach bolts encapsulated into the polyethylene (not shown). These are directed through three or more holes ( 40 ) in the valve flange and clamped by nuts (also not shown).
Oak-wood staves of the desired number, variety and degree of toast can be lowered into wine within the tank. That may be fitted with a cord which has a float at the loose end, so that the pack can be retrieved after it has become spent, ie. has given up most of its oak flavour and has become soaked through with liquid usually sinking.
The container of this invention can optionally be used to mature a wide range of different wines, spirits or other liquid foods, such as “Tabasco” or other foods or non-foods that may benefit from exposure over time to a controlled amount of oxygen.
Whilst the above description includes the preferred embodiments of the invention, it is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention.
It will be also understood that where the word “comprise”, and variations such as “comprises” and “comprising”, are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features.
The reference to any prior art in this specification is not, and should not be taken as, to an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge in Australia. | A container assembly for controlling rate of oxygen transfer from the atmosphere into a liquid stored in the container assembly comprising, a container ( 1 ) having a body, the walls of the body having an oxygen permeability within a predetermined range chosen for the liquid being stored, a frame ( 2 ) for supporting the container and bracing at least one of the walls of the container against bulging, a pair of access openings ( 3 ) beneath the frame for allowing entry of the tynes of a forklift, a neck ( 7 ) with an open mouth extending from an upper wall of the body, the upper wall being shaped so as to allow substantially all air to flow out of the body through the neck as the container is filled to the level of the bottom of the neck and, an outlet ( 4 ) for draining liquid from the container arranged near a bottom wall of the body. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to fastening devices, and more particularly to a device for securing a panel within a window opening in a wall of a building vulnerable to storm damage to protect the window from flying debris.
[0003] 2. Description of the Prior Art
[0004] Residents of regions of the country subject to severe but slow-moving storms such as hurricanes and the like generally have sufficient but limited time to install protective panels or other devices over the windows to protect the glass in them from flying debris. A number of panels and fastening devices have been devised or proposed to facilitate the rapid installation of protective panels in window openings. For example, U.S. Pat. No. 5,430,981 issued to Scott discloses a “Device for Installing Decorative Panels in Front of Existing Window Panes.” The disclosed transparent clip is secured to a window opening in a permanent manner that precludes easy removal and reuse of the decorative panels, and the clips do not appear to be readily adaptable to different thicknesses of panels or to uneven surfaces of a window opening.
[0005] In another example, U.S. Pat. No. 6,219,978 issued to Wood discloses a “Device for Covering Windows and Doors During Severe Storms” that relies on relatively complex and expensive “slide-arm-and-bolt assemblies” installed along a first edge of a panel and a resilient gasket installed along the opposite, second edge of the panel. The gasket holds the second edge against the window frame and the sliding bolt is adjusted outward to secure the first edge against the window frame. Wood's device permits reuse and rapid installation but is relatively complex and expensive, particularly for houses having numerous windows. In his U.S. Pat. No. 6,334,282, Wood also discloses a similar device that employs a pivoting lever with a foot at an outer end of the lever. The lever pivots on a pin supported by a plate attached to the panel and a spring biases the lever to engage the foot against the window frame when the spring end is released from a retracted position. This device and method exhibits the same disadvantages as in the '978 patent.
[0006] U.S. Pat. No. 6,363,670 issued to Dewitt discloses a device having a spring-loaded pin supported on a bracket, which is installed at intervals around a panel to be installed in the window opening after holes corresponding to the pin locations are drilled into the window frame surrounding the panel position. This device requires that the holes and pin/bracket positions be accurately aligned, and thus, while reusable, is relatively difficult to install. Rodrigues, in U.S. Pat. No. 6,330,768 discloses a cross brace device that extends from one side of the window frame to the opposite side, securing a panel between the cross brace and the window. While reusable, it is heavy, complex, and relatively expensive.
[0007] Renfrow, in U.S. Pat. No. 6,393,777 discloses channel-shaped brackets that are permanently installed on the wall containing the window just above and below the window opening. The upper brackets open downwards and the lower brackets open upwards, so that a panel may be slid laterally into the brackets from one side of the window and secured with a set screw in each bracket. Reusable and inexpensive, but requires accurate installation of the brackets and the panel is not set into the window opening but placed over the opening. This requires larger, more expensive panel sizes, and the edges of the panel are more exposed to the wind and possible failure of the protection.
[0008] In U.S. Patent Application Publication No. 2006/0123717, Huminski discloses a metal “h”-shaped bracket having “J”-shaped slots punched in the vertical portion of the bracket for hanging a panel, the panel being gripped between the “legs” of the bracket, upon screws driven into the soffit above a window opening. It is reusable and uncomplicated, but is installed over the window opening, not within it. The bracket appears to secure only the top edge of the panel above the window opening, leaving the other edges of the panel to be unsecured or, perhaps, secured by other means not disclosed.
[0009] Thus, there is a need for a fastening device for securing protective window panels within a window frame that is inexpensive to fabricate, install and reuse, permits rapid installation of the panels, can be adapted to different panel thicknesses and to various kinds of window openings without drilling holes into the window opening or permanently attaching the device to the area of or around the window opening.
SUMMARY OF THE INVENTION
[0010] Accordingly there is disclosed a panel fastener for securing a panel within a window opening. The fastener resembles a block letter F in cross section and comprises an elongated base plate member (the vertical portion of the “F”) having at least one first hole through it at a first (i.e., the lower) end; and first and second spaced, parallel flanges integral with and extending perpendicularly from a first side of the base plate member. The flanges are placed respectively at a second (i.e., the top) end and a midpoint of the base plate member and spaced apart a distance slightly greater than the thickness of the panel to be secured between them.
[0011] The first flange extending from the second (top) end of the base plate member includes at least one hole through it to receive a second screw oriented toward the second flange to secure the edge of the panel between the first and second flanges. A second screw passed through the first hole in the base member and oriented in the opposite direction from the flanges is tightened against the side of the window opening when the panel (with several fasteners attached around the perimeter of the panel) is placed within the opening. The panel is thus secured within the window opening without drilling holes into the side of the window opening. These second screws at each fastener location provide an adjustability to variations in the window opening dimensions and to variations in the surface unevenness of the window openings.
[0012] The fastener is easy to fabricate from extruded aluminum strips. The holes punched or drilled in the base plate and the first (top) flange may be threaded by the screw when one is first inserted in the respective holes of the aluminum fastener. Panels using these fasteners may be easily installed and removed. The fasteners may also be used in panels of various thicknesses. Other sizes of fasteners—e.g., wherein the spacing between the flanges is varied—may be easily adapted to a wider range of panel thicknesses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a perspective view of one embodiment of a hurricane clip according to the present invention;
[0014] FIG. 2 illustrates the perspective view of FIG. 1 of one embodiment of a hurricane clip according to the present invention with hex head screws inserted into the threaded holes;
[0015] FIG. 3 illustrates a second perspective view of the embodiment of FIG. 1 in position as if it would be installed on the edge of a panel, the panel shown in phantom;
[0016] FIG. 4 illustrates one embodiment of a panel installed within a window opening using several of the hurricane clips as illustrated in FIGS. 1 and 2 ; and
[0017] FIG. 5 illustrates a detail view of one of the hurricane clips according to the present invention as installed on the edge of the panel shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the following description, the same reference numbers are used in the various figures to identify the same structures of the invention as illustrated. Referring to FIG. 1 there is illustrated a perspective view of one embodiment of a hurricane clip or panel fastener 10 according to the present invention. The panel fastener 10 is preferably a one piece component fabricated as a segment of an elongated extrusion of a suitable material such as aluminum. Segments—and panel fasteners 10 —are formed by cutting the extrusion at equal intervals, e.g., at one inch intervals, thus forming one inch wide segments. Alternate materials may include but are limited to thermoplastic, composite materials, wood and other cellulosic materials. In FIG. 1 an elongated base plate 12 includes first and second ends 14 , 16 and first and second flanges 20 , 22 attached respectively to the base plate 12 at right angles. The base plate 12 further includes at least a first threaded hole 26 in the first end 14 . A second threaded hole 26 ′ may be provided as shown. The threaded holes may be tapped to accept a 10-32 or other suitable machine screw as may be predetermined according to the particular application. The flanges 20 , 22 are spaced apart a predetermined distance 24 , typically at least one-half inch. In the illustrative example, for use with panels approximately three-fourths of an inch thick, the spacing would be slightly more than 0.750 inch and preferably approximately 0.813 inch to 1.00 inch.
[0019] The first flange 20 includes a threaded hole 28 located at or near the center portion of the flange 20 and preferably an Allen or hex head socket screw 30 or Phillips head screw 30 threaded into the hole 28 for retaining the panel fastener 10 on the panel upon which it is installed as illustrated in FIG. 3 (to be described). The screws 30 for example may be approximately one inch long and have a size 10-32 thread or other suitable diameter and pitch. Hex head or Allen head machine screws 30 are preferred because of their socket-head feature, which resists tampering. However, other head styles such as slotted pan head or slotted or Phillips round head may be satisfactory and more readily available. The holes 26 , 26 ′ and 28 may be separately tapped or tapped as the screws 30 are inserted for the first time when the screws 30 are fabricated of a harder material (e.g., steel) than the base plate 12 or flange 20 (e.g., aluminum).
[0020] In one typical example, the panel fastener 10 may be adapted from a type F750 aluminum corner manufactured by Brunner Enterprises, Inc., West Seneca, N.Y. 14224 or www.brunnerent.com. This corner material has a cross section that closely resembles a capital block letter “F” having its horizontal extensions or flanges separated by 0.755 inches for receiving panels (see, e.g., panel 40 in FIG. 3 ) that are nominally 0.750 inches thick between them. The addition of the threaded holes in the prescribed locations and the hex socket or Allen head screws 30 inserted therein enables the segments of the aluminum corner strips to be modified into the panel fastener 10 .
[0021] Referring to FIG. 2 there is illustrated the perspective view of FIG. 1 of one embodiment of a hurricane clip or panel fastener 10 according to the present invention with hex head or Allen head screws 30 inserted into the threaded holes 26 , 26 ′, and 28 .
[0022] Referring to FIG. 3 there is illustrated a second perspective view of the embodiment of FIG. 1 in position as if it would be installed on the edge of a panel 40 having a thickness dimension 42 , the panel 40 shown in phantom. For adequate protection against flying debris, the panel(s) supported by the panel fasteners disclosed herein should be cut from rigid panel material approximately 0.750 inches thick; however, panels of lesser thickness, e.g., one-half inch thick may be suitable, particularly for smaller windows, and have the advantage of lighter weight that may facilitate installation. Suitable materials include but are not limited to plywood, pressed board products, exterior wallboard, polycarbonate sheet, composite sheet, sheet metal, and the like. When thinner materials are used for the panel 40 , the spacing between the flanges of the panel fastener 10 will need to be reduced proportionately. The screw 30 is provided in the first flange 20 to securely clamp the edge of the panel 40 between the flanges 20 , 22 of the panel fastener 40 by turning the screw 30 toward the surface of the panel 40 (and toward the second flange) so that the panel is clamped between the end of the screw 30 and the surface of the second flange 22 . In some applications it may be appropriate to insert a shim (not shown but readily understood by persons of skill in the art) between the screw 30 and the surface of the panel 40 to distribute the force of the tightened screw 30 . After a suitable number of panel fasteners are secured to the edges of the panel 40 , the panel is ready to be installed within the window, as will be described in conjunction with FIG. 4 .
[0023] Referring to FIG. 4 there is illustrated one embodiment of a panel 40 installed within a window opening using several of the hurricane clips or panel fasteners 10 as illustrated in FIGS. 1 and 2 . A panel 40 having a width 44 and a height 46 is shown placed within a window opening 50 of a building. The panel 40 is held in place within the window opening 50 by four panel fasteners 10 as shown by tightening the screws 30 , which pass through the first end 14 of the base 12 , against the corresponding sides 52 (see FIG. 5 ) of the window opening 50 . The screws 30 permit adjusting the panel fastening to fit the dimensions 44 , 46 of the window opening 50 and to adjust for uneven surfaces along the sides 52 of the window opening.
[0024] FIG. 4 illustrates a panel secured within a window opening using only four panel fasteners 10 , which is an adequate number for small window openings. In other installations, more panel fasteners 10 would be required to provide sufficient support for a larger, heavier panel. For removal, the screws may be loosened slightly and the panel 40 lifted away from the opening 50 . The panel fasteners 10 may be left on the panel 40 for reinstallation or removed for reuse on a different panel.
[0025] Referring to FIG. 5 there is illustrated a detail view of one of the hurricane clips or panel fasteners 10 according to the present invention as installed on the edge of the panel 40 shown in FIG. 4 . The screws 30 permit adjustments for the dimensions 44 , 46 of the window opening 50 and for uneven surfaces on the face of the sides 52 of the window opening 50 . In some cases it may be necessary to move the panel fastener 10 along the edge of the panel 40 to improve the fit of the panel 40 within the opening 50 .
[0026] In use, the panel fasteners 10 and panels 40 described herein may be used to secure panels 40 within window or door openings 50 for any purpose, not just security from flying debris. A principle feature of the panel fasteners 10 is that they permit relatively quick, temporary mounting of protective panels within the openings of buildings at minimum cost for materials and labor. Further, the panel fasteners are reusable and adjustable to variations in the dimensions of openings to be covered.
[0027] While the invention has been shown in only one of its forms, it is not thus limited to the specific embodiment illustrated and described herein but is susceptible to various changes and modifications without departing from the spirit thereof and falling within the scope of the appended claims setting forth the invention. It will be appreciated that the novel configuration of the panel fasteners herein described permits a wide variety of applications to be satisfied. The panels 40 may be made of nearly any rigid sheet material. If it is necessary to protect the surface of the panel 40 from damage by the point end of the screws 30 as they are tightened against the panel 40 , small, shim-like pads (not shown) may be used between the point end of the screw 30 and the surface of the panel 40 .
[0028] Further, as is well known to persons skilled in the art, machine and other types of screws are available having a variety of point end configurations such as an oval point or a hollow flat point, for example. Similarly, the panel fastener 10 or hurricane clip of the present invention may be secured using a wide variety of machine screws 30 . Other materials may be used to fabricate the panel fasteners 10 or hurricane clips, such as other metals, thermoplastic or composite materials, wood or other cellulosic materials, as long as the panel fastener base-and-flange units may be fabricated at reasonable cost in volume. Processes suitable for such fabrication include injection molding, extrusion, and the like. | An F-shaped panel fastener for securing a panel within a window opening comprises a bracket having first and second parallel flanges extending perpendicularly from a base plate member. The first and second flanges are spaced apart to receive the thickness of the panel edge to be secured between them by a screw inserted through the first flange. Several fasteners are installed around the perimeter of the panel. The panel is installed within an exterior window frame using screws passed through the base plate of each fastener to contact the window frame surface. | 4 |
[0001] The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2006-0097936 (filed on Oct. 9, 2006), which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] This document relates to a washing machine.
[0004] 2. Description of the Related art
[0005] Generally, a washing machine is an apparatus for removing contaminants from laundry by using an emulsification function of detergent and a current caused by rotation of a pulsator or a drum in a state that the laundry is received in the pulsator or the drum together with washing water and detergent.
[0006] In recent years, a drum washing machine, in which the laundry and the washing water are collided by lifting and dropping the laundry as a side of a drum is horizontally installed, acquires popularity. This drum washing machine is in the limelight among users, since it causes damage to the laundry as little as possible while providing excellent washing effects.
[0007] A conventional drum washing machine includes a drum in which a laundry is received, a tub arranged in the drum to store washing water containing detergent, a driving motor driving the drum and a case forming a main body profile of the drum washing machine.
[0008] Hereinafter, the operation of the conventional drum washing machine will be explained.
[0009] First, once the washing machine is operated after the user puts the laundry into the drum, a washing process is performed as the laundry received in the drum and the washing water stored in the tub are collided by the rotation of the drum. And, after completing the washing process, a dehydrating process for removing the washing water or rinsing water from the laundry is performed as the drum is rotated at a high speed and a draining process is performed at the same time. After completing the dehydrating process, the user may take out the laundry to dry it or a drying process is further performed.
[0010] Meanwhile, according to the conventional drum washing machine, a siphon brake hole is formed on one side of a drain hose to prevent a siphon phenomenon after finishing the draining process.
[0011] In other words, the siphon brake hole is formed to prevent the siphon phenomenon which naturally drains the washing water even though the drain pump is temporally deactivated when the drain hose is disposed at a lower position than a drain pump. Further, the washing water, which backflows via the siphon brake hole, flows into a dispenser along a backflow hose.
SUMMARY
[0012] The present embodiment has been made to solve the above problems, and it is an object of the present embodiment to provide a washing machine designed to prevent washing water from being reflowed into a drum by blocking the washing water drained through a siphon brake hole from being flowed into a dispenser during the draining process. That is, an object of the present embodiment to provide a washing machine structure capable of obviating the problem in that a dehydrating effect is reduced as the washing water drained through the siphon brake hole is reflowed into the drum.
[0013] In accordance with one aspect of the present embodiment, the above and other objects can be accomplished by the provision of a washing machine. The washing machine includes a tub; a drain hose discharging washing water stored in the tub to outside, in which a siphon brake hole is formed at one side of the drain hose; a backflow hose guiding the washing water drained through the siphon brake hole during the draining process, as one end of the backflow hose is connected to the siphon brake hole and the other end is directly/indirectly connected to the tub; and a switching element preventing the washing water back-flowed into the backflow hose from being flowed into the tub.
[0014] In another aspect of the present embodiment, there is provided a washing machine. The washing machine includes a tub; a drum received in the tub; a dispenser connecting the tub and a water supply hose, in which detergent is provided; a drain pump draining washing water stored in the tub; a drain hose extended from the drain pump and provided with a siphon brake hole formed at its one side; a backflow hose extended from the siphon brake hole to the dispenser; and a switching element provided in an inner side of the backflow hose to open/close the hose depending on specific conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an external perspective view showing a drum washing machine according to a preferred embodiment of the present invention.
[0016] FIG. 2 is a side cross-sectional view showing a drum washing machine according to a preferred embodiment of the present invention.
[0017] FIG. 3 is a system diagram showing a siphon brake device according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Hereinafter, the present invention will be explained in detail with reference to accompanying drawings. However, the present invention is not limited to the following examples, but various variations and modifications may be made without departing from the scope of the present invention by adding, alternating and deleting another constituent.
[0019] Hereinafter, the present invention will be described with a drum washing machine by way of example to explain an idea of the present invention. However, the idea of the present invention is not limited to the drum washing machine, but it embraces all kinds of washing machines including an upright washing machine.
[0020] FIG. 1 shows an external profile of a drum washing machine according to a preferred embodiment of the present invention and FIG. 2 shows a side of a drum washing machine according to a preferred embodiment of the present invention.
[0021] Referring to FIGS. 1 and 2 , the drum washing machine 10 according to a preferred embodiment of the present invention includes a case 100 forming external profile of the washing machine; a tub 300 installed inside the case 110 to store washing water and a front of the tub is opened; a drum 210 rotatably received inside the tub and a front of the drum is opened to put the laundry therein; a front cover 140 mounted on the front of the case 110 and provided with a laundry input opening 101 ; and a door 100 rotatably connected to one side of the front cover 140 to selectively open/close the laundry input opening 101 .
[0022] In addition, the drum washing machine 10 further includes a driving motor 170 connected to the drum 210 through a driving shaft 171 in order to forcibly rotate the drum 210 ; a control panel 130 mounted on one side of the upper portion of the front cover 140 and provided with a plurality of buttons 131 to input operating condition of the washing machine; a dispenser 120 disposed at a side of the control panel 130 and drawably installed in the case 110 , and through which detergent and fabric softener are supplied; and a water supply valve 191 controlling the flow of washing water into the dispenser 120 .
[0023] In addition, the drum washing machine 10 further includes a water supply pipe 192 connecting the water supply valve 191 with the dispenser 120 and transporting washing water, which is fed from the outside as the water supply valve 191 is opened, to the dispenser 120 ; and a bellows 121 connecting the dispenser 120 with the tub 300 and providing a water course which runs into the tub 300 with washing water and detergent are mixed together.
[0024] In addition, the drum washing machine 10 further includes a damper 160 mounted on the lower portion of the tub 300 and damping the vibration generated as the drum 210 rotates; a drain pipe 180 connected to a bottom of the tub 300 in order to drain washing water stored in the tub 300 ; a drain pump 181 connected to the drain pipe 180 in order to forcibly drain washing water discharged from the drain pipe 180 ; and a drain hose 182 providing a water course which discharges washing water discharged from the drain pump 181 to the outside.
[0025] Further, a siphon brake device 400 is provided between the drain hose 182 and the dispenser 120 , and further explanation of the siphon brake device 400 will be described later.
[0026] In addition, the drum washing machine 10 further includes a drying fan 150 supplying outdoor air into the drum 210 during the drying process; a drying duct 153 connecting the drying fan 150 with the drum 210 ; a heater 151 heating the sucked outdoor air; a connecting pipe 202 discharging the high-temperature high-moisture air imbibed moisture from the inside of the drum 210 to the outside; and an exhaust duct 200 connected to the connecting pipe 202 and mounted on a side of the case 100 .
[0027] Hereinafter, the operation of the drum washing machine with the above mentioned constituents will be explained.
[0028] First, the user opens the door 100 and puts the laundry into the drum 210 . And, the user pushes a start button after inputting the operating condition through the buttons 131 provided in the control panel 130 .
[0029] And then, the water supply valve is opened and therefore the washing water supplied through the water supply pipe 192 from the outside flows into the dispenser 120 . And, the washing water flowed into the dispenser 120 is mixed with the detergent stored inside the dispenser 120 . And, the washing water mixed with the detergent flows into the tub 300 through the bellows 121 . the washing water continues to flow therein until a predetermined level is reached.
[0030] And, the water supply valve 191 is closed and the driving motor 170 starts to run when the washing water, which is to be flowed into the tub 300 , reaches the predetermined level. And, the drum 210 is rotated by the driving shaft 171 which rotates as the driving motor 170 rotates. The laundry inputted into the drum 210 collides with the washing water, since the laundry is lifted to the highest point and fallen as the drum 210 rotates. And, the contaminants stuck into the laundry are removed by the emulsification function of the washing water containing the detergent while colliding the washing water and the laundry.
[0031] And, the draining process is started when the washing process is finished. In other words, the washing water contaminated during the washing process goes to the drain pump 181 through the drain pipe 180 . And, the washing water moved to the drain pump 181 is discharged out of the washing machine 10 via the drain hose 182 by driving the drain pump 181 .
[0032] And, when the rinsing process starts after finishing the drain process, the water supply valve 191 is opened and therefore clean washing water flows into the drum 210 through the water supply pipe 192 , and thus, the rinsing process is progressed.
[0033] And, when the rinsing process is completed, the dehydrating process which is to dehydrate water soaked into the laundry by rotating the drum 210 at high speed is progressed. Here, the water generated from the dehydrating process is drained by operating the drain pump, and the siphon brake device prevents some of the drained water from being reflowed into the drum. The siphon brake device will be described later.
[0034] After that, electricity is applied to the heater 151 and therefore the air is heated to a high temperature when the drying process begins. And, the high-temperature low-moisture air is flowed into the tub 300 by rotating the drying fan 150 , and thus, the laundry in the tub 300 is dehydrated by the inflow dry air. And, the air, which is turned into the low-temperature high-moisture air as the laundry is dehydrated, is discharged out of the drum washing machine 10 through the exhaust duct 200 .
[0035] FIG. 3 shows a system diagram of a siphon brake device according to a preferred embodiment of the present invention.
[0036] Referring to FIG. 3 , the siphon brake device 400 includes a siphon brake hole 402 ; a backflow hose 401 connecting the siphon brake hole 402 with a backflow hole 122 formed in the dispenser 120 ; and a switching element 403 opening/closing the backflow hole 122 .
[0037] Particularly, one side of the dispenser 120 is connected to the water supply pipe 192 , detergent and fabric softener are stored in the dispenser to mix them with washing water flowed into the dispenser through the water supply pipe 192 . The washing water mixed with the detergent is flowed into the tub 300 through the bellows 121 .
[0038] The lower portion of the tub 300 is connected to the drain pipe 180 , and the drain pipe 180 is connected to one side of the drain pump 181 . And, the other side of the drain pump 181 is connected to the drain hose 182 to drain the washing water, which is discharged from the drain pump 181 , out of the drum washing machine 10 .
[0039] Meanwhile, a siphon brake hole 402 is formed in one side of the drain hose 182 to prevent a siphon phenomenon by inflowing air into the drain hose 182 . The siphon phenomenon, which drains washing water inside the tub 300 out of the drum washing machine 10 when the drain pump is stopped for a while, is prevented because air is flowed into the siphon brake hole 402 .
[0040] And, the siphon brake hole 402 and the backflow hole 122 of the dispenser 120 are connected to each other by the backflow hose 401 .
[0041] And, a switching element 403 for selectively opening/closing the backflow hole 122 is formed in one side of the backflow hole 122 . Particularly, the switching element 403 is closed by the high pressure washing water which is generated when the drain pump 181 operates. On the contrary, the switching element 403 is opened in case that the low pressure washing water is generated as the drain pump 181 is stopped. In other words, the switching element 403 is closed at a predetermined hydraulic pressure and more, and it is opened at a predetermined hydraulic pressure and less.
[0042] This switching element 403 closes the backflow hole 122 when the drum washing machine 10 conducts the draining process, as it is operated by the high pressure washing water generated by the drain pump 181 . Therefore, it prevents the washing water drained out of the siphon brake hole 402 from being flowed into the dispenser 120 . Accordingly, the drainage performance of the drum washing machine 10 is improved.
[0043] Here, the position of the switching element 403 is not restricted to one side of the backflow hole 121 in the dispenser 120 , but the switching element 403 may be formed in any selected point of the backflow hose 401 in order to selectively open/close the backflow hose 401 . Further, a check valve or an electromagnetic valve may be used as a switching element 403 .
[0044] Hereinafter, the operation of the siphon brake device 400 will be explained.
[0045] First, the washing water stored in the tub 300 is flowed into the drain pump 181 through the drain pipe 180 when the drum washing machine 10 begins the draining process. After that, the washing water runs through the drain hose 182 as the drain pump 181 operates.
[0046] And, some of the washing water is flowed into the siphon brake hole 402 formed in the drain hose 403 . The drained washing water moves toward the dispenser 120 through the backflow hose 401 .
[0047] At this time, the switching element 403 is operated by the high pressure washing water caused by the drain pump 181 , and thus, it closes the backflow hole 122 . Therefore, it prevents the washing water from being flowed into the dispenser 120 . Accordingly, the re-entry of the washing water toward the dispenser 120 is prevented, and the re-entry of the washing water drained through the drain hose 182 toward the tub 300 is prevented. | Disclosed is a washing machine. The washing machine comprises a tub; a drain hose discharging washing water stored in the tub to outside, in which a siphon brake hole is formed at one side of the drain hose; a backflow hose guiding the washing water drained through the siphon brake hole during the draining process, as one end of the backflow hose is connected to the siphon brake hole and the other end is directly/indirectly connected to the tub; and a switching element preventing the washing water back-flowed into the backflow hose from being flowed into the tub. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Divisional of U.S. patent application Ser. No. 11/612,327, filed on Dec. 18, 2006, now U.S. Pat. No. 7,716,948, the contents of which are hereby incorporated herein by reference for all purposes.
SUMMARY OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of silica crucibles and more particularly to a silica crucible having a doped layer formed in the wall.
2. Background of the Invention
The Czochralski (CZ) process is well-known in the art for production of ingots of single crystalline silicon, from which silicon wafers are made for use in the semiconductor industry.
In the CZ process, metallic silicon is charged in a silica glass crucible housed within a susceptor. The charge is then heated by a heater surrounding the susceptor to melt the charged silicon. A single silicon crystal is pulled from the silicon melt at or near the melting temperature of silicon.
In addition to the CZ process, fused silica crucibles are used to melt metallic silicon, which is then poured—from a nozzle formed into the crucible—into a mold to create a polycrystalline silicon ingot, which is used to make solar cells. As with the CZ crucible, a heater surrounds a susceptor, which holds the crucible.
When fused glass crucibles are so used, metallic silicon in the crucible melts—at least in part—as a result of radiant heat transmitted by the heater through the susceptor and crucible. The radiant heat melts the silicon in the crucible, which has a melting point of about 1410 degrees C., but not the crucible. Once the silicon in the crucible is melted, however, the inner surface of the crucible beneath the surface of the molten silicon is heated to the same temperature as the molten silicon by thermal conduction. This is hot enough to deform the crucible wall, which is pressed by the weight of the melt into the susceptor.
The melt line is the intersection of the surface of the molten silicon and the crucible wall. Because the wall above the melt line is not pressed into the susceptor by the weight of the melt, i.e., it is standing free, it may deform. It is difficult to control the heat to melt the silicon, and keep it molten, while preventing the wall above the melt line from sagging, buckling or otherwise deforming. Maintaining precise control over the heat slows down the CZ process and thus throughput of silicon ingots.
It is known in the art to form a fused crucible with doped silica in the outer layer. The element used to dope the silica is one that promotes crystallization, such as aluminum, when the crucible is heated. Crystallized silica is much stronger than fused glass and will not deform as a result of heat in furnaces of the type used in the CZ and similar processes.
One such known approach dopes the outer layer of a crucible with aluminum in the range of 50-120 ppm. Relatively early in the course of a long CZ process, the outer wall crystallizes as a result of the aluminum doping. The crystallized portion is more rigid than the remainder of the crucible and therefore supports the upper wall above the melt line.
This prior art approach produces at least two kinds of problems, depending on the level of doping. First, the doping level must be high enough to create a rigid outer wall that supports the upper wall above the melt line. If the doping level is too low, the wall is subject to deformation in a manner similar to an undoped crucible. But when the doping level is high enough to support the upper wall, that portion of the wall beneath the melt line is subject to very high heat during the CZ process. This forms a very thick crystalline layer below the melt line. As a result of the prolonged heat and thick crystalline layer, the wall beneath the melt line may crack.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 are cross-sectional, highly schematic, side views of a mold showing sequential stages for forming a crucible of the type having a funnel at the lower end thereof.
FIG. 4 is a cross-sectional view of a crucible so formed.
FIG. 5 is a cross-sectional view of an alternative crucible formed according to the present invention in use during a CZ process.
FIG. 6 is a cross-sectional view of the crucible of FIG. 4 in use during a process for making solar cells.
DETAILED DESCRIPTION
Indicated generally at 10 in FIG. 1 is a system for making a fused glass crucible. The system includes a crucible mold 12 that is rotatable on a vertical axel 14 . Mold 12 includes a generally horizontal surface 14 on which a bottom portion of a crucible is formed, as well be seen. The mold also includes a generally upright surface 16 against which a wall portion of the crucible is formed. In FIG. 1 , system 10 is configured to form a crucible of the type having a nozzle at a lower end thereof. To this end, a graphite plug 18 is positioned in a lower end of the mold to form a passageway that communicates with a nozzle (not shown) that is attached to the crucible after it is fused. For the details of manufacturing a crucible having such a nozzle, reference is made to U.S. patent application Ser. No. 11/271,491 for a Silica Vessel with Nozzle and Method of Making, filed Nov. 9, 2005, which is hereby incorporated herein by reference for all purposes.
System 10 includes a bulk grain hopper 20 and a doped grain hopper 22 . The flow of grain from each hopper is controlled by regulating valves 24 , 26 , respectively. A feed tube 28 introduces flow of silica grain into mold 12 from either one of or both of the hoppers depending upon how valves 24 , 26 are set. Feed tube 28 is vertically movable into and out of mold 12 . This facilitates selectively depositing grain on upright surface 16 and on generally horizontal surface 14 , as well be further explained. A spatula 30 is also vertically movable and in addition is horizontally movable to shape grain in mold 12 as it rotates.
Consideration will now be given to how system 12 is used to make a crucible. First, hopper 20 is loaded with bulk silica grain 32 . And hopper 22 is loaded with aluminum-doped silica grain 34 . Silica grain 34 may be doped with aluminum in the range of about 85-500 ppm.
Next, mold 12 is rotated at a rate of about 100 rpm, feed tube 28 is positioned as shown in FIG. 1 , and valve 26 is opened to begin depositing doped grain 34 in a band or collar 36 about the perimeter of mold 12 . The feed tube is moved vertically to deposit doped grain as shown. The rotation rate is high to keep the doped grain in collar 36 above a predetermined level on generally upright surface 16 . If the rotation rate is too low, doped grain falls into lower portions of the mold, which is undesirable. In the present embodiment, the radially outer surface of collar 36 comprises the outermost portion of the uppermost part of the crucible wall. The doped grain that forms the collar is deposited in a layer that has a thickness (measured along a radial axis of mold 12 ) that is defined by the position of spatula 30 . This thickness may have a range of about 0.7-2.0 mm in the fully formed crucible. As will be seen, there is an outermost layer of silica grain that is not fused. This prevents burning of the mold and makes it easier to remove the crucible from the mold. The thickness of this unfused grain must be taken into account to provide the 0.7-2.0 mm thickness in the finished product.
After collar 36 is laid down as described above, valve 26 is closed, and valve 24 as opened, as shown in FIG. 2 . In addition, the rate of rotation of mold 12 is reduced to 75 rpm. This permits some of the bulk grain 32 to fall to the lower portion of mold 12 . As bulk silica grain feeds from hopper 20 out of feed tube 28 , the feed tube moves vertically to coat the side and bottom of the mold with a layer 38 of bulk grain silica as shown. Spatula 30 shapes the bulk grain layer into the form of a crucible. As can be seen, layer 38 covers substantially all of collar 36 . Graphite plug 18 defines an opening through layer 38 in the shape of the plug.
With reference to FIG. 3 , after the silica grain crucible is defined in mold 12 as shown in FIG. 2 , spatula 30 and feed tube 28 are withdrawn. Electrodes 40 , 42 are vertically movable into and out of the interior of mold 12 . The electrodes are attached to a DC power supply 46 that can apply power to the electrodes in a selectable range between about 300 KVA and 1200 KVA. When sufficient power is supplied to the electrodes, an extremely hot plasma ball forms around the electrodes. The heat so generated creates a fusion front that fuses the silica grain beginning at the inner surface of the formed crucible and proceeding to the outer surface. This fusion front fuses most of layer 38 and the collar 36 of doped silica grain but stops—as a result of stopping the application of power to electrodes 40 , 42 —before it fuses an outermost unfused layer 49 of grain that includes both bulk silica grain 38 and doped silica grain 36 . As previously mentioned, the depth of the grain deposited into mold 12 must take into account this unfused layer 49 so that a depth of the fused doped grain 36 , as shown in FIG. 4 , is in the range of 0.7-2.0 mm. A unitary fused glass crucible 50 is shown in FIG. 4 after it is removed from mold 12 and graphite plug 18 has been removed.
It can be seen that an upper portion of crucible 50 has been cut off to produce a flat upper rim 52 . This provides a crucible of a predetermined height and also provides a flat upper rim. As can be seen, in FIG. 4 , collar 36 provides an outermost and uppermost portion of crucible 50 . After the upper portion of the cut is made, collar 36 —in the present embodiment—extends about 50 mm downwardly from rim 52 . It should be appreciated, however, that collar 36 could be formed to extend much further down the crucible—as much as ⅔ or ⅓ of the way down thus providing a much taller collar. As will be described shortly, a shorter caller is preferred.
Turning now to FIG. 5 , indicated generally at 54 is a crucible in use in a CZ process. Crucible 54 is made in substantially the same manner as crucible 50 except that it does not have an opening in a lower portion thereof. This is accomplished simply by using a mold having a continuous smooth lower surface and omitting use of a graphite plug, like plug 18 . Crucible 54 includes an aluminum doped collar 56 , which is formed as described above in connection with crucible 50 . Like crucible 50 , crucible 56 has been cut along a plane at right angles to its longitudinal axis. This produces a substantially flat rim 58 .
Crucible 54 is supported in a susceptor 60 that is inside a furnace (not shown). The susceptor is surrounded by a heater 62 . Crucible 54 has been charged with metallic silicon that has melted, which is now referred to as the melt 64 , in response to heat produced by heater 62 inside the furnace. A single silicon seed crystal 61 is held by a holder 63 , which slowly draws seed crystal 61 from the molten silicon in accordance with the CZ process. A crystalline ingot 65 forms, also in accordance with the CZ process, on the lower end of seed crystal 61 . Melt line 66 is defined about the perimeter of crucible 54 . The melt line progressively lowers as ingot 65 forms and is pulled from melt 64 .
The melt 64 is at a temperature of about 1400 degrees C. As a result, the surface of crucible 54 beneath the melt line is also at that temperature. Even though the heat from the melt makes the crucible below melt line 66 very soft, the weight of the melt presses the crucible into susceptor 60 thus preventing any deformation of crucible 54 below melt line 66 . As the metallic silicon melts, the heat begins to crystallize crucible 54 in collar 56 as a result of the aluminum doped silicon within the collar. The portion of the crucible that is crystallized is hardened. This creates a relatively rigid crystalline ring or collar around the crucible, which stabilizes the portion of the crucible wall that is not crystallized. In other words, the rigid collar prevents the softer uncrystallized wall above the melt line from collapsing or otherwise deforming even as melt line 66 lowers to the bottom of the crucible.
Finally, crucible 50 is shown in use in FIG. 5 . It also is held in a susceptor 68 . Likewise a heater 70 surrounds the susceptor 68 with all of the structure shown in FIG. 6 being contained within a furnace (not shown). Silicon melt 72 was formed by melting metallic silicon in crucible 50 by heating it with heater 70 in the furnace. A nozzle 74 , which was formed with graphite plug 18 , on the lower portion of crucible 50 is plugged during while the silicon is melted. Once fully molten, the plug is removed, and melt 72 pours through nozzle 74 —as shown in the drawing—into molds (not shown) that are used to make solar cells.
As with the crucible of FIG. 5 , the FIG. 6 crucible walls are supported as a result of the crystalline ring formed when collar 36 begins to crystallize early in the CZ process. As a result, the walls of the crucible are supported above the melt line.
It should be appreciated that the aluminum-doped collars, like collars 36 , 58 , can be formed so that the lower portion thereof is substantially at or slightly above the melt line when the crucibles are used. Or they may be slightly below the melt line—at least at the beginning of the CZ process. A good position for the lower end of the collar is less than about 5% of the crucible height below the melt line.
The following examples demonstrate the advantages of the invention.
Example A
A crucible like crucible 50 was formed that has a height of 400 mm, 270 mm inner diameter, and 10 mm wall thickness. In this example the crucible was doped with 100 ppm aluminum to form a collar, like collar 36 that extends 150 mm down from rim 52 . The collar is 1.4 mm thick and defines an outermost and uppermost surface of the crucible as shown in the drawing. A charge of 120 kg metallic silicon was charged and kept in the crucible for 120 hours without problems.
Example B
A crucible like crucible 50 was formed that has a height of 400 mm, 270 mm inner diameter, and 10 mm wall thickness. In Example B the crucible was doped with 500 ppm aluminum to form a collar, like collar 36 that extends 50 mm down from rim 52 . The collar is 1.6 mm thick and defines an outermost and uppermost surface of the crucible as shown in the drawing. A charge of 120 kg metallic silicon was charged and kept in the crucible for 120 hours without problems.
Example C
A crucible like crucible 50 was formed that has a height of 400 mm, 270 mm inner diameter, and 10 mm wall thickness. In this example the crucible was doped with 100 ppm aluminum to form a collar, like collar 36 that extends 310 mm down from rim 52 , which is substantially all of the generally upright outer wall of the crucible. The collar defines an outermost and uppermost surface of the crucible as shown in the drawing. A charge of 120 kg metallic silicon was charged and in the crucible. In this example, the melt overlaps substantially with the collar. Put differently, the melt line was substantially above the lower edge of the collar. After 50 hours of holding the melt, the crucible showed cracking between the substantially upright wall portion and the substantially horizontal bottom portion. This cracking results from the melt being in close proximity to the doped, and therefore crystallized, collar.
Although the examples each use aluminum as a dopant, it should be appreciated that the invention could be implemented with any dopant that promotes crystallization, e.g., Barium.
As can be seen, when the doped portion and the melt do not overlap, or overlap only slightly, the problems associated with the prior art fully doped outer crucible wall can be avoided. In addition, when the process use is known, i.e., how much silicon will be charged in the crucible and how quickly the melt will be drawn down, a crucible can be designed in which there is overlap between the collar and the melt, but only for a few hours, not enough to damage the crucible, during the early stages of the process. As a result, the problems associated with the prior art can be avoided even where there is overlap of the melt and the doped collar in the early stages of the process.
While the invention has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense. Indeed, it should be readily apparent to those skilled in the art in view of the present description that the invention can be modified in numerous ways. The inventor regards the subject matter of the invention to include all combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. | A fused glass crucible includes a collar of doped aluminum silica that defines uppermost and outermost surfaces of the crucible. The melt line that defines the surface of molten silicon in the crucible may be substantially at the lower end of the collar or slightly above it. Crystallization of the collar makes it hard and therefore supports the remaining uncrystallized portion of the crucible above the melt line. The melt line may also be below the lower end of the collar, especially if the melt is drawn down or poured early in the process. Because there is little or no overlap or because the overlap does not last long, the doped aluminum collar is not damaged by the heat of from the melt. | 8 |
FIELD OF THE INVENTION
This invention relates to an improved injection well velocity logging method and apparatus.
BACKGROUND OF THE INVENTION
Secondary recovery methods to produce oil from subterranean formations include injection of steam, carbon dioxide, and natural gases to drive oil toward recovery wells. Such methods can significantly increase the recovery of oil from many formations, but each is relatively expensive. It is common to use the fuel equivalent of about one-third of the produced oil to produce steam for a steam drive recovery operation. Carbon dioxide and natural gas are also expensive to procure and compress. These recovery processes are therefore economical only if they are carried out in an efficient manner. An important aspect of the efficiency of these processes is the profile of the injection of the drive fluid through multiple sets of well casing perforations and into the formation. This injection profile indicates to the operator, for example, whether portions of the formation are being bypassed, or whether perforations are plugged.
The profile of the injection of drive fluids is typically determined from measuring the velocity of the fluids going down the well borehole, or the velocity profile. This velocity profile is typically determined by either a turbine-type meter or by radioactive tracers. Turbine-type meters are typically lowered into the wellbore on a line. An impeller rotates at a speed which is proportional to the vapor flow, driving a small generator which produces an electrical signal which is proportional to the speed of the impeller rotation. Because turbine meters do not directly measure velocity, but measure the rotation speed of an impeller, they are subject to errors due to calibration. They also require generation of the electronic signal, which relates to the fluid velocity, and transmission of that signal up the borehole.
Radioactive tracers measure velocity by calculation of the time required for a slug of a radioactive tracer to reach detectors which are placed at intervals within the wellbore. The high speeds at which fluids travel down an injection well result in this method rendering data which is of limited resolution. The resolution of the data is particularly troublesome if the sets of perforations are relatively close to each other.
It is also desirable to minimize handling of radioactive tracers. These tracers must not only be handled when injected, but their diluted existence in production fluids must also be considered along with disposal of unused radioactive tracer material.
It is therefore an object of the present invention to provide a method and an apparatus capable of measuring the velocity profile in an injection well wherein radioactive tracers are not required and wherein the velocity can be sampled across a significant portion of the cross-section of the wellbore. It is another object to provide such a method and apparatus which does not require electronic devices or conduction of electronic signals within the wellbore.
SUMMARY OF THE INVENTION
These and other objects of the present invention are achieved by a method to log velocities in a portion of a wellbore comprising the steps of:
providing a high drag member which passes through the portion of the wellbore to be logged with little frictional resistance against the wellbore walls and provides a high drag resistance for fluids passing around the high drag member within the wellbore;
suspending the high drag member within the wellbore by a line;
moving the high drag member within the wellbore at a velocity which results in tension on the line at the wellhead which equals or slightly exceeds the weight of the drag member and line in the wellbore; and
determining the velocity of the fluids within the portion of the wellbore by measuring the rate at which the line is being taken up or fed out when the tension on the line slightly exceeds the weight of the drag member and line in the wellbore.
These and other objects are also accomplished by a well logging apparatus capable of measuring fluid velocities within a wellbore comprising:
a) a high drag member which passes through the portion of the wellbore to be logged with little frictional resistance against the wellbore walls and provides a high drag resistance for fluids passing around the high drag member within the wellbore;
b) a line capable of suspending the high drag member within the wellbore;
c) a means to maintain a tension on the line at the wellhead which equals or slightly exceeds the weight of the high drag member and line in the borehole;
d) a means for lowering and raising the high drag member within the wellbore at varying rates; and
e) a means for measuring the speed at which the line is going into the wellbore or being pulled out of the wellbore.
The apparatus and method of this invention are capable of logging velocities in a wellbore by directly measuring the rate at which the high drag member is spooling out or being taken up while maintaining a tension on the line which is about equal to the weight of the line in the wellbore. The need for electronic instrumentation within the borehole is thus eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the apparatus of the present invention.
FIG. 2 is a cross-sectional view of a preferred high drag member.
FIG. 3 is a drawing of an alternative preferred high drag member.
FIG. 4 is a schematic diagram of an alternative apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a high drag member, 1, is shown suspended within a casing, 2, in a wellbore, 11, by a line, 3. The line is reeled up and down from a spool, 4. Means to determine the tension on the line at the wellhead is shown as a conventional line weight indicator, 5, on a horizontal section of the line. The line weight indicator, 5, also measures the rate at which the line is going into or out of the borehole and tracks the amount of line in the borehole. The line can then be directed into the wellbore over a sheave, 6, and through conventional wellhead valves and lubricators, 7. The lubricators minimize the flow of well fluids out of the wellhead, while maintaining a minimal drag force on the line. The wellhead also comprises a means for injection of fluids, 10, and a tubing, 12, which extends to a portion of the wellbore which is within an oil bearing formation. The annular space between the tubing and the casing is typically sealed with a packer, 13.
In a preferred embodiment, the rate at which the line is taken up or let out can be directly controlled by way of a feedback controller, 8, providing a control signal, 9, to the spool drive, 4. The feedback controller, 8, preferably considers the amount of line in the borehole and calculates the weight of this line. The feedback controller, 8, preferably also adds the weight of the high drag tool, 1, and the weight of the line within the borehole and controls the speed at which the line is reeled out or taken up to maintain the tension measured by the line weight indicator, 5, at about this total weight. When this total weight, minus an estimate of the frictional drag of the drag member against the borehole walls, is equal to the line weight indication measured, the speed at which the line is being taken in or spooled out is approximately the velocity of the fluids within the wellbore. The weight of the high drag member and the line are preferably minimized, so that these weights can be neglected in estimating the fluid drag around the high drag member, and the tension on the line at the point the line is attached to the high drag member.
Of course, the pressure at the wellhead for example, at the lubricator, 7, and the flow rate at which fluids, 10, are injected, are monitored and preferably held constant. Changes in the rate at which fluids can be injected, or changes in wellhead pressure are indications that the drag member is not, for some reason, traveling in the wellbore at the same speed as the wellbore fluids.
Particularly if the fluids in the wellbore are liquids, the weights of the line and high drag member considered in controlling the speed that the slickline is lowered or raised in the wellbore is preferably the buoyed weight, or the net weight of the components in the wellbore fluids.
Referring now to FIG. 2, details of a preferred high drag member are shown within a casing, 2, suspended by a line, 3. The line, 3, is preferably attached to the high drag member by a swivel, 20, attached to a bar, 24, around which the high drag member is assembled. The drag of the high drag member can be provided by a plurality of flexible seals, 21 (fine shown). The seals are preferably of a diameter which is about equal to the interval diameter of the casing, 2, in the segment of the wellbore in which fluid velocity is to be logged. These seals can be made of a flexible plastic material such as neoprene, and can be separated by a foam, 25. The foam functions to keep the seals in place. The seals, 21, may be attached to the bar, 24, by washers, 22. The washers may be separated by sleeves, 23.
Another embodiment of the high drag member is shown in FIG. 3, with the high drag member in an expanded configuration. The collapsed configuration is used to draw the high drag member back out of the wellbore after a logging run. Referring to FIGS. 1 and 3, the high drag member is shown in a casing 2, below the tubing, 12, and packing, 13. The high drag member is suspended from a line, 31. The drag is created by an inverted parachute, 32, which is made of a flexible material such as a fabric or a flexible polymeric film. The parachute is hung from the line by a plurality of hangers, 34, connected to a slip ring, 33. The hangers may be stiff wires, or they may be flexible wires or cords. If the hangers are stiff, they are pivotably connected to the ring, 33. In the expanded configuration, the ring, 33, is optionally secured to the line at a location which results in the hangers, 34, being shorter than the length of the line from the point the ring is attached to the point the line is attached to the parachute at an attachment point, 35, which is centrally located on the parachute. When the ring is attached to the line at such a point, the parachute will tend to stay expanded. When the ring is secured to the line when the parachute is in the expanded configuration, it can be released from the line prior to lifting this high drag member out of the wellbore. With the ring, 33, released from the line 31, the outer rim of the parachute will fall below the center point of the parachute, and instead of forming a parachute, which will tend to expand outward to the walls of the casing, the parachute will form a cone. The hangers, 34, are preferably longer than the radius of the parachute, so that when the ring is released, the parachute will hang from the line attachment point, 35. In this configuration, it can be drawn up through the casing and tubing with a minimal resistance from fluids flowing down the tubing and casing.
Preferably, the slip ring, 33, is not affixed to the line, but is free to slide up and down. When the tension on the line at the attachment point, 35, is low, the parachute, 32, will be held in the open position by the flow of fluids down the wellbore.
The rim of the parachute, 32, may contain a springy band, 36, attached to its circumference to help maintain the shape of the parachute. The springy band is preferably a metal band encased within a wear-resistant surface coating. The springy band must be sufficiently flexible to pass through any tubing which may be present in the injection well.
FIG. 4 shows an alternative apparatus of the present invention. This apparatus is similar to FIG. 1, and elements are numbered identically, except that the line weight indicator, 5, control signal, 9, and feedback controller, 8, of FIG. 1 are replaced with a simple mechanical arrangement. In FIG. 4, tension is maintained by a mechanical drag element, 15, which is controlled by tension from a control spring, 16, attached to a traveling sheave, 17. The traveling sheave, 17, is shown in a low tension position. A phantom sheave, 18, is shown in a high tension position. When the traveling sheave is pulled toward the high tension position by the line, it pulls on the control spring, 16, which reduces drag on the spool, 4, through the mechanical drag element, 15. A fixed sheave, 19, is equipped with a counter and integrater, 20, to determine and record the line speed and the amount of line in the borehole. The spring, 16, must be equipped with an adjustment to provide a tension which slightly exceeds the weight of the high drag member, 1, plus the weight of the line, 3, in the wellbore when the high drag member is in the portion of the wellbore in which velocities are to be logged. The apparatus of FIG. 4 has the advantage of being simple and inexpensive.
These preferred high drag members can provide a very high resistance to flow around the member within the wellbore, while at the same time maintaining a low frictional resistance against the walls of the wellbore. The frictional forces of the high drag member against the wellbore walls at typical fluid velocities are preferably less than about the weight of the high drag member. This frictional force will then be sufficiently low that errors in its estimation will not significantly affect the logging of well fluid velocities.
The apparatus of the present invention is inserted into the wellbore, and then injection of fluids is established and maintained as the high drag member is lowered into the wellbore at a rate which results in no net fluid force on the high drag member, therefore enabling a direct measurement of the fluid velocities based on the rate that the line is spooled off.
When the high drag member of the present invention is utilized to log velocities in a steam injection application, it may be desirable to provide a temporary separator to separate any liquids which may be in the injection steam from the injection system. This prevents any accumulation of liquids either above or below the high drag member from affecting the tension on the high drag member. Accumulated liquids may be disposed of by injection into the wellbore after logging is complete. It has been found that liquids which are injected with steam will generally travel to the bottom of the wellbore, and exit the casing from the lower most perforations. Separating liquids from injection steam during velocity logging, and assuming that liquids would normally travel to the lowest perforations, will generally improve the accuracy of the velocity log obtained. | A device having a large fluid drag tendency is lowered into a well at a rate which gives no net drag against the fluid. The condition of no net drag is indicated by the tension in a line used to lower the tool into the well. When the spool-off rate is such that this tension force is equal to or slightly exceeds the weight of the tool plus the weight of the line in the borehole the tool is moving at a speed equal to the average flow velocity in the well. This velocity may be determined by measurement of the spool-off rate. | 4 |
This application claims priority benefit under 35 USC § 119(e) from U.S. Provisional Application No. 60/447,110 filed Jun. 9, 2003, and U.S. Provisional Application No. 60/410,635 filed Sep. 13, 2002.
FIELD OF THE INVENTION
The field of this invention is trauma surgery, combat medicine, and emergency medical services.
BACKGROUND OF THE INVENTION
As recently as the early 1990s, surgical operations for trauma were directed at the anatomic repair of all injuries at time of the initial operation. It was observed during these exercises that many patients became hypothermic, acidotic, and coagulopathic. Patients showing these three signs often died. Death often occurred in the operating room due to exsanguination, or postoperatively, due to the complications of prolonged shock and massive transfusion to replace blood lost as a result of the trauma.
One of the most notable developments in the recent evolution of surgery has been the reintroduction of the concept of staged laparotomy to overcome the deficiencies of the repair all-at-once approach. This new strategy of staged laparotomy employing new tactics that have been termed damage control is now used in 10% to 20% of all trauma laparotomies.
This strategy opens the way for a variety of new devices and methods for control of hemorrhage from solid organs or viscera. Although there are procedures for controlling these injuries, none of these procedures utilize optimal devices or tactics in their execution. Each area offers technological opportunities to improve the devices and procedures for applying those devices.
Two of the three immediate goals of damage control operations are to contain or stop, as quickly as possible, hemorrhage from major wounds of the solid viscera and to stop bleeding from injured intra-abdominal blood vessels. The third immediate goal of damage, control operations is to immediately arrest fecal or contents spillage from wounded hollow viscera. Such enteral wounds to the hollow viscera commonly occur in multiple areas of the bowel and colon. While existing methods and procedures, including the use of standard vascular instruments, bowel clamps, umbilical tape, and sutures, do allow the rapid control of vascular and visceral injuries in many cases, the standard techniques and tools have not been designed for temporary placement as part of a staged operation. Specifically, the vascular instruments or clamps have long handles that would be subjected to torque associated with temporary packing and closure of the abdomen. In addition, these instruments are not constructed of materials suitable for medium-term implantation and may have features that would cause the devices to become healed into the wound, rather than be easily removable.
During damage control procedures, time is of the essence. Every minute that passes without hemostatic control leads to further blood loss, shock and risk of intraoperative exsanguination. Every minute that passes without control of enteral spillage leads to increased risk of infection and septic death.
Typical vascular injuries requiring hemostatic control may include, for example, a wound to the descending abdominal aorta, the iliac arteries and veins, superior mesenteric vessels, vena cava or the portal vein, renal arteries and veins, and lumbar arteries. Typical enteric injuries requiring spillage control include wounds to the duodenum, small bowel, or colon. These wounds are, most commonly, multiple. The existing methods for controlling these include clamping and sewing, stapling, or resection of the involved bowel segment. All these current methods take much more time than the approach enabled by the methods and devices described below.
New devices, procedures and methods are needed to support the strategy of damage control in patients who have experienced abdominal injury. Such devices and procedures are particularly important in the emergency, military, and trauma care setting.
SUMMARY OF THE INVENTION
The devices and methods described below provide for improved treatment of wounds, including achieving hemostasis and leakage control in hollow body vessels such as the small and large intestines, arteries and veins as well as ducts leading to the gall bladder and other organs. The devices are clips for hollow vessels, variously designed to make them suitable for emergency closure of vessels. The clip is capable of partially occluding a structure with a tangential wound or completely obstructing both ends of a completely divided blood vessel or hollow viscus. It is highly desirable that clamps be designed to be left behind for a period of time ranging from several minutes to several days without the attached handles. The clamps are designed to minimize the chance of tissue ingrowth, thus allowing for improved ease of removal. The ideal clamp would have a very low profile, secure holding properties, be incapable of eroding into other structures, would not crush or destroy the wall of the clamped vessel, even if left for a period of days, would be easy to apply, would evenly distribute the compression force on the vessel, would be able to straddle, in a partially occluding way, a tangential wound of a major vessel or bowel. Features of the vascular and bowel clips include broad, controlled, force distribution on the tissue, even force distribution, both longitudinally and laterally on the vessel or bowel tissue. Additional key features of the vascular and bowel clips of the present invention include controlled movement, ease of placement, ease of locking in place, ease of removal, biocompatibility for medium to long-term implantation, minimal projections away from the clip, lack of sharp edges to cause further trauma during placement, and removal of the clip applier so that there are no long surfaces projecting from the clip area. The vascular and bowel clips may be placed through an open surgical access site or through a laparoscopic access and manipulation system.
Once a clip has been placed, it remains in place either temporarily or permanently. Temporary placement necessitates removal of the clip after a period of time. Long-term placement necessitates that the clip be able to sustain its function indefinitely. In this application, the clip is fabricated from materials that permit medium to long-term implantation. The clip design minimizes undercuts and features that would promote tissue ingrowth, thus restricting removal. In another embodiment, the clip may be fabricated, completely or partially, from resorbable materials that obviate the need to remove the clip in a subsequent surgical procedure. The clip applier is fabricated from materials that are suitable for short-term tissue or vascular contact. The clips themselves are fabricated from materials with smooth outer surfaces that do not encourage tissue or clot ingrowth. Thus, the clips may be removed with minimal re-bleeding.
The clips may be partially or entirely radiopaque so that they can be visualized on fluoroscopy or X-ray and easily located on subsequent follow-up.
The current medical practice of using sutures and current clips is not an optimized solution to open visceral and vascular wound repair. The current techniques almost always cause a tourniquet effect and require substantially more time to place than is desired, thus increasing the chance of accelerated deterioration of the patient's condition. The devices and methods described herein distinguish over the current medical practice because the present invention is tailored to the needs of open vascular or bowel repair. The clips have soft serrated jaws to grab the vessel wall and prevent spillage, but not strangulate the vasculature within the wall. They have short stubby grasping handles that are activated by tools that provide mechanical advantage and extension of reach into small spaces. The clips are suited for either open surgical implantation and removal, or they are suited for laparoscopic placement and removal using specialized access, grasping and delivery instruments. When the clips of the present invention are removed from the patient, re-bleeding does not occur because there is minimal penetration of the wound tissues or clot into the interstices of the clips.
Another feature of the clips is reduction in the length of those portions of the implantable clip (the actuating lever arms) that projects away from the actual clamping surface. This minimization of projection away from the clamping surface is accomplished by use of more than one hinge point, telescoping members and applier grasping points located between the hinge point and the clamping surface. In another embodiment, the grasping tabs projecting away from the clip are minimized by folding them in a direction opposite to that in which they are compressed to open the clip. Folding the tabs back onto the clip allows the tabs to be completely or nearly completely eliminated as a projection. The folding tabs have their own hinge points or they rotate around the main clamp axis. In another embodiment, the tabs are rotated perpendicular to the direction of compression to move them out of the way so that they do not project away from the clip jaws.
Another feature of the clips is the parallelism of the jaws. In the closed or nearly closed configuration, the jaws separate and close along a linear path rather than an arcuate path. Thus, there are no pinch points near the hinge area of the clips. The clips comprise hinges that permit linear or nearly linear travel. This linear travel feature near the closed position means that the jaws close with even, predictable force distribution on the vessel.
Another feature of the clips is the broad force distribution both longitudinally along the vessel to be clipped and laterally across the vessel being clipped. These clips of the present invention are not narrow but, instead, are broad. They typically comprise circular or elliptical pads that can encompass a substantial amount of vessel tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a side view of the clip in its open state.
FIG. 1B illustrates a side view of the clip in the closed state.
FIG. 1C illustrates a top view of a generally circular clip.
FIG. 2A illustrates a side view of the clip in the open position around a vessel with a clip applier attached.
FIG. 2B illustrates a side view of the clip in the closed position occluding the vessel with the clip applier removed.
FIG. 3A illustrates a section of bowel with multiple transverse wounds;
FIG. 3B illustrates the section of bowel with clips applied to prevent fecal spillage.
FIG. 4 illustrates a packaging system that delivers multiple clips in a convenient manner.
FIG. 5A illustrates a top view of an elliptical clip with its major axis oriented perpendicular to the clip hinge.
FIG. 5B illustrates a top view of an elliptical clip oriented with its major axis parallel to the clip hinge.
FIG. 5C illustrates a top view of a circular clip.
FIG. 5D illustrates a top view of a clip of with a rounded triangular configuration.
FIG. 6A illustrates a cross-sectional view of a bowel vessel wall showing the internal vasculature.
FIG. 6B illustrates a cross-sectional view of a bowel vessel wall with a clip applied preventing enteral spillage but maintaining blood flow within the internal vasculature.
FIG. 6C illustrates a cross-sectional view of a bowel vessel with a clip applied preventing enteral spillage but also causing collapse of the vasculature internal to the bowel vessel wall.
FIG. 7A illustrates a top view of a blood vessel that is completely occluded by a clip.
FIG. 7B illustrates a top view of a blood vessel that is partially occluded by a clip.
FIG. 7C illustrates a top view of a blood vessel that is completely severed and is completely occluded by a single clip.
FIG. 8A illustrates a side view of a clip wherein the jaws move on linear axes and are open.
FIG. 8B illustrates a side view of the clip wherein the jaws move on linear axes and are closed.
FIG. 8C illustrates a side view of the clip wherein the jaws move on linear telescoping axes and are open.
FIG. 8D illustrates a side view of the clip wherein the jaws move on linear telescoping axes and are closed.
FIG. 9A illustrates a side view of a clip, shown with the jaws fully opened, wherein the jaws rotate angularly to encompass a wide vessel but close in a linear fashion on spring loaded telescoping linear bearings.
FIG. 9B illustrates a side view of the clip, shown with the jaws rotated to the parallel but slightly open configuration, wherein the jaws rotate angularly to encompass a wide vessel but close in a linear fashion on spring loaded telescoping linear bearings, shown with the jaws fully opened.
FIG. 9C illustrates a side view of the clip, shown with the jaws rotated to the parallel configuration and are fully closed, wherein the jaws rotate angularly to encompass a wide vessel but close in a linear fashion on spring loaded telescoping linear bearings.
FIG. 10A illustrates a side view of the clip with the jaws rotated angularly to the open position wherein Pad material of variable thickness is used to equalize pressure distribution over the closed pads.
FIG. 10B illustrates a side view of the clip with the jaws rotated angularly to the closed position, wherein pad material of variable thickness is used to equalize pressure distribution over the closed pads.
FIG. 11A illustrates a side view of the clip in the open position around a vessel with a clip applier attached, according to aspects of an embodiment of the invention. In this embodiment, the opening tabs are rotated outward with the clip in the open position;
FIG. 11B illustrates a side view of the clip in the closed position occluding the vessel with the clip applier removed, according to aspects of an embodiment of the invention. In this embodiment the opening tabs are rotated inward to minimize projections with the clip in the closed position;
FIG. 12A illustrates a side view of the clip in the closed position with folding tabs unfolded and ready for compression.
FIG. 12B illustrates a side view of the clip in the open position with the folding tabs compressed together and the jaws spread apart
FIG. 12C illustrates a side view of the clip in the closed position with the jaws in opposition and the tabs folded inward to minimize projections.
FIGS. 13A and 13B are side views of a clip with no tab projections beyond the hinge.
FIG. 13C is a top view of the clip of FIGS. 13A and 13A .
FIGS. 14A , 14 B and 14 C illustrate the clip applicator for use with the clip shown in FIGS. 13A through 13C .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A illustrates a side view of a clip 10 of the present invention. The clip 10 comprises a plurality of jaws 12 , further comprising a frame 14 and a pad 16 , a main hinge 18 , a plurality of main struts 20 , a plurality of opening tabs 22 , a plurality of grasping detents 24 , and a plurality of optional serrations 26 on one or more of the pads 16 . The clip 10 further comprises an optional secondary hinge 28 , a plurality of optional secondary struts 30 , a plurality of main pivot points 32 , an optional spring 34 , an optional lock 36 , an optional hinge bracket 38 , and a plurality of optional secondary pivot points 40 .
Referring to FIG. 1A , the jaws 12 of the clip 10 are shown in their open configuration. The frame 14 provides rigid support and orientation for the pads. 16 . The top and bottom frames 14 are connected to a main hinge 18 through a plurality of main struts 20 . Each of the main struts 20 is rigidly affixed to the opening tab 22 with the grasping detent 24 formed into the opening tab 22 . In this embodiment, the main hinge 18 is connected to the secondary hinge 28 by a plurality of hinge brackets 38 . The main struts 20 are rotationally connected to the main hinge 18 and the main pivot points 32 . The secondary struts 30 are connected to the secondary hinge 28 and the secondary pivot points 40 . The serrations 26 are formed on the surface of the pads 16 . The spring 34 is affixed between the main pivot points 32 and causes both of the frames 14 to be forced toward each other.
Further, referring to FIG. 1A , the clip 10 utilizes a parallelogram hinge design to facilitate parallelism in the jaws 12 in the open, closed and partially open configurations.
The clip frame 14 , the main struts 20 and secondary struts 30 as well as the main pivot points 32 , secondary pivot points 40 , the main hinge 18 , the secondary hinge 28 , the plurality of hinge brackets 38 and the opening tabs 22 are fabricated from generally rigid materials such as, but not limited to, stainless steel, cobalt-nickel alloys, nitinol, tantalum, titanium, polylactic acid, polyglycolic acid, platinum, polypropylene, polyethylene, polyimide and the like. Where resorbable materials such as polylactic acid and polyglycolic acid are used, the clips will disintegrate within the body over a period of time, thus obviating the need to remove the clip 10 , and preventing or limiting ingrowth or overgrowth of body tissue over the clip components, thus facilitating removal. The pads 16 are fabricated from non-rigid, compliant materials such as open or closed cell foam, low durometer elastomers, resorbable compliant materials, and the like. The foams may be fabricated from a variety of polymers including but not limited to polyurethane, polyvinyl chloride and the like. The frame 12 or at least one other component of the clip 10 is preferably radiopaque and visible under fluoroscopy or X-Ray. All or most components of the clip 10 are fabricated from resorbable materials such as PLA or PGA so that the clip 10 eventually erodes or dissolves and goes away (preferably after healing is complete).
The opening tabs 22 are rigidly affixed to the main struts. Inward force applied to the opening tabs 22 causes a moment arm to rotate the main struts 20 around the main hinge 18 to the open position. The grasping detents 24 permit an instrument, such as forceps, Allis Clamp, Kocher Clamp, or the like, to grasp the opening tabs 22 in such a way that they do not slip off inadvertently.
The spring 34 is, preferably, a leaf spring and is fabricated from materials such as, but not limited to, stainless steel 316L, titanium, Elgiloy, nitinol and the like. The spring 34 is affixed between the two jaws and is pre-loaded to force the jaws toward the closed position. The spring 34 is designed to compress the pads 16 around the body vessel or lumen with enough force to close the lumen of the vessel but not enough force to close the vasculature within the body vessel wall. For example, a bowel can be closed with a distributed pressure of 20 mm Hg or less while a blood vessel would be closed with a pressure exceeding blood pressure. Typical diastolic blood pressures in a shock patient may be as low as 50 mm Hg so this would be the typical upper limit of the pressure generated by a clamp designed to compress a section of bowel. Thus, the bowel clamp spring system will provide pressures in the range of 2 to 50 mm Hg and more preferably between 10 and 20 mm Hg. The pressure may be calculated as the force applied by the spring 34 divided by the surface area of one of the pads 16 . The spring characteristics, such as the spring material, size, thickness, etc. are selected to achieve the desired spring force and resultant clamping force applied by the clip. When used to close a blood vessel, the clamping force is preferably much higher. A vascular clamp system is required to seal off a blood vessel at a systolic blood pressure of 100 to 300 mm Hg in hypotensive and hypertensive patients, respectively. Accordingly, clamps intended for use on blood vessels are provided with springs of sufficient strength such that the clamps can apply a force of 100 to 300 mm Hg on the vessels to which they are applied. The pads 16 are soft and distribute the applied pressure evenly over the surface of the body vessel.
The pads 16 comprise optional serrations 26 that prevent slippage of the pads on the surface of the body vessel. The serrations 26 may be configured so as to impinge on each other tip to tip or they may be configured to interlock with each other. The pads 16 preferably comprise a central opening so that they provide a line of tissue compression, not a broad plane of compression. The supporting frame 14 is, also, preferably hollow and provides exposure to the tissue in its central region when looking in a direction perpendicular to the plane of the frame 14 .
FIG. 1B illustrates a side view of the clip 10 with the jaws 12 in their closed position. The opening tabs 22 are rotated apart and the serrations 26 on the pads 16 are in parallel touching contact. The maintenance of the parallel position of the jaws 12 permits closure of the vessel between the pads 16 without pinching and overcompression at one point and under-compression at another point. This feature of the clip 10 may be termed force parallelism and refers to an even force distribution on the tissue along the entire hinge-to-tip length of the clip.
The total projection of the non-jaw parts of the clip 10 with the jaws 12 in the closed position does not extend a distance greater than the distance D between the exterior of the closed frames 14 of the jaws 12 . Thus, if the clip jaws 12 open to a maximum outside frame distance of 15 mm, the maximum total projection of any non-jaw 12 structure along a given axis when the jaws 12 are in the closed position will not be greater than 15 mm. Such non-jaw 12 projections include opening tabs 22 , struts 20 and 30 and the like.
FIG. 1C illustrates a top view of the clip 10 comprising the jaws 12 , further comprising the plurality of frames 14 , the main pivot points 32 , the secondary pivot points 40 , the main hinge 18 , the secondary hinge 28 , the plurality of main struts 20 (not shown), the plurality of secondary struts 30 (not shown), the plurality of opening tabs 22 , the spring 34 (not shown), and the plurality of grasping detents 24 . The plurality of pads 16 are not visible in this view as they are on the other side of the frame 14 .
Referring to FIG. 1C , the jaws 12 , further comprising the frames 14 and the pads 16 , are of a circular or donut configuration. In the preferred embodiment, the center of the frame 14 is open. In another embodiment, the center of the frame 14 could advantageously be closed. The jaws 12 project along a major axis (line 19 ), generally leading perpendicularly away from the main hinge 18 . The jaws 12 project also along a minor axis (line 21 ) leading generally parallel to the direction of the main hinge 18 . The jaws 12 are broad and are designed to encompass a large amount of tissue and, therefore have substantial major and minor axes. The minor axis (along line 21 ) of the jaw 12 should be no smaller than 25% of the major axis (along line 19 ) of the jaw 12 and, preferably no smaller than 40% of the distance subtended by the major axis. In another embodiment, the minor axis and major axis are switched, such that the major axis is parallel to the hinge and the longitudinal axis of the vessel to be closed.
In FIG. 1C , the opening tabs 22 are aligned so that the main hinge 18 is located between the opening tabs 22 and the main struts 20 . In yet another embodiment of the clip 10 , the opening tabs 22 are positioned between the main hinge 18 and the frames 14 . In this embodiment, the main struts 20 are forced open by force applied to the opening tabs 22 . However, the projection of the opening tabs 22 beyond the main hinge 18 is eliminated, thus minimizing the projection of the clip 10 and minimizing its profile. Such minimized profile is advantageous when leaving the clip 10 implanted within the patient. Referring to FIGS. 2A and 2B , depending on the position of the opening tabs 22 , the grasper jaws 52 on the graspers will be closed or overlapped closed to open the jaws 12 on the clip 10 . The opening tabs 22 can also be positioned so that the grasper jaws 52 are open when the clip 10 jaws 12 are open. In a further embodiment, the grasper jaws 52 grab the main hinge 18 on the clip 10 . A central shaft (not shown) is then advanced or retracted, pushing the opening tabs 22 to open jaws 12 .
FIG. 2A illustrates a side view of a clip 10 of the present invention in the open position and aligned around a blood vessel 70 . A grasping instrument 50 is positioned to open the clip 10 . The grasping instrument 50 comprises a plurality of grasper jaws 52 , a hinge 54 , shafts 56 , a ratchet lock 58 and finger loops 60 .
Referring to FIGS. 2A and 1A , the grasper jaws 52 of the grasping instrument 50 are positioned within the grasping detents 24 on the opening tabs 22 of the clip 10 . By applying inward pressure to close the two finger loops 60 , the grasper jaws 52 are closed, thus closing the opening tabs 22 on the clip 10 and rotating the clip jaws 12 open against the force exerted by the spring 34 . The ratchet lock 58 maintains closure of the grasper jaws 52 , until such time as release is desired. The opened clip 10 is positioned around a blood vessel 70 , further comprising a vessel wall 72 and a vessel lumen 74 . In FIG. 2A , the vessel lumen 74 is open.
FIG. 2B illustrates a side view of the clip 10 of the present invention with its jaws 12 in the closed position and aligned around and occluding or closing the lumen 74 of the blood vessel 70 . The ratchet lock 58 further comprises a ratchet lock top 62 and a ratchet lock bottom 64 .
In this illustration, the ratchet lock top 62 on the grasper 50 has been separated from the grasper lock bottom 64 , the finger loops have been rotated open and the grasper jaws 52 are open. The opening tabs 22 on the clip 10 are opened, allowing the spring (not shown) to bring the jaws 12 of the clip 10 into contact with and compress the vessel wall 72 .
Referring to FIGS. 2A and 2B , such graspers 50 may be forceps or other commercially available instruments such as a Kocher Clamp, an Allis Clamp, or the like. In order to fully utilize the benefits of the invention, however, specialized graspers 50 may be desirable. This is especially true in the embodiment where the opening tabs 22 on the clip 10 are located between the main hinge 18 and the jaws 12 . In this embodiment, a grasper jaw 52 that specifically mates with the internal opening tabs 22 and forces the opening tabs 22 open will be advantageous. The long shafts 56 are advantageous for all applications since they extend the reach of the surgeon into tight spaces not normally accessible with the fingers. In addition, the long shafts 56 help apply a large moment around hinge 54 to move the jaws 52 against substantial spring force.
Referring to FIGS. 1A , 1 B, 1 C, 2 A and 2 B, the diameter of the jaws 12 of the clip 10 ranges from about 0.1 cm to 10 cm depending on the tissue being compressed. More preferably, the diameter of the clip 10 ranges from about 0.2 cm to 5 cm.
FIG. 3A illustrates a longitudinal section of a bowel, blood vessel, or other body vessel 70 . The bowel, blood vessel, or other body vessel comprises the wall 72 and the lumen 74 . A plurality of wounds 76 further comprise this section of bowel, blood vessel, or other body vessel 70 . These wounds 76 project into the lumen 74 but do not transect the entire vessel 70 .
FIG. 3B illustrates the section of the bowel, blood vessel or other body vessel 70 with clips 10 applied over the wounds 76 . The clips 10 are applied to the vessel wall 72 so as to completely seal off the lumen 74 from leakage. However, a through passage is still present within the lumen 74 of the vessel 70 . For example, this configuration would permit perfusion of vasculature and tissue downstream of a blood vessel while stopping hemorrhage though the wounds 76 .
FIG. 4 illustrates a top view of a packaging system 80 for the clips 10 . The packaging system comprises the plurality of clips 10 , a carrier 82 , a plurality of dividing walls 84 , a sliding seal 86 , a draw tab 88 , a sterile barrier 90 , an optional secondary sterile barrier 92 , a plurality of guiding detents 94 , and a plurality of notches 96 .
Referring to FIG. 4 , this embodiment shows five clips 10 located within the carrier 82 and separated by dividing walls 84 . The optional secondary sterile barrier 92 is removed prior to accessing the sterile barrier 90 as part of double aseptic technique. The sterile barrier 90 is typically a polymer tray fabricated from thermoformed PVC, PETG, polystyrene, or the like. The secondary sterile barrier 92 is typically a heat sealed polyethylene or Tyvek® bag or polymer tray with a heat sealed Tyvek® lid, or the like. The carrier 82 further comprises a plurality of guiding detents 94 to facilitate positioning of the graspers 50 on the clips 10 . The sliding seal 86 maintains sterility of each unused clip 10 while allowing access to one or more clip 10 at a time. The sliding seal 86 slides along the carrier 82 and seals against the dividing wall 84 to provide such sterile barrier. Optional notches 96 in the carrier and sterile barrier 90 provide tactile feel for locating the sliding seal 86 correctly on the dividing walls 84 .
FIG. 5A illustrates the clip 10 of the present invention with the elliptical jaw 12 configuration. In this embodiment, the ellipse is oriented with its major axis parallel to the axis of the main hinge 18 . The jaws 12 of the present invention project substantially in a direction lateral to the major axis of the jaws 12 , which is generally perpendicular to the axis of the main hinge 18 . The major axis of the jaws 12 can be defined as the axis moving away from the main hinge 18 or other moving part of the clip 10 .
FIG. 5B illustrates the clip 10 of the present invention with the elliptical jaw 12 configuration. In this embodiment, the ellipse is oriented with its major axis perpendicular to the axis of the main hinge 18 .
FIG. 5C illustrates the clip 10 of the present invention wherein the jaws 12 are of circular configuration.
FIG. 5D illustrates the clip 10 of the present invention wherein the jaws 12 are of a rounded triangular configuration. The pointed side of the triangle is on the side of the clip 10 away from the main hinge 18 . In another embodiment, the pointed side of the triangle is on the same side as the main hinge 18 . Other geometric configurations may also be appropriate for the jaws 12 .
FIG. 6A illustrates an enteral vessel 70 in cross-sectional view. The enteral vessel 70 further comprises the wall 72 , the lumen 74 and wall vasculature 78 . The enteral vessel 70 is typically a bowel such as the esophagus, small intestine or large intestine but may also include other body lumens that are highly vascularized. The vasculature 78 includes arteries, veins and capillaries.
FIG. 6B illustrates the enteral vessel 70 with the clip 10 applied to the exterior of the wall 72 so as to completely collapse and seal the lumen 74 . The pressure exerted by the clip 10 is sufficient to close the lumen 74 but not enough to cause collapse of the vasculature 78 .
FIG. 6C illustrates the enteral vessel 70 with the clip 10 applied to the exterior of the wall 72 so as to completely collapse and seal the lumen 74 . The pressure exerted by the clip 10 is sufficient to not only close the lumen 74 but is also sufficient to cause collapse of the vasculature 78 .
FIG. 7A illustrates a top view of a section of vessel 70 with a clip 10 applied so as to completely occlude the lumen 74 all the way across the width of the vessel 70 .
FIG. 7B illustrates a top view of a section of vessel 70 comprising the wound 76 partially severing the vessel wall 72 . The clip 10 applied so as to completely occlude the lumen 74 around the wound 76 but still allowing some flow through lumen 74 in the region not collapsed by the clip 10 . The large width of the clip 10 facilitates completely encircling and sealing the wound 76 to the vessel.
FIG. 7C illustrates a top view of a section of vessel 70 comprising the wound 76 that completely transects the vessel wall 72 . The clip 10 is applied to the vessel wall 72 of both of the severed ends of the vessel 70 so as to completely occlude the lumen 74 of both sections of the severed vessel 70 . The large width of the clip 10 facilitates completely sealing the transecting wound 76 to both ends of the vessel.
FIG. 8A illustrates another embodiment of a clip 10 of the present invention wherein one or more of the jaws 12 move along a linear bearing 90 . In the preferred embodiment, the clip 10 comprises the jaws 12 , the linear bearing 90 , a plurality of linear ratchet teeth 92 , a release 94 , a ratchet lock 96 , a spring 100 , and an optional damper 102 .
The clip 10 of the present embodiment is shown with the jaws 12 in the open position. One of the jaws 12 is permanently affixed to the base of the linear bearing 90 . The other jaw 12 is permanently affixed to and moves with the ratchet lock 96 over the linear bearing 90 . The plurality of linear ratchet teeth 92 are permanently affixed along the linear bearing 90 with the ramped ends toward the immovable jaw 12 and the flat ends away from the immovable jaw 12 . The spring 100 is connected between the two jaws 12 so that the jaws are placed under the correct tension. The spring 100 pulls the jaws 12 together. The ratchet lock 96 engages the plurality of linear ratchet teeth 92 with a spring-loaded tooth and may be easily moved away from the immovable jaw 12 . The ratchet lock 96 cannot move toward the immovable jaw 12 unless the release 94 is depressed. At this time, the spring 100 forces the jaws together. The optional damping system 102 (not shown) may be used to prevent too quick a movement of the movable jaw 12 toward the immovable jaw 12 .
Referring to FIGS. 1A and 8A , the jaws 12 of this embodiment of the clip 10 are fabricated from the same materials and in the same configuration as the jaws 12 of the clip in FIG. 1A .
FIG. 8B illustrates the clip 10 of FIG. 8A with the jaws 12 in the closed position.
FIG. 8C illustrates another embodiment of the clip 10 of the present invention. The clip 10 comprises the jaws 12 , a locking, telescoping linear bearing 104 , a spring 100 , an optional damper 102 (not shown) and a release 94 .
The jaws 12 are held apart by the locking, telescoping linear bearing 104 against the compression force of the spring 100 . The release 94 engages features within the telescoping, locking, linear bearing 104 to prevent compression until such time as the release 94 is depressed or otherwise activated. At this time, the spring 100 brings the jaws 12 together. The optional damper 102 controls the rate of jaw 12 movement.
FIG. 8D illustrates the clip 10 of the embodiment shown in FIG. 8C with the jaws 12 in the closed position. The telescoping, locking, linear bearing 104 is fully compressed and does not project beyond the perimeter of the clip 10 jaws 12 . This embodiment minimizes the projections from the implantable clip 10 , a particularly advantageous feature.
FIG. 9A illustrates another embodiment of the clip 10 of the present invention with its jaws 12 in the fully open position. The clip 10 comprises the jaws 12 , a plurality of ratcheting hinges 110 , a telescoping locking linear bearing 104 , a release 94 , a spring 100 and an optional damper 102 (not shown).
Referring to FIG. 9A , this embodiment of the clip 10 utilizes multiple opening mechanisms of rotation and linear separation. The plurality of ratcheting hinges 110 are affixed to the jaws 12 . The telescoping locking linear bearing 104 is rotationally connected to the ratcheting hinges 110 . The spring 100 is connected between the jaws 12 and acts to force the jaws 12 toward the closed position. The optional damper 102 (not shown) is affixed between the jaws 12 and controls the rate of jaw 12 closure.
The ratcheting hinges 110 are manually opened by rotation to allow for maximum separation of the jaws 12 so as to surround a large vessel.
FIG. 9B illustrates the clip 10 of FIG. 9A with the jaws 12 in an intermediate position. The jaws 12 are closed manually on the ratcheting hinges 110 . Following complete rotation, the jaws 12 are in the parallel position. The spring 100 is pre-loaded under tension in this configuration. The telescoping linear bearing 104 is in its fully open position.
FIG. 9C illustrates the clip 10 of FIG. 9A with the jaws 12 in the fully closed position. The spring 100 forces the jaws 12 closed after the release 94 is activated. The release 94 or a separate release (not shown) can optionally be used to unlock the jaws 12 for rotation about the ratcheting hinges 110 . The telescoping linear bearing 104 is fully compressed in this configuration and does not project beyond the general envelope of the jaws 12 . In practice, the spring 100 and the optional damper 102 are affixed inside the telescoping linear bearing 104 .
FIG. 10A illustrates yet another embodiment of the clip 10 of the present invention. The clip 10 is shown with the jaws 12 in the open position. The clip 10 , in this embodiment, comprises a plurality of jaws 12 that are further comprised by a frame 14 and a pad 16 . The jaws rotate around a main hinge 18 . A plurality of opening tabs 22 are rigidly affixed to the frames 14 . A spring 34 biases the jaws 12 toward the closed position.
Referring to FIG. 10A , by bringing the opening tabs 22 into close proximity, the jaws 12 are separated maximally. The pads 16 are designed with greater thickness toward the hinge 18 . These variable thickness pads 16 help distribute the force on the tissue being clamped. The frames 14 are further apart toward the hinge than toward the outside of the jaws 12 . This extra separation near the hinge helps prevent pinching the tissue and maximizes force distribution over the tissue. The pads 16 are fabricated from the same materials as those used in the clip 10 shown in FIG. 1A . In yet another embodiment of the clip 10 of FIG. 10A , the pads 16 may be of constant thickness but of decreasing hardness approaching the hinge 18 . In this embodiment, the frames 14 of the jaws 12 could be roughly parallel to each other in the closed position.
FIG. 10B shows the clip 10 of FIG. 10A with its jaws 12 move to the closed position by the spring 34 . Note that the interface between the pads 16 is even and parallel, even though the frame 14 of one jaw 12 is not parallel to the frame 14 of the opposing jaw 12 . The opening tabs 22 are rotated apart around the hinge 18 . While this embodiment of the clip 10 provides for approximately even (but not completely even) force distribution on the tissue with less complexity than the other clip 10 embodiments. The design relies on a very soft material in the construction of the pads 16 . The serrations 26 are shown in an interlocking configuration.
FIG. 11A shows an open clip 10 , comprising a plurality of opening tabs 22 and jaws 12 , further comprising a plurality of frames 14 and pads 16 , which are disposed around a vessel 70 , and a clip applier 50 , according to aspects of another embodiment of the invention optionally, a spring (not shown) is used to bias the jaws open or closed as required. In this embodiment, the opening tabs are angled apart when the clip jaws 12 are in the open position. The clip applier is open enough to grab the opening tabs 22 .
FIG. 11B shows a closed clip 10 , comprising a plurality of opening tabs 22 and jaws 12 , which are clamped to close the vessel 70 . The clip applier 50 is closed sufficiently to force the opening tabs 22 closed, thus forcing the jaws 12 closed. The opening tabs 22 are now aligned parallel to the jaws 12 and have minimal or no projection out of the plane of the jaws, thus facilitating implantation. The clip applier 50 may also be configured to be closed when the jaws 12 of the clip 10 are open and open when the jaws 12 of the clip 10 are closed. This requires that the operator expand the clip applier 50 to close the jaws 12 of the clip 10 , potentially an easier motion on the part of the operator. A ratcheting mechanism or locking mechanism (not shown) maintain the jaws 12 of the clip 10 in the closed position once positioned there by the clip applier 50 .
Referring to FIGS. 2A , 3 A, 3 B, 4 , 6 A, 6 B, 7 A, 7 B, 7 C, and 11 A, the methodology for implanting these clips 10 , also known as clamps, is to place them through an open wound or incision. They are generally grasped by a grasping tool 50 and removed from their sterile package with the jaws 12 in the open position. The clips 10 are located properly over the vessel 70 or wound 76 . At this point, the grasping tool 50 is opened and the jaws 12 of the clip 10 are allowed to close. Readjustment may be required in order to obtain the desired hemostasis or leakage control. The clips 10 are left implanted and the wound is covered appropriately until such time as the patient is stabilized and the wound can be correctly and permanently repaired.
FIG. 12A illustrates another embodiment of the clip 10 comprising a plurality of opposing jaws 12 , further comprising a frame 14 and a pad 16 , a hinge mechanism 18 , an upper folding tab 80 , a lower folding tab 82 , and a spring, (not shown).
The jaws 12 rotate around the hinge mechanism 18 and are constrained radially by the hinge mechanism 18 . The jaws 12 are fabricated using the frame 14 and the pad 16 which are permanently affixed to each other. The spring is affixed to the jaws 12 and is biased to force the jaws 12 together into the closed position. The upper folding tab 80 is radially constrained around the hinge mechanism 18 and is free to fold inward until it is essentially flush with the frame 14 . The upper folding tab 18 has a projection that engages with the jaw 12 in the region of the hinge mechanism 18 so that when the upper folding tab 80 is forced downward by manual pressure, the upper jaw 12 is forced to rotationally open around the hinge mechanism 18 . The lower folding tab 82 is radially constrained by the hinge mechanism 18 and rotates freely around the hinge mechanism 18 between pre-set limits. The lower folding tab 82 , when forced upward, engages with a projection on the jaw 12 in the region of the hinge mechanism 18 and causes the lower jaw 12 to open.
FIG. 12B illustrates the clip 10 of the embodiment shown in FIG. 12A , with the jaws 12 in their open configuration. The upper folding tab 80 and the lower folding tab 82 have been compressed together forcing the jaws 12 to open.
FIG. 12C illustrates the clip 10 of the embodiment shown in FIG. 12A with the tabs 80 and 82 released and the jaws 12 closed by action of the spring (not shown). The upper tab 80 and the lower tab 82 have each been folded inward to be essentially flush with the respective frame 14 of the jaw 12 . An optional locking detent or lock (not shown) is preferable to ensure that the folding tabs 80 and 82 remain in place once folded inward and until such time as release is desired. When release of the tabs 80 and 82 is desired, manual force is preferably used to overcome the lock and allow the tabs 80 and 82 to be folded outward so that they can be compressed to open the jaws 12 .
The folding tabs 80 and 82 enable the clip 10 to be configured without any projections or with minimal projections so that they may be left in the body for a period of time, temporarily or permanently, and will not erode surrounding tissues.
In a further embodiment, the tabs 80 and 82 do not fold out but pull out from the clip 10 like a drawer. Once the tabs 80 and 82 have been used to open and then allow the clip 10 to close, the tabs 80 and 82 of this embodiment, are pushed inward so that they now comprise minimal or negligible projections. The tabs 80 and 82 slide on rails or slots in the clip 10 , in this embodiment, and optionally comprise detents or interference locks to prevent unwanted outward expansion after the tabs 80 and 82 are pushed in.
FIGS. 13A through 13C illustrate a clip 10 constructed without rearwardly extending opening tabs. FIGS. 13A and 13B are side views of a clip 10 with no tab projections beyond the hinge. The jaws are shown in the open configuration in FIG. 13A and in the close position in FIG. 13B . The jaws 12 , frame 14 and a pad 16 are constructed as described above in relation to other embodiments of the clips. The hinge spring 18 , which biases the clip to the closed position, is covered by a hinge housing 112 . In this embodiment, the clamp jaws 12 are forced open by force applied to the opening tabs 22 with the specially adapted grasping instrument shown in FIGS. 14A and 14B . The opening tabs are positioned between the hinge 18 and the distal extent of the jaws. The projection of the opening tabs 22 beyond the main hinge 18 is thus eliminated, minimizing the projection of the clip 10 and minimizing its profile. This minimized profile is advantageous when leaving the clip 10 implanted within the patient. FIG. 13C is a top view of hinge shown in FIG. 13A . Though the spring is shown in this view, it will typically be covered by the hinge housing to provide a uniform rounded outer surface to the clip. The spring is concentrically wound around the hinge, having one end embedded in the lower jaw and one end embedded in the upper jaw. The spring biases the clip closed with a pre-determined, controlled force determined by the size and material of the spring. The spring characteristics are chosen to limit the force applied to the vessel, as described in relation to the leaf spring of FIGS. 1A through 1C . Grasping tabs 22 are visible between the hinge and the jaws. Preferably the tabs are arranged to avoid torsion on the clip, and the illustrated arrangement includes two spaced apart tabs attached one jaw, and a single tab on the opposite jaw, disposed under the gap established by the other tabs. The clip of this embodiment has rounded exterior surfaces and rounded edges.
FIG. 14A the clip applier or grasping instrument 50 to be used with the clips of FIGS. 13A through 13C . The clip applier exerts force on tabs or surfaces between the hinge and the center of the jaws. The grasping instrument is constructed as described above, with the hinge 54 , shafts 56 , ratchet lock 58 and finger loops 60 described above. The grasper jaws 52 include bosses 114 which extend inwardly toward the opposite grasping jaw, leaving a hinge accommodating space 116 between the grasping jaw hinge 54 and the bosses. With the grasping instrument open, it can be positioned to place the clip hinge 18 into the hinge accommodating space, as shown in FIG. 14A , with the bosses in apposition to the tabs of the clip. As shown in FIG. 14B , when the grasping instrument is closed, the bosses force the tabs apart, thereby forcing the jaws open against the bias of the spring. FIG. 14C is a top view of the clip and clip applier of FIG. 14A and FIG. 14B . In this view, prongs 118 of one grasping jaw 52 are visible. The prongs of the clip applier project beyond the hinge of the clip so that they may exert force on pads or tabs located inward of the hinge.
Application of the implantable vessel clipping system provides improved speed of hollow organ, blood vessel and enteral trauma repair and minimizes the amount of hemorrhage and infection. The implantable nature of these clips facilitates damage control procedures wherein the patient can be allowed to stabilize prior to definitive repair of the injuries. Such damage control procedures have been shown to improve patient outcomes and save lives.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. For example, the spring-loaded clamps or clips can, instead, be closed on ratcheting mechanisms to a specific amount of compression, rather than by spring action. The spring-loaded clips may also be forced closed under the attraction force of opposite pole permanent or electronic magnets. Permanent magnets manufactured from neodymium iron boron are suitable for this purpose. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Devices and methods for achieving hemostasis and leakage control in hollow body vessels such as the small and large intestines, arteries and veins as well as ducts leading to the gall bladder and other organs. The devices and methods disclosed herein are especially useful in the emergency, trauma surgery or military setting, and most especially during damage control procedures. In such cases, the patient may have received trauma to the abdomen, extremities, neck or thoracic region. The devices utilize removable or permanently implanted, broad, soft, parallel jaw clips with minimal projections to maintain vessel contents without damage to the tissue comprising the vessel. These clips are applied using either standard instruments or custom devices that are subsequently removed leaving the clips implanted, on a temporary or permanent basis, to provide for hemostasis or leakage prevention, or both. These clips overcome the limitations of clips and sutures that are currently used for the same purposes. The clips come in a variety of shapes and sizes. The clips may be placed and removed by open surgery or laparoscopic access. | 8 |
This is a continuation-in-part of application U.S. Ser. No. 10/346,987 filed Jan. 17, 2003 now U.S. Pat. No. 7,042,444.
FIELD OF THE INVENTION
This invention relates generally to organic light emitting diode (OLED) displays and, more particularly, to an OLED display with a touch screen.
BACKGROUND OF THE INVENTION
Modem electronic devices provide an increasing amount of functionality with a decreasing size. By continually integrating more and more capabilities within electronic devices, costs are reduced and reliability increased. Touch screens are frequently used in combination with conventional soft displays such as cathode ray tubes (CRTs), liquid crystal displays (LCDs), plasma displays and electroluminescent displays. The touch screens are manufactured as separate devices and mechanically mated to the viewing surfaces of the displays.
US 2002/0175900 A1 by Armstrong, published Nov. 28, 2002, describes a touch system for use with an information display system including a frame defining an opening corresponding in size and shape to an information display area of a display. On each side is positioned an array of light emitting devices with a light-transmissive prism positioned along each array of light emitting devices such that light emitted from the light emitting devices is directed across the touch input area. The system also includes light detection devices positioned at each corner of the frame. In a preferred embodiment, the light emitting devices are organic light emitting diodes.
When such a touch screen is used with a flat panel display, the touch screen is simply placed over the flat panel display and the two are held together by a mechanical mounting means such as an enclosure. These prior art arrangements combining touch screens and OLED displays suffer from a variety of drawbacks. The use of frames increases the parts count, weight, and cost of the device. The separation between the touch screen and display increases thickness. Redundant components found in the display and touch screen further increase cost and decrease performance as compared to more integrated solutions. Moreover, the need for separate cabling for the touch screen increases manufacturing costs
Thus, there remains a need for an improved touch screen, flat panel display system that minimizes device weight, removes redundant materials, decreases cost, eliminates special mechanical mounting designs, increases reliability, and minimizes the degradation in image quality.
SUMMARY OF THE INVENTION
The need is met according to the present invention by providing an OLED display and touch screen system that includes a substrate; an OLED display including an array of individually addressable OLEDs formed on the substrate; and a touch screen including an OLED light emitter formed on the substrate the OLED light emitter defining an optical cavity for reducing the angle of emission of light from the OLED light emitter and a light sensor formed on the substrate across the display from the OLED light emitter, and optics located around the display above the OLED light emitter and the light sensor for directing light emitted from the OLED light emitter across the display to the light sensor.
ADVANTAGES
The display according to the present invention is advantageous in that it provides a thin, light, easily manufacturable display having reduced weight, size, and cost and a greater reliability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view showing the basic structure of an integrated OLED display and touch screen according to the present invention;
FIG. 2 is a schematic top view of the integrated OLED display and touch screen;
FIGS. 3 a, b , and c are schematic top views of an integrated OLED display and touch screen showing alternate locations of the emitters and sensors;
FIG. 4 is a schematic side view of an integrated OLED display and touch screen wherein the optics located around the frame are mirrored surfaces of the frame according to one embodiment of the invention;
FIG. 5 is a schematic side view of an integrated OLED display and touch screen wherein the optics located around the frame are light pipes; and
FIG. 6 is a schematic side view of an integrated OLED display and touch screen wherein the OLED display is a bottom emitting display.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a top-emitting OLED display device with an integrated optical touch screen according to one embodiment of the present invention includes a rectangular substrate 42 with an encapsulating cover 44 . Located on the substrate is an OLED display 60 including electrodes and multiple layers of materials such as hole-injection layers and electron transport layers as is well known in the art (not shown). Light 49 emitted from the display passes through the encapsulating cover 44 or is reflected from the substrate 42 and is emitted through the encapsulating cover 44 . At one side of the rectangular substrate 42 is an array of infrared OLED light emitters 62 . Infrared OLED light emitters are known and can be made, for example, by doping OLED devices with rare-earth ions such as neodymium or erbium. At the opposite side of the rectangular substrate 42 is an array of infrared light sensors 64 . The sensors may include filters to improve their frequency response.
As shown in FIG. 2 , a second pair of emitter and sensor arrays are arranged on the other two sides of the rectangular substrate 42 . According to the present invention, both the light emitters 62 and sensors 64 are integrated on the same substrate as the OLED display 60 . Optics, such as mirrors 66 are arranged over the encapsulating cover 44 directly above the emitter and sensor arrays for directing light emitted from the light emitters 62 across the display to the light sensors 64 . The mirrors 66 can be constructed using glass or plastic prisms with a reflective side arranged at approximately 45 degrees to the cover 44 . Alternatively, the mirrors can be supported at approximately 45 degree angles with respect to the cover 44 . A touch screen controller (not shown) is connected to the touch screen to operate the emitters 62 and sensors 64 .
Referring to FIGS. 3 a, b and c , a top view of alternative arrangements of the light emitters 62 and sensors 64 are shown. In the arrangement shown in FIG. 3 a , the light emitters 62 are located in two arrays adjacent two contiguous edges of the display 60 and the sensors 64 are located in two arrays adjacent the other two edges of the display 60 . In the arrangement shown in FIG. 3 b , the light emitters 62 and sensors 64 are interdigitated in arrays surrounding the display 60 . In the arrangement shown in FIG. 3 c , emitter arrays are located on all four sides of the display area 60 and sensors 64 are located at the corners of the display 60 , similar to the arrangement shown by Armstrong in published US Patent Application 2002/0175900.
In operation, the infrared OLED light emitters 62 emit light in every direction. The light is reflected from the 45 degree mirrors 66 located above the emitters and pass over the surface of the OLED display 60 . After passing over the surface of the OLED display, the light is reflected by the 45 degree mirrors located above the sensors 64 to the infrared sensors 64 . The sensors 64 detect the light and produce feedback signals that are supplied to the touch screen controller and interpreted in a conventional manner to locate the position of an object that interrupts the light from the emitters 62 . Because the touch screen elements are integrated on a common substrate with the display, a single connector may be used for both the touch screen and the display. Elements of the touch screen controller and/or the display controller may be integrated on the substrate.
Because each infrared OLED light emitter 62 emits light in every direction, a single emitter can be used in conjunction with multiple sensors 64 to detect a touch. Alternatively, multiple emitters can be used in conjunction with a single sensor to detect a touch. The emitters and sensors can be energized sequentially or in common to optimize the performance of the touch screen under a wide variety of conditions, including high ambient light, low-power operation, a noisy environment, or high performance mode.
Because OLED light emitting elements emit light equally in every direction, not all of which will strike the 45 degree mirrors, the performance of the present invention can be enhanced by increasing the amount of light that is emitted orthogonally to the substrate so that a greater percentage of the light will reflect from the mirrors. In conventional practice, up to 80% of the light emitted is lost because it is not transmitted through the cover or substrate of the display. Instead the light may be emitted in a direction parallel to the substrate and will waveguide through the light emissive layers. Therefore, reducing the amount of light emitted parallel to the substrate that propagates through the light emissive layers of organic materials by waveguiding action will increase the amount of light that is emitted usefully toward the mirrors.
A reduced angle of emission from the OLED light emitting elements can be achieved by forming an optical cavity between the electrodes providing current to the OLED light emitting elements. Electrodes can be made of highly reflective, thin layers of metal. By making the electrode opposite to the direction of emission completely reflective and the electrode though which light passes partially reflective, an optical cavity can be formed. The optical cavity must be tuned to the preferred frequency at which light is to be emitted by carefully depositing layers of the required thickness. The light within the cavity will form a standing wave pattern at the desired frequency and with a reduced angle of emission. Optical cavities of this type are known in the art, as are suitable metallic electrodes, for example silver. See for example published US US Patent application 20030184892 published 2003 Oct. 2, by Lu et al., which is incorporated herein by reference. It is also possible to use optical cavity designs that produce coherent laser light as described in published US patent application No. US20030161368 published 2003 Aug. 28 by Kahen et al. and US20020171088 published 2002 Nov. 21 by Kahen et al. which are incorporated herein by reference. Applicants have demonstrated both incoherent and coherent OLED light emission having a reduced angle of emission from the perpendicular that is suitable for the present invention.
In a bottom-emitting display, the electrode 18 must be partially reflective while the electrode 30 can be totally reflective. In a top-emitter configuration, the electrode 18 is reflective while the electrode 30 is partially reflective.
Applicants have demonstrated the use of an optical cavity for the enhancement of light emission from an OLED structure with both white-light emitting materials and for red, green, and blue light-emitting materials. In all cases, the use of a properly sized cavity with the use of a thin layer of silver or silver compounds as the partially reflective electrode and a thicker layer of either silver or aluminum or compounds of aluminum or silver as the reflective electrode results in greater light emission orthogonal to the electrodes and with a narrower spectrum. Partially transparent electrodes may also consist of a two-layer structure in which a first layer is a transparent conductor and a second layer is a partially reflective mirror.
In conventional practice, the use of an optical cavity in a display application has the significant drawback of a color change as the display is viewed at angles other than the orthogonal. In the present invention, no such disadvantage is seen since only light that is emitted toward the mirror is used and the emitted light is not intended for viewing.
The emitters may be energized sequentially to provide multiple signals thereby increasing the signal-to-noise ratio of the result and providing a more detailed map of any touching implement that inhibits the transmission of the infrared light. In yet another mode, the emitters are energized simultaneously and the relative amount of light sensed by the sensors 64 are used to detect a touch. In this arrangement, the emitters 62 can be a single long emitter with a single control signal.
The use of multiple emitters and sensors enables a very robust sensing apparatus. Single-point failures can be overcome and convex shapes can be detected. High-reliability operation is possible by combining signals from various emitters sensed by various sensors. The infrared signal itself may be modulated to overcome background noise or different frequencies of infrared light may be emitted and detected.
Referring to FIG. 4 , the 45 degree mirrors 66 located above the emitters 62 and sensors 64 may be formed by a reflective surface on an enclosure 70 enclosing the integrated display and touchscreen. Referring to FIG. 5 , the optics for directing light emitted from the light emitter 62 across the display to the light sensor 64 may comprise light pipes 72 .
Referring to FIG. 6 , a bottom-emitting OLED display device with an integrated optical touch screen according to another embodiment of the present invention includes a rectangular substrate 42 with an encapsulating cover 44 . Located on the substrate is an OLED display 60 including electrodes and multiple layers of materials such as hole-injection layers and electron transport layers as is well known in the art (not shown). Light 49 emitted from the display passes directly through the substrate 42 or is reflected from the encapsulating cover 44 and passes through the substrate 42 .
Because the present invention does not require a separate frame or substrate for the touch screen, it reduces the weight, size (thickness), and cost of a combined touch screen and OLED display device.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
42 substrate
44 encapsulating cover
49 emitted light
60 OLED display
62 light emitter
64 light sensor
66 mirror
70 enclosure
72 light pipe | An OLED display and touch screen system includes a substrate; an OLED display including an array of individually addressable OLEDs formed on the substrate; and a touch screen including an OLED light emitter formed on the substrate the OLED light emitter defining an optical cavity for reducing the angle of emission of light from the OLED light emitter and a light sensor formed on the substrate across the display from the OLED light emitter, and optics located around the display above the OLED light emitter and the light sensor for directing light emitted from the OLED light emitter across the display to the light sensor. | 7 |
COPYRIGHT NOTICE
[0001] ©2007 Electro Scientific Industries, Inc. A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR §1.71(d).
TECHNICAL FIELD
[0002] The present disclosure relates to specimen processing systems and, in particular, to stage architecture for control of two- or three-dimensional positioning of a processing device relative to a target specimen.
BACKGROUND INFORMATION
[0003] Wafer transport systems configured for use in semiconductor wafer-level processing typically include a stage having a chuck that secures the wafer for processing. Sometimes the stage is stationary, and sometimes it is moveable. Some applications require that the stage move linearly in one, two, or three Cartesian dimensions, with or without rotation. The speed of the stage motion can dictate the throughput of the entire wafer processing platform if a significant amount of the total process time is spent aligning and transporting the wafer.
[0004] For applications including optical processing, a moveable optics assembly can be mounted above the wafer surface, thereby minimizing the wafer transport distances required. The primary direction of stage motion is referred to as the “major axis,” and the direction of stage motion perpendicular to the primary direction is referred to as the “minor axis.” The chuck holding the wafer, or specimen, to be processed may be mounted to a major axis stage for movement along the major axis, a minor axis stage for movement along the minor axis, or in stationary position below the major and minor axes. The major axis stage may support the minor axis stage, or they may be independent of each other.
[0005] Stage design of such optical systems is becoming more critical as electrical circuit dimensions shrink. One stage design consideration is the impact of process quality stemming from vibrational and thermal stability of the wafer chuck and optics assembly. In the case in which the laser beam position is continually adjusted, state-of-the-art structures supporting the laser assembly are too flexible to maintain the required level of precision. Moreover, as circuit dimensions shrink, particle contamination becomes of greater concern.
SUMMARY OF THE DISCLOSURE
[0006] A “split axis stage” architecture is implemented as a multiple stage positioning system that, in a preferred embodiment, supports a laser optics assembly and a workpiece having a surface on which a laser beam is incident for laser processing. The multiple stage positioning system is capable of vibrationally and thermally stable material transport at high speed and rates of acceleration. A “split axis” design decouples driven stage motion along two perpendicular axes lying in separate, parallel planes. In a preferred embodiment, motion in the horizontal plane is split between a specimen (major axis or lower) stage and a scan optics assembly (minor axis or upper) stage that move orthogonally relative to each other.
[0007] A dimensionally stable substrate in the form of a granite, or other stone slab, or a slab of ceramic material, cast iron, or polymer composite material such as Anocast™, is used as the base for the lower and upper stages. The slab and the stages are preferably fabricated from materials with similar coefficients of thermal expansion to cause the system to advantageously react to temperature changes in a coherent fashion. The substrate is precisely cut (“lapped”) such that portions of its upper and lower stage surfaces are flat and parallel to each other. In a preferred embodiment, a lower guide track assembly that guides a lower stage carrying a specimen-holding chuck is coupled to a lower surface of the substrate. An upper guide track assembly that guides an upper stage carrying a laser beam focal region control subsystem is coupled to an upper surface of the substrate. Linear motors positioned along adjacent rails of the guide track assemblies control the movements of the lower and upper stages.
[0008] The massive and structurally stiff substrate isolates and stabilizes the motions of the laser optics assembly and the specimen, absorbs vibrations, and allows for smoother acceleration and deceleration because the supporting structure is inherently rigid. The stiffness of the substrate and close separation of the stage motion axes result in higher frequency resonances, and less error in motion along all three axes. The substrate also provides thermal stability by acting as a heat sink. Moreover, because it is designed in a compact configuration, the system is composed of less material and is, therefore, less susceptible to expansion when it undergoes heating. An oval slot cut out of the middle of the substrate exposes the specimen below to the laser beam and allows for vertical motion of the laser optics assembly through the substrate. Otherwise, the specimen is shielded by the substrate from particles generated by overhead motion, except for the localized region undergoing laser processing.
[0009] A laser beam focal region control subsystem is supported above the lower stage and includes a vertically adjustable optics assembly positioned within a rigid air bearing sleeve mounted to the upper stage by a support structure. The rigidity of the support structure allows for faster and more accurate vertical motion along the beam axis. The inner surface of the sleeve acts as an outer race, and the outer surface of the lens acts as an inner race, thus forming an air bearing guiding the vertical motion of the focal region of the laser beam. Vertical motion is initiated by a lens forcer residing at the top end of the sleeve, which imparts a motive force to the optics assembly to adjust its height relative to the workpiece on the lower chuck, and in so doing, adjusts the focal region of the laser relative to the work surface. An isolation flexure device, rigid along the beam axis and compliant in the horizontal plane, buffers excess motion of the lens forcer from the optics assembly.
[0010] The split axis stage design is applicable to many platforms used in semiconductor processing including dicing, component trim, fuse processing, inking, printed wire board (PWB) via drilling, routing, inspection, and metrology. The advantages afforded by such a design are also of benefit to a whole class of mechanical machining tools.
[0011] Additional aspects and advantages will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an isometric view of a decoupled, multiple stage positioning system.
[0013] FIG. 2 is a partly exploded isometric view of the positioning system of FIG. 1 , showing upper and lower stages that, when the system is assembled, are mounted to a dimensionally stable substrate such as a stone slab.
[0014] FIG. 3 is an isometric view of the positioning system of FIG. 1 , showing the upper stage supporting a scan lens and upper stage drive components.
[0015] FIG. 4 is an isometric view of the positioning system of FIG. 1 , showing the lower stage supporting a specimen-holding chuck and lower stage drive components.
[0016] FIGS. 5A , 5 B, and 5 C are diagrams showing alternative guide track assembly configurations for moving one or both of the upper and lower stages of the positioning system of FIGS. 1-4 .
[0017] FIG. 6 is an exploded view of a preferred embodiment of a laser beam focal region control subsystem that includes an air bearing sleeve assembly housing a scan lens and guiding its vertical (Z-axis) motion.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] FIGS. 1 and 2 show a decoupled, multiple stage positioning system 10 , which, in a preferred embodiment, supports components of a laser processing system through which a laser beam propagates for incidence on a target specimen. Positioning system 10 includes a dimensionally stable substrate 12 made of a stone slab, preferably formed of granite, or a slab of ceramic material, cast iron, or polymer composite material such as Anocast™. Substrate 12 has a first or upper flat major surface 14 and a second or lower flat major surface 16 that has a stepped recess 18 . Major surfaces 14 and 16 include surface portions that are plane parallel to each other and conditioned to exhibit flatness and parallelism within about a ten micron tolerance.
[0019] A surface portion of upper major surface 14 and a first guide track assembly 20 are coupled to guide movement of a laser optics assembly stage 22 along a first axis, and a surface portion of lower major surface 16 and a second guide track assembly 24 are coupled to guide movement of a specimen stage 26 along a second axis that is transverse to the first axis. Optics assembly stage 22 supports a laser beam focal region control subsystem 28 , which includes a scan lens 30 that depends downwardly below lower major surface 16 of substrate 12 . Specimen stage 26 supports a specimen-holding chuck 32 . The guided motions of stages 22 and 26 move scan lens 30 relative to laser beam processing locations on a surface of a specimen (not shown) held by chuck 32 .
[0020] In a preferred implementation, substrate 12 is set in place so that major surfaces 14 and 16 define spaced-apart horizontal planes and guide track assemblies 20 and 24 are positioned so that the first and second axes are perpendicular to each other and thereby define respective Y- and X-axes. This split axis architecture decouples motion along the X- and Y-axes, simplifying control of positioning the laser beam and chuck 32 , with fewer degrees of freedom allowed.
[0021] FIG. 3 shows in detail optics assembly stage 22 , which operates with first guide track assembly 20 shown in FIG. 2 . First guide track assembly 20 includes two spaced-apart guide rails 40 secured to support portions of upper major surface 14 and two U-shaped guide blocks 42 supported on a bottom surface 44 of optics assembly stage 22 . Each one of guide blocks 42 fits over and slides along a corresponding one of rails 40 in response to an applied motive force. A motor drive for optics assembly stage 22 includes a linear motor 46 that is mounted on upper major surface 14 and along the length of each guide rail 40 . Linear motor 46 imparts the motive force to propel its corresponding guide block 42 for sliding movement along its corresponding guide rail 40 . Each linear motor 46 includes a U-channel magnet track 48 that holds spaced-apart linear arrays of multiple magnets 50 arranged along the length of guide rail 40 . A forcer coil assembly 52 positioned between the linear arrays of magnets 50 is connected to bottom surface 44 of optics assembly stage 22 and constitutes the movable member of linear motor 46 that moves optics assembly stage 22 . A suitable linear motor 46 is a Model MTH480, available from Aerotech, Inc., Pittsburgh, Pa.
[0022] Each rail guide 40 —guide block 42 pair of first guide track assembly 20 shown in FIG. 2 is a rolling element bearing assembly. Alternatives for guide track assembly 20 include a flat air bearing or a vacuum preloaded air bearing. Use of either type of air bearing entails removal of each guide rail 40 , exposing the surface portions of upper surface 14 to form guide surfaces, and substitution for each guide block 42 the guide surface or bearing face of the bearing, which is attached to bottom surface 44 of laser optics assembly stage 22 . Vacuum preloaded air bearings, which have a pressure port and a vacuum port, hold themselves down and lift themselves off the guide surface at the same time. Use of vacuum preloaded air bearings needs only one flat guide surface; whereas use of opposed bearing preloading needs two flat, parallel guide surfaces. Suitable air bearings are available from New Way Machine Components, Inc., Aston, Pa. Thus, depending on the type of guide track assembly used, surface portions of upper major surface 14 may represent a guide rail mounting contact surface or a bearing face noncontacting guide surface.
[0023] A pair of encoder heads 60 secured to bottom surface 44 of optics assembly stage 22 and positioned adjacent different ones of guide blocks 42 includes position sensors that measure yaw angle and distance traveled of optics assembly stage 22 . Placement of the position sensors in proximity to guide rails 40 , guide blocks 42 , and linear motors 46 driving each of stages 22 and 26 ensures efficient, closed-loop feedback control with minimal resonance effects. A pair of stop members 62 limits the travel distance of guide blocks 42 in response to limit switches included in encoder heads 60 that are tripped by a magnet (not shown) attached to substrate 12 . A pair of dashpots 64 dampen and stop the motion of optics assembly stage 22 to prevent it from overtravel movement off of guide rails 40 .
[0024] An oval slot 66 formed in substrate 12 between and along the lengths of guide rails 40 provides an opening within which scan lens 30 can travel as optics assembly stage 22 moves along guide rails 40 . A pair of through holes 68 formed in the region of stepped recess 18 in substrate 12 provides operator service access from upper surface 14 to encoder heads 60 to maintain their alignment.
[0025] FIG. 4 shows in detail specimen stage 26 in operative association with second guide track assembly 24 of FIG. 2 . Second guide track assembly 24 includes guide rails, U-shaped guide blocks, linear motors, U-channel magnet tracks, magnets, forcer coil assemblies, and encoder heads that correspond to and are identified by the same reference numerals as those described above in connection with first guide track assembly 20 . Linear motors 46 and the components of and components supported by second guide track assembly 24 are mounted on a surface 70 of a specimen stage bed 72 .
[0026] The mechanical arrangement of stages 22 and 26 and motors 46 results in reduced pitch and roll of stages 22 and 26 , and enhances accuracy of high velocity motion. Symmetric placement of motors 46 on opposite sides of stages 22 and 26 improves control of yaw. The placement of motors 46 along the sides of stages 22 and 26 , as opposed to underneath them, minimizes thermal disturbance of critical components and position sensors.
[0027] Second guide track assembly 24 and specimen stage 26 supporting chuck 32 fits into and is secured within stepped recess 18 . Surface 70 of specimen stage bed 72 is secured against a surface portion 74 of lower major surface 16 adjacent the wider, lower portion of stepped recess 18 , and chuck 32 is positioned below the innermost portion of stepped recess 18 of lower major surface 16 and moves beneath it in response to the motive force imparted by linear motors 46 moving specimen stage 26 along second guide track assembly 24 . A pair of stop members 76 limits the travel distance of guide blocks 42 in response to limit switches included in encoder heads 60 that are tripped by a magnet (not shown) attached to substrate 12 . A pair of dashpots 78 dampen and stop the motion of specimen stage 26 to prevent it from overtravel movement off of guide rails 40 .
[0028] A first alternative to guide track assembly 24 is a magnetic preloaded air bearing using specimen stage bed 72 as a bearing land or guideway. Use of a magnetic preloaded air bearing entails removal of each guide rail 40 , exposing the surface portions of specimen stage bed 72 , and the removal of each guide block 42 , providing on the bottom surface of specimen stage 26 space for mounting the air bearing with its (porous) bearing face positioned opposite the exposed surface portion.
[0029] FIG. 5A is a schematic diagram showing the placement of two magnetic preloaded air bearings 100 in the this first alternative arrangement. A steel plate, or steel laminate structure 102 , is fixed on surface 70 in the space between and along the lengths of forcer coil assemblies 52 . Two spaced-apart flat air bearings 100 are fixed to corresponding surface portions 104 of a bottom surface 106 of specimen stage 26 and run along the lengths of linear motors 46 . A suitable air bearing is a silicon carbide porous media flat bearing series Part No. S1xxxxx, available from New Way Machine Components, Inc., Aston, Pa. A sheet magnet 108 is positioned in the space between air bearings 100 on bottom surface 106 of specimen stage 26 and spatially aligned with steel plate 102 so that the exposed surfaces of magnet 108 and steel plate 102 confront each other. The magnetic force of attraction urges sheet magnet 108 downwardly toward steel plate or steel laminate 102 as indicated by the downward pointing arrow in FIG. 5A , and the net force of air bearings 100 urges specimen stage 26 upwardly away from surface 70 from specimen stage bed 72 , as indicated by two parallel upward pointing arrows in FIG. 5A . The simultaneous application of opposed magnetic force and pressurized air creates a thin film of air in spaces 110 between (porous) bearing faces 112 of air bearings 100 and bearing guideways 114 on surface 70 . The lift force of air bearings 100 equals twice the sum of the weight of specimen stage 26 and the magnetic force of magnet 108 . Linear motors 46 impart the motive force that results in nearly zero friction motion of specimen stage 26 along the lengths of bearing guideways 114 .
[0030] A second alternative to guide track assembly 24 is a vacuum preloaded air bearing using specimen stage bed 72 as a bearing land or guideway. Similar to the above-described first alternative to guide track assembly 20 , use of a vacuum preloaded air bearing entails removal of each guide rail 40 , exposing surface portion 114 of specimen stage bed 72 , and the removal of each guide block 42 , providing on bottom surface 106 of specimen stage 26 space for mounting the vacuum loaded air bearing, with its pressure land positioned opposite exposed surface portion 114 .
[0031] FIG. 5B is a schematic diagram showing the placement of two vacuum preloaded air bearings 120 in the second alternative arrangement. Two spaced-apart vacuum preloaded air bearings 120 are fixed to corresponding surface portions 104 of bottom surface 106 of specimen stage 26 and run along the lengths of linear motors 46 . A suitable air bearing is a vacuum preloaded air bearing series Part No. S20xxxx, available from New Way Machine Components, Inc., Aston, Pa. Vacuum preloaded bearings 120 simultaneously hold themselves down and lift themselves off bearing guideways 114 on surface 70 . Each vacuum preloaded bearing 120 has a pressure land that is divided into spaced-apart land portions 122 a and 122 b . A vacuum area 124 is located between land portions 122 a and 122 b . The simultaneous application and distribution of air pressure and vacuum pressure creates a thin film of air in spaces 126 between pressure land portions 122 a and 122 b of vacuum preloaded air bearings 120 and bearing guideways 114 on surface 70 . Linear motors 46 impart the motive force that results in nearly zero friction motion of specimen stage 26 along the lengths of the bearing guideways 114 .
[0032] A third alternative to guide track assembly 24 entails the use of either a magnetic preloaded air bearing of the first alternative, or a vacuum preloaded air bearing of the second alternative in the absence of specimen stage bed 72 , as well as each guide rail 40 and each guide block 42 .
[0033] FIG. 5C is a schematic diagram showing specimen stage 26 riding on magnetic preloaded air bearings or vacuum preloaded air bearings 140 along bottom surface 142 of substrate 12 . When substrate 12 is in a horizontal disposition, magnetic preloaded or vacuum preloaded air bearings 140 develop sufficient force to overcome the gravitational force on specimen stage 26 as it rides along bottom surface 142 . Skilled persons will appreciate that laser optics assembly stage 22 can similarly be adapted to ride on magnetic preloaded air bearings or vacuum preloaded air bearings along upper major surface 14 of substrate 12 . The stage configuration can use mechanical linear guides in place of the air bearings described above. Other devices for measuring position, such as interferometers, can be implemented in this positioning system design.
[0034] The mass of substrate 12 is sufficient to decouple the mass of optics assembly stage 22 and the mass of specimen stage 26 , including the specimen mounted on it, so that the guided motion of one of stages 22 and 26 contributes a negligible motive force to the other one of them. The masses of stages 22 and 26 moving along the X- and Y-axes are low, and thereby allow high acceleration and high velocity processing and limit heat generation in linear motors 46 . Because the center of mass of the laser beam focal region control subsystem 28 is aligned with the center of mass of optics assembly stage 22 , perturbations in the motion of optics assembly stage 22 are minimized.
[0035] Laser optics assembly stage 22 has an opening 200 that receives control subsystem 28 , which includes an air bearing assembly 202 containing scan lens 30 . Control subsystem 28 controls the axial position of a laser beam focal region formed by scan lens 30 as the laser beam propagates generally along a beam axis 206 , which is the optic axis of scan lens 30 , and through scan lens 30 for incidence on a work surface of a target specimen supported on specimen stage 26 .
[0036] FIG. 6 shows in greater detail the components of control subsystem 28 and its mounting on laser optics assembly stage 22 . With reference to FIG. 6 , control subsystem 28 includes a lens forcer assembly 210 that is coupled by a yoke assembly 212 to scan lens 30 contained in the interior of an air bushing 214 of air bearing assembly 202 . A suitable air bushing is Part No. S307501, available from New Way Machine Components, Inc., Aston, Pa. Lens forcer assembly 210 , which is preferably a voice coil actuator, imparts by way of yoke assembly 212 a motive force that moves scan lens 30 and thereby the focal region of the laser beam to selected positions along beam axis 206 .
[0037] Voice coil actuator 210 includes a generally cylindrical housing 230 and an annular coil 232 formed of a magnetic core around which copper wire is wound. Cylindrical housing 230 and annular coil 232 are coaxially aligned, and annular coil 232 moves axially in and out of housing 230 in response to control signals (not shown) applied to voice coil actuator 210 . A preferred voice coil device 210 is an Actuator No. LA 28-22-006 Z, available from BEI Kimco Magnetics, Vista, Calif.
[0038] Annular coil 232 extends through a generally circular opening 234 in a voice coil bridge 236 having opposite side members 238 that rest on uprights 240 ( FIG. 1 ) mounted on laser optics assembly stage 22 to provide support for laser beam focal region control subsystem 28 . Voice coil bridge 236 includes in each of two opposite side projections 242 a hole 244 containing a tubular housing 250 through which passes a rod 252 extending from an upper surface 254 of a guiding mount 256 . Each rod 252 has a free end 258 . Guiding mount 256 has on its upper surface 254 an annular pedestal 260 on which annular coil 232 rests. Two stacked, axially aligned linear ball bushings 264 fit in tubular housing 250 contained in each hole 244 of side projections 242 of voice coil bridge 236 . Free ends 258 of rods 252 passing through ball bushings 264 are capped by rod clamps 266 to provide a hard stop of lower travel limit of annular coil 232 along beam axis 206 .
[0039] Housing 230 has a circular opening 270 that is positioned in coaxial alignment with the center of annular coil 232 , opening 234 of voice coil bridge 236 , and the center of annular pedestal 260 of guiding mount 256 . A hollow steel shaft 272 extends through opening 270 of housing 230 , and a hexagonal nut 274 connects in axial alignment hollow steel shaft 272 and a flexible tubular steel member 276 , which is coupled to yoke assembly 212 as further described below. Hexagonal nut 274 is positioned in contact with a lower surface 278 of annular coil 232 to drive flexible steel member 276 along a drive or Z-axis 280 in response to the in-and-out axial movement of annular coil 232 . Hollow steel shaft 272 passes through the center and along the axis of a coil spring 282 , which is confined between a top surface 284 of housing 230 and a cylindrical spring retainer 286 fixed at a free end 290 of hollow steel shaft 272 . Coil spring 282 biases annular coil 232 to a mid-point of its stroke along Z-axis 280 in the absence of a control signal applied to voice coil actuator 210 .
[0040] Yoke assembly 212 includes opposed yoke side plates 300 (only one shown) secured at one end 302 to a surface 304 of a yoke ring 306 and at the other end 308 to a multilevel rectangular yoke mount 310 . Scan lens 30 formed with a cylindrical periphery 312 and having an annular top flange 314 fits in yoke assembly 212 so that top flange 314 rests on surface 304 of yoke ring 306 . Scan lens 30 contained in the interior of air bushing 214 forms the inner race of air bearing assembly 202 , and an inner surface 316 of air bushing 214 forms the outer race of air bearing assembly 202 . The implementation of air bearing assembly 202 increases the rigidity of scan lens 30 in the X-Y plane but allows scan lens 30 to move along the Z-axis in a very smooth, controlled manner.
[0041] Flexible steel member 276 has a free end 320 that fits in a recess 322 in an upper surface 324 of yoke mount 310 to move it along Z-axis 280 and thereby move scan lens 30 along beam axis 206 . An encoder head mount 326 holding an encoder 328 and attached to voice coil bridge 236 cooperates with an encoder body mount 330 holding an encoder scale and attached to guiding mount 256 to measure, using light diffraction principles, the displacement of guiding mount 256 relative to voice coil bridge 236 in response to the movement of annular coil 232 . Because flexible tubular steel member 276 is attached to annular coil 232 , the displacement measured represents the position of scan lens 30 along beam axis 206 .
[0042] A quarter-waveplate 340 secured in place on a mounting ring 342 is positioned between a lower surface 344 of rectangular yoke mount 310 and top flange 314 of scan lens 30 . A beam deflection device 346 , such as a piezoelectric fast steering mirror, attached to optics assembly stage 22 ( FIG. 3 ) is positioned between rectangular yoke mount 310 and quarter-waveplate 340 . Fast steering mirror 346 receives an incoming laser beam 348 propagating along beam axis 206 and directs laser beam 348 through quarter-waveplate 340 and scan lens 30 . Quarter-waveplate 340 imparts circular polarization to the incoming linearly polarized laser beam, and fast steering mirror 346 directs the circularly polarized laser beam for incidence on selected locations of the work surface of a target specimen supported on specimen stage 26 . When fast steering mirror 346 is in its neutral position, Z-axis 280 , beam axis 206 , and the propagation path of laser beam 348 are collinear. When fast steering mirror 346 is in operation, the propagation path of laser beam 348 is generally aligned with beam axis 206 .
[0043] Flexible steel member 276 is rigid in the Z-axis direction but is compliant in the X-Y plane. These properties of flexible steel member 276 enable it to function as a buffer, isolating the guiding action of air bearing assembly 202 containing scan lens 30 from the guiding action of lens forcer assembly 210 that moves scan lens 30 .
[0044] Lens forcer assembly 210 and air bearing assembly 202 have centers of gravity and are positioned along the Z-axis. Voice coil bridge 236 of lens forcer assembly 210 has two depressions 350 , the depths and cross sectional areas of which can be sized to achieve the axial alignment of the two centers of gravity. Such center of gravity alignment eliminates moment arms in control system 28 and thereby helps reduce propensity of low resonant frequency vibrations present in prior art cantilever beam designs.
[0045] Several examples of possible types of laser processing systems in which positioning system 10 can be installed include semiconductor wafer or other specimen micromachining, dicing, and fuse processing systems. In a wafer dicing system, laser beam 348 moves along scribe locations on the wafer surface. In a wafer fuse processing system, a pulsed laser beam 348 moves relative to wafer surface locations of fuses to irradiate them such that the laser pulses either partly or completely remove fuse material.
[0046] It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims. | A split axis stage architecture is implemented as a multiple stage positioning system that is capable of vibrationally and thermally stable material transport at high speed and rates of acceleration. A split axis design decouples stage motion along two perpendicular axes lying in separate, parallel planes. A dimensionally stable substrate in the form of a granite, or other stone slab, or of ceramic material or cast iron, is used as the base for lower and upper stages. The substrate is precisely cut (“lapped”) such that its upper and lower stage surface portions are flat and parallel to each other. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to a lighting apparatus and mounting assembly for mobile vehicles, and more particularly to a pivotable light apparatus with light emitting diodes (LEDs), integral USB charger and universal mounting assembly which is mountable in various configurations of a mobile vehicle including the method of illuminating, making and operating the same.
[0002] The primary purpose of a light assembly on mobile vehicles such as bicycles is to provide illumination and conspicuity for the cyclist. Light assemblies aid the cyclist in seeing the road ahead of them at times of day and night when there is not enough ambient light to safely ride a bicycle and also allow the cyclist to be seen by oncoming motorists.
[0003] In the prior art, light assemblies have used a single beam of light, which limited the field of vision due to the small size of the single beam of light. For cyclists riding at night, particularly at higher speeds, it is advantageous to have more light and a wider-angle beam than that of a single beam.
[0004] Another disadvantage of the prior art was the difficulty of charging the power supply to the light assembly. The cyclist would have to carry spare batteries as a backup in case of power loss.
[0005] Another important feature in light assemblies is the ease with which the apparatus can be mounted and dismounted on a mobile vehicle, such as a bicycle. This is often necessary when a cyclist has two or more bicycles and does not want to purchase a dedicated light for each bike or if the cyclist wants to remove only the light assembly from the bike for example due to fear of theft of the light assembly.
[0006] Therefore it is desirable to provide a pivotable LED light apparatus with light emitting diodes, integral battery charger and a universal mounting assembly which is mountable in various configurations of a mobile vehicle, as provided by the present invention.
SUMMARY OF THE INVENTION
[0007] The present invention provides a lighting apparatus usable with a mobile vehicle such as a bicycle. In one embodiment, the lighting apparatus includes a first housing, which includes a power source such as rechargeable batteries and a switch mechanism. A second housing is also included which is comprised of light emitting elements such as LEDs. The advantages of LEDs are their smaller size and weight, increased power efficiency, durability, longer life and instant on-off capability. The limitation is that the LEDs provide stationary beams and the cyclist could not easily manipulate the emitting angle of the resultant beam. However, the housings in the present invention are connected by a pivoting mechanism, which allows relative movement between the two housings and permits electrical communication between the light emitting diodes and the batteries. The pivoting mechanism allows the lighting apparatus to provide illumination at different emission angles. The switch mechanism further allows for multiple configurations of the LEDs. The LEDs may be selected to all turn on; all turn off, turn on in a predesignated configuration or turn on in a sequential or nonsequential flashing mode.
[0008] The first housing also includes an integral charging port in order to recharge the batteries. The USB charger is integrated into the unit, and therefore obviates the need to externally couple the charger with the light assembly in order to charge the batteries.
[0009] According to one aspect of the present invention, the lighting apparatus is adapted to a universal mounting assembly. The mounting assembly may be interchangeably attached and detached on different bicycles or on different mounting positions on a particular bike. In the prior art, one disadvantage was that each mount was specific to one specific diameter of handlebar due to the fastener assembly. The problem was that the mount was not adaptable to be used in different configurations: on the top or bottom of the handlebars or on the stem. The mounting assembly of the present invention comprises of a polymeric fastener, such as a TPE or rubber strap for example. In one embodiment, various sizes of straps are provided in order to properly fit various sizes of bicycle stems and handlebars. Alternatively, the fastener can be a universal strap with cutouts in preconfigured locations to allow the mounting assembly to be sized to fit various configurations of a mobile vehicle. In the prior art, the fasteners were often cumbersome to use and required additional accessories like screwdrivers to affix the fastener to the bike. The mounting assembly of the present invention requires no additional tools and improves the ease of attaching and detatching the mounting assembly from a mobile vehicle.
[0010] In another embodiment of the present invention, a lighting apparatus is configured to be used on a mobile vehicle, which includes a first housing including a first weatherproof chamber enclosed by an upper horizontal surface, a lower horizontal surface, a rear vertical surface, a front surface, and two side surfaces; one or more rechargeable lithium ion batteries placed inside said first weatherproof chamber; a switch on the first housing that may be placed at the upper horizontal surface; an integral charging port on the first housing that may be placed at the rear vertical surface for recharging said batteries; a pedestal located on the lower horizontal surface; a second housing including a second weatherproof chamber, a front vertical surface, a rear faceted surface, and two elongated side arms extending rearward, wherein each arm has an inside face; two or more LEDs placed inside said second weatherproof chamber, each light emitting diode capable of emitting up to at least 180 lumens; wherein said switch controls electrical input from said batteries to said LEDs; a transparent window on the front vertical surface of the second housing; a pivoting mechanism that connects and allows relative pivotal movement between the first and second housings, wherein said second housing is adjustable to pivot in angles from 25 degrees vertically above to 25 degrees vertically below the horizontal axis of the lighting apparatus; and a universal mounting apparatus for detachably attaching to said pedestal and to the mobile vehicle.
[0011] In an aspect of the embodiment, the switch is a push-button switch with a weatherproof cover. In another aspect of the embodiment, the two or more LEDs are capable of operating in a mode selected from the group consisting of: all off, one LED on, two LEDs on, all LEDs on, and a flashing day time mode. In a further aspect of the embodiment, the two or more LEDs are powered on non-simultaneously in the flashing daytime mode. For example, the LEDs can light sequentially or randomly at predetermined intervals, e.g. LEDs emit light every 0.75 seconds. In a yet further aspect of the embodiment, the pedestal is adapted for attaching to the universal mounting apparatus. In another aspect, the pedestal comprises a rectangular column, a first end of said rectangular column attaches to the lower horizontal surface of the first housing, a second end of said rectangular column extends outward to form a base plate, wherein said column has a square cross section. In another variation of the embodiment, the charging port comprises a micro USB port with a flexible cover. In another aspect, the embodiment includes a means for fastening the universal mounting apparatus to the mobile vehicle. In certain aspects, the means for fastening comprises a rubber strap. In certain other aspects, the rubber strap is selected from the group consisting of a small strap, a medium strap and a large strap. In another configuration of the embodiment, the first and second housings are formed of a fusion sealed rigid material. In other aspects of the embodiment, the first housing has a substantially rectangular horizontal cross section that tapers from the front to the rear, wherein a receiving aperture is formed on the front end of each side surface, wherein the front surface has an outwardly concaved contour. In certain aspects, the two side arms of the second housing envelop the first housing, wherein there is a pivot pin on the inside face of each arm, wherein said pivot pins engage the receiving apertures on the first housing. In other aspects, the pivot pins have a hollow tubular structure for conducting electrical wires between the first housing and the second housing. In certain other aspects, a friction device is fitted over each pivot pin to maintain friction between the first and second housings, such as a torque O ring. In another aspect of the embodiment, the lighting apparatus is adapted to be used on a bicycle.
[0012] In another embodiment, a lighting apparatus configured for use on a mobile vehicle includes a universal mounting assembly for interchangeably attaching to a mobile vehicle in one or more mounting configurations. The universal mounting assembly includes a channel assembly with a substantially rectangular rigid body for engaging a pedestal, said channel assembly including: a recess at the upper surface of the channel assembly bound by a front wall, two side walls, and a bottom plane, wherein the rear of the recess is open, wherein said two side walls are perpendicular to the front wall, wherein each side wall has a rim that forms a groove inside the recess, a knob protruding on the front face of the channel assembly, two parallel raised tabs on a bottom surface of the channel assembly, a rear lower wall on the bottom surface of the channel assembly, said rear lower wall including a substantially rectangular window; a rubber strap member including a back end block, a middle strap portion, and a front-end block, wherein an elongated cutout extends from the middle strap portion to the front-end block; wherein the middle strap portion is adapted to pass through the substantially rectangular window; wherein the elongated cutout is adapted to engage with the knob on the front face of the channel assembly.
[0013] In another aspect of the embodiment, the front end block of the strap member is about the same as thick as the middle strap portion, is a little over twice as wide as the center strap portion, and has a rounded curvature on the peripheral of the front end block, and wherein the back end block is wider and thicker than the center strap portion, includes two slits on a first surface for fitting on the two parallel raised tabs on the bottom surface of the channel assembly, and is curved on a second surface for fitting on a tubular object. In certain aspects, the bottom plane includes a cutout tab formed between two parallel cutouts, said cutout tab having a raised notch at the rear opening of the recess, said cutout tab extends outside of the recess forming a finger tab.
[0014] In a further embodiment, a method of illuminating a mobile vehicle includes the steps of: providing a first housing comprising one or more lithium ion rechargeable batteries, wherein said first housing comprises an integral charging port for recharging said batteries; providing a second housing comprising two or more LEDs each capable of outputting at least 180 lumens; controlling electrical input from said batteries to said LEDs using a switch on said first housing for; and pivoting said second housing relative to said first housing a pivotal mechanism to provide illumination at different emission angles. In another aspect of the embodiment, the first housing comprises a pedestal for attaching to a mounting apparatus. In certain aspects, the embodiment further includes providing a translucent window on a forward vertical surface of the second housing. In other aspects, the first and second housings are formed of a rigid material. In certain other aspects, three LEDs are provided. In further aspects, the three LEDs are capable of being independently controlled. In another aspect of the embodiment, the switch is a push-button switch. In various aspects, the mobile vehicle is a bicycle.
[0015] In yet a further embodiment, a method of making a lighting apparatus configured for use on a mobile vehicle includes the following steps in any order: making a first housing including a first weatherproof chamber enclosed by an upper horizontal surface, a lower horizontal surface, a rear vertical surface, a front surface, and two side surfaces; installing one or more rechargeable lithium ion batteries placed inside said first weatherproof chamber; providing an integral charging port on said first housing, e.g., on the rear vertical surface capable of recharging said batteries; providing a pedestal on the lower horizontal surface; positioning a switch on the first housing, e.g., on the upper horizontal surface; making a second housing including a second weatherproof chamber and a front vertical surface; providing a transparent window on the front vertical surface of the second housing; installing two or more LEDs inside said second weatherproof chamber, each light emitting diode capable of emitting up to at least 180 lumens; connecting the first housing and the second housing via a pivoting mechanism that allows relative pivotal movement between the first and second housings, wherein said second housing is adjustable to pivot in angles from 25 degrees vertically above to 25 degrees vertically below the horizontal axis of the lighting apparatus; and providing a universal mounting apparatus for detachably attaching said pedestal and to the mobile vehicle.
[0016] In another aspect of the embodiment, the switch controls electrical input from said batteries to said diodes. In certain other aspects of the embodiment, the switch is a push on-off switch. In another variation of the embodiment, the pedestal is adapted for slidably attaching to the universal mounting apparatus. In yet another aspect, the embodiment further includes a means for fastening the universal mounting apparatus to the mobile vehicle. In a further aspect, the means for fastening comprises a polymeric strap, such as a rubber strap. In another variation of the embodiment, the rubber strap is selected from the group consisting of a small strap, a medium strap and a large strap. In other aspects of the embodiment, the first and second housings are formed of a fusion sealed rigid material. In other configurations of the embodiments, the pivoting mechanism comprises a friction device, such as a torque O-ring to maintain the second housing at a predetermined configuration. In a further aspect of the embodiment, the three LEDs are capable of operating sequentially. In a yet further aspect, the method includes a flashing daytime mode capable of emitting 180 lumens every 0.75 seconds. In various aspects, the lighting apparatus is adapted to be used on a bicycle.
[0017] According to another embodiment, a method of operating a lighting apparatus includes the following steps: charging the lighting apparatus, wherein said lighting apparatus includes a first housing including the electrical switch, one or more rechargeable batteries, and a charging outlet, a second housing including two or more LEDs, and a pivot mechanism connecting the first housing and the second housing and allowing the first housing to pivot against the second housing, wherein at least one of said LEDs is equipped with a narrow angle beam reflector, and at least one of said LEDs is equipped with a wide angle beam reflector; turning on said light apparatus by actuating an electrical switch causing electrical power to be supplied to all of one or more LED to output light with a total light output of up to 540 lumens or more. Depending on the specification of the wide angle beam reflector, lighting pattern from said mobile device can create a wide angle beam wherein said angle is at least 30 degrees from the centerline of said one or more LED.
[0018] According to another aspect, the embodiment includes actuating said electrical switch so that only one of said LED emits light. In another aspect, actuating said electrical switch causes only two of said LED to emit light. In a further aspect, actuating said electrical switch causes the LEDs to emit light sequentially, one at a time, or two or more at a time. In a yet further aspect, the electrical switch is a push-button switch that is actuated by pushing the button to the desired configuration. In another aspect, the embodiment includes pivoting said second housing relative to said first housing up or down up to 25 degrees each direction. In yet another aspect, the embodiment includes attaching a universal mounting apparatus to a mobile vehicle, and attaching said lighting apparatus to said universal mounting apparatus.
[0019] In a further embodiment, a lighting apparatus configured for use on a mobile vehicle, comprises a first weatherproof housing including an electrical switch, one or more rechargeable batteries, and a charging outlet; a second weatherproof housing including more than one LED, wherein at least one of said LED is equipped with a narrow angle beam reflector, at least one of said LED is equipped with a wide angle beam reflector, and the combined light output capacity of the LED is at least 500 lumen; and a weatherproof pivot mechanism that connects the first housing and the second housing and allows the first housing to pivot against the second housing.
[0020] In another aspect of the embodiment, the lighting apparatus includes an electrical circuit so configured that by actuating said electrical switch the LED operate in various modes including: only one of said LED emits light, only two of said LEDs emit light, and all of said LEDs emit light at the same time. In yet another aspect of the embodiment, the lighting apparatus includes an electrical circuit so configured that by actuating said electrical switch the LED emits light sequentially. In a further aspect of the embodiment, the electrical switch is a push-button switch. In a yet further aspect of the embodiment, the pivot mechanism allows said second housing pivot relative to said first housing up or down up to 25 degrees in each direction. In another variation of the embodiment, the lighting apparatus further includes a universal mounting apparatus for attaching said lighting apparatus to a mobile vehicle. In yet another variation of the embodiment, the light apparatus is made to be used on a bicycle.
[0021] Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 illustrates a perspective side view of the lighting apparatus.
[0023] FIG. 2 illustrates a perspective rear view of the lighting apparatus.
[0024] FIG. 3 illustrates a perspective rear view of the universal mounting assembly.
[0025] FIG. 4 illustrates a perspective side view of the universal mounting assembly.
[0026] FIG. 5 illustrates a perspective front view of the universal mounting assembly.
[0027] FIG. 6 is a flow chart for a method of illuminating a mobile vehicle.
[0028] FIG. 7 is a flow chart for a method of making a lighting apparatus.
[0029] FIG. 8 is a flow chart for a method of operating a lighting apparatus.
[0030] FIG. 9 illustrates a perspective view from above showing the light emitting diodes including a narrow angle beam reflector and two wide-angle beam reflectors. The pivoting mechanism is also shown.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 shows one embodiment of the lighting apparatus ( 100 ) including a first housing 101 which houses rechargeable batteries, such as Li Ion batteries (not shown), and an integral charging port with a flexible cover 103 on a rear vertical surface 107 capable of recharging the batteries. A pedestal 104 is located on a lower horizontal surface 108 , for attaching to a universal mounting apparatus 105 . A second housing 106 is shown consisting of three 180 lumen light emitting diodes 114 (capable of emitting 180, 360 and 540 lumens), encased in a transparent window 109 on a forward vertical surface 110 and a pivoting mechanism 111 which allows relative pivotal movement between the first and second housings. The pivoting mechanism provides a maximum pivoting angle of 25 degrees vertically above and below the horizontal axis thereby allowing the user to select the desired emission angle of the light. A switch mechanism 112 on an upper horizontal surface 113 provides electrical input from said battery to said diodes, whereby illumination is provided.
[0032] In another aspect of the embodiment, the lighting apparatus is provided wherein the pedestal 104 comprises a slidable member on the lower horizontal surface 108 of the first housing. In other various aspects of the embodiment the slidable member of the pedestal 104 attaches to the mounting apparatus 105 to form a lighting apparatus assembly on a mobile device. In other certain aspects, the illuminated mobile device is a bicycle (not shown).
[0033] In another aspect of the embodiment, the lighting apparatus is provided wherein the mounting apparatus 105 further comprises a means for fastening (not shown) the mounting apparatus 105 to a mobile vehicle (not shown). In other various aspects of the embodiment, the means for fastening the mounting apparatus to the mobile device is a rubber strap coupled on a first end to a formed seat and on a second end to a formed tab. In certain aspects the rubber strap means for fastening and the slideable member means for fastening create a universal mounting device to the mobile device. In certain aspects the mobile device is a vehicle. In other various aspects the vehicle is a bicycle.
[0034] In another aspect of the embodiment, the lighting apparatus 100 is provided wherein the first 101 and second 106 housings are formed of a fusion sealed rigid material. In other various aspects of the embodiment, wherein the three LEDs 114 operate sequentially to provide varied light output. In another aspect of the embodiment, the switch mechanism 112 is a push on-off switch.
[0035] FIG. 2 shows the rear perspective view of the lighting apparatus ( 200 ) having a first housing 201 , connected to the second housing 206 by a pivoting mechanism 211 . The first housing includes an integral charging port 203 on the rear vertical surface 207 and a switch 212 . A universal mounting apparatus 205 is shown on the lower horizontal surface 208 of the first housing 201 .
[0036] In another embodiment as shown in FIG. 3 , a universal mounting assembly 310 is configured to a lighting apparatus (not shown) which is capable of being attached in one or more mobile device mounting configurations. In certain aspects of the embodiment, the universal mounting assembly 310 includes a channel assembly 311 capable of being rigidly coupled to a pedestal (not shown) of the lighting apparatus, wherein the pedestal slidably engages with a recess 312 in the channel assembly 311 . The recess 312 includes a bottom plane 313 , and a rear face 314 which is open. The bottom plane 313 includes a cutout tab 315 formed between two parallel cutouts, said cutout tab having a raised notch 316 at the rear opening of the recess 312 , said cutout tab extends outside of the recess forming a finger tab 317 . The channel assembly 311 includes a rear wall 319 having a cutout window 318 to engage a fastening means, such as a rubber strap member 321 . The rubber strap member 321 includes a first rubber strap end tab 322 , a middle strap portion 323 and a second rubber strap end cover 324 . wherein an elongated cutout extends from the middle strap portion 323 to the front-end block; wherein the middle strap portion 323 is adapted to pass through the substantially rectangular window 318 and wherein the elongated cutout is adapted to engage with a knob 320 on the front face of the channel assembly. In yet another aspect of the embodiment, the rubber strap is designed to accommodate various lengths and diameters, for example, small, medium, and large
[0037] FIG. 4 shows a side view of the universal mounting apparatus 410 , including a rubber strap member 421 having a first end 422 and a second end 424 . The first end 422 is engaged with the cutout window (not shown) at the rear wall of the universal mounting apparatus 410 . In one aspect of the embodiment, the front end of the rubber strap member 422 has a rounded curvature 425 , for fitting on a tubular object, such as a handlebar or stem of a mobile vehicle.
[0038] FIG. 5 shows another side view of the universal mounting apparatus 510 having a channel assembly with a recess 512 for engaging a pedestal (not shown). The mounting apparatus 510 includes a rubber strap member 521 with a first rubber strap end 522 and a second rubber strap end cover 524 which engages with the knob 520 to attach the mounting assembly to the mobile vehicle.
[0039] In a further embodiment, a method of illuminating a mobile vehicle 600 is shown in FIG. 6 and includes the steps of powering a lighting apparatus by using one or more lithium ion rechargeable batteries 610 , wherein said first housing comprises an integral charging port for recharging said batteries; providing a second housing including two or more LEDs 620 each capable of outputting at least 180 lumens; controlling electrical input from said batteries to said LEDs actuating a switch 630 on said first housing; and pivoting said second housing relative to said first housing a pivotal mechanism 640 to provide illumination at different emission angles. Charging can be achieved by connecting an external charger to the integral charging port 650 . The relative angle between the first housing and the second housing is maintained by friction between the two housings, which can be enhanced by using a friction ring. In another aspect of the embodiment, the first housing comprises a pedestal for attaching to a mounting apparatus. In certain aspects, the embodiment further includes providing a translucent window on a forward vertical surface of the second housing. In other aspects, the first and second housings are formed of a rigid material. In yet other aspects, three LEDs are provided. In a further aspect, the three LEDs are capable of being independently controlled. In another aspect of the embodiment, the switch is a push-button switch. In various aspects, the mobile vehicle is a bicycle.
[0040] In a yet further embodiment, a method of making a lighting apparatus configured for use on a mobile vehicle 700 is shown in FIG. 7 and includes the following steps in any order: making a first housing including a first weatherproof chamber 710 enclosed by an upper horizontal surface, a lower horizontal surface, a rear vertical surface, a front surface, and two side surfaces; installing one or more rechargeable lithium ion batteries inside said first weatherproof chamber 720 ; providing an integral charging port 730 on said first housing, e.g., on the rear vertical surface capable of recharging said batteries; providing a pedestal on the lower horizontal surface 740 ; positioning a switch on the first housing 750 , e.g., on the upper horizontal surface; making a second housing including a second weatherproof chamber 760 and a front vertical surface that can be flat or curved; providing a transparent window on the front vertical surface of the second housing 770 that can be flat or curved; installing two or more LEDs inside said second weatherproof chamber 780 , each light emitting diode capable of emitting up to at least 180 lumens; connecting the first housing and the second housing via a pivoting mechanism 790 that allows relative pivotal movement between the first and second housings, wherein said second housing is adjustable to pivot in angles from 25 degrees vertically above to 25 degrees vertically below the horizontal axis of the lighting apparatus; and providing a universal mounting apparatus 795 for detachably attaching said pedestal to the mobile vehicle.
[0041] In another aspect of the embodiment, the switch controls electrical input from said batteries to said diodes directly or indirectly. For example, the switch sends a signal to an electronic circuit, and the electronic circuit controls the flow of electricity to the LEDs according to the signal from the switch. In certain other aspects of the embodiment, the switch is a push on-off switch. In another variation of the embodiment, the pedestal is adapted for slidably attaching to the universal mounting apparatus. In yet another aspect, the embodiment further includes a means for fastening the universal mounting apparatus to the mobile vehicle. In a further aspect, the means for fastening comprises a rubber strap. In another variation of the embodiment, the rubber strap is selected from the group consisting of a small strap, a medium strap and a large strap. In other aspects of the embodiment, the first and second housings are formed of a fusion sealed rigid material. In other configurations of the embodiments, the pivoting mechanism comprises a torque O-ring to maintain the second housing at a predetermined configuration. In a further aspect of the embodiment, the three LEDs are capable of operating sequentially. In a yet further aspect, the method includes a flashing daytime mode capable of emitting 180 lumens every 0.75 seconds. In various aspects, the lighting apparatus is adapted to be used on a bicycle.
[0042] According to another embodiment, a method of operating a lighting apparatus 800 , shown in FIG. 8 includes the following steps: charging the lighting apparatus 810 , wherein said lighting apparatus includes a first housing including the electrical switch, one or more rechargeable batteries, and a charging outlet, a second housing including two or more LEDs, and a pivot mechanism connecting the first housing and the second housing and allowing the first housing to pivot against the second housing, wherein at least one of said LEDs is equipped with a narrow angle beam reflector, and at least one of said LEDs is equipped with a wide angle beam reflector; turning on said light apparatus 820 by actuating an electrical switch causing electrical power to be supplied to all of one or more LED to output light with a total light output of up to 540 lumens or more. Depending on the specification of the wide angle beam reflector, lighting pattern from said mobile device can create a wide angle beam wherein said angle is at least 30 degrees from the centerline of said one or more LED.
[0043] According to another aspect, the embodiment includes actuating said electrical switch so that only one of said LED emits light 830 . In another aspect, the method includes actuating said electrical switch so that only two of said LEDs emit light 840 . In a further aspect, the method includes actuating said electrical switch so that the LEDs emit light sequentially 850 , one at a time, or two or more at a time. The sequence may or may not be random. In a yet further aspect, the electrical switch is a push-button switch that is actuated by pushing. In another aspect, the embodiment includes pivoting said second housing relative to said first housing up or down up to 25 degrees each direction 860 . In yet another aspect, the method includes attaching a universal mounting apparatus to a mobile vehicle, and attaching said lighting apparatus to said universal mounting apparatus 870 .
[0044] In a further embodiment as shown in FIG. 9 , a lighting apparatus 900 configured for use on a mobile vehicle (not shown), comprises a first weatherproof housing 901 including an electrical switch 912 , one or more rechargeable batteries (not shown), and a charging outlet (not shown); a second weatherproof housing 906 including three LEDs 914 , 915 , 916 , wherein at least one of said LED is equipped with a narrow angle beam reflector, at least one of said LED is equipped with a wide angle beam reflector, and the combined light output capacity of the LED is at least 500 lumen; and a weatherproof pivot mechanism 911 that connects the first housing and the second housing and allows the first housing to pivot against the second housing.
[0045] In another aspect of the embodiment, the lighting apparatus 900 includes an electrical circuit (not shown) so configured that by actuating said electrical switch 912 the LEDs ( 914 , 915 , 916 ) operate in various modes including: only one of said LED emits light, only two of said LEDs emit light, and all of said LEDs emit light at the same time. In yet another aspect of the embodiment, the lighting apparatus includes an electrical circuit so configured that by actuating said electrical switch the LED emits light sequentially. In a further aspect of the embodiment, the electrical switch 912 is a push-button switch that is actuated by pushing. In a yet further aspect of the embodiment, the pivot mechanism 911 allows said second housing 906 to pivot relative to said first housing 901 up or down up to 25 degrees in each direction. In another variation of the embodiment, the lighting apparatus 900 further includes a universal mounting apparatus (not shown) for attaching said lighting apparatus to a mobile vehicle (not shown). In yet another variation of the embodiment, the light apparatus is made to be used on a bicycle (not shown).
[0046] In another aspect of the embodiment, the LEDs ( 914 , 915 , 916 ) are shown with a narrow angle beam reflector and wide angle beam reflectors.
[0047] Whereas the invention has been described by way of example and in terms of the specific embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | A lighting apparatus usable with a mobile vehicle, which includes first and second housings which contain the power source, the switch mechanism and the light emitting elements therein. A pivoting mechanism allows relative pivotal movement between the two housings thereby allowing the user to manipulate the desired emission angle of illumination. The pivoting mechanism also permits electrical communication between the power source (rechargeable batteries) and the light emitting elements. The lighting apparatus includes an integral charging port for recharging the batteries, such as a micro USB port. The lighting apparatus is adapted to the mobile vehicle by a universal mounting assembly which is configured to be interchangeably attached and detached to fit on different configurations on a particular vehicle. The mounting assembly comprises of a rigid assembly, which attaches the lighting apparatus to the mounting assembly with a flexible fastener to attach the mount to the vehicle. | 8 |
FIELD
[0001] This disclosure relates to a pry bar hand tool useful for a variety of construction/demolition projects including, but not limited to, removing stucco, roofing, siding, decking, wood flooring, tile, drywall, plaster and lath, and millwork.
BACKGROUND
[0002] Pry bar hand tools are known in the prior art that are purportedly suitable for removing items such as shingles, nails, and insulation. These known hand tools suffer from a number of problems. For example, these known hand tools are often designed to perform a single task, such as shingle and nail removal. However, users often try to use the tools to perform other construction/demolition tasks which the tools are not designed for. This can cause damage to the tools. In addition, because the tools are used under rugged conditions, these tools are often designed to have replacement parts which can make the replaceable portions of the tools weak and prone to breakage during use.
SUMMARY
[0003] A tined pry bar hand tool is described that is designed for use in a large number of construction/demolition projects including, but not limited to, removing stucco, roofing, siding, decking, wood flooring, tile, drywall, plaster and lath, and millwork. The tool is rugged and long lasting. In addition, since it is a hand tool, the tool is relatively light in weight which is an important consideration as the tool may often be held above a users head during use. For example, the tool can have a weight of about 7 pounds or less, compared with a weight of 9 or 10 pounds or more in some prior pry bar hand tools.
[0004] In one embodiment, the tined pry bar hand tool includes a head formed by a unitary, one-piece block of metal. The head has a substantially horizontal bottom surface with a front edge and a rear edge. A substantially planar, vertical rear surface extends upwardly from the rear edge of the bottom surface to a top edge. A substantially horizontal top surface portion extends forwardly from the top edge, with the top surface portion being parallel to the bottom surface. A continuously angled portion extends from an end of the top surface portion to the front edge of the bottom surface. A plurality of tines extend from the front edge toward the rear surface and end a predetermined distance from the top surface portion. The tines are generally rectangular with front edges that correspond to the front edge of the bottom surface and that are substantially parallel to the rear edge. Gaps are formed between the plurality of tines, with the gaps extending vertically from the continuously angled portion to the bottom surface and extending from the front edges of the tines to rear ends of the gaps. The gaps decrease continuously in width from the front edges to the walls. In addition, a handle is connected to the head, with the handle including a shaft extending from the rear surface.
DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of the tined pry bar tool.
[0006] FIG. 2 is a side view of the tined pry bar tool of FIG. 1 .
[0007] FIG. 3 is a top view of the head of the tined pry bar tool.
[0008] FIG. 4 illustrates details of the connection between the shaft and the head.
DETAILED DESCRIPTION
[0009] With reference initially to FIG. 1 , a tined pry bar tool 10 is illustrated as including a head 12 and a handle 14 . The head 12 is a unitary, one-piece construction of a block of metal such as steel. By making the head out of a single piece of metal, breakage of parts and loosening of connections is minimized.
[0010] With reference to FIG. 1 and 2 , the head 12 has a substantially flat, horizontal bottom surface 20 extending from a non-continuous front edge 22 of the head to a bottom rear edge 24 . A substantially flat, vertical rear surface 26 extends upwardly from the rear edge 24 to a top, rear edge 28 of the head. A substantially horizontal, solid top surface portion 30 extends forwardly from the top, rear edge 28 to a continuously angled portion 32 that extends from an end 34 of the top surface portion 30 to the front edge 22 . The top surface portion 30 is substantially parallel to the bottom surface 20 . In addition, the head 12 includes substantially vertical, solid side surfaces 36 that extend from the bottom surface 20 to the top surface portion 30 and the angled portion 32 , and extends from the front edge 22 to the rear surface 26 . Only one side surface is visible in FIG. 2 ; it being understood that the opposite side surface is identical to the surface 36 that is visible in FIG. 2 .
[0011] With reference to FIG. 3 , the head 12 includes a plurality of integrally formed tines 40 . The tines 40 are formed by creating spaced gaps or slots 42 in the head 12 that extend from the front edge 22 toward the rear surface 26 , and from the continuously angled portion 32 to the bottom surface 20 . The gaps 42 stop short of the end 34 of the top surface portion 30 , so that there is a section 44 of the angled portion 32 between the ends of the gaps 42 and the end 34 of the top surface portion 30 that is solid.
[0012] The tines 40 thus extend from the front edge 22 toward the rear surface 26 , stopping short of the top surface portion 30 . The tines 40 are generally rectangular when viewed in the top plan view of FIG. 3 , with front edges that correspond with the front edge 22 and that are substantially parallel to the top, rear edge 28 . Thus, the tines 40 can be described as having front edges 22 , it being realized that the front edge 22 is non-continuous as it is formed by all of the front edges of the tines 40 . The gaps 42 have rear ends that define walls 46 that extend substantially vertically from the angled portion 32 to the bottom surface 20 . The gaps 42 decrease continuously in width W from the front edge 22 to the walls 46 whereby the tines 40 increase continuously in width from the front edges 22 .
[0013] The head 12 can have the following exemplary dimensions. With reference to FIG. 2 , the length L can be about 4.0 inches, the height H about 1.25 inches, the length L tp of the top surface portion 30 of about 0.75 inches, and the angle a between the angled portion 32 and the bottom surface 20 of about 20 degrees. With reference to FIG. 3 , the head 12 can have a constant width W between the side surfaces 36 from the rear surface 26 to the front edge 22 of about 3.75 inches, the tines can have a length L T of about 2.75 inches, each tine can have a width W T of about 0.375 inches, each gap can have a width W G at the front edges of about 0.1875 inches, and the rear ends of the gaps 42 can have a width W W of about 0.09375 inches. Although it is to be realized that other dimensions could be used, these particular dimensions are beneficial for a number of reasons. The angle α provides more leverage for prying compared to prior art designs which have an angle of about 15 degrees. In addition, the top surface portion 30 helps to reduce the weight of the head 12 compared to a head where the rear surface 26 and the angled portion 32 directly join. Further, the tines are wider than tines on prior art tools, which increases the strength of the tines making them less prone to breakage.
[0014] The handle 14 extends from the rear surface 26 at an angle β of about 40 degrees relative to horizontal. Referring to FIGS. 1 , 2 and 4 , the handle 14 comprises a substantially solid shaft 16 that is connected to the head 12 and extends from the rear surface 26 , and a sleeve 18 that surrounds the shaft 16 . The shaft 16 and sleeve 18 are made of metal, for example aluminum.
[0015] The shaft 16 and sleeve 18 are generally circular, although other shapes, such as square, can be used. The sleeve 18 is slidably disposed around the shaft 16 to permit adjustment in the length of the handle 14 . An adjustable locking mechanism 54 is provided between the shaft 16 and the sleeve 18 to allow adjustment of the handle length. For example, as illustrated, the adjustable locking mechanism 54 can be formed by a spring loaded button 56 disposed toward an end of the shaft 16 , and a number of holes 58 formed in the sleeve 18 . By pushing in the button 56 and sliding the sleeve 18 relative to the shaft 16 until the button snaps into place in a new hole 58 , the length of the handle 14 can be adjusted. Other adjustable locking mechanisms can be used as well. To facilitate the users grip on the tool, the free end of the handle 14 can be provided with a rubber sleeve 60 .
[0016] It is important that a secure connection be provided between the handle 14 and the head 12 . An exemplary connection is illustrated in FIG. 4 . A hole 70 is drilled into the end 72 of the shaft 16 , and the hole is tapped to create internal threads. The end 72 of the shaft 16 is also cut to provide the proper angle for mating with the rear surface 36 . In addition, a hole 76 is drilled through the head 12 extending from the bottom surface 20 to the rear surface 36 . The hole 76 is also tapped to create threads. A threaded rod 78 is then threaded into the hole 76 in the head 12 and into the hole 70 in the shaft 16 . This draws the end 72 of the handle 16 into intimate contact with the rear surface 36 of the head 12 . Once the rod 78 is fully inserted, any of the rod 78 extending out of the hole 76 from the bottom surface 20 is cut off, and the hole at the bottom surface 20 is welded closed 80 .
[0017] The tined pry bar hand tool described herein may be embodied in other forms without departing from its spirit or characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A tined pry bar hand tool includes a head that is formed by a unitary, one-piece block of metal. The head includes a plurality of tines integrally formed thereon. The construction of the head makes it less prone to breakage, and suitable for a variety of construction/demolition projects. | 4 |
This claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/074,493, entitled “Reclosable Circulating Valve for Well Completion Systems,” filed Feb. 12, 1998.
BACKGROUND OF THE INVENTION
In the completion of wells drilled into subterranean formations, a casing string is normally run into the well and cemented to the wall of the well. Then perforating guns are used to create perforation tunnels through the casing. The perforation tunnels are created adjacent the formation at pay zones to allow fluids, such as oil or gas, to flow from the formation into the well.
During the well completion phase, a fracture operation may be used to increase the permeability of the formation. A fracture operation typically involves lowering a work string to a point adjacent the formation to be fractured, i.e. near the perforation tunnels. Then fracturing fluid is pumped out of the lower end of the work string and into the perforation tunnels at a pressure sufficient to cause the bedding planes of the formation to separate. This separation of the bedding planes creates a network of permeable fractures through which formation fluid can flow into the well after completion of the fracture operation.
The fractures have a tendency to close once the fracture pressure is relaxed. Thus, proppants (e.g. sand, gravel, or other particulate material) are routinely mixed with the fracturing fluid to form a slurry which carries the proppants into the fractures where they remain to prop the fractures open when the pressure is reduced. A condition referred to as screen-out may occur when a portion of the proppants comes out of the perforation tunnels and fills up the annular space between the casing and the work string. Screen-out can occur more than once during a fracture operation.
Whenever screen-out occurs or after the fracture operation is completed, it is necessary to circulate the fracturing fluid out of the work string. Typically, a mechanical valve with multiple open/close capability is required to permit circulation of the fracturing fluid out of the work string.
SUMMARY OF THE INVENTION
In general, in one aspect, the invention features a valve for use in a tool positioned in a well that includes a body having a bore and a port connected to permit fluid communication between the well and the bore. A piston is supported in the body for movement between an open position to open the port and a closed position to close the port. A rupture disc is responsive to fluid pressure in the well and ruptures when a predetermined pressure is applied so that fluid pressure is communicated to the piston to move it from the closed position to the open position. A lock member secures the piston in the closed position after the piston moves from the open position to the closed position.
Other features will become apparent from the following claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of a well completion system in which an embodiment of the invention is used.
FIGS. 2A-2B are vertical cross-sectional views of a circulating valve in respective first and second positions according to an embodiment of the invention.
FIG.3 is a horizontal cross-section view of a portion of the circulation valve;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings wherein like characters are used for like parts throughout the several views, FIG. 1 depicts a well completion system 10 which includes a wellbore 12 extending from the surface (not shown) through a fracture zone 14 . Lining the wellbore 12 is casing 16 which is held in place by a cement sheath 18 . The casing 16 and the cement sheath 18 are provided with a plurality of perforations 20 which are aligned to define perforation channels 22 through which fluids may flow into or out of the formation adjacent to the wellbore 12 . While the wellbore 12 is shown as a cased, vertical wellbore, it should be clear that the invention is equally applicable in open, underreamed, horizontal, and inclined wellbores.
A downhole tool 26 positioned in the wellbore 12 includes a tubing string 28 which extends from the surface (not shown) to the fracture zone 14 . The tubing string 28 is concentrically received in the wellbore 12 such that an annular passage 30 is defined between the inner wall 32 of the casing 16 and the outer wall 34 of the tubing string 28 . Packers 36 , 39 are set in the annular passage 30 to isolate the section of the wellbore 12 which lies adjacent the fracture zone 14 . Packer 36 divides the annular passage 30 into an upper annular passage 38 and a lower annular passage 40 . The downhole tool 26 includes a circulation valve 42 which may be actuated to permit fluid communication between the inside of the tubing string 28 and the upper annular passage 38 .
The tubing string 28 can be divided in two segments, with an upper segment 58 connected to the upper end of the circulating valve 42 and the bottom segment 62 connected to the lower end of the valve 42 .
In operation, fracturing fluid with proppants is pumped down the bore of the tubing string 28 . The circulation valve 42 is maintained in the closed position so that the fracturing fluid pumped down the bore of the tubing string 28 exits the lower end of the tubing string and rises up the lower annular passage 40 . As the lower annular passage 40 fills with the fracturing fluid, the fracturing fluid is forced into the perforation channels 22 to initiate fractures in the formation. As more fluid is pumped down the bore of the tubing string 28 , the fractures are enlarged.
Eventually a point of screen-out is reached at which a portion of the proppants come out of the perforation channels and fills the lower annular passage 40 surrounding the bottom segment 62 of the tubing string 28 . When screen-out occurs, pumping more fracturing fluid will only further exert pressure on the formation. Proppants will also build up in the tubing string 28 .
When screen-out occurs, the proppants can be removed by circulating the fracturing fluid out of the tubing string 28 . To accomplish this, fluid is pumped from the surface through the upper annular passage 38 between the casing 16 and tubing string 28 . When the flow reaches a predetermined pressure, the circulation valve 42 opens to allow the fluid in the upper annular passage to flow into the tubing string 28 . The fluid flowing into the tubing string 28 then pushes the fracturing fluid (along with the proppants) up the tubing string 28 to the surface. The same operation can also be performed in conditions other than screen-out, such as after completion of the well.
Referring to FIGS. 2A-2B, and 3 the circulating valve 42 includes a housing body 50 having a top portion 52 which is threadably connected to a bottom portion 54 . The upper end of the top portion 52 includes a threaded receptacle 56 for connecting to the upper segment 58 of the tubing string 28 (shown in FIG. 1 ). The lower end of the bottom portion 54 includes a threaded stub 60 for connecting to the lower segment 62 of the tubing string 28 (shown in FIG. 1 ). The housing body 50 is provided with a throughbore 64 which permits fluid communication between the upper segment 58 and the lower segment 62 of the tubing string 28 .
In the top portion 52 of the housing body 50 is a pocket 65 in which a rupture disc 66 is mounted. The rupture disc 66 is exposed to the casing pressure, i.e., the pressure in the upper annular passage 38 , through a port 68 at the outer edge of the pocket 65 . The inner edge 70 of the pocket 65 is connected to a port 72 which opens to the interior of the housing body 50 . The top portion 52 of the housing body 50 also includes circulating ports 74 which may communicate with the throughbore 64 .
A mandrel 80 disposed inside the housing body 50 is held in place in the housing body by a collet 82 which is mounted on a collar ring 84 in the bottom portion 54 of the housing body 50 . The mandrel 80 can be movable up and down by fluid pressure relative to the housing body 50 . The mandrel 80 includes a bore 86 which is coincident with the throughbore 64 of the housing body 50 . In its up position as shown, the mandrel 80 closes the circulating ports 74 such that fluid communication between the upper annular passage 38 and the throughbore 64 is prevented. Sealing rings 106 are seated in slots in the mandrel 80 to seal the circulating port 74 .
A mandrel lock 90 that includes radial segments 92 is engageable in a groove 94 , as shown in FIG. 2B in the bottom portion 54 of the housing body 50 . The radial segments 92 are held in place against the end wall 96 of the groove 94 by screws 98 . The mandrel lock 90 also includes garter springs 99 which are arranged to force the lock 90 radially inward to engage the mandrel 80 when the screws 98 are sheared. Once the screws are sheared, the lock 90 can snap into a locking groove 100 in the mandrel 80 to permanently maintain the mandrel 80 in a closed position, i.e. a position where the mandrel 80 covers the circulating ports 74 .
The rupture disc 66 prevents casing pressure from acting on the mandrel 80 until the disc 66 is burst by applying a predetermined pressure on the casing. When the rupture disc 66 bursts, casing pressure is communicated to the pressure surface 112 through the port 72 . The casing pressure acts on the pressure surface 112 to push the mandrel 80 downwardly until a shoulder 114 on the mandrel 80 lands on the mandrel lock 90 and shears the screws 98 . When the mandrel 80 moves downwardly, the circulating ports 74 are uncovered to permit fluid to flow into the throughbore 64 and up the tubing string 28 .
In operation, the circulating ports 74 are initially closed by the mandrel 80 , which is in its up position. Fluid pumped into the tubing string 28 from the surface passes through the bore 86 of the mandrel to the lower segment 62 of the tubing string where it exits into the lower annular passage 40 . When it is desired to move a fluid mixture out of the tubing string 28 , fluid is pumped down the upper annular passage 38 . The rupture disc 66 is exposed to the fluid pressure in the upper annular passage 38 . The rupture disc 66 bursts when the fluid pressure in the upper annular passage 38 reaches a predetermined rupture pressure.
When the rupture disc 66 bursts, fluid flows into the port 72 to the pressure surface 112 of the mandrel 80 to apply pressure on the mandrel 80 . The fluid pressure acts on the mandrel 80 and moves the mandrel 80 down to uncover the circulating ports 74 . At the end of the downward stroke of the mandrel 80 , the mandrel shoulder 114 hits the lock segments 92 and, if sufficient force is applied, the screws 98 holding the segments 92 in the groove 94 are sheared. Once the screws 98 are sheared, the garter springs 99 move the lock 90 radially inward until the lock segments 92 are resting on the outer wall of the mandrel 80 .
To close the circulating ports 74 , a pressure differential between the inside of the tubing string 28 and the casing 16 is required to move the mandrel 80 up. This is achieved by pumping fluid at high rate into the tubing string 28 . The fluid pumped into the tubing string 28 exits through the circulating ports 74 into the upper annular passage 38 . The pressure loss across the circulating ports 74 creates the pressure differential required to move the mandrel up to close the circulating ports 74 . At the end of the upward stroke of the mandrel 80 , the lock segments 92 snap into the locking groove 100 and lock the mandrel 80 permanently in the closed position.
The fluid rate of the circulating ports 74 can be controlled by varying the diameter of the ports. A lower flow rate results in a lower pressure applied on the mandrel.
The opening of the valve does not depend on pressure differential and the rupture disc is exposed to absolute casing pressure. Therefore, accurate knowledge of fluid density or pressure at the valve is not critical. The inner wall of the mandrel can be made smooth to minimize susceptibility to erosion during very high rate large volume fracturing operations.
In an operation where it is desired to fracture multiple zones or where a valve with multiple open/close capability is required, multiple circulating valves may be used to circulate fluid out of the tubing string. The valves may be arranged in the upper section of the tubing string above the packer. The rupture disc of the different valves can be pre-set to burst at different casing pressures.
Although the circulation valve has been described with respect to fracturing operation during well completion, it should be clear that the circulation valve may be used in any downhole application where it is desired to recirculate fluid out of a flow conduit concentrically received in a wellbore. For instance the circulation valve may be used during a well clean-up operation or with a fracture/gravel-packing operation.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. The appended claims are intended to cover all such modifications and variations which occur to one of ordinary skill in the art. | A valve for use in a tool positioned in a well that includes a body having a bore and a port connected to permit fluid communication between the well and the bore. A piston is supported in the body for movement between an open position to open the port and a closed position to close the port. A rupture disc is responsive to fluid pressure in the well and ruptures when a predetermined pressure is applied so that fluid pressure is communicated to the piston to move it from the closed position to the open position. A lock member secures the piston in the closed position after the piston moves from the open position to the closed position. | 4 |
FEDERAL RESEARCH STATEMENT
None.
CROSS-REFERENCE TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a gas turbine engine, and more specifically to an air-cooled turbine rotor blade with a thick TBC and a low cooling flow.
2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
In a gas turbine engine, a high temperature gas flow is passed through the turbine to produce mechanical work to drive the compressor and, in an industrial gas turbine engine, to also drive an electric generator and produce electrical energy. Passing a higher temperature gas flow into the turbine can increase the efficiency of the engine. However, the turbine inlet temperature is limited by the material properties of the first stage stator vanes and rotor blades as well as the amount of cooling that can be produced by passing cooling air through these airfoils (vanes and blades). If the turbine inlet temperature is too high, then the first stage vanes and blades can become too hot and even melt. Thus, one method of increasing the turbine inlet temperature is to form the turbine vanes and blades from even higher temperature resistant materials.
Another method of allowing for an increase in the turbine inlet temperature is to provide cooling for the airfoils. Airfoil designers try to minimize the amount of cooling air used in the airfoils since the cooling air is typically bled off from the compressor and thus is not used to produce work and the energy used to compress the air is thus wasted. Complex airfoil internal cooling circuits have been proposed that include combinations of convection cooling, impingement cooling and even film cooling of the airfoil outer surfaces.
FIG. 1 shows a typical first stage turbine blade external pressure profile. As seen in FIG. 1 , the forward region of the pressure side surface experiences a higher hot gas static pressure while the entire suction side external surface of the airfoil is at a much lower hot gas static pressure than the pressure side. The vertical dashed line in FIG. 1 represents the highest pressure on the external surface of the airfoil just downstream from the leading edge region. One can see that the pressure on the suction side opposite from the highest pressure on the pressure side is much lower.
FIGS. 2 through 4 shows a prior art cooling circuit for a first stage turbine blade in an industrial gas turbine (IGT) engine. This cooling circuit is referred to as a 1+5+1 forward flowing serpentine cooling circuit and includes a leading edge cooling air supply channel 11 located in the leading edge region of the airfoil to supply cooling air to a leading edge impingement cavity 12 through a row of metering and impingement holes 13 , and with a showerhead arrangement of film cooling holes 14 and gill holes 15 on both sides of the leading edge region to provide film cooling on the leading edge region.
The airfoil mid-chord region is cooled by a 5-pass forward flowing serpentine flow circuit that includes a first leg or channel 21 adjacent to a trailing edge region, followed by the second leg 22 , third leg 23 , fourth leg 24 and fifth leg 25 to form the serpentine flow path. As seen in FIG. 2 , film cooling holes 35 are used on the pressure side and suction side walls to discharge cooling air from some of the legs 21 - 25 that form the serpentine flow circuit.
Also seen in FIGS. 2 and 4 is the trailing edge region cooling circuit that includes a trailing edge cooling air supply channel 31 that feeds into a row of metering and impingement holes 32 and impingement cavities 33 that form a series of metering and impingement holes followed by impingement cavities to provide cooling for the trailing edge region. A row of cooling air exit holes is arranged along the trailing edge to discharge the cooling air. A row of film cooling holes 35 is connected to the first impingement cavity 33 to discharge film cooling air onto the pressure sidewall.
For a forward flowing 5-pass serpentine cooling design of FIGS. 2-4 used in the airfoil mid-chord region, the cooling air flows toward the leading edge and discharges into the high hot gas side pressure section of the pressure side. In order to satisfy the back flow margin (the hot gas flow does not flow into the internal cooling passages of the airfoil), a high cooling air supply pressure is needed for the FIG. 2 design, and therefore will induce a high leakage flow. In the FIG. 2 airfoil cooling circuit, the blade tip section is cooled with two tip turns in conjunction with local film cooling. Cooling air bleed off from the 5-pass serpentine flow circuit will reduce the cooling performance for the serpentine flow circuit. Independent cooling flow circuits from the mid-chord cooling circuit is used to provide cooling for the airfoil leading and trailing edges.
As the TBC technology improves and more IGT engine turbine blades are applied with relatively thick or low conductivity TBC, the amount of cooling air required is reduced. As a result, there is not sufficient cooling airflow for the prior art 1+5+1 cooling circuit of FIGS. 2-4 . Cooling air flow for the blade leading edge trailing edges has to be combined with the mid-chord cooling circuit to form a single 5-pass flow circuit in order to provide adequate cooling for the entire airfoil using the low flow cooling air used for low cooling flow airfoils. However, for a single forward flowing 5-pass serpentine cooling circuit with total blade cooling flow, the BFM (back flow margin) may become a serious design issue.
In order to avoid the BFM issue described above in the FIG. 2 cooling circuit, the forward flowing 5-pass serpentine circuit of FIG. 2 can be transformed into an aft flowing 5-pass serpentine circuit as seen in the FIGS. 5 and 6 design. The FIGS. 5 and 6 design transforms the airfoil cooling with a single 5-pass aft flowing serpentine cooling circuit that includes a forward section leading edge impingement cavity 46 and an aft flowing serpentine flow circuit with a first leg 41 located adjacent to the impingement cavity 46 , a second leg 42 , a third leg 43 , a fourth leg 44 and a fifth leg 45 that forms the 5-pass serpentine aft flowing circuit. A row of metering and impingement holes 47 connects the first leg 41 to the impingement cavity 46 , and a showerhead arrangement of film cooling holes 48 connects the impingement cavity 46 to discharge the layer of film cooling air onto the leading edge of the airfoil. The fifth leg 45 is connected to a row of trailing edge exit holes 49 to discharge the spent serpentine flow cooling air through the trailing edge of the airfoil.
For the forward section of the blade leading edge impingement cooling in the FIG. 5 designs, it is normally designed in conjunction with leading edge backside impingement cooling plus a showerhead arrangement of film cooling holes with pressure side and suction side film discharge cooling holes (not shown in FIG. 5 or 6 ). Cooling air is supplied from the first up-pass channel 41 of the 5-pass serpentine circuit. The impingement cooling air is normally fed through a row of metering holes 47 , and impinged onto the backside of the airfoil leading edge surface to provide backside impingement cooling of the leading edge prior to discharging the spent impingement cooling air as film cooling air through the showerhead holes and the P/S and S/S gill holes. One possible drawback for the 5-pass aft flowing serpentine cooling circuit of FIGS. 5 and 6 is the heat pick up by the cooling flow. As the cooling air reaches the airfoil trailing edge, the heated cooling air looses its cooling potential since the cooling air is being heated as it travels through the 5 legs of the serpentine circuit. Thus, with the cooling circuit of FIGS. 5 and 6 , a turbine upgrade may become a design limitation.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide for a turbine rotor blade with a cooling circuit that can be used on a blade with a relatively thick TBC and a relatively low cooling airflow.
It is another object of the present invention to provide for a turbine rotor blade which overcomes the back flow margin (BFM) issued that occur in the prior art single pass forward flowing 5-pass serpentine circuit in the 1+5+1 blade cooling circuit of the prior art.
It is another object of the present invention to provide for a turbine rotor blade cooling circuit that overcomes the blade design limitation of the prior art aft flowing 5-pass serpentine cooling circuit in which the cooling air becomes too hot to provide adequate cooling for the trailing edge end of the blade.
These objectives and more are achieved in the turbine blade cooling circuit of the present invention which includes a 5-pass serpentine flow circuit with a forward flowing near wall cooling at the airfoil mid-chord section and a 3-pass aft flowing serpentine circuit connected to an end of the forward flowing circuit to form a dual pass near wall serpentine flow cooling channel. Cooling air is supplied top channels on the pressure side and the suction side walls at a mid-chord region to flow up toward the blade tip, then turns at a tip turn channel and flows downward in channels on the pressure side and the suction side walls where the two paths merge into a common third leg that flows up toward the blade tip in-between the two down-pass channels of the second legs. The cooling air then flows around a tip turn in-between the tip turns between the first and second legs, and then flows down in a common fourth leg channel in-between the first legs on the pressure side and suction side walls. The cooling air then flows into a fifth common leg located adjacent to the trailing edge region where the cooling air is gradually bled off through multiple trailing edge metering and impingement holes and impingement cavities to cool the trailing edge region, and then discharged through a row of trailing edge cooling exit holes. A leading edge impingement cavity with showerhead film cooling holes and gill holes is connected to the common third leg channel that forms a mid-chord chamber between the pressure side and suction side channels that form the second leg of the serpentine flow circuit.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a graph of the external pressure profile of a prior art first stage turbine rotor blade.
FIG. 2 shows a cross section view along a radial direction of a prior art blade cooling circuit of the 1+5+1 forward flowing serpentine cooling circuit.
FIG. 3 shows an isometric view of the prior art first stage turbine blade of FIG. 2 .
FIG. 4 shows a flow diagram of the 1+5+1 forward flowing serpentine circuit of FIG. 2 .
FIG. 5 shows a cross section view along a radial direction of another prior art first stage blade cooling circuit of the 5-pass aft flowing serpentine cooling circuit.
FIG. 6 shows a flow diagram of the aft flowing serpentine circuit of FIG. 5 .
FIG. 7 shows a cross section view along the radial direction of the serpentine flow cooling circuit of the present invention.
FIG. 8 shows a cut-away view of the blade cooling circuit through a line A-A in FIG. 7 .
FIG. 9 shows a cut-away view of the blade cooling circuit through a line B-B in FIG. 7 .
FIG. 10 shows a flow diagram of the cooling circuit of the present invention in FIGS. 7 through 9 .
FIG. 11 shows a cross section view through a mid-chord line of the cooling circuit of the present invention of FIGS. 7 through 10 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a new cooling circuit for an airfoil of a turbine rotor blade, preferably for an IGT engine rotor blade, that can be used with a relatively (in terms of the prior art) thick TBC and with relatively low cooling flow which will be needed in the new engines that are being designed. FIG. 7 shows a cross section view through a slice of the blade along a radial direction of the airfoil in which the leading edge and trailing edge with the pressure sidewall and the suction sidewall clearly defined. Pressurized cooling air from an external source to the blade is supplied to a common supply cavity 65 formed within the blade root (see FIG. 9 ) and then splits up to flow into a first up pass 51 along the pressure side wall and a first up pass 52 along the suction side wall. Each pass or passage 51 and 52 includes pin fins extending across to add rigidity to the airfoil walls and to promote heat transfer from the hot metal surfaces to the cooling airflow.
Located forward of the two first up pass channels 51 and 52 are two down pass channels 53 and 54 with one down pass channel 53 located along the pressure side wall and the other 54 located along the suction side wall. Again, each of these channels includes pin fins extending across the channel. The two up pass channels 51 and 52 are connected to the two down pass channels 53 and 54 through a separate tip turn channel 58 that also provides cooling to the blade tip section of the tip turn channel 58 .
A first mid-chord chamber 55 is formed between the down pass channels 53 and 54 , and a second mid-chord chamber 56 is formed between the two up pass channels 51 and 52 . A leading edge impingement cavity 71 is located I the leading edge region and is connected to the first mid-chord chamber 55 through a row of metering and impingement holes 72 . A showerhead arrangement of film cooling holes 73 is connected to the leading edge impingement cavity 71 as well as pressure side and suction side gill holes 74 .
In the trailing edge region of the airfoil is a trailing edge up pass channel 57 with pin fins extending across the channel, where the channel 57 is connected to the second mid-chord chamber 56 through a root turn channel 68 as seen in FIGS. 10 and 11 . A row of metering and impingement holes 62 and impingement cavities 63 is connected to the trailing edge up pass channel 57 to provide cooling for the trailing edge region of the airfoil. A row of trailing edge exit holes or slots 64 is connected to the impingement cavities 63 to discharge the spent cooling air from the airfoil and cool the trailing edge.
FIG. 8 shows a cross section of the blade through a line A-A shown in FIG. 7 with the pressure sidewall on the left of this figure. The first mid-chord chamber 55 is shown in-between the two up-pass channels 53 and 54 formed on the pressure side and the suction side walls. The pin fins 66 are shown extending across the two channels to promote heat transfer from the hot metal surfaces to the cooling air. The tip turn 58 between the first mid-chord chamber 55 and the second mid-chord chamber 56 is seen at the top of FIG. 8 . The cooling air that flows down through the two down-pass channels 53 and 54 is collected in the first mid-chord chamber 55 , which then flows up through the tip turn channel 58 and into the second mid-chord chamber 56 that is shown in FIG. 9 .
FIG. 9 shows a cross section view through the line B-B in FIG. 7 and includes the second mid-chord chamber 56 located in-between the two up-pass channels 51 and 52 formed within the pressure side wall and the suction side wall. The common cooling air supply cavity 65 is shown connected to the two up-pass channels 51 and 52 . The tip turn channel 58 is shown that connects the second mid-chord chamber to the first mid-chord chamber 55 at the blade tip turn. The cooling air from the first mid-chord chamber 55 flows through the tip turn channel 58 and into the second mid-chord chamber 56 of FIG. 9 , which then flows down and into the root turn channel 59 and into the trailing edge up-pass channel 57 .
In operation, cooling air is fed into the near wall cooling flow circuits on the first pressure side and first suction side up-pass cooling channels 51 and 52 and flows upward and around the pin fins 66 that extend across these channels. The cooling air then turns across the blade tip section in the first tip turn channels 58 formed on both sides of the airfoil wall at the blade tip. The cooling air then flows down through the first pressure and suction side near wall down-pass cooling channels 53 and 54 and around the pin fins that extend across these two channels. The cooling air then flows into the first mid-chord chamber 55 that is formed in-between the two down pass channels 53 and 54 .
The cooling air that flows through the first mid-chord chamber 55 is partially bled off through a row of metering and impingement holes 72 to provide impingement cooling for the backside of the leading edge surface of the airfoil. The spent impingement cooling air in the L/E impingement cavity 71 then flows out through the showerhead film cooling holes 73 to provide a layer of film cooling air for the leading edge, and if the gill holes 74 are used provide additional film cooling for the airfoil.
The cooling air from the first mid-chord chamber 55 that is not bled off through the row of metering and impingement holes 72 then flows around the tip turn channel 58 and into the second mid-chord chamber 56 that is formed between the two up-pass channels 51 and 52 . The cooling air collected in the second mid-chord chamber 56 then flows though the root turn channel 59 and into the trailing edge up-pass channel 57 and then through the row of impingement holes and impingement cavities and then through the row of T/E exit holes or slots 64 and out from the airfoil. For the trailing edge cooling circuit, a series of straight holes or multiple impingement cooling holes can be used for the cooling of the airfoil T/E region.
The serpentine flow cooling circuit of the present invention includes two 5-pass serpentine circuits that are part separate and part interconnected. One 5-pass serpentine circuit includes a first leg or channel 51 , a second leg 53 , a third leg 55 , a forth leg 56 and a fifth leg 57 and flows in that direction. The second 5-pass serpentine circuit includes a first leg or channel 52 , a second leg 54 , a third leg 55 , a fourth leg 56 and a fifth leg 57 . I these first and second 5-pass serpentine circuits, the third leg 54 , the fourth leg 56 and the fifth leg 57 are common to both 5-pass serpentine circuits. Only the first and second legs are separate from each other.
This cooling air circuit of the present invention is totally different from the prior art method of cooling with the 5-pass serpentine flow cooling circuit. The prior art 5-pass serpentine flow cooling air is fed through the blade aft section and then flows forward in the forward flowing serpentine circuit or fed through nears the blade leading edge forward section and then flows aft toward the trailing edge for the aft flowing serpentine circuit design. The 5-pass serpentine cooling air in the serpentine flow cooling circuit of the present invention is fed through the blade mid-chord section. Since the cooling air temperature is fresh (not yet heated up) and the blade mid-chord section contains more metal than both the L/E and T/E ends of the airfoil, a maximum use of the cooling air potential is achieved with a low mass average temperature and yield a higher stress rupture life for the blade. In addition, the use of near wall cooling in the airfoil mid-chord section will maximize the benefit of using a thick TBC. Since the forward flowing circuit for the 5-pass serpentine includes only two cooling flow channels, the BFM issue described above in the prior art serpentine circuit will also be minimized.
In the serpentine flow circuit of the present invention, locating the two mid-chord chambers 55 and 56 between the near wall mid-chord cooling channels 51 - 54 will minimize the overheating of the cooling air as occurs in the cited prior art serpentine flow circuits. The use of the triple or 3-pass serpentine flow circuit in the airfoil mid-chord chamber will provide cooling for the airfoil tip cap and recirculation of warm cooling air for the near wall and into the backside of the near wall flow channel to heat up the inner wall for the near wall cooling channel and reduce the through wall thermal gradient and prolong the airfoil LCF (Low Cycle Fatigue) life.
Major design features and advantages of the serpentine flow cooling circuit of the present invention over the cited prior art serpentine circuits are described below. Minimize the blade BFM issue with two forward flowing serpentine channels instead of the 5-pass forward flowing serpentine cooling channels. The blade total cooling air is fed through the airfoil mid-chord section and flows toward the airfoil leading edge that maximizes the use of the cooling potential for the cooling air. The use of near wall cooling with total airfoil cooling flow for the airfoil mid-chord section will maximize the cooling potential with a thick TBC. Higher cooling mass flow through the airfoil main body yields a lower mass average blade metal temperature that translates into a higher stress rupture life for the blade. The 5-pass serpentine flow circuit of the present invention consumes less pressure than the forward flowing 5-pass serpentine circuit of the prior art which results in a lower cooling supply pressure requirement and thus lower leakage flow.
All the high heat transfer in the serpentine turns for the 5-pass serpentine circuit occurs along the blade pressure and suction peripherals which will enhance the blade tip section convection cooling. In addition, the tip turns for the mid-chord chamber triple pass serpentine circuit also provides additional tip section cooling. As a result of the cooling circuit design, better cooling for the blade tip is produced.
The combination of near wall and traditional serpentine cooling for a forward then aft flowing 5-pass cooling flow design maximizes the use of cooling air and provides a very high overall cooling efficiency for the entire airfoil.
The aft flowing serpentine cooling flow circuit used for the airfoil main body will maximize the use of cooling for the main stream gas side pressure potential. A portion of the air is discharged at the aft section of the airfoil where the gas side pressure is low and thus yields a high cooling air to mainstream potential to be used for the serpentine channels and maximize the internal cooling performance for the serpentine circuit.
The third and fourth serpentine cooling channels are located behind the first and second serpentine channels and thus will heat up the inner ribs for the first and second near wall serpentine flow passages and improve the airfoil LCF capability.
Shielding the third and fourth serpentine channels provide better cooling potential for the airfoil trailing edge cooling and lower cooling air pressure to the trailing edge which yields a better trailing edge cooling geometry. | A turbine blade with a low flow cooling circuit that includes two 5-pass serpentine flow circuits that are partially separated and partial combined to form the low flow capability while providing adequate cooling for the blade. The pressure sidewall and the suction sidewall both include an up-pass channel and a down-pass channel to form the first two legs of two serpentine flow circuits. Positioned between the up-pass and down-pass channels are two mid-chord channels that form third and fourth legs of the common serpentine flow circuit. A fifth leg is formed through a trailing edge up-pass channel that provides cooling air for a trailing edge cooling circuit with exit holes. The forward most mid-chord chamber that forms the third leg supplies impingement cooling air to the leading edge cooling circuit that also includes film cooling holes for the leading edge surface. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to the field of pressure responsive valves, particularly those as used in fuel injectors for internal combustion engines for draining of fuel and timing fluid when predetermined fluid pressures are exceeded, and as is used in other applications where fast, predictable response times and minimum space requirements are prime considerations.
2. Description of Related Art
The competing demands for increased fuel economy and improved pollution control has led internal combustion engine designers to give increased attention to improvements in fuel supply systems, particularly fuel injection systems. However, these efforts have lead to more complex designs and more demanding performance characteristics, and has required the number of components to be increased and the size to be decreased.
For example, U.S. Pat. Nos. 4,721,247 and 4,986,472 (which are owned by the assignee of this application) address the problem of achieving the high injection pressures (on the order of 30,000 psi and above) required to reduce the levels of hydrocarbons, nitrogen oxides and particulate mass over the entire range of engine operating speeds. Furthermore, to achieve adequately high pressure at low engine speed without excessive pressures being generated at high engine speeds, the fuel injectors of these patents use a coil spring-loaded, pressure responsive valve to drain timing fluid from a timing chamber, that forms an intermediate hydraulic link in an injection plunger assembly, whenever the pressure of the timing fluid exceeds a predetermined value.
While an improvement over then existing fuel injections systems, such fuel injectors do not represent an optimized design, at least in part due to the fact that coil spring type relief valves can be subject to slow response rates resulting in pressure oscillation and valve chatter affects the ability to obtain adequate pressure regulation. Furthermore, due to the relationship between spring rate and springs size inherent in helical coil springs, the use of coil springs for the pressure responsive component of a valve imposes size constraints on the extent to which the size of a fuel injector, or any other device using such a valve, can be reduced. Also, coil springs are subject to spring relaxation which can affect the reliability of the precision pressure control achieved thereby.
Pressure responsive valves have long been known for use in a variety of environments in which a band-like spring element serves as the pressure responsive component for opening or closing a fluid port. In many cases, as shown in U.S. Pat. Nos. 4,708,156 and 4,194,435, the band member is a resiliently stretchable ring that is made of rubber or a rubber-like material and is mounted in tension over an annular surface containing at least one port. When the fluid pressure becomes great enough, it stretches the band so as to uncover the port to permit the outflow of fluid. However, such elastomeric bands cannot be subjected to either high temperatures or high pressure levels, such as those experienced in high pressure fuel injectors.
Pressure responsive control valves using band-like spring elements of metal are also known (see, for example, U.S. Pat. Nos. 233,432; 4,095,617; and 5,014,918). In the case of the air compressor of U.S. Pat. No. 233,432, a band-like ring valve is beveled at each side and is received in a beveled seat which flanks an annular opening in a circumferential wall of a compression cylinder. To allow the ring valve to expand to allow air being compressed to exit the opening, the ring is cut or split; but, to close the annular opening at the split, a joint or cover is attached to the ring, or the ends of the ring are oppositely tapered and made to overlap each other, or a double-ring arrangement, in which the cuts of the rings are on opposite sides, is provided.
In contrast, in the airblast fuel injector for gas turbine fuel injectors Of U.S. Pat. No. 5,014,918, a spring valve in the form of a cantilever reed valve is formed of a partially cylindrical, arcuate band-like member that is machined from tubing stock. The spring valve lies against the inner surface of a cylindrical seat member. One end of the spring member is attached to the seat member by set screws at an area diametrally opposite the fuel outlet port formed in the seat member.
While the band-like valve spring members of the preceding two cases may be suitable for situations in which the pressure of the fluid being regulated is not that great and/or a high degree of precision is not required, such spring members would not be able to meet the demands for precision control that are necessary in high pressure fuel injectors for internal combustion engines that are being designed to have increased fuel economy and improved pollution control characteristics because such high performance injectors require fast response times and must meet minimum space requirements. Furthermore, in comparison to a continuous annular valve spring member, such split valve spring members are more difficult to make and install.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object to provide a pressure responsive spring valve which will, on the one hand, be able to function at high pressures and temperatures, and on the other hand, will attain a high degree of precision control in a minimum of space.
A second objective of the present invention is to provide an improved high pressure fuel injector for internal combustion engines which can achieve the demanding performance characteristics of the more complex new injector designs within limited space requirements.
Another object of the present invention is to provide spring valves which are able to fulfill the preceding objects.
A still further object is to provide spring valves of the continuous and split ring types that can adjustably achieve higher degrees of precision regulation than has previously been possible.
Yet another object of the present invention is to provide a high pressure fuel injector for internal combustion engine that uses an improved valve arrangement in a way that is easier to package in the injector, especially smaller size injectors, at lower cost, while enhancing reliability and durability.
These and other objects are achieved in accordance with various embodiments of the present invention. First of all, in all cases, a band-like valve spring member is used since it reduces the number of parts and the space requirements relative to that required for a coil spring type pressure control valve. Furthermore, whether a split or continuous spring type spring member is used, in accordance with preferred embodiments, by giving the spring member a configuration which is different from that of the circumferential wall of the valve body on which it sits, while matching their surfaces in the area of the outlet port(s) of the valve member, higher and more predictably and precisely controlled operating pressures are achieved since the spring force of the ring member is concentrated at the port area(s).
In the most preferred embodiments, the spring member of the pressure responsive valve is a continuous ring and is mounted on the outside of the injector barrel. However, for lower pressure applications or designs where it is not feasible to put the ring member on the injector barrel, closed ring and split ring embodiments are provided which are mounted on the periphery of the timing plunger. In both cases, means are provided by which the pressure force can be adjusted to insure that the proper pressure level and level of precision are achieved. In the case of a split ring embodiment, the spring member is a split circular ring and the configuration of the circumferential wall of the valve body is of an at least partially convex curvature having a radius that is smaller than that of the circular ring. A mounting means is provided for mounting the split circular spring member on the valve body with its center shifted radially relative to the center of the circular shape of the circumferential wall of the valve body to an extent which produces an opening of the split ring with ends of the split ring firmly engaged on the surface area(s) containing the outlet port(s) so as to seal the at least one port formed therein. The mounting means comprises a radially inwardly directed projection extending from the spring member at a point opposite the split therein and which is received in a mounting bore formed in the valve body. An adjusting means is provided for adjusting the pressure applied by the engagement of the ends of the split ring on said surface area of the circumferential wall of the valve body in the form of a plurality of shims, a variable number of which may be disposed within the mounting bore for varying the extent to which the projection of the split circular ring is received in the mounting bore, or blocks of variable height may be used.
In one embodiment, a continuous band-like, resilient valve spring member may be provided with a circular shape and the circumferential configuration of the circumferential wail of the valve body may be square with corners in the form of convex arc segments to which the circumferential configuration of the spring member is able to match itself. At least one outlet port is provided in each of a first pair of opposite comers of the circumferential wall of the valve body. A throughhole extends between a second pair of opposite corners of the circumferential wail of the valve body, and a pin member is slidably received in the throughhole at each of these second opposite comers. A spring means is provided between the pin members for urging them outwardly into engagement with the spring member, and by selecting the force of the spring means, the precision of the pressure regulation produced by the spring member can be improved. At the same time, the force of the pin members on the spring member serves to reduce ring stresses in the spring member.
In another embodiment, the circumferential wall of the valve body, which preferably is formed by the injector body but can be the timing plunger, has an elliptical configuration and a continuous spring member is provided which has a circular circumferential configuration, the diameter of the circular configuration of the spring member being greater than that at a minor diameter of the elliptical configuration and less than that at a major diameter of the elliptical configuration. At least one outlet port is provided at each of opposite ends of the major diameter of the elliptical configuration of the circumferential wall of the valve body. The difference between the major diameter of the ellipse of the valve body and the initial diameter of the spring member before mounting thereon is used to control the preload which must be overcome for the valve to begin to open. Alternatively, instead of providing the valve body with an elliptical circumferential configuration, nonelliptical configurations may be used in which four or more flats have been cut (which may be left unfinished) and on which at least four convex arc segments are machined at points corresponding to the ends of major and minor diameters of the resultant configuration. Outlet ports are provided at the points corresponding to the major diameter in a surface area having a radius of curvature that is smaller than the half length of the major diameter, and the points corresponding to the ends of the minor diameter area on a closed surface area that has a radius of curvature that is larger than the half length of the major diameter. The flats serve to provide improved drainage and leave a clearance area between the spring member. Additionally, a clearance is left between the valve body and the spring member at the surface areas at the ends of the minor diameter into which the spring ring member can bend as the fluid pressure from the outlet ports lift the spring member. In a still further modified form, three symmetrically arranged ports can be provided instead of diametrally disposed ones with a surface area of larger radius being disposed between each pair of surface areas in which ports are provided.
These and other objects features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments of the invention when viewed in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross sectional view of an open nozzle fuel injector with pressure responsive limiting valves designed in accordance with the present invention;
FIGS. 1a, 1b and 1c are enlarged views of the encircled detail A in FIG. 1 at commencement of the injection stroke, when an excess pressure situation occurs during the injection stroke, and during a hold-down phase at the end of the injection cycle, respectively;
FIG. 2 is a partial cross sectional view of a closed nozzle fuel injector with pressure responsive limiting valves designed in accordance with the present invention at the start of the timing phase;
FIG. 3 is a partial cross sectional view of a lower portion of a second open nozzle fuel injector with pressure responsive I%ting valves in accordance with the present invention;
FIG. 4 is a vertical cross section of a timing plunger with a limiting valve in accordance with an embodiment of the present invention, the plunger being shown in an inverted orientation relative to that of FIGS. 1-2;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4 but with the spring member being shown unsectioned;
FIG. 6 is a top plan view of another embodiment of a timing plunger in accordance with the invention;
FIG. 7 is a side elevation of the timing plunger of FIG. 6 with a spring member shown in section;
FIGS. 8a and 8b are cross-sectional views taken along line 8--8 of FIG. 6 showing two forms for the timing plunger thereof;
FIGS. 9a and 9b are cross-sectional views taken along line 9--9 of FIG. 7 and corresponding to the two forms of the timing plunger shown in FIGS. 8a and 8b.
FIG. 10 is a cross-sectional view of an injector barrel configuration for forming a valve body of a pressure limiting valve according to another embodiment of the invention;
FIGS. 11 and 12 are cross-sectional views of pressure limiting valves in which modified forms of injector barrel configurations for serve as the valve body of the pressure limiting valve;
FIG. 13 is a partial sectional view of another embodiment of a timing plunger with pressure limiting valve in accordance with the invention; and
FIG. 14 is a modified form of the embodiment of FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an open nozzle unit fuel injector in accordance with the present invention, which is designated generally by reference numeral 1. The fuel injector 1 is intended to be received within a recess in the head of an internal combustion engine (not shown) in a conventional manner. The injector 1 is formed of an injector body 3, that has an upper injector barrel part 3a (the section of which is shown on the left having been taken along a plane at a right angle to the section shown at the right in FIGS. 1 and 1a-1c), a lower injector barrel part 3b, an injector cup 3c having an injection nozzle having spray orifices for spraying fuel into the combustion chamber (not shown) of an internal combustion engine, and a retainer 5 having a shoulder 5a for capturing the injector cup 3c. The retainer 5 receives the the injector cup 3c, supported on shoulder 5a with spray nozzle 4 projecting from the bottom end thereof. The lower barrel part 3b is received in the retainer 5 supported on the injector cup 3c. Furthermore, retainer 5 secures the injector cup 3c and lower lower barrel part 3b together in end-to-end fashion with the upper barrel part 3a. For this purpose, the top end of the retainer 5 has internal threads 6a by which it is connected to external threads 6b on the bottom end of upper injector body part 3a, as shown. A central bore extends through the parts 3a-3c of the injector body 3 of the fuel injector 1, and a reciprocating plunger assembly 7 is disposed in this central bore.
The plunger assembly 7 includes three plungers. An upper plunger 8, an injection plunger 9 and a timing plunger 10 disposed therebetween. The fuel injector 1 is part of a fuel injection system having a plurality of such injectors, each of which is driven by a rotating camshaft (not shown) via a conventional drive train assembly which includes a link 11 that causes the plunger assembly 7 to reciprocate in synchronism therewith. The injection system also includes a fuel pump which supplies all of the fuel injectors by a common rail system (not shown) which requires three common fluid rails within the cylinder head, one for supplying fuel into the injection chamber, one for draining away fuel that is not injected and the third which supplies timing fluid (which may also be fuel) to vary the timing of the injection event by varying the quantity of timing fluid supplied to a variable volume timing chamber defined between the bottom of the upper plunger 8 and the top of the timing plunger 10. These aspects are not novel to the present invention and are described in greater detail in the above-noted U.S. Pat. No. 4,721,247. The ' 247 patent also describes the need to drain timing fluid, at the end of each injection cycle to assure a sharp cut off of the injection event and whenever the injection pressure exceeds a preset value during the injection stroke to preclude excessive wear and stress in the injector's drive train.
For purposes of draining the timing fluid, at the end of each injection cycle and whenever the injection pressure exceeds a preset value during the injection stroke, in accordance with the present invention, the timing plunger 10 has an axial passage 10a which communicates with a plurality of radial bores 10b and 10c which open into annular groove 10d and annular undercut 10e through corresponding outlet ports. The upper barrel part 3a has an annular groove 13 at its inner surface and this groove 13 connects with a valve passage 15 which connects, in turn, with the drain rail of the the engine head via a drain passage 16. However, flow to drain passage 16 (and accordingly from the timing chamber via axial passage 10a, radial bores 10b, annular groove 10d and valve passage 15) is regulated by a high pressure limiting valve 17 that is of one of the forms described in greater detail below. Similarly, flow from the timing chamber, via axial passage 10a, radial bores 10c, annular groove 10e, and low pressure space 18 to drain passage 16 is regulated by a second high pressure limiting valve 19 (which has been omitted in FIG. 1 to show the undercut 10e more clearly, but shown in the enlarged detail of FIGS. 1a-1c) that is also of one of the forms described in greater detail below. In this way, a higher preset value can be used to control the draining of timing fluid during injection than at its conclusion.
FIG. 2 shows a unit fuel injector 1' of the closed nozzle type in which parts that correspond to parts of the injector 1' of FIG. 1 have been given like reference numerals that are distinguished by a prime (') designation. In this case, draining of timing fluid occurs at the end of the injection cycle in the same manner described above relative to the injector of FIG. 1, when the pressure set by pressure limiting valve 17' is exceeded and draining of timing fluid during downward travel of the plunger assembly 7' is controlled by a second pressure limiting valve 19' which is disposed within an annular recess at the outlet end of bores 10'c. From the standpoint of this invention, and in particular, timing fluid supply, pressure regulation and drainage, the very different injectors of FIGS. 1 and 2 can be treated as being same, so that only a single description of the inventive aspects of both will be provided.
Initially, with the injector 1, 1' in the raised position shown in FIG. 2, an injection timing mode is commenced in which timing fluid is supplied via a timing fluid supply passage 20, 20' to the reduced diameter lower end of upper plunger 8, 8', and in a conventional manner, the supplied timing fluid displaces the timing plunger 10, 10' against the force of timing spring s, filling variable volume timing chamber T with an amount of timing fluid designed to appropriately adjust the timing at which injection of fuel from nozzle 4, 4' commences. With the appropriate quantity of timing fluid and fuel having been metered into the injector 1, 1', the injection stroke is performed (FIG. 1a) with upper plunger and timing plunger moving downwardly in unison due to the hydraulic link formed between them by the timing fluid in timing chamber T and with these plunger in engagement with the plunger 9. When the injection pressure is above the preset value determined by valve 19, 19' during the injection stroke, as illustrated in FIG. 1b, timing fluid causes the portion of the valve 19, 19' closing bores 10c to move radially outwardly to allow the timing fluid to pass out of the timing chamber T via passage 10a, bores 10c, annular groove 10e and low pressure space 18, 18' to drain passage 16, 16'(it is noted that even though valve 19 appears to contact the inner wall of the upper barrel 3a in this figure, a clearance is maintained at all times to prevent wear). At the end of the injection cycle, the remaining timing fluid is released during a hold-down phase (FIG. 1c), when the pressure of the timing fluid exceeds the opening pressure of valve 17, 17', in a similar manner, only using bores 10'b and groove 10'd, instead of ports 10c and groove 10e, to communicate axial passage 10a, 10'a with drain passage 16, 16' via connecting passage 15, 15'.
Alternatively, as reflected by the open nozzle injector 1" of FIG. 3 (in which parts that correspond to parts of the injector 1' of FIG. 2 have been given like reference numerals that are distinguished by a double prime (") designation), the second pressure limiting valve 19" can be arranged on the upper barrel part 3"a instead of on the timing plunger. In this case, timing plunger 10" has only a single set of radial ports 10"bc which communicate axial passage 10"a with a single annular groove 10"de which is longer that is equivalent to both of the grooves 10d and 10e. Additionally, a second drain passage 21 is provided in the barrel. Thus, when annular groove 10"de overlaps passage 21 during the injection stroke of the plunger assembly 7", pressure limiting valve 19" regulates the release of timing fluid from the timing chamber via drain passage 21, and at the end of injection, draining of the remaining timing fluid is regulated by the pressure limiting valve 17" via drain passage 15".
Having described one preferred environment in which a pressure limiting valve in accordance with the present invention finds particularly advantageous utility, the basic attributes of the inventive pressure limiting valve and various forms in which it can be embodied will now be described with reference to FIGS. 4-11. However, in each case, the specific identity of the component which serves as the valve body of the pressure limiting valve should be viewed as being an independent variable relative to the structural requirements of the valve itself. That is, given that a described configuration of the circumferential wall of the valve body of any embodiment can be provided on another component, and given that the described spring member can be used in the particular environment in which such a component is used, any type of component whatsoever may serve as the valve body of any embodiment in place of the specific structural element described, e.g., an injector barrel or other tubular structure can be used in place of a timing plunger as can other piston-like structures, and vice versa.
The pressure limiting valve 25 of FIGS. 4 and 5 has a valve body 26, which may be a timing plunger, in which an axial passage 27 runs from end face 26a into intersecting connection with, in this case, a pair of radially extending ports 28 which open out of the circumferential wall 26b that has been machined onto the valve body 26. In this regard, as can be seen from FIG. 5, circumferential wall 26b is elliptical and ports 28 open through it at the ends of its major diameter D M . A valve spring member 29, formed of a ring of spring steel, is mounted over circumferential wall 26b and is prevented from falling off by a snap ring clip 30. Two point loading of the valve spring member 29 is produced at the surface areas of wail 26b surrounding the outlets of ports 28 due to the difference in configuration of the valve spring member 29 relative to circumferential wall 26b. In particular, the valve spring member 29 has a circular shape of a diameter that is greater than the minor diameter d m of circumferential wall 26b and smaller than its major diameter D M so that the spring member is bent into an out-of-round shape at the ends of major diameter D M but with a gap g being maintained between the spring member 29 and the circumferential wall 26b being maintained at both sides of the port areas. The gap allows the spring member 29 to undergo further bending during operation and can be used to control the maximum distortion of the ring-shape of valve spring member 29 for purposes of preventing contact with the inner wall of the upper barrel 3a (or engine head in those cases where the injector barrel serves as the valve body) and for limiting stress in the spring member. The difference between the major diameter D M and the initial, i.e., undistorted interior diameter of the circular spring member 29 is selected to control the preload on the valve spring member 29.
The pressure to be limited by valve 25 is introduced, e.g., from a timing chamber, through axial passage 27 and ports 28 to the portions of spring member 29 which cover and seal the outlets of ports 28. As long as the pressure force on the exposed area of the valve spring member 29 is smaller than the ring deformation force, the ports 28 remain closed. When the pressure force exceeds the preset preload, the ring is deformed further into a more elongated shape and the pressurized fluid starts escaping through the resultant clearance between the inner surface of the valve spring member 29 and the surface of circumferential wall 26b and then into a free space below the plunger or into a drain passage. As the spring member becomes more elongated, gap g closes, thereby setting a limit to the amount of elongation, i.e., valve lift. When the fluid pressure drops back below the preload, spring member 29 reseals the ports; however, since the contact area around the port outlets is relatively large, a fuel film is trapped between the valve spring member 29 and the contact areas of circumferential wall 26b and produces a hydraulic damping, along with that produced by fuel in gap g, to minimize valve chatter.
Importantly, because the valve spring member 29 is loaded in bending instead of being stretched in a normal press or shrink fit, a lower effective spring rate can be achieved. The obtaining of a lower spring rate, in turn, makes the valve spring member less affected by manufacturing tolerances and permits a finer control of opening pressure. During operation, the spring member 29 is free to turn and this has the effect of causing any wear or erosion to be distributed over the entire circumference of spring member 29. Furthermore, as the spring member turns, the bending stresses are gradually reversed, preventing any permanent distortion or load relaxation. However, in high stress situations where fatigue poses a greater problem, the spring member 29 can be fixed to prevent rotation thereof by the provision of a pin on the inside of the spring member that is received in a recess in the valve body 26, similar to the situation shown in FIGS. 13 and 14. In such a case, the pin should be located at a point of low stress and should not act to apply an outward force on the spring member (in contrast to the situation described below relative to the pin of FIGS. 13 and 14.
In FIGS. 6 and 7, a pressure limiting valve 35 is shown of the type which would be usable, for example, for timing plunger 10, 10' of FIGS. 1, 2. Thus, the valve body 36 has a first axial passage 37 which connects to a first pair of radial bores 38 (FIGS. 8a and 8b), which have ports which open into an annular recess 39. The valve 35 does not control the flow of fluid through passage 37 and bores 38, such being regulated by an external, pressure limiting valve which is the counterpart of valve 17, 17' of FIGS. 1, 2. However, instead of using a common passage to communicate with both sets of radial bores 10c, 10'c and 10d, 10'd, in this embodiment, a separate pair of axial passages 42 are provided for communicating the pressurized fluid with the second set of radial bores 40. The second set of radial bores have ports which open at a circumferential wall that, instead of being machined into an elliptical shape, achieves an equivalent effect by being formed of convex segments 41a and 41c that have been machined to a curvature that approximate circular cylindrical segments and flats 41b that have been cut into the perimeter of valve body 36 so as to produce a major diameter D M and a minor diameter d m . As in the preceding embodiment, the ports of bores 40 open at the ends of the major diameter D M and are closed by an initially circular valve spring member that has been elongated over the convex segments 41a to sealingly close the ports of bores 40 under a predetermined preload, while leaving a small clearance between the inner surface of the spring member 43 and the segments 41a. This clearance (which is not apparent in FIG. 9a, but is similar to that shown in FIGS. 11 or 12) functions in the same way and for the same purposes as the gap g in the FIG. 4 and 5 embodiment. The circular segment surface areas 41a of the circumferential wall have a eater radius of curvature at the ends of the minor diameter d m than at the ends of the major diameter D M .
This configuration of flats and convex segments and the four resultant gaps g' between the valve spring member 43 and the flats 41b provide a greater total clearance than the two gaps g of FIG. 5 while enabling a smaller radial clearance to be achieved at surface 41a. This affords a greater area for drainage between the spring member 43 and the valve circumferential wall 36 of the valve body 35. At the same time, the spring member 43 is still able to respond to a pressure above that of its preload by expanding away from the ports 40 by bending of the valve spring member 43 toward the segments 41a. Furthermore, this embodiment obtains greater control from the standpoint of a precision factor P f which is measured as the pressure at which the valve opens, p o , divided by the pressure at which maximum flow occurs p m , i.e., P f =P o /P m , (the closer the precision factor is to 1, the more precise is the control) since it is possible to achieve a more defined surface area upon which the fluid pressure acts.
While the degree of preload on the valve spring member 43 of this embodiment can be set in the same manner noted relative to the embodiment of FIGS. 4 and 5, by modifying the valve body of FIGS. 8a and 9a in the manner shown in FIGS. 8b and 9b, not only can the degree of preload be more precisely set, but ring stresses in the valve spring member can be reduced and a capability to change the preload obtained. In particular, a crossbore is provided through the valve body 36 along minor diameter d m . Am adjustment pin 47 is disposed in each end of the crossbore, and these pins 47 are urged radially outwardly against the valve spring member 43 by an adjustment spring 49 that is situated in the crossbore between the inner ends of the adjustment pins 47. The pins 47 have partially spherical heads.
FIG. 10 illustrates implementation of a modified form of the limiting valve concept of FIGS. 6-9 on the exterior of a cylindrical valve body, such as where the valve body 36' is formed by the barrel of a fuel injector, as is the case for the pressure limiting valves 17, 17', 17" and 19" in FIGS. 1-3. Here again, the equivalent of an elliptical configuration is produced by machining convex segment, i.e., of an elliptical, circular or complex curvature, surface areas 41'a and 41'c and cutting flats 41'b on the circumferential wall of the valve body 36'; although, achieving a more nearly elliptical shape is not a goal being sought and the benefit to using more sides is that it decreases the amount of material that is removed from the valve body and the extent that the valve body is weakened as a result. The radius of curvature R of the convex segment surface areas 41'a located at the ends of the major diameter D M is smaller than the half length of the major diameter, while the radius of curvature r of the convex segment surface areas 41'a located at the ends of the minor diameter d m is larger than the half length of the major diameter D M . As is the case for flats 41b, the flats 41'b improve drainage and can be left unfinished. A valve spring member of the same character already described is mounted over the valve body 36' to produce pressure regulation of fluid passing from central bore 50 (or a timing or other plunger therein) out of radial bores 40', also, in the same manner indicated above.
A more preferred, modified form of the preceding embodiment is the valve 35" shown in FIG. 11, where like reference numerals have again been used to identify like components with a double-prime (") being used to distinguish this embodiment. In this case, the convex segment surface areas 41"a are elliptical segments that span 90° of arc centered on the minor diameter d m and a single small flat 41"b is cut into the valve body 36' at each side thereof creating gaps g" that merge into a clearance space c between the inside of spring member 43 and surface areas 41"a. Ports 40", once again, are formed at the opposite ends of the major diameter D M , and the surface areas into which they open are machined to a circular or complex curvature against which the spring member 43 can engage to close the ports 40". When the valve opens, the spring member 43 moves away from the ports 40" to the extent controlled by the size of gap c, i.e., until the spring seats against surface areas 41a", and the gaps g" provide a drainage path. An important characteristic of valve 35" is the fact that nodes n, at which the distance between the valve spring 43 and the valve body 36" always remains constant, are formed at the junction of the surface areas 41"a and the flats 41"b. These nodes have the effect of keeping the coaxial arrangement of the spring member 43 with respect to the valve body 36", i.e., it prevents shifting of the valve spring member 43 along either diameter d m or D M when the spring opens or closes (when it is fully off valve body 36), thereby preventing damaging stresses from being produced.
While all of the preceding embodiments have been provided with a pair of ports on surfaces at the diametrally opposed ends of the major diameter D M , such is not a prerequisite. Likewise, in the preceding valves 35, 35', 35", planar flats 41b, 41'b, 41"b have been cut into the valve body and such is not necessary either. In FIG. 12, a modified form of the preceding embodiment is shown in which three ports 40"' are disposed symmetrically 120° apart and the gap-forming "flats" have been arcuately cut. In this case, a surface area at which a bore 40"' has its outlet is disposed opposite a respective surface area 41"'a; nonetheless, as shown in FIG. 12, the surface areas define a respective minor diameter d m of the valve body and with the surface areas carry the outlet ports of bores 40"' defining the major diameter D M , i.e., these surface areas are tangent to an inscribing circle of the respective diameter.
Such a 3-port arrangement has the advantage that no special steps need be taken to insure that the valve spring member 43 remains coaxial relative to the valve body 36... since the three ports have a self-centering effect. On the other hand, for a valve body of a given diameter, a three port arrangement as shown in FIG. 12 necessitates that the valve spring 43 be thinner than it would for the opposed port arrangements of the prior embodiments if the same opening pressure is to be achieved and if the same spring member is used, a higher pressure will be required to cause the valve 35"' to open.
As noted in the background portion of this specification, split ring pressure limiting spring valves of the type used in the prior art are only suitable for situations in which the pressure of the fluid being regulated is not that great and/or a high degree of precision is not required, such that the prior spring valves would not be able to meet the demands for precision control that are necessary in high pressure fuel injectors for internal combustion engines that are being designed to have increased fuel economy and improved pollution control characteristics and which necessitate fast response times and minimum space requirements. Furthermore, it was pointed out that, in comparison to a continuous annular valve spring member, such split ring valve spring members are more difficult to make and install.
Nonetheless, there are situations in which it is simply not feasible to use a continuous annular spring valve member due to the size and/or configuration of the components into which the valve is to be incorporated. For example, in fuel injectors of the above-described types, it is sometimes not possible to configure the barrel of the injector to have a pressure limiting valve spring member on its exterior, and at the same time, with especially small fuel injectors and/or relatively low fluid control pressures, it may not be possible to obtain a high enough degree of precision if a closed ring type valve is incorporated into the timing plunger as the shown, for example, in the embodiment of FIGS. 4 and 5.
That is, a precision factor, as defined above, of about 0.8 can be obtained when a spring member as disclosed herein is mounted on the outside of the barrel of a fuel injector which serves as its valve body. On the other hand, due to the high stiffness of a continuous annular ring, when very small diameters of one-half inch or less are involved, the precision factor associated with the use of a pressure responsive spring valve with a spring member of a closed annular shape drops to around 0.6 to 0.7, a degree of precision that is unacceptable for a fuel injector which requires fast response times to obtain increased fuel economy and improved pollution control characteristics. For such circumstances, the split ring embodiments of FIGS. 13 and 14 can be more advantageous.
In the pressure limiting valve of FIG. 13, the valve body 57 is a cylindrical pin or plunger, the circumferential wall 59 of which has had a flat 59a symmetrically cut from adjoining quadrants on one half of the cross section so as to leave a convex segment surface area 59b therebetween which must be machined to a single complex curvature (or like circular segment surface areas 59'b, as is the case shown in FIG. 14), so that the end portions 65a of valve spring member 65 will be able to match themselves to surface area 59b or surface areas 59'b to seal the ports of passages 62, 62'. On the other hand, as reflected by apparant differences between the valve bodies of valves 55, 55' of FIGS. 13 and 14, apart from the surface areas 59b, 59'b, substantial freedom exists in the manner in which the remainder of the cross-section of valve body 57, 57' is configured.
An axial passage 60, 60' extends from one end face of the valve body 57, 57' axially through it into communication with the pair of radial bores 62, 62' that have outlet ports in surface area 59b, or surface areas 59'b. The valve spring member 65 is formed of a thick ring that has been cut on one side producing facing ring end portions 65a. Spring member 65 has a larger diameter than valve body 57, 57' and has a mounting projection 65b that is received in a mounting recess 59c, 59'c that is disposed diametrally opposite and centrally with respect to bores 62, 62'. The length of the mounting projection 65b is such as to position the center C s of spring member 65 sufficiently rearwardly of the center C b of the valve body 57 so as to draw the ends 65a of the spring member against surface area 59b or surface areas 59'b, thereby opening the spring member and firmly engaging its end portions on the surface area(s) 59b (59"b) for sealingly closing the outlet ports of the bores 62, 62'.
Because only the end portions of the valve spring member 65 engage on the valve body 57, 57', its preloading is concentrated in the area of the outlet ports of bores 62, 62', thus increasing the pressure which can be regulated. Furthermore, this concentrated closing preload can be increased and precisely adjusted by the provision of a plurality of shims, the number/thickness of which that are received in mounting recess 59c, 59'c, between the bottom of the mounting recess and the facing end of mounting projection 65b, 65'b, can be varied. Alternatively, blocks of varying size may be used instead of shims. By varying the number of shims, or the size of blocks, used, the spring center C s can be shifted farther from valve body center C b , with the result that the preload on the ends of the split valve spring member 65 is increased. By way of example, with a spring member 65 having a stiffness of 2700 lbs./in., a maximum stress of 70,000 psi can be achieved and the pressure of the fluid being controlled can be regulated with a precision factor of 0.8.
As can be appreciated from the foregoing, neither the specific type of injector nor the number of pressure limiting valves or their placement is critical to the present invention. What is important is that a valve spring member be mounted over a valve body member in a way that permits the preloading of the spring member to be concentrated in the area of the one or more outlet ports to be closed thereby, such that high pressures can be regulated with precision. Also, as a general rule, a continuous ring is preferable to a split ring, and mounting of the valve spring member on a larger outer surface of an enclosing cylindrical body (such as an injector barrel) is preferred over mounting of the valve spring member on a smaller inner member (such as on a timing plunger).
INDUSTRIAL APPLICABILITY
The present invention will find applicability in a wide range of applications where high pressures need to be regulated with precision. Of particular significance, however, will be in the automotive arts, particularly fuel injection systems as described above. That is, in systems where a fluid, the pressure of which is being regulated, travels through passages and bores in cylindrical and tubular bodies that can serve as a valve body over which a band-like spring member can be suitably mounted. | A pressure responsive spring valve which is able to function at high pressures and temperatures, and can attain a high degree of precision control in a minimum of space, as well as an improved high pressure fuel injector for internal combustion engines which uses such a spring valve to achieve the demanding performance characteristics of the more complex new injector designs within limited space requirements. In all cases, a band-like spring valve member is used to reduce the number of parts and the space requirements therefor relative to that required for a coil spring type pressure control valve. Furthermore, whether a split or continuous ring type spring member is used, in accordance with preferred embodiments, by giving the spring member a configuration which is different from that of the circumferential wail of the valve body on which it sits, while producing a matching of their surfaces in the area of the outlet port(s) of the valve member, higher pressures and precision factors are achieved since the spring force of the spring member is concentrated at the port area(s). | 8 |
TECHNICAL FIELD
The present invention relates to a method of working a hot-rolled stainless steel strip, in particular an austenitic stainless steel strip, for the purpose of reducing thickness, enhancing mechanical strength and providing a good surface finish.
DESCRIPTION OF THE BACKGROUND ART
Stainless steel strips can be hot-rolled to a final thickness of the order of 3 mm. After surface conditioning the strips, including among other things pickling the strip, the hot-rolled strips can be used without further thickness reduction in certain applications. However, subsequent cold-rolling of the hot-rolled strips is required in many other applications. This subsequent cold-rolling process is intended to achieve one or more or all of the following effects, viz to further reduce the thickness of the strips, to enhance the mechanical strength and/or to improve the surfaces of the strips.
Before being cold-rolled, the hot-rolled strips are annealed and pickled, and scrap-ends are welded onto both ends of the strips. The actual cold-rolling process is carried out conventionally in several passes through a cold-rolling mill, therewith enabling the thickness to be reduced by up to about 80%, normally 0-60%, for instance for cold-rolled strips which are intended for use as construction materials after having been slit into narrower strips. The scrap-ends must be removed before the strip can finally be coiled.
Cold-rolling dramatically increases the mechanical strength of the steel, which is in itself desirable for many applications, and this particularly concerns cold-rolling of austenitic stainless steel. However, the strips also become practically impossible to work, e.g. to bend, stamp, emboss, etc.; properties which are in many cases necessary in order to enable the strips to be used as construction materials. It is therefore necessary to anneal the strips upon completion of the cold-rolling process, by heating the strips to a temperature above the re-crystallization temperature of the steel, i.e. to a temperature above 1,050° C. This treatment greatly reduces the mechanical strength of the strip, normally to an order of magnitude of 250 MPa yield point. According to current standards, a yield point of 190-220 MPa must be calculated for in construction work.
The properties obtained with conventional techniques, for instance a relatively low yield point, are desirable properties in the majority of cases, although conventional techniques are irrational in several aspects. However, improvements have been proposed with the intention of rationalizing manufacture. For instance, it is proposed in SE 467 055 (WO 93/19211) to reduce thickness in conjunction with an annealing process by stretching the hot strip. However, a higher mechanical strength is a desirable property in certain applications, such as for constructional applications. The properties of the final cold-rolled strip are not improved in this latter respect when practicing the aforesaid method, and neither is such improvement intended.
SUMMARY OF THE INVENTION
The object of the invention is to produce stainless steel strips, particularly stainless austenitic steel strips, having a desired thin thickness and a higher mechanical strength than that achieved in the conventional manufacture of cold-rolled stainless austenitic steel strips while obtaining an acceptable surface finish at the same time. These and other objects can be achieved by cold-rolling a hot-rolled strip with an at least 10% thickness reduction to a thickness which is at least 2% and at most 10% greater than the intended final thickness of the finished product, by annealing the thus cold-rolled strip at a temperature of between 1,050° C. and 1,200° C., and cold-stretching the strip after said annealing process so as to plasticize and permanently elongate the strip, therewith obtaining a reduction in thickness of 2-10%.
The strip which is subjected to cold-rolling in accordance with the invention may consist of a hot-rolled strip that has not undergone any treatment other than being cooled and coiled after being hot-rolled. Thus, in this case, cold-rolling is performed on a hot-rolled strip on which oxide scale still remains on the surfaces thereof. However, the starting material for the cold-rolling process also may consist of a strip which has been surface-treated by a process technique that includes pickling of the hot-rolled strip.
In principle, the cold-rolling process can be carried out in several passes through a corresponding number of mutually sequential roll stands, although it will preferably be carried out in one single pass. The maximum reduction in thickness that can be achieved in one single pass will depend on the steel grade, the initial dimensions of the strip, and the capacity of the rolling mill. It can be said generally that one single pass will result in a maximum thickness reduction of about 30%, normally at maximum 25%. This means that in the majority of cases, the thickness of the hot rolled strip will be reduced by 10 to 60%, preferably by 10 to 40% when practicing the invention, this reduction being dependent on the initial thickness of the strip and the final thickness desired. The strip is annealed at a temperature of between 1,050° C. and 1,200° C. and then cooled to room temperature before being cold-stretched.
The strip is cold-stretched in a strip stretching mill which may be of any known kind, for instance the kind used to de-scale the surfaces of hot-rolled strips prior to pickling. The strip is preferably cold-stretched by a combination of high stretches and bending of the strip around rolls. The cold-stretching process is carried out to a degree such as to permanently elongate the strip and therewith obtain a thickness reduction of 2-10%. As a result of the combination of high stretches and bending of the strip around rolls of relatively small diameter, the decrease in width will be minimal and practically negligible. The reduction in strip thickness will therefore correspond essentially to the degree of elongation achieved. The material is plasticized as a result of the cold-stretching process, the yield point increasing in the order of 100 MPa, and still higher in the case of certain steel grades.
A characteristic feature of the inventive method is that it takes place continuously, by which is meant that the method does not include any reversing steps, for instance reverse rolling, re-coiling between the various steps or like reverses. In order to make a continuous process possible, the manufacturing line preferably includes, in a known manner, strip magazines, so called loopers, at the beginning and at the end of the manufacturing chain, i.e. prior to cold-rolling and subsequent to cold-stretching of the strip.
The inventive method will normally also include pickling of the annealed strip. The strip is preferably pickled prior to being cold-stretched, although it is also conceivable to pickle the strip after the cold-stretching process. The strip is preferably shot-blasted prior to being pickled.
Further characteristic features and aspects of the invention and advantages afforded thereby, together with the properties of the product produced will be apparent from the following detailed description of the invention and from the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to the accompanying drawings, in which
FIG. 1 illustrates very schematically the principles of the invention according to a first preferred embodiment;
FIG. 2 illustrates in more detail the manufacturing line according to the preferred embodiment;
FIG. 3 illustrates in larger scale and in more detail a cold-stretching mill used in the inventive method;
FIG. 4 is a bar chart illustrating the 0.2 proof stress values achieved before and after cold-stretching;
FIG. 5 illustrates achieved ultimate tensile strengths in a corresponding manner;
FIG. 6 is a bar chart illustrating the thickness reduction achieved with different degrees of cold-stretching;
FIG. 7 illustrates the reduction in width with different degrees of cold-stretching in a corresponding manner; and
FIG. 8 illustrates highly schematically a modified manufacturing line on which the inventive method is applied.
DETAILED DESCRIPTION OF THE INVENTION
The manufacturing line illustrated very schematically in FIG. 1 comprises a coil loof (rewinder) hot-rolled strip to be uncoiled, uncoiling capstan 1, a cold-rolling mill 2 consisting of one single roll stand 2 of the so-called Z-high type, an annealing furnace 3, a cooling box 4, a shot-blasting machine 16, a pickling bath 5, a cold-stretching mill 6 and a recoiler 7 which takes up the finished steel strip.
FIG. 2 shows the manufacturing line in more detail, wherein the same reference numerals have been used for units that find correspondence in FIG. 1. In addition to the aforesaid units, the manufacturing line also includes a shearing unit 8, a welding machine 9, a strip feeder 10 which feeds hot-rolled strip 11 taken from the rewinder 1 to the shearing unit 8 and the welding machine 9, a hot-rolled strip looper generally referenced 12, a thickness measuring means 13 which measures the thickness of the hot-rolled strip 11 upstream of the rolling mill 2, and a thickness measuring means 14 which measures the thickness of the cold-rolled strip 11B downstream of the cold-rolling mill 2, the shot-blasting machine 16, a wiping and rinsing box 17 downstream of the pickling bath 5, a pair of guide rollers 18, the cold-stretching mill 6, a looper generally referenced 20 for the storage of cold-rolled and cold-stretched finished strip 11F, a front feeder 21, and a drive motor and power transmission means together referenced 22 for operating the recoiler 7.
The manufacturing line also includes a large number of guide rollers, direction changing rollers, and an S-mill arrangement that comprises two or four rolls. The S-mill arrangement is thus comprised of a two-roll S-mill 25 downstream of the welding machine 9, a two-roll S-mill 26 upstream of the cold-rolling mill 2, a four-roll S-mill 27 between the cold-rolling mill 2 and the annealing furnace 3, a four-roll S-mill 28 upstream of the cold-stretching mill 6, a two-roll S-mill 29 downstream of the cold-stretching mill 6, a strip centre guide 19, the strip magazine 20, and a terminating two-roll S-unit 31 between the looper 20 and the recoiler 7. The primary function of the S-mill is to increase or decrease the tension in the strip and to keep the strip in tension.
The hot-rolled strip looper 12 includes direction changing rollers 34,35,36 and 37, of which the roller 35 is coupled to a strip tensioning unit in a known manner. Correspondingly, the cold-rolled strip looper 20 includes direction changing rollers 39, 40, 41, 42, 43 and 44, of which the roller 40 is connected to a strip tensioning unit, also in a known manner.
The manufacturing line illustrated in FIG. 2 operates in the following manner. It is assumed that manufacture is in the phase illustrated in the Figure, i.e. that the hot-rolled strip looper 12 and the cold-rolled strip looper 20 contain a given amount of strip, that hot-rolled strip 11A is being uncoiled from the rewinder 1, and that the finished strip 11F is being coiled on the recoiler 7. The line is driven by several driven rollers, primarily driven S-mill rollers in a known manner. After having passed through the hot-rolled strip looper 12, the thickness of the strip is measured with the aid of the thickness measuring means 13 upstream of the cold-rolling mill 2 and is cold-rolled in the mill 2 in one single pass, whereafter the thickness of the cold-rolled strip 11B is measured by the thickness measuring means 14. The hot-rolled strip 11A will normally have an initial thickness of 3 to 4 mm and is reduced by 10-30% in the cold-rolling mill 2. The roll nip is adjusted in accordance with the results of the thickness measurements so as to obtain a cold-rolled strip 11B of desired thickness, corresponding to 2-10% greater than the intended finished dimension after cold-stretching the strip in the terminating part of the manufacturing line.
The cold-rolling process imparts a high degree of hardness to the strip 11B, and the strip is therefore passed into the annealing furnace 3 after having passed the four-roller S-mill 27. The strip 11B is heated throughout its thickness in the annealing furnace 3 to a temperature of between 1,050° C. and 1,200° C., i.e. to a temperature above the re-crystallization temperature of the austenitic steel, and is maintained at this temperature long enough for the steel to re-crystallize completely. The strip is then cooled in the cooling box 4. When heating the strip in the annealing furnace 3, which in accordance with the present embodiment does not take place in a protecting gas atmosphere (something which would be possible per se), oxides form on the sides of the strip, partially in the form of oxide scale. The strip is substantially de-scaled in the shot-blasting machine 6, and then pickled in the pickling bath 5 comprised of appropriate pickling chemicals, wherein the pickling process can be effected in a known manner. The thus cold-rolled, annealed and pickled strip 11E is led through the wiping and rinsing box 17 and thereafter through the cold-stretching mill 6 between the four-roller S-mill 28 and the two-roller S-mill 29 which function to hold the strip in tension and prevent the same from sliding.
FIG. 3 illustrates the design of the cold-stretching mill 6. The cold-stretching mill 6 comprises three strip-stretching units 47, 48 and 49. Each stretching unit includes a respective lower roller 50, 51, 52 journalled in a stationary base 53, 54, 55, and a respective upper stretching roller 56, 57, 58 journalled in a respective roller holder 59, 60, 61. The positions of the roller holders in relation to the strip and in relation to the lower stretching rollers 50, 51, 52 can be adjusted by means of jacks 62, 63, 64 respectively. The upper strip-stretching rollers 56, 57, 58 are initially in upper positions (not shown), so that the strip 11E, which is held stretched between the S-mills 28 and 29, will extend straight through the cold-stretching mill 6. Starting from this initial position, the upper stretching rollers 56, 57 and 58 are lowered by means of the jacks 62, 63, 64 to the positions shown in FIG. 3, whereby the strip 11E-11F will form a winding passway, as shown in FIG. 3, while at the same time being stretched in its cold state to a degree of such high magnitude as to plasticize the strip. According to the illustrated embodiment, the lower stretching rollers 50, 51 and 52 have diameters of 70, 200 and 70 mm respectively, whereas the upper stretching rollers 56, 57 and 58 have diameters of 70, 70 and 200 mm respectively. As a result of the chosen setting of the adjustable upper strip-stretching rollers 56, 57, 58 and by virtue of the chosen diameters of the rollers, that part of the strip which passes through the cold-stretching mill will be plasticized as the strip continues to be drawn through said mill 6 and to be bent about the stretching rollers, therewith obtaining permanent elongation of the strip and therewith a reduction in strip thickness of 2-10%, normally 2-5%. The width of the strip is also reduced slightly at the same time, although the reduction is only one-tenth of the elongation and can be essentially ignored. The permanent elongation of the strip also results in a thickness reduction which corresponds essentially to the elongation of the strip. A finished strip 11F of desired final thickness can be obtained by adapting the reduction in strip thickness achieved by cold-rolling the strip in the cold-rolling mill 2 to the thickness reduction obtained by cold-stretching the strip in the cold-stretching mill 6, or vice versa, said strip being coiled onto the recoiler 7 after having passed through the cold-rolled strip looper 20. The drive machinery of the integrated manufacturing line described above consists of the drive machinery 22 coupled to the strip recoiler 7.
When desiring greater reductions than those achievable with a cold-rolling mill that comprises only one roll stand and only one cold-stretching mill, a plurality of roll stands 2A, 2B, etc., can be coupled sequentially in series, as illustrated in FIG. 8. This Figure also illustrates the possibility of placing the pickling bath 5 downstream of the cold-stretching mill 6. In this case, the cold-stretching mill may also function to de-scale the strip surfaces, therewith possibly eliminating the need for a shot-blasting machine upstream of the pickling bath.
DESCRIPTION OF TESTS CARRIED OUT
Three different standardized austenitic stainless steel grades were used in the tests, ASTM 304, 316L and 316 Ti. The mechanical properties of the material were determined prior to and after cold-stretching the material, which had earlier been cold-rolled and then annealed (re-crystallization treated). The mechanical strength properties of the tested 304-material are set forth in Table 1, where
e=nominal elongation in %
R p 0.2=0.2% proof stress in the transverse direction, MPa
Rm=ultimate tensile strength in the transverse direction, MPa
TABLE 1______________________________________ Cold-rolled & Cold-rolled, annealed strip annealed & cold- ε = 0% stretched stripTest Steel grade Elongation ε % R.sub.p 0.2 R.sub.m R.sub.p 0.2 R.sub.m______________________________________1 ASTM 304 4.0% 283 653 394 6962 ASTM 304 4.8% 283 614 405 6613 ASTM 304 5.0% 273 619 418 674______________________________________
Table 2 shows measured strip widths and strip thicknesses prior to and after the strip has been cold-stretched, and also shows the percentile reductions in thickness and widths achieved in the cold-stretching process.
TABLE 2______________________________________ Cold rolled & Cold rolled, annealed strip ε = annealed & coldElong- 0% stretched strip Differenceation Thick- Thick- Width Thick-Test ε % Width ness Width ness % ness %______________________________________A 3.2% 1036 4.20 1033 4.07 0.29% 3.10%B 3.5% 1275 2.85 1271 2.75 0.31% 3.51%C 4.8% 1269 2.50 1265 2.40 0.32% 4.00%D 4.8% 1294 2.50 1290 2.39 0.31% 4.40%______________________________________
The results shown in Table 1 and Table 2 are also illustrated graphically in FIGS. 4 and 5 and in FIGS. 6 and 7. | The invention relates to a method of working a hot-rolled stainless steel strip, particularly an austenitic stainless strip, with the intention of reducing the thickness and enhancing the mechanical strength of the strip. The method is characterized by
cold-rolling the hot-rolled strip with at least a 10% thickness reduction to a thickness which is at least 2% and at most 10% greater than the intended final thickness of the finished product;
annealing the thus cold-rolled strip at a temperature of between 1,050° C. and 1,250° C.; and
cold-stretching the strip after the annealing process so as to plasticize and permanently elongate the strip and therewith reducing its thickness by 2-10%. | 2 |
BACKGROUND
Sufficient bus capacitance is needed to ensure that a solid state power source operates in accordance with power quality requirements. Typical requirements include highly localized capacitance and minimal series inductance, while adhering to one or more package constraints. Such requirements impose challenges in terms of size, cost, and thermal performance. For example, it is desirable to be able to cheaply manufacture capacitors to fit into a small form-factor or profile while still being able to operate the capacitors at elevated power levels and temperatures.
BRIEF SUMMARY
An embodiment is directed to a method comprising: obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.
An embodiment is directed to a capacitor manufactured by application of an additive manufacturing technique, comprising: a plurality of conductor layers, a plurality of dielectric layers interspersed between the conductor layers, and a first busbar coupled to a first subset of the conductor layers, the first subset comprising at least two layers.
Additional embodiments are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements.
FIGS. 1A-1C illustrate an exemplary drawing of an assembly comprising a plurality of capacitors;
FIG. 2 illustrates a form-factor for a capacitor;
FIG. 3 illustrates a printed power capacitor comprising an integrated busbar;
FIG. 4 illustrates an assembly drawing for an assembly comprising a busbar; and
FIG. 5 illustrates a flow chart of an exemplary method.
DETAILED DESCRIPTION
It is noted that various connections are set forth between elements in the following description and in the drawings (the contents of which are included in this disclosure by way of reference). It is noted that these connections in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. In this respect, a coupling between entities may refer to either a direct or an indirect connection.
Exemplary embodiments of apparatuses, systems, and methods are described for providing an ability to cheaply manufacture capacitors to fit into a small form-factor or profile while still being able to operate the capacitors at elevated power levels and temperatures. Embodiments may leverage additive manufacturing techniques in the manufacture or fabrication of one or more capacitors. The capacitors may be manufactured in accordance with one or more shapes or geometries. In some embodiments, a capacitor may include an integrated busbar. The integrated busbar may couple to a second busbar that is external to the capacitor. One or more parameters of the integrated busbar may be selected based on electrical (e.g., power) and thermal considerations.
Referring to FIGS. 1A-1C (collectively referred to as FIG. 1 ), a drawing 100 of an assembly 150 is shown. The assembly 150 may include a number of devices or components, such as one or more capacitors 102 . The capacitors 102 may be included in one or more enclosures or housings 104 . For example, in the exemplary embodiment shown in FIG. 1 , two capacitor housings 104 may be included providing for a nominal total capacitance equal to five-hundred microfarads (500 mFd), wherein a first set of six capacitors 102 may be located in a first housing 104 a , and a second set of six capacitors 102 may be located in a second housing 104 b ,. One skilled in the art would appreciate that a different number of capacitors 102 , a different value of total capacitance, and/or a different number of capacitors per housing 104 may be used in some embodiments.
The embodiment shown in FIG. 1 represents the capacitors 102 having been manufactured in accordance with a “can or box-like” shape or geometry. FIG. 2 shows another exemplary embodiment, wherein a capacitor 202 has a brick-like shape. In some embodiments, the capacitor 202 may be used as an alternative to, or as a supplement to, one or more of the capacitors 102 .
As described herein, additive manufacturing techniques may be used in some embodiments to construct a capacitor. The shapes for the capacitors 102 and 202 are illustrative. In some embodiments, other geometries or shapes may be used. For example, ‘L’, ‘Z’, and ‘snake’ shapes may be used for a capacitor in some embodiments.
Referring back to FIG. 1 , if the assembly 150 and its constituent components are manufactured using conventional techniques, the capacitors 102 may be formed by bringing two pre-existing plates into proximity with one another. For example, using conventional manufacturing techniques, the two plates may be arranged so as to be substantially parallel to one another, and a (pre-existing) dielectric material may be inserted between the plates.
Turning to FIG. 3 , an example of a power capacitor 302 is shown. In some embodiments, the capacitor 302 may correspond to one or more of the capacitors 102 and 202 of FIGS. 1-2 . The capacitor 302 may be manufactured using cold spray and additive manufacturing techniques, such that the capacitor 302 may be built “from the ground-up.” A direct write technology and a laser engineered net shaping (LENS) technique may be used to manufacture the capacitor 302 . The direct write technology, which may serve to deposit material for electric pathways, may allow for a distribution of capacitance, which would result in a reduction in inductance (relative to conventional manufacturing techniques) for the same capacitor performance. The LENS technique may be used to fabricate parts (e.g., metal parts) for the capacitor 302 from a computer-aided design (CAD) model by using a powder injected into a molten pool created by a laser beam.
The capacitor 302 may include one or more integrated busbars, such as busbars 304 and 306 . The busbar 304 may couple to a positive (+) voltage bus of a power supply and the busbar 306 may couple to a negative (−) or reference voltage bus of the power supply. The busbars 304 and 306 may be included so as to reduce the temperature of the capacitor 302 when the capacitor 302 dissipates heat.
The busbars 304 and 306 may be associated with printed graphite conductor layers 312 . The conductor layers 312 may be interleaved or alternated, such that a first conductor layer 312 may be associated with the busbar 306 , a second conductor layer 312 proximate the first conductor layer 312 may be associated with the busbar 304 , a third conductor layer 312 proximate the second conductor layer 312 may be associated with the busbar 306 , etc. Interspersed between the conductor layers 312 may be a printed dielectric layer 314 .
In some embodiments, the conductor layers 312 may be composed of a graphite oxide material to enhance thermal conductivity. In some embodiments, the dielectric layers 314 may be composed of polyimide.
Referring to FIG. 4 , an assembly drawing 400 is shown. The assembly drawing 400 may correspond to the assembly drawing 100 of FIG. 1 .
The assembly drawing 400 may be associated with one or more busbars. For example, the busbars may be denoted by reference characters 404 and 406 in FIG. 4 . The busbar 404 may be associated with a positive (+) voltage and may couple to a first busbar (e.g., busbar 304 ) integrated in a capacitor and the busbar 406 may be associated with a negative (−) or reference voltage and may couple to a second busbar (e.g., busbar 306 ) integrated in the capacitor. The busbars 404 and 406 may be brought out to one or more tabs or points 414 and 416 , respectively. The tabs 414 and 416 may be used for one or more purposes, such as test points or to facilitate connecting an assembly associated with the drawing 400 to another assembly or piece of equipment.
The busbars 404 and 406 may be coupled to a cold plate (not shown). The cold plate may be used as part of a thermal mitigation strategy to reduce the temperature of one or more capacitors or to serve as a heat sink for drawing heat out of the capacitors.
Turning now to FIG. 5 , a flow chart of an exemplary method 500 is shown. The method 500 may be executed in connection with one or more systems, assemblies, components, or devices, such as those described herein. The method 500 may be used to cheaply manufacture capacitors to fit into a small form-factor or profile while still being able to operate the capacitors at elevated power levels and temperatures.
In block 502 , a specification of operational requirements may be obtained, e.g., received or generated. The operational requirements may specify one or more electrical characteristics (e.g., power, voltage, current), temperature characteristics, etc.
In block 504 , a design may be generated that meets the requirements of block 502 . For example, as part of block 504 , a count of capacitors may be selected, a shape or geometry for the capacitors may be selected, one or more materials used to construct the capacitors may be selected, one or more techniques for manufacturing the capacitor may be selected, one or more features of the capacitor may be selected (e.g., a count of layers, integration of a busbar), etc.
In block 506 , an assembly, a component, or any other entity at any level of abstraction may be manufactured in accordance with the design of block 504 . For example, as part of block 506 a multilayer capacitor with an integrated busbar may be manufactured. The capacitor may be coupled to an assembly or other entity as part of block 506 .
In block 508 , the manufactured design may be tested. For example, the manufactured design may be tested to ensure that it satisfies the operational requirements of block 502 . In the event that one or more of the requirements are not satisfied, flow may proceed from block 508 to, e.g., block 504 (not shown in FIG. 5 ) in order to modify the design. Otherwise, flow may proceed from block 508 to block 510
In block 510 , the manufactured design may be implemented. For example, if a capacitor is manufactured in connection with block 510 , the capacitor may be coupled to an assembly. The coupling of the capacitor and the assembly may include coupling an integrated busbar of the capacitor to a busbar located on the assembly.
The method 500 is illustrative. In some embodiments, one or more of the blocks or operations (or a portion thereof) may be optional. In some embodiments, additional blocks or operations not shown may be included. In some embodiments, the blocks or operations may execute in an order or sequence that is different from what is shown in FIG. 5 .
Embodiments of the disclosure may be used in connection with one or more applications or environments, such as power sources, converters, inverters, motor drives, links, input/output filters, etc. In connection with use on a link, such as a direct current (DC) link, capacitance may be distributed across or along the link while reducing inductance along the link. As such, link performance may be enhanced.
As described herein, in some embodiments various functions or acts may take place at a given location and/or in connection with the operation of one or more apparatuses, systems, or devices. For example, in some embodiments, a portion of a given function or act may be performed at a first device or location, and the remainder of the function or act may be performed at one or more additional devices or locations.
Embodiments may be implemented as one or more apparatuses, systems, and/or methods. In some embodiments, instructions may be stored on memory or one or more computer-readable media, such as a transitory and/or non-transitory computer-readable medium. The instructions, when executed (by, e.g., one or more processors), may cause an entity (e.g., an apparatus or system) to perform one or more methodological acts as described herein.
Aspects of the disclosure have been described in terms of illustrative embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure. For example, one of ordinary skill in the art will appreciate that the steps described in conjunction with the illustrative figures may be performed in other than the recited order, and that one or more steps illustrated may be optional. | Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique. | 7 |
This application is a continuation of application Ser. No. 505,859 filed June 20, 1983 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an input device for inputting a graphic pattern such as a hand-written character by using a switching matrix, and more particularly to an input device which can reduce the number of signal lines to be taken out when the device is implemented by an integrated circuit module.
2. Description of the Prior Art
In the development of large scale integrated circuit (LSI) modules, the signal processing capability of the integrated circuit module has remarkably been increased. On the other hand, the number of integrated circuit modules used has been reduced and the number of signal lines taken out of the internal circuits is restricted by the number of input/output terminals which can be provided in the integrated circuit module. For example, in a 16 ×16 switching matrix circuit, it is necessary to take out 16 input signal lines and 16 output signal lines, or total of 32 signal lines from the LSI module. As a result, a bonding area on the LSI wafer, terminals of the LSI package and a pattern area on a printed circuit board are factors in cost increases and result in increases in the size of the equipment.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an input device which can reduce the number of signal lines, particularly the number of output signal lines to be taken out from an integrated circuit so that a compact and inexpensive integrated circuit package is provided.
It is another object of the present invention to provide an input device comprising matrix input means having a plurality of switches arranged for inputting a pattern, signal generating means for generating a signal to identify the actuation of the switches, and discrimination means responsive to the signal supplied from the signal generating means through the matrix input means for discriminating the switch actuated, which discrimination means examines an interval of the signals supplied from the sequentially actuated switches to discriminate the actuated switch.
It is another object of the present invention to provide an input device comprising a plurality of switching matrices, signal generating means for generating a plurality of signals, signal supply means for supplying the signals to the plurality of switch matrices in different patterns from each other, signal receiving means for receiving the signals from the plurality of switching matrices in different patterns, and discrimination means for discriminating the actuated ones of the plurality of switching matrices by the signals from the signal receiving means.
The other objects of the present invention will be apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a circuit diagram of a pattern input unit having a switching matrix circuit in an input device of the present invention,
FIG. 1B is a circuit diagram of an example of the matrix switch,
FIG. 2 shows a signal waveform of a scan pulse in the pattern input unit,
FIG. 3 is a block diagram of the input device of the present invention,
FIG. 4 is a diagram showing an arrangement of key stacks,
FIG. 5 is a diagram showing a stroke sequence of an input pattern,
FIG. 6 is a diagram showing a manner of storing data in the key stacks,
FIG. 7 is a flow chart for signal processing, and
FIG. 8 shows a circuit diagram of another configuration of the pattern input unit having the switching matrix circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows an example of the wiring arrangement in the input device of the present invention. In the illustrated arrangement, input/output signal lines comprising ten input signal lines I1-I10 and five output signal lines S1-S5 are arranged for a handwritten pattern input unit having 10×10 (=100) switch contacts. A matrix switch SW as shown in FIG. 1B is arranged at each of the crosspoints of the input/output signal lines I1-I10 and S1-S5. The switches SW are shown by circles O in FIG. 1A. As shown in FIG. 1A, the pattern input unit is divided into left and right quadrants. In the left quadrant, the input signal lines I1-I5 and I6-I10 sequentially correspond to the output signal lines S1-S5. In the right quadrant, the input signal lines I1, I8, I5, I2, . . . at every seventh occurrence correspond to the output signal lines S1-S5 and the output signal lines S1, S4, S2, S5, . . . at every third occurrence correspond to the input signal lines I1-I10. Accordingly, when a handwritten pattern is inputted to the switch matrix, the quadrant of the switch contact at the position corresponding to the pattern can be determined by the sequence of the output signal lines corresponding to the sequence of the input signal lines.
FIG. 2 shows an example of timing pulses for scanning the sequential input signal lines I1-I10. In a well-known dynamic scan system, the input timing pulses I1-I10 are sequentially supplied to the output signal lines S1-S5 and key codes are composed by the combinations of the input signal line numbers I and the output signal line numbers S.
An overall configuration of the input device of the present invention is shown in FIG. 3, in which INP denotes the pattern input unit of FIG. 1A, CPU denotes a processor, KSK denotes a key stack memory which stores key code signals Xn. SC denotes a stack counter which specifies an address of the key stack memory, X1, X2, Y1 and Y2 denote working registers, CNT denotes a counter which counts time, ROM denotes a control memory which stores a control sequence shown in FIG. 7, and ET denotes a table. After the quadrant of the content of the key stack memory has been discriminated, a code thereof is set in the table. Yn denotes a coded key input signal supplied from the processor CPU, D2 denotes a decoder for decoding the key input signal Yn to the scan pulse as shown in FIG. 3, d1 denotes a key code generator which receives the output signals S1-S5 from the pattern input unit INP and generates the key code signals Xn corresponding to the input pattern by the combination with the scan pulse In, and OUT denotes a display which displays an output signal Zn of the processor CPU.
An example of a key stack in a memory of the processor CPU which stores the key code signals Xn of the input pattern is shown in FIG. 4. The key stack stores the key code signals Xn in the sequence of entry and also stores discrimination signals paired with the key code signals Xn, for discriminating whether the output signals Sn from the pattern input unit INP for forming the sequential key code signals Xn were generated sequentially with respect to the scan pulse In or generated at an interval of a predetermined number of scan pulses, that is, whether they were generated in the left quadrant of the pattern input unit of FIG. 1A or in the right quadrant. The purpose for storing the pairs of the key code signals and the discrimination signals is as follows.
As shown in FIG. 5, let us assume that a kanji character " " is inputted to the pattern input unit having the 10×10 switching matrix. Assuming that the strokes of the character " " are written as indicated by the order of the numerals shown in FIG. 5, the key code signals Xn are stored in the key stack of FIG. 4 in that order. In a usual hand-written pattern input process, the movement from points 6 to 7 in FIG. 5 is much faster than the movement from points 7 to 8. The difference between the velocities of movement is counted and discriminated by the counter CNT in the processor CPU and the resulting discrimination signal is stored in the key stack KSK in pair with the key code signal Xn.
An example of the key code signals stored in the key stack KSK of FIG. 4 when the hand-written kanji pattern " " of FIG. 5 is entered into the pattern input unit of FIG. 1A is shown in FIG. 6, in which the key code signals are represented by the input/output signal line numbers which form the key code signals instead of the actually generated binary codes and the identification signals for indicating the velocities of the sequential inputs are represented by "1" or "0" intervals T of the input timing. In FIG. 6, STEP indicates writing steps represented by the stroke sequence of the hand-written input process of FIG. 5. For example, in a step 8 of FIG. 6, the input/output signal line numbers are I6 and S2, and the discrimination signal T is "1" which represents the timing interval for the movement from points 7 to 8. The timing intervals in both adjacent steps are "0". It is, therefore, determined that the pattern input was temporarily interrupted at the stroke 7→8. In a step 14, the timing interval T is "0" and the timing intervals in both adjacent steps are also "0" but the input/output signal line numbers representing the key code signal changes between the steps 14 and 15 and the output signal line number subsequently changes at every third step. Accordingly, it is determined that the hand-written input pattern moved from the left quadrant to the right quadrant in the pattern input unit of FIG. 1. As seen from FIG. 1A, when the output signal line number changes from S5 to S1 for the sequential change of the input signal line number, it is determined that the input pattern moved from the left quadrant to the right quadrant, and when the output signal line number changes from S1 to S5, it is determined that the input pattern moved from the right quadrant to the left quadrant. In any case, in the steps 2 to 15 in the key stack of FIG. 6, it is determined from the change of the key code signal and the status of the timing interval T that the hand-written input was made in the left quadrant of the pattern input unit of FIG. 1A.
FIG. 7 shows a flow chart for discriminating the quadrant of the input pattern by the processor CPU. In FIG. 7, SC denotes the stack counter for specifying the store address of the key stack of FIG. 4 and X1, X2, Y1 and Y2 denote the working registers.
First, it is regarded that the key code signals have been stored in the key stack and the key stack address SC is set to "1" so that the input signal line number In stored at the address 1 is loaded in the register X1 and the output signal line number Sn is loaded in the register X2. Then, the stack address SC is incremented. In a step ○1 , the timing interval T is checked. Since T is "0" in the illustrated example, the input signal line number is loaded in the register Y1 and the output signal line number is loaded in the register Y2 in the following step, and in a step ○2 , a difference |X1-Y1 | between the input signal line numbers stored in the registers X1 and Y1 is checked, and in a step ○3 , a difference |X2-Y2| between the output line numbers X2 and Y2 is checked. If any one of the differences is "1", it is determined that the sequential movement of the switch contacts occurred in the left quadrant of the input pattern unit of FIG. 1A and signal processing for the left quadrant is performed (JOB1). Then, the process returns to the initial state. If neither |X1-Y1 | nor |X2-Y2 | is "1" in the steps ○2 and ○3 , the process goes to a step ○4 where a sum of the input line numbers stored in the registers X2 and Y2 is compared with "6" to determine if the output signal line number in the input pattern of FIG. 1A changed from S1 to S5 or from S5 to S1. If the sum is equal to "6", it is determined that the movement across the left and right quadrants in the input pattern of FIG. 1A occurred and necessary processing is performed (JOB2). If the sum is not equal to "6", it is determined that non-sequential movement of the switch contact occurred in the right quadrant of the input pattern of FIG. 1A and necessary processing is carried out (JOB3). Then, the process returns to the initial state.
The 10×10 switching matrix circuit is inherently provided with ten input signal lines I1-I10 and ten output signal lines S1-S10. However, the input device of the present invention is provided with only five output signal lines S1-S5 which are dually combined with the ten input signal lines I1-I10 in the left and right quadrants, and the data in the key stack which represent the addresses of the switch contacts in the left and right quadrants by the input/output signal line numbers I1-I10 and S1-S5 are converted to represent the input/output signal lines I1-I10 and S1-S10.
For example, in the JOB3, the input/output signal line numbers I10 and S4 corresponding to the key code at the final step 22 of the stroke sequence shown in FIG. 5 are converted to the input/output signal line numbers I10 and S9. Such a code conversion may be readily attained by a combination of a decoder and an encoder. In the JOB2 which is carried out when the sum (X2+Y2) of the output signal line numbers is equal to "6", the movement of the right quadrant is discriminated if the output signal line number changes from S5 to S1 and the same code conversion as that in the JOB3 is performed, and if the output signal line number changes from S5 to S1, the movement to the left quadrant is discriminated and the same code conversion as that in the JOB1 is performed.
In this manner, the input pattern codes converted in the JOB's 1-3 are supplied to the display OUT having the 10×10 dot matrix to display the kanji character " " as shown in FIG. 5. By supplying the input pattern code to a pattern recognition apparatus, information such as "YAMA" or "SAN" can be retrieved from the kanji character " ".
Instead of dividing the switching matrix circuit of the pattern input unit of FIG. 1A into the two quadrants, i.e., the left and right quadrants, it may be divided into four quadrants with the sequence of arrangement of the input/output signal lines being different in the respective quadrants so that 32×32 switching matrix circuit can be processed with 16 input signal lines and 16 output signal lines or total of 32 input/output signal lines. A flow chart of signal processing therefor will be readily understood from the flow chart for the two-quadrant matrix circuit shown in FIG. 7. Based on the sequential and non-sequential changes of the strokes of the timing intervals T stored in pair with the input/output signal line numbers, one of the four quadrants in which the stroke of the input pattern moved can be readily determined.
As described hereinabove, according to the present invention, the number of input/output signal lines required to the input device comprising the switching matrix circuit, particularly the number of output signal lines is remarkably reduced in comparison with prior art device, and the input devices can be implemented by a compact and inexpensive integrated circuit. | An input device has a matrix input unit having a plurality of switches for inputting a pattern, a signal generator for generating signals identifying the actuation of the switches, and a discriminator responsive to the signals from the signal generator to discriminate the actuated one of the switches. The discriminator discriminates the actuated switch by checking an interval of the signals from the sequentially actuated switches. | 7 |
BACKGROUND OF THE INVENTION
[0001] In the field of diseased or cancerous tissue detection, many methods require subjecting the patient to doses of X-ray radiation or to painful biopsies, especially for breast cancer detection. More recently, researchers discovered that dysfunction of the neuronal control of the vasculature due to cancerous lesions leads to temporal or periodic perfusion changes. By measuring, recording and analyzing these periodic perfusion changes, typically through infrared (IR) imaging, diseased or cancerous tissue can be detected. While these periodic perfusion changes appear to be associated with most types of diseased or cancerous tissue, skin cancer and other cancers near the surface of the skin are most likely to be detected using IR imaging. Such a method is described in U.S. Pat. Nos. 5,810,010, 5,961,466 and 5,999,843, all to Michael Anbar, and hereby incorporated by reference.
[0002] In particular, breast cancer appears to be very susceptible to detection through IR imaging. Breast cancer detection by this method involves taking a series of IR images of the breast. This series of IR images will show both neuronal control and non-neuronal control of periodic perfusion changes in a cancerous breast. These IR images are then converted into thermal images with a temperature associated with each portion of the thermal image. The thermal images are then analyzed by finding the average temperature and standard deviation of temperature for each subarea within the thermal images. Clusters of subareas having abnormal average temperatures or standard deviations are indicative of cancer. It is anticipated that breast cancer may generally be detected by imaging the appropriate lymph nodes, the so-called “signal nodes,” which tend to have increased biological activity if cancer is present.
[0003] The frequency of the periodic perfusion changes can also be used to detect cancer. Neuronal control generally has a lower frequency than non-neuronal control of periodic perfusion. Therefore, by analyzing the thermal images and determining the periodic perfusion frequency for each of the subareas, clusters of subareas having higher frequencies are indicative of cancer.
[0004] The use of IR images for cancer detection places very stringent requirements on an IR imager. The small temperature changes associated with neuronal and non-neuronal perfusion require an IR imager sensitivity of less than 0.01° C. While IR imagers having this level of sensitivity have been demonstrated, these IR imagers have not successfully been built in quantity.
[0005] In view of the desirability of non-invasive means of cancer detection that do not require subjecting the patient to X-ray radiation exposure, there exists a need for a method that places lower requirements upon IR imager sensitivity. A method that requires lower sensitivity will lead to increased manufacturability and lower IR imager cost. Lower cost IR imagers can lead to greater accessibility to cancer screening and detection.
SUMMARY OF THE INVENTION
[0006] A first embodiment of the present invention comprises a method of detecting diseased tissue including recording first and second series of IR images of a predetermined area of tissue. The first and second series of IR images are recorded in corresponding first and second bands of IR wavelengths, the two bands of IR wavelengths being different. The first and second series of IR images are converted into corresponding first and second series of thermal images. The predetermined area of tissue is subdivided into a plurality of subareas. A first plurality of average temperature values is determined for each of the plurality of subareas from a corresponding one of the first series of thermal images. A first average temperature is determined using the first plurality of average temperature values. A second plurality of average temperature values is determined for each of the plurality of subareas from a corresponding one of the second series of thermal images. A second average temperature is determined using the second plurality of average temperature values. The resulting first and second pluralities of average temperature values for each of the plurality of subareas is then analyzed for possible diseased tissue. Tissue corresponding to a cluster of at least six adjacent subareas having a spatial distribution of corresponding first plurality of average temperature values that is less than about 20% or more than about 100% of the first average temperature is preliminarily determined to be diseased. Tissue corresponding to the cluster preliminarily determined to be diseased is further analyzed. If the cluster has a spatial distribution of corresponding second plurality of average temperature values that is less than about 20% or more than about 100% of the second average temperature, tissue corresponding to the cluster is confirmed to be diseased.
[0007] Another embodiment of the present invention comprises a method of detecting diseased tissue including recording first and second series of IR images of a predetermined area of tissue. The first and second series of IR images are recorded in corresponding first and second bands of IR wavelengths, the two bands of IR wavelengths being different. The first and second series of IR images are converted into corresponding first and second series of thermal images. The predetermined area of tissue is subdivided into a plurality of subareas. A first plurality of average temperature values and a first plurality of temperature standard deviations are determined for each of the plurality of subareas from a corresponding one of the first series of thermal images. A second plurality of average temperature values and a second plurality of temperature standard deviations are determined for each of the plurality of subareas from a corresponding one of the second series of thermal images. For each of the plurality of subareas, each corresponding one of the first plurality of average temperature values is divided by a corresponding one of the first plurality of temperature standard deviations to determine a corresponding one of a first plurality of homogeneity of skin temperature (HST) values for the plurality of subareas. For each of the plurality of subareas, each corresponding one of the second plurality of average temperature values is divided by a corresponding one of the second plurality of temperature standard deviations to determine a corresponding one of a second plurality of HST values for the plurality of subareas. A first average HST value is determined using the first plurality of HST values while a second average HST value is determined using the second plurality of HST values. The resulting first and second pluralities of HST values for each of the plurality of subareas are then analyzed for possible diseased tissue. Tissue corresponding to a cluster of at least six adjacent subareas having a corresponding spatial distribution of first plurality of HST values that is less than about 20% or more than about 100% of the first average HST value is preliminarily determined to be diseased. Tissue corresponding to the cluster preliminarily determined to be diseased is further analyzed. If the cluster has a corresponding spatial distribution of second plurality of HST values that is less than about 20% or more than about 100% of the second average HST value, tissue corresponding to the cluster is confirmed to be diseased.
[0008] In yet another embodiment, the present invention comprises a method of detecting diseased tissue including recording first and second series of infrared images of a predetermined area of tissue. The first and second series of infrared images are recorded in respective first and second bands of infrared wavelengths, with the second band of infrared wavelengths different from the first band of infrared wavelengths. The first and second series of infrared images are converted into corresponding first and second series of thermal images. The predetermined area of tissue is subdivided into a plurality of subareas. A first plurality of average temperature values is determined for each of the plurality of subareas, with each of the first plurality of average temperature values for each of the plurality of subareas being determined from one of the first series of thermal images. A second plurality of average temperature values is determined for each of the plurality of subareas, with each of the second plurality of average temperature values for each of the plurality of subareas being determined from one of the second series of thermal images. First and second radiance measurements are taken at respective first and second bands of infrared wavelengths of known healthy tissue. The first and second radiance measurements of known healthy tissue are correlated. The first and second plurality of average temperature values for each of the plurality of subareas are correlated. The correlated first and second plurality of average temperature values for each of the plurality of subareas is then analyzed. When a spatial distribution of slopes of the correlated first and second plurality of average temperature values corresponding to a cluster comprising at least six adjacent subareas is different from a slope of the correlation of known healthy tissue, tissue corresponding to the cluster is determined to be diseased.
[0009] In still another embodiment, the present invention comprises a method of detecting diseased tissue including recording first and second series of IR images of a predetermined area of tissue. The first and second series of IR images are recorded in corresponding first and second bands of IR wavelengths, the two bands of IR wavelengths being different. The first and second series of IR images are converted into corresponding first and second series of thermal images. The predetermined area of tissue is subdivided into a plurality of subareas. A first plurality of average temperature values and a first plurality of temperature standard deviations are determined for each of the plurality of subareas from a corresponding one of the first series of thermal images. A second plurality of average temperature values and a second plurality of temperature standard deviations are determined for each of the plurality of subareas from a corresponding one of the second series of thermal images. A first average temperature standard deviation is determined using the first plurality of temperature standard deviations. A second average temperature standard deviation is determined using the second plurality of temperature standard deviations. The resulting first and second pluralities of temperature standard deviations for each of the plurality of subareas are then analyzed for possible diseased tissue. Tissue corresponding to a cluster of at least six adjacent subareas having a spatial distribution of corresponding temperature standard deviations that is less than about 20% or more than about 100% of the first average temperature standard deviation is preliminarily determined to be diseased. Tissue corresponding to the cluster preliminarily determined to be diseased is further analyzed. If the cluster has a corresponding spatial distribution of second plurality of temperature standard deviations that is less than about 20% or more than about 100% of the second average temperature standard deviation, tissue corresponding to the cluster is confirmed to be diseased.
[0010] In further embodiments, alternative data analysis is possible. This alternative data analysis may include finding contributing frequencies for each subarea and determining that tissue corresponding to a cluster having a spatial distribution of less than a lower threshold frequency or more than an upper threshold frequency is diseased. The data may undergo fast Fourier analysis for this frequency determination. The data in the two series of thermal images can be correlated with diseased tissue having a different correlation intercept than healthy tissue. The contrast in the two series of IR images can be enhanced by subjecting the predetermined area of tissue to thermal stress, such as by directing a cooling flow of air across the area of tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention is described in reference to the following Detailed Description and the drawings in which:
[0012] FIG. 1 is diagram of the blood perfusion process that can be detected by embodiments of the present invention,
[0013] FIG. 2 is an average temperature histogram generated by a first embodiment of the present invention,
[0014] FIG. 3 is a contributing frequency histogram generated by second and third embodiments of the present invention,
[0015] FIG. 4 is a correlation plot generated by fourth and fifth embodiments of the present invention,
[0016] FIG. 5 is an HST value histogram generated by sixth and seventh embodiments of the present invention,
[0017] FIG. 6 is a temperature standard deviation histogram generated by an eighth embodiment of the present invention
[0018] FIG. 7 is a block diagram of an apparatus for implementing the first through third embodiments of the present invention,
[0019] FIG. 8 is a block diagram of an apparatus for implementing the fourth and fifth embodiments of the present invention,
[0020] FIG. 9 is a block diagram of an apparatus for implementing the sixth and seventh embodiments of the present invention, and
[0021] FIG. 10 is a block diagram of an apparatus for implementing the eighth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Various embodiments of the present invention are described in detail with reference to the drawings. While the following description will generally discuss each embodiment separately, two or more embodiments may be combined to increase the accuracy of diseased or cancerous tissue detection. Further, while the present description will generally use only two bands of IR wavelengths, the use of three or more bands of IR wavelengths will further increase system sensitivity to diseased tissue.
[0023] FIG. 1 illustrates an area of tissue and skin 100 , of which a portion is diseased, such as by a cancerous lesion. This area of tissue and skin 100 is imaged by a diagnostic system 110 employing the methodology of the present invention. The diagnostic system 110 comprises a dual-band IR imager 112 and a computer 114 .
[0024] In the healthy portion of the area of tissue and skin 100 , the body regulates its temperature using neuronal modulation of blood perfusion 120 . The neuronal modulation of blood perfusion 120 includes vasodilation to cool the body and vasoconstriction to warm the body in the body's effort to maintain a desired temperature 122 . This results in normal temperature oscillations 124 about the desired temperature 122 . The body uses the skin as a radiator to remove excess heat causing the skin temperature 126 to oscillate. The skin temperature 126 oscillates over a band of neuronal thermoregulatory frequencies (TRFs) 128 . The skin therefore radiates an IR flux 130 as excess heat is given off by the skin in the body's effort to maintain the desired temperature 122 . While this process is generally discussed in terms that the tissue underlying the skin is cancerous, this method lends itself to the detection of skin cancer as well. For that reason, while the term tissue and skin may be used separately, skin will also be considered tissue for the purposes of this description.
[0025] The diagnostic system 110 takes a series of infrared images of the tissue and skin 100 using the dual-band IR imager 112 and processes the resultant images using the computer 114 . The actual images will be composed of many individual pixels, each corresponding to a different portion of the imaged tissue and skin 100 . The dual-band IR imager 112 may be based upon a 256 pixel by 256 pixel or 480 pixel by 640 pixel dual-band IR photodetector array. To increase sensitivity, the dual-band IR imager 112 images the tissue and skin 100 in two different bands of IR wavelengths resulting in two different series of IR images. By using the two different series of IR images, the occurrence of false positives and false negatives may be reduced. The second series of IR images in the second band of IR wavelengths may serve as a check on the first series of IR images in the first band of IR wavelengths, thereby increasing overall diagnostic system 110 sensitivity depending upon the data analysis method. The use of N independent bands of IR wavelengths generally leads to a {square root}N increase in sensitivity. With the two bands used throughout this description, this increase in sensitivity leads from a single band IR diagnostic system having a sensitivity of 30 m° C. to a dual-band IR diagnostic system 110 having a sensitivity of 21 m° C. Alternatively, if 30 m° C. is the desired diagnostic system 110 sensitivity, then the dual-band IR imager 112 can incorporate two single-band IR photodetector arrays each having a sensitivity of 42 m° C., thereby improving manufacturability.
[0026] The increased sensitivity of the dual-band IR imager 112 over a single-band IR imager decreases the occurrence of false positive and false negatives due to tissue and skin variations. Different portions of the skin may radiate different levels of IR flux, even though both the skin and the underlying tissue are healthy. As an example, a birthmark will likely radiate heat differently than normal skin. Similarly, a tattoo may create a false positive or false negative, as it too will radiate heat differently than normal skin. For a very sensitive single-band IR imager, a large freckle may lead to a false positive or false negative. However, by using two series of IR images, each taken in different bands of IR wavelengths, false positives and false negatives due to variations in skin color will be minimized. Variations in the underlying tissue can also affect detection of diseased tissue. While a breast may have relatively uniform tissue, an arm will include areas of significant muscle tissue adjacent to bony regions such as the elbow and wrist, resulting in IR image variations.
[0027] The nitric oxide (NO) modulation of blood perfusion 140 will be described next. A diseased portion of the tissue and skin 100 , due to a cancer 142 in this discussion, provokes an immune response 144 within the tissue and skin 100 . This immune response 144 results in increased macrophage activity 146 , which produces NO 148 . Some cancers, such as breast cancer, are known to elevate the local level of ferritin 150 within the diseased tissue. Elevated levels of ferritin 150 further increases the amount of NO 148 produced within the diseased tissue. Nitric oxide causes vasodilation 152 of the capillary bed leading to enhanced blood perfusion 156 within the diseased tissue. A side effect of the presence of NO is that neuronal control (vasodilation and vasoconstriction) of the capillary bed is impaired 154 . The net result is that temperature in the diseased tissue will be controlled more by NO-based blood perfusion rather than by neuronal processes. That is, NO controlled temperature oscillations 158 will dominate over the attenuated neuronal temperature oscillations 160 .
[0028] A second side effect of NO controlled blood perfusion is an increase in spatial homogeneity of skin temperature 162 . That is, there will be less temperature variation in the skin surface temperature due to the NO-induced vasodilation of the capillary bed. NO controlled blood perfusion will occur at non-neuronal TRFs 164 , as will be discussed in detail below. As with healthy tissue, the temperature of the skin overlying diseased tissue will create an IR flux 166 that can then be imaged by the dual-band IR imager 112 .
[0029] The first embodiment of the present invention is based upon the average temperature of the imaged tissue. The first embodiment converts the first and second series of IR images into thermal images, i.e., converts each pixel from the IR image to a corresponding temperature. Each individual thermal image therefore is a two-dimensional array of temperatures and each of the first and second series of thermal images is a series of two-dimensional arrays of temperatures. At the preferred imaging rate of 30 to 60 images per second and a 10 to 60 second series of images, the first and second thermal images can readily include over 1000 individual thermal images. The first embodiment next subdivides the tissue area imaged into a number of subareas. These subareas correspond to two pixel by two pixel portions of the thermal images or larger. A preferred upper limit on the subarea size is an eight pixel by eight pixel subarea as larger areas will tend to average out any local variations that might indicate the presence of diseased tissue.
[0030] The first embodiment then finds the average temperature value for each of these subareas. This is done for each individual thermal image in both the first and the second series of thermal images resulting in first and second pluralities of average temperature values. These first and second pluralities of average temperature values are then analyzed in view of FIG. 2 . FIG. 2 illustrates a histogram showing all of the average temperature values for the first plurality of average temperature values 200 . Curve 202 is the composite curve showing the average temperature values for skin overlying both healthy and diseased tissue. Curve 204 corresponds to the average temperature values for the skin overlying a healthy region of tissue. Curve 204 therefore corresponds to skin whose underlying tissue is thermally regulated by neuronal control of blood perfusion. The peak temperature value for this healthy tissue is denoted T H . In regions of skin overlying diseased or cancerous tissue, the average temperature value curve 206 is formed. Due to the generally vasodilated state of the capillary bed in diseased tissue, the average temperature value for these regions is greater. The higher peak average temperature value for these diseased regions is denoted by T D .
[0031] A preliminary determination that a cancerous lesion may be present requires that a cluster of six adjacent subareas each have abnormal average temperature values. A first average temperature value for the first series of thermal images is calculated. This first average temperature value is preferably found by proportionately weighting each of the subareas based upon their size. In particular, when a spatial distribution of the first average temperature values within the cluster of six adjacent subareas is less than about 20% or more than about 100% of the first average temperature value, tissue corresponding to the cluster of six adjacent subareas is preliminarily determined to be diseased. This preliminary determination is confirmed if the same series of calculations and comparisons on the second series of thermal images yields the same cluster of six adjacent subareas.
[0032] As each of the first and second series of IR images is preferably taken periodically, TRFs can be determined. The second embodiment of the present invention makes use of these TRFs. FIG. 3 illustrates a TRF histogram for both healthy and diseased tissue 300 . Curve 302 is a composite for both the healthy and diseased tissue while curve 304 corresponds to healthy tissue and curve 306 corresponds to diseased tissue. Curve 304 for healthy tissue reflects neuronal control blood perfusion and generally has a frequency of between 10 and 700 milliHertz. In contrast, curve 306 for diseased tissue reflects NO-based control of blood perfusion and has a higher frequency, generally in the range of 0.8 to 2.0 Hz.
[0033] The second embodiment makes use of the differences in TRFs by finding the contributing frequency for each subarea in the first series of thermal images. This contributing frequency may be determined by analyzing the average temperature value for a subarea based on the known periodic nature of the first series of thermal images. The preferred method to determine the contributing frequency is to subject the average temperature values to a fast Fourier transform that rapidly finds the frequency components or ranges of frequencies for a time varying signal. As shown in FIG. 3 , while more healthy tissue subareas had a TRF of F H , there is some variation about this frequency. However, very few healthy tissue subareas had a TRF as high as F D , the strongest of the diseased tissue TRFs. Once the contributing frequency for each subarea using the first series of thermal images is determined, first lower and upper threshold frequencies are found, preferably by weighting each subarea based upon their size. As before, a cluster of six adjacent abnormal subareas leads to a preliminary diseased tissue diagnosis. In particular, when a spatial distribution of the contributing frequency of the cluster is less than the first lower threshold frequency or more than the first upper threshold frequency, tissue corresponding to the cluster is preliminarily diagnosed as being diseased. This preliminary diagnosis is confirmed if the same series of determinations and comparisons on the second series of thermal images yields the same cluster of six adjacent subareas.
[0034] The third embodiment is similar to the second embodiment in that it uses the contributing frequency of each subarea. In particular, the third embodiment uses the amplitude of the contributing frequencies. As shown in FIG. 3 , the diseased tissue curve 306 has only a small frequency amplitude at F H , thus providing another means for cancer discrimination. The third embodiment therefore searches for a cluster in which a spatial distribution of the amplitude of the contributing frequency is less than a first lower threshold amplitude or more than a first upper threshold amplitude. The first lower and upper threshold amplitudes are determined using the first series of thermal images and is preferably weighted by subarea size. As with the previous embodiments, the use of the second series of thermal images is used to confirm a preliminary diseased diagnosis from the first series of thermal images.
[0035] In contrast to the first three embodiments that use the two series of thermal images sequentially, the fourth embodiment uses the two series of thermal images in parallel. FIG. 4 illustrates a series of correlation curves 400 for two different bands of IR wavelengths, the two bands centered around λ 1 and λ 2 . The fourth embodiment includes taking a baseline radiance measurement of known healthy skin and tissue in the two different bands of IR wavelengths, thereby generating a healthy skin and tissue correlation curve 402 . This healthy correlation curve 402 can be mathematically defined most simply in terms of a slope and an intercept, that is λ 2 =m H λ 1 +b H . It should be noted that depending upon the wavelengths within the two bands of IR wavelengths, the properties of the skin and underlying tissue, etc., additional terms might be required to more accurately describe the correlation. In the simple slope and intercept form, the precise values for m H and b H will likely be a function of the skin and the underlying tissue. For example, the m H and b H values for a breast cancer screening will likely be different from the m H and b H values for a bony structure such as the wrist or ankle. Once the appropriate healthy correlation curve 402 is determined, the subareas within the first and second series of thermal images will also be correlated. This correlation may produce subareas having diseased correlation curve 404 or 406 . Diseased correlation curve 404 may be described as λ 2 =m D1 λ 1 +b D1 , while diseased correlation curve 406 may be described as λ 2 =m D2 λ 1 +b D2 . The fourth embodiment then compares the slope m D1 or m D2 with m H . If a spatial distribution of the m D1 or m D2 values for a cluster are different than m H , then the tissue corresponding to the cluster is determined to be diseased. How different the slope values will be will depend upon the types of underlying tissue as noted above, as well as the specific wavelengths λ 1 and λ 2 chosen.
[0036] The radiance measurements of healthy skin taken for the fourth embodiment may be made as a function of integration time for the dual-band IR imager 112 , the temperature of the skin and tissue being imaged, or a combination thereof. The temperature of the skin and tissue can be varied by directing either a warming or a cooling stream of air on the skin and tissue resulting in thermal stress to the skin and tissue. Alternatively, this thermal stress may be induced by directing a flow of water vapor to the skin and tissue. While this thermal stress finds particular application with the fourth (and fifth) embodiments, it can readily be used in conjunction with the other embodiments as well.
[0037] Due to the oscillatory nature of thermal regulation, the sensitivity of the fourth (and fifth) embodiments can be increased. By finding the contributing frequency for each of the subareas, the correlation between the two series of thermal images can be made at neuronal frequencies or at NO modulation frequencies. It is anticipated that correlations made at NO modulation frequencies will be especially sensitive for discriminating healthy versus diseased skin and tissue regions.
[0038] While the fourth embodiment uses the slope of the correlation between the two series of thermal images, the fifth embodiment uses the intercept of the correlation between the two series of thermal images. To this end, the fifth embodiment compares b D1 or b D2 with b H . When the spatial distribution of b D1 or b D2 for a cluster are different from b H , tissue corresponding to the cluster is diagnosed as being diseased. As before, this difference is a function of the underlying tissue and the specific wavelengths chosen.
[0039] The sixth embodiment of the present invention is based upon detectable differences in the HST between healthy and diseased skin and tissue. The HST for a subarea is found by determining both the average temperature value and the temperature standard deviation and then dividing the average temperature value by the temperature standard deviation. The HST is found for each subarea for each of the first series of thermal images. FIG. 5 shows the resultant histogram 500 of HST values from the first series of thermal images for the skin overlying both healthy and diseased tissue. Curve 502 is the overall HST curve while curve 504 corresponds to healthy skin and tissue while curve 506 corresponds to diseased skin and tissue. The temperature standard deviation found in diseased tissue is lower than that of healthy tissue due to the overall vasodilated state of the capillary bed. This lower standard deviation results in higher HST values for diseased skin and tissue regions, centered about HST D as shown in FIG. 5 . In contrast, healthy skin and tissue temperature is controlled by neuronal processes that include both vasodilation and vasoconstriction. This results in wider variations in skin temperature, larger temperature standard deviations and therefore smaller HST values. FIG. 5 shows the healthy skin and tissue regions to have HST values centered about HST H . An overall first average HST for the first series of thermal images is also computed. A preliminary diseased tissue diagnosis is made when spatial distribution of a cluster of six adjacent subareas have HST values of less than about 20% or more than about 100% of the first average HST. This preliminary diagnosis is confirmed if the same series of calculations and comparisons on the second series of thermal images yields the same cluster of six adjacent subareas.
[0040] The seventh embodiment makes use of the differences in TRFs of the HST values by finding the contributing frequency for each subarea in the first plurality of HST values. The seventh embodiment will generate a frequency histogram similar to that of FIG. 3 in that healthy tissue subareas will have a TRF of HST values with some variation about a healthy tissue center frequency. Likewise, diseased tissue subareas will have TRF of HST values with some variation about a higher diseased tissue center frequency. Once the contributing TRF of HST values for each subarea using the first series of thermal images is determined, a first average contributing frequency is found. A cluster of six adjacent abnormal subareas leads to a preliminary diseased tissue diagnosis. In particular, when a spatial distribution of the magnitude of the contributing TRF of HST values of the cluster is less than about 20% or more than about 100% of the first average contributing frequency, tissue corresponding to the cluster is preliminarily diagnosed as being diseased. This preliminary diagnosis is confirmed if the same series of determinations and comparisons on the second series of thermal images yields the same cluster of six adjacent subareas.
[0041] FIG. 6 illustrates a temperature standard deviation histogram 600 employed by the eighth embodiment of the present invention. The eighth embodiment requires determining the temperature standard deviation for each of the subareas for each one of the first series of thermal images. Curve 602 corresponds to the resultant overall histogram for the temperature standard deviations and is a combination of a curve 604 representing the temperature standard deviations for healthy skin and tissue and curve 606 representing the temperature standard deviations for diseased skin and tissue. The standard deviation for diseased skin and tissue will be lower as noted above due to the generally vasodilated state of the capillary bed leading to more constant temperatures relative to skin and tissue under neuronal controlled blood perfusion. A preliminary diagnosis of diseased skin and tissue corresponding to a cluster of six adjacent subareas requires the cluster to have a spatial distribution of temperature standard deviation of less than about 20% or more than about 100% of a first average temperature standard deviation based upon the first series of thermal images. The preliminary diagnosis based upon temperature standard deviation is confirmed if the same series of determinations and comparisons on the second series of thermal images yields the same cluster of six adjacent subareas.
[0042] Each of the embodiments will now be described in reference to FIGS. 7 through 10 . The first through third embodiments are illustrated by the block diagram shown in FIG. 7 . In each of the first through third embodiments, two series of IR images of the tissue are recorded in two corresponding different bands of IR wavelengths by the dual-band IR imager 112 . The two series of IR images are then converted by a converter 704 into two series of thermal images. An averager 706 then determines a series of average temperatures for each of the subareas using both series of thermal images. The averager 706 also determines an overall average temperature using both series of thermal images. All of this average temperature information is then analyzed by an analyzer 708 in the first embodiment. In the second embodiment, the two series of thermal images undergo frequency analysis, i.e., the contributing frequencies for the subareas are determined, by a frequency analyzer 710 . The contributing frequencies are then analyzed by the analyzer 708 to determine if any clusters indicate the presence of diseased tissue based upon contributing frequencies. Like the second embodiment, the third embodiment uses the frequency analyzer 710 . The third embodiment requires the analyzer to analyze the amplitude of the contributing frequencies and any clusters having unusual frequency amplitudes may be diagnosed as corresponding to diseased tissue.
[0043] The fourth and fifth embodiments are illustrated in the block diagram of FIG. 8 . As with the first three embodiments, two series of IR images of the tissue are recorded in two corresponding different bands of IR wavelengths by the dual-band IR imager 112 . The two series of IR images are then converted by the converter 704 into two series of thermal images. The averager 706 then determines a series of average temperatures for each of the subareas using both series of thermal images. The dual-band IR imager 112 also records radiance images in both bands of IR wavelengths, which are subsequently converted into thermal images. Both sets of average temperature data and the radiance image data are correlated by a correlator 722 . An analyzer 724 then analyzes the correlation data produced by the correlator 722 . In the fourth embodiment, the analyzer 724 analyzes the slope of the correlation data while in the fifth embodiment the analyzer 724 analyzes the intercept of the correlation data. FIG. 8 also illustrates an element 726 for subjecting tissue to a thermal stress. As noted above, the element 726 can create this thermal stress by directing a stream of warm or cool air over the tissue or by directing a mist at the tissue. While the element 726 is illustrated only in FIG. 8 corresponding to the apparatus for implementing the fourth and fifth embodiments, it can readily be included apparatuses for implementing the first through third and sixth through eighth embodiments.
[0044] An apparatus for implementing the sixth and seventh embodiments is illustrated in block fashion in FIG. 9 . As with the first five embodiments, two series of IR images of the tissue are recorded in two corresponding different bands of IR wavelengths by the dual-band IR imager 112 . The two series of IR images are then converted by the converter 704 into two series of thermal images. In the sixth embodiment, the two series of thermal images are then processed by the processor 744 . The processor 744 determines average temperatures and standard deviations for each of the subareas using both series of thermal images. The processor 744 then determines HST values for each of the subareas for both series of thermal images. Lastly, the processor 744 determines the average HST value for both series of thermal images. An analyzer 746 then analyzes this HST data to determine if any clusters correspond to diseased tissue. In the seventh embodiment, the two series of thermal images undergo frequency analysis by the frequency analyzer 710 . The resultant frequency analyzed data is then analyzed by the analyzer 746 to determine of diseased tissue is present.
[0045] FIG. 10 illustrates the various blocks required for implementing the eighth embodiment of the present invention. Two series of IR images of the tissue are recorded in two corresponding different bands of IR wavelengths by the dual-band IR imager 112 . The two series of IR images are then converted by a converter 704 into two series of thermal images. These two series of thermal images then undergo a series of processes by the processor 744 described above. The various averaged data is then analyzed by an analyzer 764 . In the eighth embodiment, the analyzer 764 determines if any clusters have abnormal standard deviations that would indicate the presence of diseased tissue.
[0046] The diagnostic system 110 , and in particular, the dual-band IR imager 112 will now be described in greater detail. The first and second bands of IR wavelengths detected by the dual-band IR imager 112 are preferably within the long wavelength IR (LWIR), which corresponds to radiation having a wavelength of eight to twelve microns. For example, the first band of IR wavelengths might cover the wavelength range of eight to nine microns while the second band of IR wavelengths might cover from ten to eleven microns. The LWIR is preferred as the human body IR emissions peak within this range of wavelengths. The first and second bands of IR wavelengths could alternatively be in the middle wavelength IR (MWIR) corresponding to radiation having a wavelength of three to five microns. As a further alternative, the two bands of IR wavelengths could include one in the LWIR and one in the MWIR.
[0047] The dual-band IR imager 112 may be formed in one of several ways. The dual-band IR imager 112 could include two single-band IR photodetector arrays, each sensitive to different bands of IR wavelengths. Alternatively, the two single-band IR photodetector arrays could be identical with the different bands of IR wavelength response due to filters. Using two single band IR photodetectors will require the use of a beam splitter to cause spatially registered images to be focused on each of the single-band IR photodetector arrays. While the use of two single-band IR photodetector arrays will probably decrease the cost of each single-band IR photodetector array, the overall system cost will likely increase. Such a two photodetector array-based dual-band IR imager 112 will require the aforementioned beamsplitter, and probably two separate coolers as each single-band IR photodetector array will require cooling. Such a two photodetector array-based dual-band IR imager will also require very tight tolerances to ensure that the image is truly spatially registered on both photodetector arrays, thereby reducing manufacturability.
[0048] A single dual-band IR photodetector array appears more feasible and manufacturable. Several dual-band photodetector technologies have been demonstrated including those using HgCdTe and GaAs-based multiple quantum well (MQW) semiconductor materials. Dual-band photodetectors using HgCdTe semiconductor materials have high quantum efficiencies, but place strict requirements on the HgCdTe manufacturing process. While dual-band HgCdTe photodetectors operating in the MWIR and LWIR have shown excellent performance, the use of HgCdTe semiconductor material for the preferred LWIR-LWIR configuration places extremely strict requirements on the starting HgCdTe semiconductor material. For these reasons, it appears unlikely that a commercial HgCdTe dual-band IR camera is feasible using current manufacturing technology.
[0049] GaAs-based MQW semiconductor material appears to be a more manufacturable technology and is thus preferable for the present invention. The GaAs-based starting material is commercially available from several sources and the fabrication processes are in use in a number of facilities. GaAs-based MQW semiconductor material may be fabricated into quantum well IR photodetectors (QWIPs) and enhanced QWIPs (EQWIPs). Dual-band QWIPs and EQWIPs have been demonstrated to date with the EQWIP offering better sensitivity due to its resonant optical cavity and reduced noise. Various embodiments of the EQWIP are described and claimed in U.S. Pat. Nos. 5,539,206, 6,133,571, 6,157,042, and 6,355,939 and are hereby incorporated by reference. Additional preferred embodiments of the EQWIP are described in copending application numbers 21201 and 21301.
[0050] The present invention, by imaging a human being, encounters problems should the patient move during the image taking portion of the process. To minimize this effect, the images for the two different series of IR images are preferably taken in an alternating fashion. That is, first an IR image is taken from the first band of IR wavelengths and then an IR image is taken from the second band of IR wavelengths. By alternating the IR wavelength bands, the correlation between the first image in both series of IR images increases when compared to taking all of the first series of IR images over the course of 10 to 60 seconds and then taking all of the second series of IR images. To further minimize problems due to patient motion, the imaging rate should be relatively high, preferably in the range of 30 to 60 Hz or greater. An added benefit of the increased imaging rate is that any of the embodiments using frequency-based analysis will have increased frequency resolution.
[0051] The computer 114 within the diagnostic system 110 will be required to store significant quantities of data and undertake substantial numerical processing. The computer 114 will need to store several thousands of individual IR images and thermal images for each patient. As each of these could include 640 pixels by 480 pixels-worth of data, a rather sizeable hard disk drive and large amount of RAM will be beneficial. Due to the substantial amount of numerical processing that will be undertaken, a separate numerical processing board may be advantageous.
[0052] Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, such changes and modifications should be construed as being within the scope of the invention. | A method of and apparatus for detecting diseased tissue based upon infrared imaging in two different bands of infrared wavelengths is described. The use of two series of infrared images taken in two different bands of infrared wavelengths increases sensitivity to the subtle temperature changes caused by diseased skin and tissue, especially in the case of cancerous tissue. By sensing skin temperature, the homogeneity thereof, the time variations thereof and the correlation between the two series of infrared images, the present invention decreases the rate of false positives and false negatives. The increased discrimination due to two series of infrared images allows for reliable detection of diseased or cancerous tissue even in the presence of skin tone variations such as birthmarks, tattoos and freckles. The present invention finds special application in the field of breast cancer detection where subtle skin temperature variations may readily be sensed using two series of infrared images. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of fingernail protectors. More particularly, the present invention concerns fingernail protectors that have a clip-on design. Specifically, a preferred embodiment of the present invention is directed to fingernail protectors that have an arcuate shape. The present invention thus relates to fingernail protectors of the type that can be termed arcuately shaped clips-ons.
2. Discussion of the Related Art
Heretofore, it was known in the prior art to provide fingernail protectors. A conventional fingernail protector is typically an O-shaped tapered tube. For example, it has been known to insert the tip of one's finger into the open base of a truncated cone.
A previously recognized problem has been that fingers that are inserted into such O-shaped fingernail protectors loose their tactile sensitivity because the finger pads are covered by the fingernail protector. Therefore, what is needed is a fingernail protector that does not degrade tactile sensitivity.
An unsatisfactory previously recognized solution to the problem of tactile sensitivity degradation was to provide an O-shaped fingernail protector that included a fingertip pad opening. A disadvantage of this previously recognized solution is that tactile sensitivity is still degraded by the complete enclosure of at least a portion of the finger by the O-shaped fingertip protector.
Another previously recognized problem has been that heat and moisture builds up within such an O-shaped fingernail protector because the entire perimeter of at least a portion of the finger is enclosed. Therefore, what is also needed is a fingernail protector that does not permit heat and moisture to build up.
One unsatisfactory previously recognized solution to the problem of heat and moisture buildup was to provide fingernail protectors with ventilation holes. A disadvantage of this previously recognized solution is that a large proportion of the surface area of the skin is still covered by such nail protectors. Further, this previously recognized solution also has the disadvantage of not encouraging convection currents across the skin surface of the finger where only one vent hole is provided.
Yet another previously recognized problem has been that fingernail protectors with enclosed tips necessarily limit the length of fingernails that can be inserted into such protectors. Therefore, what is also needed is a fingernail tip protector that does not have a maximum permissible nail length.
An unsatisfactory previously recognized solution to the problem of limited nail length capacity was to provide an open ended truncated conical O-shaped finger nail protector. A disadvantage of this previously recognized solution is that such simple open ended tubes do not permit the dissipation of heat and moisture or the maintenance of tactile sensitivity. Heretofore these requirements have not been fully met without incurring various disadvantages.
The below-referenced U.S. patents disclose embodiments that were at least in-part satisfactory for the purposes for which they were intended but which had certain disadvantages. The disclosures of all the below-referenced prior United States patents in their entireties are hereby expressly incorporated by reference into the present application for purposes including, but not limited to, indicating the background of the present invention and illustrating the state of the art.
U.S. Pat. No. 3,967,631 discloses a fingernail cap. Although this fingernail cap is provided with an opening that permits some degree of tactile sensitivity at the fingertip pad, this fingernail cap completely encloses the tip of the fingernail and completely surrounds the base of the fingertip joint.
U.S. Pat. No. 4,089,066 discloses a fingernail protector. Although this fingernail protector does not limit the length of the nail with which it is used, this fingernail protector completely surrounds the fingertip thereby limiting tactile sensitivity and permitting heat and moisture to accumulate.
U.S. Pat. No. 4,960,138 discloses a fingernail protective device. Although an embodiment of this device permits the accommodation of any length nail, this embodiment necessarily limits tactile sensitivity and is not well suited to dissipating heat and moisture because the majority of the open surface area is located primarily at the tip of the fingernail.
U.S. Pat. No. 4,966,174 discloses a fingernail protector. Although this protector provides for relatively large volume of air around the fingernail, it necessarily limits tactile sensitivity and can only be used with nails of a certain length.
U.S. Pat. No. 4,972,857 discloses a fingernail polish protector. Although this protector provides for relatively large volume of air around the fingernail, it necessarily limits tactile sensitivity.
U.S. Pat. No. 5,085,234 discloses a fingernail shielding method. Although the truncated octagonal shaped tube used by the method permits the accommodation of any length nail, tactile sensitivity is necessarily limited by the method and the dissipation of heat and moisture is necessarily limited by the fact that the sole air vent opening is provided at the tip of the fingernail.
U.S. Pat. No. Des. 329,923 discloses a fingernail protector guard. This fingernail protector guard necessarily limits tactile sensitivity, limits the dissipation of heat and moisture through the provision of only one opening and can only be used with fingernails of a certain length.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a fingernail protector that maintains tactile sensitivity. Another object of the invention is to provide a fingernail protector that provides convection currents. Another object of the invention is to provide a fingernail protector that can be used with varying length nails. Another object of the invention is to provide a fingernail protector that can be clipped-on over the side of a finger so as to be frictionally retained in place, thereby protecting a fingernail. Yet another object of the invention is to provide a fingernail protector that can be manufactured rapidly with a minimum of equipment.
In accordance with a first aspect of the invention, these objects are achieved by providing an arcuate sheath comprising: a resilient arcuate section having a proximal open end and a distal open end, said arcuate section defining a first axis and subtending an angle of at least approximately 180° ; a flared arcuate section connected to said resilient arcuate section, said flared arcuate section having a first open end that is connected to said distal open end of said resilient arcuate section and a second open end, said flared arcuate section rising obliquely away from said resilient arcuate section; and an elongated arcuate section connected to said flared arcuate section, said elongated arcuate section having a connected open end that is connected to said second open end of said flared arcuate section and a free open end, said elongated arcuate section defining a second axis. In a preferred embodiment, the arcuate sheath also includes a first tab connected to said resilient arcuate section, said first tab having a first tab base that is connected to said resilient arcuate section and a first tab top, said first tab extending substantially orthogonally away from said resilient arcuate section and defining a first tab plane that is substantially parallel to said first axis.
Still another object of the invention is to provide a method of protecting a fingernail. In accordance with another aspect of the invention, this object is achieved by providing a method of at least partially enclosing a fingernail in need of protection, said method comprising: providing an arcuate sheath including a resilient arcuate section having a proximal open end and a distal open end, said arcuate section defining a first axis and subtending an angle of at least approximately 180° ; a flared arcuate section connected to said resilient arcuate section, said flared arcuate section having a first open end that is connected to said distal open end of said resilient arcuate section and a second open end, said flared arcuate section rising obliquely away from said resilient arcuate section; and an elongated arcuate section connected to said flared arcuate section, said elongated arcuate section having a connected open end that is connected to said second open end of said flared arcuate section and a free open end, said elongated arcuate section defining a second axis that is substantially parallel to said first axis; and sliding the arcuate sheath over the side of a finger so as to frictionally retain said arcuate sheath on said finger and at least partially enclose said fingernail. In a preferred embodiment, the method also includes applying force to said fingernail protector to deflect said resilient arcuate section.
An effect of the present invention is to protect fingernail polish from becoming physically disrupted while it dries.
Other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
A clear conception of the advantages and features constituting the present invention, and of the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification; wherein, like reference numerals designate the same elements in the several views, and in which:
FIG. 1A illustrates an isometric view of a first embodiment of a fingernail protector according to the present invention;
FIG. 1B illustrates a top elevational view of the fingernail protector shown in FIG. 1A;
FIG. 1C illustrates a dynamic sectional view of the fingertip protector shown in FIG. 1A;
FIG. 1D illustrates a side elevational view of the fingernail tip protector shown in FIG. 1A;
FIG. 1E illustrates a sectional view of the fingernail tip protector shown in FIG. 1A;
FIG. 2A illustrates an isometric view of a second embodiment of a fingernail protector according to the present invention;
FIG. 2B illustrates a top elevational view of the fingernail protector shown in FIG. 2A;
FIG. 2C illustrates a dynamic sectional view of the fingertip protector shown in FIG. 2A;
FIG. 2D illustrates a side elevational view of the fingernail tip protector shown in FIG. 2A; and
FIG. 2E illustrates a sectional view of the fingernail tip protector shown in FIG. 2A.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention and various features and advantageous details thereof are explained more fully with reference to exemplary, and therefore non-limiting, embodiments described in detail in the following disclosure and with the aid of the drawings.
1. Overview
The fingernail protector according to the present invention is designed to protect fingernails during the polish drying process and enable the polish to dry free of any dents, chips, tears or sheet marks. The fingernail protector is preferably lightweight and smooth.
The presently disclosed fingernail protector works especially well when the base of a polished nail is set at the top of the base of the fingernail protector, and the fingernail protector is clipped to the finger so that air drying vents are close to, but not touching, the top of the fingernail. Accordingly, the fingernail protector is spaced away from the upper surface of a fingernail and does not mar polish that has been coated onto the upper surface of the nail.
The fingernail protector according to the present invention can be used throughout an individual's normal day or may be clipped on at night so as to allow a fingernail to dry as the individual is comfortably sleeping. The fingernail protector fulfills the need for a neat and clean appearance of painted nails and will frequently eliminate the need for repolishing any, or all, of an individual's fingernails. If less than all of an individual's fingernails require repolishing, this situation can be readily addressed by the fact that each finger is individually enclosed by an individual fingernail protector.
The fingernail protector permits day to day living without ruining nails. The fingernail protector is especially useful where children must be attended to. The fingernail protector can include a snap enclosure. The fingernail protector can include air vents. Preferably the base of the fingernail protector has air vents. The fingernail protector can include a bridge on the inner circumference to protect a nail from hitting the top of the fingernail protector. Although the use of polyurethane for subcomponents of the fingernail protector might be advantageous under certain circumstances, such as interchangeable cylindrical springs, polyethylene is preferred because it is not readily soluble in acetone, which is a major component in fingernail polish remover. There is no maximum nail length for use with this embodiment. The fingernail protector will not break, scratch or dent.
2. First Embodiment
Referring to FIG. 1A, a fingernail protector according to the present invention includes a resilient arcuate section 100. Resilient arcuate section 100 includes a proximal open end 110 and a distal open end 120. Resilient arcuate section 100 defines a first axis.
The fingernail protector includes a flared arcuate section 200. A first open end 210 of flared arcuate section 200 is connected to the distal open end 120 of resilient arcuate section 100. Flared arcuate section 200 also includes a second open end 220.
The fingernail protector includes an elongated arcuate section 300. A connected open end 310 of elongated arcuate section 300 is connected to the second open end 220 of flared arcuate section 200. Elongated arcuate section 300 defines a second axis. Elongated arcuate section 300 includes a free open end 370, as shown in FIGS. 1A, 1B and 1D.
The bottom of the fingernail protector is open completely so that the pad of a finger to which the fingernail protector is attaches will retain tactile sensitivity. This nearly complete openness also discourages the build up of heat and moisture. While the embodiment shown is fabricated from a single piece of material, subcomponents of the fingernail protector can be fabricated separately, from the same, or other materials.
Referring now to FIG. 1B, the elongated arcuate section 300 can include a plurality of elongated slots 320. Slots 320 are preferably circumferentially distributed around the periphery of elongated arcuate section 300.
Although this embodiment is shown with elongated slots 320 in the C-shaped housing, the elongated slots 320 could be replaced by cylindrical holes. Such air vents, whether slots or holes, permit rapid drying of fingernail products.
The use of a durable and flexible plastic, such as, for example, a polyethylene, or a polypropylene copolymer, permits a "living hinge" to be molded into the fingernail protector. The elongated arcuate section 300 can include a recess 350 that can function as such a "living hinge." Such a "living hinge" permits repetitive and substantial flexure of the fingernail protector along an axis while avoiding permanent polymeric disruption, thereby inhibiting fracture of the material from which the fingernail protector is formed. Recess 350 can define a hinge axis that is preferably substantially coaxial with one of slots 320 and preferably substantially parallel to the second axis.
Referring now to FIG. 1C, the arrows represent forces exerted onto the fingernail protector during a clip-on process, whereby the fingernail protector is removably attached to an individual's finger. The phantom lines indicate the deflected shape of the fingernail protector due to the strain that results from the force represented by the arrows. While elongated arcuate section 300 preferably subtends an angle of less than approximately 180°, resilient arcuate section 100 preferably subtends an angle of more than approximately 180°, so as to provide adequate frictional engagement with the individual's finger. In a preferred embodiment, resilient arcuate section 100 is partially cylindrical. However, resilient arcuate section 100 can approximate a polygonal cross section such as, for example, a square, a hexagon or an octagon.
Referring now to FIG. 1D, the free open end 370 of elongated arcuate section 300 can define an open end plane that is nonorthogonal to both the first axis and the second axis. Preferably, the free open end 370 returns acutely toward resilient arcuate section 100 with regard to said flared arcuate section 200. This geometrical configuration permits the free open end of the fingernail protector to function as an artificial finger tip surface that extends beyond the tip of the finger nail, especially when an individual's finger is slightly bent. Further, for maximum tactile sensitivity, the user can straighten the finger and touch an object with the uncovered pad of the finger. In this instance, the open end of the fingernail protector would rise obliquely away from the object, without necessarily contacting the object.
Referring now to FIG. 1E, a first tab 160 is connected to resilient arcuate section 100 at a first tab base. First tab 160 defines a first tab plane and rises orthogonally away from resilient arcuate section 100. Similarly, a second tab 180 is connected to resilient arcuate section 100 at a second tab base. Second tab 180 defines a second tab plane and rises orthogonally away from resilient arcuate section 100. A compression spring 170 can be located between first tab 160 and second tab 180.
The compression spring 170 is optional and can be omitted from this embodiment. The material from which the compression spring is made has a "memory aspect" that is advantageous to providing a snug fit on the individual's finger. Although this embodiment is depicted as including a squeeze butterfly for expansion of the C-shaped housing, the shape of the butterfly can be modified to any appropriate configuration. Also, the butterfly can be omitted from this embodiment.
It will be appreciated that there is a gap depicted between resilient arcuate section 100 and elongated arcuate section 300. The portion of the fingernail protector that directly surrounds the majority of the fingernail is elongated arcuate section 300 and this structure is slightly angled up. This angling up permits hyperextension of the hand without pushing the outer surface of the nail against the inner surface of the fingernail protector.
Although the preferred embodiment shown in FIGS. 1A-1E includes two tabs, it is within the level of ordinary skill in the art after having knowledge of the invention disclosed herein to provide the fingernail protector with more than two, or less than two tabs.
3. Second Embodiment
Referring now to FIG. 2A, resilient arcuate section 101 includes a proximal open end 111 and a distal open end 121. Resilient arcuate section 101 defines a first axis.
The fingernail protector includes a flared arcuate section 201. A first open end 211 of flared arcuate section 201 is connected to the distal open end 121 of resilient arcuate section 101. Flared arcuate section 201 also includes a second open end 221.
The fingernail protector includes an elongated arcuate section 301. A connected open end 311 of elongated arcuate section 301 is connected to the second open end 221 of flared arcuate section 201. Elongated arcuate section 301 defines a second axis. Elongated arcuate section 301 includes a free open end 371.
The bottom of this embodiment of the fingernail protector is open completely so that the pad of a finger to which the fingernail protector is attaches will retain tactile sensitivity. Again, this nearly complete openness discourages the build up of heat and moisture. While this embodiment is fabricated from a single piece of material, subcomponents of the fingernail protector can be fabricated separately, from the same, or other materials.
Referring now to FIG. 2B, the elongated arcuate section 301 can include a plurality of elongated slots 321. Slots 321 are preferably circumferentially distributed around the periphery of elongated arcuate section 301.
Although this embodiment is shown with elongated slots 321 in the C-shaped housing, the elongated slots 321 could be replaced by cylindrical holes. As noted above, such air vents, whether slots or holes, permit rapid drying of fingernail products. While elongated arcuate section 301 preferably subtends an angle of less than 180°, resilient arcuate section 101 preferably subtends an angle of more than 180°, so as to provide adequate frictional engagement with the individual's finger. In a preferred embodiment, resilient arcuate section 101 is partially cylindrical. However, resilient arcuate section 101 can approximate a polygonal cross section such as, for example, a square, a hexagon or an octagon.
Referring now to FIG. 2C, resilient arcuate section can include a first radially outwardly turning edge 190 and a second radially outwardly turning edge 195. While elongated arcuate section 301 is preferably less than semicylindrical, resilient arcuate section 101 is preferably more than semicylindrical, so as to provide adequate frictional engagement with the individual's finger.
Referring now to FIG. 2D, the free open end 371 of elongated arcuate section 301 can define an open end plane that is not orthogonal to the first axis. Preferably, the free open end 371 returns acutely toward resilient arcuate section 101 with regard to said flared arcuate section 201.
Referring now to FIG. 2E, a first tab 161 is connected to resilient arcuate section 101 at a first tab base. First tab 161 defines a first tab plane and rises orthogonally away from resilient arcuate section 101. A substantially cylindrical hem 165 can be provided at the top of first tab 161.
Although this embodiment is depicted as including a single planar tab for griping the C-shaped housing, the shape of the tab can be modified to any appropriate configuration. Further, the tab can be omitted from this embodiment.
It will again be appreciated that there is a gap depicted between resilient arcuate section 101 and elongated arcuate section 301. The portion of the fingernail protector that directly surrounds the majority of the fingernail is elongated arcuate section 301 and this structure is slightly angled up. As noted above, this angling up permits hyperextension of the hand without pushing the outer surface of the nail against the inner surface of the fingernail protector.
Although the preferred embodiment shown in FIGS. 2A-2E includes one tab, it is within the level of ordinary skill in the an after having knowledge of the invention disclosed herein to provide the fingernail protector with more than one tab. Further all tabs can be omitted from the fingernail protector.
The disclosed embodiment shows a tab as the structure for performing the function of providing a separate grip with which to attach and remove the fingernail protector, but the structure for providing a separate grip can be any other structure capable of performing the function of providing a separate grip, including, by way of example a hole, a loop or a handle.
Conveniently, the arcuate sheath of the present invention can be made of any flexible material. For the manufacturing operation, it is moreover an advantage to employ a plastic material, such as for example a polypropylene copolymer (Shell Polypropylene 7C50, high impact copolymer). However, the arcuate sheath of the present invention can be fabricated from any one, or more, of polyethylene, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), cellulose acetate butyrate (CAB), vinylidene chloride (SARAN), fluorocarbons (TEFLON, KEL-F, KYNAR), polycarbonates, polyurethanes, polypropylenes, nylons, and acetals (DELRIN). The selection of these materials should be based, at least in part, on resistance to acetone which is a common ingredient in fingernail care products.
Conveniently, the fabrication of the present invention can be carried out by using any method such as for example, molding. For the manufacturing operation, it is moreover an advantage to employ a injection molding method.
All the disclosed embodiments are useful in conjunction with providing a protective barrier such as fingernail protectors that are used for the purpose of shielding colored polish that is drying, or for the purpose of shielding clear enamel that is drying, or the like. There are virtually innumerable uses for the present invention, all of which need not be detailed here. All the disclosed embodiments can be realized without undue experimentation.
Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest to those of ordinary skill in the an that various additions, modifications and rearrangements of the features of the present invention may be made without deviating from the spirit and scope of the underlying inventive concept.
For example, ease of attachment could be enhanced by providing additional or different hinge structures. Similarly, although polypropylene copolymers are preferred as the sheath material, any other suitable material could be used in its place. Similarly, the individual components need not be constructed of the disclosed materials or be formed in the disclosed shapes, but could be provided in virtually any configuration which employs a sheath so as to provide protection for a fingernail in need thereof. Specifically, all the disclosed features of each disclosed embodiment can be combined with, or substituted for, the disclosed features of every other disclosed embodiment except where such features are mutually exclusive.
It is intended that the appended claims cover all such additions, modifications and rearrangements. Expedient embodiments of the present invention are differentiated by the appended subclaims. | Systems and methods for protecting fingernails are described. A fingernail protector includes: a resilient arcuate section having a proximal open end and a distal open end, the arcuate section 1) defining a first axis, 2) including a recess formed in the resilient arcuate section that defines a hinge axis that is substantially parallel to the first axis, the recess increasing the flexibility of the resilient arcuate section with regard to the first axis and 3) subtending an angle of at least approximately 180°; a flared arcuate section connected to the resilient arcuate section, the flared arcuate section having a first open end that is connected to the distal open end of the resilient arcuate section and a second open end, the flared arcuate section rising obliquely away from the resilient arcuate section; and an elongated arcuate section connected to the flared arcuate section, the elongated arcuate section defining a second axis and having i) a connected open end connected to the second open end of the flared arcuate section, and ii) a free open end. All of the connected open end of the elongated arcuate section is connected to the second open end of the flared arcuate section. The systems and methods provide advantages in that the fingernail protector that maintains tactile sensitivity, provides convection currents and can be used with varying length nails. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to adhesive materials, and particularly to a new group of dermatologically acceptable, moisture vapor-permeable, pressure-sensitive adhesive compositions which can be used in various medical contexts, including as a component of a wound dressing.
Wound management has developed rapidly in recent years due to advances in the understanding of the wound healing process and to the advent of new materials and techniques for use in wound dressings. In particular, much activity has occurred in the development of pressure-sensitive adhesive, moisture vapor-permeable wound dressings. These wound dressings provide coverings that protect wounds from further harm, enhance the natural healing process, and prevent bacterial invasion. Despite the availability of these newly-developed materials, infection is still a common complication associated with conventional dressings.
A wound is a loss of continuity of skin or mucous membrane due to accidental injury or planned surgery. Wound healing is essentially the replacement of dead or damaged tissue by healthy, living cells. Healing can occur either by partial or complete regeneration or by repair. Regeneration implies complete restitution to regain the original tissue structure. Repair, on the other hand, involves formation of a new permanent structure, a scar. Wound healing is typically a two-step process, involving regeneration of epithelial tissue and repair of connective tissue.
Among the various factors which affect wound healing are, for example, host resistance, environment and location of the wound, and the presence of bacteria. The patient's overall health, metabolic and nutritional status determine resistance. Blood flow, lymphatic drainage, temperature and humidity are important in respect of the environment and location of a wound. Bacteria at the wound site can proliferate and cause infection.
Wound dressings should possess a number of important characteristics in order to protect the wound and enhance its ability to heal. An ideal wound dressing should (i) have optimal water permeability to prevent desiccation of the wound and fluid accumulation under the covering; (ii) prevent microbial invasion from the environment; (iii) have no antigenic properties; (iv) be an elastic-plastic film to facilitate intimate covering of all possible contours of the human body; (v) be capable of both adhering well to the wound and being readily removable without causing any damage to the tissue beneath the covering; and (vi) be inexpensive to produce and readily amenable to storage.
Modern wound dressings are generally constructed of a backing sheet with a pressure-sensitive adhesive on one side. The backing sheet is typically moisture vapor permeable, allowing water vapor to escape from the wound site while preventing liquid water from entering or escaping from the site. In addition, bacteria are prevented from passing through the wound dressing. The adhesive provides the desired pressure-sensitive adherence for securing the backing to the wound site and retaining the backing in the desired position.
High moisture vapor-permeability of a dressing prevents maceration of the skin due to occlusion of transepidermal fluid lost from the body and delamination of the dressing from the wound site, as will be explained below. Many modern wound dressings are known for their high moisture vapor-permeability, as measured by the moisture vapor transmission rate (MVTR). For example, U.S. Pat. Nos. 4,340,043 and 4,360,369 disclose an adhesive-coated, polymeric sheet material having a high MVTR. This material is commercially available as a wound dressing marketed, under the mark Op-Site®, by Nephew & Smith, Ltd. See also U.S. Pat. No. 4,233,969.
The moisture permeability of such dressings is a function of the moisture permeability of both the polymeric film and the pressure-sensitive adhesive used. Many wound dressings use moisture permeable adhesives. For example, U.S. Pat. No. 3,645,835 (Hodgson) discloses both a moisture vapor-permeable backing material and a moisture vapor-permeable pressure-sensitive adhesive. The Hodgson patent also teaches that both the backing material and adhesive are unaffected by water, i.e., they neither swell nor absorb water. U.S. Pat. Re. No. 31,887, a reissue of the Hodgson patent, specifically discloses the backing material as a polyurethane and the adhesives as a polyvinyl ethyl esters or an acrylate. See also U.S. Pat. No. 4,638,797.
Polyurethane adhesives have been developed which are suitable for wound dressings. For example, U.S. Pat. No. 3,796,678 discloses a polyurethane adhesive which is highly branched and isocyanate-blocked with monofunctional alcohols. U.S. Pat. No. 4,626,475 relates to a polyurethane having improved adhesive properties, accomplished by using a bicyclic amide acetal additive. Aqueous-based polyurethane adhesives have also been developed. See, for example, U.S. Pat. Nos. 4,442,259 and 4,507,430. As explained above, the overall goal of wound dressings is to prevent infection and to provide an environment that promotes wound healing. To prevent infections, modern wound dressings are continuous, or occlusive, that is, there are no openings in the dressing through which bacteria from the environment can reach the wound site. Even with an occlusive dressing, however, infection may occur at the wound site if the dressing loses its integrity or if bacteria are already present at the wound site or the surrounding skin. Loss of integrity allows microbes from the environment to reach the wound site and cause infection. Bacteria already present at a wound site can also proliferate and cause infection.
The principle cause of integrity failure of an occlusive film dressing is delamination of the dressing from the wound site. Delamination is a function of the moisture permeability of the dressing and the ability of the dressing to absorb fluid. If the dressing does not have a high enough MVTR, then fluid from the wound or surrounding skin can accumulate. If the pressure-sensitive adhesive used neither absorbs this fluid nor allows it to reach an absorbent layer, then delamination between the pressure-sensitive adhesive and the wound site and/or surrounding skin will occur. If the delamination reaches the edge of the dressing, loss of dressing integrity results in the wound site being exposed to environmental microbes, i.e., loss of the bacterial barrier. The integrity of a dressing thus, is a function of both its moisture vapor permeability and fluid swellability. One of the major problems with current wound dressings is the use of materials with an insufficiently high MVTR to avoid delamination and pressure-sensitive adhesives unable to absorb fluid.
Attempts have been made to develop water-swellable adhesives by incorporating various substances into the adhesive which absorb water. Most of these attempts utilize gel adhesives. For example, U.S. Pat. No. 4,661,099 discloses a water-absorptive polyurethane gel adhesive wherein polyols are immobilized in the cross-linked polyurethane. U.S. Pat. No. 4,367,732 relates to a polystyrene-based gel adhesive in which water-swellable hydrocolloids are dispersed. See also U.S. Pat. No. 3,648,835 and Re. No. 31,887. Upon absorbing water, such gels tend themselves to dissolve in the water. Gel adhesives generally lack the inherent stability and storage convenience of solid adhesives. See also U.S. Pat. Nos. 4,233,969, 4,156,066 and 4,156,067, directed to polyurethane films that are water-swellable.
Even if a dressing maintains integrity, the enclosed environment provided by dressings may allow bacteria present at the wound site on the surrounding skin to multiply unduly and lead to infection. Numerous bacteria are present on human skin. Some may survive an initial application of a topical antimicrobial agent and act as seeds for subsequent growth. Continuous application of an antimicrobial agent would be highly desirable.
Recently, several wound dressings have been developed wherein an antimicrobial agent is applied or added to the polymeric film or, more preferably, to the adhesive. For example, U.S. Pat. Nos. 4,554,317 and 4,643,180 disclose application of an agent to the surface of a membrane or adhesive, respectively. Other attempts have been directed to the formation of a chemical complex between the antimicrobial agent and the film or adhesive. U.S. Pat. Nos. 4,542,012 and 4,323,557 teach complexing iodine with polyvinylpyrrolidone residues in polymer. Release of the antimicrobial agent depends, however, on its appropriate dissociation from the chemical complex.
Still other prior art dressings teach a physical combination of the antimicrobial agent and polymer or adhesive. For example, U.S. Pat. No. 4,614,787 discloses a pharmacologically active agent dispersed through a cured polymeric film to which an adhesive may be applied. U.S. Pat. No. 4,310,509 discloses a flexible-backing material to which is applied a composition of a broad-spectrum antimicrobial agent homogeneously and stably dispersed in a pressure-sensitive adhesive. U.S. Pat. No. 4,460,369 discloses an adhesive-coated, liquid-impervious, moisture vapor-permeable, thin polymer sheet in which a solid antibacterial material in a finely divided form is incorporated within the adhesive. U.S. Pat. Nos. 4,156,066 and 4,156,067 disclose that a medicament may be added to a lactone-modified polyurethane which is applied to the skin as a film. See also U.S. Pat. Nos. 3,896,789 and 3,769,071, which disclose addition of other bioactive agents, such as retinoic acid and 5-fluorouracil, to a polyurethane adhesive.
A problem inherent in these prior art attempts is that since most adhesives are not water-soluble, water-soluble antimicrobials may only exist as a separate phase dispersed throughout the adhesive. For example, the Berglund Pat. discloses that if an antimicrobial is water-soluble and is in a water solution, a stable water-in-oil emulsion is formed upon mixing with the adhesive. If, on the other hand, an antimicrobial is soluble in an organic solvent and is in solution in that solvent, and the organic solvent is miscible with the adhesive solution, then the solvent of the adhesive extracts the solvent of the antimicrobial solution, causing the antimicrobial to separate out as distinct, minute, separate phase particles.
Still another approach utilizes adhesives in which the bioactive agent can be truly dissolved in the adhesive. For example, U.S. Pat. Nos. 4,307,717 and 4,675,009, both issued to Hymes et al., disclose a flexible backing material provided with a hydrophilic, adhesive matrix which has a solid phase of a polysaccharide and a liquid phase of an alcohol, carbohydrate and/or protein, where a medicinal agent is "molecularly dispersed," rather than encapsulated, in the matrix. The Hymes '009 Pat. is a continuation-in-part of the '717 Pat. and states that the adhesive is capable of absorbing moisture and that the medicinal agent is "molecularly dissolved and/or suspended" in the adhesive matrix.
Despite recognition of the many practical wound dressing design problems, proper solution to all these problems in a single wound dressing has not been demonstrated in the prior art. Despite improvements in modern wound dressings, dressing materials are needed that comprise higher-MVTR compositions and pressure-sensitive adhesives. The MVTR of a pressure-sensitive adhesive is usually the limiting factor in the total moisture permeability of a film-backed dressing. Moreover, even though adhesives should optimally absorb or transport fluid, nearly all medically suitable, pressure-sensitive adhesives which are currently available are unaffected by water, i.e, they neither swell nor absorb water.
While effective to some degree, conventional wound dressings which incorporate drugs and other bioactive agents in a pressure-sensitive adhesive layer are generally limited to solvent-based (rather than aqueous-based) antimicrobial agents or drugs, since most pressure-sensitive adhesives are hydrophobic. When water-soluble agents are placed within these adhesive systems, water-in-oil emulsions form or the agents precipitate out as solid particles. Release of the agent requires diffusion of particulates through a hydrophobic matrix.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a film-backed adhesive material which includes a pressure-sensitive polyurethane adhesive characterized by a unique balance of both hydrophilic and hydrophobic characteristics, such as moisture vapor-permeability, an ability to absorb fluid without dissolving, and a capability to dissolve water-soluble agents in a solid solution, rather than forming an emulsion or precipitate.
It is also an object of the present invention to provide a medically suitable, pressure-sensitive adhesive that has a very high moisture vapor-permeability and, thus, minimizes fluid accumulation due to trapped moisture beneath the adhesive.
It is additionally an object of the present invention to provide a pressure-sensitive adhesive that swells without dissolving on exposure to water or other body fluids and, thus, minimizes delamination between the wound site and adhesive due to fluid accumulation.
It is a further object of the present invention to provide a pressure-sensitive adhesive within which water-soluble bioactive agents may be dissolved.
It is yet another object of the present invention to provide a method for the ready preparation of a wound dressing, which method can accommodate the use of water-soluble, bioactive agents without the disadvantages of precipitation and emulsion-formation discussed above.
In accomplishing the foregoing objects, there has been provided, according to one aspect of the present invention, an adhesive composition which comprises a polymer adhesive that is soluble or dispersible in water and is low-temperature curable to form a solid which is single-phase at ambient temperature, pressure-sensitive, dermatologically acceptable, moisture vapor-permeable and resistant to dissolution when exposed to water. The adhesive composition preferably contains a bioactive agent dissolved therein.
In a preferred embodiment, the polymer adhesive is the product of a process comprising the steps of (A) reacting a prepolymer compound comprising a plurality of hydroxyl groups and a polyisocyanate capping agent to form an isocyanate-terminated capped prepolymer comprising polyurethane units; (B) reacting a portion of the terminal isocyanate groups of the capped prepolymer with a derivatizing agent comprising a group reactive with isocyanate, in particular a hydroxyl group, and a low-temperature curable group to form a derivatized capped prepolymer; and (C) reacting the derivatized capped prepolymer with a chain extension agent reactive with isocyanate, in particular with water, to effect chain extension of the derivatized capped prepolymer, whereby a polymer is formed, until the polymer attains a determined level of tackiness, at which point chain extension is halted by addition of a chain termination agent reactive with isocyanate.
In accordance with another aspect of the present invention, there is provided a cured adhesive composition comprising a polymer adhesive which is the product of a process comprising the steps of (A) providing a water-soluble derivatized capped prepolymer, (B) subjecting the derivatized capped prepolymer to chain extension to form a polymer, until a determined level of tackiness is attained, wherein a chain termination agent is added, and (C) subjecting the polymer to low-temperature curing. Preferably, a bioactive agent is dissolved in the adhesive.
In accordance with yet another aspect of the present invention, there is provided a water vapor-permeable, pressure-sensitive adhesive wound dressing, comprising a flexible backing coated with a pressure-sensitive adhesive layer provided on at least a portion of the surface of the backing, wherein the adhesive layer comprises a cured adhesive composition as described above, preferably comprising a bioactive agent dissolved therein.
In accordance with a further aspect of the present invention, there is provided a process for producing a wound dressing as described above.
In accordance with yet a further aspect of the present invention, there is provided a process for producing an uncured polymer adhesive as described above.
In accordance with still another aspect of the present invention, there is provided a process for producing a cured polymer adhesive as described above.
Other objects, features and advantages of the present invention will become obvious to those skilled in the art from the following detailed description. It should be noted, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such changes.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description of the present invention, process steps are carried out at room temperature and atmospheric pressure unless otherwise specified. The phrase "pressure-sensitive adhesive" means that a composition thus qualified is inherently tacky, viscoelastic and cohesive in its dry (cured) state. The expression "aqueous-based" refers to a solvent or carrier which is water or a mixture of water and a miscible solvent such as an alcohol. The term "low-temperature curable" refers to groups which are capable of cross-linking under the influence of actinic radiation, which includes ultraviolet light and electron emission, as well as free radicals, pH shift or other mechanisms which are capable of functioning at approximately room temperature. The term "polyfunctional" is used with reference to a compound having two or more reactive groups, including low-temperature curable groups. A material is "dermatologically acceptable" if it does not cause noticeable skin irritation.
Polymer adhesives according to the present invention are preferably obtained by treating a water-soluble compound, referred to as a derivatized capped prepolymer, which comprises a plurality of first terminal groups and a plurality of low-temperature curable groups, with a second compound, referred to as a chain extension agent, which is reactive with the first terminal groups, resulting in formation of a polymer. The chain extension is terminated when the resulting polymer achieves a desired tackiness, by reacting the polymer with a third compound, referred to as a chain termination agent, reactive with the first terminal group. Incorporation of the chain termination agent into the chain halts further chain growth and completes formation of the uncured polymer adhesive. Preferably the derivatized capped prepolymer is reacted with an excess of the chain extension agent, based on the content of the first terminal group of the derivatized capped prepolymer.
Preferably the first terminal group is an isocyanate group, in which case the chain extension agent is preferably water, a polyol or a polyamine. The first terminal group may also be an ester group, in which case the chain extension agent is preferably ammonia or a polyamine. The first terminal group may also be an isothiocyanate group.
The chain extension is preferably conducted using at least a two-fold equivalent excess of the chain extension agent.
The chain extension reaction may be conducted at room temperature or at elevated temperatures of up to approximately 100° C. In general, temperatures of about 20° C to about 90° C. can be used to increase the reaction rate. Elevated temperature may be particularly advantageous where the derivatized capped prepolymer has been prepared using an aliphatic polyisocyanate.
The chain extension reaction is allowed to proceed until the reaction mixture acquires a desired adhesive capability. The characteristics of the adhesive or adhesive capability are generally given in terms of optimal bonding strength for a given substrate or substrates at workable viscosity levels. Adhesive capability of the reaction mixture can be tested qualitatively or quantitatively. Qualitative monitoring simply involves removing samples from the reaction mixture and evaluating their adhesive properties by touch or by an elementary test of adhesiveness between two substrates. In more quantitative procedures, the reaction mixture is monitored, for example, via measurement of viscosity.
In general, the viscosity of the reaction mixture increases as the chain extension reaction proceeds. Sufficient correlation may be established between the viscosity of the reaction mixture and its adhesive capability to permit the use of viscosity measurements as a means of monitoring the reaction. Useful viscosities may vary over a wide range, depending on such factors as the nature of the derivatized capped prepolymer, the percent solids of the reaction mixture, and the temperature of the reaction mixture.
A chain termination agent may be added to control the chain extension of the derivatized capped prepolymer, that is, to slow the reaction and prevent gelation of the derivatized capped prepolymer, before complete termination of the polymerization. The amount of chain termination agent used depends on such factors as the comparative reactivities of the chain extension agent and the chain termination agent with the derivatized capped prepolymer, and the desired rate of reaction. The monofunctional chain termination agent used to control chain extension of the derivatized capped prepolymer may be any compound capable of reacting with the first terminal group so as to retard or prevent its reaction with the chain extension agent. A variety of monofunctional chain termination agents are suitable. Where the first terminal group is an isocyanate group, suitable monofunctional chain termination agents include alcohols, such as methanol, ethanol, isopropanol and phenol; primary or secondary monamines like ammonia, methylamine, ethylamine and isopropylamine; oximes such as acetone oxime, butanone oxime, cyclohexanone oxime; and alkanol amines like ethanol amine. In accordance with another aspect of the present method, a combination of two or more monofunctional chain termination agents can be used. An example of such a combination, used where the first terminal group is an isocyanate group, is that of an alcohol with a more reactive chain termination agent, such as an oxime. The alcohol in the combination may provide some chain termination function but is used primarily as a diluent or co-solvent, while the more reactive chain termination agent provides the major proportion of the reaction with the isocyanate group.
In addition to alcohols, other co-solvents may be employed pursuant to the present invention. These co-solvents should be miscible with water or a water-alcohol mixture and, unless intended for use as a monofunctional chain termination agent, should be inert to the first terminal groups. Preferred co-solvents are volatile solvents, such as acetone or methyl ethyl ketone, the use of which can facilitate drying of the adhesive compositions. The co-solvent may be added prior, during, or subsequent to chain extension.
When the desired viscosity and/or adhesive capability has been attained, additional monofunctional chain termination agent, e.g., the chain termination agent used for reaction control or a second, different agent reactive with the first terminal group, is added to the reaction mixture in an amount at least equal to or substantially greater than the amount of unreacted first terminal groups in the derivatized capped prepolymer, on an equivalent basis. The amount of unreacted first terminal groups remaining in the derivatized capped prepolymer at the time the desired adhesive capability is attained will vary with the nature of the derivatized capped prepolymer and the degree of chain extension. Although this amount can be measured, thereby allowing calculation of the minimum quantity of additional chain termination agent to be added, it is generally more convenient and satisfactory to simply employ an excess amount of the chain termination agent.
By reaction of the additional chain termination agent with the remaining first terminal groups in the derivatized capped prepolymer, the chain extension reaction is terminated. The effectiveness of the chain termination agent in terminating chain extension, i.e., the rate and extent of reaction with the remaining first terminal groups is increased by using an excess amount of the agent and, consistent with such increased effectiveness, the resultant adhesive compositions tend to have a longer shelf life. Reasonable excesses of the additional chain termination agent, for example, in the range of a 10% to 100% equivalent excess, in general do not adversely effect the adhesive capability.
The additional chain termination agent should be capable of forming a reaction product with the first terminal group that is very stable to water, for reasonable periods of time at room temperature. The additional chain termination agent can be any of the aforementioned monofunctional chain termination agents, or may be a polyfunctional chain termination agent such as a diol, diamine or dioxime. Preferred chain termination agents are the more reactive monofunctional materials, exemplified by the aforementioned oximes and amines. It is also possible to use ammonia. Although alcohols can be used as the additional chain termination agent, and are often added in excess for such purpose and for purposes of dilution, they are preferably employed in conjunction with a more reactive chain termination agent to insure a maximum shelf life for the product. For example, various primary and secondary amines may be used in conjunction with the alcohol; ammonia is particularly useful in this regard.
The additional chain termination agent may be added to the reaction mixture at any temperature up to about 100° C. Generally, the same temperature used for chain extension is also used for this addition.
The derivatized capped prepolymer is preferably formed by reacting a second water-soluble compound, referred to as a capped prepolymer, which comprises a plurality of the first terminal groups, with a derivatizing agent. The derivatizing agent comprises a first functional group which is reactive with the first terminal groups, and a second functional group which is low-temperature curable. The reaction is carried out such that a portion of the first terminal groups of the capped prepolymer are reacted with the first functional groups of the derivatizing agent, leaving the remainder of the first terminal groups available to react with the chain extension agent to effect polymerization.
The second functional group, i.e. the low-temperature curable group, preferably is curable under the action of actinic radiation, which includes ultraviolet radiation and electron emission, as well as pH shift or free radicals. In a preferred embodiment, the low-temperature curable group is an ethylenically unsaturated group, and particularly preferably is an activated vinyl group.
Preferably, about 5 to 80% of the first terminal groups of the capped prepolymer are reacted with the first functional group of the derivatizing agent. Particularly preferably, 5 to 50% of said first functional groups are so reacted.
In a preferred embodiment, the first terminal group of the capped prepolymer is an isocyanate group and the first functional group of the derivatizing agent is a hydroxyl or amine group. The derivatizing agent is preferably a hydroxyalkyl ester of a (C 1 -C 6 )-α,β-unsaturated carboxylic acid. Suitable esters include hydroxyalkyl acrylates, methacrylates, crotonates and itaconates. The hydroxyalkyl ester is preferably a hydroxyethyl ester, such as hydroxyethyl acrylate and hydroxyethyl methacrylate. Other examples of suitable acrylates include 1,2,6-hexanetriol diacrylate, pentaerythritol triacrylate and neopentaerythritol triacrylate.
The first terminal group may also be an ester group, in which case the first functional group is preferably an amine group. In this embodiment, the derivatizing agent is preferably an aminoalkyl amide of a (C 1 -C 6 )-α,β-unsaturated carboxylic acid. Suitable amides include aminoalkyl acrylamides, methacrylamides, crotonamides and itaconamides.
The capped prepolymer is preferably formed by reacting a polyfunctional compound, hereinafter referred to as a capping agent, which comprises a plurality of the first terminal group with a water-soluble prepolymer which comprises a plurality of a second terminal group reactive with the first terminal group. The capping agent reacts with the terminal groups of the prepolymer, and thus "caps" the prepolymer with first terminal groups on the terminal ends of the prepolymer.
In a preferred embodiment, the first terminal group is an isocyanate group and the second terminal group is a hydroxyl group. This results in formation of a urethane capped prepolymer. These prepolymers are prepared by the well-known method of reacting a polyol with an aliphatic or aromatic polyisocyanate. Particularly preferably, the prepolymer is a polyoxyalkylene polyol or a polyester polyol. Carboxymethylcellulose can also be used as the prepolymer. Excess polyisocyanate is usually employed to insure reaction of all the polyol hydroxyl groups and to minimize crosslinking due to reaction of two or more isocyanate groups of the same molecule.
Particularly preferred polyols used in accordance with the present invention are hydrophilic polyoxyethylene polyols, that is, hydrophilic polyols comprising recurring oxyethylene (--CH 2 --CH 2 --O--) units. These polyols and the prepolymers prepared from them exhibit an especially high degree of hydrophilicity, particularly those comprising at least 20 mole %, more particularly at least 40 mole % oxyethylene units. Such polyols and prepolymers are therefore especially suitable, in terms of water solubility and reactivity, for use in accordance with the present invention.
The advantages attendant to the hydrophilicity of the polyoxyethylene polyols also extend to the adhesive materials in accordance with the invention. Adhesive compositions can be prepared to have a relatively high solids content, for example, as high as 60% on a weight basis, and have favorable stability characteristics, i.e., minimal or no tendency to form gels or to coagulate while sitting or to undergo phase separation. Also, the compositions can be readily diluted with polar solvents such as water and alcohols.
The advantages realized by the use of hydrophilic polyoxyethylene polyols and prepolymers are obtained without the use of surfactants, thus avoiding the presence of such materials and their effects on process steps of the present invention. Such surfactants are commonly necessary for reactions of more hydrophobic prepolymers.
The use of excess capping agent, such as polyisocyanate, in preparing the capped prepolymers will generally provide a composition containing unreacted capping agents. Chain extension of the resulting derivatized capped prepolymer thus entails reaction of the first terminal groups of such unreacted capping agents.
Although polyisocyanates having an isocyanate functionality of three or more may be used in preparation of prepolymers used herein, it is generally preferred to employ diisocyanates. Both aliphatic and aromatic diisocyanates can be used. Suitable diisocyanates include: 1,6-hexamethylene diisocyanate, isophorone diisocyanate, 2,3,4-trimethyl-1,6-hexane diisocyanate, trimethylene di isocyanate, toluene-2,4-diisocyanate, diphenylmethane-4,4'-diisocyanate, biphenyl-4,4'-diisocyanate, and 3,3'-dimethyl-4,4'-diisocyanate-1,1'-biphenyl.
Aliphatic polyisocyanates are preferred insofar as the resultant prepolymers generally react more slowly with water than those prepared from aromatic polyisocyanates. This permits better process control, and possibly the use of less monofunctional chain termination agent. However, from the standpoint of minimizing reaction time, prepolymers prepared from aromatic polyisocyanates are preferred albeit in the presence of a potentially greater amount of chain termination agent. Other considerations which might effect the choice of a particular polyisocyanate include the hydrophobic/hydrophilic properties imparted to the resultant prepolymer and factors such as cost, availability and toxicity.
In another preferred embodiment, the first terminal group is an ester group and the second terminal group is an amine group. In this embodiment, the prepolymer is preferably a polyaminoalkylene polyamine.
The prepolymer is preferably formed by reacting a first water-soluble monomer which comprises a plurality of the second terminal group with a second water-soluble monomer which is reactive with the second terminal group. When the second terminal group is a hydroxyl group, the first water-soluble monomer is preferably a polyol and the second water-soluble monomer is preferably an epoxide compound such as ethylene oxide or propylene oxide; these monomers react to form the preferred polyoxyalkylene polyols. Suitable polyols include ethylene glycol, glycerol, trimethylolpropane and pentaerythritol, and also a mixture of ethylene glycol and glycerol. The prepolymer preferably has a molecular weight of about 3 to 15 kilodaltons. The resulting isocyanate capped prepolymer has an NCO-value of 2.5-3.0, that is, the average capped prepolymer comprises 2.5-3.0 unreacted isocyanate groups.
The preferred polyoxyethylene polyols may comprise only recurring oxyethylene units, or may comprise other recurring units provided by other alkylene oxides. Where the polyols comprise more than one type of oxyalkylene units, the recurring oxyethylene units should be present in sufficient amount to provide a satisfactory hydrophilic/hydrophobic balance and, as indicated above, an oxyethylene content of at least 20 mole %, more particularly at least 40 mole %, is preferred. The polyoxyethylene polyols can be admixed with other polyols, including hydrophobic polyols, prior to reaction with the polyisocyanate, again provided that a satisfactory hydrophilic/hydrophobic balance is provided.
When the second terminal group is an amine group, the first water-soluble monomer is preferably a polyamine and the second water-soluble monomer is preferably an aziridene compound. Particularly preferably, the first water-soluble monomer is ethylenediamine and the second water-soluble monomer is aziridene.
In another preferred embodiment, the prepolymer is a copolymer. In this embodiment, the prepolymer preferably comprises polyvinylpyrrolidone.
Alternatively, the derivatized capped prepolymer may be formed directly by reacting a water-soluble prepolymer with one or more siloxane compounds comprising a low-temperature curable group.
After the derivatized capped prepolymer has been chain-extended and the remaining first terminal groups have been reacted with a chain termination agent, a photoinitiator may be added to the reaction mixture, in an amount from about 0.1% to 5% by weight of the reaction composition. Suitable photoinitiators include benzophenone, acetophenone, azobenzene, acenaphthenequinone, o-methoxybenzophenone, thioxanthen-9-one, xanthen-9-one, 7-H-benz(de)anthracen-7-one, 1-naphthaldehyde 4,4'-bis(dimethylamino)- benzophenone, fluorene-9-one, 1'-acetonaphthone, 2'-acetonaphthone, anthraquinone, 2-tert-butyl anthraquinone, 4-aminobenzophenone, 4'-methoxyacetophenone, 2,2-diethoxyacetophenone, and benzaldehyde.
The adhesive composition of the present invention is aqueous-based, that is, the adhesive carrier or solvent includes water in large quantity, including residuum from the preparatory reaction and any amount added thereafter. In general, the carrier comprises at least 10% water by weight, with a proportion of up to 75% by water typically acceptable. An adhesive composition according to the present invention can be used as is or, if desired, can be diluted with water, an alcohol, or another water-miscible solvent. The solutions tend to be infinitely dilutable with alcohols and with water/alcohol mixtures containing about 50% or more by volume of alcohol. They may also be diluted with water alone to a solid content of about 15% to 20% on a weight basis. As a function of the particular adhesive prepared, and of the presence of co-solvents in the composition, the polymeric adhesive may begin to precipitate below about 15% water content.
A major advantage of an adhesive composition within the present invention is an ability to be diluted with water and, hence, the ability to dissolve water-based agents and drugs to form a solid solution, without the agent or drug precipitating or forming an emulsion. A large variety of water-based drugs, including heat labile drugs, may be dissolved in the compositions of the present invention due to its water miscibility and low temperature of curing, as is explained below. It is contemplated that any coagulant, antibiotic, antifungal agent, topical anesthetic, anti-inflammatory agent or mixture thereof that is water soluble or water miscible may be dissolved in the adhesive composition. Examples of such agents include an enzyme, a protein, a growth factor, a hormone, a biocidal agent, an antiseptic agent, an antibacterial agent, an antifungal agent, an antiviral agent, an anti-histamine, an anti-inflammatory agent, an anti-pruritic agent, a keratolytic agent, an skin-protective agent, a rubefacient, a topical anesthetic, a hemostatic agent, an anti-anginal agent, a vitamin, a nutritional mineral, a water-soluble polyol compound, collagen or nicotine. In particular, enzymes, such as papain, trypsin, collagenase, subtilisin, ficin, pepsin, lysozyme, streptokinase, fibrinolysin, pinguinain, travase, bromelin and glucose oxidase; antibiotics such as gentamicin sulfate; anti-microbials like polyvinylpyrrolidone-iodine and chlorhexidine digluconate; growth factors, including platelet-derived growth factor, transforming growth factors-α and -β, fibroblast growth factor, epidermal growth factors and angiogenesis factor; thrombin and other hemostatic agents; water-soluble cellulose compounds, including alkali metal salts of carboxymethyl cellulose, hydroxyethyl cellulose; polyols including polyoxyethylene, starch and casein; humectants like gluconic acid and glycerin; vitamins such as B 1 , B 2 , B 6 , B 12 and C; minerals, including water-soluble forms of calcium, magnesium, potassium, sulfur and zinc; and nicotine.
An adhesive according to the present invention is particularly well-suited for use with agents which exist only in water-solution. For example, chlorhexidine digluconate is a well-known broad-spectrum antimicrobial that only exists as a water-based compound, i.e., chlorhexidine digluconate cannot be dried down to a solid. Addition of chlorhexidine digluconate to a conventional, solvent-based adhesive, which is not water-miscible, would result in an emulsion.
The present invention also contemplates the production of a water-swellable adhesive that is suitable for use in wound dressings and other medical products, especially those that come into contact with bodily fluids. Thus, the uncured adhesive composition of the present invention can be spread or coated onto various backings, thereby to form dressings, drapes, tapes and the like, by means well-known to the industry, such as drawing, rolling and spraying. A preferred backing material in this context is a polyurethane film having a thickness of between about 0.0005 and 0.0015 inch (about 0.00013 to 0.0038 cm). The adhesive can be uniformly coated onto such film material to a wet thickness of about 001 to 0.003 inch (about 0.0025 to 0.007 cm) and dried at a temperature in the range of 60° C. The film carrying the dried adhesive layer thus obtained is then fully cured, e.g., by exposure to ultraviolet radiation, typically between 219 and 425 nanometers. A suitable exposure would be for about 20 seconds at 0.5 watts per square centimeter, but equivalent exposures are suitable. The result is a dressing with a fully cured, solvent-resistant, water swellable, transparent adhesive with a MVTR of about 6700 g/m 2 /24 hours.
According to the present invention, a polymer adhesive as described above can be applied, preferably after the dissolution thereinto of at least one bioactive agent, to a flexible backing suitable for a wound dressing or drape, and then is subjected to low-temperature curing, i.e. by cross-linking irradiation. (Before the exposure to actinic radiation, the polymer adhesive is preferably subjected to low-temperature removal of any solvent which is present.) In this manner, the polymer adhesive is cured to form a single-phase solid retaining the hydrophilic nature of the prepolymer starting material. Alternatively, the polymer adhesive may be cured on a first substrate and subsequently laminated to a second substrate.
The examples which follow serve further to illustrate the present invention.
Example 1. Adhesive Formulation A
Isophorone diisocyanate was reacted with a glycerin-based triol which was adducted with ethylene oxide and propylene oxide (molecular weight: 10,000). The ethylene oxide was approximately 75 weight-percent of the adduct. The resulting capped prepolymer had an NCO-value of 2.8. Hydroxyethyl methacrylate (HEMA) was added to this capped prepolymer in an amount to react with 80% of the free NCOs and reacted for two hours under nitrogen at 35° C. One hundred grams of water were then added to 100 grams of the derivatized capped prepolymer. The reaction mixture was stirred for 60 minutes until an increase in viscosity was noted and some entrapment of carbon dioxide, generated by the reaction, occurred. Ethanol (200 grams) was added to reduce viscosity and the reaction mixture was then stirred for an additional twenty minutes at room temperature. Sufficient ammonium hydroxide was then added to halt chain extension, bringing the pH of the mixture to about 10. A photoinitiator, 2,2-diethoxyacetophenone, was added to a concentration of 1% of total composition weight. The resulting composition was stable, had low viscosity and was clear, with approximately 30% non-volatiles. Upon drying and curing by exposure to ultraviolet radiation, a fully cured pressure-sensitive adhesive which swelled in the presence of water was obtained.
Example 2. Adhesive Formulation B
To the capped prepolymer of Example 1 (NCO-value: 2.8), HEMA was added to react with 20% of the free NCO groups and reacted for two hours under nitrogen at 35° C. Water (100 grams) was then added to 100 grams of the derivatized capped prepolymer. The reaction mixture was stirred for fifteen minutes until an increase in viscosity was noted and there occurred some entrapment of carbon dioxide generated by the reaction. Two hundred grams of ethanol were added, and the reaction mixture was then stirred for an additional twenty minutes at room temperature. The reaction mixture was periodically tested for adhesiveness during this time by removing small samples, partially drying each sample, and touch-testing for "tack." Sufficient ammonium hydroxide was then added to halt chain extension, bringing the pH of the mixture to about 10. After this mixture was completely reacted, 2,2-diethoxyacetophenone was added to a concentration of 1% of the total composition weight. The resulting product was stable, had low viscosity, was clear with approximately 30% non-volatiles. Upon drying and U.V. curing, a fully cured pressure-sensitive adhesive which swelled in the presence of water was obtained.
Example 3. Wound Dressing
A uniform coating of the uncured wet polyurethane adhesive from Example 1 was applied to a 1.5 mil-thick (0.0015 inch or 0.0038 cm) polyurethane film on a polyethylene liner using a number 25 Mayer rod. The coating was then dried at 60° C. for ten minutes. After drying, the adhesive coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 . The adhesive exhibited excellent tack and swelled moderately in the presence of water.
Example 4. Wound Dressing
A uniform coating of the uncured wet polyurethane adhesive from Example 2 was applied, via a number 25 Mayer rod, to a 1.5 mil-thick polyurethane film on a polyethylene liner. The coating was then dried at 60° C. for ten minutes. After drying, the adhesive-coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 . The adhesive exhibited excellent tack and swelled greatly in the presence of water.
Example 5. Wound Dressing with Antimicrobial
Five grams of a 45% polyvinylpyrrolidoneiodine complex (PVP-I) was added to 100 ml of the uncured wet polyurethane adhesive formulation of Example A uniform coating of this polyurethane adhesive was applied to a 1.5 mil-thick polyurethane film on a polyethylene liner by means of a number 25 Mayer rod. The coating was then dried at 60° C. for sixty minutes. After drying, the adhesive coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 .
Example 6. Wound Dressing with Antimicrobial
Five grams of a 20% chlorhexidine digluconate water solution was added to 200 ml of the uncured wet polyurethane adhesive formulation of Example 1. With a number 25 Mayer rod, a uniform coating of this polyurethane adhesive was applied to a 1.5 mil-thick polyurethane film on a polyethylene liner. The coating was then dried at 60° C. for sixty minutes. After drying, the adhesive-coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 .
Example 7. Wound Dressing with Antimicrobial
Five grams of a 20% gentamicin water solution was added to 100 ml of the uncured wet polyurethane adhesive formulation of Example 1. A uniform coating of this polyurethane adhesive was applied to a 'I.5 mil-thick polyurethane film on a polyethylene liner by means of a number 25 Mayer rod. The coating was then dried at 60° C. for sixty minutes. After drying, the adhesive-coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 .
Example 8 Wound Dressing with Coagulant
Five grams of a 20% thrombin water solution was added to 100 ml of the uncured wet polyurethane adhesive formulation of Example 1. A uniform coating of this polyurethane adhesive was applied to a 1.5 mil-thick polyurethane film on a polyethylene liner via a number 25 Mayer rod. The coating was then dried at 60° C. for sixty minutes. After drying, the adhesive-coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 .
Example 9. Wound Dressing with Protein
One-half gram of a 10% glucose oxidase water solution was added to 100 ml of the polyurethane adhesive formulation of Example 1. A uniform coating of this polyurethane adhesive was applied to a polyurethane film (1.5 mil) on a polyethylene liner by means of a number 25 Mayer rod. The coating was then dried at 60° C. for sixty minutes. After drying, the adhesive-coated film was exposed to U.V. radiation at 425 nm for five minutes at 0.007 watts/cm 2 .
Example 10. Antimicrobial Activity
The biological activity of the dressing prepared according to Examples 6 and 7, respectively, was determined by a "Zone of Inhibition" test, whereby discs of dressing, 19 mm in diameter, were placed on agar (TSA) plates that had been inoculated with 0.5 McFalland standard of Staphylococcuscus aureus or Escherichia coli. After incubation for 18 hours at 37° C., the zones of inhibition of bacterial growth were measured and recorded. Control discs for comparison were made following the same procedures outlined in Examples 6 and 7 but using an acrylic-based adhesive composition ("MD-0129"; product of Semex Medical Corp.) or a rubber-based adhesive system ("Nacor 72-9574"; National Starch Corp.) in place of the polyurethane-based adhesive composition of the present invention. The results are shown below:
______________________________________Wound Dressing S. aureus E. coli______________________________________Example 6 4 mm 4 mm(chlorhexidine digluconate)Example 7 8 mm 8 mm(gentamicin)Acrylic-based adhesive* 0 mm 0 mm(chlorhexidine digluconate)Acrylic-based adhesive 0 mm 0 mm(gentamicin)Rubber-based adhesive* 0 mm 0 mm(chlorhexidine digluconate)Rubber-based adhesive 0 mm 0 mm(gentamicin)______________________________________ *Coagulation observed
Example 11. Moisture Vapor Transmission Rate
Ten milliliters of distilled water were contained in a vial having a 1.8 cm-diameter opening which was covered with a polyurethane adhesive film having a nominal thickness of 1 mil (0.001 inch or 0.0025 cm). The arrangement was weighed, at 36° C. (saturated humidity) for 24 hours and reweighed to determine water loss. Moisture vapor permeability rate, expressed in terms of "g/m 2 /24 hours," was calculated. For comparison, a 1 mil-thick acrylic adhesive film ("TM1620-00"; product of Semex Medical Corp.) and a 1 mil-thick polyisobutylene rubber adhesive film ("ARclad"; product of Adhesive Research, Inc.) were tested in the same fashion. The results are as shown below:
______________________________________Film Type MVTR______________________________________Polyurethane adhesive film 6,686Acrylic adhesive film 2,361Isobutylene rubber adhesive film 1,715Open Vial (no film) 10,229______________________________________
Example 12. Water Absorption
The films from Example 11, including the comparison films, were soaked in water, patted dry with a paper towel, and weighed. The films were then dried in an oven for 1 hour at 60° C. and reweighed. The percentage of water absorption ("absorp. %") was calculated for each film by dividing the difference between the wet (soaked) weight and the dry weight by the dry weight. The results are as shown below:
______________________________________Film Type Absorp. %______________________________________Polyurethane adhesive film 397%Acrylic adhesive film 15.5%Isobutylene rubber adhesive film 0.2%______________________________________ | A dermatologically-acceptable, moisture vapor-permeable, pressure-sensitive adhesive composition that is a single-phase solid at ambient temperature and resists dissolution when exposed to water, comprises a polymer adhesive which is the product of a process comprising the steps of chain extending a water-soluble derivatized capped prepolymer which comprises a first terminal group and a low-temperature curable group, until the resultant polymer attains a determined level of tackiness, and then subjecting the polymer to low-temperature curing. The adhesive is used to advantage in medical products like adhesive bandages, plasters, dressings and surgical drapes, and can dissolve water-soluble bio-active additives. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a plasma display panel, referred to hereinafter as a PDP.
2. Description of the Related Arts
PDPs have been extensively employed for monitors of television receivers and computers, and the structures as well as the materials thereof are still further under improvements.
AC type PDPs of three-electrode structure are commercially on production for color display devices. This structure is such that a pair of sustain electrodes is arranged for each line of the display matrix, and an address electrode is arranged for each row of the matrix. Colors to be displayed are determined by controlling the amount of light emitted from respective fluorescent materials of R (Red), G (Green) and B (Blue).
In this kind of PDP is employed as a discharge gas a Penning gas in which a small amount of xenon (Xe) gas is mixed with neon gas (Ne). Upon generating a discharge between a pair of sustain electrodes in pair the discharge gas emits an ultra violet ray. The fluorescent material is excited by this ultra violet lay so as to emit its light. The mixing ratio in the discharge gas is optimized in consideration of the margin of driving voltages, the deterioration of the fluorescent materials and the dielectric protection layer caused by bombardment thereto. The mixing ratio is typically 2 to 10 percent.
As a prior art, it has been known that a helium (He) gas is added into the above-described Penning gas (Ne+Xe). The addition of the helium gas improves the luminous efficiency as well as the color purity.
The increase in the xenon gas content decreases the excited light emission from the neon gas so as to relatively increase light emission of the fluorescent material, resulting in an improvement of the display color purity. On the contrary, the discharge firing voltage increases considerably; therefore, it is impossible to expect a distinct improvement in the color purity within the practical range of driving voltages. Moreover, the xenon gas emitting a near-infrared ray together with the ultra violet ray causes a problem in that the increase of the xenon gas enhances a possibility of disturbing an infrared remote controller of electric appliances or an infrared communication equipment located near the PDP.
On the other hand, there is another problem in that though the addition of helium gas improves the light emitting efficiency as well as the color purity as described above, the further addition thereof accelerates the sputtering of the fluorescent materials and the protection layer, resulting in a short operation life of the PDP. Furthermore, these is a problem of helium lessening the voltage margin of the AC driving voltages. Still more, the effect of xenon gas to suppress the near infrared ray is small, but the addition of helium gas adequate to suppress the near infrared ray considerably shortens the operation life, and the less operating margin makes the driving difficult.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide a PDP that allows a decrease in the relative strength of the visual lights emitted from the neon gas so as to improve the color impurity, together with a decrease in the near-infrared light emitted from Xe gas.
It is another object of the present invention to enhance the operation margin in the AC driving voltage.
The plasma display panel according to the present invention including a pair of substrates comprises a mixture of discharge gases contained between the substrates; the mixture consists of neon gas, xenon gas and krypton gas, wherein a percentage content of the krypton gas is selected in the range of from 1 to 14 percent of the mixture, so that near-infrared rays radiated from the xenon gas during a gas discharge are retarded.
The above-mentioned features and advantages of the present invention, together with other objects and advantages, which will become apparent, will be more fully described hereinafter, with references being made to the accompanying drawings which form a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a perspective view of an internal structure of a PDP related to the present invention;
FIG. 2 shows a relation between krypton (Kr) density and display characteristics;
FIG. 3 shows a relation between krypton (Kr) density and luminous efficiency; and
FIG. 4 shows a relation between the a third component density and a near-infrared ray suppression effect.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter is described a first preferred embodiment of the present invention, with reference to FIG. 1 illustrating an internal structure of a PDP 1 in which the present invention is embodied.
PDP 1 is a surface discharge type PDP of AC drive provided with sustain electrodes X and Y arranged in parallel in pairs, having an electrode matrix of three-electrode structure wherein sustain electrodes X & Y and an address electrode A correspond to each single cell. Sustain electrodes X & Y extend along a line direction, i.e. the horizontal direction. A first sustain electrode Y in the pair is used as a scan electrode for selecting cells, by each line, in an addressing operation. An address electrode A extends along a row direction, i.e. a vertical direction, for selecting cells by each row, and may also be called a data electrode.
Sustain electrodes X & Y are disposed upon an inner surface of a front glass substrate 11 of a pair facing each other so that a pair of the sustain electrodes X & Y form a line L which is an array of the cells in horizontal direction of the screen.
Sustain electrodes X & Y are respectively formed with a transparent electrode 41 and a metal film 42 for decreasing the electrical resistance, and are coated with a dielectric layer 17 for the AC driving. The material of dielectric layer 17 is formed of a low melting-temperature glass including PbO (lead oxide) having a dielectric constant of approximately 10. Upon the surface of dielectric layer 17 is coated a protection layer 18 having a large secondary electron emission coefficient typically formed of MgO (magnesium oxide) film. Dielectric layer 17 and MgO film 18 are transparent. Upon an inner surface of a back substrate 21 are provided an under coat layer 22, address electrodes A, an insulating layer 24, separating walls 29 and fluorescent material layers 28R, 28G and 28B, for displaying three colors, red, green and blue (R, G, B), respectively. Each separating wall is straight when viewed from the top side. Separating walls 29 divide discharge space 30 into each sub pixel (unit light emitting areas) along the line direction, and keep the gaps, i.e. the heights, of the discharge space 30 uniform, typically approximately 150 μm. Discharge spaces 30 is filled with a discharge gas particular to the present invention, that is, a mixture of neon, xenon and krypton gases according to the ratios described latter. Gas pressure therein is approximately 500 Torr. Fluorescent material layers 28R, 28G and 28B are formed by printing pastes the fluorescent materials typically disclosed in Table 1, and then being baked, so that predetermined visible lights can be emitted, respectively.
TABLE 1______________________________________EMITING COLOR FLUORESCENT MATERIAL______________________________________R (Y, Gd)BO.sub.3 :E.sup.3+G Zn.sub.2 SiO.sub.4 :MnB 3(Ba, Mg)O.8Al.sub.2 O.sub.3 :Eu.sup.2+______________________________________
15 A single pixel of the display is formed of three cells aligning along the line direction. Structural elements in each sub pixel form the cell. Because the layout pattern of separating walls is of a stripe pattern, discharge space 30 corresponding to each row is continuous along the row direction crossing over all the lines. The emitting color of sub pixels in each row is identical.
PDP 1 described above is fabricated according to the sequence of the steps such that upon glass substrates 11 & 12 are fabricated respective predetermined structural elements so as to make the front and back substrate assemblies; the front and back substrate assemblies are stacked and peripheral portion thereof are sealed with each other, the gas sealed therein is exhausted, and the discharge gas is filled thereinto. The PDP 1 is then connected to a driving unit which is not shown in the figures, so as to be employed as a display device of television receiver hung on a wall, a monitor of computer system, etc.
In displaying with PDP 1, a display period allocated to a single frame is divided into a reset period for equalizing wall charges of the entire screen in order to prevent effects of the previous lighting state, an addressing period for addressing, i.e. setting the lighting/non-lighting, each cell in accordance with the data contents to be displayed, and a sustain period for sustaining the lighting state so as to secure the brightness of the required gradation level.
During the reset period, a reset pulse whose peak value exceeds the breakdown voltage of the surface discharge is applied to selected sustain electrodes, typically the respective sustain electrodes X of all the lines, while the other sustain electrodes, Y, are kept on the ground level. Upon the rise of the reset pulse there are generated strong surface discharges between the respective pairs of sustain electrodes X & Y of all the lines, resulting in the generation of wall charges in a great quantity in the cells. The effective cell voltage in each is lowered by offsetting the wall voltage therein with the applied voltage. Upon the fall of the reset pulse, the wall voltage itself becomes the effective voltage and causes a self-discharge so as to discharge almost all the wall charges in all the cells, whereby the entire screen becomes is in a uniformly non-charged state.
During the address period, one of the lines is selected sequentially from a side of the arrayed lines by applying a scan pulse onto the corresponding sustain electrode Y. Concurrently with the selection of the line, an address pulse is applied to the address electrode A which corresponds to the cells to be lit. In the cells applied with the address pulse on the selected line is generated an opposing discharge between the sustain electrode Y and an address electrode A, and then shifts to a surface discharge. This sequence of the discharges is the address discharge. Thus, the address discharge forms the charged state only in the cells to be lit.
During the sustain period, sustain pulses are applied alternately to sustain electrodes X and sustain electrodes Y. The peak value of the sustain pulses is lower than the surface discharge breakdown voltage. Upon each application of the sustain pulses the surface discharge takes place only in the cells in which the charged state has been formed. Application cycle of the sustain pulses is constant. There are applied sustain pulses of the quantity preset according to the weight of brightness. During the surface discharge the fluorescent materials are excited by the ultra violet ray emitted from the xenon gas in the discharge gas, so as to emit the color R, G or B, respectively. The displayed color is determined by the ratio of brightness of each cell of R, G and B of a single pixel.
Hereinafter is described the contents of the discharge gas. FIG. 2 is a graph to show the relation between the density of krypton gas and the display characteristics. FIG. 3 is a graph to show the relation between the density of krypton gas and the light emitting characteristics.
Neon spectrum ratio SR=S580/S590 of a visible light strength S580 of 580 nm wavelength emitted from neon gas to another visible light strength S590 of 590 nm wavelength of red light zone emitted from the red fluorescent material layer 28R were measured while the xenon gas component was fixed at 4% in the discharge gas measured by the partial pressure, then the krypton gas component was varied, where the remainder was the neon gas. In order to evaluate the disturbance of neon light to the visible display lights, the spectrum S590 was chosen as representative of the display of visible lights.
With 0% krypton gas content, in other words 96% neon gas +4% xenon gas measured by partial pressure, the spectrum ratio SR was 0.33. On this sample, when the sustain voltage was gradually lowered from the static display state where all the cells are lit to the minimum sustain voltage for the first extinction of a lit cell V smN , the sustain pulse measured by the peak value was 208 V. The minimum sustain voltage for the first extinction of a lit cell V smN corresponds to the lower limit V smin of the margin of the sustain voltage in the dynamic display of practical use.
The discharge gas was exhausted once from the above sample PDP, a second discharge gas was filled again therein so as to make a second sample PDP including 2% krypton component, that is 94% Ne+4% Xe+2% Kr measured by the partial pressure. In the second sample PDP, the neon spectrum strength ratio SR was 0.24. In the same way, the further increase in the krypton content provides the less neon spectrum strength ratio SR as indicated with black dots in FIG. 2. This means that the unnecessary visible light spectrum strength S580 emitted from the neon gas was relatively lowered so that the ultraviolet ray strength to excite the fluorescent material is relatively increased resulting in an enhancement of the purity of the color to be displayed. However, the minimum sustain voltage for the first extinction V smN tends to increase as the krypton density is increased as indicated with black triangles ▴ in FIG. 2. As seen in FIG. 2, when the Kr component is more than approximately 1%, the color purity represented by the spectrum strength ratio SR is improved by more than 30%. On the other hand, the upper limit of the sustain voltage is approximately 230 V due to the restriction caused from the practical circuit. In order to achieve a stable display using a sustain voltage lower than 230 V the krypton density has to be less than 14%. In other words, the krypton density range to accomplish the object of the present invention is 1 to 14%; and the more preferable range in consideration of the difference in the light emission efficiency 8±2%, that is 6 to 10%. Though the effect of adding the krypton varies somewhat according to the xenon density, at the practical range of the xenon density of from 1 to 10% the appropriate range of the krypton density is approximately those values described above.
The increase in the above-mentioned minimum sustain voltage for first extinction V smN can be controlled by the employment of a mixture of an alkaline earth metal compound, that is typically strontium oxide, magnesium oxide or calcium oxide, for the protection layer, as disclosed in detail in U.S. Pat. No. 4,198,585.
A mere increase in the xenon density decreases the spectrum strength ratio SR as described in the PRIOR ART of the present specification. However, the increase in the minimum sustain voltage V smN caused thereby is much more than the increase in the case where the krypton density is increased. Accordingly, it is impossible to expect the considerable improvement in the color purity by means of increasing the xenon density.
FIG. 4 is a graph showing the relation between the density of the third component Kr or He in Ne+Xe and the effect to suppress the near-infrared ray. There was investigated a ratio SS of the sum S IR of spectrum strengths of the near-infrared rays having wavelengths 820 nm, 880 nm and 980 nm, each radiated from the xenon gas to the strength S590 of the above-mentioned light in the red zone emitted from the fluorescent material, that is the ratio SS=S IR /S590. The investigation was carried out by the use of two independent samples A and B each having the identical structure, however respectively filled with krypton gas and helium gas, so that the krypton gas and the helium gas are never mixed with each other.
As seen in FIG. 4, with the increase of krypton density the near-infrared spectrum strength ratio SS radiated from the xenon gas is drastically decreased. Thus, the radiation which will disturb infrared remote controller used for TV, etc. is suppressed. On the contrary, even though the helium gas added as the third component can decrease the infrared spectrum with the increase of its density, the degree is a little.
Helium has a smaller collision cross-section than neon. Accordingly, by the increase in the helium component, the amount of kinetic energy loss caused from the collision of ions in the discharge space decreases whereby sputtering of fluorescent material 28R, 28R and 28B and MgO film 18 is accelerated, resulting in shortening operation life of the PDP. On the contrary, krypton, since having a larger collision cross-section than neon, can suppress sputtering. Thus, krypton gas can contribute to the suppression of the near-infrared radiation and the enhancement of the operation life of the panel.
Moreover, as seen in TABLEs 2 and 3, the addition of krypton gas can improve the luminous efficiency to the same degree as the addition of helium gas, while the required operational voltage margin can be maintained. The figures in TABLEs 2 and 3 are those measured with the panels having the best luminous efficiency. The voltage V fl indicates a minimum sustain voltage for first lighting a cell when the sustain voltage is gradually increased after the addressing operation is performed for the entire-cell lighting, and corresponds to the upper limit V smax of the sustain voltage margin. The difference between the minimum sustain voltage V fl for first lighting a cell and the above-mentioned minimum sustain voltage for first extinguishing the light V smN is the operational voltage margin. The addition of helium gas decreased the voltage margin from 15 V to 3 V. The addition of krypton gas increased the voltage margin from 0 V to 15 V.
TABLE 2______________________________________3rd Brightness Sustain Chroma (white) Lumin' Effic.comp. cd/m.sup.2 Volt. X Y lm/W______________________________________None 81.6 200 V 0.338 0.346 0.4686He (18%) 99.2 210 0.312 0.331 0.5516Kr (8%) 112.0 230 0.316 0.326 0.5432______________________________________
TABLE 3______________________________________Panel 3.sup.rd Component V.sub.smN V.sub.f1 Voltage Margin______________________________________A None 198 V 213 V 15 VA He(18%) 206 209 3B None 208 208 0B Kr(8%) 224 239 15______________________________________
33 As described above, according to the present invention, the addition of krypton gas into a mixture of neon gas and xenon gas enhances the luminous efficiency, improves the color purity and suppresses the near-infrared ray radiation while the voltage margin of the driving pulses are maintained.
Though in the above description of the preferred embodiment was typically referred to an AC type surface discharge PDP 1, it is apparent that the present invention can be applied to a DC type surface discharge PDP, and an AC or DC type opposing discharge PDP. Furthermore, the present invention can be applied to aplasma addressed liquid crystal, usually referred to as a PALC.
The may features and advantages of the invention are apparent from the detailed and thus, it is intended by the appended claims to cover all such features and advantages of the methods which fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, the detailed disclosure is not intended to limit the invention and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the claimed invention. | A plasma display panel including a pair of substrates comprises a mixture of discharge gases contained between the substrates; the mixture consists of neon gas, xenon gas and krypton gas, wherein a percentage content of the krypton gas is selected in the range from 1 to 14 percent of the mixture, whereby near-infrared rays radiated from the xenon gas during the gas discharge is retarded while the operational margin of the AC driving voltage is preferably maintained. | 7 |
RELATED APPLICATION
[0001] The present invention claims priority to provisional application No. 60/358,807 filed on Feb. 22, 2002.
FEDERAL RESEARCH STATEMENT
[0002] This invention was made with Government support under Grant Number 5R44HL62038 awarded by the National Institute of Health.
TECHNICAL FIELD
[0003] The present invention relates generally to optical pressure sensors and, more specifically, to an ultra-miniature fiber optic pressure sensor embedded in an angioplasty guidewire.
BACKGROUND
[0004] Each year in the United States, five million patients get initial diagnosis of a heart attack, and nearly one million patients undergo coronary angioplasty, or other interventional procedures, to open or restore flow through stenosed vessels. Angiography is the standard method for assessing lesion severity, but it only provides an anatomic view of the lumen of the vessel, often in only one plane. Clinical benefits, as well as other benefits, would result if a real-time assessment of the functional severity of the lesion and its effect on blood flow were possible. A current method for attempting to acquire this information is the Doppler guidewire via which flow (or flow velocity) can be measured at the lesion. For reliable measurements, a catheter must be accurately positioned and must be stable during the entire data collection interval. This is difficult to do and, consequently, this method is not widely used. In addition, the necessary equipment is expensive and requires an elaborate training program for proficient use. A method involving direct measurement of pressure, rather than velocity, will have distinct advantages. Direct pressure measurements are easier to interpret, more familiar to medical personnel, require less expensive recording instruments and signal processing devices, and the position of the catheter is less critical. In addition, velocity measurements assess flow only through the lesion, while pressure measurements also assess the effects of collateral flow from other sources. This collateral flow can mediate the effect of the lesion in some cases. A direct-reading pressure catheter system can be used during angioplasty to monitor the progress and the immediate effects of the procedure on pressure distal to the lesion.
[0005] During angioplasty procedures, it is useful to be able to measure pressure distal to the lesions before, during, and after dilatation by the balloon. A procedure currently being investigated is the measurement of distal pressure during maximal vasodilatation. This is referred to as “functional flow reserve” and is a measure of the effect of the pressure drop across the lesion at maximal flow. This is currently measured through the lumen of the angioplasty catheter, but has limited fidelity, and can itself add to the severity of the lesion and the measured pressure drop. A narrow pressure sensor for direct pressure measurements was introduced in the U.S. market in February 1999, by RADI of Sweden called PressureWire™. The PressureWire™ sensor has a 360 micron diameter. However, there are several limitations with this sensor: (1) cost effectiveness, (2) mechanical characteristics, and (3) pressure measurement stability during angioplasty procedures. The current invention is related to a disposable sensor that reduces these limitations.
[0006] With the advent of the RADI PressureWire™, many studies have been conducted to determine the specific usefulness of such a device for diagnosis and an assessment of the effectiveness of the treatment during angioplasty. The high interest in such a device is demonstrated with over 20 papers presented about the RADI PressureWire™ at the ACC meeting held March, 2000 in Anaheim Calif. A new index, the Fractional Flow Reserve (FFR), defined as FFR=Pa/Pd (Pa=aortic pressure and Pd=distal coronary pressure), can be obtained by such a device and is now considered to be an accurate, quantitative and cost effective method for diagnosis and assessment. In particular, the method is effective for accurately determining the clinical significance of moderate stenoses. These are difficult to determine with current angiography procedures.
[0007] Presently the most common mass-produced disposable pressure sensors in the medical industry are silicon electronic devices with a typical size of several millimeters in diameter for the sensing area, usually used together with fluid-filled catheters as external pressure transducers. They are based on the piezoresistive or capacitive properties of silicon crystal and need complex circuitry for signal processing, drift compensation, and noise reduction before the information is made available to the medical personnel. These devices have an inherently high hysteresis and significant short-term creep (i.e., within a few hours) and thus need frequent re-calibration. They cannot easily perform static DC measurements. They also need to have a certain minimum size for the pressure-sensing mechanism to generate an adequate signal, so it is difficult to reduce the size down to the sub-millimeter region at a reasonable cost. The RADI PressureWire™ overcomes the size problem. However, it is an electronic sensor and the inherent problems described above remain, including a drift problem. In addition, the narrow (high impedance) cable must be adequately shielded to reduce RF interference. The desired feel (or stiffness) of the guidewire is therefore very difficult to achieve.
[0008] Fiber-optic sensors for direct pressure measurements are generally known in the art. Fiber-optic sensors are of a relatively simple design, have an inherently smaller potential size, and offer other advantages. A fiber-optic sensor is safe, involving no electrical connection to the body; because the primary signal is optical it is not subject to electrical interference, is very small and flexible, and can be included in catheters for multiple sensing. In addition, fiber-optic devices lend themselves well to existing mass production techniques.
[0009] U.S. Pat. No. 5,987,995 to the present assignee describes a fiber-optic pressure catheter that is suited to be low-cost and disposable. The sensor of the '995 patent includes a ribbon reflector, in contact with a polyurethane window, as the key sensing element that translates mechanical deformation, due to pressure, to an optical intensity variation of a signal beam. For some applications, the sensor of the '995 patent is undesirably large.
[0010] It would therefore be desirable to provide a pressure sensing system that is capable of providing a sufficient amount of deflection for the membrane in order to improve the accuracy of the device, increase the sterility of the system, and provide a means for adjusting the sensitivity so that consistent pressure readings are obtained if the sensor is disconnected from the light source and monitoring system.
SUMMARY
[0011] The present invention provides an improved pressure monitoring system particularly suited for use during angioplasty procedures.
[0012] In one aspect of the present invention, an improved fiber-optic pressure includes an optical fiber and a sensor head that is coupled to the optical fiber. The sensor head has a first portion having a membrane and a second portion. The membrane comprises a substrate having a rectangular center portion having a pair of first sides having a first length and a pair of second sides having a second length. The membrane has a plurality of parallel grooves and ribs formed around the center portion to allow the membrane to deflect inward.
[0013] In one constructed embodiment the grooves and ribs are formed parallel to the first sides and second sides. Two continuous rectangular grooves parallel to the center portion were used. The grooves have the ribs therebetween. The ribs are preferably discontinuous to facilitate flexing of the membrane.
[0014] In a further aspect of the invention, a method of forming a pressures sensor comprises forming a top portion of a sensor housing; on a first substrate, etching a rectangular portion with a plurality of grooves defining a plurality of ribs around the center portion, and on a second side of the substrate etching to form a pedestal extending from the center portion.
[0015] In yet another embodiment of the invention, an optical connecting system includes a housing having a central axis, a first optical fiber coupled to the housing having a first end and a second optical fiber coupled to the housing along the central axis having a second end. A lens and a lens scanning device movably coupled to the lens is also included within the housing. The lens is disposed on the central axis of the housing. The lens scanning device moves the lens relative to the housing to direct light from the first end to the second end.
[0016] In yet another aspect of the invention a connector for connecting an optical fiber to the housing includes a collet having a flange portion and a hollow tube portion for receiving the guidewire, said tube portion having a taper. A cap portion having a channel therethrough has a second taper portion that corresponds to the first taper portion. A spring is used to couple the collet to the cap.
[0017] Advantages of the invention include that the sensor measures blood pressures in the range of 0 to 300 mmHg with long-term stability and high fidelity. Also, the pressure sensor, imbedded in the guidewire, is stable for time periods compatible with prolonged guidewire implantation (up to 72 hours) although only 20 minutes is normally required in angioplasty use. Further pressure readings are independent of temperature over a range of at least 20° C. to 50° C. In addition to its functional properties, the pressure-sensor imbedded in a guidewire will be designed to be disposable and will, therefore, be available at a reasonable cost.
[0018] Other advantages of the present invention are also apparent. By providing grooves and ribs in the membrane, the present invention allows the device to be fabricated using MEMS processing techniques while allowing a substantial amount of pedestal deflection.
[0019] Yet another advantage of the invention is that repeatability is enhanced by the improved optical connecting system. That is, because a pressure sensor may be required to be decoupled during angioplasty, when the pressure sensor is reconnected, the optical connecting system adjusts the directional light between the two optical fiber ends so that consistent readings may be generated.
[0020] The sterility of the system is also improved by providing an improved connector for connecting the optical fiber to the housing. The connectors are relatively inexpensive and provide a tight seal for mounting the optical fiber to the housing.
[0021] Other advantages and features of the present invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a block diagrammatic view of the optical pressure sensing system according to the present invention.
[0023] [0023]FIG. 2 is a simplified schematic view of a sensor head coupled to an optical fiber according to the present invention.
[0024] [0024]FIG. 3 is a top view of a wafer used to form the present invention.
[0025] [0025]FIG. 4 is a top view of a chip having various cells used in forming the housing of the present invention.
[0026] [0026]FIG. 5 is a top view of the chip having a mask pattern thereon.
[0027] [0027]FIG. 6 is an enlarged view of the mask pattern of both of the cell types of FIGS. 4 and 5.
[0028] [0028]FIG. 7 is an enlarged mask of the first cell of FIG. 6.
[0029] [0029]FIG. 8 is a cross-sectional view of the first cell after etching with the first mask.
[0030] [0030]FIG. 9 is an elevational view of a second mask on the first and second cells.
[0031] [0031]FIG. 10 is an enlarged elevational view of the mask on the first and second cells.
[0032] [0032]FIG. 11 is a cross-sectional view of the first cell after etching with the second mask.
[0033] [0033]FIG. 12 is an elevational view of the chip having a third mask thereon.
[0034] [0034]FIG. 13 is a plot of the first cell having an enlarged view of the third mask of FIG. 12.
[0035] [0035]FIG. 14 is a cross-sectional view of the hole created after etching using the mask of FIG. 13.
[0036] [0036]FIG. 15 is a lateral cross-sectional view of the hole created by the mask of FIG. 13.
[0037] [0037]FIG. 16 is an elevational view of the chip having a fourth mask thereon.
[0038] [0038]FIG. 17 is an enlarged view of the first cell having the fourth mask thereon.
[0039] [0039]FIG. 18 is a cross-sectional view of the rectangular hole created by etching using mask four.
[0040] [0040]FIG. 19 is an elevational view of the chip having a fifth mask on the first cell.
[0041] [0041]FIG. 20 is an enlarged elevational view of the first cell having the fifth mask thereon.
[0042] [0042]FIG. 21 is an enlarged view of the mask of FIG. 20.
[0043] [0043]FIG. 22 is a cross-sectional view of the first cell after etching using the masks 1 , 2 , 3 , and 5 .
[0044] [0044]FIG. 23 is a cross-sectional view of the connector system of the present invention.
[0045] [0045]FIG. 24 is an enlarged cross-sectional view of the lens scanning device of FIG. 23.
[0046] [0046]FIG. 25 is a cross-sectional view of a guidewire cap formed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] In the following figures the same reference numerals will be used to illustrate the same components.
[0048] Although the invention is illustrated in the context of a fiber-optic sensor suitable for use in the human body, it will be appreciated that this invention may be used with other applications requiring pressure sensing.
[0049] Referring now to FIG. 1, a pressure sensing system 10 has a sensor unit 12 and a light transmitting and receiving unit 14 . Sensor unit 12 extends to the location in which the pressure is to be measured. Sensor unit 12 provides a spectral modulation of the light to light transmitting and receiving unit 14 . Light transmitting and receiving unit 14 converts the modulation into the spectral fringe pattern and also converts into a pressure reading with a microprocessor (or sends the digitized signal of the fringe pattern to a computer to convert a pressure reading).
[0050] Sensor unit 12 comprises a sensor head 16 , an optical fiber 18 within a guidewire 20 , and a connecting system 24 . The sensor unit 12 further includes a coil tip 26 and a spring coil 28 that are typically associated with an angioplasty device. The sensor head 16 may, for example, be placed in a human artery to measure blood pressure or placed within the brain to measure fluid pressure. Optical fiber 18 is connected between the connector 24 and the sensor head 16 .
[0051] Light transmitting and receiving unit 14 is connected through an optical fiber to the adaptive fiber connector 24 . The light transmitting and receiving unit 14 includes an optical coupler 32 , a spectrometer/CCD device 34 , a white light source 36 , an optical fiber 38 , and a second optical fiber 40 . Optical fibers 38 and 40 are used to couple the spectrometer/CCD 34 and the white light source 36 , respectively, to fiber coupler 32 . The coupler 32 is also used as a beam splitter to send light returned by the sensor head 16 to spectrometer 34 .
[0052] Spectrometer 34 is used to analyze the light received from the sensor head 16 . Spectrometer 34 may divide the light into its wavelength components. Spectrometer 34 preferably uses a linear detector such as a series of charge coupling devices (CCD). Spectrometer 34 converts the detected light signal from the sensor 16 into a desirable output format such as digital signals.
[0053] Light source 36 is preferably a wide band light source such as a white light source. One example of a desirable white light source is a tungsten-halogen source.
[0054] Light transmitting and receiving unit 14 may also have a computer 42 associated therewith. Computer 42 is used to perform mathematical calculations with the digitized output of spectrometer 34 to determine the pressure and various calibrations and adjustments as will be further described below. A monitor 44 may be used to display the pressure as calculated by the computer 42 . The spectrometer 34 and optical coupler 32 may be contained on a compact computer board, which is inserted into computer 42 . Such a light digitizer is manufactured by Ocean Optics.
[0055] One constructed embodiment of the invention includes guidewire 20 being formed of a hypo-allergenic tube of approximately five feet long having a 300 micron outer diameter. Spring coil 26 has the same outer diameter as the guidewire and is about eight to ten inches long. The sensor head 16 may be formed approximately two to three millimeters long. The coil tip may be tapered in diameter and be approximately one inch long. The coil tip is preferably made of platinum. The optical fiber 18 within the guidewire 20 with cladding and protective cover of polyimide has approximately a 90 micron outer diameter. The core of the optical fiber is a multi-mode optical fiber having a core diameter of approximately 60 microns.
[0056] Referring now to FIG. 2, one embodiment of sensor head 60 is illustrated coupled to optical fiber 18 that has a cladding and polyimide casing 46 . Optical fiber 18 has a first end 48 that is polished smooth to be optically flat. The end 48 preferably has a coating 50 disposed thereon. The coating 50 is preferably formed of titanium dioxide (TiO 2 ) or zinc sulfide (ZnS). Coating 50 may be about 0.7 to 3 microns but is approximately 2 microns thick.
[0057] Sensor head 16 has a housing 52 . Housing 52 has a top portion 54 and a bottom portion 56 . The top portion 54 includes a membrane 58 , a pedestal 60 and a cavity 62 . The optical fiber is positioned between the top portion 54 and the bottom portion 56 . Preferably, the top portion 54 has membrane 58 , pedestal 60 and cavity 62 integrally formed therewith. The housing 52 may be formed of a silicon material with a metallic material coating such as titanium grade 5 . The system works in a similar manner to that described in U.S. Pat. No. 5,987,995, which is incorporated by reference herein. A portion of light from the light source 36 never leaves optical fiber 18 . That is, the light reflects from end 48 and travels back through the optical fiber 18 . To increase and generate a desired pattern of reflectance of the end 48 , a portion of the light passes through the coating 50 and reflects from the end thereof: The coating 50 works as an Etalon so that the spectrum of the reflected light from the two surfaces is “spectrally” modulated (forming white light fringes). Some light leaves the coating 50 and bounces from the pedestal 60 back into the coating 50 and through the fiber core 18 . This bounced light is also spectrally modulated in such a way that the fringes are a complement of these of the reflected light by the coating 50 . As the pressure increases, the amount of the pedestal 60 in front of the optical fiber 18 varies. The amount varies from almost no pedestal in front of the reflective end to partially in front of the optical fiber 18 . Thus, it is the deflection of the membrane 58 that controls the amount of movement of the pedestal 60 . Thus, it is desirable to provide a suitable amount of movement of the pedestal 60 . The light returning from the sensor head consists of a superposition of two fringes: one from the coating 50 and the other from the pedestal 60 . The pressure is determined from a contrast of the superimposed fringes as is described in U.S. Pat. No. 5,987,995. It is to be noted that with this system the pressure is not directly determined by the amount of light reflected by the pedestal but is obtained as the contrast change of the superimposed fringes. Unlike the light variation measurements such as these taught in U.S. Pat. No. 5,018,529, this method of the measurement is a ratio measurement that makes the system robust against mechanical (fiber bending) and temperature fluctuations.
[0058] Referring now to FIG. 3, the way in which the top of the sensor housing 54 and the bottom of the sensor housing 56 are made is described. In FIG. 3, a wafer 70 is illustrated having a chip 72 that is etched to form the present invention.
[0059] Referring now to FIG. 4, chip 72 is illustrated in further detail. The chip is divided into a number of cells H 1 and H 2 . H 1 ultimately becomes the top portion 54 of the sensor housing and H 2 becomes the bottom portion of sensor housing 56 .
[0060] In one constructed embodiment, the length of chip 72 , L 1 was 16 millimeters, the length of each cell, Lc is 3 millimeters, the width of each cell, Wc is 1000 microns, and the width of the end portions, Wes is approximately 2 millimeters. The system is illustrated with respect to a coordinate system having an origin C at 0, 0. Thus, an X axis 72 and a Y axis 74 are illustrated.
[0061] Referring now to FIG. 5, a first mask 76 is provided. One mask for one H 1 cell and one H 2 cell is illustrated. The mask is repeated on each of the cells. The shaded areas illustrate the areas to be etched. The wafer from which the process is started is preferably about four or six inches in diameter and about 140 microns thick. Mask 1 is a lithographic mask that is applied to the surface except at the masked portions. Thus, when etching is performned, the illustrated shaded area will be etched.
[0062] Referring now to FIGS. 6 and 7, mask 1 has various dimensions.
[0063] Ltn=530
[0064] Wtn=200
[0065] Lup=700
[0066] Lmb=1200
[0067] Lfs=1100
[0068] Wmb=205
[0069] Wmb/2=205/2=102.5
[0070] Wgv=25
[0071] Wsp=4
[0072] Lgl=Lmb−2*(Wgv+Wsp)=1200−2*(25+5)=1140
[0073] Lgs=Lgl−2*(Wgv+Wsp)=1140−2*(25+5)=1080
[0074] Wgp=85
[0075] As can be seen, the mask 76 has various portions that correspond to the grooves in the surface. That is, a top view of the device after etching looks like FIG. 7 so the grooves and mask portions will be described together. Mask 1 has a center portion 78 , two vertical portions 80 and 81 on the left side of the center portion 78 , and two vertical portions 82 and 83 on the right side of the center portion 78 . It should be noted that right and left are described with respect to FIG. 7. That is, vertical portions 80 - 83 are parallel to the longitudinal sides of the center portion 78 . Mask 1 further includes horizontal portions 84 , 85 , 86 , and 87 . Horizontal portions 84 extend laterally and are parallel with the top and bottom sides of the center portion 78 . Thus, the grooves formed by the vertical and horizontal portions 80 - 87 include discontinuous outer grooves 80 , 82 , 84 , and 86 that are longer in size than their respective corresponding inner grooves 81 , 83 , 85 , and 87 . The lengths of the grooves formed by the masked portions 81 and 83 are preferably as long as the center portion 78 . The grooves formed by the horizontal portions 85 and 87 are as long as the center portion, two ribs and the width of the grooves 81 and 83 . The length of the grooves formed by the masked portions 80 and 82 are preferably as long as the longitudinal walls of the center portion 78 plus the width of two ribs and the width of the grooves 85 and 87 . The length of the grooves formed by the portions 84 and 86 are preferably as long as the lateral width of the center portion 78 , four ribs formed between the horizontal walls 81 , 82 , and 83 and the width of the grooves formed by the portions 81 , 82 , and 83 .
[0076] The mask 76 and grooves are preferably elongated and rectangular in shape. Dimensions of the grooves and thus the widths of the ribs formed by the system are described below:
[0077] Ltn=530
[0078] Wtn=200
[0079] Lup=700
[0080] Lmb=1200
[0081] Lfs=1100
[0082] Wmb=205
[0083] Wmb/2=205/2=102.5
[0084] Wgv=25
[0085] Wsp=4
[0086] Lgl=Lmb−2*(Wgv+Wsp)=1200−2*(25+5)=1140
[0087] Lgs=Lgl−2*(Wgv+Wsp)=1140−2*(25+5)=1080
[0088] Wgp=85
[0089] Referring now to FIG. 8, a cross-sectional view along line A—A of FIG. 7 is illustrated. The partially etched cell H 1 has a center portion 90 , a first longitudinal rib 92 , a second longitudinal rib 94 , a third longitudinal rib 96 , and a fourth longitudinal rib 98 . A first longitudinal groove 100 is disposed between the first rib 92 and the second rib 94 . A second longitudinal groove is positioned adjacent to the rib 94 . A third longitudinal groove 104 is disposed between the rib 96 and 98 . A fourth longitudinal groove is disposed adjacent to the rib 98 . Thus, the etching of the grooves 100 - 106 and the center portion 90 form the ribs 92 . Each groove 100 - 106 is preferably formed to have a flat portion 108 . The grooves in the lateral direction preferably have the same dimensions. Thus, the figure of a lateral direction would have the same dimensions except the width Wgp becomes Lgs. The dimensions of the ribs and grooves are:
[0090] Wgv=25
[0091] Wgb=5
[0092] Wgp=85
[0093] Wpb=65
[0094] Wsp=5
[0095] Dgv=15.7
[0096] Referring now to FIG. 9, a second mask 110 is illustrated. As can be seen, mask 110 extends between cells H 1 and H 2 .
[0097] Referring now to FIG. 10, the mask 110 is used to form breaking lines so that the various cells may be broken apart into their corresponding housing portions. The various dimensions with respect to the mask 2 are:
[0098] Wc=1.0 mm
[0099] We=400
[0100] Lc=3.0 mm
[0101] Lsl=500
[0102] Wa=280
[0103] Wan=210
[0104] Referring now to FIG. 11, cross-sectional view of cell H 1 is illustrated. As can be seen, breaking lines 112 and 114 run longitudinally with respect to the cell H 1 . As mentioned above, the breaking lines 112 and 114 allow the top portion of housing 54 to be formed. The dimensions in the cross-sectional view are:
[0105] Wwt=(Wa−Wmb)/2=(280−205)/2=37.5
[0106] Wsn=(We−Wa)/2=(400−280)/2=60
[0107] Dbl=about 110
[0108] It should be noted that the etchings described above with respect to FIGS. 3 - 11 are formed on the first side (side A) of the cells (or the wafer). Later, the etching on the second sides will be illustrated. For the etching of the grooves and ribs, preferably KOH is used in the etching process. The breaking lines may be etched using a DRIE etching process. Because the edges of the etching may form sharp corners, a brief HNA etching may be used to round the corners. The entire side A after the etching process may be coated with titanium Grade 5 . The thickness of the film may, for example, be 1.5 microns on the flat surfaces. The titanium Grade 5 alloy consists of (Ti— 6 Al—4V) since an amorphous Ti film is desired.
[0109] Referring now to FIG. 12, a third mask 120 is illustrated on chip 72 . This mask is used to determine the height of pedestal 60 . Mask 120 is on the opposite side of the device as FIGS. 3 - 11 .
[0110] Referring now to FIG. 13, mask 120 is shown in an enlarged scale from that of FIG. 12. The dimensions of the mask correspond to the dimensions of the end of the pedestal 60 of FIG. 2. The dimensions are:
[0111] Wc=1.0 mm
[0112] Wc/2=0.5 mm
[0113] Ls=1300
[0114] LI=1700
[0115] Wp=65
[0116] Wpn=40
[0117] The dimensions of the rectangular hole 122 shown in FIG. 14 and 15 are:
[0118] Wp=65
[0119] Wpn=40
[0120] Dph=50
[0121] Referring now to FIGS. 16 and 17, a fourth mask 124 is illustrated. Fourth mask 124 is also formed on the lower surface of the cell H 1 . The etching allows for the size of the optical fiber so that the optical fiber may be inserted within the top portion of housing 54 . The dimensions of mask 124 are:
[0122] Lfs=1900
[0123] Lls=1100
[0124] Wfs=90
[0125] Referring now to FIG. 18, the cell H 1 is illustrated with the rectangular slot 126 formed from mask 4 . Rectangular slot 126 as mentioned above is used to receive the optical fiber during assembly. The dimensions of the rectangular slot 126 are:
[0126] Wfs=90
[0127] Dfh=90
[0128] The etching process uses a photolithography process, and DRIE etching as mentioned above.
[0129] The cell H 1 is preferably planarized in a known manner before performing the fifth mask 128 described below.
[0130] Referring now to FIG. 19, the chip 72 is illustrated having a mask 128 . Mask 128 has registration portions 130 and a rectangular portion 132 .
[0131] Referring now to FIGS. 20 and 21, enlarged versions of the rectangular portion 132 are illustrated. The rectangular portion 132 has an opening 134 therein. The opening 134 corresponds to the pedestal so that the pedestal area is not further etched. The rectangular portion 132 is used to etch out the cavity 62 shown in FIG. 2. The dimensions of the etchings are:
[0132] R1=R2=R3=R4=R5=70
[0133] Rd=340
[0134] Wsl=15
[0135] Lue=700
[0136] Lcl=1200
[0137] Lls=1100
[0138] Wcs=205
[0139] Wp=65
[0140] Wpn=40
[0141] Referring now to FIG. 22, a cross-sectional view of the top portion 54 is illustrated. As can be seen, cavity 62 is illustrated while allowing the membrane and pedestal to remain fixedly thereto. As can be seen the titanium layer 135 remains while the silicon is etched away at the grooves. The dimensions illustrated on the cavity are:
[0142] Wcs=205
[0143] Dt=140 to the membrane.
[0144] Referring now to FIG. 23, connecting system 24 is illustrated. Connecting system 24 has optical fiber 30 that is connected to fiber optic coupler 32 within the light transmitting and receiving unit 14 . The second optical fiber as shown in FIG. 1 is coupled to sensor head 16 . The connecting system 24 has a housing 140 that has a cavity 142 therein. Cavity 142 includes an imaging lens 144 and a lens scanning device 146 . The lens scanning device 146 positions the imaging lens 144 with respect to the optical fiber 30 and the optical fiber 18 . The scanning device is capable of moving the lens in a vertical direction illustrated by arrow 148 . The vertical direction corresponds to the lateral axis of the housing 140 which is perpendicular to the optical axis and the longitudinal axis of the housing 140 . The lens scanning device 146 is also capable of positioning the lens horizontally as indicated by arrow 151 . That is, the lens scanning device 146 is capable of moving the lens 144 in a horizontal direction perpendicular to the longitudinal axis (direction 148 ) and optical axis of the housing 140 . The optical fiber 18 may be positioned within the housing 140 using a sanitization cap 150 . Sanitization cap 150 is used to prevent the system from becoming contaminated during the angioplasty procedure. The cap 150 is removable from the housing 140 and is fixedly attached to the housing using a pin 152 . Pin 152 is removable and fits within a recess 154 in the cap 150 . The cap 150 has a channel 156 having a diameter sized to receive the optical fiber 18 and the guidewire 20 .
[0145] Referring now to FIG. 24, lens scanning device 146 is illustrated in further detail. Lens scanning device 146 includes a lens holder 156 used to receive imaging lens 144 therein. Lens holder 146 has a vertical motion lever, arm 158 coupled thereto. Lens holder 156 also has a horizontal motion lever arm 160 coupled thereto. Vertical motion lever arm 158 is coupled to a screw 162 which in turn is moved by piezo device 164 .
[0146] The horizontal motion lever arm 160 is coupled by way of a screw 166 to a piezo device 168 . Movement of the screw 166 caused by the piezo device 168 moves the lens holder 156 in a horizontal direction. Thus, the lens may be positioned in a horizontal direction and vertical direction by piezo devices 164 and 168 by pushing screws 162 and 166 .
[0147] In the guidewire application, the sanitization cap end of the guidewire 120 cannot be larger than the diameter of the tube. For angioplasty procedures, a tube carrying a stent-balloon must be placed over the guidewire to place the stent in an injured part of a coronary artery. The end of the guidewire has to be removed from the fiber connector when the stent is applied. Thus, the connector has to be such that when a user of the connector disconnects or connects the guidewire to the fiber connector, the optical fiber 18 has to be reconnected in such a way that maintains consistent pressure readings. Because the connection takes place while the sensor is within the patient's artery, sensitivity or offset adjustments are not practical. The connector 24 is thus adapted by using the mechanism shown in FIG. 24. It is the desired goal of the system by monitoring the spectrometer 34 to form an image of the core of optical fiber 30 on the optical fiber 18 . If this is not achieved coupling efficiency is reduced and a signal offset level may be formed. This makes the system unreliable. The lens scanning device 146 is capable of moving the lens to compensate for the offset. The piezo devices 164 and 168 are capable of a displacement of 7 microns. Because of the leverage created by the lever arms 158 and 160 , up to 70 microns of movement may be achieved. Thus, an image formed by the lens may move up to 140 microns due to optical leverage. The lever arms may be formed using an electrode discharge machining process.
[0148] In operation, the purpose is to project the image of the core of the source fiber 30 on the fiber. The visibility of the fringes from the coating 50 of FIG. 2 is used for this aim. The light in the core of the guidewire goes to the end of the fiber sensor 60 when it returns the spectrum modulated by the coating 50 . The light that strikes the other part of the end face of the guidewire does not contain any fringes and is reflected back to the detector 34 . By moving the piezo stacks, the lever arms are moved. This movement may be controlled by the computer 42 . By monitoring the visibility of the fringes, the position with the maximum visibility becomes the desired location. In a practical implementation, coarse scanning may be used followed by fine scanning. That is, the position of the system may be easily found using a 10 micron accuracy followed by 4 micron accuracy steps.
[0149] Referring now to FIG. 25, a second embodiment of the sanitization cap connector 150 ′ is illustrated. In this embodiment, the connector 150 ′ is coupled to the housing 140 . The connector 150 ′ includes a collet 170 . The collet 170 has a flange portion 172 and a hollow tube portion 174 . Guidewire 18 is received within the hollow tube portion 174 . The connector 150 ′ also includes a cap 176 that is positioned within an angular opening 178 . The angular opening 178 corresponds to the conical shape of the cap 176 . The cap 176 has a flange 180 extending therefrom. A tension spring 182 is used to couple the cap 180 to the collet 170 . The spring is positioned between the flanges 172 and the flange 180 of cap portion 176 . The cap is preferably formed of stainless steel. The cap 176 has a channel 184 therein. The channel 184 has a tapered surface 186 therein. The tapered surface 186 corresponds to a taped surface 188 of the collet. Thus, as the hollow tube portion 174 is inserted within the cap, the tapered surfaces 186 and 188 act to hold the guidewire 20 therein. A guidewire stop 190 may also be coupled to the cap portion 176 . Guidewire stop 190 may be press fit and have a diameter smaller than the diameter of the guidewire 20 . This prevents the guidewire 20 from being positioned too far within the housing 140 .
[0150] The tension spring 182 pulls the collet 170 in the cap 176 which holds the guidewire 20 in place. When the guidewire 20 is released, one pulls the flange out of the collet. This releases the guidewire holding force. The cap can be released from the housing 140 by pulling it outward. This helps prevent accidental release of the guidewire 20 from the fiber connector 24 .
[0151] While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims. | The fiber optic pressure sensing system includes a sensor housing formed using MEMS processing. The sensor housing has ribs and grooves in both horizontal and vertical directions relative to the surface to allow the membrane to flex in a consistent manner. The flexing of the membrane allows the pedestal to be repeatedly positioned in response to pressure acting on the extension of the sensor head and membrane. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dust-removing mechanism in an open-end spinning frame.
2. Description of the Prior Art
FIG. 1 of the accompanying drawings illustrates a conventional open-end spinning frame. A sliver A as it is introduced into a spinning unit 1 is advanced while being sandwiched between a feed roller 2 and a presser 3, and is separated into fibers by a combing roller 4 which rotates at a high speed that is surrounded by an outer wall 20 extending along the outer peripheral surface of the combing roller 4 with a predetermined clearance therebetween. The separated fibers are then transferred in the direction of the arrow along the circumferential surface of the combing roller 4 into a fiber feed channel 5. The fibers as they emerge from the fiber feed channel 5 are carried on a current of air and rotated at a high speed, and then are deposited on an inner peripheral surface of a rotor 6 in which a vacuum is developed. The fibers are thereafter pulled as a yarn out of a yarn delivery passage (not shown), and the yarn is wounded on a bobbin to form a yarn package.
The outer wall 20 has an opening 21 through which the circumferential surface of the combing roller 4 is partially exposed to a dust-removing chamber 7 disposed adjacent to the combing roller 4. Impurities and foreign matter B such as leaf pieces and neps, for example, in the sliver are discharged through the opening 21 into the dust-removing chamber 5 under centrifugal forces of the combing roller 4 as it separates the sliver. Other impurities and foreign matter B such for example as short fibers, waste cotton, and dust are separated from the surface of the combing roller 4 by an air stream produced by the rotation of the latter and then are discharged into the dust-removing chamber 7. The dust-removing chamber 7 has a small air inlet 7a in one end thereof, but is of a substantially closed construction. The other end of the dust-removing chamber 7 has an outlet 7b connected to a trash pipe 8 for delivering the impurities B. The trash pipe 8 is coupled to a side of a dust collector duct 9 which is shared by other spinning units. The dust collector duct 9 leads through an air blower 10 to a dust collector chamber (not shown). The impurities B separated and discharged into the dust-removing chamber 7 are discharged therefrom into the trash pipe 8 on a suction stream of air created by the action of the air blower 10, and then are collected through the dust collector duct 9 into the dust collector chamber.
The conventional dust-removing mechanism of the foregoing construction has suffered from the following shortcoming: As described above, the impurities B are carried on a current of air from the dust-removing chamber 7 into the trash pipe 8. Since it is necessary to develop a relatively strong suction air stream in the dust-removing chamber 7 for delivery of the impurities B, the dust-removing chamber 7 is of substantially closed construction. Therefore, a suction force due to the vacuum in the rotor 6 tends to be developed in the dust-removing chamber 7. This suction force is liable to cause the impurities B once separated from the fibers to be drawn back into the rotor 6 on a suction air stream generated by the latter, and to be deposited in the rotor 6. One solution to avoid such an undesirable phenomenon would be to increase the speed of air flow in the dust-removing chamber 7. However, such an air flow would peel not only the impurities but longer fibers off the surface of the combing roller 4, resulting in a poorer yarn yield. The outlet 7b of the dust-removing chamber 7 is constricted for increasing the speed of air flow and hence tends to get clogged with the impurities B passing therethrough.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a dust-removing mechanism for open-end spinning frames which has a dust-removing chamber vented to atmosphere for effective separation of impurities from a combing roller substantially without depending on a suction current of air, and which delivers out the separated impurities on an air stream or other means such as a conveyor.
Another object of the present invention is to provide a dust-removing mechanism having a large dust-removing opening and capable of separating impurities only, without discharging yarn-forming fibers.
According to the present invention, there is provided a dust-removing mechanism in an open-end spinning frame having a rotor, including a combing roller for separating a supplied sliver into fibers, an outer wall surrounding the combing roller and having a dust-removing opening, and a dust-removing chamber into which the dust-removing opening opens, so that impurities will be separated from the sliver by the combing roller and discharged through the dust-removing opening into the dust-removing chamber, wherein the improvement comprises a rear wall disposed upstream in the direction of rotation of the combing roller and having an edge and a front wall disposed downstream with respect to the direction of combing roller rotation, the front and rear wall edges jointly defining the dust-removing opening, there being an angle α formed between first and second lines passing through the front and rear wall edges and the center of the combing roller, an angle β formed between a third line passing through the center of the combing roller and the center of an opening in the rotor and a fourth line passing through the center of the combing roller perpendicularly to the third line, an angle Υ formed between a surface of the front wall and a fifth line extending parallel to the fourth line through the front wall edge, and an angle δ formed between a surface of the rear wall and a sixth line extending parallel to the fourth line through the rear wall edge, the angles being in the following ranges:
40°≦α≦45°
0°≦β≦5°
40°≦Υ≦45°
0°≦δ≦20°
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a conventional dust-removing mechanism in an open-end spinning frame;
FIG. 2 is a plan view of a dust-removing mechanism showing the manner in which air flows in a dust-removing chamber;
FIG. 3 is a plan view of a dust-removing chamber in a dust-removing mechanism according to the present invention; and
FIG. 4 is a side elevational view of a dust-removing chamber according to another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 2, a spinning unit 1 to which the principles of the present invention are applicable includes combing roller 4 having a central axis 4a and a rotor 6 having a central axis 6a intersecting the central axis 4a at the center of the combing roller 4.
The combing roller 4 is surrounded by an outer wall 20 having a dust-removing opening 21 defined by a rear wall 22 disposed upstream in the direction (indicated by the arrow) of rotation of the combing roller 4 and a front wall 23 disposed downstream in the same direction. The dust-removing opening 21 communicates with an open-type dust-removing chamber 7 which is vented to atmosphere through an apertured plate or screen 11 (FIG. 4) covering the dust-removing chamber 7. Impurities B separated and discharged into the dust-removing chamber 7 fall onto a conveyor 24 positioned in the dust-removing chamber 7, and are delivered thereby in the direction of the arrow into a dust collector duct (shown at 9 in FIG. 1), from which they are carried on an air current into a dust collector chamber. Any suction current of air produced by an air blower (shown at 10 in FIG. 1) does not affect the dust-removing opening 21, and the air flow in the dust-removing chamber 7 remains substantially undisturbed by the suction air stream caused by the rotor 6.
With a conventional closed-type dust-removing chamber disclosed in Japanese Laid-Open Patent Publication No. 51-1732, the dust-removing capability is controlled by an angle Υ' formed between the front wall 23 and a line passing through an edge of the front wall 23 and the center 4a of the combing roller 4. For open-type dust-removing chambers, however, it has been found that the dust-removing capability is also affected by an opening angle α, and the positions and inclinations of the front and rear walls.
More specifically, a consideration of dust-removing mechanisms in open-end spinning frames requires study of the behavior of currents of air in the area of the dust-removing opening. The study by the inventors has revealed that there are basically three currents of air involved in the dust-removing opening. One of the three currents of air is a suction current of air S produced by the rotation of the rotor 6 and directed toward the rotor 6 in the vicinity of the edge 23a of the front wall 23. The second air current is a stream of air t accompanying the rotating air flow along the outer peripheral surface of the combing roller 4. The third air current is a supplementing air flow u generated when the rotating air flow around the combing roller 4 is peeled off as a boundary layer, the supplementing air flow u being largely dependent on the shape of the dust-removing opening 21.
The components of the fibers separated by the combing roller 4 are divided into several groups according to form and gravity, and move on the rotating air flow between the combing roller 4 and the outer wall 20. When the fibers reach the dust-removing opening 21, relatively heavy seed pieces and neps fly out into the dust-removing chamber 7 under central forces. Those fibers which have large surface areas and a small apparent specific gravity remain trapped in the rotating air flow and move therewith. Other impurities B such as trash and dust, for example, having an intermediate specific gravity are displaced slightly radially outwardly into the accompanying air current t. For increased dust-removing capability, it is required that the accompanying air current t be spread in the dust-removing chamber 7 to discharge the impurities B such as trash and dust. If the dust-removing opening 21 were too small, the suction air current S would be too intensive to allow the accompanying air current t to be spread out since the latter would be repelled by the suction air current S and absorbed into the rotating air flow again.
As the dust-removing opening 21 is larger, the accompanying air flow t would be spread well for improved dust-removing capability. If the dust-removing opening 21 were too large, however, the rotating air flow would be peeled off as the boundary layer at an increased rate, with the result that the fibers would be disoriented and the supplementing air flow u would become stronger. The impurities once discharged would then be carried by the supplementing air flow u, join the rotating air flow and the suction air flow S, and be deposited in the rotor 6. Accordingly, there is a preferred range for the size of the dust-removing opening 21. In the following description, the size of the dust-removing opening 21 is defined by an opening angle α, as shown in FIG. 3, which is formed between a line passing through the center 4a of the combing roller 4 and the edge 23a of the front wall 23 and a line passing through the center 4a and an edge 22a of the rear wall 22.
If the front wall edge 23a were displaced downstream for enlarging the dust-removing opening 21, the suction force caused by the rotor 6 would become more influential and the suction air current S would be increased. The impurities displaced into the accompanying air current t and tending to be separated from the rotating air flow would be blocked by the suction air current S and become more likely to join the rotating air flow. Therefore, there is a limitation on the position of the front wall edge 23a in the upstream direction. In the following description, the position of the front wall edge 23a is defined by an angle β, as shown in FIG. 3, formed between a line I passing through the center 4a of the combing roller 4 perpendicularly to a line connecting between the centers 6a, 4a of an opening in the rotor 6 and the combing roller 4, and a line II passing through the center 4a of the combing roller 4 and the front wall edge 23a.
If the angle of inclination of the front wall 23 were too large, then the rotating air flow caused by the rotation of the combing roller 4 would be peeled off by the edge 23a, disturbing the fibers and resulting in a loss of fibers. If the front wall 23 is inclined at a proper angle, then it allows the rotating air flow to move smoothly, and the accompanying air current t becomes a laminar flow along the front wall 23 for good dust removal. If the angle of inclination were too small, the rotating air flow and the accompanying air current t would impinge on the front wall 23, producing swirls which would be carried on the suction air current S to permit the separated impurities to be absorbed again into the rotor 6. Accordingly, it is expected that there is a preferred range of angles of inclination of the front wall 23.
The angle of inclination of the front wall 23 is defined by an angle Υ formed between a line III parallel to the line I and the surface of the front wall 23.
The position of the edge 22a of the rear wall 22 is directly related to the size of the dust-removing opening 21, and the edge 22a has the same function as that of the front wall edge 23a.
If the angle of inclination of the rear wall 22 were too large, the accompanying air current t produced by the rotation of the combing roller 4 would easily be dispersed for increased dust removal efficiency, but the supplementing air current u for compensating for a boundary layer separation would be increased and the impurities to be absorbed again into the rotor 6 would be increased, resulting in a poorer yarn quality. If the angle of inclination of the rear wall 22 were too small, it would become difficult for the accompanying air current t to be dispersed, lowering the dust removal efficiency. Therefore, there is a proper rear wall position and a proper angle of inclination of the rear wall 22. In the following description, the angle of inclination of the rear wall 22 is defined by an angle δ formed between a line IV parallel to the line I and the surface of the rear wall 22.
According to the present invention, it is required that the edge 23a of the front wall 23 be positioned on the line I or upstream of the line I, and the angle β be in the range of from 0° to 5°. It is preferred that the angle α of the dust-removing opening 21 be in the range of from 40° to 45°.
It is also preferred that the angle Υ of inclination of the front wall 23 be in the range of from 40° to 45° and the angle δ of inclination of the rear wall 22 be in the range of from 0° to 20°.
The advantages of the present invention will appear clear from the following example:
EXAMPLE
Using the spinning unit as shown in FIG. 2 with dimensions varied, spinning operations were effected under the following spinning conditions:
Sliver supplied:
Material: Cotton 100%
Fineness: 4.3 g/in.
Average fiber length: 23 mm
Grain: 420 gr/6 yd
Sliver U%: 4.0%
Trash content: 250 mg/kg
Spinning condition:
Spinning time: 8 H
Yarn count: 7' S
Twist constant: 4.8
Rotor RPM: 60,000 rpm
Combing roller RPM: 8,000 rpm
The quality of yarns produced is evaluated according to U%, and the dust removal efficiency is evaluated according to the amount of dust deposited in the rotor. The results are shown in the following table:
TABLE__________________________________________________________________________ No.Items 1 2 3 4 5 6 7 8 9 10 11 12 Remarks__________________________________________________________________________Inventive device x O O O x O O O x x x x No. 12 = closed(marked with O) dust-removingDust- α.sup.o 35 40 45 45 45 45 40 45 55 55 45 35 chamberremoving β.sup.o 5 5 5 0 5 5 5 0 5 10 -5 5 (suction pressurechamber γ.sup.o 40 40 45 40 45 45 45 45 45 40 40 40 = 110 mmAg)dimensions δ.sup.o 0 5 10 0 -20 0 20 20 0 0 0 0Amount of depo- 1.5 0.4 0.3 0.7 1.4 0.6 1.5 0.3 2.5 0.9 1.7 1.3sit in rotor mg/kgU Start 9.8 9.8 9.8 9.8 10.1 9.8 9.8 9.7 13.2 10.7 10.1 9.8% End 10.0 9.8 9.8 9.8 10.4 9.8 9.8 9.7 13.9 10.9 10.6 9.9__________________________________________________________________________
As is apparent from the above table, the amounts of deposited dust in the rotor after 8 hours of operation of the spinning unit equipped with the dust-removing chamber according to the present invention are all below 1.0 mg/kg, and therefore the dust-removing chamber of the invention has an excellent dust removal efficiency. The U% of the spun yarns is 10% or below, and hence the dust-removing mechanism of the invention achieves a good yield of fibers of good quality.
With the arrangement of the present invention, the dust-removing chamber is of the open type vented to atmosphere, and hence is free from a reduced dust removal efficiency and a poor yarn yield due to mutual interaction of air currents in the dust-removing chamber. The dimensions and angles of the dust-removing chamber are selected to be optimum so that yarns can be spun under good conditions for stable yarn spinning operation.
While in the embodiment of FIG. 2 the conveyor 24 is employed for discharging the impurities B, an opening 12 and a confronting suction inlet 13 may be provided in a lower portion of the dust-removing chamber, as shown in FIG. 4, for delivering dust on an air stream. Since the dust-removing chamber is open to atmosphere, the air stream flowing through the opening 12 and the suction inlet 13 is under a low pressure, and therefore does not adversely affect the dust removal operation.
In the illustrated embodiment, the combing roller 4 has a vertical central axis. However, the combing roller 4 may be arranged such that its central axis extends horizontally. The rotor 6 according to the foregoing embodiment is of the self-discharge type having an air-discharging hole. However, the present invention is also applicable to a rotor of the forced-discharge type having no air-discharging hole.
Although certain preferred embodiments have been shown and described, it should be understood that many changes and modifications may be made therein without departing from the scope of the appended claims. | A dust-removing mechanism in an open-end spinning frame has a dust-removing chamber into which a dust-removing opening opens, the dust-removing opening being defined by a rear wall disposed upstream in the direction of rotation of the combing roller and having an edge and a front wall disposed downstream in the direction, there being an angle α formed between first and second lines passing through the front and rear wall edges and the center of the combing roller, an angle β formed between a third line passing through the center of the combing roller and the center of an opening in the rotor and a fourth line passing through the center of the combing roller perpendicularly to the third line, an angle Υ formed between a surface of the front wall and a fifth line extending parallel to the fourth line through the front wall edge, and an angle δ formed between a surface of the rear wall and a sixth line extending parallel to the fourth line through the rear wall edge, the angles being in the following ranges:
40°≦α≦45°
0°≦β≦5°
40°≦Υ≦45°
0°≦δ≦20°. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of and claims priority to U.S. application Ser. No. 10/073,122, now U.S. Pat. No. 6,773,327, filed Feb. 12, 2002, and U.S. application Ser. No. 10/305,265, filed Nov. 27, 2002, both of which are incorporated herein by reference.
TECHNICAL FIELD
This description relates to an electromechanical toy.
BACKGROUND
Toys that have moving parts are well known. For example, dolls and plush toys such as stuffed animals are made with moveable appendages.
SUMMARY
A toy may be configured to closely resemble a live animal and to respond to stimuli in a realistic manner that is consistent with the way in which a real animal would respond. For example, when the toy is designed to resemble a dog or a cat, the toy may be configured to move in a manner consistent with the movements of a dog or a cat. This realistic movement, in conjunction with a realistic fur coat coupled to and covering inner mechanical components, may be used to provide a strikingly realistic toy.
For example, the toy animal may turn in the direction of a sound or touch. The body of the toy animal may pivot in conjunction with animation of the head of the toy animal, which is attached to the body of the toy animal. The toy animal may wag it's tail and it's back region as it moves forward or backward. The toy animal may include side panels that replicate walking motion of the arms and paws of the toy animal as the toy animal moves forward or backward.
In another general aspect, a toy includes a body, a wheel region that rotates about a wheel axis and is coupled to the body, a back region coupled to the body, and an actuation system within the body. The actuation system is coupled to the back region to oscillate the back region about a back axis perpendicular to the wheel axis as the wheel region rotates.
In an implementation in which the toy is configured to resemble an animal, oscillation of the back region resembles a rear hip motion of the animal as the animal walks.
Implementations may include one or more of the following features. For example, the toy may include a drive wheel region that rotates about a drive wheel axis that is parallel to the wheel axis and causes the body to move in a direction perpendicular to the drive wheel axis. The toy may include a motor, and a second actuating system coupled to the motor and to the drive wheel region to move the body in a direction that is perpendicular to the drive wheel axis. Motion of the body may cause the wheel region to rotate about the wheel axis.
The back region may include a crank attached to a lower surface of the back region and coupled to the actuation system to oscillate the back region as the wheel region rotates. The actuation system may include a crank device attached to the crank, a coupling device attached to the crank device, and a wheel device attached to the coupling device and to the wheel region. The wheel device may be fixed to an axle of the wheel region.
The crank device may include a crank gear, the coupling device may include a coupling gear, and the wheel device may include a wheel gear. Alternatively, the crank device may include a crank pulley, the wheel device may include a wheel pulley, and the coupling device may include a coupling belt that wraps around the crank pulley and the wheel pulley.
The toy may further include a side panel external to and attached to the body, and an actuating device coupled to the wheel region and to the side panel to oscillate the side panel about a side panel axis that is parallel to the wheel axis as the wheel region rotates. The actuating device may include a protrusion on the side panel that engages a cam on the wheel region.
In an implementation in which the toy is configured to resemble an animal, the side panel is configured to resemble the arms or paws of the animal and oscillation of the side panel resembles a back and forth motion of the arms or paws of the animal as the animal walks.
A tail may be connected to the back region to oscillate as the back region oscillates.
The back region may include a back panel and cylindrical projections that extend from side surfaces of the back panel. The cylindrical projections are shaped to fit within cavities of the body. The back axis may be defined by the cylindrical projections.
In an implementation in which the toy is configured to resemble an animal, movement of the the tail resembles a tail wagging motion of the animal as the animal walks.
The toy may also include a motor that causes the toy to move in a forward direction and a backward direction, with both directions being perpendicular to the wheel axis. The toy may include a pendulum rotatably attached to an inside surface of the body and a pivoting member coupled to the pendulum and to a cavity of the body. The pendulum is free to oscillate about an axis that is perpendicular to the direction in which the toy moves. The pivoting member is free to oscillate about a pivot within the cavity. The pendulum may oscillate in response to successive movements of the toy in the forward and backward directions. The pivoting member may oscillate about the pivot in response to oscillation of the pendulum. At least a portion of the pivoting member may be external to the body. The toy may include an output device within the body. The controller causes the output device to output a signal when the pivoting member oscillates.
In an implementation in which the toy is configured to resemble an animal, the pivoting member is configured to resemble the tongue of the animal and oscillation of the pivoting member resembles a panting motion of the animal. In this implementation, the output device may output a panting sound as the pivoting member oscillates.
In another general aspect, a toy includes a body, a controller within the body, a head region coupled to the body, an actuation system coupled to the head region, and a motor within the body. The head region includes an elongated neck device and a head attached to the elongated neck device. The motor is coupled to the controller and to the actuation system to activate the actuation system in response to a signal from the controller. When activated, the actuation system rotates the elongated neck device about a neck axis, rotates the head about a head axis, and rotates the head about a tilt axis that is different from the head axis in response to a signal from the controller.
Implementations may include one or more of the following features. For example, the actuation system may include first and second elongated devices that connect at one end to a pulley coupled to the motor and at another end to a lever within the head region. The first and second elongated devices may extend from the pulley along sides of the elongated neck device, and to the lever. The elongated neck device may include a first end that couples to a post attached to the body, and a second end that couples to the lever. The first end of the elongated neck device may define the neck axis and the second end of the elongated neck device may define the head axis.
The actuation system may include a pivot device that is attached to the lever and the elongated neck device at the second end of the elongated neck device. The pivot device may include a post that defines the tilt axis.
In another general aspect, a method of moving a toy includes rotating an elongated neck device attached to a body of the toy about a neck axis, rotating a head attached to the elongated neck device about a head axis, and rotating the head about a tilt axis that is different from the head axis. All rotations are performed by a motor within the toy body and in response to a signal from a controller within the toy body.
In another general aspect, a method of moving a toy includes rotating a wheel attached to a body of the toy about a wheel axis to cause the body of the toy to move, and pivoting a first portion of the body relative to a second portion of the body about a pivoting axis that is perpendicular to the wheel axis while the body of the toy moves in a direction perpendicular to the wheel axis and the pivoting axis due to rotation of the wheel.
Implementations may include one or more of the following features. For example, the method may also include determining the position of the first body portion relative to the second body portion. Pivoting the first body portion relative to the second body portion may be based on the determined position.
The method may further include oscillating a pendulum rotatably attached to an inside surface of the body about an axis that is perpendicular to the direction in which the toy moves in response to successive movements of the toy in a forward and backward direction, and oscillating a pivoting member coupled to the pendulum and to a cavity of the body in response to oscillation of the pendulum. The method may include outputting a signal to an output device within the body when the pivoting member is oscillating.
In another general aspect, a toy includes a body including a first body portion and a second body portion, a wheel attached to the body of the toy, and an actuation system within the body. The wheel is able to rotate about a wheel axis to cause the body of the toy to move in a direction perpendicular to the wheel axis. The actuation system causes the first body portion to rotate relative to the second body portion about a pivoting axis that is perpendicular to the wheel axis and the direction of motion of the toy.
Implementations may include one or more of the following features. For example, the first body portion may house a wiper contact that includes electrically-conductive paths and the second body portion may house a set of conductive wipers that protrude from a surface of the second body portion and contact the electrically-conductive paths. The toy may include a controller coupled to the electrically-conductive paths to determine a location of the first body portion relative to the second body portion. The toy may also include a sensory region on the body of the toy and coupled to the controller. The controller is coupled to the actuation system to activate the actuation system upon receiving input from the sensory region. The sensory region may include a microphone and the controller may activate the actuation system in response to input from the sensory region that indicates a sound has been detected.
The toy may include a head region attached to the first body portion. The actuation system animates the head region after causing the first body portion to rotate relative to the second body portion.
The toy may further include a pendulum rotatably attached to an inside surface of the body and a pivoting member coupled to the pendulum and to a cavity of the body. The pendulum is free to oscillate about an axis that is perpendicular to the direction in which the toy moves. The pivoting member is free to oscillate about a pivot within the cavity. The pendulum may oscillate in response to successive movements of the toy in forward and backward directions. The pivoting member may oscillate about the pivot in response to oscillation of the pendulum. The toy may include an output device within the body that outputs a signal when the pivoting member oscillates.
In another general aspect, a toy includes a body including a first body portion and a second body portion, a controller within the body, a motor within the body and coupled to the controller, a steering system coupled to the motor and to the body, a head region coupled to the body, and an actuation system coupled to the motor and the head region. The steering system is configured to rotate the first body portion relative to the second body portion. The motor is configured to actuate the steering system to cause the first body portion to rotate relative to the second body portion and to cause the actuation system to animate the head region simultaneously with the relative motion between the first and second body portions when the controller receives a sensed condition.
Implementations may include one or more of the following features. For example, the toy may also include a wheel region attached to the body to rotate about a wheel axis, a second motor, and a second actuating system coupled to the second motor and to the wheel region to move the body in a direction that is perpendicular to the wheel axis. The toy may include a wheel region defining a wheel axis and coupled to the motor to move the toy in a forward direction and a backward direction, with both directions being perpendicular to the wheel axis.
The toy may also include a pendulum rotatably attached to an inside surface of the head region and free to oscillate about an axis that is perpendicular to the direction in which the toy moves, and a pivoting member coupled to the pendulum and to a cavity of the head region, the pivoting member being free to oscillate about a pivot within the cavity. The pendulum may oscillate in response to successive movements of the toy in the forward and backward directions. The pivoting member may oscillate about the pivot in response to oscillation of the pendulum. At least a portion of the pivoting member may be external to the head region. The toy may include an output device within the body. The controller causes the output device to output a signal when the pivoting member oscillates.
The actuation system may include first and second elongated devices that connect at one end to a pulley coupled to the motor and at another end to a lever within the head region. The first and second elongated devices may extend from the pulley along sides of the elongated neck device, and to the lever.
The elongated neck device may include a first end that couples to a post attached to the body, and a second end that couples to the lever. The first end of the elongated neck device may define the neck axis and the second end of the elongated neck device may define the head axis.
The actuation system may animate the head region by rotating the elongated neck device about a neck axis, rotating the head region about a head axis, and rotating the head region about a tilt axis that is different from the head axis in response to a signal from the controller. The actuation system may include a pivot device that is attached to the lever and to the elongated neck device at the second end of the elongated neck device. The pivot device may include a post that defines the tilt axis.
The steering system may cause the first body portion to rotate in a direction relative to the second body portion.
The actuation system may rotate the elongated neck device about the neck axis in a direction that is equivalent to the direction that the first body portion rotates relative to the second body portion.
The actuation system may rotate the elongated neck device about the head axis in a direction that is equivalent to the direction that the first body portion rotates relative to the second body portion.
The steering system may include a steering bar fixed within the first body portion, a hinge device fixed within the second body portion, and linkages that couple the steering bar to the hinge device. Actuation of the steering system may include rotating the steering bar to cause the linkages to move so as to cause the first body portion to move relative to the second body portion.
In another general aspect, a toy includes a body including a first body portion and a second body portion, a sensory region on the body, a controller that receives input from the sensory region on the body, a motor within the body and coupled to the controller, and an actuating system coupled to the motor and to the first and second body portions. The actuation system moves the first body portion relative to the second body portion when the controller receives input from the sensory region. The actuating system moves the first body portion relative to the second body portion in a direction that is based on the location of the sensory region on the body.
Implementations may include one or more of the following features. For example, the sensory region may include a touch-sensitive device. The touch-sensitive device may include a capacitively-coupled device or an inductively-coupled device. The sensory region may include a pressure-activated switch, a light-sensing device, or a sound-sensing device.
The actuating system may move the first body portion relative to the second body portion in a direction towards the sensory region. The actuating system may move the first body portion relative to the second body portion in a direction away from the sensory region. The actuating system may move the first body portion relative to the second body portion by pivoting the first body portion relative to the second body portion about a pivot axis. The pivot axis may intersect the first and second body portions. The toy may further include a wheel region attached to the body to rotate about a wheel axis, a second motor within the body, and a second actuating system coupled to the second motor and to the wheel region to move the body in a direction that is perpendicular to the wheel axis.
Aspects of the toy can include one or more of the following advantages. For example, the animation of the head region and the actuation of the steering system are controlled by a single motor. Such a design reduces manufacturing costs and imparts a realism to the toy. The toy also may perform more realistically by reacting to a sensed input from a user by moving towards or away from the sensed input. Lastly, when the toy is in the form of a dog or domestic animal, the combined motion of the tail and the back region imparts further realism to the toy.
Other features will be apparent from the description, the drawings, and the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a toy.
FIGS. 2–4 are perspective views of an internal assembly of the toy of FIG. 1 .
FIGS. 5 and 6 are block diagrams of the internal assembly of FIGS. 2–4 .
FIG. 7 is a block diagram showing the arrangement of sub-assemblies of the internal assembly of FIGS. 2–4 .
FIGS. 8–10 are exploded perspective views of the sub-assemblies of FIG. 7 .
FIGS. 11 and 13 are perspective views of the internal assembly of FIGS. 2–4 with body panels removed.
FIG. 12 is an exploded perspective view of the internal assembly of FIGS. 2–4 with the body panels removed.
FIG. 14 is a top view of the internal assembly of FIGS. 2–4 with the body panels removed.
FIG. 15 is a front view of the internal assembly of FIGS. 2–4 with the body panels removed.
FIG. 16 is a side view of the internal assembly of FIGS. 2–4 with the body panels removed.
FIG. 17 is a perspective view of a portion of a head region of the internal assembly of FIGS. 2–4 .
FIG. 18 is a perspective view of a portion of an interior of the head region of the internal assembly of FIGS. 2–4 .
FIG. 19 is a perspective view of an interior of a first body portion of the internal assembly of FIGS. 2–4 .
FIG. 20 is an exploded perspective view of an interior of the first body portion of the internal assembly of FIGS. 2–4 .
FIG. 21 is a side view of a second base of a second body portion of the internal assembly of FIGS. 2–4 .
FIG. 22 is a perspective view of the interior of the first body portion of the internal assembly of FIGS. 2–4 .
FIGS. 23 , 27 , and 29 are side views of a back region and a third actuation system of the internal assembly of FIGS. 2–4 .
FIGS. 24 , 28 , and 30 are rear views of the back region and the third actuation system of the internal assembly of FIGS. 2–4 .
FIG. 25 is a perspective view of an interior of the back region of the internal assembly of FIGS. 2–4 .
FIG. 26 is a flow chart of a procedure performed by the toy of FIG. 1 .
FIGS. 31 and 32 are perspective views of a portion of the head region of the internal assembly of FIGS. 2–4 .
FIGS. 33–36 are block diagrams showing relative motion between the first and second body portions of the internal assembly of FIGS. 2–4 .
FIG. 37 is a side view of the back region and another implementation of the third actuation system.
FIG. 38 is a rear view of the back region and the other implementation of the third actuation system of FIG. 37 .
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Referring to FIGS. 1–4 , a toy 100 is designed to resemble a dog and to provide realistic movement in response to a sensed condition. To this end, the toy 100 has an internal assembly 105 of interconnected parts surrounded by a flexible skin 110 . The movements of the internal assembly 105 in response to sensed conditions, in combination with the manner in which the flexible skin 10 is attached to the internal assemble 105 , permits the toy 100 to mimic the appearance and mannerisms of a dog in a strikingly realistic manner.
The internal assembly 105 includes a set of moveable regions coupled to a body 115 . The moveable regions include one or more wheel regions 120 , a back region 125 , a head region 130 , and side regions 135 . The interconnected parts of the internal assembly 105 may be made of any suitable combination of materials, such as, for example, plastic and metal.
The internal assembly 105 also includes a set of input regions coupled to the body 115 . The input regions include a sensory region 140 within the head region 130 , a sensory region 145 within the back region 125 , and sensory regions 147 on a side of the body 115 . The sensory regions 140 , 145 , and 147 each include pressure sensitive switches that actuate an underlying button switch within the body 115 when a user touches the toy 100 at a location 150 , 155 , or 157 ( FIG. 1 ) near the respective sensory region 140 , 145 , or 147 .
The flexible skin 110 is shaped to fit over and mate with the internal assembly 105 . Features, such as eyes 160 and a nose 165 snap into mating cavities of the skin 110 and the internal assembly 105 . The flexible skin 110 may be made of a resilient material that is covered with one or more external soft layers, such as pile that resembles an animal's coat. As shown in FIG. 1 , the toy 100 is in the shape of a dog and the flexible skin 110 resembles the coat of a dog.
Referring also to FIGS. 5–16 , the body 115 of the toy 100 houses components that control operation of the toy 100 . FIGS. 5 and 6 show identical components, but to facilitate clarity, some components are shown with dashed lines in FIG. 5 while other components are shown with dashed lines in FIG. 6 . FIG. 7 is an overview block diagram showing the general arrangement of sub-assemblies 700 , 705 , and 710 of the internal assembly 105 . FIGS. 8–10 show exploded views of the sub-assemblies 700 , 705 , and 710 , respectively.
As shown in FIGS. 5 and 6 , the body 115 includes a first body portion 500 and a second body portion 505 . The first body portion 500 includes a first body panel 510 connected to a first base 515 (as shown in FIGS. 2–4 ). The first body panel 510 includes body panel pieces 900 and 905 (as shown in FIGS. 9 and 10 ) that mate to protect the components housed within the first body portion 500 .
As also shown in FIGS. 5 and 6 , two of the wheel regions 120 and the head region 130 connect to the first base 515 of the first body portion 500 . Additionally, the side regions 135 attach to the first body panel 510 of the first body portion 500 . The second body portion 505 includes a second body panel 520 connected to a second base 525 (as shown in FIGS. 2–4 and 8 ). Two of the wheel regions 120 connect to the second base 525 , and the back region 125 attaches to the second body panel 520 . The second body panel 520 houses the sensory regions 147 , which are positioned below the back region 125 .
As also shown in FIGS. 5 and 6 , the first body portion 500 houses a first motor 535 coupled to a first actuation system 540 and a second motor 545 coupled to a second actuation system 550 . The first actuation system 540 is coupled to the two wheel regions 120 that are connected to the first base 515 . The second actuation system 550 is coupled to the head region 130 and to a steering system 528 (discussed below).
As also shown in FIGS. 5 and 6 , the second body portion 505 houses internal control circuitry 555 and an energy source 560 that supplies power to the circuitry 555 . The energy source 560 may be provided by batteries 561 (shown in FIG. 8 ) that are placed within a compartment 562 (shown in FIG. 4 ) on a lower side of the second base 525 . The internal control circuitry 555 is turned off and on by a switch 565 (shown in FIG. 4 ) that is accessible from the first base 515 . The internal control circuitry 555 is connected to an audio device 570 housed within the head region 130 . The internal control circuitry 555 includes one or more of a processor or a controller, passive and active electronic components, and memory.
As also shown in FIGS. 5 and 6 , the second body portion 505 also houses a third actuation system 585 that couples the back region 125 to the two wheel regions 120 that are connected to the second base 525 .
As shown in FIG. 6 , the body 115 houses the steering system 528 , which is formed from several components attached to the first and second bases 515 and 525 . The steering system 528 includes a steering bar 530 (shown in FIG. 9 ) that is housed within the first body portion 500 and is fixed to the first base 515 . The steering system 528 also includes a hinge device 575 (shown in FIG. 9 ) housed within the second body portion 505 and fixed to the second base 525 of the second body portion 505 . The hinge device 575 couples to the steering bar 530 through linkages 580 (shown in FIG. 9 ).
As shown in FIG. 9 , the second motor 545 is mounted to a frame 910 with frame brackets 912 and 914 . The frame 910 is attached to a frame base 915 that is attached to a wheel base 920 . The wheel base 920 is attached to the first base 515 . Attachment between pieces may be accomplished using any suitable technique, such as, for example, mating between screws on one piece and tapped holes on the other piece, snap or friction fit between the pieces, or adhesive attachment between the pieces.
As shown in FIGS. 9 and 14 – 16 , the second actuation system 550 couples to a motor shaft 925 of the second motor 545 . The second actuation system 550 includes a shaft pulley 930 fixed to the motor shaft 925 , a drive belt 935 , and a drive pulley 940 (shown also in FIGS. 11–13 ). The drive belt 935 frictionally engages the shaft pulley 930 and the drive pulley 940 .
As shown in FIGS. 9 and 11 – 16 , the second actuation system 550 includes a drive shaft 945 , a worm gear 950 connected to the drive shaft 945 , a set of gears 955 , 960 , 965 , 970 , 975 , 980 , 985 , 990 , and 995 , and a spring 1000 . Gear 955 includes a first set of gear teeth that couple to the worm gear 950 and a second set of gear teeth that couple to teeth on gear 960 . Gear 960 is frictionally engaged with gear 965 . For example, the gear 960 includes serrations that mate with serrations of the gear 965 . Both of the gears 960 and 965 are supported on the frame base 915 by a shaft 1005 .
Gear 965 couples to a first set of teeth on gear 970 . Both of gears 970 and 955 are supported on the frame base 915 by a shaft 1010 . Gear 975 is coupled to a second set of teeth on gear 970 and is frictionally engaged with gear 980 . For example, gear 975 includes a hex head 1015 that mates with a hex socket (not shown) of the gear 980 . The teeth on gear 980 couple with the teeth on gear 985 . Gear 985 is supported on the frame 910 by a shaft 1025 (as shown in FIGS. 14 and 17 ).
The teeth on gear 975 couple with a first set of teeth on gear 995 . The teeth on gear 990 couple with a second set of teeth on gear 995 . Gear 995 is supported on the frame base 915 by a shaft 1020 . Gears 980 , 975 , and 990 are supported on the frame base 915 by a shaft 1030 , which is frictionally engaged with gear 990 to rotate as gear 990 is rotated.
Referring to FIGS. 9 and 11 – 17 , the second actuation system 550 further includes a neck pulley 1035 supported on the frame 910 with the shaft 1025 . The neck pulley 1035 is frictionally engaged with gear 985 and/or the shaft 1025 to rotate as gear 985 rotates.
Referring in particular to FIG. 17 , the neck pulley 1035 includes a pair of posts 1040 and 1045 that receive, respectively, elongated devices 1050 and 1055 that extend into the head region 130 . The elongated devices 1050 and 1055 are made of any flexible material, such as, for example, string or fabric, that becomes slack in the absence of any tensioning or pulling force. The elongated devices 1050 and 1055 wrap around an outer circumference 1060 of the neck pulley 1035 , intersect at a location on a side of the neck pulley 1035 opposite the posts 1040 and 1045 , and wrap around a cylindrical post 1065 of the head region 130 .
Referring also to FIG. 10 , the first body portion 500 includes a protective plate 1067 that attaches to the frame 910 and covers the cylindrical post 1065 , the neck pulley 1035 , and the elongated devices 1050 and 1055 .
As shown in FIGS. 10–17 , the head region 130 includes a neck device 1070 that is integral with the cylindrical post 1065 . The cylindrical post 1065 is configured to rotate about an axis 3100 (shown in FIGS. 31 and 32 ) that is defined by a shaft 1069 (shown in FIG. 17 ) that is fixed to a post 1071 (shown in FIG. 9 ) of the frame 910 . The neck device 1070 includes guide members 1075 and 1080 (shown in FIGS. 10 , 11 , 16 , and 17 ) that receive, respectively, the elongated devices 1050 and 1055 .
The head region 130 includes a first rounded portion 1085 that mates with a second rounded portion 1090 and receives a plate 1095 that houses the audio device 570 . The first rounded portion 1085 and the second rounded portion 1090 mate together to form a shape that resembles a head ( FIGS. 2–4 ). The first rounded portion 1085 is configured to house the sensory region 140 and to receive the eyes 160 and the nose 165 ( FIGS. 2–6 and 10 ).
Referring in particular to FIG. 17 , the guide members 1075 and 1080 guide the elongated devices 1050 and 1055 from the neck pulley 1035 along sides of the neck device 1070 , and to a tilt lever 1100 (shown also in FIG. 10 ) housed within the first rounded portion 1085 . The elongated devices 1050 and 1055 are secured to, respectively, posts 1105 and 1110 on the tilt lever 1100 . The tilt lever 1100 and the neck device 1070 are attached to a pivot device 1115 (shown also in FIGS. 10 and 12 – 16 ). In particular, the tilt lever 1100 includes a hole 1102 (shown in FIGS. 10 and 12 ) and the neck device 1070 includes a hole 1072 (shown in FIGS. 10 and 12 ). The holes 1072 and 1102 receive a shaft 1117 (shown in FIGS. 16 and 17 ). The shaft 1117 passes through holes 1119 of the pivot device 1115 (shown in FIGS. 10 and 12 ). The tilt lever 1100 and the neck device 1070 are free to rotate about an axis 3117 (shown in FIGS. 31 and 32 ) defined by the shaft 1117 of the pivot device 1115 . The axis 3117 is approximately parallel to the axis 3100 .
As shown in FIGS. 10 and 12 – 16 , the pivot device 1115 includes a post 1120 that mates with a post 1125 ( FIG. 10 ) of the plate 1095 . In this way, the pivot device 1115 and the plate 1095 are able to rotate freely about an axis 3125 (shown in FIGS. 31 and 32 ) extending along the longitudinal length of the posts 1120 and 1125 relative to each other. In general, the axis 3125 is not parallel to the axis 3117 . In one implementation, the axis 3125 is approximately perpendicular to the axis 3117 .
Referring again to FIGS. 10 and 17 , and also to FIG. 18 , the head region 130 includes a pivoting member 1700 that fits within a lower cavity formed from a raised panel 1702 of the first rounded portion 1085 . The pivoting member 1700 fits through an opening of the plate 1095 . The opening is sized to receive the pivoting member 1700 when the plate 1095 is attached to the first rounded portion 1085 .
As shown in FIG. 18 , the pivoting member 1700 has protrusions 1705 that mate with recesses 1707 within the raised panel 1702 . The pivoting member 1700 is formed from a first piece 1704 and a second piece 1706 . The first piece 1704 extends out of the first rounded portion 1085 from one side of the protrusions 1705 , and the second piece 1706 extends from another side of the protrusions 1705 . A catch device 1710 extends from the pivoting member 1700 and through a slot 1715 (shown also in FIG. 10 ) within the raised panel 1702 when the pivoting member 1700 is inserted into the cavity of the raised panel 1702 (as shown in FIG. 18 ).
As shown in FIG. 18 , the catch device 1710 defines a catch slot 1720 that receives a first end of a connector 1725 . A second end of the connector 1725 is rotatably fixed to a lower end 1730 of a pendulum 1735 . The pendulum 1735 includes a pivot bar 1740 that fits within a cylindrical depression 1745 on the inside surface 1750 of the first rounded portion 1085 . The pivot bar 1740 is free to rotate about its longitudinal axis so that the lower end 1730 of the pendulum 1735 is free to rotate.
Referring to FIGS. 3 , 4 , 10 , and 17 , to protect the pivoting member 1700 , the head region 130 includes a cover 1755 that attaches to a back side of the plate 1095 and covers the portion of the pivoting member 1700 that is received within the opening of the plate 1095 .
With reference again to FIGS. 9 , 12 , 13 , and 16 , gears 980 , 975 , and 990 are supported on the frame base 915 by the shaft 1030 , which is frictionally engaged with gear 990 to rotate as gear 990 is rotated. As shown in FIGS. 11 and 12 , the shaft 1030 is frictionally engaged with a post 1205 that is attached to or integral with the steering bar 530 . In this way, the steering bar 530 rotates as the shaft 1030 rotates. The steering bar 530 includes posts 1210 and 1215 that extend from a plane 1220 of the steering bar 530 (shown in FIGS. 9 and 12 ).
Referring to FIGS. 9 , 11 – 14 , and 16 , first ends of the linkages 580 connect to the posts 1210 and 1215 and second ends of the linkages 580 couple to posts 1225 and 1230 of the hinge device 575 . As shown in FIGS. 9 , 11 , 13 , 14 , and 16 , the hinge device 575 includes posts 1245 and 1250 that align with, respectively, threaded posts 1255 and 1260 (shown in FIG. 8 ) of the second base 525 when the hinge device 575 is placed on the second base 525 . The hinge device 575 includes a post 1235 that aligns with a threaded post 1237 (shown in FIGS. 9 and 19 ) on the first base 515 . The threaded post 1237 is received within a hole 1240 (shown in FIG. 8 ) of the second base 525 to join the first body portion 500 with the second body portion 505 . The hinge device 575 is fixed to the second base 525 with screws 1269 (shown in FIG. 14 ) having threads that mate with respective threads of the posts 1255 and 1260 . The second base 525 is fixed to the first base 515 with a screw 1270 (shown in FIG. 11 ) having threads that mate with threads of the post 1237 .
Referring also to FIGS. 19 and 20 , the first motor 535 is mounted to the first base 515 by base brackets 1800 and 1805 (shown also in FIG. 10 ). As also shown in FIG. 5 , the first motor 535 connects with the first actuation system 540 . The first actuation system 540 is mounted between the wheel base 920 and the first base 515 (shown also in FIG. 9 ).
With particular reference to FIGS. 9 , 10 , 19 , and 20 , the first actuation system 540 includes a set of gears 1810 , 1815 , 1820 , 1825 , and 1830 , and a clutch 1835 , that couple to a motor shaft 1840 ( FIG. 10 ) of the first motor 535 . The first actuation system 540 also includes an axle 1845 that couples to the two wheel regions 120 within the first body portion 500 .
As shown in FIGS. 19 and 20 , gear 1810 is mounted to the shaft 1840 to rotate as the shaft 1840 rotates. Teeth of gear 1810 engage a first set of teeth on gear 1815 . A second set of teeth on gear 1815 engage a first set of teeth on gear 1820 . A second set of teeth on gear 1820 engage a first set of teeth on gear 1825 . A second set of teeth on gear 1825 engage teeth on gear 1830 , which is fixed to the clutch 1835 . The clutch 1835 is formed with a socket 1847 that mates with the axle 1845 such that, as the clutch 1835 rotates, the axle 1845 rotates. The axle 1845 mates with sockets 1850 of the wheel regions 120 .
Referring to FIGS. 9 , 10 , 19 , and 20 , each of the side regions 135 includes a connector 137 formed on an inside surface of the side region 135 . Each connector 137 mates with a connector 902 formed on an outside surface of the body panel piece 900 or 905 . Each of the side regions 135 includes a protrusion 139 that is sized to fit within a slot 517 of the first base 515 and a slot 518 of the wheel base 920 . The slot 518 mates with the slot 517 when the wheel base 920 is attached to the first base 515 . The protrusion 139 is sized to extend through the slots 517 and 518 , and into a wheel recess 519 that receives one of the front wheel regions 120 . The protrusion 139 is formed with an edge 141 that engages a cam 122 of the front wheel region 120 when the side region 135 is attached to the body panel piece 900 or 905 .
Referring to FIG. 21 , the second base 525 of the second body portion 505 includes a set of conductive wipers 2000 that protrude from a lower surface 2005 of the second base 525 . Referring to FIG. 22 , the first body portion 500 houses a wiper contact 2010 that is mounted within grooves 2012 (shown in FIG. 20 ) of the wheel base 920 . The wiper contact 2010 is secured to the first base 515 using screws 2015 that mate with posts 2020 of the first base 515 (shown also in FIG. 20 ). As shown in FIGS. 9 , 19 , and 20 , the posts 2020 of the first base 515 protrude through aligned holes 2025 of the wheel base 920 .
With reference to FIG. 22 , the wiper contact 2010 includes electrically-conductive paths 2030 – 2055 that have different shapes and are spaced apart from each other by a distance equivalent to the distance separating each of the wipers 2000 . When the first body portion 500 is joined with the second body portion 505 , the wipers 2000 contact the paths 2030 – 2055 . The paths 2030 – 2055 are electrically connected to the circuitry 555 by conductive and insulated wires.
Referring again to FIGS. 2–4 and 8 , and also to FIGS. 23–25 , the back region 125 includes a back panel 2200 and a tail 2205 (shown in FIGS. 2–4 , 8 , and 25 ) connected to the back panel 2200 . The back panel 2200 includes cylindrical projections 2210 and 2215 that extend from, respectively, side surfaces 2220 and 2225 of the back panel 2200 . The cylindrical projection 2210 is shaped to fit within a cavity 2230 (shown in FIG. 8 ) of the second body panel 520 and a cavity (not shown) formed between a curved region (not shown) of an open side 2235 (shown in FIG. 8 ) of the second body panel 520 and a curved region 2240 of an internal piece 2245 (shown in FIG. 8 ) mounted to the second base 525 . As shown in FIGS. 23 and 24 , the back panel 2200 is configured to rotate or pivot about an axis 2250 extending from the projection 2210 to the projection 2215 .
With reference to FIG. 25 , the back panel 2200 includes a lower surface 2252 having an opening 2255 . The opening 2255 receives a crank fixture 2260 that defines an opening 2262 . As shown in FIGS. 23 and 24 , the crank fixture 2260 is shaped to couple to the third actuation system 585 and is configured to move transversely and rotationally relative to the opening 2255 .
Referring to FIGS. 23 and 24 , the third actuation system 585 includes a crank 2265 , a crank gear 2280 , a coupling gear 2285 , and wheel gear 2290 . The crank 2265 includes an opening 2270 and the crank gear 2280 includes an opening 2282 offset from the center of rotation of the crank gear 2280 . The crank 2265 and the crank gear 2280 are coupled together by an eccentric pin 2275 that is inserted through the openings 2270 and 2282 . The crank gear 2280 includes teeth that mate with teeth on the coupling gear 2285 , and the coupling gear 2285 includes teeth that mate with teeth on the wheel gear 2290 . The wheel gear 2290 is fixed to an axle 2295 of one of the wheel regions 120 (also referred to as the wheel region 2296 ) within the second body portion 505 .
Referring also to FIGS. 8 and 11 – 14 , the third actuation system 585 is retained within the second body portion 505 between the second body panel 520 and the second base 525 . In particular, the third actuation system 585 fits between base shelves 2300 and 2305 that protrude from the second base 525 and a wheel shelf 2310 ( FIG. 8 ) that fits within and secures to a cavity 2315 of the base 525 .
Referring to FIG. 26 , the toy 100 performs a procedure 2600 during operation. Initially, the internal circuitry 555 of the toy 100 receives a signal from the switch 565 to turn on the toy 100 (step 2605 ). Next, the internal circuitry 555 receives input from one or more of the input regions (step 2610 ). For example, with reference to FIG. 1 , the circuitry 555 may receive input from the sensory region 140 within the head region 130 in response to pressure applied to the location 150 of the toy 100 . As another example, the circuitry 555 may receive input from the sensory region 145 within the back region 125 in response to pressure applied to the location 155 of the toy 100 . As a further example, the circuitry 555 may receive input from one of the sensory regions 147 within the second body portion 505 in response to pressure applied to the location 157 of the toy 100 .
As shown in FIGS. 5 and 6 , upon receiving the input (step 2610 ), the circuitry 555 determines the output device and which of the first and second motors 535 and 545 to actuate (step 2615 ) to cause an appropriate response from the toy 100 . For example, the circuitry 555 may determine that the first and second motors 535 and 545 and the output device should be activated. As another example, the circuitry 555 may determine that only one of the first motor 535 , the second motor 545 , or the output device should be activated.
If the circuitry 555 determines (step 2615 ) that the first motor 535 should be actuated, then the first motor 535 is actuated (step 2620 ). If the circuitry 555 determines (step 2620 ) that the output device should be actuated, then the output device is actuated (step 2623 ). If the circuitry 555 determines (step 2620 ) that the second motor 545 should be actuated, then the second motor 545 is actuated (step 2625 ).
Actuation of the first motor 535 (step 2620 ) causes actuation of the wheel regions 120 within the first body portion 500 (step 2630 ). In particular, with reference to FIGS. 5 , 10 , 19 , and 20 , actuation of the first motor 535 rotates the motor shaft 1840 , which rotates gear 1810 . As gear 1810 rotates, gear 1815 rotates, which causes gear 1820 to rotate. Rotation of gear 1820 causes rotation of gear 1825 , which causes rotation of gear 1830 and the clutch 1835 . As mentioned, the clutch 1835 is keyed with the axle 1845 . Thus, as the clutch 1835 rotates, the axle 1845 rotates, which causes the wheel regions 120 within the first body portion 500 to rotate. Rotation of the wheel regions 120 causes the toy 100 to move forward (that is, in the direction of arrow 180 in FIG. 1 ) or backward (that is, in the direction of arrow 185 in FIG. 1 ), depending on the direction of rotation of the motor shaft 1840 .
As the wheel regions 120 within the first body portion 500 are rotated (step 2630 ) and the toy 100 moves forward and backward, the back region 125 is actuated (step 2635 ). In particular, with reference to FIGS. 8 and 23 – 25 , as the wheel region 120 within the first body portion 500 is rotated, both wheel regions 120 within the second body portion 505 are rotated because the toy 100 is moving forward or backward. As the wheel region 2296 is rotated, the wheel gear 2290 fixed to the axle 2295 rotates, causing the coupling gear 2285 to rotate. Rotation of the coupling gear 2285 causes rotation of the crank gear 2280 .
As the crank gear 2280 rotates, the pin 2275 rotates, causing the crank 2265 to move in a periodic motion. In this way, the energy of the rotation of the wheel region 2296 is imparted into translation of the crank 2265 . Referring also to FIGS. 27 and 28 , as the crank 2265 is moved upward (by the force of the pin 2275 ), the crank 2265 pushes on a side 2700 of the back panel 2200 and the back panel 2200 is rotated about the axis 2250 in the direction of arrow 2800 . Referring also to FIGS. 29 and 30 , as the crank 2265 is moved downward (by the force of the pin 2275 ), the crank 2265 pulls on the side 2700 of the back panel 2200 and the back panel 2200 is rotated about the axis 2250 in the direction of arrow 3000 . Thus, in operation, as the toy moves forward or backward, the back panel 2200 oscillates about the axis 2250 . Furthermore, the tail 2205 , which is attached to the back panel 2200 , moves in a wagging motion as the back panel 2200 oscillates.
As the wheel regions 120 within the first body portion 500 are actuated (step 2630 ) and the toy 100 moves forward and backward, the side regions 135 are actuated (step 2640 ). In particular, with reference to FIGS. 9 , 10 , 19 , and 20 , as the wheel regions 120 within the first body portion 500 are actuated (step 2630 ), the cams 122 in each of the wheel regions 120 are rotated. As one of the cams 122 rotates, the edge 141 of the protrusion 139 that is engaged with the cam 122 moves along the outer perimeter of the cam 122 . The protrusion 139 is attached to the side region 135 , which is rotatably attached to the body panel piece 900 or 905 . In this way, as the protrusion 139 moves along the outer perimeter of the cam 122 , the side region 135 rotates about the connector 137 , thus causing the side region 135 to oscillate, that is, move in a back and forth or periodic motion. Such a motion imparts a realistic appearance that the toy 100 is walking forward or backward.
Actuation of the output device (step 2623 ) causes the output device to output a response. For example, if the output device is the audio device 570 , actuation of the audio device 570 causes the audio device 570 to emit one or more sounds such as, for example, a bark, a pant, a whine, a growl, or a yawn if the toy 100 is in the form of a dog. In general, the one or more sounds emitted from the audio device 570 would correlate with the design or appearance of the toy 100 . The one or more sounds emitted from the audio device 570 may correlate with actuation of the first and/or second motors. Thus, if the first motor 535 causes the toy 100 to move forward and backward in a rapid motion, the audio device 570 may emit several panting sounds.
Referring also to FIG. 18 , as the wheel regions 120 are actuated (step 2630 ), the toy 100 moves forward 180 or backward 185 and the lower end 1730 of the pendulum 1735 swings. Thus, the lower end 1730 swings backward (that is, away from the first rounded portion 1085 ) as the toy 100 moves forward, and the lower end 1730 swings forward (that is, toward the first rounded portion 1085 ) as the toy 100 moves backward. As the lower end 1730 swings backward, the connector 1725 moves the catch device 1710 backward, which causes the first and second pieces 1704 and 1706 of the pivoting member 1700 to pivot about an axis 1880 defined along protrusions 1705 in the direction of arrow 1885 . As the lower end 1730 swings forward, the connector 1725 moves the catch device 1710 forward, causing the first and second pieces 1704 and 1706 of the pivoting member 1700 to pivot about the axis 1880 in the direction of arrow 1890 .
In the illustrated implementation, where the toy 100 is shaped to resemble a dog, the first piece 1704 resembles a tongue. Thus, as the toy 100 moves back and forth in rapid succession, the lower end 1730 swings forward and backward rapidly (that is, the lower end 1730 oscillates) and the tongue bobs up and down in a rapid succession. Simultaneous with the rapid motion of the tongue, the circuitry 555 actuates the audio device 570 to emit a panting sound. In this way, a realistic panting action is imparted to the toy 100 .
Actuation of the second motor 545 (step 2625 ) causes actuation of the head region 130 (step 2645 ). In particular, with reference to FIGS. 6 and 9 – 17 , actuation of the second motor 545 causes the motor shaft 925 to rotate, which causes the shaft pulley 930 to rotate. As the shaft pulley 930 rotates, the drive belt 935 , through frictional engagement with the shaft pulley 930 and the drive pulley 940 , causes the drive pulley 940 to rotate. The drive pulley 940 rotates the worm gear 950 , which is coupled to the first set of gear teeth on gear 955 . In this way, gear 955 is rotated. As gear 955 rotates, the second set of gear teeth engage the teeth on gear 960 and cause gears 960 and 965 to rotate. As gear 965 rotates, the teeth on gear 965 engage the first set of teeth on gear 970 to cause gear 970 to rotate. The second set of teeth on gear 970 rotate and cause gear 975 to rotate. Because gear 980 is frictionally engaged with gear 975 , gear 980 rotates with gear 975 and causes gear 985 to rotate.
As shown in FIGS. 11 and 16 , gear 985 is frictionally engaged with the neck pulley 1035 . Thus, as gear 985 rotates, the neck pulley 1035 rotates and actuates the elongated devices 1050 and 1055 (seen in FIG. 17 ) to animate the head region 130 , as detailed below.
Referring also to FIG. 31 , the elongated device 1055 is tensioned or pulled and the elongated device 1050 is slackened due to the rotation of the pulley 1035 in a first direction. The combined motion of the elongated devices 1050 and 1055 causes the neck device 1070 to rotate about the axis 3100 extending along the shaft 1069 and in the direction of arrow 3105 . Next, after the neck device 1070 rotates a predetermined distance, the elongated device 1055 pulls a first side 3110 of the tilt lever 1100 and the elongated device 1050 provides slack to a second side 3115 of the tilt lever 1100 . This combined motion rotates the tilt lever 1100 about the axis 3117 extending along the shaft 1117 in the direction of arrow 3120 . The rotation of the tilt lever 1100 causes the first rounded portion 1085 (and anything fixed to the first rounded portion 1085 ) to rotate about the axis 3125 extending along the longitudinal length of the posts 1120 and 1125 in the direction of arrow 3130 .
Referring also to FIG. 32 , the elongated device 1055 is slackened and the elongated device 1050 is tensioned or pulled due to rotation of the pulley 1035 in a second direction that is opposite the first direction. The combined motion of the elongated devices 1055 and 1050 causes the neck device 1070 to rotate about the axis 3100 in the direction of arrow 3135 . After the neck device 1070 rotates a predetermined distance, the elongated device 1055 provides slack to the first side 3110 of the tilt lever 1100 and the elongated device 1050 pulls the second side 3115 of the tilt lever 1100 . This combined motion rotates the tilt lever 1100 about the axis 3117 in the direction of arrow 3140 . The rotation of the tilt lever 1100 in the direction of arrow 3140 causes the first rounded portion 1085 (and anything fixed to the first rounded portion 1085 ) to rotate about the axis 3125 in the direction of arrow 3145 .
The combined motion of the neck device 1070 and the first rounded portion 1085 imparts a realistic motion to the toy 100 and is achieved with a single actuation system, that is, the second actuation system 550 .
Moreover, actuation of the second motor 545 (step 2625 ) causes actuation of the steering system 538 (step 2650 ). In particular, with reference to FIGS. 6 , 8 , 9 , 11 – 16 , and 20 – 22 , and as discussed above, gear 975 is rotated as the second motor 545 is actuated. Rotation of gear 975 causes rotation of gear 995 , which causes rotation of gear 990 . Gear 990 is fixed to the shaft 1030 and the shaft 1030 rotates as gear 990 rotates, which causes the post 1205 and the steering bar 530 to rotate. As the steering bar 530 rotates, the linkages 580 connected to the posts 1210 and 1215 of the steering bar 530 are pulled or pushed.
Referring also to FIG. 33 , as the steering bar 530 rotates in a first direction (indicated by arrow 3300 ), a first linkage 3305 is pulled while a second linkage 3310 is pushed. The first and second linkages 3305 and 3310 are connected, respectively, to posts 1230 and 1225 of the hinge device 575 . Thus, the force applied to the linkages 3305 and 3310 causes the first body portion 500 to rotate relative to the second body portion 505 about an axis 2100 defined by the posts 1235 and 1237 in the direction of arrow 3315 .
Referring also to FIG. 34 , as the steering bar 530 rotates in a second direction (indicated by arrow 3400 ) that is opposite the first direction 3300 , the first linkage 3305 is pushed while the second linkage 3310 is pulled. The force applied to the linkages 3305 and 3310 causes the first body portion 500 to rotate relative to the second body portion 505 about the axis 2100 in the direction of arrow 3415 .
Actuation of the steering system 538 (step 2650 ) may be in response to input received from one of the sensory regions 147 (step 2615 ). Thus, if the circuitry 555 receives a signal from a sensory region 147 on a first side 590 ( FIGS. 5 , 6 , 33 , and 34 ) of the second body portion 505 , the first body portion 500 rotates in the direction of arrow 3315 ( FIG. 33 ), that is, toward the location of the input. Alternatively, if the circuitry 555 receives a signal from a sensory region 147 on a second side 595 ( FIGS. 5 , 6 , 33 , and 34 ) of the second body portion 505 , the first body portion 500 rotates in the direction of arrow 3415 ( FIG. 34 ), that is, toward the location of the input.
Actuation of the steering system 538 (step 2650 ) may, for particular input (step 2615 ) occur simultaneously with actuation or animation of the head region 130 (step 2645 ). Thus, for example, if the circuitry 555 receives input from the sensory region 147 on the first side 590 ( FIGS. 5 , 6 , 33 , and 34 ) of the second body portion 505 , the circuitry 555 simultaneously causes the first body portion 500 to rotate in the direction of arrow 3315 ( FIG. 33 ) and causes the head region 130 to animate as shown in FIG. 32 . As another example, if the circuitry 555 receives input from the sensory region 147 on the second side 595 ( FIGS. 5 , 6 , 33 , and 34 ) of the second body portion 505 , the circuitry 555 simultaneously causes the first body portion 500 to rotate in the direction of arrow 3415 ( FIG. 34 ) and causes the head region 130 to animate as shown in FIG. 31 .
Referring also to FIGS. 35 and 36 , as the first body portion 500 rotates relative to the second body portion 505 , the wiper contact 2010 fixed to the first body portion 500 passes over the set of conductive wipers 2000 on the second body portion 505 . The electrical signal from the conductive paths 2030 – 2055 of the wiper contact 2010 changes as the wiper contact 2010 moves across the wipers 2000 . The circuitry 555 receives the electrical signal and determines the position of the first body portion 500 relative to the second body portion 505 . The circuitry 555 decides whether additional actuation of the first or second motors or the output device is required (step 2655 ) based on the position of the first body portion 500 relative to the second body portion 505 . If no additional actuation is required, the circuitry 555 awaits a signal from the switch 565 to turn off the toy 100 (step 2660 ) or the circuitry 555 enters sleep mode if no input has been received within a predetermined period of time.
Other implementations are within the scope of the following claims. For example, the toy 100 may be designed to resemble other animals, such as a cat. The toy 100 also may be designed without a flexible skin. The flexible skin 110 may include rigid pieces, such as, for example, posts, that interfit with cavities of the internal assembly 105 to facilitate securing of the skin 110 to the assembly 105 . Additionally, ears, eyes, and a nose may be formed into the skin 110 instead of the internal assembly 105 to facilitate securing of the skin 110 to the assembly 105 . The toy 100 may include a resilient material between the internal assembly 105 and the flexible skin 110 to further enhance realism of the toy 100 .
The sounds emitted from the audio device 570 may correlate with the form of the toy 100 . Thus, if the toy 100 is in the form of a cat, the audio device 570 may emit a purring sound or a meowing sound.
The toy may include additional sensory regions positioned within any one or more of the first body portion 500 , the second body portion 505 , one or more wheel regions 120 , the head region 130 , or one or more side regions 135 .
One or more of the sensory regions may include a magnetic switch, such as, for example, a reed switch or a Hall effect sensor, that is actuated by an external magnet when the magnet is placed at the location near the sensory region. One or more of the sensory regions may include touch-sensitive devices. For example, the sensory region may be made of a conductive material and be a capacitively-coupled device such that when a user touches the toy 100 at the location of the sensory region, a measured capacitance associated with the capacitively-coupled device changes and the change is sensed. As another example, the sensory region may be made of a conductive material and be an inductively-coupled device. In this case, when a user touches the toy 100 at the location of the sensory region, a measured inductance associated with the inductively-coupled device changes and the change is sensed.
One or more of the sensory regions may include a pressure sensing device such as, for example, a pressure-activated switch in the form of a membrane switch. One or more of the sensory regions may include a light-sensing device, such as, for example, an IR-sensing device or a photocell. Additionally or alternatively, one or more of the sensory regions may include a sound-sensing device such as, for example, a microphone.
The internal control circuitry, the battery, and the output device may be housed in other parts of the internal assembly. For example, the circuitry, the battery, and the audio device may all be housed in the first body portion or all be housed in the second body portion.
The toy 100 may be of any design, such as, for example, a doll, a plush toy such as a stuffed animal, a dog or other animal, or a robot. The output device may be an optical device or an electromechanical device.
In another implementation, the elongated devices 1050 and 1055 may be made of a flexible, yet firm material, such as a wire strip that may be pulled or pushed.
Referring also to FIGS. 37 and 38 , in another implementation, the third actuation system 585 is formed of the crank 2265 , a crank pulley 3780 , a coupling belt 3785 , and a wheel pulley 3790 . The crank pulley 3780 includes an opening 3782 offset from the center of rotation of the crank pulley 3780 . The crank 2265 and the crank pulley 3780 are coupled together by the eccentric pin 2275 inserted through the openings 2270 and 3782 . The crank belt 3785 is frictionally engaged with the crank pulley 3780 and the wheel pulley 3790 . The wheel pulley 3790 is fixed to the axle 2295 of the wheel region 2296 within the second body portion 505 .
As the wheel region 2296 is rotated, the wheel pulley 3790 fixed to the axle 2295 rotates, causing the coupling belt 3785 to move and rotate the crank pulley 3780 . | A toy is configured to closely resemble a live animal and to respond to stimuli in a realistic manner that is consistent with the way in which a real animal would respond. For example, when the toy is designed to resemble a dog or a cat, the toy may be configured to move in a manner consistent with the movements of a dog or a cat. This realistic movement, in conjunction with a realistic fur coat coupled to and covering inner mechanical components, may be used to provide a strikingly realistic toy. | 0 |
CROSS REFERENCE TO PRIOR APPLICATION
[0001] This application claims benefit under Title 35 U.S.C. 119(e) of U.S. Provisional Application No. 60/457,130, filed Mar. 24, 2003, which is hereby incorporated by reference in its entirety. The related application filed herewith, Non-Nucleoside Reverse Transcriptase Inhibitors (J. P. Dunn et al.), is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to the field of antiviral therapy and, in particular, to non-nucleoside reverse transcriptase inhibitors for treating Human Immunodeficiency Virus (HIV) mediated diseases. The invention provides novel heterocyclic compounds, pharmaceutical compositions comprising these compounds, methods for treatment or prophylaxis of HIV mediated diseases employing said compounds in monotherapy or in combination therapy, and a process for preparing novel heterocyclic compounds.
BACKGROUND OF THE INVENTION
[0003] The human immunodeficiency virus HIV is the causative agent of acquired immunodeficiency syndrome (AIDS), a disease characterized by the destruction of the immune system, particularly of the CD4 + T-cell, with attendant susceptibility to opportunistic infections. HIV infection is also associated with a precursor AIDS—related complex (ARC), a syndrome characterized by symptoms such as persistent generalized lymphadenopathy, fever and weight loss.
[0004] In common with other retroviruses, the HIV genome encodes protein precursors known as gag and gag-pol which are processed by the viral protease to afford the protease, reverse transcriptase (RT), endonuclease/integrase and mature structural proteins of the virus core. Interruption of this processing prevents the production of normally infectious virus. Considerable efforts have been directed towards the control of HIV by inhibition of virally encoded enzymes.
[0005] Currently available chemotherapy targets two crucial viral enzymes: HIV protease and HIV reverse transcriptase. (J. S. G. Montaner et al. Antiretroviral therapy: ‘the state of the art”, Biomed & Pharmacother. 1999 53:63-72; R. W. Shafer and D. A. Vuitton, Highly active retroviral therapy ( HAART ) for the treatment of infection with human immunodeficiency virus type 1, Biomed. & Pharmacother. 1999 53:73-86; E. De Clercq, New Developments in Anti - HIV Cehmotherap. Curr. Med. Chem. 2001 8:1543-1572). Two general classes of RTI inhibitors have been identified: nucleoside reverse transcriptase inhibitors (NRTI) and non-nucleoside reverse transcriptase inhibitors (NNRTI).
[0006] NRTIs typically are 2′,3′-dideoxynucleoside (ddN) analogs which must be phosphorylated prior to interacting with viral RT. The corresponding triphosphates function as competitive inhibitors or alternative substrates for viral RT. After incorporation into nucleic acids the nucleoside analogs terminate the chain elongation process. HIV reverse transcriptase has DNA editing capabilities which enable resistant strains to overcome the blockade by cleaving the nucleoside analog and continuing the elongation. Currently clinically used NRTIs include zidovudine (AZT), didanosine (ddI), zalcitabine (ddC), stavudine (d4T), lamivudine (3TC) and tenofovir (PMPA).
[0007] NNRTIs were first discovered in 1989. NNRTI are allosteric inhibitors which bind reversibly at a nonsubstrate binding site on the HIV reverse transcriptase thereby altering the shape of the active site or blocking polymerase activity. (R. W. Buckheit, Jr., Non - nucleoside reverse transcriptase inhibitors: perspectives for novel therapeutic compounds and strategies for treatment of HIV infection, Expert Opin. Investig. Drugs 2001 10(8)1423-1442; E. De Clercq The role of non 0- nuceloside reverse transcriptase inhibitors ( NNRTIs ) in the therapy of HIV -1 infection, Antiviral Res. 1998 38:153-179; G. Moyle, The Emerging Roles of Non - Nucleoside Reverse Transcriptase Inhibitors in Antiviral Therapy, Drugs 2001 61(1):19-26) Although over thirty structural classes of NNRTIs have been identified in the laboratory, only three compounds have been approved for HIV therapy: efavirenz, nevirapine and delavirdine. Although initially viewed as a promising class of compounds, in vitro and in vivo studies quickly revealed the NNRTIs presented a low barrier to the emergence of drug resistant HIV strains and class-specific toxicity. Drug resistance frequently develops with only a single point mutation in the RT.
[0008] While combination therapy with NRTIs, PIs and NNRTIs has, in many cases, dramatically lowered viral loads and slowed disease progression, significant therapeutic problems remain. The cocktails are not effective in all patients, potentially severe adverse reactions often occur and the rapidly-replicating HIV virus has proven adroit at creating mutant drug-resistant variants of wild type protease and reverse transcriptase.
[0009] There remains a need for safer drugs with activity against wild type and commonly occurring resistant strains of HIV. Benzyl-pyridazinone compounds have been extensively investigated as thyroxin analogs which can decrease plasma cholesterol without stimulating cardiac activity (A. H. Underwood et al. A thyromimetic that decreases plasma cholesterol without increasing cardiovascular activity Nature 1986 324(6096):425-429; P. D. Leeson et al. Selective thyromimetics. Cardiac - sparing thyroid hormone analogs containing 3+- arylmethyl substituents J. Med Chem 1989 32(2):320-326; P. D. Leeson et al. EP 0188351). WO9624343 (D. J. Dunnington) discloses oxo-pyridazinylmethyl substituted tyrosines are selective antagonists for the haematopoietic phosphatase SH2 domain which may render them useful to increase erythropoiesis and haematopoiesis. WO 9702023 (D. J. Dunnington) and WO9702024 (D. J. Dunnington) further disclose these compounds are specific inhibitors of the human Stat 6 SH2 domain and may be useful for treating asthma, allergic rhinitis and anemia. WO2001085670 (H. Shiohara et al.) discloses related malonamide derivatives useful for treating circulatory diseases. EP 810218 (D. A. Allen et al.) discloses benzoyl substituted benzyl-pyridazinone compounds which are cyclooxygenase inhibitors and potential antiinflammatory or analgesic compounds. None of the references teaches therapy for HIV infections or inhibition of HIV reverse transcriptase.
SUMMARY OF THE INVENTION
[0010] The present invention relates to a compounds according to formula I, methods for treating diseases mediated by human immunodeficieny virus by administration of a compound according to formula I, pharmaceutical compositions for treating diseases mediated by human immunodeficieny virus containing a compound according to formula I, and processes to prepare a compound according to formula I
[0011] wherein;
[0012] X 1 is selected from the group consisting of R 5 O, R 5 S(O) n , R 5 CH 2 , R 5 CH 2 O, R 5 CH 2 S(O) n , R 5 OCH 2 , R 5 S(O) n CH 2 and NR 5 R 6 ;
[0013] X 2 is selected from the group consisting of o-phenylene, 1,2-cyclohexenylene, O, S, and NR 7 ;
[0014] R 1 and R 2 are
[0015] (i) each independently selected from the group consisting of hydrogen, C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylalkylsulfonyl, C 1-4 haloalkoxy, C 1-4 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, nitro and cyano; or,
[0016] (ii) taken together are —CH═CH—CH═CH—; or,
[0017] (iii) taken together along with the carbons to which they are attached to form a five- or six-membered heteroaromatic or heterocyclic ring with a one or two heteroatoms independently selected from the group consisting of O, S and NH;
[0018] R 3 and R 4 are each independently selected from the group consisting of hydrogen, C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkoxy, C 1-6 alkylthio, C 1-6 haloalkoxy, C 1-6 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, nitro and cyano;
[0019] R 5 is selected from the group consisting of phenyl, naphthyl, pyrdinyl, pyridinyl N-oxide, indolyl, indolyl N-oxide, quinolinyl, quinolinyl N-oxide, pyrimidinyl, pyrazinyl and pyrrolyl; wherein, said phenyl, said naphthyl, said pyrdinyl, said pyridinyl N-oxide, said indolyl, said indolyl N-oxide, said quinolinyl, said quinolinyl N-oxide, said pyrimidinyl, said pyrazinyl and said pyrrolyl groups are optionally substituted with one to three substituents independently selected from the group consisting of hydrogen, C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkoxy, C 1-6 alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylalkylsulfonyl, C 1-6 haloalkoxy, C 1-6 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, acyl, alkoxycarbonyl, carbamoyl, N-alkylcarbamoyl, N,N-dialkylcarbamoyl, nitro and cyano;
[0020] R 6 is hydrogen, C 1-6 alkyl, or acyl;
[0021] R 7 is hydrogen or C 1-4 alkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, thiol, alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, halogen, amino, alkylamino, dialkylamino, aminoalkyl, alkylaminoalkyl, and dialkylaminoalkyl;
[0022] n is an integer from 0 to 2; and,
[0023] hydrates, solvates, clathrates and acid addition salts thereof, with the proviso that if X 2 is ortho-phenylene, R 5 can not unsubstituted phenyl.
[0024] The invention also relates to a process for preparing a compound according to formula I wherein X 1 is OR 5 or SR 5 , R 5 is an optionally substituted aryl and R 1 —R 4 , R 1 and X 2 are as defined hereinabove.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In one embodiment of the invention there is provided a compound according to formula I,
[0026] wherein X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof.
[0027] In another embodiment of the invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is optionally substituted phenyl; and, R 1 , R 2 , R 7 , X 2 and n are as defined hereinabove.
[0028] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is optionally substituted phenyl; and, R 2 , R 7 , X 2 and n are as defined hereinabove.
[0029] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is monosubstituted phenyl; and, R 2 , R 7 , X 2 and n are as defined hereinabove.
[0030] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is 2,5-disubstituted phenyl; and, R 2 , R 7 , X 2 and n are as defined hereinabove.
[0031] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is 3,5-disubstituted phenyl; and, R 2 , R 7 , X 2 and n are as defined hereinabove.
[0032] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl, R 5 is 2,4-disubstituted phenyl; and R 2 , R 7 , X 2 and n are as defined hereinabove.
[0033] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 3 is hydrogen or fluoro; R 4 is selected from the group consisting of hydrogen, chloro, fluoro and methyl; R 5 is 2,6-disubstituted phenyl; and, R 2 , R 7 , X 2 and n are as defined hereinabove.
[0034] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 and R 2 are independently hydrogen, C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkoxy, C 1-6 alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 haloalkoxy, C 1-6 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, nitro and cyano; R 3 is hydrogen or fluoro; and, R 4 , R 5 , R 7 , X 2 and n are as defined hereinabove.
[0035] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is optionally substituted phenyl; n is 0 to 2; and R 7 and X 2 are as defined hereinabove.
[0036] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is monosubstituted phenyl; n is 0 to 2; and R 7 and X 2 are as defined hereinabove.
[0037] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is monosubstituted phenyl and the substituent is selected from the group consisting of halogen, cyano, C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 1-6 alkylthio and C 1-6 haloalkoxy; and, R 4 , R 7 , X 2 and n are as defined hereinabove.
[0038] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,5-disubstituted phenyl; n is 0 to 2; and R 1 and X 2 are as defined hereinabove.
[0039] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,5-disubstituted phenyl and the substituents are independently selected from the group consisting of halogen, cyano, C 1-6 alkyl, C 1-6 haloalkyl, C 1-64 alkoxy, C 1-6 alkylthio and C 1-6 haloalkoxy; and, R 4 , R 7 , X 2 and n are as define hereinabove.
[0040] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 3,5-disubstituted phenyl; n is 0 to 2; and R 7 and X 2 are as defined hereinabove.
[0041] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 3,5-disubstituted phenyl and the substituents are independently selected from the group consisting of halogen, cyano, C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 1-6 alkylthio and C 1-6 haloalkoxy; and, R 4 , R 7 , X 2 and n are as defined hereinabove.
[0042] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,4-disubstituted phenyl; n is 0 to 2; and R 7 and X 2 are as defined hereinabove.
[0043] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,4-disubstituted phenyl and the substituents are independently selected from the group consisting of halogen, cyano, C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 1-6 alkylthio and C 1-6 haloalkoxy; and, R 4 , R 7 , X 2 and n are as defined hereinabove.
[0044] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,6-disubstituted phenyl; n is 0 to 2; and R 7 and X 2 are as defined hereinabove.
[0045] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is 2,6-disubstituted phenyl and the substituents are independently selected from the group consisting of halogen, cyano, C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 1-6 alkylthio and C 1-6 haloalkoxy; and, R 4 , R 7 , X 2 and n are as defined hereinabove.
[0046] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 3 and R 4 are independently hydrogen, chloro, fluoro or methyl; R 5 is optionally substituted pyridinyl, pyridinyl N-oxide, indolyl, indolyl N-oxide, quinolinyl, quinolinyl N-oxide, pyrimidinyl, pyrazinyl and pyrrolyl; and, X 2 , R 1 , R 2 , R 3 , R 7 and n are as defined hereinabove.
[0047] In another embodiment of the present invention there is provided a compound according to formula I wherein R 1 and R 2 along with the carbon atoms to which they are attached form a phenyl, dihydropyran, dihydrofuran or furan ring; and, X 1 , X 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove.
[0048] In another embodiment of the present invention there is provided a compound according to formula I wherein X 1 is OR 5 or SR 5 ; R 1 and R 2 along with the carbon atoms to which they are attached form a phenyl, dihydropyran, dihydrofuran or furan ring; R 3 is hydrogen, R 4 is hydrogen or fluoro; R 5 is optionally substituted phenyl; and, X 2 , R 7 and n are as defined hereinabove.
[0049] In another embodiment of the present invention there is provided a method for treating an HIV infection, or preventing an HIV infection, or treating AIDS or ARC, comprising administering to a host in need thereof a therapeutically effective amount of a compound of formula I
[0050] wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof.
[0051] In another embodiment of the present invention there is provided a method for treating an HIV infection, or preventing an HIV infection, or treating AIDS or ARC, comprising administering to a host in need thereof a therapeutically effective amount of a compound of formula I wherein: X 1 is OR 5 ; R 1 is methyl, ethyl, trifluoromethyl or halogen; R 2 and R 4 are independently hydrogen, fluoro, chloro, methyl or ethyl; R 3 is hydrogen or fluoro; R 5 is optionally substituted phenyl; and, X 2 , R 7 and n are as defined hereinabove.
[0052] In another embodiment of the present invention there is provided a method for treating an HIV infection, or preventing an HIV infection, or treating AIDS or ARC, comprising co-administering to a host in need thereof a therapeutically effective amount of a compound of formula I wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof, and at least one compound selected from the group consisting of HIV protease inhibitors, nucleoside reverse transcriptase inhibitors, non-nucleoside reverse transcriptase inhibitors, CCR5 inhibitors and viral fusion inhibitors.
[0053] In another embodiment of the present invention there is provided a method for treating an HIV infection, or preventing an HIV infection, or treating AIDS or ARC, comprising co-administering to a host in need thereof a therapeutically effective amount of a compound of formula I wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof, and at least one compound selected from the group consisting of zidovudine, lamivudine, didanosine, zalcitabine, stavudine, rescriptor, sustiva, viramune efavirenz, nevirapine and delavirdine and/or the group consisting of saquinavir, ritonavir, nelfinavir, indinavir, amprenavir and lopinavir.
[0054] In another embodiment of the present invention there is provided a method for inhibiting a retrovirus reverse transcriptase comprising administering a compound of formula I wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof.
[0055] In another embodiment of the present invention there is provided a method for inhibiting a retrovirus reverse transcriptase having at least one mutation with respect to wild type virus comprising administering to a host in need thereof, a therapeutically effective amount of a compound of formula I wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove; and, hydrates, solvates, clathrates; and, acid addition salts thereof.
[0056] In another embodiment of the present invention there is provided a method treating an HIV infection, or preventing an HIV infection, or treating AIDS or ARC, wherein the host is infected with a strain of HIV which exhibits reduced susceptibility to efavirenz, nevirapine or delavirdine comprising administering to a host in need thereof a therapeutically effective amount of a compound of formula I wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove; and, hydrates, solvates, clathrates and acid addition salts thereof.
[0057] In another embodiment of the present invention there is provided a pharmaceutical composition comprising a therapeutically effective quantity of a compound of formula I wherein, wherein, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and n are as defined hereinabove, and hydrates, solvates, clathrates and acid addition salts thereof with the proviso that if X 2 is ortho-phenylene, R 5 can not unsubstituted phenyl, in admixture with at least one pharmaceutically acceptable carrier or diluent sufficient upon administration in a single or multiple dose regimen for treating diseases mediated by human immunodeficieny virus inhibit HIV.
[0058] In another embodiment of the present invention there is provided a process for preparing a heterocycle of formula I, wherein X 1 is OR 5 or OCH 2 R 5 and R 5 is an optionally substituted aryl, or heteroaryl moiety; X 2 is O, S, or NR 7 and R 1 —R 4 and R 7 are as defined hereinabove,
[0059] which process comprises the steps of: (i)(a) coupling an aryl compound of formula IIa wherein X 4 is hydrogen, alkoxycarbonyl or CN, with (A) an arylboronic acid or an aryl halide, or (B) an aralkyl halide to produce an ether of formula IIb; and, if X 4 is hydrogen;
[0060] (b) (A) brominating the methyl group with N-bromosuccinimide and (B) displacing the bromide (X 4 ═Br) with sodium cyanide to produce the corresponding nitrile (X 4 ═CN), and, optionally, (C) hydrolyzing the nitrile to an alkoxycarbonyl (X 4 ═CO 2 alkyl) or an O-alkyl imidate hydrochloride (X 4 ═C(═NH 2 + )OR Cl −
[0061] (ii)(A) treating a compound of formula IIb (X 4 =alkoxycarbonyl) sequentially with hydrazine hydrate to form the acyl hydrazide (IIb; X 4 ═CONHNH 2 ) and, (a) phosgene, or a phosgene equivalent, to produce an oxadiazolone of formula I wherein X 2 is O; or, (b) sequentially with an alkyl isocyanate (R 7 NCO) to produce a diacylhydrazone (IIb; X 4 ═C(═O)NHNHC(═O)NHR 7 ) and with base to produce the triazolone I (X 2 ═NR 7 ); or, (B) treating a nitrile of formula IIb (X 4 ═CN) sequentially (a) with acid and alcohol to produce the O-alkyl imidate hydrochloride (X 4 ═C(═NH 2 + )OR Cl − ), (b) with O-methylthiocarbazine (NH 2 NHC(═S)OMe)to produce IIb wherein
[0062] X 4 is a methoxythiadiazoline according to formula (III), and (c) with aqueous acid to hydrolyze said methoxythiadiazoline and produce a compound of formula I wherein X 2 is S. In another embodiment of the present invention there is provided a process as described above for preparing a compound of formula I wherein X 1 is OR 5 , R 5 is optionally substituted aryl or heteroaryl and the ether is prepared by coupling an arylboronic acid and a phenol IIa in the presence of a Cu(II) salt.
[0063] In another embodiment of the present invention there is provided a process as described above for preparing a compound of formula I wherein X 1 is OR 5 , R 5 is optionally substituted aryl or heteroaryl and the ether is prepared by coupling an aryl halide and a phenol IIa n the presence of a Cu(I) salt.
[0064] In another embodiment of the present invention there is provided a process as described above for preparing a compound of formula I wherein X 1 is OCH 2 R 5 or OR 5 , R 5 is an optionally substituted aryl or heteroaryl moiety and the ether is prepared by coupling an aryl halide or heteroaryl halide further substituted by electron withdrawing groups, or an optionally substituted aralkyl halide and a phenol Ia, in the presence of a base.
[0065] In another embodiment of the present invention there is provided a process as described above for preparing a compound of formula I wherein X 1 is —OCH 2 R 5 , R 5 is optionally substituted aryl and the ether is formed by coupling an alcohol R 5 CH 2 OH and IIa said coupling catalyzed by an a dialkylazodicarboxylate and triaryl or trialkylphosphine.
[0066] In another embodiment of the present invention there is provided a process as described above for preparing an oxadiazolone compound of formula I by treating a compound of formula IIb wherein X 1 is OR 5 or —OCH 2 R 5 , R 5 is optionally substituted aryl or heteroaryl, X 4 is C(═O)NHNH 2 with phosgene.
[0067] In another embodiment of the present invention there is provided a process as described above for preparing an oxadiazolone compound of formula I by treating a compound of formula IIb wherein X 1 is OR 5 or —OCH 2 R 5 , R 5 is optionally substituted aryl or heteroaryl, X 4 is C(═O)NHNH 2 with carbonyl diimidazole.
[0068] In another embodiment of the present invention there is provided a process as described above for preparing a triazolone compound of formula I by treating a compound of formula IIb wherein X 1 is OR 5 or —OCH 2 R 5 , R 5 is optionally substituted aryl, X 4 is C(═O)NHNH 2 sequentially with methyl isocyanate or ethyl isocyanate and methanolic sodium hydroxide.
[0069] In another embodiment of the present invention there is provided a process as described above for preparing a thiadiazolone compound of formula I by treating a compound of formula IIb wherein X 1 is OR 5 or —OCH 2 R 5 , R 5 is optionally substituted aryl, X 4 is C(═NH 2 + ) Cl − sequentially with hydrazinecarbothioic acid O-methyl ester and aqueous acid.
Definitions
[0070] The phrase “a” or “an” entity as used herein refers to one or more of that entity; for example, a compound refers to one or more compounds or at least one compound. As such, the terms “a” (or “an”), “one or more”, and “at least one” can be used interchangeably herein.
[0071] The phrase “as defined hereinabove” refers to the first definition provided in the Summary of the Invention.
[0072] The term “C 1-6 alkyl” as used herein denotes an unbranched or branched chain, saturated, monovalent hydrocarbon residue containing 1 to 6 carbon atoms. Examples of alkyl groups include, but are not limited to, lower alkyl groups include methyl, ethyl, propyl, i-propyl, n-butyl, i-butyl, t-butyl or pentyl, isopentyl, neopentyl, hexyl.
[0073] The term “haloalkyl” as used herein denotes an unbranched or branched chain alkyl group as defined above wherein 1, 2, 3 or more hydrogen atoms are substituted by a halogen. Examples are 1-fluoromethyl, 1-chloromethyl, 1-bromomethyl, 1-iodomethyl, trifluoromethyl, trichloromethyl, tribromomethyl, triiodomethyl, 1-fluoroethyl, 1-chloroethyl, 1-bromoethyl, 1-iodoethyl, 2-fluoroethyl, 2-chloroethyl, 2-bromoethyl, 2-iodoethyl, 2,2-dichloroethyl, 3-bromopropyl or 2,2,2-trifluoroethyl.
[0074] The term “cycloalkyl” as used herein denotes a saturated carbocyclic ring containing 3 to 8 carbon atoms, i.e. cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl.
[0075] The term “aryl” as used herein means a monocyclic or polycyclic-aromatic group comprising carbon and hydrogen atoms. Examples of suitable aryl groups include, but are not limited to, phenyl, tolyl, indenyl, and 1- or 2-naphthyl, as well as benzo-fused carbocyclic moieties such as 5,6,7,8-tetrahydronaphthyl. An aryl group can be unsubstituted or substituted with one or more suitable substituents which substituents include C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkoxy, C 1-6 alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 haloalkoxy, C 1-6 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, acyl, alkoxycarbonyl, carbamoyl, N-alkylcarbamoyl, N,N-dialkylcarbamoyl, nitro and cyano.
[0076] A “heteroaryl group” or “heteroaromatic”as used herein means a monocyclic- or polycyclic aromatic ring comprising 15 carbon atoms, hydrogen atoms, and one or more heteroatoms, preferably, 1 to 3 heteroatoms, independently selected from nitrogen, oxygen, and sulfur. As well known to those skilled in the art, heteroaryl rings have less aromatic character than their all-carbon counter parts. Thus, for the purposes of the invention, a heteroaryl group need only have some degree of aromatic character. Illustrative examples of heteroaryl groups include, but are not limited to, pyridinyl, pyridazinyl, pyrimidyl, pyrazyl, triazinyl, pyrrolyl, pyrazolyl, imidazolyl, (1,2,3,)- and (1,2,4)-triazolyl, pyrazinyl, pyrimidinyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, thienyl, isoxazolyl, indolyl, quinolinyl, and oxazolyl. A heteroaryl group can be unsubstituted or substituted with one or more suitable substituents selected from hydroxy, oxo, cyano, alkyl, alkoxy, haloalkoxy, alkylthio, halo, haloalkyl, nitro, alkoxycarbonyl, amino, alkylamino, dialkylamino, aminoacyl, alkylsulfonyl, arylsulfinyl, alkoxycarbonyl, carbamoyl, N-alkylcarbamoyl, N,N-dialkylcarbamoyl, acyl unless otherwise indicated. A nitrogen atom in the heteroaryl ring can optionally be an N-oxide.
[0077] The term “heterocyclyl” means the monovalent saturated cyclic radical, consisting of one or more rings, preferably one to two rings, of three to eight atoms per ring, incorporating one or more ring heteroatoms (chosen from N,O or S(O) 0-2 ), and which can optionally be substituted with one or more, preferably one to three substituents selected from hydroxy, oxo, cyano, alkyl, alkoxy, haloalkoxy, alkylthio, halo, haloalkyl, nitro, alkoxycarbonyl, amino, alkylamino, dialkylamino, aminoacyl, alkylsulfonyl, arylsulfinyl, alkoxycarbonyl, carbamoyl, N-alkylcarbamoyl, N,N-dialkylcarbamoyl, acyl unless otherwise indicated. Examples of heterocyclic radicals include, but are not limited to, furanyl, tetrahydropyranyl, tetrahydrothiophenyl and the like.
[0078] The term “alkoxy group” as used herein means an —O-alkyl group, wherein alkyl is as defined above such as methoxy, ethoxy, n-propyloxy, i-propyloxy, n-butyloxy, i-butyloxy, t-butyloxy, pentyloxy, hexyloxy, heptyloxy including their isomers.
[0079] The term “alkylthio group” as used herein means an —S-alkyl group, wherein alkyl is as defined above such as meththio, eththio, n-propylthio, i-propylthio, n-butylthio, i-butylthio, t-butylthio, pentylthio including their isomers.
[0080] The term “haloalkoxy group” as used herein means an —O-haloalkyl group, wherein haloalkyl is as defined above. Examples of haloalkoxy groups include, but are not limited to, 2,2,2-trifluoroethoxy, difluoromethoxy and 1,1,1,3,3,3-hexafluoro-iso-propoxy.
[0081] The term “haloalkthio group” as used herein means an —S-haloalkyl group, wherein haloalkyl is as defined above. An example of haloalkthio groups includes, but are not limited to, 2,2,2-trifluoroeththanthiol.
[0082] The term “aryloxy group” as used herein means an O-aryl group wherein aryl is as defined above. An aryloxy group can be unsubstituted or substituted with one or more suitable substituents. Preferably, the aryl ring of an aryloxy group is a monocyclic ring, wherein the ring comprises 6 carbon atoms, referred to herein as “(C 6 ) aryloxy”. The term “optionally substituted aryloxy” means the aryl or group may be substituted with one to three groups selected from the group consisting of C 1-6 alkyl, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 1-6 alkoxy, C 1-6 alkylthio, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 haloalkoxy, C 1-6 haloalkylthio, halogen, amino, alkylamino, dialkylamino, aminoacyl, acyl, alkoxycarbonyl, carbamoyl, N-alkylcarbamoyl, N,N-dialkylcarbamoyl, nitro and cyano.
[0083] The term “heteroaryloxy group” as used herein means an O-heteroaryl group, wherein heteroaryl is as defined above. The heteroaryl ring of a heteroaryloxy group can be unsubstituted or substituted with one or more suitable substituents. Examples of heteroaryl groups include, but are not limited to, 2-pyridyloxy, 3-pyrrolyloxy, 3-pyrazolyloxy, 2-imidazolyloxy, 3-pyrazinyloxy, and 4-pyrimidyloxy.
[0084] The term “acyl” or “alkylcarbonyl” as used herein denotes a radical of formula C(═O)R wherein R is hydrogen, unbranched or branched alkyl containing 1 to 6 carbon atoms or a phenyl group.
[0085] The term “alkoxycarbonyl” as used herein denotes a radical of formula C(=O)OR wherein R is, unbranched or branched alkyl as described above.
[0086] The term “acylamino” as used herein denotes a radical of formula —NH-(acyl) where acyl is as defined herein.
[0087] The term “arylboronic acid” as used herein denotes a radical of formula ArB(OH) 2 wherein Ar is an optionally substituted aryl group as described above.
[0088] The term “alkylene” as used herein denotes a divalent linear or branched saturated hydrocarbon radical, having from one to six carbons inclusive, unless otherwise indicated. Examples of alkylene radicals include, but are not limited to, methylene, ethylene, propylene, 2-methyl-propylene, butylene, 2-ethylbutylene.
[0089] The term “arylalkyl” or “aralkyl” as used herein denotes the radical R′R″—, wherein R′ is an aryl radical as defined herein, and R″ is an alkylene radical as defined herein and the arylalkyl group is attached through the alkylene radical. Examples of arylalkyl radicals include, but are not limited to, benzyl, phenylethyl, 3-phenylpropyl.
[0090] The term “halogen” as used herein means fluorine, chlorine, bromine, or iodine. Correspondingly, the meaning of the term “halo” encompasses fluoro, chloro, bromo, and iodo. The term “hydrohalic acid” refers to an acid comprised of hydrogen and a halogen.
[0091] The term “alkylsulfinyl” as used herein means the radical —S(O)R′, wherein R′ is alkyl as defined herein. Examples of alkylaminosulfonyl include, but are not limited to methylsulfinyl and iso-propylsulfinyl.
[0092] The term “alkylsulfonyl” as used herein means the radical —S(O) 2 R′, wherein R′ is alkyl as defined herein. Examples of alkylaminosulfonyl include, but are not limited to methylsulfonyl and iso-propylsulfonyl.
[0093] The terms “amino”, “alkylamino” and “dialkylamino” as used herein refer to —NH 2 , —NHR and —NR 2 respectively and R is alkyl as defined above. The two alkyl groups attached to a nitrogen in a dialkyl moiety can be the same or different. The terms “aminoalkyl”, “alkylaminoalkyl” and “dialkylaminoalkyl” as used herein refer to NH 2 (CH 2 )n—, RHN(CH 2 )n—, and R 2 N(CH 2 )n— respectively wherein n is 1 to 6 and R is alkyl as defined above
[0094] The prefix “carbamoyl” as used herein means the radical —CONH 2 . The prefix “N-alkylcabamoyl” and “N,N-dialkylcarbamoyl” means a radical CONHR′ or CONR′R″ respectively wherein the R′ and R″ groups are independently alkyl as defined herein.
[0095] The term “conjugate base” as used herein means the chemical species produced when an acid (including here a carbon acid) gives up its proton.
[0096] Compounds of formula I exhibit tautomerism. Tautomeric compounds can exist as two or more interconvertable species. Prototropic tautomers result from the migration of a covalently bonded hydrogen atom between two atoms. Tautomers generally exist in equilibrium and attempts to isolate an individual tautomers usually produce a mixture whose chemical and physical properties are consistent with a mixture of compounds. The position of the equilibrium is dependent on chemical features within the molecule. For example, in many aliphatic aldehydes and ketones, such as acetaldehyde, the keto form predominates while; in phenols, the enol form predominates. Common prototropic tautomers include keto/enol (—C(═O)—CH—⇄—C(—OH)═CH—), amide/imidic acid (—(═O)—NH—⇄—C(—OH)═N—) and amidine (—C(═NR)—NH—⇄—C(—NHR)═N—) tautomers. The latter two are particularly common in heteroaryl and heterocyclic rings and the present invention encompasses all tautomeric forms of the compounds.
[0097] Compounds of formula I which are basic can form pharmaceutically acceptable acid addition salts with inorganic acids such as hydrohalic acids (e.g. hydrochloric acid and hydrobromic acid), sulphuric acid, nitric acid and phosphoric acid, and the like, and with organic acids (e.g. with acetic acid, tartaric acid, succinic acid, fumaric acid, maleic acid, malic acid, salicylic acid, citric acid, methanesulphonic acid and p-toluenesulfonic acid, and the like).
[0098] The term “solvate” as used herein means a compound of the invention or a salt, thereof, that further includes a stoichiometric or non-stoichiometric amount of a solvent bound by non-covalent intermolecular forces. Preferred solvents are volatile, non-toxic, and/or acceptable for administration to humans in trace amounts.
[0099] The term “hydrate” as used herein means a compound of the invention or a salt thereof, that further includes a stoichiometric or non-stoichiometric amount of water bound by non-covalent intermolecular forces.
[0100] The term “clathrate” as used herein means a compound of the invention or a salt thereof in the form of a crystal lattice that contains spaces (e. g., channels) that have a guest molecule (e. g., a solvent or water) trapped within.
[0101] The term “nucleoside and nucleotide reverse transcriptase inhibitors” (“NRTI”s) as used herein means nucleosides and nucleotides and analogues thereof that inhibit the activity of HIV-1 reverse transcriptase, the enzyme which catalyzes the conversion of viral genomic HIV-1 RNA into proviral HIV-1 DNA.
[0102] Typical suitable NRTIs include zidovudine (AZT) available under the RETROVIR tradename; didanosine (ddI) available under the VIDEX tradename.; zalcitabine (ddC) available under the HIVID tradename; stavudine (d4T) available under the ZERIT trademark.; lamivudine (3TC) available under the EPIVIR tradename; abacavir (1592U89) disclosed in WO96/30025 and available under the ZIAGEN trademark; adefovir dipivoxil [bis(POM)-PMEA] available under the PREVON tradename; lobucavir (BMS-180194), a nucleoside reverse transcriptase inhibitor disclosed in EP-0358154 and EP-0736533 and under development by Bristol-Myers Squibb; BCH-10652, a reverse transcriptase inhibitor (in the form of a racemic mixture of BCH-10618 and BCH-10619) under development by Biochem Pharma; emitricitabine [(−)-FTC] licensed from Emory University under U.S. Pat. No. 5,814,639 and under development by Triangle Pharmaceuticals; beta-L-FD4 (also called beta-L-D4C and named beta-L-2′,3′-dicleoxy-5-fluoro-cytidene) licensed by Yale University to Vion Pharmaceuticals; DAPD, the purine nucleoside, (−)-beta-D-2,6,-diamino-purine dioxolane disclosed in EP-0656778 and licensed to Triangle Pharmaceuticals; and Iodenosine (FddA), 9-(2,3-dideoxy-2-fluoro-b-D-threo-pentofuranosyl)adenine, an acid stable purine-based reverse transcriptase inhibitor discovered by the NIH and under development by U.S. Bioscience Inc.
[0103] The term “non-nucleoside reverse transcriptase inhibitors” (“NNRTI”s) as used herein means non-nucleosides that inhibit the activity of HIV-1 reverse transcriptase.
[0104] Typical suitable NNRTIs include nevirapine (BI-RG-587) available under the VIRAMUNE tradename; delaviradine (BHAP, U-90152) available under the RESCRIPTOR tradename; efavirenz (DMP-266) a benzoxazin-2-one disclosed in WO94/03440 and available under the SUSTIVA tradename; PNU-142721, a furopyridine-thio-pyrimide; AG-1549 (formerly Shionogi # S-1153); 5-(3,5-dichlorophenyl)-thio-4-isopropyl-1-(4-pyridyl)methyl-1H-imidazol-2-ylmethyl carbonate disclosed in WO 96/10019; MKC-442 (1-(ethoxy-methyl)-5-(1-methylethyl)-6-(phenylmethyl)-(2,4(1H,3H)-pyrimidinedione); and (+)-calanolide A (NSC-675451) and B, coumarin derivatives disclosed in U.S. Pat. No. 5,489,697
[0105] The term “protease inhibitor” (“PI”) as used herein means inhibitors of the HIV-1 protease, an enzyme required for the proteolytic cleavage of viral polyprotein precursors (e.g., viral GAG and GAG Pol polyproteins), into the individual functional proteins found in infectious HIV-1. HIV protease inhibitors include compounds having a peptidomimetic structure, high molecular weight (7600 daltons) and substantial peptide character, e.g. CRIXIVAN as well as nonpeptide protease inhibitors e.g., VIRACEPT.
[0106] Typical suitable PIs include saquinavir available in hard gel capsules under the INVIRASE tradename and as soft gel capsules under the FORTOVASE tradename; ritonavir (ABT-538) available under the NORVIR tradename; indinavir (MK-639) available under the CRIXIVAN tradename; nelfnavir (AG-1343) available under the VIRACEPT; amprenavir (141W94), tradename AGENERASE, a non-peptide protease inhibitor; lasinavir (BMS-234475; originally discovered by Novartis, Basel, Switzerland (CGP-61755); DMP-450, a cyclic urea discovered by Dupont; BMS-2322623, an azapeptide under development by Bristol-Myers Squibb, as a 2nd-generation HIV-1 PI; ABT-378; AG-1549 an orally active imidazole carbamate.
[0107] Other antiviral agents include hydroxyurea, ribavirin, IL-2, IL-1 2, pentafuside and Yissum Project No. 11607. Hydroxyurea (Droxia), a ribonucleoside triphosphate reductase inhibitor, the enzyme involved in the activation of T-cells. Hydroxyurea was shown to have a synergistic effect on the activity of didanosine and has been studied with stavudine. IL-2 is disclosed in Ajinomoto EP-0142268, Takeda EP-0176299, and Chiron U.S. Pat. Nos. RE 33,653, 4,530,787, 4,569,790, 4,604,377, 4,748,234, 4,752,585, and 4,949,314, and is available under the PROLEUKIN (aldesleukin) tradename as a lyophilized powder for IV infusion or sc administration upon reconstitution and dilution with water; a dose of about 1 to about 20 million 1 U/day, sc is preferred; a dose of about 15 million 1 U/day, sc is more preferred. IL-12 is disclosed in WO96/25171 and is available as a dose of about 0.5 microgram/kg/day to about 10 microgram/kg/day, sc is preferred. Pentafuside (DP-178, T-20) a 36-amino acid synthetic peptide, disclosed in U.S. Pat. No. 5,464,933 and available under the FUZEON tradename; pentafuside acts by inhibiting fusion of HIV-1 to target membranes. Pentafuside (3-100 mg/day) is given as a continuous sc infusion or injection together with efavirenz and 2 PI's to HIV-1 positive patients refractory to a triple combination therapy; use of 100 mg/day is preferred. Yissum Project No. 11607, a synthetic protein based on the HIV-1 Vif protein. Ribavirin, I-.beta.-D-ribofuranosyl-1H-1,2,4-triazole-3-carboxamide, is described in U.S. Pat. No. 4,211,771.
[0108] The term “anti-HIV-1 therapy” as used herein means any anti-HIV-1 drug found useful for treating HIV-1infections in man alone, or as part of multidrug combination therapies, especially the HAART triple and quadruple combination therapies. Typical suitable known anti-HIV-1 therapies include, but are not limited to multidrug combination therapies such as (i) at least three anti-HIV-1 drugs selected from two NRTIs, one PI, a second PI, and one NNRTI; and (ii) at least two anti-HIV-1 drugs selected from NNRTIs and PIs. Typical suitable HAART—multidrug combination therapies include:
[0109] (a) triple combination therapies such as two NRTIs and one PI; or (b) two NRTIs and one NNRTI; and (c) quadruple combination therapies such as two NRTIs, one PI and a second PI or one NNRTI. In treatment of naive patients, it is preferred to start anti-HIV-1 treatment with the triple combination therapy; the use of two NRTIs and one PI is preferred unless there is intolerance to PIs. Drug compliance is essential. The CD4.sup.+and HIV-1-RNA plasma levels should be monitored every 3-6 months. Should viral load plateau, a fourth drug, e.g., one PI or one NNRTI could be added.
[0110] The term “wild type” as used herein refers to the HIV virus strain which possesses the dominant genotype which naturally occurs in the normal population which has not been exposed to reverse transcriptase inhibitors. The term “wild type reverse transcriptase” used herein has refers to the reverse transcriptase expressed by the wild type strain which has been sequenced and deposited in the SwissProt database with an accession number P03366.
[0111] The term “reduced susceptibility” as used herein refers to about a 10 fold, or greater, change in sensitivity of a particular viral isolate compared to the sensitivity exhibited by the wild type virus in the same experimental system.
Abbreviations
[0112] The following abbreviations are used throughout this application and they have the meaning listed below:
[0113] AIBN azo-bis-isobutyrylnitrile
[0114] atm atmospheres
[0115] BBN or 9-BBN 9-borabicyclo[3.3.1]nonane
[0116] Boc tert-butoxycarbonyl
[0117] BOC 2 O Di-tert-butyl pyrocarbonate or boc anhydride
[0118] Bn benzyl
[0119] cbz or Z benzyloxycarbonyl
[0120] DABCO diazabicyclooctane
[0121] DAST diethylaminosulfur trifluoride
[0122] DCE 1,2-dichloroethane
[0123] DCM dichloromethane
[0124] DEAD diethyl azodicarboxylate
[0125] DIAD di-iso-propylazodicarboxylate
[0126] DIBAL-H di-iso-butylaluminumhydride
[0127] DMA N,N-dimethyl acetamide
[0128] DMAP 4-N,N-dimethylaminopyridine
[0129] DMF N,N-dimethylformamide
[0130] dppf 1,1′-Bis(diphenylphosphino)ferrocene
[0131] EDCI 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride
[0132] EtOAc ethyl acetate
[0133] Et 2 O diethyl ether
[0134] Et ethyl
[0135] EtOH ethanol
[0136] LAH lithium aluminum hydride
[0137] LiHMDS lithium hexamethyl disilazane
[0138] h hour(s)
[0139] HOAc acetic acid
[0140] i-Pr iso-propyl
[0141] m minute(s)
[0142] Me methyl
[0143] MeCN acetonitrile
[0144] MeOH methanol
[0145] MTBE methyl t-butyl ether
[0146] NBS N-bromosuccinimide
[0147] NMP N-methylpyrrolidone
[0148] PCC pyridinium chlorochromate
[0149] PDC pyridinium dichromate
[0150] psi pounds per square inch
[0151] pyr pyridine
[0152] rt or RT room temperature
[0153] TEA or Et 3 N triethylamine
[0154] Tf triflate CF 3 SO 2 —
[0155] TFA trifluoroacetic acid
[0156] THF tetrahydrofuran
[0157] TLC thin layer chromatography
[0158] TMHD 2,2,6,6-tetramethylheptane-2,6-dione
[0159] TsOH p-toluenesulfonic acid
Examples of Compounds
[0160] representative examples of [3-phenoxybenzyl]pyridazinones within the scope of the invention are provided in the following table. These examples and preparations are provided to enable those skilled in the art to more clearly understand and to practice the present invention. In general, the nomenclature used in this Application is based on AUTONOMT v.4.0, a Beilstein Institute computerized system for the generation of IUPAC systematic nomenclature. If there is a discrepancy between a depicted structure and a name given that structure, the depicted structure is to be accorded more weight.
TABLE I [M + H] + cpd (mw) # Structure Name mp I-1 5-(4-Chloro-3-phenoxy-benzyl)- 3H-[1,3,4]oxadiazol-2-one (302.7195) I-2 5-[4-Chloro-3-(2-chloro-phenoxy)- benzyl]-3H-[1,3,4]oxadiazol-2-one (337.1646) I-3 5-[3-(3-Bromo-phenoxy)-4-chloro- benzyl]-3H-[1,3,4]oxadiazol-2-one (381.6156) I-4 5-[4-Chloro-3-(2-chloro-phenoxy)- benzyl]-3H-[1,3,4]thiadiazol-2-one (353.2292) I-5 5-[3-(3-Bromo-phenoxy)-4-chloro- benzyl]-3H-[1,3,4]thiadiazol-2-one (397.6802) I-6 5-[3-(3-Bromo-phenoxy)-4-chloro- benzyl]-4-ethyl-2,4-dihydro- [1,2,4]triazol-3-one 408 (408.685) I-7 5-[4-Chloro-3-(2-chloro-phenoxy)- benzyl]-4-ethyl-2,4-dihydro- [1,2,4]triazol-3-one 364 (364.234) I-8 5-[4-Chloro-3-(3-chloro-phenoxy)- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 350 (350.2069) I-9 5-[4-Chloro-3-(3-chloro-phenoxy)- benzyl]-4-ethyl-2,4-dihydro- [1,2,4]triazol-3-one 364 (364.23) I-10 5-[4-Chloro-3-(3-chloro-phenoxy)- benzyl]-4-propyl-2,4-dihydro- [1,2,4]triazol-3-one 378 (378.26) I-11 5-[3-(3-Bromo-phenoxy)-4-chloro- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 394 (394.65) I-12 5-[3-(3-Bromo-phenoxy)-4-methyl- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 374 (374.23) I-13 5-[4-Chloro-3-(3,5-dibromo-phenoxy)- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 473.55 (474) I-14 5-[4-Chloro-3-(3,5-dichloro-phenoxy)- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 402.64 (404) I-15 5-[3-(5-Bromo-2-chloro-phenoxy)- 4-chloro-benzyl]-4-methyl-2,4- dihydro-[1,2,4]triazol-3-one 430 (429.1) I-16 4-Chloro-3-[2-chloro-5-(4-methyl- 5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 375 (375.21) I-17 3-[2-Chloro-5-(4-methyl- 5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 341 (340.77) I-18 3-[2-Methyl-5-(4-methyl- 5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 321 (320.35) I-19 5-[2-Chloro-5-(4-methyl- 5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-isophthalonitrile 366 (365.78) 217.8-219.1 I-20 5-[4-Chloro-3-(3-chloro-phenoxy)- benzyl]-4-phenyl-2,4-dihydro- [1,2,4]triazol-3-one 412 (412.27) I-21 4-Chloro-3-[6-chloro-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 393 (393.2) I-22 3-Chloro-5-[6-chloro-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 447 (447.09) 167.8-171.2 I-23 5-[3-(3-Bromo-5-chloro-phenoxy)- 4-chloro-2-fluoro-benzyl]-4- methyl-2,4-dihydro-[1,2,4]triazol-3-one 447 (447.09) 212.3-215.8 I-24 3-Chloro-5-[6-chloro-2-methoxy-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 405 (405.24) 194.4-198.6 I-25 3-Chloro-5-[6-chloro-2-hydroxy-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile 391 (391.21) 185-186.2 I-26 5-[4-Chloro-3-(3-chloro-5- difluoromethyl-phenoxy)-2-fluoro- benzyl]-4-methyl-2,4-dihydro- [1,2,4]triazol-3-one 461 (461) 180.6-185.2 I-27 3-[6-Chloro-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-5-difluoromethyl- benzonitrile 408 (408.77) 190.7-192.8 I-28 3-[6-Bromo-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-5-chloro-benzonitrile 436 (437.66) 188-190 I-29 3-[6-Bromo-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-5-chloro-benzonitrile 372 (372.79) 198.6-201.9 I-30 3-Difluoromethyl-5-[2-fluoro-6- methyl-3-(4-methyl-5-oxo-4,5- dihydro-1H-[1,2,4]triazol-3- ylmethyl)-phenoxy]-benzonitrile (388.35) I-31 3-Difluoromethyl-5-[2-fluoro-6- methyl-3-(4-ethyl-5-oxo-4,5- dihydro-1H-[1,2,4]triazol-3- ylmethyl)-phenoxy]-benzonitrile (402.38) I-32 3-[6-Bromo-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-5-difluoromethyl- benzonitril (453.22) I-33 3-Chloro-5-[6-ethyl-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-benzonitrile (386.82) I-34 5-[6-Chloro-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-isophthalonitrile (383.77) I-35 5-[6-Bromo-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-isophthalonitrile (428.22) I-36 5-[2-Fluoro-6-methyl-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-isophthalonitrile (363.35) I-37 5-[6-Ethyl-2-fluoro-3- (4-methyl-5-oxo-4,5-dihydro-1H- [1,2,4]triazol-3-ylmethyl)- phenoxy]-isophthalonitrile (377.38)
Preparation of Compounds of the Invention
[0161] Compounds of the present invention can be made by a variety of methods depicted in the illustrative synthetic reaction schemes shown and described below. The starting materials and reagents used in preparing these compounds generally are either available from commercial suppliers, such as Aldrich Chemical Co., or are prepared by methods known to those skilled in the art following procedures set forth in references such as Fieser and Fieser's Reagents for Organic Synthesis; Wiley & Sons: New York, Volumes 1-21; R. C. LaRock, Comprehensive Organic Transformations, 2 nd edition Wiley-VCH, New York 1999; Comprehensive Organic Synthesis, B. Trost and I. Fleming (Eds.) vol. 1-9 Pergamon, Oxford, 1991; Comprehensive Heterocyclic Chemistry, A. R. Katritzky and C. W. Rees (Eds) Pergamon, Oxford 1984, vol. 1-9; Comprehensive Heterocyclic Chemistry II, A. R. Katritzky and C. W. Rees (Eds) Pergamon, Oxford 1996, vol. 1-11; and Organic Reactions, Wiley & Sons: New York, 1991, Volumes 1-40. The following synthetic reaction schemes and examples are merely illustrative of some methods by which the compounds of the present invention can be synthesized, and various modifications to these synthetic reaction schemes can be made and will be suggested to one skilled in the art having referred to the disclosure contained in this Application.
[0162] The heterocyclic compounds of the present invention are prepared by a two-stage process (Scheme 1) comprising construction of an appropriately substituted aryl ring 2 and subsequently introducing the heterocyclic ring 3. Although stages can be accomplished in any order, the heterocyclic ring is generally introduced after the modifications of the aryl ring are completed. Substituted alkyl m-hydroxyphenylacetate 1a or m-hydroxyphenylacetonitrile 1b derivatives are convenient starting materials. They are often commercially available or readily prepared from commercially available precursors. Alternatively the aryl ring may be substituted with a methyl 1c or carboxylic acid ester Id substituent which is subsequently converted to 1b (for example, see schemes 4 and 5). One skilled in the art will also appreciate the substituents can altered after introduction of the heterocyclic ring.
[0163] Preparation of Phenylacetic Acid and Phenylacetonitile Precursors (Scheme 1)
[0164] Ethyl 3-hydroxy-4-methylphenylacetate (5a) was prepared from ethyl 3-methoxy-4-hydroxy-phenylacetate as shown in Scheme 2. The phenol was converted to the triflate ester 4b which was subjected to displacement with Me 2 Zn, DIBAL-H and PdCl 2 (dppf) (E.-i. Negishi in Metal - catalyzed Cross - Coupling Reactions, F. Diederich and P. J. Stang (eds.), Wiley-VCH, Mannheim 1998, chap. 1; E. Erdik, Tetrahedron 1992 48:9577-9648) to afford the 4c. Boron tribromide demethylation afforded 5a. Ethyl 3-hydroxy-4-ethylphenylacetate 5b was prepared by Friedel-Crafts acylation of 4d which afforded ethyl 4-acetyl-3-methoxyphenylacetate (4e). Reduction of the ketone with triethylsilane and TFA produced the corresponding 4-ethyl substituted derivative 4f which was demethylated with BBr 3 to afford 5b. Ethyl 3-hydroxy-4-iso-propylphenylacetate (5c) was prepared by Wittig olefination of 4e and subsequent catalytic hydrogenation of the 2-propenyl substituent to yield 4h. Demethylation with boron tribromide produced 5c.
[0165] Ethyl 3,4-dimethyl-5-hydroxyphenylacetate (8) was prepared by formylation of 6a and esterification of the resulting carboxylic acid 6b to produce ethyl 3-formyl-4-hydroxy-5-methoxyphenyl acetate (7a). Reduction of the aldehyde and hydrogenolysis the resulting benzyl alcohol afforded 7b. The second methyl substituent was introduced by sequential treatment of 7b with triflic anhydride which yielded 7c and displacement with Me 2 Zn, PdCl 2 (dppf) and DIBAL-H (supra) to produce 7c. Boron tribromide mediated demethylation afforded 8. (Scheme 3).
[0166] Ethyl 4-chloro-3-hydroxyphenyl acetate (10) was prepared from 4-chloro-3-methoxytoluene by sequential free radical bromination (9b), nucleophilic displacement of the bromine atom with cyanide (9c) and a two-step hydrolysis of the nitrile to the amidine hydrochloride 9d and subsequently to the ethyl ester 9e. Boron tribromide mediated demethylation as described previously afforded 10. (Scheme 4)
[0167] 6-Methyl derivatives were prepared from 3-hydroxy-2-methylbenzoic acid (11) which was chlorinated (NaOCl/NaOH) and esterified to afford 13. Cupric acetate mediated coupling (infra) of benzeneboronic acid provided the diaryl ether 14. The nitrile was introduced by sequential reduction, mesylation and cyanide displacement to afford 17. The mesylate underwent an in situ displacement by chloride during the mesylation reaction.
[0168] 6- fluoro- and chloro-derivatives were available from 6-chloro-2-fluoro-3-methylphenol (18) and 3-bromo-2,4-dichlorotoluene (19), respectively (Scheme 6). The base-catalyzed reaction of 18 and p-fluoro-nitrobenzene yielded dairyl ether 20. Conversion of the nitro substiuent to the corresponding amine followed by diazotization and reduction produced 4-chloro-2-fluoro-3-phenoxytoluene (22). One skilled in the art will appreciate that the availability of amino-substituted aryl groups affords the possibility to replace the amino substiuent with a variety of other substituents utilizing the Sandmeyer reaction. Cupric chloride-mediated coupling (see infra) of 19 afforded the corresponding 2,4-dichloro-3-phenoxytoluene (23). Elaboration of the acetonitrile sidechain in 24 and 25 was accomplished by benzylic bromination and displacement.
[0169] Benzofuran 31 and dihydrobenzofuran 29 derivatives (Scheme 7) were prepared from dihydrobenzofuran (26). Acylation with ethyl chloro oxalate produced the a-ketoester 27 which was reduced to the corresponding phenylacetic acid derivative 28a under Wolff-Kischner conditions. The preparation of 29 by a Wilgerodt reaction also has been reported (J. Dunn et al. J. Med Chem 1986 29:2326). Freidel-Crafts acylation with acetyl chloride afforded the acetyl derivative 28b which was converted to the acetate 28c under Baeyer-Villiger conditions and subsequently hydrolyzed to 29. The corresponding benzofuran analogs were prepared by benzylic bromination and concomitant dehydrohalogention to yield 31.
[0170] Preparation of Aryl Ether Intermediates (Scheme 1: 2: X═O or S)
[0171] The preparation of diaryl ethers has been reviewed (J. S. Sawyer, Recent Advances in Diaryl Ether Synthesis, Tetrahedron 2000 56:5045-5065). The diaryl ethers required herein were prepared by three different methods (Scheme 8): (i) Cu(OAc) 2 catalyzed condensation of substituted benzene boronic acids and phenols (D. A. Evans et al., Synthesis of Diaryl Ethers through the Copper - Promoted Arylation of Phenols with Aryl Boronic Acids. An Expedient Synthesis of Thyroxine, Tetrahedron Lett., 1998 39:2937-2940 and D. M. T. Chan et al., New N - and O - Arylations with Phenylboronic Acids and Cupric Acetate, Tetrahedron Lett. 1998 39:2933-2936; Scheme 1, conditions (a), (b), (e), (f), (i); (ii) by variations of the Ullmann diaryl ether synthesis with Cu(I) salts (J.-F. Marcoux et al., A General Copper - Catalyzed Synthesis of Diaryl Ethers, J. Am. Chem. Soc. 1997 119:10539-540; E. Buck et al, Ullmann Diaryl Ether Synthesis:Rate Acceleration by 2,2,6,6- tetramethylheptane- 3,5- dione, Org Lett. 2002 4(9):1623-1626); conditions (c), (d) and (h); or by nucleophilic aromatic displacement reactions (Sawyer supra pp 5047-5059; conditions Scheme 1(g) and (1). An alternative process utilizing palladium-catalyzed coupling procedures also has been reported (G. Mann et al., Palladium - Catalyzed Coupling Involving Unactivated Aryl Halides. Sterically Induced Reductive Elimination to Form the C—O Bond in Diaryl Ethers, J. Am. Chem. Soc., 1999 121:3224-3225). One skilled in the art will appreciate that optimal procedure will vary depending on the nature and position of substituents on the aryl rings.
[0172] Substituted m-cresol derivatives are also suitable substrates for coupling using these procedures. After introduction of the meta substituent the intermediate can be converted to the corresponding phenylacetonitrile derivative by bromination and cyanide displacement (Scheme 9).
[0173] coupling of compounds with a fused aryl, heteroaryl or heterocyclic ring to produce diaryl ethers, alkylaryl ethers or arylaralkylethers can be carried out by the same procedures. The preparation of aralkyloxy benzofuranylacetate and aryloxydihydrobenzofuranylacetate derivatives is exemplified in Scheme 10. Aralkoxybenzofurans are prepared by Mitsunobu coupling of the alcohol and the hydroxybenzofuranacetic acid.
[0174] Aralkyl aryl ethers were prepared using Mitsunobu conditions (Scheme 11; 0. Mitsunobu, Synthesis 1981 1-28). Alternatively aralkyl ethers can be prepared via a classical Williamson ether synthesis (J. March, Advanced Organic Chemistry; 4 th Edition; Wiley & Sons: New York, 1992;pp. 386-87) or utilizing palladium-catalyzed coupling (M. Palucki et al., Palladium - catalyzed Intermolecular Carbon - Oxygen Bond Formation: A New Synthesis of Aryl Ethers, J. Am. Chem. Soc. 1997 119:3395-96).
[0175] Preparation of Diphenylamine Intermediates (Scheme 1; X═NR 6 )
[0176] Diphenylamine compounds with in the scope of the present invention can be prepared by palladium-catalyzed coupling reactions as described by Hartwig ( Transition Metal Catalyzed Synthesis of Aryl Amines and Aryl Ethers from Aryl Halides and Triflates: Scope and Mechanism, Angew. Chem. Int. Ed. Eng. 1998 37:2046-67)
[0177] Preparation of Diphenyl Methane Intermediates (Scheme 1: 2: X═CH 2 or C═O)
[0178] Diphenylmethane compounds of the present invention can be prepared by reduction of the corresponding benzoyl derivatives 42. While reductions are conveniently carried out with triethylsilylhydride and trifluoroacetic acid, a variety of other procedures to effect this transformation are well known within the art.
[0179] The preparation of the requisite benzoyl derivatives has been described in U.S. Pat. No. 5,886,178 (D. A. Allen et al.). The synthesis of benzoyl substituted benzofuran derivatives have also been reported in U.S. Pat. No. 4,780,480 (J. P. Dunn) and the scientific literature (J. P. Dunn et al. Analgetic and Antiinflammatory 7- Aroylbenzofuran -5- ylacetic acids and 7- Aroylbenzothiophene -5- ylacetic Acids, J. Med. Chem. 1986 29:2326) These references are hereby incorporated by reference in its entirety.
[0180] Introduction of the Heterocyclic Ring (Scheme 1; 3)
[0181] The oxadiazolone, thiadiazolone and triazolone compounds of the present invention can be prepared by cyclization of a diacyl hydrazone derivative according to formula V. Without wishing to be limited by a specific mechanism or sequence of reaction steps, the oxadiazolones can be prepared by treating an acylhydrazone IV with the appropriate acyl derivative and cyclizing the resulting diacyl compound One skilled in the art will appreciate that IV is an ambident nucleophile and initial reaction could be at either the carbonyl oxygen or the nitrogen and subsequent ring closure of either produces the same product
[0182] 2-Oxo-2,3-dihydro-1,3,4-oxadiazoles 49 can be prepared by cyclization of an acyl hydrazide 46b with phosgene (or equivalents such as carbonyl diimidazole, alkyl chloroformates and the like) to directly produce the desired oxadiazole. (A. Hetzheim, 1,3,4 Oaxadiazoles in Methoden der Organischen Chemie ( Houben - Weyl ) E. Schaumann (ed), Hetarene III/Teil 3, Band E8c; Thieme Verlag, Stuttgart; 1994, pp531-536) (Scheme 13) 2-Oxo-2,3-dihydro-1,3,4-thiadiazoles 53 are prepared by condensation of an O-alkyl imidate 51 and methoxythiocarbonyl hydrazide which produce a 2-methoxy-3,4-thidiazole derivative 52 which was hydrolyzed to the corresponding 2-oxo-2,3-dihydro-1,3,4-thiadiazole 53 under acidic conditions (H. Kristinsson et al., Synthesis of Heterocycles. V 1,3,4- Thiazol -2(3 H ) one, Helv. Chim. Acta 1982 65:2606). Alternatively, cyclization of N-acyl-N′-alkoxycarbonyl hydrazides with Lawesson's reagent can directly produce the thiadiazole (B. P. Rasmussen et al. Bull. Soc. Chim. Fr. 1985 62). Triazolones 48 were prepared by carbamoylation of an acyl hydrazide 46d with ethyl isocyanate to yield an N-acyl-N-carbamoylhydrazide 47 cyclized to the triazolone 48 upon treatment with methanolic potassium hydroxide.
Dosage and Administration
[0183] The compounds of the present invention may be formulated in a wide variety of oral administration dosage forms and carriers. Oral administration can be in the form of tablets, coated tablets, dragees, hard and soft gelatine capsules, solutions, emulsions, syrups, or suspensions. Compounds of the present invention are efficacious when administered by other routes of administration including continuous (intravenous drip) topical parenteral, intramuscular, intravenous, subcutaneous, transdermal (which may include a penetration enhancement agent), buccal, nasal, inhalation and suppository administration, among other routes of administration. The preferred manner of administration is generally oral using a convenient daily dosing regimen which can be adjusted according to the degree of affliction and the patient's response to the active ingredient.
[0184] A compound or compounds of the present invention, as well as their pharmaceutically useable salts, together with one or more conventional excipients, carriers, or diluents, may be placed into the form of pharmaceutical compositions and unit dosages. The pharmaceutical compositions and unit dosage forms may be comprised of conventional ingredients in conventional proportions, with or without additional active compounds or principles, and the unit dosage forms may contain any suitable effective amount of the active ingredient commensurate with the intended daily dosage range to be employed. The pharmaceutical compositions may be employed as solids, such as tablets or filled capsules, semisolids, powders, sustained release formulations, or liquids such as solutions, suspensions, emulsions, elixirs, or filled capsules for oral use; or in the form of suppositories for rectal or vaginal administration; or in the form of sterile injectable solutions for parenteral use. A typical preparation will contain from about 5% to about 95% active compound or compounds (w/w). The term “preparation” or “dosage form” is intended to include both solid and liquid formulations of the active compound and one skilled in the art will appreciate that an active ingredient can exist in different preparations depending on the target organ or tissue and on the desired dose and pharmacokinetic parameters.
[0185] The term “excipient” as used herein refers to a compound that is useful in preparing a pharmaceutical composition, generally safe, non-toxic and neither biologically nor otherwise undesirable, and includes excipients that are acceptable for veterinary use as well as human pharmaceutical use. The term “excipient” as used herein includes both one and more than one such excipient.
[0186] Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier may be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material. In powders, the carrier generally is a finely divided solid which is a mixture with the finely divided active component. In tablets, the active component generally is mixed with the carrier having the necessary binding capacity in suitable proportions and compacted in the shape and size desired. Suitable carriers include but are not limited to magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. Solid form preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0187] Liquid formulations also are suitable for oral administration include liquid formulation including emulsions, syrups, elixirs, aqueous solutions, aqueous suspensions. These include solid form preparations which are intended to be converted to liquid form preparations shortly before use. Emulsions may be prepared in solutions, for example, in aqueous propylene glycol solutions or may contain emulsifying agents such as lecithin, sorbitan monooleate, or acacia. Aqueous solutions can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing, and thickening agents. Aqueous suspensions can be prepared by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well known suspending agents.
[0188] The compounds of the present invention may be formulated for parenteral administration (e.g., by injection, for example bolus injection or continuous infusion) and may be presented in unit dose form in ampoules, pre-filled syringes, small volume infusion or in multi-dose containers with an added preservative. The compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, for example solutions in aqueous polyethylene glycol. Examples of oily or nonaqueous carriers, diluents, solvents or vehicles include propylene glycol, polyethylene glycol, vegetable oils (e.g., olive oil), and injectable organic esters (e.g., ethyl oleate), and may contain formulatory agents such as preserving, wetting, emulsifying or suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient may be in powder form, obtained by aseptic isolation of sterile solid or by lyophilisation from solution for constitution before use with a suitable vehicle, e.g., sterile, pyrogen-free water.
[0189] The compounds of the present invention may be formulated for topical administration to the epidermis as ointments, creams or lotions, or as a transdermal patch. Ointments and creams may, for example, be formulated with an aqueous or oily base with the addition of suitable thickening and/or gelling agents. Lotions may be formulated with an aqueous or oily base and will in general also containing one or more emulsifying agents, stabilizing agents, dispersing agents, suspending agents, thickening agents, or coloring agents. Formulations suitable for topical administration in the mouth include lozenges comprising active agents in a flavored base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerin or sucrose and acacia; and mouthwashes comprising the active ingredient in a suitable liquid carrier.
[0190] The compounds of the present invention may be formulated for administration as suppositories. A low melting wax, such as a mixture of fatty acid glycerides or cocoa butter is first melted and the active component is dispersed homogeneously, for example, by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool, and to solidify.
[0191] The compounds of the present invention may be formulated for vaginal administration. Pessaries, tampons, creams, gels, pastes, foams or sprays containing in addition to the active ingredient such carriers as are known in the art to be appropriate.
[0192] The compounds of the present invention may be formulated for nasal administration. The solutions or suspensions are applied directly to the nasal cavity by conventional means, for example, with a dropper, pipette or spray. The formulations may be provided in a single or multidose form. In the latter case of a dropper or pipette, this may be achieved by the patient administering an appropriate, predetermined volume of the solution or suspension. In the case of a spray, this may be achieved for example by means of a metering atomizing spray pump.
[0193] The compounds of the present invention may be formulated for aerosol administration, particularly to the respiratory tract and including intranasal administration. The compound will generally have a small particle size for example of the order of five (5) microns or less. Such a particle size may be obtained by means known in the art, for example by micronization. The active ingredient is provided in a pressurized pack with a suitable propellant such as a chlorofluorocarbon (CFC), for example, dichlorodifluoromethane, trichlorofluoromethane, or dichlorotetrafluoroethane, or carbon dioxide or other suitable gas. The aerosol may conveniently also contain a surfactant such as lecithin. The dose of drug may be controlled by a metered valve. Alternatively the active ingredients may be provided in a form of a dry powder, for example a powder mix of the compound in a suitable powder base such as lactose, starch, starch derivatives such as hydroxypropylmethyl cellulose and polyvinylpyrrolidine (PVP). The powder carrier will form a gel in the nasal cavity. The powder composition may be presented in unit dose form for example in capsules or cartridges of e.g., gelatin or blister packs from which the powder may be administered by means of an inhaler.
[0194] When desired, formulations can be prepared with enteric coatings adapted for sustained or controlled release administration of the active ingredient. For example, the compounds of the present invention can be formulated in transdermal or subcutaneous drug delivery devices. These delivery systems are advantageous when sustained release of the compound is necessary and when patient compliance with a treatment regimen is crucial. Compounds in transdermal delivery systems are frequently attached to an skin-adhesive solid support. The compound of interest can also be combined with a penetration enhancer, e.g., Azone (1-dodecylaza-cycloheptan-2-one). Sustained release delivery systems are inserted subcutaneously into to the subdermal layer by surgery or injection. The subdermal implants encapsulate the compound in a lipid soluble membrane, e.g., silicone rubber, or a biodegradable polymer, e.g., polyactic acid.
[0195] Suitable formulations along with pharmaceutical carriers, diluents and excipients are described in Remington: The Science and Practice of Pharmacy 1995, edited by E. W. Martin, Mack Publishing Company, 19th edition, Easton, Pa. A skilled formulation scientist may modify the formulations within the teachings of the specification to provide numerous formulations for a particular route of administration without rendering the compositions of the present invention unstable or compromising their therapeutic activity.
[0196] The modification of the present compounds to render them more soluble in water or other vehicle, for example, may be easily accomplished by minor modifications (salt formulation, esterification, etc.), which are well within the ordinary skill in the art. It is also well within the ordinary skill of the art to modify the route of administration and dosage regimen of a particular compound in order to manage the pharmacokinetics of the present compounds for maximum beneficial effect in patients.
[0197] The term “therapeutically effective amount” as used herein means an amount required to reduce symptoms of the disease in an individual. The dose will be adjusted to the individual requirements in each particular case. That dosage can vary within wide limits depending upon numerous factors such as the severity of the disease to be treated, the age and general health condition of the patient, other medicaments with which the patient is being treated, the route and form of administration and the preferences and experience of the medical practitioner involved. For oral administration, a daily dosage of between about 0.01 and about 100 mg/kg body weight per day should be appropriate in monotherapy and/or in combination therapy. A preferred daily dosage is between about 0.1 and about 500 mg/kg body weight, more preferred 0.1 and about 100 mg/kg body weight and most preferred 1.0 and about 10 mg/kg body weight per day. Thus, for administration to a 70 kg person, the dosage range would be about 7 mg to 0.7 g per day. The daily dosage can be administered as a single dosage or in divided dosages, typically between 1 and 5 dosages per day. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect for the individual patient is reached. One of ordinary skill in treating diseases described herein will be able, without undue experimentation and in reliance on personal knowledge, experience and the disclosures of this application, to ascertain a therapeutically effective amount of the compounds of the present invention for a given disease and patient.
[0198] In embodiments of the invention, the active compound or a salt can be administered in combination with another antiviral agent, such as a nucleoside reverse transcriptase inhibitor, another nonnucleoside reverse transcriptase inhibitor or HIV protease inhibitor. When the active compound or its derivative or salt are administered in combination with another antiviral agent the activity may be increased over the parent compound. When the treatment is combination therapy, such administration may be concurrent or sequential with respect to that of the nucleoside derivatives. “Concurrent administration” as used herein thus includes administration of the agents at the same time or at different times. Administration of two or more agents at the same time can be achieved by a single formulation containing two or more active ingredients or by substantially simultaneous administration of two or more dosage forms with a single active agent.
[0199] It will be understood that references herein to treatment extend to prophylaxis as well as to the treatment of existing conditions, and that the treatment of animals includes the treatment of humans as well as other animals. Furthermore, treatment of a HIV infection, as used herein, also includes treatment or prophylaxis of a disease or a condition associated with or mediated by HIV infection, or the clinical symptoms thereof.
[0200] The pharmaceutical preparations are preferably in unit dosage forms. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
[0201] The pharmaceutical compositions in Example 23 are given to enable those skilled in the art to more clearly understand and to practice the present invention. They should not be considered as limiting the scope of the invention, but merely as being illustrative and representative thereof.
[0202] The compounds of formula I may be prepared by various methods known in the art of organic chemistry. The starting materials for the syntheses are either readily available from commercial sources or are known or may themselves be prepared by techniques known in the art. The following examples (infra) are given to enable those skilled in the art to more clearly understand and to practice the present invention. They should not be considered as limiting the scope of the invention, but merely as being illustrative and representative thereof. The starting materials and the intermediates of the synthetic reaction schemes can be isolated and purified if desired using conventional techniques, including but not limited to, filtration, distillation, crystallization, chromatography, and the like. Such materials can be characterized using conventional means, including physical constants and spectral data.
[0203] Unless specified to the contrary, the reactions described herein preferably are conducted under an inert atmosphere at atmospheric pressure at a reaction temperature range of from about −78° C. to about 150° C., more preferably from about 0° C. to about 125° C., and most preferably and conveniently at about room (or ambient) temperature, e.g., about 20° C. Moreover, the reaction conditions are exemplary and alternative conditions are well known. The reaction sequences in the following examples are not meant to limit the scope of the invention as set forth in the claims.
EXAMPLE 1
Ethyl 4-Chloro-3-methoxyphenylacetate
[0204] [0204]
[0205] Step 1
[0206] A solution of 4-chloro-3-methoxytoluene (9a; 0.5 g; 3.2 mmol), NBS (0.57 g; 3.2 mmol) and benzoyl peroxide (0.031 g; 0.13 mmol) and 32 mL of DCE were heated at reflux for 3 h. The reaction mixture was cooled, diluted with CH 2 Cl 2 and washed with water and brine. The organic extract was dried filtered and evaporated to yield the bromomethyl compound 9b which was used without further purification.
[0207] Step 2
[0208] The 28 g (0.166 mmol) of 9b from the previous step, NaCN (28 g; 0.58 mmol; 3.5 equiv.) and 500 mL of 90% aqueous EtOH were stirred at room temperature overnight. The crude residue was partitioned between EtOAc/H2O (359 mL of each), washed with brine, dried, filtered and evaporated. Silica gel chromatography and elution with a gradient (100% hexane—90:10 hexane:EtOAc) yielded 21 g of 9c.
[0209] Step 3
[0210] Gaseous HCl was slowly bubbled into a cooled solution of 4-chloro-3-methoxyacetonitrile (9b) in toluene (10 mL), ether (10 mL) and EtOH (1 mL) for about 10 min. The reaction was stoppered and stored at −30° C. for one week. TLC failed to detect any remaining starting material. The solvent was evaporated and the yellow solid was stirred with Et 2 O, filtered and washed with Et 2 O and dried in a vacuum oven to yield 0.57 g (90%) of ethyl 4-chloro-3-methoxyphenylmethylimidate (9d).
[0211] Step 4
[0212] A solution of 0.57 g of 9d and 10 mL of H 2 O was heated at 40° C. for 3 h. The reaction was cooled to rt and extracted with EtOAc. The reaction was dried (MgSO4), filtered and evaporated and the resulting product 9e was used without further purification.
EXAMPLE 2
4-chloro-3-(3-bromo-5-fluorophenoxy)phenylacetonitrile
[0213] [0213]
[0214] Step 1
[0215] A mixture of NBS (1.066 g; 5.99 mmol), benzoyl peroxide (0.069 g; 0.28 mmol) and 54 (1.80 g; 5.70 mmol) and 20 mL of CCl 4 were heated to 90° C. for 2.5 h, cooled to rt, poured into water (100 mL) and extracted with CH 2 Cl 2 (2×80 mL) and the combined organic extracts dried (Na 2 SO 4 ), filtered and evaporated to yield 2.25 g of bromomethyl derivative 55 as a colorless oil which was used directly in the subsequent step.
[0216] Step 2
[0217] A mixture 2.25 g of 55, NaCN.(0.839 g; 17.12 mmol) and 20 mL of 90% aqueous ethanol were stirred at room temperature for 24 h. The volume was reduced to about 25% of the original volume in vacuo. The resulting mixture was diluted with EtOAc (80 mL) and poured into 40 mL saturated NaCl and 40 mL of H 2 O. The organic phase was dried (Na 2 SO 4 ), filtered and evaporated and the crude product purified by silica gel chromatography and eluted with an hexane:EtOAc gradient (10:1→6:1) to yield 1.10 g (56.6%) of 56 as a colorless oil.
EXAMPLE 3
[3-(2-Chloro-phenoxy)-4-methyl-phenyl]-acetic acid ethyl ester
[0218] [0218]
[0219] Step 1
[0220] To a cooled solution of ethyl 4-hydroxy-3-methoxyphenylacetate (4a; 13.7 g; 65.2 mmol) and 260 mL of CH 2 Cl 2 under N 2 atmosphere was added dropwise triflic anhydride (16 mL; 97.9 mmol) followed by dropwise addition of pyridine (8.9 mL; 8.8 mmol). The reaction was stirred in an ice-water bath for 3 h. The solution was transferred to a separatory funnel and washed with water and brine, dried (Na 2 SO 4 ), filtered and evaporated. to yield 21 g (90%) of 4b.
[0221] Step 2
[0222] To a solution of ethyl 3-methoxy-4-trifluorosulfonyloxyphenylacetate (4b) in 4 mL of THF cooled in an ice-water bath was added slowly a solution of Pd(dppf)Cl 2 (0.024 g; 0.029 mmol) and DIBAL-H (6 mL; 0.058 mmol; 1.0M in PhMe)and a small quantity of THF followed by dimethylzinc (0.29 mL; 0.58 mmol; 2.0 M in PhMe). After addition was completed the ice bath was removed and the reaction allowed to warm to rt and then heated to reflux for 1 h. The reaction was carefully quenched with a small quantity of water, filtered through a pad of CELITE® and the solids washed thoroughly with EtOAc. The combined organic extracts were washed with water and brine, dried (MgSO 4 ) and the solvent evaporated to afford 0.240 g (85%) of ethyl 3-methoxy-4-methylphenylacetate (4c).
[0223] Step 3
[0224] To a solution of 4c (2.2 g; 8.0 mmol) and 250 mL CH 2 Cl 2 cooled to −78° C. was added dropwise via syringe BBr 3 (9.8 mL; 0.104 mol). After 1 h at −78° C. the reaction was stirred for 4 h in an ice-water bath. The reaction mixture was recooled to −78° C. and the reaction quenched aqueous NaHCO 3 then warmed to rt and the organic phase washed with water, saturated NaHCO 3 and brine. The organic phase was dried (MgSO 4 ) and the solvent evaporated to afford 1.4 g of ethyl 3-hydroxy-4-methylphenylacetate (5a).
[0225] Step 4
[0226] To a suspension of 5a (4.8 g; 25 mmol), 2-chlorobenzeneboronic acid (7.8 g; 50 mmol), Cu(OAc) 2 (5 g; 27.5 mmol), powdered 4 Å molecular sieves (15 g) and 250 mL of CH 2 Cl 2 . After 4 days starting material was still evident by tic and an addition 5.0 g of the boronic acid was added. The reaction was stirred for an additional day and the suspension filtered through a pad of CELITE® and silica gel. The solids were washed well with CH 2 Cl 2 . The combined filtrates were washed sequentially with 2N HCl (2×25 mL), NaHCO 3 (25 mL), water and brine. The extracts were dried (MgSO 4 ), filtered and evaporated. The crude product was purified by silica gel chromatogaphy and eluted with 25% EtOAc:hexane to yield 2.2 g (28%) of 33b.
[0227] Step 6
[0228] A mixture of 0.72 g (2.6 mmol) of 57, HOAc (3.5 mL), HCl (7 mL) and H 2 O (3.5 mL) were heated at reflux for 6 h, cooled to rt, diluted with water and extracted with EtOAc. The combined extracts were washed sequentially with water, sat'd NaHCO 3 , and brine, dried (Na 2 SO 4 ), filtered and concentrated. The crude product was purified by chromatography on silica gel. The eluted product, which still contained the 3-chloropyridazine was dissolved in HOAc (20 mL) and NaOAc (0.2 g) and reisolated to yield 0.4 g (50%) of 58 as a white solid; m.p. 116-118.
EXAMPLE 4
3-(2-Chloro-phenoxy)-4-ethyl-phenyl]-acetic acid ethyl ester
[0229] [0229]
[0230] Step 1
[0231] To a stirred solution of ethyl 3-methoxyphenylacetate (16.0 g; 82.38 mmol) in CH 2 Cl 2 (200 mL) at rt was added dropwise AcCl (9.88 mL; 138.9 mmol) followed by stannic chloride (16.9 mL; 169 mmol; 1.0 M solution in CH 2 Cl 2 ) The reaction mixture was stirred at rt for 6 h and poured into an ice-water mixture. The aqueous phase was extracted with CH 2 Cl 2 and the combined extracts were washed with water, dried (Na 2 SO 4 ) and the solvent removed in vacuo. The crude product 4e was purified by chromatography on silica gel and eluted with CH 2 Cl 2 :EtOAc (20:1) to yield 13.96 g (69.5%) of a white solid.
[0232] Step 2
[0233] To a solution of 4e (19 g; 80.42 mmol) and 200 mL of TFA cooled to 0° C. was added an excess of Et 3 SiH and the reaction allowed to warm to rt for 3 h. Excess TFA was removed in vacuo and the residue partitioned between water and CH 2 Cl 2 . The crude product was purified by chromatography on silica gel and eluted with CH 2 Cl 2 :hexane (3:1) to yield 3.0 g (16%) of 4f.
[0234] Step 3
[0235] A solution of ethyl 4-ethyl-3-methoxyphenylacetate (4f; 3.0 g; 13.50 mmol) and CH 2 Cl 2 (80 mL) cooled to −78° C. and a solution of (5.10 mL; 53.94 mmol; 1.0 M in CH 2 Cl 2 ) over 30 min. After 1 at −78° C. the reaction was allowed to warm to rt and stirred for 12 h. The reaction was cooled in an ice-water bath and the reaction quenched with 20 mL of water. The aqueous phase was extracted with CH 2 Cl 2 :EtOAc (4:1 v/v), dried (Na 2 SO 4 ), filtered and evaporated. The crude product was purified by silica gel chromatography and eluted with a CH 2 Cl 2 :EtOAc gradient (100:1→100:4) to yield 5b (2.0 g; 71%): m.s. 209.2 (M+H) + .
[0236] Step 4
[0237] A solution of ethyl 4-ethyl-3-hydroxyphenylacetate (5b, 0.20 g; 0.96 mmol), 2-iodo-chlorobenzene (0.18 mL; 1.44 mmol), Cs 2 CO 3 (0.469 g; 1.44 mmol), TMHD (0.020 mL; 0.096 mmol) and NMP (15 mL) was degassed with a stream of nitrogen for 15 m. Cuprous chloride (0.48 g; 4.8 mmol) was added and the solution was degassed. The reaction mixture was heated to 120° C. for 11 h then cooled to rt. The suspension was filtered through a pad of CELITE® and the solid washed thoroughly with EtOAc. The combined filtrate was washed with 2N HCl, dried (Na 2 SO 4 ) and the solvent evaporated. The product was purified by chromatography on silica gel and eluted with EtOAc:hexane (1:10). to yield 0.31 g (39%) of 33d.
EXAMPLE 5
[3-(3-Chloro-phenoxy)-4-isopropyl-phenyl]-acetic acid ethyl ester
[0238] [0238]
[0239] Step 1
[0240] To a suspension of PPh 3 CH 3 + Br − (36.29 g; 101.6 mmol) in THF (150 mL) cooled to −40° C. was added dropwise n-BuLi (40.6 mL; 1.6M in hexanes) and the resulting solution was allowed to warm to −10° C. for 10 m and re-cooled to −40° C. To the resulting solution was added in one portion ethyl 4-acetyl-3-methoxyphenylacetate (see Example 4; step 1) and the reaction mixture was stirred at 0° C. for 30 m and warmed to rt and stirred for an additional 2 h. The reaction mixture was diluted with hexane filtered through a pad of CELITE® and the solids wash with hexane:Et 2 O (5:1 v/v; 60 mL). The combined organic layers were washed with water (50 mL) and brine (50 mL), dried (Na 2 SO 4 ), filtered and evaporated to yield a yellow oil. The product was purified by silica gel chromatography and eluted with CH 2 Cl 2 :hexane (1:1→2:1) to yield 9.1 g of 4g.
[0241] Step 2
[0242] A suspension of 4 g (9.0 g; 38.41 mmol), 5% Pd/C (380 mg) in 50 mL HOAc and 50 mL EtOH was shaken under a hydrogen atmosphere (50 psi) for 7 h. The mixture was filtered through a pad of CELITE® and the filtered catalyst was washed with EtOAc. The solvents were evaporated under reduced pressure and the residue dissolved in MTBE and carefully washed with sat'd HaHCO 3 , water and brine. The resulting solution was dried (Na 2 SO 4 ), filtered and evaporated to yield ethyl 4-iso-propyl-3-methoxyphenylacetate (4 h; 9.0 g) as a yellow oil.
[0243] Step 3
[0244] A solution of 4 h (3.38 g; 14.30 mmol) and CH 2 Cl 2 (150 mL) were cooled to −78° C. and a solution of BBr 3 (5.41 mL; 57.22 mmol) in 130 mL of CH 2 Cl 2 were added dropwise over a 30 m period. The reaction mixture was stirred at −78° C. for 1 h, allowed to warm to rt for 4 h and re-cooled to −78° C. and carefully quenched with sat'd. NaHCO 3 (80 mL). The aqueous layer was extracted with CH 2 Cl 2 (1×100 mL), EtOAc (50 mL) and the combined aqueous layers washed with water and brine, dried (Na 2 SO 4 ) and evaporated to yield a light brown oil. The phenol was purified by silica gel chromatography and eluted with CH 2 Cl 2 :hexane (3:1)→CH 2 Cl 2 →CH 2 Cl 2 :EtOAc (100:4) to yield ethyl 4-iso-propyl-3-hydroxyphenylacetate (5c; 3.0 g; 94%)
[0245] Step 4
[0246] To a solution of 5c (1.0 g; 4.5 mmol),, 3-chlorobenzeneboronic acid (0.844 g; 5.4 mmol), cupric acetate (0.899 g; 4.95 mmol), 4 Å molecular sieves (5.0 g) and CH 2 Cl 2 (50 mL) was added TEA (3.14 mL; 22.53 mmol) and the reaction was stirred for 3 days. The reaction mixture was filtered through a pad of CELITE®. The top layer containing the molecular sieves was removed and stirred with CH 2 Cl 2 and refiltered. The combined organic filtrates were washed with 2N HCl, brine, dried (Na 2 SO 4 ), filtered and evaporated. The crude product was chromatographed with silica gel and eluted with a gradient of hexane/EtOAc (90%hexane/EtOAc) to yield 33f (1.0 g; 66%).
[0247] Step 6
[0248] A mixture of 0.64 g (1.44 mmol) of 59, HOAc (12 mL), HCl (24 mL) and H 2 O (12 mL) were heated at reflux for 16 h, cooled to rt and extracted with EtOAc. The combined extracts were washed with H 2 O, dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford a brown solid. The crude product was purified by chromatography on silica gel and eluted with a gradient of CH 2 Cl 2 :EtOAc (15:1→8:1) to yield 0.10 g (20%) of 60.
EXAMPLE 6
Ethyl 4-methyl-3-(3-fluorophenoxy)phenylacetate
[0249] [0249]
[0250] To a stirred solution of 32b (0.80 g; 4.12 mmol) and 7 mL NMP under a N 2 atmosphere was added 1-bromo-3-fluorobenzene (0.69 mL; 6.18 mmol), TMHD (0.086 mL; 0.41 mmol), Cs 2 CO 3 (2.68 g; 8.24 mmol) and Cu(I)Cl (0.204 g; 2.06 mmol ). The reaction was heated to 120° C. for 3 h. The reaction mixture was cooled to ambient temperature, and quenched with a mixture of 2 N HCl and EtOAc. The aqueous layer was thrice extracted with EtOAc and the combined organic layers were washed with water and brine, dried (MgSO 4 ), filtered and evaporated to dryness. The crude product was chromatographed on silica gel and eluted with hexane:Et 2 O (9: 1) which yielded 33c (0.60 g; 50%).
EXAMPLE 7
3-(3-Chloro-phenoxy)-4,5-dimethyl-benzoic acid ethyl ester
[0251] [0251]
[0252] Step 1
[0253] A mixture of 4-hydroxy-3-methoxyphenylacetic acid (6a; 1.0 g; 5.49 mmol) and hexamethylenetetramine (0.808 g; 5.76 mmol) and TFA (7 mL) were stirred and heated at 90° C. for 4 h. The reaction was cooled and excess TFA removed in vacuo and 35 mL of ice and water was added to the residue. The resulting dark brown solution was stirred at rt for 20 m. The aqueous solution was extracted with Et 2 O (40 mL) and the extract was dried (Na 2 SO 4 ), filtered and evaporated to afford 0.70 g of 6b (61%; m.s. (M+H) + =211.13; mw=210).
[0254] Step 2
[0255] To a solution of 6b (4.0 g; 19.03 mmol) in EtOH (80 mL) was added con H 2 SO 4 (1 mL). The reaction was heated at reflux for 6 h. Approximately 80% of the EtOH was removed in vacuo and the residue partitioned between EtOAc/H 2 O (1:1) the organic phase residue washed with 10% NaHCO 3 , water (100 mL), dried (Na 2 SO 4 ), filtered and evaporated to afford a brown oil 7a (88%; m.s. (M+H) + =239.19; mw=238.3).
[0256] Step 3
[0257] A mixture of 7a (3.70 g; 15.53 mmol), 5% Pd/C (0.350 g), HOAc (45 mL) were shaken under a H2 atmosphere (40 psi) for 8 h. TLC showed product and the corresponding benzyl alcohol. An additional 300 mg of Pd/C in 25 mL HOAc was added and hydrogenation continued for another 8 h. A second portion of 0.15 g of Pd/C in HOAc (15 mL) was added and reaction continued for another 12 h. The mixture was diluted with EtOAc and filtered through a pad of CELITE®. The catalyst was washed with EtOAc and the combined organic extracts dried (Na 2 SO 4 ) and evaporated. The product was purified by silica gel chromatography and eluted with CH 2 Cl 2 :hexane (4:1) to afford 2.64 g of 7b (75.8%).
[0258] Step 4
[0259] To a solution of 7b (5.87 g; 26.175 mmol) in CH 2 Cl 2 cooled to 0° C. was added pyridine (3.60 mL; 44.51 mmol) followed by dropwise addition of triflic anhydride (6.605 mL; 39.26 mmol) over about 20 min. The reaction was stirred at 0° C. for 3.5 h. The reaction mixture was extracted with dilute HCl and half-saturated NaHCO 3 , dried (Na 2 SO 4 ) and evaporated to yield 9.41 g of 7c as a brown oil (100%).
[0260] Step 5
[0261] To a suspension of PdCl 2 (dppf) (0.650 g; 0785 mmol) in THF (40 mL) cooled to 0° C. was added dropwise a solution of DIBAL-H (1.0 M in PhMe; 1.57 mL; 1.57 mmol). The resulting mixture was stirred at 0° C. for 5 minutes and a solution of 7c in 5 mL of THF was added followed by Me 2 Zn (23 mL;46.0 mmol; 1.0 M in PhMe). The mixture was stirred at 0° C. for 5 m and heated at reflux for 2.5 h then cooled to rt for 30 m. The reaction was poured into dilute HCl and extracted with EtOAc (2×100 mL), dried (Na 2 SO 4 ), and evaporated. The crude product was purified by silica gel chromatography and eluted with CH 2 Cl 2 :hexane (1:2→1:1→2:1 v/v) to yield 5.1 g (87.6%) of 8.
[0262] Step 6
[0263] A solution of ethyl 3,4-dimethyl-5-methoxyphenylacetate (8; 0.560 g; 2.519 mmol) and CH 2 Cl 2 (40 mL) was cooled to −78° C. and a solution of BBr 3 (10.1 mL; 10.1 mmol; 1.0 M in CH 2 Cl 2 ) dropwise over 10 min. After 1 h at −78° C. the reaction was allowed to warm to rt and stirred for 12 h. The reaction was cooled in an ice-water bath and the reaction quenched with 15 mL of ice/water. The aqueous phase was extracted with CH 2 Cl 2 :EtOAc (3:1 v/v), dried (Na 2 SO 4 ), filtered and evaporated to yield 8 (0.52 g; 99%; m.s. 209.21 (M+H) + ).
[0264] Step 7
[0265] To a suspension of ethyl 3,4-dimethyl-5-hydroxyphenylacetate (8, 1.0 g; 4.8 mmol), 3-chloro-benzeneboronic acid (0.901 g; 5.762 mmol), Cu(OAc) 2 (0.959 g; 5.28 mmol), powdered 4 Å molecular sieves (5 g) and 40 mL of CH 2 Cl 2 . After 40 h starting material was still evident by tlc and an addition 0.35 g of the boronic acid was added. The reaction was stirred for an additional 72 h. The reaction mixture was filtered through a pad of CELITE® and silica gel. The solids were washed well with CH 2 Cl 2 . The combined filtrates were washed sequentially with 2N HCl (2×25 mL), NaHCO 3 (25 mL), water and brine. The extracts were dried (Na 2 SO 4 ), filtered and evaporated. The crude product was purified by silica gel chromatogaphy and eluted with EtOAc:hexane (1:15→1:10) to yield 33e (1.0 g; 65%; m.s. (M+H) + =319.34, mw=318).
[0266] Step 8
[0267] To a solution of 1.0 g of 33e (3.14 mmol), 0.935 g (6.276 mmol) of 3,6-dichloropyrazine in 10 mL dry DMF cooled in an ice-water bath was added portionwise 0.313 g NaH (7.825 mmol; 60% in oil). The reaction stirred at 0° C. for 5 m then was allowed to warm to ambient temperature and stirred for 14 hour. The reaction was poured onto a mixture of ice, water and sodium bisulfate. The mixture was extracted thoroughly with EtOAc and the combined extracts were washed with 5% LiCl, water and brine. The extract was dried (MgSO 4 ), filtered and evaporated and the residue chromatographed on silica gel and eluted with hexane:EtOAc (10:1→8:1) to yield 1.0 g (73.9%) of 61: m.s. (M+H) + =431.29).
[0268] Step 9
[0269] A mixture of 1.0 g (2.318 mmol) of 61, HOAc (12 mL), HCl (24 mL) and H 2 O (12 mL) were heated at reflux for 16 h, cooled to rt and extracted with EtOAc. The combined extracts were washed with H 2 O, dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford a brown solid. The crude product was purified by chromatography on silica gel and eluted with a gradient of CH 2 Cl 2 :EtOAc (8:1) to yield 0.150 g (18%) of 62 as a brown solid; m.s. (M+H) + =341.27; mw=340.8.
EXAMPLE 8
(4-chloro-2-methyl-3-phenoxy-phenyl)-acetonitrile
[0270] [0270]
[0271] Step 1
[0272] To a suspension of 3-hydroxy-2-methylbenzoic acid (11; 22.8 g; 0.15 mol) and water (300 mL) cooled in an ice-water bath was added 3 M NaOH to adjust pH to about 10 (ca 60 mL). NaOCl (208 mL; 5.35% aqueous solution; 0.15 mol) was added dropwise over about 30 m while maintaining the temperature between 2-6° C. After the addition was completed, 90 mL of 3 M HCl was added in one portion. The resulting precipitate was collected and dried on a sintered glass filter. The crude product was recrystallized from Et 2 O:hexane (ca. 3:1) to yield a yellow solid 12 (12.24 g; 44%).
[0273] Step 2
[0274] A solution of 12 (12.24 g; 65.6 mmol), MeOH (200 mL) and con H 2 SO 4 (3.85 mL) was stirred overnight at rt then heated to reflux for 6 h. The solution was cooled, concentrated to approximately 10% of the original volume and the residue redissolved in EtOAc. The organic phase was washed with sat'd. NaHCO 3 and brine, dried, filtered and evaporated. The crude product was purified by silica gel chromatography and eluted with a EtOAc:hexane gradient (1:9→4:6). The combined fractions were evaporated to yield 13 (8.32 g; 63.2%).
[0275] Step 3
[0276] To a solution of methyl 4-chloro-3-hydroxy-2-methylbenzoate (13; 1.0 g; 4.98 mmol), benzeneboronic acid (1.52 g; 12.5 mmol), cupric acetate (1.00 g; 5.48 mmol), 4A molecular sieves (1 g), and CH 2 Cl 2 (25 mL) was added TEA (3.47 mL; 24.9 mmol) and the reaction was stirred overnight. Starting material was still detected by tlc and an additional 0.62 g of benzeneboronic acid was added and stirred for another 24 h. The reaction mixture was filtered through a pad of CELITE®. The top layer containing the molecular sieves was washed with CHCl 3 . The combined organic filtrates were evaporated. The crude product was chromatographed with silica gel and eluted with hexane/EtOAc gradient (100:0→85:15) to yield 14 (0.82 g; 60%).
[0277] Step 4
[0278] To a solution of methyl 4-chloro-2-methyl-3-phenoxybenzoate (14; 0.780 g; 2.81 mmol) dissolved in PhMe (20 mL) cooled in an ice-water bath was added dropwise DIBAL-H (7.41 mL; 7.41 mmol; 1.0 M in PhMe) The reaction was quenched by sequentially adding MeOH, H 2 O, and con HCl. The organic phase was extracted with Et 2 O. The combined organic extracts were washed with sat'd. NaHCO 3 , water and brine, dried (Na 2 SO 4 ), filter and evaporated to yield 15 as a white oil which was used in the next step without further purification.
[0279] Step 5
[0280] To a solution of 15 (0.736 g; 2.96 mmol) dissolved in pyridine (10 mL) was added dropwise methanesulfonyl chloride (0.252 μL; 5.92 mmol) over 5 min. After 30 min a small quantity of starting material was evident and an addition 25 μL of methanesulfonyl chloride was added. The reaction was partitioned between Et2O and 5% HCl. The organic phase was twice washed with 5% HCl, water, sat'd. NaHCO3 and brine. The organic extract was dried (MgSO 4 ), filtered and evaporated. The crude product was chromatographed on silica gel eluting with 10% EtOAc:hexane to yield the benzylic chloride 16 (0.220 g) as a colorless oil.
[0281] Step 6
[0282] The benzyl chloride 16 (0.220 g; 0.82 mmol) was dissolved in EtOH (1 mL) and KCN (0.107 g; 1.64 mmol and 1 mL of water. The mixture was heated to reflux and CH 3 CN (0.3 mL) was added to produce a homogenous solution which was allow to reflux overnight. The reaction mixture was concentrated in vacuo and partitioned between water and CH 2 Cl 2 . The organic phase was washed twice with brine, dried (MgSO 4 ), filtered and evaporated to yield 17 (0.210 g) sufficiently pure for further processing.
EXAMPLE 9
Ethyl 4-chloro-3-(3-cyano-5-fluorophenoxy)phenylacetate
[0283] [0283]
[0284] To a solution of ethyl 4-chloro-3-hydroxyphenylacetate (34a; 1.4 g; 6.5 mmol) and NMP (13 mL) was added potassium carbonate (2.7 g; 19.6 mmol) and 1.2 g of 3,5-difluorobenzonitrile (1.2 g; 8.5 mmol). The reaction mixture was heated to 120° C. and monitored by TLC. After 3.5 h an additional 0.9 g of K 2 CO 3 was added and at 5.5 h an additional 0.9 g of K 2 CO 3 and 0.3 g of 3,5-difluorobenzonitrile was added. After 8 h of heating the reaction was cooled to rt and the reaction mixture was filtered through a pad of CELITE® and the solid cake was washed well with EtOAc. The filtrate was washed with 2 portions of 2N HCl, 1N NaOH, water and brine. The organic extract was dried (MgSO 4 ), filtered and evaporated to yield 1.3 g of the ether 35a.
EXAMPLE 10
Ethyl 4-chloro-3-(2,5-dichlorophenoxy)phenylacetate
[0285] [0285]
[0286] A solution of ethyl 4-chloro-3-hydroxyphenylacetate (34a; 2.0 g; 9.3 mmol), 2,5-dichloro-bromobenzene, Cs 2 CO 3 (6.0 g; 18.6 mmol), TMHD (0.38 mL; 1.9 mmol) and NMP (15 mL) was degassed with a stream of nitrogen for 15 m. Cuprous chloride (0.5 g; 4.7 mmol) was added and the solution again was degassed. The reaction mixture was heated to 120° C. for 18 h then cooled to rt. The suspension was filtered through a pad of CELITE® and the solid washed thoroughly with EtOAc. The combined filtrate was washed with 2N HCl, dried (Na 2 SO 4 ) and the solvent evaporated. The product was purified by chromatography on silica gel and eluted with EtOAc:hexane (1:10) to yield 35b (0.554 g; 16%).
EXAMPLE 11
4-Chloro-3-(4-bromophenoxy)toluene
[0287] [0287]
[0288] A solution of 2-chloro-4-methylphenol (36; 3.0 g; 21 mmol), 4-bromobenzeneboronic acid (5.0 g; 24 mmol), cupric acetate (4.2 g; 23.1 mmol), 4 Å molecular sieves and CH 2 Cl 2 (210 mL) was added TEA (9.8 mL; 70 mmol) and the reaction was stirred for 3 days. The reaction mixture was filtered through a pad of CELITE®. The top layer containing the molecular sieves was removed and stirred with CH 2 Cl 2 and refiltered. The combined organic filtrates were washed with 2N HCl, brine, dried (Na 2 SO 4 ), filtered and evaporated. The crude product was chromatographed with silica gel and eluted with a gradient of hexane/EtOAc (100:0→90:10) to yield 37a.
EXAMPLE 12
4-chloro-3-phenoxytoluene
[0289] [0289]
[0290] To a solution of benzeneboronic acid (1.9 g; 15.8 mmol) dissolved in CH 2 Cl 2 (250 mL) was added 2-chloro-5-methylphenol (36; 2.5 g; 17.5 mmol), cupric acetate (3.5 g; 19.3 mmol), TEA ((12.3 mL; 87.7 mmol) and 12.5 g of 4A molecular sieves. The reaction was stirred for 24 h and an additional aliquot of benzeneboronic (2.4 g; 19.3 mmol) was added and stirring continued for an additional 48 hr. The reaction mixture was filtered through a bed of CELITE® and the filtered solids were washed thoroughly with CH 2 Cl 2 . The combined organic extracts were washed with 2N HCl, H 2 O, sat'd NaHCO 3 , H 2 O and brine, dried (MgSO 4 ) filtered and evaporated. The crude product was purified by silica gel chromatography and eluted with hexane:EtOAc (9:1) to yield 37b (1.6 g; 47.1%) as a clear oil.
EXAMPLE 13
4-Chloro-2-fluoro-3-phenoxytoluene
[0291] [0291]
[0292] Step 1
[0293] A solution of 4-chloro-2-fluoro-3-hydroxytoluene (18; 0.161 g; 1.0 mmol), p-fluoronitro-benzene (0.141 g; 1.0 mmol), K 2 CO 3 (0.276 g; 2 mmol) and DMF (4 mL) was heated to reflux for 4 h under a N 2 atmosphere. The reaction was cooled to rt and poured into water and stirred for several minutes. The aqueous solution was extracted twice with CH 2 Cl 2 and the combined organic extracts washed with brine, dried (MgSO 4 ), filtered and evaporated to yield 20.
[0294] Step 2
[0295] A solution of 20 (1.58 g; 5.3 mmol), stannous chloride dihydrate (6.0 g; 26.6 mmol) and EtOH (5 mL) were heated to 70° C. stirred overnight. The reaction mixture was added to a small quantity of ice and made basic with 10% Na 2 CO 3 . The aqueous phase was extracted with EtOAC (5 mL) which resulted in an emulsion. About 7 mL of ethylenediamine was added to chelate tin which resulted in a blue aqueous solution. The EtOAc was washed with water and brine, dried (NaHCO 3 ), filtered and evaporated to yield 1.35 g of 21 which was carried on to the next step.
[0296] Step 3
[0297] A solution of 21 (0.830 g; 3.3 mmol) was dissolved in HOAc (2.25 mL) and added to a solution of ice-water (7.5 mL) and HCl (1.2 mL). A solution of NaNO 2 (0.254 g; 5.6 mmol) and H 2 O (1.5 mL) was added over a 10-15 m period. The resulting solution was stirred for several minutes then added dropwise over 15 m to a suspension of FeSO 4 .7H 2 O (0.917 g; 3.3 mmol) and DMF (10.5 mL). The reaction was stirred for 0.5 h and a mixture of hexanes:EtOAc (1:1; 30 mL) was added. The organic phase was washed thrice with water, dried (MgSO 4 ), filtered and concentrated in vacuo. The dark oil was purified by chromatography on silica gel and eluted with an EtOAc:hexane gradient (0:100→20:80) which yielded 22 as a clear oil (0.450 g; 58%).
EXAMPLE 14
[3-(3-Bromo-5-fluoro-phenoxy)-4-chlorophenyl]acetonitrile (63b)
[0298] [0298]
[0299] Step 1
[0300] Cesium carbonate (11.4 g; 8.79 mmol) was added to a solution of 2-chloro-5-methylphenol (18; 2.5 g; 17.53 mmol) and NMP (16 mL). The resulting slurry was degassed and the flask alternately purged and refilled with nitrogen. 1,3-Dibromo-fluorobenzene (3.54 g; 28.13 mmol), TMHD (0.92 mL; 0.81 g; 4.41 mmol) and Cu(I)Cl (0.87 g; 8.79 mmol) were added sequentially and the reaction mixture was heated to 110° C. for 6 h. The reaction mixture was cooled to ambient temperature, filtered through a bed of CELITE® and the filter cake washed thoroughly with EtOAc. The filtrate was washed sequentially with dilute HCl, dilute NaOH, water and brine. The organic extract was dried (Na 2 SO 4 ), filtered and evaporated. The residue was chromatographed on silica gel and eluted with hexane:Et 2 O which yielded 1.8 g (32%) of 37c as a colorless oil.
[0301] Step 2
[0302] A mixture of 37c (1.8 g; 5.704 mmol), NBS (1.066 g; 5.989 mmol), benzoyl peroxide (0.069 g; 0.28 mmol) and CCl 4 (20 mL) was heated to 90° C. for 2.5 h. The reaction mixture was cooled to room temperature and poured into 100 mL of H 2 O. The mixture was extracted with CH 2 Cl 2 (2×80 mL), dried (Na 2 SO 4 ) and evaporated to yield 63a (2.25 g) as a colorless oil.
[0303] Step 3
[0304] A solution of 63a (2.25 g; 5.704 mmol), NaCN (0.839 g; 17.12 mmol) and 20 mL of 90% aqueous EtOH was stirred at room temperature for 24 h. The solvent was evaporated and the residue partitioned between EtOAc (100 mL) and H 2 O (100 mL). The EtOAc phase was washed with H20 and saturated brine. The organic extracts were dried (Na 2 SO 4 ) and evaporated. The crude product was purified by silica gel chromatography and eluted with a hexane/EtOAc gradient (10:1→6:1) to yield 1.10 g (56.6%) of 63b as a colorless oil.
EXAMPLE 15
[3-(3-Chloro-phenoxy)-4-ethyl-phenyl]-acetic acid ethyl ester
[0305] [0305]
[0306] To a solution of ethyl 4-ethyl-3-hydroxyphenylacetate (4f; 1.0 g; 4.81 mmol), 3-chlorobenzeneboronic acid (1.56 g; 10.1 mmol), cupric acetate (0.96 g; 5.29 mmol), 4A molecular sieves (5 g), and CH 2 Cl 2 (48 mL) was added TEA (3.34 mL; 24.05 mmol) and the reaction was stirred for 4 days. The reaction mixture was filtered through a pad of CELITE®. The top layer containing the molecular sieves was removed and stirred with CH 2 Cl 2 and refiltered. The combined organic filtrates were washed with 2N HCl, brine, dried (Na 2 SO 4 ), filtered and evaporated. The crude product was chromatographed with silica gel and eluted with hexane/EtOAc (90%hexane/EtOAc) to yield 33e (0.38 g; 25%).
EXAMPLE 16
[3-(3-Bromo-phenoxy)-4-chloro-phenyl]-acetonitrile
[0307] [0307]
[0308] To a flask was charged with 3-hydroxy-4-methylphenylacetonitrile (32a; 0.92 g; 6.2 mmol), Cu(OAc) 2 (1.3 g; 6.9 mmol), 3-bromobenzeneboronic acid (1.1 g; 5.5 mmol) and powdered 4 Å molecular sieves, was added CH 2 Cl 2 (62 mL) followed by pyridine (2.5 mL; 31 mmol). The reaction was stirred at rt for 3 days. The suspension was filtered through a bed of CELITE®/silica gel and the solid washed with CH 2 Cl 2 . The combined filtrates were washed sequentially with 2N HCl (2×25 mL), NaHCO 3 (25 mL), water and brine. The extracts were dried (MgSO 4 ), filtered and evaporated. The crude product 76 was sufficiently pure to use in the next step.
EXAMPLE 17
[3-(3-Bromo-phenoxy)-4-fluoro-phenyl]-acetonitrile
[0309] [0309]
[0310] Step 1
[0311] To a solution of 2-fluoro-4-methylphenol (79; 3.0 g; 24 mmol), 3-bromobenzeneboronic acid (5.3 g; 24 mmol), cupric acetate (4.8 g; 23.1 mmol), 4 Å molecular sieves (15 g)and CH 2 Cl 2 (240 mL) was added TEA (17 mL; 120 mmol) and the reaction was stirred for 4 days. The molecular sieves were filtered and washed well with CH 2 Cl 2 . The combined organic filtrates were washed with 2N HCl, brine, 2N NaOH, water and brine, dried (Na 2 SO 4 ), filtered and evaporated. The crude product was chromatographed with silica gel and eluted with hexane:EtOAc (90%hexane:EtOAc) to yield 80 (5.7 g; estimated purity 72%).
[0312] Step 2
[0313] A solution of 80 (4.1 g; 14.6 mmol), NBS (2.6 g; 14.6 mmol), AIBN (0.25 g; 1.50 mmol) and 146 mL of CCl 4 was heated at reflux for 5.0 h, cooled to rt and the precipitated succinimide filtered through a pad of CELITE®. The filtrate was evaporated and the crude product 81a was sufficiently pure to use in the next step.
[0314] The crude bromomethyl compound 81a from the previous step was dissolved in 73 mL of 90% aq. EtOH and 2.5 g of NaCN (49.01 mmol) was added. The reaction mixture was stirred overnight at rt. The solid material was filtered through a pad of CELITE® and the filtrate was evaporated. The crude product purified by silica gel chromatography and eluted with 30% EtOAc:hexane to yield the nitrile 81b (2.4 g; 54%).
EXAMPLE 18
(7-Hydroxy-benzofuran-5-yl)-acetic acid ethyl ester
[0315] [0315]
[0316] Step 1
[0317] To a solution of 28a (5.0 g; 24.2 mmol) and anhydrous CH 2 Cl 2 (75 mL) was added sequentially acetyl chloride ((2.42 mL; 33.9 mmol) and SnCl4 (5.39 mL; 46.1 mmol; 1 M solution in CH 2 Cl 2 ). The reaction was stirred at room temperature for 50 minutes and poured into a mixture of ice and 2 N HCl (200 mL). The organic phase was separated and diluted with about 50 mL of CH 2 Cl 2 and thrice washed with water (100 mL) and once with brine (100 mL). The organic phase was dried (MgSO 4 ), filtered and evaporated to yield 28b (6.0 g) which contained about 10% of 28a. The crude product was used without further purification.
[0318] Step 2
[0319] To an ice-cold solution of 28b (6.01 g; 24.2 mmol) and CH 2 Cl 2 (100 mL) under a nitrogen atmosphere was added sequentially a solution of MCPBA (11.9 g; 48.4 mmol) and CH 2 Cl 2 (12 mL) followed by TFA (2.14 mL; 27.8 mmol). The reaction mixture was stirred at rt overnight. The reaction mixture was cooled to 0° C. and a 5% aqueous Na 2 SO 3 solution (150 mL) was added slowly with stirring. The mixture was stirred for 5 minutes after addition was completed and precipitated m-chlorobenzoic acid was filtered. The solid was with CH 2 Cl 2 and the combined filtrates were washed with 10% NaOH (2×250 mL), 2 N HCl (200 mL), water and brine. The resulting solution was dried (MgSO 4 ), filtered through a pad of CELITE and concentrated in vacuo to yield 28c (4.1 g).
[0320] Step 3
[0321] To a solution of dihydrofuran derivative 28c (14.6 g; 0.0553 mol) and CC1 4 (500 mL) was added NBS (10.3 g; 0.0580 mol) and AIBN (1.4 g). The reaction was heated to reflux for 30 minutes under a nitrogen atmosphere. The reaction was cooled, the solid succinimide filtered, and the organic phase was washed with 0.5 M NaHSO 4 (150 mL) and brine. The product was dried (Na2SO4), filtered and evaporated to yield 15.2 g of a yellow syrup. The crude product was purified by silica gel chromatography and eluted with a EtOAc:hexane gradient (3:97→10:90) to yield 10.3 g (78.1%) of 30.
[0322] Step 4
[0323] A solution of 30 (10.3 g; 39.3 mmol), EtOH (250 mL) and saturated NaHCO 3 (100 mL) were heated to reflux for 1 h. The reaction mixture was cooled to room temperature and the EtOH removed in vacuo. Ice was added to the residue aqueous solution and the reaction carefully acidified to about pH 2 with 2 N HCl. The resulting mixture was extracted with EtOAc (2×300 mL) and the combined organic phase washed with brine, dried (NaSO 4 ), filtered and evaporated to yield a brown oil (8.8 g). The crude product was run through a silica gel column with 15% EtOAc:hexane to yield 31 (5.44 g; 62.9%) as a white solid.
EXAMPLE 19
5-(4-Chloro-3-phenoxy-benzyl)-3H-[1,3,4]oxadiazol-2-one (49)
[0324] [0324]
[0325] To a solution of ester 46a (517 mg, 2.03 mmol) dissolved in EtOH (10 mL) was added hydrazine hydrate (1.3 mL of an 85% solution) was and the mixture was heated to reflux overnight. The volatile materials were removed, and the residual material was dissolved in EtOAc (50 mL). The solution was washed with brine (20 mL) and dried (MgSO 4 ), filtered, and the volatile materials were evaporated to provide the desired acyl hydrazine 46b (460 mg, 82%) as a white solid. An oven dried 100 mL flask was charged with the 46b (152 mg, 0.55 mmol) and flushed with nitrogen. CH 2 Cl 2 (6 mL) and pyridine (45 μL, 0.55 mmol) were added, and the solution was stirred for 1 min. A solution of phosgene in methylene chloride (570 μL, 1.93 M, 1.098 mmol) was added dropwise via syringe, and the reaction was stirred for 10 m. Water (15 mL) and CH 2 Cl 2 (10 mL) were added to the reaction mixture, the layers were separated, and the organic layer was washed with water (10 mL) and brine (10 mL). The solution was dried with anhydrous Na 2 SO 4 , the solution was filtered, and the volatile materials were evaporated to provide 27 (168 mg, 100%; ms (El): (M + )=302).
EXAMPLE 20
5-[4-Chloro-3-(2-chloro-phenoxy)-benzyl]-3 H-[1,3,4]thiadiazol-2-one (31)
[0326] [0326]
[0327] HCl was bubbled through the ice cold solution of nitrile 50 (210 mg, 0.76 mmol) toluene (5 mL) and ethanol (49 μL, 0.87 mmol) for 10 min. The resulting mixture was stored in a sealed flask at 3° C. overnight. Ethyl ether was added to the reaction mixture, and the imidate ester 51 (209 mg) was collected as a white solid by filtration. This material was added in 3 portions to a suspension of hydrazinecarbothioic acid O-methyl ester (55 mg, 0.52 mmol) (Mattes, R. et al. Chem. Ber. 1980 113:1981-88) in anhydrous dioxane (3 mL). The heterogeneous reaction mixture was stirred at rt for 4 h, and then heated to reflux overnight. The reaction was then cooled to rt, and the solvent was removed by evaporation. Chilled water (20 mL) was added, and the mixture was thrice extracted CH 2 Cl 2 (20 mL). The organic layer was washed with water (20 mL), brine (20 mL), and dried over sodium sulfate. The solution was filtered, and the solvent was evaporated. Purification of the remaining material by flash chromatography (eluent: 25% to 50% ethyl acetate: hexanes) provided the desired methoxythiadiazole 52. A solution of 52, THF (3 mL) and con HCl (1 mL) was stirred overnight. The solution was stirred overnight, ether (20 mL) was added, and the layers were separated. The organic layer was washed with water (10 mL), brine (10 mL), dried (MgSO 4 ). The solvent d was evaporated, and the remaining material was purified by silica gel flash chromatography (10%-25% EtOAc:hexanes) to provide 76 mg of 53 (38% from imidate ester; ms (EI): (M + )=353).
EXAMPLE 21
5-[4-Chloro-3-(2-chloro-phenoxy)-benzyl]-4-methyl-2,4-dihydro-[1,2,4]triazol-3-one (48)
[0328] [0328]
[0329] To a solution of ester 46c (219 mg, 0.67 mmol) and EtOH (10 mL) was added hydrazine hydrate (1.2 mL; 85% aqueous solution) and the solution was heated to reflux for 4 h. The volatile materials were removed, and the remaining material was dissolved in EtOAc (50 mL). The solution was washed with water (20 mL), brine (20 mL), and dried (MgSO 4 ). The solution was filtered, and the volatile materials were evaporated to provide acyl hydrazine 46d (200 mg, 96%) as a white solid. To a solution of 46d (96 mg, 0.31 mmol) and anhydrous THF (4 mL) under a N 2 atmosphere was added ethyl isocyanate (40 μL, 0.50 mmol) and the mixture was stirred overnight. The volatile materials were evaporated, and the resulting diacylhydrazone 47 dissolved in methanol (4 mL). Potassium hydroxide (173 mg, 3.1 mmol) was added, and the mixture was heated to reflux for 2 days. CH 2 Cl 2 (20 mL) and water (10 mL) were added, and the aqueous layer was acidified with 10% HCl. The layers were separated, and the aqueous layer was extracted twice with CH 2 Cl 2 (20 mL). The combined organic layers were washed with water (10 mL), brine (10 mL), and dried (Na 2 SO 4 ). The solution was filtered, the volatile materials evaporated, and the residue was purified by silica gel column chromatography and eluted with EtOAc to provide 48 (54 mg, 48% from acylhydrazine 47; ms: 364 (M+H) + ).
EXAMPLE 22
HIV Reverse Transcriptase Assay: Inhibitor IC 50 determination
[0330] HIV-1 RT assay was carried out in 96-well Millipore MultiScreen MADVNOB50 plates using purified recombinant enzyme and a poly(rA)/oligo(dT) 16 template-primer in a total volume of 50 μL. The assay constituents were 50 mM Tris/HCl, 50 mM NaCl, 1 mM EDTA, 6 mM MgCl 2 , 5 μM dTTP, 0.15 μCi [ 3 H] dTTP, 5 μg/ml poly (rA) pre annealed to 2.5 μg/ml oligo (dT) 16 and a range of inhibitor concentrations in a final concentration of 10% DMSO. Reactions were initiated by adding 4 nM HIV-1 RT and after incubation at 37° C. for 30 min, they were stopped by the addition of 50 pi ice cold 20%TCA and allowed to precipitate at 4° C. for 30 min. The precipitates were collected by applying vacuum to the plate and sequentially washing with 3×200 μl of 10% TCA and 2×200 μl 70% ethanol. Finally, the plates were dried and radioactivity counted in a Packard TopCounter after the addition of 25 μl scintillation fluid per well. IC 50's were calculated by plotting % inhibition versus logio inhibitor concentrations.
TABLE 2 RT inhibition Compound # IC 50 (μM) 4 0.19515 8 0.2865 9 0.4437 7 0.4473
EXAMPLE 23
Pharmaceutical Compositions
Composition for Oral Administration
[0331] [0331] Ingredient % wt./wt. Active ingredient 20.0% Lactose 79.5% Magnesium stearate 0.5%
[0332] The ingredients are mixed and dispensed into capsules containing about 100 mg each; one capsule would approximate a total daily dosage.
Composition for Oral Administration
[0333] [0333] Ingredient % wt./wt. Active ingredient 20.0% Magnesium stearate 0.5% Crosscarmellose sodium 2.0% Lactose 76.5% PVP (polyvinylpyrrolidine) 1.0%
[0334] The ingredients are combined and granulated using a solvent such as methanol. The formulation is then dried and formed into tablets (containing about 20 mg of active compound) with an appropriate tablet machine.
Composition for Oral Administration
[0335] [0335] Ingredient Amount Active compound 1.0 g Fumaric acid 0.5 g Sodium chloride 2.0 g Methyl paraben 0.15 g Propyl paraben 0.05 g Granulated sugar 25.5 g Sorbitol (70% solution) 12.85 g Veegum K (Vanderbilt Co.) 1.0 g Flavoring 0.035 ml Colorings 0.5 mg Distilled water q.s. to 100 ml
[0336] The ingredients are mixed to form a suspension for oral administration.
Parenteral Formulation (IV)
[0337] [0337] Ingredient % wt./wt. Active ingredient 0.25 g Sodium Chloride qs to make isotonic Water for injection to 100 ml
[0338] The active ingredient is dissolved in a portion of the water for injection. A sufficient quantity of sodium chloride is then added with stirring to make the solution isotonic. The solution is made up to weight with the remainder of the water for injection, filtered through a 0.2 micron membrane filter and packaged under sterile conditions.
Ingredient % wt./wt. Active ingredient 1.0% Polyethylene glycol 1000 74.5% Polyethylene glycol 4000 24.5%
[0339] The ingredients are melted together and mixed on a steam bath, and poured into molds containing 2.5 g total weight.
Topical Formulation
[0340] [0340] Ingredients grams Active compound 0.2-2 Span 60 2 Tween 60 2 Mineral oil 5 Petrolatum 10 Methyl paraben 0.15 Propyl paraben 0.05 BHA (butylated hydroxy anisole) 0.01 Water q.s. 100
[0341] All of the ingredients, except water, are combined and heated to about 60° C. with stirring. A sufficient quantity of water at about 60° C. is then added with vigorous stirring to emulsify the ingredients, and water then added q.s. about 100 g.
Nasal Spray Formulations
[0342] Several aqueous suspensions containing from about 0.025-0.5 percent active compound are prepared as nasal spray formulations. The formulations optionally contain inactive ingredients such as, for example, microcrystalline cellulose, sodium carboxymethylcellulose, dextrose, and the like. Hydrochloric acid may be added to adjust pH. The nasal spray formulations may be delivered via a nasal spray metered pump typically delivering about 50-100 microliters of formulation per actuation. A typical dosing schedule is 2-4 sprays every 4-12 hours.
[0343] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof.
[0344] The foregoing invention has been described in some detail by way of illustration and example, for purposes of clarity and understanding. It will be obvious to one of skill in the art that changes and modifications may be practiced within the scope of the appended claims. Therefore, it is to be understood that the above description is intended to be illustrative and not restrictive. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the following appended claims, along with the full scope of equivalents to which such claims are entitled.
[0345] All patents, patent applications and publications cited in this application are hereby incorporated by reference in their entirety for all purposes to the same extent as if each individual patent, patent application or publication were so individually denoted. | This invention relates to novel heterocyclic compounds of formula I wherein R 1 —R 4 , X 1 and X 2 are as defined in the summary and pharmaceutically acceptable salts and solvates thereof, methods to inhibit or modulate Human Immunodeficiency Virus (HIV) reverse transcriptase with compounds of formula I, pharmaceutical compositions containing of formula I admixed with at least one solvent, carrier or excipient and processes to prepare compounds of formula I. The compounds are useful for treating disorders in which HIV and genetically related viruses are implicated | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to sewing machines and more particularly is directed to feed controlling mechanism for sewing machines.
2. Description of the Prior Art
Sewing machines are conventionally provided with mechanism for moving a feed dog through work feeding and return strokes, and for imparting relative vertical movement to the feed dog and throat plate of the machine so as to expose the feed dog during feeding strokes above the throat plate. It is also known to provide a sewing machine with stitch regulating means enabling an operator to vary the length of the feed stroke to be imparted to the feed dog during its operation. One example of a machine so equipped is shown and described in U.S. Pat. No. 3,420,200 of R. E. Johnson for Modular Sewing Machines issued Jan. 7, 1969.
SUMMARY OF THE INVENTION
In accordance with the invention, feed advancing mechanism, feed lifting mechanism and a stitch regulator are interconnected in an improved manner enabling an operator to simultaneously adjust the timing of the operation of the feed advancing and the feed lifting mechanisms when selecting a stitch length with the stitch regulator. The feed advancing mechanism, feed lifting mechanism and stitch regulator are interconnected through a single eccentric, and the resulting construction is less expensive as well as less subject to vibration than prior art feed control means such as the feed control means of the aforementioned U.S. Patent and other known control means including a stitch regulator in association with a rotatable constant breadth cam and yoke which is operably connected to a feed dog.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a sewing machine according to the invention;
FIG. 2 is a right hand elevational view of the sewing machine of FIG. 1 with the hand wheel removed;
FIG. 3 is a rear elevational view of the sewing machine of FIG. 1;
FIGS. 4A, 5A, 6A, and 7A are fragmentary right hand elevational views illustrating the operation of the stitch regulator and associated mechanism of the sewing machine of FIG. 1;
FIGS. 4B, 5B, 6B, and 7B are fragmentary side elevational views partially in section illustrating the relative locations of a feed dog and throat plate for positions of the stitch regulator and associated mechanism illustrated in FIGS. 4A, 5A, 6A and 7A respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and in particular to FIGS. 1, 2 and 3, reference character 10 designates a C-shaped frame including a pair of substantially parallel extremities 12 and 14 joined by a connecting portion 16. The lower extremity 14 is secured by a set screw 18 within the channel 20 of a block 22 that is fixedly mounted on a platform 24, and the upper extremity 12 is secured to a plate 26 which is in turn affixed to a support plate 28 of a needle module 30. Connecting portion 16 of the frame is secured to the support plate 32 of a control module 34.
A yoke 36 is secured by screws 38 and 40 to support plate 28 at a distance therefrom established by spacers 42 and 44. A bracket 46 is also secured to plate 28 at 48 and 49. A needle bar gate 50 located between the bracket 46 and a flanged portion 51 of yoke 36 slidably supports a needle bar 52. The needle bar extends through bearings in the gate 50 and holes in both the flanged portion 51 of yoke 36 and in bracket 46. As shown the needle bar includes at its lower extremity a needle bar clamp 54 in which an eye-pointed thread carrying sewing machine needle 55 is secured. The needle bar 52 is secured to a fitting 56 having one end of stud shaft 58 pivotally mounted therein; the other end of the stud shaft being slidable in a slot 60 in support plate 28. The stud shaft 58 is affixed to one end 62 of a link 64 having its other end 66 pivotally mounted at 68 to a crank 70. A thread take-up arm 71 is integral with the crank connected end 66 of link 64.
An arm shaft 72 having a balancing counterweight 74 thereon connects at one end with the crank 70 and at its other end with a hand wheel 76 which is formed with annular belt grooves 78 and 80. The belt groove 78 accommodates a drive belt 82 from a suitable source of power (not shown) such as a drive pulley on an electric motor which may be supported on plate 32. Rotation of the hand wheel upon the application of power to the drive belt 82 results in the rotation of arm shaft 72 and the crank 70 which in turn acts through link 64, stud shaft 58 and fitting 56 to produce reciprocating motion of the needle bar 52 and the needle 55 attached thereto.
A rotary loop taker 84 is provided to cooperate with needle 55 in the formation of stitches. Such loop taker, which may be of any known or conventional type suitable for the formation of either chain or lock stitches, is carried in a frame 86 which is secured by screws 88 to a plate 90 that is affixed at 91 to the lower extremity 14 of frame 10. A driving connection extends to the loop taker 84 from hand wheel 76 and includes a belt 92 engaged both in groove 80 in wheel 76 and a groove 93 in a wheel 94 on a shaft 96. Rotation of hand wheel 76 causes the belt 92 to drive wheel 94 and the shaft 96 which acts through a gear 98 on the shaft and a meshing gear 100 to drive the loop taker.
In accordance with the invention arm shaft 72 is provided with a single eccentric 102. Such eccentric rotates with the arm shaft within the surrounding housing 104 of a pitman 106 having an arm 108 pivotally connected at 110 to a link associated with feed lifting mechanism, and an arm 114 pivotally connected through a stub shaft 116 to another link 118 associated with feed advancing mechanism. The feed lifting mechanism includes in addition to the link 112, other links 120 and 122, and a throat plate 124; and the feed advancing mechanism includes in addition to the link 118, another link 126, a shaft 128 and a feed dog arm 130. The stub shaft 116 pivotally connecting arm 114 of pitman 106 to link 118 includes a slotted boss 132 at one end slidably mounted on the flange 134 of a stitch regulator 136 which is pivotally mounted in plate 32 and which can be selectively positioned by an operator with handle 138.
Rotation of eccentric 102 by handwheel 76 results in boss 132 and the axis of stub shaft 116 being moved to and fro along flange 134 of stitch regulator 136. Arm 114 of pitman 106 acts through link 118 causing link 126 to be pivoted reciprocally through an angle dependent upon the position of the stitch regulator 136. Link 126 moves shaft 128, and the shaft reciprocates link 130 and a feed dog 140 which floats on the link and is maintained horizontal by engagement with a plate 141 secured to frame 86.
As the eccentric 102 rotates, link 112 and the link 120 which is affixed to link 112 are moved up and down and pivotally above a grooved pin 142 secured to plate 32. A spring 144 having one end connected to an arm 146 of link 120 and the other end connected to a link 122 holds one end of the link 122 against an abutment 148 on link 120. The other end of link 122 pivotally connects at 150 with a vertically slidable post 152 having its upper end secured to throat plate 124. Between its ends, link 122 is secured to a pin 154 which is maintained in contact with a bracket 156 by a spring 158 that bears against link 122. As links 112 and 120 are moved by the operation of eccentric 102 link 122 is caused to rock on pin 154 and throat plate 124 is vertically reciprocated by post 152. The throat plate includes slots 160 in alignment with feed dog teeth 162 which alternately appear above and below the planar surface 164 of the throat plate as the throat plate rises and falls.
Each revolution of shaft 72 and therefore of eccentric 102 results in a complete cyclic movement of feed dog 140, throat plate 124, needle bar 52 and thread takeup 71, such operations being relatively phased for trouble free sewing by means of a suitable arrangement and proportionment of the driving parts. The horizontal distance through which the feed dog 140 is caused to move and the length of stitch produced as a result is predetermined by an operator setting stitch regulator 136 in a selected position with handle 138.
In FIGS. 4A and 5A the stitch regulator is shown in a position resulting in a long stitch. The eccentric 102 in FIG. 4A is in the position corresponding to one extreme position (FIG. 4B position) of feed dog 140 for the long stitch, and in FIG. 5A is in the position corresponding to the other extreme position (FIG. 5B position) of the feed dog for such stitch. In FIGS. 6A and 7A the stitch rgulator is shown in a position for producing a shorter stitch. The eccentric positions in FIGS. 6A and 7A correspond to the extreme positions of the feed dog (FIGS. 6B and 7B respectively) for the shorter stitch.
When the stitch regulator 136 is moved as between the 4A and 6A positions to change stitch length it moves the pitman 106 with respect to the eccentric 102 to simultaneously alter the timing of the operation of the feed dog and throat plate with respect to rotation of the eccentric thereby enabling the feed dog teeth 162 to be maintained above the planar surface of the throat plate throughout movements of the feed dog in the forward feeding direction (indicated in FIG. 4B) regardless of the selected stitch length. If the stitch regulator 136 is positioned to reverse the slope of flange 134, the feed dog teeth are caused to appear above the throat plate during reverse movements of the feed dog thereby enabling reverse stitching to be performed on the machine. Stitch length is determined according to the reversed position of the stitch regulator and the interconnection through the eccentric 102 between the feed advancing and feed lifting mechanisms maintains the feed dog teeth above the throat plate throughout reverse feed regardless of the chosen stitch length.
Although a preferred embodiment of the invention has been shown and described it is to be understood that other embodiments are possible and that various changes and modifications may be made by one skilled in the art in the construction herein set forth without departing from the spirit and scope of the invention as set forth in the annexed claims. | A sewing machine is provided with a stitch regulator and mechanism operably connecting such stitch regulator with feed advancing and feed lifting mechanism enabling an operator when adjusting the stitch regulator to simultaneously alter the timing of the operation of both the feed advancing and feed lifting mechanisms and so maintain a desired phase relationship between them. | 3 |
BACKGROUND OF THE INVENTION
The present invention is broadly concerned with an improved slotter head assembly of the type used in box-making equipment for forming flap-defining slots in box blanks. More particularly, it is concerned with such a slotter head assembly which is improved by provision of a uniquely shaped, pressurized, fluid-actuated bladder mechanism which is received by and cooperates with a head recess having an internal surface cross-sectional shape closely resembling that of the outer bladder surface. The improved bladder mechanism cooperates with the head assembly for selectively locking the slotter blade knives in position, while permitting ready adjustment of the knife positions. In this fashion, the box blank slotting equipment can be readily altered to produce blanks of different configurations without the need for time-consuming manual knife adjustments. In preferred forms, the pressurized, fluid-actuated mechanism includes an elongated, pneumatic bladder positioned adjacent the corresponding knife blades and operable upon pressurizing the bladder to engage and lock the knives in place.
The manufacture of box blanks on an industrial scale normally involves slotting and creasing of precut corrugated sections in order to create a blank having the requisite fold lines and flaps for a given box. Normally, the slotting equipment used for this purpose includes an elongated shaft carrying a plurality of annular, rotatable slotter heads. Normally, a pair of slotting knives are secured to each head for rotation therewith. The circumferential spacing of the slotter knives thus determines the depth of the flap-defining slots for a given blank.
A persistent problem in the box-making industry stems from -the time and effort required to change the position of slotting knives on the individual slotting heads. That is to say, after a given box blank run is completed, it is often necessary to change the circumferential location of the knives in order to produce in the next run blanks of different configuration. Generally speaking, prior art slotter heads are equipped with a series of threaded bores, in the sidewall thereof, for attachment of the slotted knives by means of bolts. When it is necessary to change the location of one or more of the knives, it is necessary to remove the knife-retaining bolts, relocate the knife to a desired position, and reinstall the bolts. This practice can be relatively time-consuming, especially when it is considered that a number of heads need to be changed for each run. Moreover, the slotter heads are located within large blank-forming equipment, and it is sometimes difficult to gain access to the heads for knife changeover.
U.S. Pat. No. 5,174,184 (incorporated by reference herein) describes a slotter head assembly having pneumatically-locked slotter blades especially designed to allow for quick knife adjustment without the need for removing and reinstalling bolts or other mechanical fasteners. In the '184 patent, quick knife adjustment of the knife assembly is provided by means of a head presenting a knife-receiving slot in the periphery thereof, with one or more knives being adjustably positioned within the slot. Structure is provided for releasably locking the knives within the slot, including a pressurized fluid-actuated bladder mechanism adjacent a slot for selectively engaging and locking the knives in place.
In the preferred form disclosed in the '184 patent, the head is in the form of an annular, rotatable body having an elongated slot in the periphery thereof, permitting placement of one or more knives at any one of a number of positions around the slot. The knife-locking mechanism advantageously includes structure defining a fluid-receiving cavity and means for permitting selective filling of the cavity with pressurized fluid and for selectively draining pressurized fluid therefrom. Filling the cavity creates a locking action on the knives, while fluid drainage releases the knives. One or more elongated, pneumatic bladders formed of resilient synthetic material are provided within the rotatable head and conventional valve means is coupled with each bladder to permit selective inflation thereof with pressurized air, or, alternatively, deflation thereof. One or more shiftable plates are provided adjacent the bladders and are moveable laterally to a limited degree in response to filling or draining of the bladders. The shiftable plates are oriented for engaging the knives so that, upon inflation of the appropriate bladders, the corresponding knives are rigidly locked in place along the knife-receiving slot of the head. When it is desired to change the knife position, it is only necessary to partially or completely deflate the corresponding bladders, whereupon the knives can be manually moved to the next position and re-locked by re-inflation of the bladders.
In experimental practice with the apparatus described in the '184 patent, it has been determined that the elongated, pneumatic bladders may initially undergo radial expansion into the bladder recess excess void spaces in locations non-adjacent to the shiftable plates before locking action is imposed on the knives. Under such circumstances, the result may be that undesirable higher fluid pressure in the bladder is necessary to effect knife-locking action. Higher pressures in the bladder is undesirable because it either leads to a higher incidence of bladder failure for a given material of construction or requires that bladders be fabricated from more costly materials.
Accordingly, there is a real and unsatisfied need in the art for a simplified slotter head and knife arrangement which incorporates a pneumatic bladder assembly that achieves knife-locking action with a lower fluid pressure.
SUMMARY OF THE INVENTION
The present invention overcomes the problems outlined above, and provides a pneumatic bladder assembly in the form of a bladder and head recess having a half-round, cross-sectional shape. A head recess is adapted to receive the bladder so that the half-round portion of the bladder is in registry with the recess inner wall.
Broadly speaking, an article of the present invention is of a type which includes the knife assembly such as that disclosed in U.S. Pat. No. 5,174,184 as previously described. A description of the apparatus disclosed in the '184 patent appears above and will not be repeated here for the sake of brevity. The '184 patent, however, can be consulted for additional necessary details.
The bladder when received in the recesses is adapted so that there is only a small, generally uniform clearance between the outer lateral surface and the recess interior sidewall when the bladder is in its non-pressurized, deflated condition. The clearance between the bladder outer surface and recess sidewall is only large enough to permit movement of knives when the bladder is depressurized. The bladder assembly of the instant invention eliminates excess void space between the bladder and recess sidewall into which the bladder would otherwise expand when it is pressurized. As a result, the bladder /f the instant invention is capable of engaging and locking a knife in place within the head at pressures lower than would be required if excess void spaces existed between the bladder surface and recess sidewall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the side view of a slotter head in accordance with the invention, with the improved bladder of the assembly being shown in phantom;
FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1 and illustrating the head bladders in their relaxed positions, permitting circumferential adjustment of the knives;
FIG. 3 is an enlarged, sectional fragmentary view illustrating the head bladder in an inflated, operative position serving to lock a knife blade in place;
FIG. 4 is an enlarged, side elevational view of the improved bladder of the present invention;
FIG. 5 is a partial fragmentary, cross-sectional, enlarged top view of the improved bladder;
FIG. 6 is a partial fragmentary, cross-sectional view of the bladder inflation/deflation valve taken along the line 6--6 of FIG. 5;
FIG. 7 is a fragmentary, cross-sectional view of the improved head showing the head recess lateral opening; and
FIG. 8 is a perspective view of a knife-retaining tip adjacent the inner surface thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings, and particularly FIGS. 1-3, a slotter head assembly 120 is illustrated, as it would appear when mounted upon a rotatable shaft 122. The overall apparatus is of the type described in U.S. Pat. No. 5,174,184 (incorporated by reference), which can be consulted for all necessary details. The head assembly 120 includes an annular main body 124, at least one knife 126 carried by the body 124, and mechanism broadly referred to by the numeral 128 carried by the body 124 and operable for selectively engaging and locking the knives 126 in place.
The radially outermost section of body 124 includes an elongated, continuous recess 134 which extends circumferentially about the main body and presents an internal sidewall 136, which is preferentially generally U-shaped in cross-section, as shown in FIG. 7. Sidewall section 136 includes a center portion 137, and opposite inboard and outboard wall portions 138, 139. Recess 134 thus presents an elongated, continuous lateral opening 141 as shown in FIG. 7. It will further be observed that the walls 138, 139 are provided with short, radially and circumferentially extending keeper slots 142, 144, just inboard of the lateral opening 141.
The outer peripheral surface 131 includes a series of scale markings (not shown), the purpose of which will be described.
Referring to FIG. 1, recess 134 has an elongated bladder-receiving zone 152, as well as longer bladder-receiving zones 154 and 156. Each bladder-receiving zone 152-156 is provided with an inflation/deflation valve access aperture 152a-156a, as shown in FIGS. 1 and 2, which extends through center portion 137 of recess 134 and laterally through body 124.
A total of four arcuate, apertured, stationary backing plates 158, each extending essentially 90° about the circumference of body 124, are affixed to the latter, as best shown in FIG. 2, by means of bolts 160 extending into threaded bores 161 in the body. Each backing plate 158 includes an arcuate knife-retaining slot 162 on the inner face thereof. Furthermore, the backing plates 158 abut a shoulder region 164 of main body 124, thereby defining between the inner surfaces 166 of the backing plates 158, and the opposed recess-defining structure, a continuous knife-receiving slot 168 extending circumferentially about the periphery of main body 124.
In the illustrated embodiment, a pair of cutting knives 126 are provided. One of the knives includes a tip 170 as is conventional in equipment of this type, and is in practice normally positioned at the zero or reference point of the head and not thereafter moved. The remaining knife 126 is normally shifted circumferentially relative to the tip knife in order to alter the length of slots cut using the head. The knives 126 are themselves conventional, except that they are each provided with elongated, integral, outwardly extending retaining pins 172 (as shown in FIG. 8) adapted to be received within the knife retaining slots 162 of the backing plates 158.
The locking mechanism 128 associated with head assembly 120 includes a total of three improved, elongated pneumatic bladders 174, 176, and 178 in accordance with the present invention. As illustrated, the bladder 174 is located within zone 152 and is relatively short. On the other hand, bladder 176 is located within zone 154 and extends approximately 120° about the circumference of the head. Finally, bladder 178 is located within zone 156 and extends a full 180° about the head.
Each of the bladders 174-178 is similarly configured, differing from one another only in axial length. Thus, for the sake of brevity, only bladder 174 will be described in detail, it being understood that bladders 176 and 178 include substantially identical structure and operate in substantially the same way.
Referring to FIGS. 4 and 5, bladder 174 is preferentially made from a resilient, synthetic resin or rubber-like material and is U-shaped in a cross-section, having first and second opposite ends 179, 180. Bladder 174 presents a locking plate engaging face 181 and a U-shaped outer surface 182 extending continuously between the first and second ends 179, 180. An enlarged, solid, U-shaped bladder portion 183 is associated with first end 179 and includes a conventional inflation/deflation valve 184 extending outwardly therefrom, as shown in FIGS. 4 and 5. Valve 184 is adapted to communicate with inner fluid cavity 185. Fluid cavity 185 extends generally uniformly between first and second ends 179, 180 and includes inner cavity surface 185a which is also U-shaped in a cross-section. Fluid cavity 185 is adapted to selectively receive, contain, and release fluid under pressure.
Bladder 174 is received within recess 134 associated with zone 152, with valve 184 extending through recess center portion 137 and partially through valve access aperture 152a, as shown in FIG. 2. Enlarged portion 183 is snugly received by and in registry with a corresponding portion of recess sidewall 136. As shown in FIG. 2, bladder 174 is sized so that there is only a small, generally uniform clearance between outer bladder surface 182 and recess sidewall 136 when bladder 174 is in its non-pressurized, deflated condition. It will be appreciated that the clearance between sidewall 136 and outer bladder surface 182 is only large enough to permit movement of knives 126, as later described in detail, when the bladder is depressurized. It will be further appreciated that there is no excess void space between recess sidewall 136 and outer bladder surface 182 into which bladder 174 will first expand before bladder 174 can exert sufficient force to lock knives 126 in place. Such excess void spaces would, for example, exist between a bladder with a round outer surface positioned within a recess having a square interior surface in a cross-sectional view.
U-shaped bladder outer surface 182 is adapted to undergo only slight and generally uniform radial expansion such that the small clearance between surface 182 and sidewall 136 is completely eliminated. Thereafter, exertion of higher pressure within the bladder 174 results in the movement of locking plate engaging face 181 in an outward, lateral direction.
The mechanism 128 further includes a total of six laterally shiftable knife-locking plates 188 which are located within the lateral opening 141 and cooperatively fill the latter, being placed in end-to-end adjacency for this purpose. Referring to FIG. 2, each of the locking plates 188 is arcuate in configuration and includes outer and inner projections 198, 200 respectively situated within the keeper slots 142, 144. In this fashion, the individual locking plates 188 can move laterally within the opening 141 to a limited degree. Each locking plate 188 also presents a substantially planar knife-engaging surface 202, as well as an opposed, inner, arcuate bladder-engaging surface 204 adapted to be in abutting relationship with locking plate engaging face 181 of bladder 174, as well as with corresponding faces of bladders 176 and 178.
Head assembly 120 of the present invention differs from that shown in the '184 patent in that assembly 120 is also provided with an outer wear ring 229 and an inner wear ring 230, both preferentially fabricated from a metal such as hardened steel. Inner wear ring 230 is annular in configuration and has an innermost keyway 232 adapted to receive a locking key 233 associated with shaft 122. As best seen in FIG. 2, inner wear ring 230 is slidably received by shaft 122 and is disposed between body 124 and shaft 122. Wear ring 230 is secured to body 124 by means of conventional threaded fasteners 230a. Outer wear ring 229 is disposed on and fastened by conventional threaded fasteners (not shown) to the outer peripheral surface 131 presented by body 124. Inner and outer wear rings 230, 229 are positioned at principal wear surfaces and are adapted to be fabricated at low cost; thus, reducing wear upon and the need to replace body 124 which is more costly to fabricate. Rotational motion associated with shaft 122, thus, is transmitted from shaft 122 through key 233, keyway 232 of inner wear ring 230, to body 124.
The use and operation of assembly 120 will next be described. It will be assumed that the knives 126 forming a part of the head assembly are properly positioned for a given blank-forming run. Specifically, the tip knife is properly located at the zero or reference point of the head, and bladders 174-178 are fully inflated. Likewise, the shiftable blade is positioned as desired using head markings (not shown). As previously discussed, the operational characteristics of bladders 174-178 are identical, and thus only the operation of bladder 174 will be discussed.
When bladder 174 is pressurized by means of passing pressurized air through valve 184, outer surface 182 immediately expands radially into the small clearance between outer surface 182 and sidewall 136 and face 181 moves laterally into abutment with inner bladder engaging surface 204. It will be understood by one skilled in the art that when such clearances are eliminated between sidewall 136 and bladder surface 182, continued pressurization of bladder 174 results in the application of force by bladder 174, through locking plate 188 upon knife 126, to engage and lock the latter in place.
Experience has shown that use of the improved bladder 174 of the instant invention in the head assembly 120 requires a cavity pressure less than that required by the bladder disclosed in U.S. Pat. No. 5,174,184 to effect the selective engaging and locking of knives. It will be appreciated that such lower pressure requirements are afforded by the unique bladder design of the instant invention, i.e., because of the close correspondence between the general U-shape of bladder 174 and the U-shape of recess 134, which reduces excess void space between these elements. With such excess void spaces eliminated, bladder 174 of the instant invention avoids unnecessary and undesired radial expansion, and results in a more effective locking operation at lower bladder pressures. It is to be appreciated that the bladder of the instant invention also undergoes less undesirable axial expansion within bladder zones 152-156.
At the end of the blank run, if it is desired to alter the position of the movable blade 126, it is only necessary to deflate bladder 174 through the use of valve 184, until the bladder assumes the relaxed position illustrated in FIG. 2. At that point it is a simple matter to manually shift the movable blade along the periphery of the head assembly while the blade is retained within the slot 168. Complete removal of the blade at this time is prevented, inasmuch as the blade pins 172 are located within the slots 162 of the backing plates 158. Once the movable blade has been positioned to a new desired position, the bladder 178 is re-inflated with pressurized air, again using the valve 184. It will be appreciated that inflation of the bladder 174 serves to laterally shift the associated locking plates 188 rightwardly as viewed in FIG. 3, so that the appropriate blade-engaging surfaces 202 thereof firmly contact the movable knife and press it against the adjacent backing plate 158. This serves to firmly lock the knife 126 in place.
Of course, in the event that it is desired to shift the movable knife 126 to a location adjacent the bladder 174, the latter would be deflated to permit such movement, and then re-inflated.
As indicated previously, in normal practice, the tip knife 126 would not be moved inasmuch as it defines the zero or reference position for the head assembly 120. Nevertheless, if movement of this knife is desired, such would be effected in a manner described above.
The knives 126 are retained within the slot 168 during high speed rotation of head assembly 120, even in the event that one or more of the bladders unintentionally deflates. This retention is afforded by means of the knife pins 172 and the complemental receiving slots 162 of the backing plates 158. Of course, use of this retention structure requires that the backing plates 158 be removed when it is desired to completely disassemble the head assembly 120 and remove the knives 126 therefrom. However, this need be done only periodically, and therefore does not present a significant drawback. | Improved bladders (174-178) having a cross-sectional U-shape are provided for a rotatable slotter head assembly (120) of the type used in the slotting of box blanks is provided which includes mechanism (128) permitting rapid and easy alteration of the circumferential position of the cutting knives (126) carried by the assembly (120). Preferably, the assembly (120) includes a rotatable body (124) provided with an elongated, peripheral, knife-receiving slot (168) defined by fixed backing plates (158 ) and laterally shiftable locking plates (188). The selectively inflatable resilient bladders (174-178) are carried by the head assembly (120) and, when inflated, shift the associated movable locking plates (188) against the cutting knives (126), thereby firmly locking the latter in place. When knife adjustment is desired, one or more of the appropriate bladders (174-178) are deflated, the knives (126) are shifted as desired, and the bladders (174-178) are reinflated. | 8 |
TECHNICAL FIELD
[0001] The present invention generally relates to capacitive sensing, in particular to capacitive sensing using a resonant network. An aspect of the invention relates to a combined seat heating and capacitively occupancy sensing device.
BACKGROUND ART
[0002] A capacitive sensor, called by some electric field sensor or proximity sensor, is a sensor, which generates a signal responsive to the influence of what is being sensed (a person, a part of a person's body, a pet, an object, etc.) upon an electric field. A capacitive sensor generally comprises at least one antenna electrode, to which is applied an oscillating electric signal and which thereupon emits an electric field into a region of space proximate to the antenna electrode, while the sensor is operating. The sensor comprises at least one sensing electrode at which the influence of an object or living being on the electric field is detected. In some (so-called “loading mode”) capacitive occupancy sensors, the one or more antenna electrodes serve at the same time as sensing electrodes. In this case, the measurement circuit determines the current flowing into the one or more antenna electrodes in response to an oscillating voltage being applied to them. The relationship of voltage to current yields the complex impedance of the one or more antenna electrodes. In an alternative version of capacitive sensors (“coupling mode” capacitive sensors), the transmitting antenna electrode(s) and the sensing electrode(s) are separate from one another. In this case, the measurement circuit determines the current or voltage that is induced in the sensing electrode when the transmitting antenna electrode is operating.
[0003] The different capacitive sensing mechanisms are explained in the technical paper entitled “Electric Field Sensing for Graphical Interfaces” by J. R. Smith, published in Computer Graphics I/O Devices, Issue May/June 1998, pp 54-60. The paper describes the concept of electric field sensing as used for making non-contact three-dimensional position measurements, and more particularly for sensing the position of a human hand for purposes of providing three-dimensional positional inputs to a computer. Within the general concept of capacitive sensing, the author distinguishes between distinct mechanisms he refers to as “loading mode”, “shunt mode”, and “transmit mode” which correspond to various possible electric current pathways. In the “loading mode”, an oscillating voltage signal is applied to a transmit electrode, which builds up an oscillating electric field to a counterelectrode, which is typically at ground potential. The object to be sensed modifies the capacitance between the transmit electrode and ground. In the “shunt mode”, an oscillating voltage signal is applied to the transmit electrode, building up an electric field to a receive electrode, and the displacement current induced at the receive electrode is measured, whereby the displacement current may be modified by the body being sensed. In the “transmit mode”, the transmit electrode is put in contact with the user's body, which then becomes a transmitter relative to a receiver, either by direct electrical connection or via capacitive coupling. “Shunt mode” is alternatively referred to as the above-mentioned “coupling mode”.
[0004] Capacitive occupant sensing systems have been proposed in great variety, e.g. for controlling the deployment of one or more airbags, such as e.g. a driver airbag, a passenger airbag and/or a side airbag. U.S. Pat. No. 6,161,070, to Jinno et al., relates to a passenger detection system including a single antenna electrode mounted on a surface of a passenger seat in an automobile. An oscillator applies an oscillating voltage signal to the antenna electrode, whereby a minute electric field is produced around the antenna electrode. Jinno proposes detecting the presence or absence of a passenger in the seat based on the amplitude and the phase of the current flowing to the antenna electrode. U.S. Pat. No. 6,392,542, to Stanley, teaches an electric field sensor comprising an electrode mountable within a seat and operatively coupled to a sensing circuit, which applies to the electrode an oscillating or pulsed signal “at most weakly responsive” to wetness of the seat. Stanley proposes to measure phase and amplitude of the current flowing to the electrode to detect an occupied or an empty seat and to compensate for seat wetness.
[0005] The idea of using the heating element of a seat heater as an antenna electrode of a capacitive occupancy sensing system has been known for a long time. WO 92/17344 A1 discloses a an electrically heated vehicle seat with a conductor, which can be heated by the passage of electrical current, located in the seating surface, wherein the conductor also forms one electrode of a two-electrode seat occupancy sensor.
[0006] WO 95/13204 discloses a similar system, in which the oscillation frequency of an oscillator connected to the heating element is measured to derive the occupancy state of the vehicle seat.
[0007] U.S. Pat. No. 7,521,940 relates to a combined seat heater and capacitive sensor capable of operating, at a time, either in heating mode or in occupant-sensing mode.
[0008] The device includes a sensor/heat pad for transmitting a sensing signal, a first diode coupled to a first node of the sensor/heat pad, a second diode coupled to a second node of the sensor/heat pad, a first transistor coupled to the first diode and a second transistor coupled to the second diode. During sensing mode, the first and second transistors are opened and the nodes between the first transistor and the first diode, as well as between the second transistor and the second diode are reverse-biased to isolate the sensor/heat pad from the power supply of the heating circuit.
[0009] US 2009/0295199 discloses a combined seat heater and capacitive sensor, wherein each of the two terminals of the heating element is connected to the heating power supply via two transistors in series. The device may not operate in sensing mode and in heating mode at a time. When the device is in sensing mode, the nodes between each pair of transistors are actively kept at the same potential as the heating element by means of respective voltage followers in order to neutralize any open-switch impedance of the transistors.
[0010] The very same idea has already been disclosed in U.S. Pat. No. 6,703,845. As an alternative to transistors, that document discloses inductors to achieve a high impedance at the frequency of the oscillating signal between the heating element and the power source of the heating circuit. As in the previously discussed document, a voltage follower maintains the intermediate nodes substantially at the same potential as the heating element in order to effectively isolate, at the frequency of the oscillating signal, the power supply of the heating circuit from the heating element.
[0011] Document DE 43 38 285 A1 discloses a combined seat heater and capacitive occupancy sensor wherein the heating element, together with the vehicle body as a counterelectrode, constitutes a capacitor. The capacitor is connected to an oscillating circuit, the frequency of which depends on the capacitance between the electrodes of the capacitor. The capacitance is dependent on the dielectric constant of the material, which is present between the electrodes. Thus, when the seat is unoccupied, a low dielectric constant exists, thereby providing low capacitance. This implies that the oscillator circuit oscillates at a relatively high frequency. Conversely, when the seat is occupied by a passenger, a higher dielectric constant is present and consequently the oscillator circuit oscillates at a relatively low frequency. By providing a control circuit that is activated by the presence of a frequency of certain magnitude, an arming signal can be transmitted to the airbag sensor when the seat is occupied.
[0012] A system of a similar type is described in document DE 41 10 702 A1. In this system the capacitor, whose frequency varies depending on the occupancy state, is formed by the heating element and electrode wires arranged in the vicinity of the heating element. A central control device measures the oscillation frequency to determine the occupancy state.
[0013] Document U.S. Pat. No. 5,525,843 also relates to a combined seat heater and capacitive occupancy sensor, wherein the change of the resonance frequency of the oscillator is used to determine whether the seat is occupied or empty.
[0014] What one tries to measure with such a capacitive sensing system is the overall impedance between the heating element and a counterelectrode (typically a grounded conductive surface or structure). The behaviour of the overall impedance is that of an a priori unknown complex network of resistors, capacitors and inductors. For a given, single, frequency, that complex network is electrically equivalent to a simple parallel network of a capacitive and a resistive component. The values of these components are frequency-dependent, which means that in a given situation (e.g. for a given occupancy state), measurements at different frequencies will yield different capacitance values and different resistance values. Therefore, measurements of the capacitance and the resistance carried out at different frequencies cannot directly be compared with one another. This represents a difficulty when the capacitive sensing network is allowed to oscillate at different resonance frequencies.
[0015] The variation of the resonance frequency over a large frequency range has the additional disadvantage that electromagnetic radiation is generated over this large frequency range. This poses a problem when radiation levels defined by automotive standards for example must not be exceeded by the capacitive measurement, for example to exclude interference in the AM bands of a radio receiver located in the car where the measurement circuit is installed. It is therefore preferred to restrain the frequency range to a defined range which does not overlap a critical frequency band where only low allowed radiation levels are defined, for example the AM radio frequency bands.
[0016] Finally, if variation of the resonance frequency is allowed over a large frequency range, there is also a non-negligible risk of receiving electromagnetic interference from other electronic appliances.
TECHNICAL PROBLEM
[0017] It is an object of the present invention to provide a capacitive sensor wherein the above-mentioned drawbacks are eliminated or at least reduced. This object is achieved by a capacitive sensor as claimed in claim 1 .
GENERAL DESCRIPTION OF THE INVENTION
[0018] A capacitive sensor comprises an antenna electrode (sensing antenna electrode) for capacitively coupling to a counterelectrode to form a capacitance, this capacitance being responsive to an electric-field-influencing property of an object or person proximate to the antenna electrode (i.e. between the antenna electrode and the counterelectrode). The counterelectrode may be or may not be part of the capacitive sensor. The capacitive sensor further comprises a capacitive sensing network connected to the antenna electrode to apply an oscillating signal (current or voltage) thereto and to determine the capacitance based upon characteristics (e.g. amplitude, phase, frequency, attenuation etc.) of the oscillating signal. According to the invention, the capacitive sensing network includes at least one inductor and a plurality of reactive components arranged to form a resonant network together with the capacitance, the plurality of reactive components being activatable and deactivatable in such a way as to modify a resonance frequency of the resonant network.
[0019] According to a preferred aspect of the invention, the capacitive sensor is implemented in a combined seat heater and capacitive occupancy sensor, e.g. for a vehicle seat. Such a combined seat heater and capacitive occupancy sensor comprises a heater network including a heating element connected between a first node and a second node to dissipate heat when a heating current is caused to flow between the first and second nodes, across the heating element, and a capacitive sensing network connected to the heating element to use the heating element as a sensing antenna electrode. The heating element is arranged for forming a capacitance with a counterelectrode, the capacitance being responsive to an electric-field-influencing property of an object or person proximate to the heating element. The capacitive sensing network is configured to apply an oscillating signal to the heating element and to determine the capacitance based upon characteristics of the oscillating signal. The heater network comprises a common mode choke with at least two windings, the heating element being connected in series between a first and a second winding of the at least two windings so as to be operatively connectable to a power source via the common mode choke. The capacitive sensing network includes a plurality of reactive components, arranged to form a resonant network with the first and/or the second winding and the capacitance, the plurality of reactive components being activatable and deactivatable in such a way as to modify a resonance frequency of the resonant network.
[0020] As those skilled will appreciate, thanks to the invention, the resonance frequency of the resonant network may be adjusted, in particular depending on the capacitance between the sensing antenna electrode (or the heating element) and the counterelectrode. The oscillating voltage preferably has a frequency in the range from about 50 kHz to about 10 GHz, more preferably in the range from about 50 kHz to about 30 MHz.
[0021] By activating or deactivating different groups of the reactive components, the capacitive sensor may perform a multitude of measurements at different resonance frequency. The combination of activated or deactivated reactive components may in particular be selected in such a way that the resonance frequencies of the measurements lie within a narrow frequency band, e.g. between 120 kHz and 150 kHz. As a consequence, the capacitance values obtained from these measurements can be directly compared to one another. The same is true for the resistance values obtained. Preferably, the capacitive sensing network comprises a control loop to confine the resonance frequency within a predefined target frequency band.
[0022] Since the resonance frequency of the capacitive sensing network may be confined to a narrow frequency band, noisy frequency bands can be avoided.
[0023] Preferably, the reactive components comprise capacitors. Alternatively or additionally, the reactive components may comprise further inductors. The reactive components may be arranged electrically in parallel to the unknown capacitance (between the antenna electrode or the heating element and the counterelectrode). The reactive components may have mutually different reactance values.
[0024] Preferably, the combined seat heater and capacitive occupancy sensor or the capacitive sensor comprises an electronically controlled switching arrangement configured to individually activate and deactivate the reactive components. The switching arrangement may e.g. comprise electronically controlled switches (e.g. transistors) arranged each electrically in parallel to or in series with a respective reactive component.
[0025] The capacitive sensing network preferably includes a controller, such as e.g. a microcontroller, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a digital signal processor (DSP) or the like, operatively connected with the electronically controlled switching arrangement to control said resonance frequency by activating or deactivating the electronically controlled switches or groups thereof.
[0026] The capacitive sensing network preferably comprises means to sustain the oscillating signal in or to drive the oscillating signal into the antenna electrode or the heating element as well as a high-impedance amplifier having an input node operatively connected to the antenna electrode or the heating element to probe the oscillating signal, and an output node to provide an output signal indicative of the oscillating signal. Preferably, the capacitive sensing network derives not only the capacitive load of the heating element but also the resistive part of the complex impedance between the heating element and ground.
[0027] Generally speaking, the output signal of the high-impedance amplifier allows measuring the voltage present on the antenna electrode or the heating element substantially without disturbing the measurement by its presence. The output voltage of the high-impedance amplifier permits to derive the complex impedance and thus the capacitance between the antenna electrode or heating element and ground. As the capacitance between the antenna electrode or heating element and ground depends on whether there is or not a conductive body (e.g. an occupant) in proximity of the antenna electrode or heating element, the occupancy state of an occupiable item (e.g. hospital bed, vehicle seat, office chair, etc.) containing the antenna electrode or the heating element can be derived from the output voltage of the high-impedance amplifier. As used herein, the term “impedance” designates the modulus (absolute value) of the complex impedance, which is itself defined as the ratio between (complex) voltage and (complex) current. When reference is made to the (complex) impedance to be measured or the capacitance to be measured, these terms designate the (complex) impedance or the capacitance between the heating element and the (typically grounded) counterelectrode (e.g. the vehicle frame). In the context of the present, the term “high-impedance amplifier” designates an amplifier, the complex impedance of which has a reactive part that is substantially higher (e.g. at least five times higher) than the reactive part of the complex impedance to be measured and a resistive part that is substantially higher (e.g. at least five times higher) than the resistive part of the complex impedance to be measured.
[0028] In the case of a combined seat heater and capacitive occupancy sensor, we will in the following assume that the heating current is direct current (DC) and that the oscillating signal sustained or driven into the heating element is an AC signal within a frequency region well above DC level. This is insofar a simplification that transient states (e.g. switching on/or off of the heating current), noise and parasitic currents are not taken into account. It should be noted that the heating current need not be direct current in the strictest sense: it may be variable, but on a long time-scale, so as not to interfere with the oscillating signal used for the capacitive measurement. For sake of simplicity, we will use “DC” to designate slowly varying or constant signals.
[0029] The means to sustain an oscillating signal in or to drive an oscillating signal into the antenna electrode or the heating element preferably comprises a negative resistance device (e.g. the “active” or power-supplying part of an oscillator circuit) to sustain the oscillating signal (at the resonance frequency) in the resonant network and to compensate for resistive losses and power extracted from the resonant network. The negative resistance device and the resonant network form together an oscillator, the resonance frequency of which depends on the inductance of the resonant network, and therefore, in particular, on the capacitance to be measured.
[0030] Preferably, the capacitive sensing network comprises a feedback branch from the output node of the high-impedance amplifier to the negative resistance device to regulate the amplitude of the oscillating signal to a reference amplitude.
[0031] The means to sustain an oscillating signal in or to drive an oscillating signal into the antenna electrode or the heating element may comprise an AC source operatively connected to the heating element to drive an alternative current into the resonant network and a frequency control unit for controlling the frequency of the alternative current. In this case, the oscillation of the resonant network is constrained to oscillation at the frequency determined by the frequency control unit. Preferably, the latter frequency is equal to or close to the resonance frequency of the resonant network (preferably within a narrow range around the resonance frequency). The complex impedance to be measured can then be obtained from the complex impedance of the resonant network, which is given by the ratio of the complex voltage probed by the high-impedance amplifier and the complex current driven into the resonant network by the AC source. The frequency control unit is preferably configured to vary the frequency of the alternative current within a frequency window. More preferably, the capacitive sensing network comprises a feedback branch from the output node of the high-impedance amplifier to the frequency control unit to regulate a phase difference of the output signal and the alternative current to a reference phase difference value. The reference phase difference value is preferably set to 0°, so that the feedback branch in fact regulates the frequency control unit to the resonance frequency of the resonant network.
[0032] Preferably, the extremities of the heating element are AC-coupled with one another, e.g. with a coupling capacitor. Such coupling capacitor is chosen to have an impedance that is substantially less than the impedance of the capacitance to be measured. The coupling capacitor thus represents a short for the AC component of the current but isolates the DC component thereof. A coupling capacitor between the extremities of the heating element ascertains that the capacitive occupancy sensor remains operational even if the heating element should break.
[0033] Preferably, the capacitive sensing network comprises a driven shield electrode. As used herein, the term driven shield electrode designates a further antenna electrode that is kept at substantially the same AC potential as the sensing antenna electrode or the heating element. As a consequence, the oscillating electric field substantially cancels between the driven shield electrode and the sensing antenna electrode or the heating element. It follows that a driven shield electrode substantially prevents the sensing antenna electrode or the heating element from capacitively coupling to objects, which, as seen from the sensing antenna electrode or the heating element, lie behind the driven shield electrode. One or more driven shield electrodes may thus be used to focus the sensitivity of the sensing antenna electrode or the heating element towards a region of interest, e.g. the part of space above a vehicle seat that is occupied by a normally seated occupant. To keep the driven shield electrode the same AC potential as the sensing antenna electrode or the heating element, an amplifier with high input impedance and gain substantially equal to 1, commonly known as a voltage follower or buffer amplifier, may be connected between the sensing antenna electrode or the heating element and the driven shield electrode to keep the driven shield electrode at the same AC potential as the sensing antenna electrode or the heating element.
[0034] A preferred aspect of the present invention concerns a vehicle seat equipped with a capacitive sensor or a combined seat heater and capacitive occupancy sensor.
[0035] Yet another aspect of the present invention concerns a capacitive sensing network configured to apply an oscillating signal to an antenna electrode forming a capacitance with a counterelectrode, the capacitance being responsive to an electric-field-influencing property of an object or person proximate to the antenna electrode, and to determine the capacitance based upon characteristics of the oscillating signal. The capacitive sensing network according to this aspect of the invention comprises an interface for connecting the capacitive sensing network to a seat heater including a heating element for dissipating heat when a heating current is caused to flow across the heating element, the interface being configured for operating the heating element as the antenna electrode. The interface comprises a common mode choke including a first winding for connecting a first node of the heating element to a first terminal of a power supply, a second winding for connecting a second node of the heating element to a second terminal of the power supply. The capacitive sensing network further includes a plurality of reactive components, arranged to form a resonant network with the first and/or the second winding of the common mode choke and the capacitance when the heating element is connected between the first and second windings, the plurality of reactive components being activatable and deactivatable in such a way as to modify a resonance frequency of the resonant network.
[0036] A capacitive sensing network according to this aspect of the invention may be used in combination with seat heaters known as such. This will be highly appreciated by the automotive industry, since it may be possible to use the same type of seat heater both in a configuration without capacitive occupancy sensing ability and in a configuration with capacitive occupancy sensing ability. In a vehicle seat without occupancy sensor, the seat heater may be directly plugged to the seat heater ECU including the power supply and the temperature controller, whereas in a vehicle seat with an occupancy sensor, the capacitive sensing network as described above may be connected between the seat heater ECU and the heating element as well as the temperature sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Further details and advantages of the present invention will be apparent from the following detailed description of limiting embodiments with reference to the attached drawings, wherein:
[0038] FIG. 1 is a schematic circuit diagram of a combined seat heater and capacitive occupancy sensor according to a preferred embodiment of the invention;
[0039] FIG. 2 is a schematic diagram of a first embodiment of the plurality of reactive components shown in FIG. 1 ;
[0040] FIG. 3 is a schematic diagram of a second embodiment of the plurality of reactive components shown in FIG. 1 ;
[0041] FIG. 4 is a schematic diagram of a third embodiment of the plurality of reactive components shown in FIG. 1 ;
[0042] FIG. 5 is a schematic circuit diagram of a preferred implementation of the combined seat heater and capacitive occupancy sensor of FIG. 1 ;
[0043] FIG. 6 is a schematic illustration of a vehicle seat equipped with a combined seat heater and capacitive occupancy sensor substantially as in FIG. 1 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] FIG. 1 shows a block schematic diagram of a combined seat heater and capacitive occupancy sensor according to an embodiment of the invention. The seat heater comprises a heating element 10 , which is used by the capacitive occupancy sensor as an antenna electrode that capacitively couples to ground. The strength of the capacitive coupling between the heating element 10 and ground depends on whether an occupant is present in the zone between the heating element 10 and the grounded counter-electrode. In a loading-mode capacitive occupancy sensor for a vehicle seat, the grounded counter-electrode normally corresponds to the vehicle chassis.
[0045] Turning first to the seat heater, the heater network includes power source 12 supplying the required DC heating current to the heating element 10 to perform the heating function. The heater network comprises temperature controller 14 , which turns the DC heating current on and off, depending on the actual and required temperature of the seat heater.
[0046] The heating element 10 is connected between a first 21 and a second 22 node. When a potential difference is applied by the power supply between the first and the second nodes 21 , 22 , the heating current flows across the heating element 10 , which is thus caused to dissipate heat. The heating element 10 is operatively connected to the power source 12 with a common mode choke 16 . A first 16 . 1 and a second 16 . 2 winding thereof connects the first 21 and the second 22 node to a third 23 and a fourth 24 node, respectively. In FIG. 1 , the third node 23 corresponds to ground, whereas the fourth node 24 is operatively connected to the high potential terminal of the power source 12 via the temperature controller 14 . The common mode choke 16 exhibits low impedance to DC but substantial impedance to AC at the operating frequency of the capacitive occupancy sensor.
[0047] The temperature controller 14 is operatively connected with a temperature sensor (not shown), which is arranged in vicinity of the heating element 10 . The temperature controller 14 may comprise a user-actuatable master switch (not shown) allowing the user to activate or deactivate the seat heater as a whole and control electronics (including e.g. a thermostat) that regulate the temperature to ascertain comfortable seating. When the seat heater is operating, the temperature controller 14 opens and closes the heating circuit (pulse-width modulation of the heating current) in such a way as to achieve a preset target temperature. Preferably, the target temperature may be selected by the user using a temperature control interface (e.g. a knob, a slider, a wheel or the like). The master switch and the temperature control interface are preferably integrated in the same control element.
[0048] When the seat heater is supplied with DC heating current (i.e. when temperature controller 14 closes the heating circuit), current flows from power source 12 though the controller 14 , the node 24 herein designated as fourth node, the second winding 16 . 2 of common mode choke 16 , the node 22 herein designated as second node, the heating element 10 , the node 21 herein designated as first node, the first winding 16 . 1 of common mode choke 16 , the node 23 herein designated as the third node, which is tied to ground potential. The heating circuit is completed via the ground connection between the third node 23 and power source 12 .
[0049] The capacitive sensing network (indicated in FIG. 1 by the dotted line) comprises a high-impedance amplifier 32 , the input node 34 of which is connected to the heating element 10 at the first node 21 , an active component (in this case the negative resistance device 52 ) operatively connected to the heating element 10 at the first node 21 , a plurality of reactive components (generally indicated by reference number 36 , detailed hereinafter) and a microcontroller 90 operatively connected to receive the output signal of the high-impedance amplifier and to control the negative resistance device as well as to activate or deactivate the reactive components 36 .
[0050] Capacitors 40 and 42 symbolically represent the capacitive coupling of the heating element 10 to a grounded electrode (typically the vehicle frame). The capacitance (and hence the impedance) of these capacitors 40 , 42 depends on whether the space between the heating element 10 and the grounded electrode is occupied by a conductive body (e.g. an occupant) or not. Capacitances 40 and 42 together represent the capacitance or impedance to be measured. It should be noted that the impedance to be measured behaves in practice like a distributed network comprising of resistive, capacitive and inductive parts. It is modelled for the purpose of this application by capacitors 40 , 42 , which are paralleled by a single resistance (not shown in the drawings). However, this simplified model is valid only for a single frequency, which means that the resistance and capacitance measured at a first frequency and the resistance and capacitance measured at a second frequency cannot be compared directly, i.e. without any compensation for the difference in frequency. Such compensation may, however, be omitted if measurement errors introduced by this effect are negligibly small. This is achieved by keeping the resonance frequency within a narrow frequency band (such that variation of the resonance frequency can be neglected).
[0051] Capacitances 40 and 42 , as well as the reactive components 36 are electrically in parallel to the common mode choke 16 between the heating element 10 and ground. Accordingly, the common mode choke 16 , the reactive components 36 and the capacitance to be measured form a parallel resonant network, the resonance frequency of which depends among others on the capacitance to be measured. The reactive components 36 may be individually switched active or inactive by the microcontroller 90 in such a way as to shift the resonance frequency into a desired frequency band.
[0052] Negative resistance device 52 is preferably the active, oscillation-sustaining part of an oscillator. It sustains an oscillating current in the resonant network by compensating for resistive losses, in such a way that the resonant network operates at its resonance frequency.
[0053] The high input impedance amplifier 32 probes the AC voltage on the first node 21 and outputs a corresponding output signal on output node 44 , which is then processed further by the microcontroller 90 to derive the capacitance to be measured.
[0054] The complex impedance to be measured (and thus the capacitance to be measured) may be determined based on the frequency and the amplitude of the output signal, together with the known complex impedances of the common mode choke 16 and the reactive components 36 .
[0055] The capacitive sensing network shown in FIG. 1 further comprises a coupling capacitor 46 , which represents an AC shunt of the heating element 10 . The impedance of capacitor 46 is chosen substantially smaller than the impedance of the total capacitance to be measured. In the absence of capacitor 46 , an interruption (break) of the heating element 10 would result in a substantially smaller antenna electrode: this, in turn, would reduce the measurable capacitance. For instance, if heating element 10 shown in FIG. 1 broke in the middle, the measurement circuit would measure capacitance 40 (but not capacitance 42 ). Coupling capacitor 46 achieves an AC short between the first and second nodes 21 , 22 , i.e. the terminals of the heating element 10 . If a (single) break occurs in heating element 10 , then the capacitive sensing network remains substantially unaffected and still measures the total capacitance between the heating element 10 and ground due to the AC shunt provided by capacitor 46 .
[0056] Coupling capacitor 48 provides an AC short between the third node 23 and the fourth node 24 . Capacitor 48 avoids that any AC current is fed into the DC power source 12 and thereby possibly into the car power network.
[0057] FIG. 2 shows a first possible embodiment of the plurality of activatable or deactivatable reactive components 36 . The plurality of activatable or deactivatable reactive components 36 comprises capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 arranged electrically in parallel. Each of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 is connected in series with an electronic switch 137 . 1 , 137 . 2 , 137 . 3 or 137 . 4 , respectively. Electronic switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 are individually controllable by the microcontroller 90 (see FIG. 1 ) in order to activate or deactivate the corresponding capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 . The capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 have known capacitances and are selectively connectable in parallel to the capacitance 40 , 42 (see FIG. 1 ) to be measured. The switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 can for example be MOSFETs.
[0058] A problem which may arise when the inductance of a common mode choke is used as inductance of the parallel resonant LC tank together with the capacitance to be measured, is that the drift or temperature dependence or part tolerance of the inductance will lead to a measurement error of the unknown capacitance. The computation of the capacitance to be measured may be made independent on the complex impedance of the common mode choke 16 using the capacitors 136 . 1 , 136 . 2 , 136 . 3 or 136 . 4 or any combination thereof.
[0059] Each of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 has a known capacitance (C 136.1 , C 136.2 , C 136.3 and C 136.4 , respectively). We will assume that the open-switch capacitances of switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 can be neglected compared to the capacitance of the associated capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 .
[0060] To eliminate the potentially variable impedance, the following procedure may e.g. be executed under control of the microcontroller. A first measurement of the resonance frequency of the parallel resonant LC tank is made with a first combination of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 activated (the corresponding switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 are closed). This frequency value is stored (here as fa). A second measurement of the resonance frequency is made with a second combination of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 activated (the corresponding switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 are closed), i.e. connected in parallel to the capacitance to be measured. The so-obtained frequency value is stored (here as fb). The first and second combinations of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 have to be chosen such that the resulting frequencies fa and fb are different. The relations between the resonance frequencies and the inductive and capacitive components of the circuit may be expressed through:
[0000]
fa
=
1
2
π
·
L
·
(
Cx
+
C
1
)
fb
=
1
2
π
·
L
·
(
Cx
+
C
2
)
[0000] where L is the inductance of the common mode choke, Cx is the capacitance to be measured, C 1 is the total capacitance of the activated one(s) of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 according to the first combination and C 2 is the total capacitance of the activated one(s) of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 according to the second combination.
[0061] The two equations can be combined to yield Cx as a function of the measured frequencies fa and fb:
[0000]
Cx
=
fa
2
C
1
-
fb
2
C
2
fb
2
-
fa
2
[0062] In the latter equation, the inductance L has been eliminated and thus does not influence the capacitance measurement.
[0063] Since the inductance L and the unknown capacitance Cx may not vary much between the measurements of the resonance frequencies fa and fb, these measurements have to be carried out sufficiently shortly one after the other.
[0064] At the resonance frequency, current and voltage of the parallel resonant network are in phase and the resistive part of the impedance to be measured thus corresponds to the ratio of the voltage to the current. The microcontroller may thus determine the resistive part of the impedance to be measured by measuring the voltage and the current across the resonant network.
[0065] Another advantage of the individually activatable capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 is that the microcontroller 90 can shift the resonance frequency to a predefined (narrow) target frequency band whether the seat is occupied or free. That predefined frequency band is preferably chosen such that it does not overlap with frequency bands occupied for transmission or reception by other devices in the vicinity of the combined seat heater and capacitive occupancy sensor or reserved frequency bands (e.g. AM radio frequency bands). By appropriately choosing the target frequency band wherein the combined seat heater and capacitive occupancy sensor may operate and selecting the reactive components in such a way that by activating or deactivating combinations thereof the resonance frequency of the resonant network may be shifted into the target frequency band for any unknown capacitance within a certain specified capacitance range, it will thus be possible to prevent or reduce electromagnetic interference with other electronic devices. This ascertains that other electronic devices may operate without being disturbed by the combined seat heater and capacitive occupancy sensor and that the combined seat heater and capacitive occupancy sensor may also operate without being disturbed by the other electronic devices. Automotive standards for example define levels of electromagnetic radiation, which must be tolerated by a measurement circuit without generating a measurement error. These levels depend on the frequency. Thanks to the present invention it is thus possible to avoid frequency bands wherein the tolerable radiation levels are large.
[0066] When the capacitive sensing network is powered up, the microcontroller 90 preferably controls the capacitive sensing network to perform one or more measurements of the unknown capacitance with a power level that is lower than during the normal measurements. This is because at start-up, the capacitance to be measured is completely unknown (it may be completely different from the capacitance at the previous shut-down of the system) and, hence, it is not known which will be the resulting resonance frequency. By keeping the amplitude of the LC tank at a lower level during start-up than during normal operation, it is avoided that the system generates significant interference outside its target frequency band. During this phase, the microcontroller 90 preferably dynamically adjusts the paralleled reactance 36 in such a way as to shift the resonance frequency into to the target frequency band. The microcontroller may achieve this using a feedback loop or by the calculating the amount by which the paralleled reactance must be increased or decreased and adjusting the paralleled reactance 36 in consequence.
[0067] The microcontroller 90 preferably maintains a safety margin between the current resonance frequency and the bounds of the target frequency band so as to be able to react in case the capacitance to be measured changes between the last and the next measurement. Thus, if the resonance frequency is too close to the upper or the lower bound of the target frequency band, the microcontroller 90 activates a different combination of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 such that the thus resulting resonance frequency is shifted towards the centre of the target frequency band. The repetition rate of the impedance measurements is selected depending on the safety margin of the target frequency band and the maximum expected rate of change of the capacitance to be measured. In particular, the repetition rate is chosen sufficiently high and the safety margin of the target frequency band sufficiently large to allow the microcontroller to deal with any impedance change that does not exceed a certain predefined rate of change. Preferably, the microcontroller is configured to reduce the power level of the LC tank in case the resonance frequency should accidentally leave the target frequency (e.g. due to an abrupt change of the capacitance to be measured). Once the paralleled reactance has been adjusted to the new situation and the resonance frequency has been shifted back to the target frequency band, the power level may again be raised.
[0068] It could happen that one or more of the reactive components break partly or completely, thereby changing their value, implying that the assumption of known value is not true anymore. This problem can be solved by adding in parallel to the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 an additional set of capacitors having substantially the same capacitance values C 136.1 , C 136.2 , C 136.3 and C 136.4 . In order to check the capacitance of e.g. capacitor 136 . 1 , a measurement of the unknown capacitance may be performed a first time with capacitor 136 . 1 and a second time with the capacitor having the same nominal capacitance as capacitor 136 . 1 . If these measurements yield different resonance frequencies, it can be deduced that the capacitor 136 . 1 or its duplicate is defective.
Numerical Example (FIG. 2)
[0069] The target frequency band of the capacitive sensing network is assumed to range from 120 kHz to 150 kHz.
[0070] In this example, L (common mode choke inductance)=10 mH, C 136.1 =10 pF, C 136.2 =20 pF, C 136.3 =40 pF, C 136.4 =80 pF and switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 have negligible open-switch capacitances.
[0071] All the possible combinations of the paralleled capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 yield 16 different known capacitances, ranging from 0 pF (all switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 are open) to 150 pF (all switches 137 . 1 , 137 . 2 , 137 . 3 and 137 . 4 are closed). Assuming that 10 pF Cx 100 pF, the total capacitance C total , which is the sum of the unknown capacitance and the known capacitance, will range from 10 pF to 250 pF depending on the combination of activated capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 . The resulting resonance frequencies will range from 100.66 kHz to 503.29 kHz.
[0072] In particular, the following resonance frequencies are obtainable if the unknown capacitance Cx amounts to 10 pF:
[0000]
Activated capacitances
C known /pF
C total /pF
F res /kHz
none
0
10
503.29
C 136.1
10
20
355.88
C 136.2
20
30
290.58
C 136.1 and C 136.2
30
40
251.65
C 136.3
40
50
225.08
C 136.3 and C 136.1
50
60
205.47
C 136.3 and C 136.2
60
70
190.23
C 136.3 and C 136.1 and C 136.2
70
80
177.94
C 136.4
80
90
167.76
C 136.4 and C 136.1
90
100
159.15
C 136.4 and C 136.2
100
110
151.75
C
136.4
and C
136.1
and C
136.2
110
120
145.29
C
136.4
and C
136.3
120
130
139.59
C
136.4
and C
136.1
and C
136.3
130
140
134.51
C
136.4
and C
136.2
and C
136.3
140
150
129.95
C
136.1
to C
136.4
150
160
125.82
[0073] The usable (allowed) combinations of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 and the corresponding frequencies in the target frequency band, with Cx=10 pF, are shown in bold.
[0074] If the unknown capacitance Cx amounts to 100 pF, the obtained resonance frequencies are:
[0000]
Activated capacitances
C known /pF
C total /pF
F res /kHz
none
0
100
159.15
C 136.1
10
110
151.75
C
136.2
20
120
145.29
C
136.1
and C
136.2
30
130
139.59
C
136.3
40
140
134.51
C
136.3
and C
136.1
50
150
129.95
C
136.3
and C
136.2
60
160
125.82
C
136.3
and C
136.1
and C
136.2
70
170
122.07
C 136.4
80
180
118.63
C 136.4 and C 136.1
90
190
115.46
C 136.4 and C 136.2
100
200
112.54
C 136.4 and C 136.1 and C 136.2
110
210
109.83
C 136.4 and C 136.3
120
220
107.3
C 136.4 and C 136.1 and C 136.3
130
230
104.94
C 136.4 and C 136.2 and C 136.3
140
240
102.73
C 136.1 to C 136.4
150
250
100.66
[0075] The usable combinations of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 and the corresponding frequencies in the target frequency band, with Cx=100 pF, are shown in bold.
[0076] If the inductance of the common mode choke is not precisely known (e.g. due to temperature variations, ageing, etc.), the unknown capacitance may be determined as described above, by using different pairs of combinations of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 selected among the usable combinations. Designating by Cx i the capacitance value obtained by using a first combination (capacitance C 1,i , resonance frequency fa i ) and a second combination (capacitance C 2,i ≠C 1,i , resonance frequency fb i #fa i ), one obtains:
[0000]
Cx
i
=
fa
i
2
C
1
,
i
-
fb
i
2
C
2
,
i
fb
i
2
-
fa
i
2
(
*
)
[0077] With n usable combinations, there are
[0000]
(
n
2
)
=
n
(
n
-
1
)
[0000] possible ways of calculating Cx using the above formula (*). Preferably, the microcontroller is configured to carry out a plurality of resonance frequency measurements using different allowed combinations of the capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 , to calculate values Cx i (i=1 . . . n(n−1)) of the unknown capacitance from a plurality of combination pairs and to compute the final value Cx of the unknown capacitance as the average or the median of the individual measurements Cx i . The resistive part of the impedance is determined as the average or median of the calculated resistive parts for the different combination pairs. It should be noted that the averaging of the individual measurements of the capacitance and the individual measurements of the resistance is possible because the intervening resonance frequencies are all contained in a narrow frequency band (here: from 120 kHz to 150 kHz).
[0078] In case of interference with another electronic appliance in the neighbourhood of the capacitive sensing network, one or more of the calculated capacitance values Cx i may be invalid. If these invalid measurements were taken into account for the calculation of the average capacitance, this could give rise to a significant measurement error. Therefore, the capacitance values Cx i (i=1 . . . n(n−1)) obtained with the different capacitor combinations are preferably analysed for outliers. Any method suitable for outlier detection in a population of measurement values can a priori be used in this context. For instance, one could calculate the difference ΔCx i between each value Cx i and the average or median value Cx (ΔCx i =Cx−Cx i ) and discard those values Cx i that are more distant from the calculated average value Cx than a predetermined threshold value.
[0079] For example, taking the numerical values from the second table above, the measured resonance frequencies with C known =30 pF, 40 pF, 50 pF, 60 pF and 70 pF are located within the target frequency band. The values Cx i are calculated using different combinations of the retained resonance frequencies. For this example, it is also assumed that an interference creates a measurement error of 1% of the measured resonance frequency measured with C known =30 pF, that is, a resonance frequency of 140.99 kHz instead of the 139.59 kHz (as shown in the second table above) is measured.
[0080] The following table shows the calculated unknown capacitances Cx i (in pF) obtained by all the possible combinations of the measured resonance frequencies. The C known -values in bold characters in the left column and the top row indicate the known capacitances in pF that have been used to calculate the unknown capacitances Cx i .
[0000]
C known
30
40
50
60
40
71.5
50
83.0
100.0
60
87.4
100.0
100.0
70
89.8
100.0
100.0
100.0
[0081] The median value of all the calculated values in this example is 100 pF. A threshold is defined which determines which unknown capacitances are considered to be valid. For this example, the threshold is defined to be 10%, that is, all the values that are lower than 90% of the median value and all the values that are above 110% of the median value are discarded. From the table above, all the unknown capacitances Cx i measured with an applied known capacitance of 30 pF are therefore discarded.
[0082] As an alternative to the detection of outliers among the values Cx i (i=1 . . . n(n−1)), the microcontroller may proceed as follows. For each of the allowed combinations of capacitors 136 . 1 , 136 . 2 , 136 . 3 and 136 . 4 , several measurements of the resonance frequency and of the parallel resistance are carried out. The standard deviation of each measured resonance frequency and of the equivalent parallel resistance is calculated. If the standard deviation of the frequency and/or the parallel resistance exceeds a predetermined threshold, the corresponding measured capacitance and resistance of that resonance frequency are discarded.
[0083] The capacitors of known value can also be replaced individually or altogether with inductances, or any complex impedances, i.e. combinations of a reactive and a resistive part.
[0084] FIG. 3 shows a second possible embodiment of the plurality of activatable or deactivatable reactive components 36 (see also FIG. 1 ). According to this embodiment, the plurality of activatable or deactivatable reactive components 36 comprises a capacitor 236 c , arranged in parallel with inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 . Each of the inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 is connected in series with an electronic switch 237 . 1 , 237 . 2 , 237 . 3 or 237 . 4 , respectively. Electronic switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 are individually controllable by the microcontroller 90 (see FIG. 1 ) in order to activate or deactivate the corresponding inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 . The inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 have known inductance each and are selectively connectable in parallel to the capacitor 236 c and the capacitance 40 , 42 (see FIG. 1 ) to be measured. The switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 can for example be MOSFETs. The parallel capacitor 236 c has a known capacitance and is provided to keep the resonance frequency of the resonant network in an acceptable range while using practical inductance values for the known inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 .
[0085] To eliminate the potentially variable impedance of the common mode choke, the following procedure may e.g. be executed under control of the microcontroller 90 (see FIG. 1 ). A first measurement of the resonance frequency of the parallel resonant LC tank is made with a first combination of inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 activated (the corresponding switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 are closed). This frequency value is stored (here as fa). A second measurement of the resonance frequency is made with a second combination of the capacitors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 activated (the corresponding switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 are closed), i.e. connected in parallel to the capacitance to be measured. The so-obtained frequency value is stored (here as fb). The first and second combinations of the inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 have to be chosen such that the resulting frequencies fa and fb are different. The relations between the resonance frequencies and the inductive and capacitive components of the circuit may be expressed through:
[0000]
fa
=
1
2
π
·
L
·
L
1
L
1
+
L
·
(
Cx
+
C
236
c
)
fb
=
1
2
π
·
L
·
L
2
L
2
+
L
·
(
Cx
+
C
236
c
)
[0000] where L is the inductance of the common mode choke, Cx is the capacitance to be measured, L 1 is the total inductance of the activated one(s) of inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 according to the first combination, L 2 is the total capacitance of the activated one(s) of capacitors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 according to the second combination and C 236c is the capacitance of capacitor 236 c . These equations can be combined to yield Cx as a function of the measured frequencies fa and fb:
[0000]
Cx
=
L
1
-
L
2
(
2
π
)
2
·
L
1
·
L
2
·
(
fa
2
-
fb
2
)
-
C
236
c
.
[0086] In the latter equation, the inductance L has been eliminated and thus does not influence the capacitance measurement.
[0087] Since the inductance L and the unknown capacitance Cx may not vary much between the measurements of the resonance frequencies fa and fb, these measurements have to be carried out sufficiently shortly one after the other.
[0088] At the resonance frequency, current and voltage of the parallel resonant network are in phase and the resistive part of the impedance to be measured thus corresponds to the ratio of the voltage to the current. The microcontroller 90 ( FIG. 1 ) may thus determine the resistive part of the impedance to be measured by measuring the voltage and the current across the resonant network.
[0089] As for the embodiment of FIG. 2 , the microcontroller 90 may shift the resonance frequency of the capacitive sensing network by activating or deactivating the reactive components, i.e. in this case the inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 . The microcontroller may in particular be configured to run a similar start-up procedure and take similar measures to ascertain low or no electromagnetic interference with other appliances as described with respect to the embodiment of FIG. 1 .
[0090] Numerical Example ( FIG. 3 )
[0091] In this example, capacitor 236 c is assumed to have a capacitance of 300 pF, L (common mode choke inductance)=10 mH, and the inductances L 236.1 , L 236.2 , L 236.3 and L 236.4 of the inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 are 20 mH, 10 mH, 5 mH and 2.5 mH, respectively. It will be assumed that the open-switch capacitances of switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 can be neglected.
[0092] The target frequency band of the capacitive sensing network is assumed to range from 120 kHz to 150 kHz.
[0093] By activating or deactivating different groups of the inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 , the following resonance frequencies (Fres) may be obtained for an unknown capacitance of 0 pF:
[0000]
Activated inductances
L known /mH
L total /mH
F res /kHz
none
/
10
91.89
L
236.1
20
6.67
112.54
L
236.2
10
5
129.95
L
236.1
and L
236.2
6.67
4
145.29
L 236.3
5
3.33
159.15
L 236.3 and L 236.1
4
2.86
171.91
L 236.3 and L 236.2
3.33
2.5
183.78
L 236.3 and L 236.1 and L 236.2
2.86
2.22
194.92
L 236.4
2.5
2
205.47
L 236.4 and L 236.1
2.22
1.82
215.5
L 236.4 and L 236.2
2
1.67
225.08
L 236.4 and L 236.1 and L 236.2
1.82
1.54
234.27
L 236.4 and L 236.3
1.67
1.43
243.11
L 236.4 and L 236.1 and L 236.3
1.54
1.33
251.65
L 236.4 and L 236.2 and L 236.3
1.43
1.25
259.9
L 236.1 to L 236.4
1.33
1.18
267.9
[0094] Resonance frequencies that lie inside the target frequency band are again in bold characters.
[0095] The following table shows the same results with an unknown capacitance of 100 pF:
[0000]
Activated inductances
L known /mH
L total /mH
F res /kHz
none
/
10
79.58
L 236.1
20
6.67
97.46
L 236.2
10
5
112.54
L
236.1
and L
236.2
6.67
4
125.82
L
236.3
5
3.33
137.83
L
236.3
and L
236.1
4
2.86
148.88
L 236.3 and L 236.2
3.33
2.5
159.15
L 236.3 and L 236.1 and L 236.2
2.86
2.22
168.81
L 236.4
2.5
2
177.94
L 236.4 and L 236.1
2.22
1.82
186.63
L 236.4 and L 236.2
2
1.67
194.92
L 236.4 and L 236.1 and L 236.2
1.82
1.54
202.88
L 236.4 and L 236.3
1.67
1.43
210.54
L 236.4 and L 236.1 and L 236.3
1.54
1.33
217.93
L 236.4 and L 236.2 and L 236.3
1.43
1.25
225.08
L 236.1 to L 236.4
1.33
1.18
232.01
[0096] The usable combinations of inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 and the corresponding frequencies in the target frequency band, with Cx=100 pF, are shown in bold.
[0097] The microcontroller 90 ( FIG. 1 ) may thus control the switches 237 . 1 , 237 . 2 , 237 . 3 and 237 . 4 in such a way as to keep the resonance frequency within the target frequency band when the capacitance to be measured varies.
[0098] As for the previous example, the microcontroller may advantageously be configured such that it uses different pairs of combinations of inductors 236 . 1 , 236 . 2 , 236 . 3 and 236 . 4 selected among the usable combinations in order to measure a plurality of capacitance values Cx i . The microcontroller may then compute the final value Cx of the unknown capacitance as the average or the median of the individual measurements Cx i . The resistive part of the impedance is determined as the average or median of the calculated resistive parts for the different combination pairs.
[0099] FIG. 4 shows a third possible embodiment of the plurality of activatable or deactivatable reactive components 36 (see FIG. 1 ). According to this embodiment, the plurality of activatable or deactivatable reactive components 36 comprises a capacitor 336 c , arranged in parallel with a series of inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 . The microcontroller 90 control the overall impedance of the network of inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 by activating different groups of the inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 at a time. Each of the inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 is connected parallel to an electronic switch 337 . 1 , 337 . 2 , 337 . 3 or 337 . 4 , respectively. Electronic switches 337 . 1 , 337 . 2 , 337 . 3 and 337 . 4 are individually controllable by the microcontroller 90 (see FIG. 1 ) in order to activate or deactivate the corresponding inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 . The inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 have known inductance each may and be selectively deactivated by closing the corresponding switch 337 . 1 , 337 . 2 , 337 . 3 or 337 . 4 , respectively. The switches 337 . 1 , 337 . 2 , 337 . 3 and 337 . 4 can for example be MOSFETs. The parallel capacitor 336 c has a known capacitance and is provided to keep the resonance frequency of the resonant network in an acceptable range while using practical inductance values for the known inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 .
[0100] Numerical Example ( FIG. 4 )
[0101] In this example, capacitor 336 c is assumed to have a capacitance of 300 pF, L (common mode choke inductance)=10 mH, and the inductances L 336.1 , L 336.2 , L 336.3 and L 336.4 of the inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 are 1.25 mH, 2.5 mH, 5 mH and 10 mH, respectively. It will be assumed that the open-switch capacitances of switches 337 . 1 , 337 . 2 , 337 . 3 and 237 . 4 can be neglected.
[0102] The target frequency band of the capacitive sensing network is assumed to range from 120 kHz to 150 kHz.
[0103] By activating or deactivating different groups of the inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 , the following resonance frequencies (Fres) may be obtained for an unknown capacitance of 0 pF:
[0000]
Activated inductances
L known /mH
L total /mH
F res /kHz
L 336.1
1.25
1.11
275.66
L 336.2
2.5
2
205.47
L 336.1 and L 336.2
3.75
2.73
175.95
L 336.3
5
3.33
159.15
L 336.3 and L 336.1
6.25
3.85
148.17
L 336.3 and L 336.2
7.5
4.29
140.36
L 336.3 and L 336.1 and L 336.2
8.75
4.67
134.51
L 336.4
10
5
129.95
L 336.4 and L 336.1
11.25
5.29
126.29
L 336.4 and L 336.2
12.5
5.56
123.28
L 336.4 and L 336.1 and L 336.2
13.75
5.79
120.76
L 336.4 and L 336.3
15
6
118.63
L 336.4 and L 336.1 and L 336.3
16.25
6.19
116.79
L 336.4 and L 336.2 and L 336.3
17.5
6.36
115.19
L 336.1 to L 336.4
18.75
6.52
113.78
[0104] Resonance frequencies that lie inside the target frequency band are in bold characters.
[0105] The following table shows the same results with an unknown capacitance of 100 pF:
[0000]
Activated inductances
L known /mH
L total /mH
F res /kHz
L 336.1
1.25
1.11
238.73
L 336.2
2.5
2
177.94
L 336.1 and L 336.2
3.75
2.73
152.38
L 336.3
5
3.33
137.83
L 336.3 and L 336.1
6.25
3.85
128.31
L 336.3 and L 336.2
7.5
4.29
121.56
L 336.3 and L 336.1 and L 336.2
8.75
4.67
116.49
L 336.4
10
5
112.54
L 336.4 and L 336.1
11.25
5.29
109.37
L 336.4 and L 336.2
12.5
5.56
106.76
L 336.4 and L 336.1 and L 336.2
13.75
5.79
104.59
L 336.4 and L 336.3
15
6
102.73
L 336.4 and L 336.1 and L 336.3
16.25
6.19
101.14
L 336.4 and L 336.2 and L 336.3
17.5
6.36
99.76
L 336.1 to L 336.4
18.75
6.52
98.54
[0106] The usable combinations of inductors 336 . 1 , 336 . 2 , 336 . 3 and 336 . 4 and the corresponding frequencies in the target frequency band, with Cx=100 pF, are shown in bold.
[0107] As another option, instead of using only either switchable capacitors or inductors as in the examples of FIGS. 2-4 , switchable paralleled inductors and capacitors can be used as reactive components.
[0108] FIG. 5 shows a practical implementation of the circuit in FIG. 1 . In particular,
[0109] FIG. 5 illustrates a possible way to implement the negative resistance device 52 of FIG. 1 . FIG. 5 thus uses the same reference numbers as FIG. 1 where appropriate. Elements that have already been discussed with reference to FIG. 1 will not be discussed again for sake of conciseness. The microcontroller 90 is not shown in FIG. 5 .
[0110] The negative resistance device 52 is the active, oscillation-sustaining part of an oscillator. It is the active part of an emitter-coupled LC oscillator and is comprised of transistors 54 and 56 and a current sink (transistor 68 , resistor 70 and bias voltage source 72 ). The same circuit is implemented as oscillator core in the Motorola MC1648 ‘Voltage controlled oscillator’ integrated circuit. Transistor 54 samples the voltage across the parallel resonant network, and steers the current through transistor 56 via the common emitter connection. Current through transistor 56 is itself fed back via its collector into the parallel resonant network, thereby sustaining the oscillation of the oscillator. The current sink supplies the operating current to the circuit. A distinction is sometimes made between a current source and current sink. The former term then designates a device having a positive current flowing out of it, whereas “current sink” designates a device having a positive current flowing into it (or, likewise, a negative current flowing out of it). It the context of the present, taking into account that current is generally considered an algebraic quantity that can be positive and negative, the term “current sink” may also be a “current source”.
[0111] The high-impedance amplifier probes the AC voltage on the first node 21 and outputs a corresponding output signal on its output node 44 . If the supply current generated by the current sink is set to an appropriate value, the amplitude of the AC voltage on node 21 depends essentially only on the resistive component of the resonant network. The capacitance to be measured may then be calculated based on the frequency of the output signal of high-impedance amplifier 32 as described hereinbefore. In addition, the resistive part of the complex impedance to be measured can be determined by measuring the amplitude of the output signal on node 44 and/or the DC power drawn by the current sink from its power supply. The resonance frequency of the resonant network may be adjusted as described hereinabove.
[0112] The embodiment shown in FIG. 5 implements an ‘automatic levelling loop’ (e.g. as implemented in the Motorola MC1648 ‘Voltage controlled oscillator’ integrated circuit mentioned above). Rectifier 60 converts the peak amplitude of the output signal of high-impedance amplifier, which is proportional to the amplitude of the AC voltage at node 21 into a proportional DC voltage. An error amplifier 62 compares this DC voltage with a reference value defined by voltage source 64 , and outputs a control voltage on its output node 66 . That control voltage controls the current sink comprised of transistor 68 , resistor 70 and bias voltage source 72 in such a way that the resonant network amplitude (the amplitude of the AC voltage on node 21 ) remains substantially constant. The magnitude of the current through the current sink around transistor 68 is then inversely responsive to the parallel resistive component of the resonant network. Since the control voltage of node 66 is substantially proportional to the current through the current sink, the control voltage of node 66 can be used to calculate the resistive value of the impedance to be determined.
[0113] FIG. 6 schematically shows a vehicle seat 86 equipped with a combined seat heater and capacitive occupancy sensor, which essentially corresponds to the one shown in FIG. 1 , except for the driven shield electrode (or guard electrode) 88 connected to the first node 21 via a voltage follower 91 . The combined seat heater and capacitive occupancy sensor of FIG. 6 comprises a plurality of activatable or deactivatable reactive components 36 (also referred to as paralleled reactance) that may e.g. be implemented as shown in FIGS. 2-4 and described hereinabove.
[0114] Heating element 10 is arranged in seat 86 , more specifically underneath the seating surface. In addition to the capacitance or impedance to be measured (illustrated again by capacitors 40 and 42 ), there is an additional capacitance between the heating element 10 and the seat frame 92 . The additional capacitance is in parallel to the capacitance to be measured and may introduce considerable measurement errors, because it is not well known and may vary during the lifetime of the application. In order to suppress the influence of the additional capacitance, a guard electrode 88 is arranged between the seat heater 10 and the seat frame 92 . The guard electrode 88 may e.g. be a conductive foil or textile, which covers at least the area spanned by the heating element 10 . Preferably the guard electrode 88 is larger than the area spanned by the heating element 10 for better shielding. As indicated above, the guard electrode 88 is electrically connected to via voltage follower 91 . Voltage follower 91 has high input impedance in order not to disturb the measurement. The voltage follower 91 keeps the voltage on the guard electrode 88 substantially equal to the voltage on the heating element 10 . Therefore, when the capacitive measurement is carried out, there is no or only a very small AC voltage difference between the heating element 10 and the guard electrode 88 . As a result, substantially no AC current flows between the heating element 10 and the guard electrode 88 . The guard electrode 88 being arranged between the heating element 10 and the seat frame 92 , substantially no AC current flows between the heating element 10 and the seat frame 92 .
[0115] While specific embodiments have been described in detail, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A capacitive sensor comprises a sensing antenna electrode ( 10 ) for capacitively coupling to a counterelectrode to form a capacitance ( 40, 42 ), this capacitance being responsive to an electric-field-influencing property of an object or person proximate to the antenna electrode. The counterelectrode may be or may not be part of the capacitive sensor. The capacitive sensor further comprises a capacitive sensing network connected to the antenna electrode to apply an oscillating signal thereto and to and to determine the capacitance based upon characteristics of the oscillating signal. The capacitive sensing network includes at least one inductor ( 16 ) and a plurality of reactive components ( 36 ) arranged to form a resonant network together with the capacitance ( 40, 42 ), the plurality of reactive components being activatable and deactivatable in such a way as to modify a resonance frequency of the resonant network. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 12/997,206, filed Dec. 9, 2010 (now pending), the disclosure of which is herein incorporated by reference in its entirety. The U.S. patent application Ser. No. 12/997,206 is a national entry of International Application No. PCT/KR2009/002692, filed on May 22, 2009, which claims priority to Korean Application No. 10-2008-0056179 filed on Jun. 16, 2008, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a driver IC chip, and more particularly, to a driver IC chip and a pad layout method thereof, which are capable of improving adhesion performance of a driver IC mounted through a chip-on-glass (COG) technique.
[0004] 2. Description of the Related Art
[0005] Liquid crystal displays (LCD) refer to devices which displays image data by passing light through liquid crystal, using a characteristic that the alignment state of liquid crystal molecules differ depending on an applied voltage. Recently, a thin film transistor (TFT) LCD has been most actively used among the devices. The TFT LCD is fabricated through a technology for fabricating a silicon IC circuit.
[0006] The above-described LCD is an example of flat panel display devices which may include an organic light emitting diode (OLED) and the like.
[0007] FIG. 1 schematically illustrates the structure of a conventional LCD as an example of flat panel displays.
[0008] The TFT LCD includes a TFT array substrate and a color filter substrate which face each other and are bonded to each other with a predetermined space provided therebetween. The TFT LCD further includes an LCD panel 30 formed by injecting an liquid crystal layer into the predetermined space and a driving circuit for driving the LCD panel 30 .
[0009] The driving circuit includes a gate driver IC 40 , a source driver IC 20 , a timing control unit 10 , and a power supply unit (not illustrated). The gate driver IC 40 is configured to sequentially apply a scanning signal to gate lines at each frame, the source driver IC 20 is configured to drive a source line in response to the scanning signal of the gate driver IC 40 , the timing control unit 10 is configured to control the gate driver IC 40 and the source driver IC 20 and output pixel data, and the power supply unit is configured to supply various voltages used in the LCD.
[0010] In general, a method for connecting the driver IC to the LCD panel may include a tape automated bonding (TAB) method and a COG method. According to the TAB method, a driver IC is mounted on a thin flexible film made of polymer, that is, a tape carrier package (TCP), and the film is connected to the LCD so as to electrically connect between the driver IC and the LCD panel. According to the COG method, the driver IC is directly mounted and connected on a glass substrate of a LCD panel through a bump.
[0011] Conventionally, the TAB method has been frequently used because the TAB method has reliable connection and may be easily improved. Recently, however, with the development of micro mounting technology, the COG method has been mainly used because the COG method is favorable to miniaturization and has a low fabrication cost.
[0012] According to the COG method, an output electrode of a driver IC is directly connected to a pad so as to integrate a substrate and the driver IC. In the COG method, a bump and the pad are bonded through conductive particles positioned between the bump and the pad.
[0013] Furthermore, driver IC chips mounted on an LCD panel are connected to each other according to a line-on-glass (LOG) method in which signal lines are directly mounted on a TFT array substrate, and receive a control signal and driving voltages from a timing control unit and a power supply unit.
[0014] FIG. 2 illustrates the pad layout of a conventional driver IC chip that is mounted according to the COG method.
[0015] Referring to FIG. 2 , the driver IC chip may be formed in a rectangular shape having longitudinal sides and transverse sides on the basis of characteristics of a flat panel display device such as an LCD application.
[0016] The conventional driver IC chip 200 , which is mounted according to the COG method, includes an internal circuit 210 disposed between the longitudinal sides facing each other, an input pad 220 between the internal circuit 210 and one of the longitudinal sides, and an output pad 230 disposed between the internal circuit 210 and the other of the longitudinal sides. The driver IC chip 200 may further include a plurality of power pads 241 a to 241 d and 242 a to 242 d and the like, which are disposed therein. Reference numerals 251 and 252 represent power lines formed on glass.
[0017] When all of the internal circuit, the input pad, the output pad, the power pads and the like are designed in the driver IC chip of the flat panel display device, the area of the driver IC chip must be increased. As the area of the driver IC chip is increased, the utilization efficiency of glass may be reduced.
[0018] Thus, according to the conventional method, when a source driver IC chip and a gate driver IC chip are designed, power pads are disposed at the input pad of the source driver IC chip and the gate driver IC chip, in order to reduce an area occupied by power lines and ground lines. Alternatively, the power pads may be disposed at a left or right side surface A of the source driver IC chip and the gate driver IC chip.
[0019] When the power pads are disposed at the input pad or the side surface A of the source driver IC chip and the gate driver IC chip, a force (adhesive force) for bonding the driver IC chip 200 on glass according to the COG method may not be uniformly applied onto the entire adhesion surface of the driver IC chip 200 . That is, when the power pads exist only at the input pad, an adhesive force of the input pad section may be larger than an adhesive force of the output pad section. Thus, an electrical connection state of the output pad section having a relatively small adhesive force may be degraded. As a result, an image defect may occur. On the other hand, when the adhesive force of the output pad section is larger than the adhesive force of the input pad section, an electrical connection state of the power pads of the input pad section having a relatively small adhesive force may be degraded. As a result, image noise or frequency defect may occur.
[0020] In the source driver IC chip and the gate driver IC chip, the adhesive force may not be uniformly applied because of the structural problem of the pad layout, and an image defect or frequency defect may occur due to the non-uniform adhesive force.
SUMMARY OF THE INVENTION
[0021] Accordingly, the present invention has been made in an effort to solve the problems occurring in the related art, and an object of the present invention is to provide a driver IC chip and a pad layout method thereof, which is capable of uniformly applying an adhesive force onto an adhesion surface of a driver IC chip mounted on a flat panel display device according to a COG method.
[0022] Another object of the present invention is to provide a driver IC chip and a pad layout method thereof, which applies dummy pads for improving an adhesive force of an adhesion surface of a driver IC chip mounted on a flat panel display device according to a COG method.
[0023] In order to achieve the above object, according to one aspect of the present invention, there is provided a driver IC chip including: an input pad section disposed in a longitudinal direction at one of two longitudinal sides of the driver IC chip; an output pad section disposed in the longitudinal direction at the other of two longitudinal sides of the driver IC chip; a first power pad section disposed between an end portion of the input pad section in the longitudinal direction and an end portion of the driver IC chip corresponding to the end portion of the input pad section; a second power pad section disposed between another end portion of the input pad section in the longitudinal direction and an end portion of the driver IC chip corresponding to the another end portion of the input pad section; a third power pad section disposed between an end portion of the output pad section in the longitudinal direction and an end portion of the driver IC chip corresponding to the end portion of the output pad section; and a fourth power pad section disposed between another end portion of the output pad section in the longitudinal direction and an end portion of the driver IC chip corresponding to the another end portion of the output pad section.
[0024] According to another aspect of the present invention, there is provided a driver IC chip including: an input pad section disposed at one longitudinal side of a rectangular adhesion surface and including one or two or more input pads arranged in a longitudinal direction; an output pad section disposed at the other longitudinal side of the adhesion surface so as to face the input pad section and including two or more output pads arranged in the longitudinal direction; a first power pad section including first power pads arranged at both sides of the input pad section in the longitudinal direction at the one longitudinal side, the first power pads are arranged seriately to the input pad section; and a second power pad section including second power pads arranged at both sides of the output pad section in the longitudinal direction at the other longitudinal side and providing an adhesive force corresponding to the first power pad section, the second power pads are arranged seriately to the output pad section.
[0025] According to another aspect of the present invention, there is provided a pay layout method of a driver IC chip, including: arranging one or two or more input pads in a longitudinal direction at the center of one longitudinal side of a rectangular adhesion surface so as to form an input pad section; arranging two or more output pads in the longitudinal direction at positions of the other longitudinal side of the adhesion surface, corresponding to the input pads, so as to form an output pad section; arranging first power pads at both sides of the input pad section in the longitudinal direction at the one longitudinal side so as to form a first power pad section, the first power pads are arranged seriately to the input pad section; and arranging second power pads at both sides of the output pad section in the longitudinal direction at the other longitudinal side so as to form a second power pad section for providing an adhesive force corresponding to the first power pad, the second power pads are arranged seriately to the output power pad section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above objects, and other features and advantages of the present invention will become more apparent after a reading of the following detailed description taken in conjunction with the drawings, in which:
[0027] FIG. 1 schematically illustrates the structure of a conventional LCD as an example of flat panel displays;
[0028] FIG. 2 illustrates the pad layout of a conventional driver IC chip that is mounted according to a COG method;
[0029] FIG. 3 illustrates a driver IC chip according to an embodiment of the present invention; and
[0030] FIG. 4 illustrates a driver IC chip according to another embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
[0032] FIG. 3 illustrates a pad layout of a driver IC chip according to an embodiment of the present invention. The driver IC chip according to the embodiment of FIG. 3 may be used as a gate driver IC chip or source driver IC chip used in a flat panel display such as an LCD or OLED. The driver IC according to the embodiment of FIG. 3 is based on a COG method in which a driver IC is mounted on glass (not illustrated), and the glass may correspond to glass constituting an LCD panel.
[0033] Referring to FIG. 3 , the driver IC chip 300 according to the embodiment of the present invention includes a plurality of pads formed on an adhesion surface which is bonded to power lines over the glass through a bump. The pads may be divided into an input pad section 320 , an output pad section 330 , and a plurality of power pads 341 to 346 . Furthermore, the adhesion surface of the driver IC chip 300 indicates a surface on which the plurality of pads are formed and which faces the glass when the driver IC chip 300 is bonded according to the COG method. The adhesion surface of the driver IC chip 300 is represented by the same reference numeral as the driver IC chip 300 , for convenience of description.
[0034] The driver IC chip 300 includes an internal circuit 310 disposed in the center thereof. The internal circuit 310 is mounted inside a package. The internal circuit 310 of FIG. 3 represents a plan position corresponding to the adhesion surface. Furthermore, the plurality of pads according to the embodiment of FIG. 3 may be formed to be exposed to the adhesion surface facing the glass, for the adhesion through bumps.
[0035] According to the embodiment of FIG. 3 , the input pad section 320 is disposed in a longitudinal direction at one of two longitudinal sides of the adhesion surface of the driver IC chip 300 , and the output pad section 330 is disposed in the longitudinal direction at the other of two longitudinal sides. The input pad section 320 is used as a terminal to receive an external signal such as data or a control signal, and the output pad section 330 is used as a terminal to output a signal processed in the driver IC chip 300 . The signal outputted from the output pad section 330 may include a source driving signal in the case of a source driver IC chip and a gate driving signal in the case of a gate driver IC circuit. The input pad section 320 and the output pad section 320 may be disposed in areas deviating from the internal circuit 310 and adjacent to the respective longitudinal sides. Furthermore, the input pad section 320 may include one or more input pads arranged to have the same structure or a symmetrical structure with respect to the center of the longitudinal side, and the output pad unit 330 may include one or more output pads arranged to have the same structure or a symmetrical structure with respect to the center of the longitudinal side.
[0036] According to the embodiment of the present invention, the power pads are disposed at the two longitudinal sides of the adhesion surface of the driver IC chip 300 , where the input pad section 320 and the output pad section 330 are disposed or the two longitudinal sides and two transverse sides of the driver IC chip 300 , unlike the conventional driver IC chip in which the power pads are disposed only at the input pad section or the side surface of the driver IC chip 300 .
[0037] FIG. 3 illustrates that the power pads are disposed at the two longitudinal sides and the two transverse sides of the driver IC chip 300 . The power pads 341 a to 341 d disposed at one side of the input pad section 320 positioned at one of the two longitudinal sides of the adhesion surface are referred to as a first power pad section 341 , the power pads 342 a to 342 d disposed at another side of the input pad section 320 positioned at the one of the two longitudinal sides of the adhesion surface are referred to as a second power pad section 342 , the power pads 343 a to 343 d disposed at one side of the output pad section 330 positioned at the other of the two longitudinal sides of the adhesion surface are referred to as a third power pad section 343 , and the power pads 344 a to 344 d disposed at another side of the output pad section 330 positioned at the other of the two longitudinal sides of the adhesion surface are referred to as a fourth power pad section 344 . Furthermore, the power pads 345 a to 345 d and the power pads 355 a to 355 d disposed at the transverse sides in both sides of the adhesion surface are referred to as fifth and sixth power pad sections 345 and 346 , respectively.
[0038] The first power pad section 341 is disposed at an area closer to an end portion of the input pad section 320 in the longitudinal direction than an end portion of the driver IC chip 300 corresponding to the end portion of the input pad section 320 in the longitudinal direction, the second power pad section 342 is disposed at an area closer to another end portion of the input pad section 320 in the longitudinal direction than an end portion of the driver IC chip 300 corresponding to the another end portion of the input pad section 320 in the longitudinal direction. The third power pad section 343 is disposed at an area closer to an end portion of the output pad section 330 in the longitudinal direction than an end portion of the driver IC chip 300 corresponding to the end portion of the output pad section 320 in the longitudinal direction. The fourth power pad section 344 is disposed at an area closer to another end portion of the output pad section 330 in the longitudinal direction than the end portion of the driver IC chip 300 corresponding to the another end portion of the output pad section 330 in the longitudinal direction.
[0039] The respective power pads of the first to sixth power pad sections 341 to 346 may be electrically connected to power lines 351 to 356 for supplying power, and the power lines 351 to 356 may include power lines formed on glass according to the LOG method. That is, the power pads at the longitudinal sides and the power pads at the transverse sides may be connected through the power lines formed in the LOG method so as to bypass the driver IC chip 300 .
[0040] The first to sixth power pad section 341 to 346 may include the first power pads 341 a to 346 a for supplying a first power VDD, the second power pads 341 b to 346 b for supplying a second power VSS 1 , the third power pads 341 c to 346 c for supplying a third power VCC, and the fourth power pads 341 d to 346 d for supplying a fourth power VSS 2 .
[0041] At this time, the first power VDD may be used as a power supply voltage for processing a digital signal, the second power VSS 1 may be used as a ground voltage for processing a digital signal, the third power VCC may be used as a power supply voltage for processing an analog signal, and the fourth power VSS 2 may be used as a ground voltage for processing an analog signal.
[0042] The first power pad section 341 formed at one end portion of the input pad section 320 in the longitudinal direction on the adhesion surface of the driver IC chip 300 is electrically connected to the fifth power pad section 345 positioned at an area closer to the first power pad section 341 between the fifth and sixth power pad sections 345 and 346 disposed at both sides of the adhesion surface of the driver IC chip 300 . At this time, a first power pad 341 a of the first power pad section 341 and a first power pad 345 a of the fifth power pad section 345 are connected through a first power pad connection line 361 a , and a second power pad 341 b of the first power pad section 341 and a second power pad 345 b of the fifth power pad section 345 are connected through a second power pad connection line 361 b.
[0043] The third power pad section 343 formed at one end portion of the output pad section 330 in the longitudinal direction on the adhesion surface of the driver IC chip 300 is electrically connected to the fifth power pad section 345 positioned at an area closer to the third power pad section 343 between the fifth and sixth power pad sections 345 and 346 disposed at both sides of the adhesion surface of the driver IC chip 300 . At this time, a third power pad 343 c of the first power pad section 343 and a third power pad 345 c of the third power pad section 345 are connected through a third power pad connection line 361 c , and a fourth power pad 343 d of the first power pad section 343 and a fourth power pad 345 d of the fifth power pad section 345 are connected through a fourth power pad connection line 361 d.
[0044] The first power pad connection line 361 a, the second power pad connection line 361 b, the third power pad connection line 361 c , and the fourth power pad connection line 361 d may be formed on glass according to the LOG method or formed in the driver IC 300 .
[0045] The second power pad section 342 formed at another end portion of the input pad section 320 in the longitudinal direction on the adhesion surface of the driver IC chip 300 is connected to the sixth power pad section 346 positioned at an area closer to the second power pad section 342 between the fifth and sixth power pad sections 345 and 346 disposed at both sides of the driver IC chip 300 . At this time, a first power pad 342 a of the second power pad section 342 and a first power pad 346 a of the sixth power pad section 346 are connected through a first power pad connection line 362 a , and a second power pad 342 b of the second power section 342 and a second power pad 346 b of the sixth power pad section 346 are connected through a second power pad connection line 362 b.
[0046] The fourth power pad section 344 formed at another end portion of the output pad section 330 in the longitudinal direction on the adhesion surface of the driver IC 300 is connected to the sixth power pad section 346 positioned at an area closer to the fourth power pad section 344 between the fifth and sixth power pad sections 345 and 346 disposed at both sides of the driver IC chip 300 . At this time, a third power pad 344 c of the fourth power pad section 344 and a third power pad 346 c of the sixth power pad section 346 are connected through a third power pad connection line 362 c , and a fourth power pad 344 d of the fourth power pad section 344 and a fourth power pad 346 d of the sixth power pad section 346 are connected through a fourth power pad connection line 362 d.
[0047] The first power pad connection line 362 a , the second power pad connection line 362 b , the third power pad connection line 362 c , and the fourth power pad connection line 362 d may be formed on glass according to the LOG method or formed in the driver IC chip 300 . According to the embodiment of FIG. 3 , the first and second power pad sections 341 and 342 are formed at one longitudinal side of the adhesion surface of the driver IC chip 300 , where the input pad section 320 is formed, and the third and fourth power pads sections 343 and 344 for providing an adhesive force corresponding to the adhesive force of the first and second power pad sections 341 and 342 are formed at the other longitudinal side where the output pad section 330 is formed. Thus, according to the embodiment of FIG. 3 , the adhesive force of the adhesion surface may be uniformly applied to the entire surface.
[0048] Furthermore, according to the embodiment of FIG. 3 , the fifth and sixth power pad sections 345 and 346 are formed at two transverse sides of the adhesion surface of the driver IC chip 300 . Thus, the adhesive force of the adhesion surface may be more uniformly applied to the entire surface.
[0049] The embodiment of the present invention may be configured as illustrated in FIG. 4 .
[0050] According to the embodiment of FIG. 4 , an input pad IN constituting an input pad section 420 is formed at one of two longitudinal sides of a rectangular adhesion surface of a driver IC chip 400 , and four output pads OUT constituting an output pad section 430 are formed at the other of the two longitudinal sides. FIG. 4 illustrates that the input pad section 420 include one input pad IN. However, the present invention is not limited thereto, but the input pad section 420 may include a plurality of input pads IN arranged in the longitudinal direction. Furthermore, FIG. 4 illustrates that the output pad section 430 includes four output pads OUT. However, the present invention is not limited thereto, but the output pad section 430 may include two or more output pads arranged in the longitudinal direction.
[0051] The input pad section 420 and the output pad section 430 may be configured to have the same or a symmetrical structure with respect to the center of the longitudinal side, and may have different lengths from each other. The length difference between the input pad section 420 and the output pad section 430 may cause a difference in adhesive force. The difference in adhesive force, caused by the length difference between the input pad section 420 and the output pad section 430 , may be compensated for by dummy pads DM formed in the first power pad section 440 .
[0052] The embodiment of FIG. 4 includes a first power pad section 440 formed at the one of the two longitudinal sides. The first power pad section 440 includes first power pads VCC, VSS 2 , and DM arranged at both sides of the input pad section 420 in the longitudinal direction. The first power pads VCC, VSS 2 , and DM of the first power pad section 440 may be arranged seriately to the input pad section 430 .
[0053] Furthermore, the embodiment of FIG. 4 includes a second power pad section 450 formed at the other of the two longitudinal sides. The second power pad section 450 includes second power pads VCC, VDD, VSS 1 , VSS 2 , and DM arranged at both sides of the output pad section 430 in the longitudinal direction. The second power pads VCC, VDD, VSS 1 , VSS 2 , and DM of the second power pad 450 may be arranged seriately to the power pad section 430 , in order to provide an adhesive force corresponding to the first power pad section 440 .
[0054] In the embodiment of FIG. 4 , the first power pads of the first power pad section 440 include one or more power pads VCC for a power supply voltage for processing an analog signal, one or more power pads VSS 2 for a ground voltage for processing an analog signal, and one or more dummy pads DM. Furthermore, the second power pads of the second power pad 450 include one or more power pad VDD for a power supply voltage for processing a digital signal, one or more power pads VCC 1 for a ground voltage for processing a digital signal, a power pad VCC for a power supply voltage for processing an analog signal, a power pad VSS 2 for a ground voltage for processing an analog signal, and one or more dummy pads DM.
[0055] The number of the first power pads VCC, VSS 1 and DM of the first power pad section 440 and the number of the second power pads VCC, VDD, VSS 1 , VSS 2 and DM of the second power pad section 450 may be set to be equal to each other, in order to uniformize the adhesive force. Furthermore, the first power pad section 440 and the second power section 450 may have the same structure or a symmetrical structure. FIG. 4 illustrates a symmetrical structure.
[0056] Furthermore, the first power pads VCC, VSS 1 and DM of the first power pad section 440 and the second power pads VCC, VDD, VSS 1 , VSS 2 and DM of the second power pad section 450 may be arranged to the have the same structure or a symmetrical structure with respect to the center of the longitudinal side, in order to equalize the adhesive force. The embodiment of FIG. 4 has a symmetrical structure.
[0057] As described above, the first and second power pad sections 440 and 450 include one or more dummy pads DM. The dummy pads DM are formed to compensate for a pattern such that the first and second power pad sections 440 and 450 arranged to have the same structure or a symmetrical structure. The dummy pads DM may be arranged symmetrically with respect to the center of the longitudinal side in one or more of the first and second power pad sections 440 and 450 . Furthermore, the first power pad section 440 may include a dummy pad DM formed in an area adjacent to the input pad section 420 so as to compensate for a length difference between the input pad section 420 and the output pad section 430 .
[0058] The first and second power pad sections 440 and 450 may include one or more power pads formed in an area divided on the basis of the center of the longitudinal side and configured to provide the same power.
[0059] A pad layout method for forming the embodiment of FIG. 4 includes arranging one or two or more input pads at one longitudinal side of a rectangular adhesion surface in a longitudinal direction so as to form the input pad section 420 ;
[0060] arranging two or more output pads at positions of the other longitudinal side of the adhesion surface, corresponding to the input pads, in the longitudinal direction so as to form the output pad section 430 ; and arranging first power pads formed at the one longitudinal side so as to form the first power pad section 440 , such that the first power pads are arranged seriately to the input pad at both sides of the input pad section 420 in the longitudinal direction; and arranging second power pads formed at the other longitudinal side so as to form the second power pad section 450 for providing an adhesive force corresponding to the first power pad section 440 , such that the second power pads are are arranged seriately to the output pads at both sides of the output pad section 430 in the longitudinal direction.
[0061] The embodiment of FIG. 4 may include a third power pad section 460 and a fourth power pad section 470 which are formed at transverse sides in both sides of the adhesion surface of the driver IC chip 400 , and the third and fourth power pad section 460 and 470 include four power pads VDD, VSS 1 , VCC and VSS 2 as third and fourth power pads, respectively. The embodiment of FIG. 4 may have an adhesive force increased by the third and fourth power pad sections 460 and 470 . As a result, a uniform adhesive force may be applied to the adhesion surface of the driver IC chip 400 .
[0062] The third power pads VDD, VSS 1 , VCC and VSS 2 of the third power pad section 460 and the fourth power pads VDD, VSS 1 , VCC and VSS 2 of the fourth power pad section 470 may be arranged symmetrically with respect to the center of the longitudinal side.
[0063] In the embodiment of FIG. 4 , power pads at one side of the center of the first and second power pad sections 440 and 450 may be electrically connected to the power pads of the third power pad section 460 through a first power pad connection line (not illustrated). Furthermore, power pads at the other side of the center of the first and second power pad sections 440 and 450 may be electrically connected to the power pads of the fourth power pad section 470 through the second power pad connection line (not illustrated). The first and second power pad connection lines may be formed in an LOG type so as to bypass the driver IC chip.
[0064] As described above with reference to FIGS. 3 and 4 , the adhesive force may be uniformly applied onto the entire surfaces of the driver IC chips 300 and 400 . Thus, it is possible to prevent an image defect, image noise or noise defect which may occur due to an adhesion defect, when the driver IC chips 300 , 400 is bonded according to a COF method.
[0065] Furthermore, the power pads are formed at four sides of the driver IC chips 300 and 400 . Thus, the embodiments of the present invention not only may uniformly provide an adhesive force for four sides, but also may provide power according to various mounting methods.
[0066] The embodiments of the present invention may be applied to a panel for a source driver IC cascade type COG, a GIP (Gate In Panel) for a source driver IC cascade type COG, and an LCD module or LCD display system fabricated using the panel.
[0067] According to the embodiments of the present invention, the adhesion surface of the driver IC chip mounted on a flat panel display device according to the COG method may have a uniform adhesive force through the pads which are uniformly distributed at the longitudinal sides or transverse sides. Thus, the adhesion state between the driver IC chip and the glass may be improved, and an image defect, image noise and frequency defect may be prevented.
[0068] Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and the spirit of the invention as disclosed in the accompanying claims. | Provided is a driver IC chip of a liquid crystal display (LCD). The driver IC chip has a layout of power pads, which may uniformly apply an adhesive force on the entire adhesion surface of the driver IC chip, when the driver IC chip is mounted on a display panel according to a chip-on-glass (COG) technique. | 8 |
This is a divisional of copending U.S. application Ser. No. 760,358, filed July 30, 1985, now U.S. Pat. No. 4,667,465.
BACKGROUND OF THE INVENTION
This invention relates to internal combustion engine systems and, more particularly, to improvements in such systems which decrease noxious emissions, increase operating efficiency, and reduce maintenance requirements.
The emission of noxious gases by internal combustion engines (including Brayton turbine combustion cycle systems, diesel engines, Otto-cycle spark ignition engines, and the like) is a continuing problem. From an environmental standpoint, the noxious gases are unacceptable pollutants, and government has become heavily involved in the regulation of emission of such noxious gases. The cost to society is very substantial, as measured by the degradation of the environment plus the cost of limiting or controlling such emissions, which is ultimately paid by the consumer. It is also well known that a combustion process which results in a high level of noxious emissions is generally less efficient, from the standpoint of energy output, than the same process operating in a manner which results in a lower level of noxious emissions.
It has long been recognized in the art that controlled injection of water into a combustion engine can, under certain conditions, increase the operating efficiency and reduce the noxious emissions in the exhaust. One drawback of prior art water injection has been the almost immediate corrosion which can occur when water is introduced (either intentionally or during an injection malfunction) directly to hot engine components.
The products of combustion are rich in oxides of nitrogen (NO x ) formed when unburned oxygen combines with nitrogen, the inert component of ambient air at elevated temperatures. NO x is an environmental hazard. Excess air is technically defined as that quantity in excess of the theoretical quantity required for complete combustion of a fuel. The combustion turbine, to which the present invention has particular although not exclusive application, operates at very high excess air rates. The high excess air rates produce high levels of noxious and toxic NO x . Fuelbound nitrogen and sulfur also cause problems.
It is know that NO x and other noxious emissions can be reduced by water injection in the combustion chamber, which reduces flame temperatures. Unfortunately, heat needed to vaporize the injected water is wasted energy. Also, to preclude scaling, costly ultra-pure water is needed. Externally produced steam has also been used as an injection medium to reduce NO x , but this requires substantial additional energ and adds additional environmental hazards due to volatile anticorrosive chemicals found in high pressure steam.
In the U.S. Pat. No. 4,313,300, the quantity of NO x emissions generated by a combined gas turbine-steam boiler power plant is controlled by recycling steam boiler exhaust gas to the air compressor of the gas turbine, thereby increasing the combustor inlet humidity.
In the U.S. Pat. No. 4,231,333 fuel or water injection into an internal combustion engine is controlled based upon detection of predetermined engine conditions, such as pressure within the engine intake manifold.
In the U.S. Pat. No. 4,417,547 atomized fluid from a nozzle is injected into the carburetor of an internal combustion engine, the rate of fluid injection being varied in response to variations in engine speed and engine load.
It is among the objects of the present invention to provide internal combustion engine systems which improve over the described types of systems, and which decrease noxious emissions, increase operating efficiency, and reduce maintenance requirements.
SUMMARY OF THE INVENTION
Applicant has discovered that an ultrasonic fog generator can be used to advantage in injecting a fog into the air received by a combustion chamber, in order to improve the efficiency of the combustion chamber and/or reduce the noxious emissions in the exhaust of the combustion chamber.
A form of the invention is applicable to a turbine power generator which includes a source of input air, a source of fuel, a compressor which receives the input air, a combustion chamber which receives air from the output of the compressor and fuel from the source of fuel, a turbine which receives exhaust gases from the combustion chamber, and an electrical generator mechanically coupled with the turbine. In accordance with the improvement of this embodiment of the invention, a fogging device is provided and communicates with the input air, the fogging device being adapted to receive a fogger air supply and a fogger water supply, and to generate a fog in the source of input air. The fogging device preferably operates to achieve evaporation to dryness prior to entry into the combustion chamber; the vapor phase of the water being much less harmful than the liquid. Means are provided for sensing noxious emissions in the exhaust gases. Means are then provided for controlling the fogging device in accordance with the sensed noxious emissions. In the preferred embodiment of the invention, the sensing means is operative to sense the concentration of the noxious emissions, and the controlling means controls the fogging device to increase the water volume per unit time of the fog as the concentration of the noxious emissions increases.
In a form of the invention, the means for sensing noxious emissions in the exhaust gases includes a sensor adapted to be disposed in the exhaust gases for sensing the concentration of a noxious emission such as NO x and generating an electrical signal which depends upon said concentration. In this embodiment, the means for controlling the fogging device includes a processor responsive to the electrical signal for generating a control signal, and a pneumatic control system responsive to the control signal for controlling the supply of compressed air and the supply of water to the fogging device. The fog can be controlled by a humidity and dewpoint sensor, to assure only a vapor phase at entry to the combustion chamber. The present invention also has application to other types of systems having a combustion chamber, including diesel engines, auto-cycle spark ignition engines, and the like.
Among the advantages of the present invention are the following:
The formation of NO x is endothermic and removes available energy. Accordingly, by reducing NO x formation, a substantial increase in efficiency is obtained.
Excess air is diminished as fog vapor displaces excess air at the input to the combustion chamber. Less excess air results in less NO x formation.
When a fog, which has droplets of about 10 microns or less size, is produced, minerals dissolved therein are evaporated to dryness and travel, with little deleterious effect, through engine components as sub-micron dust particles. This reduces the need for expensive ultrapure water, often used for engine water injection in industry.
The use of an ultrasonic fogger is advantageous in providing a uniform humidity in the air which enters the combustion chamber, which overcomes uniformity problems associated with some water injection techniques.
By modifying the fog water content as a function of the measured noxious emissions, the fog can be precisely tailored to minimize noxious emissions.
In accordance with a further feature of the invention, a supply of chemical suitable for reacting with a component of the noxious emissions (for example calcium carbonate or bicarbonate or calcium oxide to react with sulfur in noxious sulfur dioxide) is provided, along with means for combining the chemical with the water supplied to the fogging device.
Further features and advantages of the invention will become more readily apparent from the following detailed description and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram, partially in schematic form, of an apparatus in accordance with an embodiment of the invention, and which can be used to practice a form of the method of the invention.
FIG. 2 is a diagram, partially in schematic crosssectional form, of a fogging unit and associated control system, as utilized in an embodiment of the invention.
FIG. 3 is a flow diagram of a routine for the processor of the FIG. 1 embodiment.
FIG. 4 is a block diagram, partially in schematic form, of an apparatus in accordance with another embodiment of the invention, and which can be used to practice a form of the method of the invention.
FIG. 5 shows a diagram of a further feature in accordance with the invention.
FIG. 6 is a flow diagram of a routine for controlling chemical concentration of the water supplied to the fogging devices.
FIG. 7 is a diagram of an adjustable heat exchanger as used in a disclosed embodiment.
FIG. 8 is a flow diagram of a routine for controlling the adjustable heat exchanger of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown an apparatus in accordance with an embodiment of the invention, and which can be used to practice a form of the method of the invention. A combustion turbine power generating system is shown, and conventionally includes a compressor 110 and a turbine 120 which are mounted on a common shaft 130 that is coupled, in the present embodiment, to a starting motor 140 and an electrical generator 150. A blower 160 provides a forced draft of air through a chamber which includes a fogging subsystem 200 and then through input duct 115 to the input opening of compressor 110. Compressed air is coupled from the output of compressor 110, via the duct 165, to an input of a combustion chamber 170. A source of fuel 171 is fed to the combustion chamber 170 via a fuel pump 175 and a fuel nozzle 178. The hot combustion gases from combustion chamber 170 are fed to the input of turbine 120 via the duct 179. As described further hereinbelow, the exhaust gases output from the turbine at 121 can be passed through a heat exchanger (shown at 190) which reclaims some of the heat of the exhaust gases, this heat being used for preheating of the input air, as indicated by the coils 190A and 190B.
A noxious emission sensing unit 300 is disposed in the path of the exhaust gases; i.e., it can be located in said exhaust gases from the combustion chamber 170 before or after the turbine 120. As illustrated, although not necessarily, the sensing unit 300 is located at the output port from which the exhaust gases leaving the turbine are emitted. The sensing unit 300 includes one or more sensing devices.
The fogging subsystem 200, which includes one or more fogging devices, is located in the path of the air that is input to the compressor 110. In the present embodiment four ultrasonic fogging devices 250 are shown, two positioned after the heating coil 190A and two after heating coil 190B.
As used herein, "fog" means water droplets in air that have a size of the order of 10 microns or less, are relatively unstable due to their small volume as compared to their surface area, and therefore evaporate to dryness in the air. The water droplets are propelled by the force of compressed air at velocities high enough to assure uniform mixing through cross flow injection into a receiving air stream. An embodiment of a fogging device 250 is shown in simplified form in FIG. 2.
Each fogging device of the present embodiment comprises a nozzle 251 having a cylindrical body 252 with a central bore 253. Compressed air from a source 291 is coupled to the bore 253. The compressed air may alternatively be bled from compressor 110. Water under pressure, from a source 292, is coupled through a transversely disposed conduit 254 that communicates with the bore 253. An adjustable resonator cup 255, facing the nozzle opening at the front end of bore 253, is mounted on an "L"-shaped standoff 256 that extends from body 252 and permits controlled dispersion of the fog.
In operation, as the pressurized air pulsates through the bore 253, water pulsates through the conduit 254 and mixes with the air in the bore 253. The ultrasonic standing shock wave in the bore shears the water particles into fine droplets. The resonator cup 255 reflects the high speed air against the emerging water particles or droplets in a manner that reduces the water droplets to a size of the order of 10 microns or less, and deflects these minute droplets outward for cross flow mixing with the primary air flow passing through the fogging subsystem 200. The droplets are formed in a tunable field whose shape can be selected by the variable distance between the opening and front flat reflective face of nozzle 251 and the resonator cup 255. The flow of both compressed air and water input to the fogging devices 250 is controlled by control unit 600, so as to increase or decrease the volume of generated fog at uniform fog density.
The type of fogging unit illustrated in FIG. 2 is described in further detail in the copending U.S. patent application Ser. No. 697,335 and ultrasonic foggers are also disclosed, for example, in U.S. Pat. Nos. 4,042,016 and 4,118,945. Suitable foggers are sold by Cool Fog Systems, Inc. of Rye Brook, N.Y.
In the present embodiment, the noxious emissions sensing unit 300 is of the type that employs an NO x sensing element which, as known in the art, is operative to produce an output electrical signal that is proportional to the concentration of oxides of nitrogen in the gases passing over the sensing element. The unit 300 may be of the type made by General Instrument Corp. or by Delco division of General Motors Corp. Also, it will be understood that sensors of other types of noxious emissions can be employed, such as an SO x sensor.
The output 300A of sensing unit 300 is coupled to an input of a processor 500. The processor 500 may comprise any suitable microprocessor, such as a Model Z80 processor sold by Zilog Corp. or other suitable general or special purpose digital or analog processors, having the conventional associated clock, memory, and input/output peripherals. Outputs 500A of the processor 500 are coupled to pneumatic control system 600 which, in the present embodiment, may be of the type, for example, manufactured and sold by Honeywell Corp. of Minneapolis, Minn. It will be understood, however, that alternative control means can be employed. In the present embodiment the pneumatic control system 600 is operative, in response to signals on lines 500A to control together (i.e., to increase together or decrease together, depending on control signals 500A) the compressed air supply from source 291 and the pressurized water supply from source 292 to the fogging units 250.
Referring to FIG. 3, there is shown a flow diagram of a routine under which the processor 500 can be controlled to receive signals from the noxious gas sensing unit 300, and generate control signals for controlling the pneumatic control system 600. In the routine of FIG. 3, interrupt signals are generated periodically or at a rate determined by the operator. Alternatively, the interrupt signal can be derived from a handshake signal from the system 600, indicating that it is ready to receive a further control signal. In the routine of FIG. 3, upon an occurrence of an interrupt signal, the level of the voltage from the noxious gas sensing unit 300 is read and stored, as represented by the blocks 611 and 612. Control signal values are then obtained from the stored sensor signal, as represented by the block 613. [The stored sensor signals can also be permanently recorded, so as to have a permanent record of noxious emission levels. A look-up table may be used, for example, to store control signal values as a function of sensor readings. Within threshold limits, the control signals will reflect an increase in water content of the fog as the level of noxious emissions increases, and vice versa, to move toward a set point emission level. However, it will be understood that suitable computed or empirically derived curves can be stored in processor 500 for obtainment of the control signals. A determination is then made (diamond 614) as to whether or not the computed control signals are different from the previously applied values. If not, block 620 is entered directly and the next interrupt is awaited. If there has been a change, the new control signals are applied to pneumatic control system 600 via the lines 500A (block 615) and the block 620 is then entered to await the next interrupt.
Referring to FIG. 4, there is shown a diagram of another embodiment of the invention in a turbine power generation system, but wherein the ultrasonic fogging unit, labelled 200', is located at the output end of the compressor 110. In this embodiment, wherein elements having like reference numerals correspond to their counterparts in the FIG. 1 diagram, the turbine 120 and the compressor 110 are coupled together via gearing 410 that is driven by the turbine 120. A portion of the gearing 410 is used to drive generator 150. In this embodiment, the compressor 110 receives ambient air, the process of compressing this air causing a rise in its temperature to, for example, 700 degrees F. [The temperatures given here and elsewhere are conditions.] The compressed and heated air from compressor 110 is passed through fogging chamber 200', which includes fogging devices 250 as previously described. The humidifying of the air cools the air to a temperature, for example, of 450 degrees F. This air enters a heat exchanger 450, where it is again heated, with heat from the turbine exhaust gases, back to a temperature of, for example, about 700 degrees F. The heat exchanger of the present embodiment is of shell and tube type and includes a number of tubes 451 through which the air to be heated is passed. The tubes are connected by heat-conducting fins. The exhaust gases exiting the turbine 120 are passed over the fins and tubes to effect the heat exchange from the exhaust gases to the compressed and humidified air entering combustion chamber 170. This embodiment has some operational advantages. The compressor will operate at a higher efficiency to compress the air before humidification, and the heated compressed air is easier to humidify. The heat exchange adds heat to the air that is cooled at constant enthalpy by the humidifying process and the heat exchange is efficient due to the temperature difference between the exhaust gases (at, say, 1000 degrees F.) and the humidified compressed air.
Referring to FIG. 5, there is shown a further feature which can be employed, for example, in the embodiments of FIGS. 1 or 4 to even further reduce noxious emissions, or in FIGS. 1 or 4 to even further reduce noxious emissions, or in other forms of the invention in conjunction with other types of internal combustion engines. In accordance with the feature of FIG. 5, a source of chemical 510 is provided, and is mixed or dissolved into the water supply 292 to the fogging subsystem 200 or 200'. The chemical is selected for combination with an expected noxious gas component of the combustion exhaust. For example, to reduce sulfur dioxide, a solution of calcium hydroxide may be used. Accordingly, the chemical 510 may be a calcium-bearing compound such as calcium oxide, calcium carbonate or calcium bicarbonate. The fogging subsystem is a particularly advantageous way of uniformly and accurately introducing the chemical into the combustion chamber without special carrier means, etc. As the water is evaporated to dryness in the fogged air, the dissolved solids are introduced to the combustion chamber as tiny particles which readily react with the undesirable noxious components. In the embodiment of FIG. 5, a bulk supply of chemical 510 is provided in a silo 520 which has a pneumatically controlled rotary valve 525 that controls the flow of chemical into water supply tank 292. The water in tank 292 is supplied to the fogging devices, as represented in FIGS. 1 and 4. An I/P transducer 528 is provided and receives a control signal from the processor 500 (e.g. FIG. 1), which is converted to a pressure signal that regulates the valve 525 to determine the concentration of the solution in tank 292. A pH sensor 529 provides a signal to the processor for monitoring the solution in tank 530. It will be understood that other techniques can be provided for controlling and maintaining the concentration of the solution provided to the fogging devices. Also, other noxious components, such as NO x can be further controlled in this way, and more than one chemical can be utilized if desired.
The control of the concentration of chemical in the water supplied to the ultrasonic fogging devices is in accordance with the sensed level of noxious emissions, such as are sensed by sensing devices in the sensor unit 300 of FIG. 1 or FIG. 4. The concentration can be under direct operator control (and thereby determined from readings at one or more of the sensors) or can be under control of the processor 500 (as indicated by the line 500B) or a separate processor.
Referring to FIG. 6, there is shown a flow diagram of a routine under which the processor 500 can be controlled to receive signals from the noxious gas sensing unit 300, and generate control signals for controlling the transducer 528 and the valve 525 to obtain the desired concentration of chemical in the water supplied to the fogging devices 250. In the routine of FIG. 6, interrupt signals are again generated periodically or at a rate determined by the operator, or can be derived from handshake signals. Upon occurrence of an interrupt signal, the level of the voltage from the noxious gas sensing unit 300 is read and stored, as represented by the blocks 651 and 652. [Again, the measured sensor signals can also be permanently recorded, so as to have a permanent record of noxious emission levels.] The measured value is then compared to a predetermined standard value range, as represented by the decision diamond 660. If the measured value is greater than the predetermined standard value range, the particular noxious emission being measured (e.g. sulfur dioxide) is higher than desired, and this results in the issuance of a control signal (block 670) which tends to open further the valve 525 to increase the concentration of the chemical 510 in the water supply. If the measured value is below the standard value range, the chemical concentration can be reduced. Accordingly, the block 680 represents the issuance of a control signal that tends to close valve 525. If, however, the measured value is within the predetermined standard range, the control signal to valve 525 maintains the valve setting at its present state. The block 690 is then entered to await the next interrupt.
It will be understood that the processor 500 can operate to control both the amount of fog generated, and the chemical concentration of the fog, based either on the sensed level of a single type of noxious emission (such as NO x ) or two or more types of noxious emissions (such as NO x and SO x ).
Referring to FIG. 7, there is shown a diagram of an adjustable heat exchanger that is utilized, for example, in the embodiment of FIG. 1, some components of which are shown again in FIG. 7. As described generally in conjunction with FIG. 1, a heat exchanger includes coil 190 located in the exhaust path, the coil 190 being coupled in a closed loop pipe with coils 190A and 190B, which heat the air to be fogged by the fogging devices 250. A pump 730 circulates the heat exchange fluid, typically water, in the closed loop system. In the FIG. 7 embodiment a temperature sensor 711 and dewpoint temperature sensor 712 are provided in the path of the input ambient air and temperature and humidity sensors 721 and 722 are also respectively provided in the path of the fogged air. The readings from these sensors are input to the processor 500. A pneumatically-controlled valve 751 regulates the flow of the heat exchange fluid around the closed loop. The valve 751 is controlled by the output of an I/P transducer 752, which operates under control of a control signal from processor 500 (e.g. FIG. 1 or FIG. 4).
In operation, the level of heat exchange is regulated, by controlling valve 751, in accordance with the amount of heat necessary to preheat the ambient air to a temperature that facilitates the humidification by the fogging devices 250. The desired level of fogging may be determined from consideration of reduction of noxious emissions (as described above) or otherwise. The temperature sensor 711 and dewpoint temperature sensor are used to determine respective properties of the input air, and heat exchange can be either manually controlled in accordance therewith, or automatically controlled such as by using a look-up table technique, to determine the level of heat exchange. It will be understood that in this and other embodiments, the humidity of the input air can be taken into account in determining the desired level of fogging by the fogging devices 250. Also, sensors 721 and 722 and/or other sensors can be used to monitor the characteristics of the humidified air.
Referring to FIG. 8, there is shown a flow diagram of a routine under which the processor 500 can be controlled to receive signals from the sensors 711 and 712 and generate control signals for controlling the transducer 752 and the valve 751 to obtain the desired heating of the input air by control of the heat exchange process. In the routine of FIG. 8, interrupt signals are again generated periodically or at a rate determined by the operator, or can be derived from handshake signals. In the routine of FIG. 8, upon an occurrence of an interrupt signal, the sensor levels are read and stored, as represented by the blocks 811 and 812. [Once again, the measured sensor signals can also be permanently recorded, so as to have a permanent record of temperature, humidity, etc.] The measured values are then input to a look-up table, which may also receive an input representing the desired humidity of the fogged air (diamond 821). The look-up table output will be a temperature variation polarity for the input air; i.e., one which dictates an increase, decrease, or no-change in temperature of the input air. [It will be understood that the look-up table, or other means can also provide values for controlling the fogging units, as described hereinabove.] If the temperature of the input air is to be increased from its present temperature then the block 831 is entered, this block representing the issuance of a control signal which tends to open further the valve 751 (FIG. 7) to increase the level of heat exchange to the input air. If the temperature of the input air is to be decreased from its present temperature, the block 833 is entered, this block representing the issuance of a control signal which tends to close further the valve 751. If the temperature of the input air is determined to be in a presently acceptable range, the control signal to the valve 751 is maintained at its present state. In all cases the block 850 is then entered to await the next interrupt.
The invention has been described with reference to particular preferred embodiments, but variations within the spirit and scope of the invention will occur to those skilled in the art. For example, as indicated above, the invention also has application to other types of internal combustion engines. Also, other arrangements of the components of the turbine power generation system can be employed. Finally, it will be understood that the control processor can utilize various other techniques for obtaining output control signals from the sensed concentration of noxious emissions or other measured or preset conditions. | An ultrasonic fog generator can be used to advantage in injecting a fog into the input air of a combustion chamber, in order to improve the efficiency of the combustion chamber and reduce the noxious emissions in the exhaust. In accordance with a feature of the disclosure, a sensor is provided to sense the concentration of noxious emissions in the exhaust of the combustion chamber. The volume per unit time of the injected fog is increased as the concentration of the noxious emissions increases, and controlled to a preselected emissions setpoint. In accordance with a further feature of the disclosure, a supply of chemical suitable for reacting with a component of the noxious emissions is provided, along with means for combining the chemical with the water supplied to the fogging device. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is directed to a training device for indicating to golfers the correct stroke direction taking into account the slope of the putting green or other terrain in close proximity to the putting green.
[0003] 2. Description of Prior Art
[0004] In the game of golf, putting greens and fringe areas alongside the greens are frequently sloped in several directions in order to add additional skill requirements for golfers. Strokes referred to as chip or lob strokes will not often not travel in a straight line to the hole once they hit the ground. Also the path of the golf ball during a putting stroke will curve according to the slope of the green between the hole and the position of the ball on the green. This concept is sometimes difficult to explain to new golfers. Verbal instruction as to where to initially direct the golf ball such as inside the right edge of the cup or one cup to the left are not readily understood.
[0005] Consequently, there is a need for a training device that will readily assist a new golfer in understanding the need to compensate for the slope of the terrain on or near the green when attempting a stroke.
BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS
[0006] These and other needs in the art are addressed by an apparatus that includes a plurality of colored balls on a support device. In one embodiment the balls are supported by a vertical shaft that is adapted to be placed within a regulation golf cup and supported in the same manner as a flagstick. In another embodiment, the training device is supported above the ground by a pair of spaced support legs.
[0007] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0009] FIG. 1 is a perspective view of an embodiment of the invention adapted to be supported within a conventional golf cup.
[0010] FIG. 2 is a top view of the device placed in a golf cup and showing possible paths of the golf ball to the golf cup.
[0011] FIG. 3 is a perspective view of a second embodiment of the invention adapted to rest upon a golfing surface such as the green or fringe area.
[0012] FIG. 4 is a perspective view of an alternate embodiment of the support member shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] FIG. 1 illustrates a first embodiment of the training device 10 which is adapted to be positioned within a conventional golf cup located on the green surface 12 . The device includes a vertical shaft 13 which is adapted to be placed in a supporting hole 45 which normally supports a flagstick within the golf cup 11 . A horizontally extending shaft having arms 15 and 14 is secured at its mid-point to vertical shaft 13
[0014] A plurality of bodies shown as spherical balls 16 - 27 are supported by arms 13 and 14 . Balls 16 - 27 may be the approximate size of a golf ball and have a central bore through which arms 15 and 14 pass. The ball closest to vertical shaft 13 may be multicolored, one half 20 being of a different color. The same is true for half ball segments 22 and 23 . The remaining balls 16 - 19 and 24 - 27 are also of different colors from each other. Balls 22 - 27 may have the same color pattern of balls 16 - 21 as they are positioned away from shaft 13 . For example balls 19 and 24 may be off of the same color as well as half balls 21 and 22 .
[0015] FIG. 2 illustrates the use of the training device. The head of a putter 31 a may be positioned to be perpendicular to a straight line 29 to the hole which would correspond to a straight put having no break to it.
[0016] On the other hand, if the putt is expected to break to the right, the putter face 31 b would be positioned as shown at 31 b.
[0017] A golfer must “read” the green to estimate how much the putt will break. Depending on the estimate the instructor would tell the student which ball to aim at.
[0018] The anticipated path of the ball based on the estimate and aiming point is illustrated by the dotted lines 16 a - 27 a. Thus if by reading the green the golf ball would break two balls to the right, the student would be told to aim for ball 19 so that the ball would enter the cup in the middle. If the balls were one inch in diameter and the put was expected to break five inches to the right, then the student would be instructed to aim at ball number 17 .
[0019] For putts that were expected to break to the left as illustrated by lines 22 a - 27 a, the same process of instruction would be used with the face of the putter being generally oriented as shown at 31 c.
[0020] A second embodiment of the invention is illustrated in FIG. 3 . The device includes a pair of spaced apart supports 41 , 43 have ground engaging foot members 42 , 44 . Members 42 and 4 may have holes 62 such that a golf tee 61 may be used to anchor the supports to the ground. A shaft 45 is supported by supports 41 , 43 . Shaft 45 would have a length for example between one foot to 10 feet and supports 41 , 43 could be one inch to several feet in height. Balls 51 - 57 are supported on shaft 45 . Supports 41 and 43 may consist of two shafts that are vertically adjusted with respect to each other by any known mechanism.
[0021] In this embodiment ball 51 could be a first color and indicate a straight shot. This embodiment is intended to be used for a chip shot in which the ball 32 is struck by a lofted club such that the ball becomes airborne as a result of the stroke. Area 41 may correspond to the fringe area around green surface 12 .
[0022] Pair of balls 52 - 57 may be of the same color but a different color that the other pairs.
[0023] In use, the instructor would again “read” the green or surface to estimate the path of the ball once it lands on the surface of the fringe or green. The student would be instructed to hit the golf ball over or under the pair of balls that would represent the estimated path of the golf ball once it hits that surface. For example, if the estimated path of the ball is 53 a, then the student would be instructed to hit the ball 32 either over or under the pair of balls 53 .
[0024] FIGS. 4 illustrates an embodiment of the support mechanism of FIG. 1 . It includes a first shaft 13 adjustably positioned within support shaft 82 which is adapted to rest in aperture 45 of golf cup 11 . A compression fitting 81 may be provided for adjusting the position of shaft 13 within support shaft 82 . Any other known adjustment mechanism such as those discussed above may also be utilized.
[0025] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
[0026] Bodies 15 - 27 and 51 - 57 are shown spherical in shape, however they may be formed as other shapes such as rectangles or other bodies of revolution. | A golf stoke training aide includes a plurality of spaced spherical objects of different colors supported on or above a golf playing surface. The aide is placed between the golfer and golf hole cup. The spaced apart spheres represent the preferred direction to strike the ball based upon the anticipated path of the ball to the hole. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. patent application Ser. No. 60/486,467, filed Jul. 14, 2003, and is a continuation-in-part of U.S. patent application Ser. No. 10/602,022, filed Jun. 24, 2003 now U.S. Pat. No. 7,004,240, issued Feb. 28, 2006, which claims priority to U.S. patent application Ser. No. 60/391,006, filed Jun. 24, 2002, and is a continuation-in-part of U.S. patent application Ser. No. 09/896,561, filed Jun. 29, 2001 now U.S. Pat. No. 6,889,754, issued May 10, 2005, which itself claims priority to U.S. patent application Ser. No. 60/215,588, filed Jun. 30, 2000. These applications are herein incorporated by reference in their entirety.
TECHNICAL FIELD
This description relates to a system for heat transfer.
BACKGROUND
Heat transport systems are used to transport heat from one location (the heat source) to another location (the heat sink). Heat transport systems can be used in terrestrial or extraterrestrial applications. For example, heat transport systems may be integrated by satellite equipment that operates within zero- or low-gravity environments. As another example, heat transport systems can be used in electronic equipment, which often requires cooling during operation.
Loop Heat Pipes (LHPs) and Capillary Pumped Loops (CPLs) are passive two-phase heat transport systems. Each includes an evaporator thermally coupled to the heat source, a condenser thermally coupled to the heat sink, fluid that flows between the evaporator and the condenser, and a fluid reservoir for expansion of the fluid. The fluid within the heat transport system can be referred to as the working fluid. The evaporator includes a primary wick and a core that includes a fluid flow passage. Heat acquired by the evaporator is transported to and discharged by the condenser. These systems utilize capillary pressure developed in a fine-pored wick within the evaporator to promote circulation of working fluid from the evaporator to the condenser and back to the evaporator. The primary distinguishing characteristic between a LHP and a CPL is the location of the loop's reservoir, which is used to store excess fluid displaced from the loop during operation. In general, the reservoir of a CPL is located remotely from the evaporator, while the reservoir of a LHP is co-located with the evaporator.
SUMMARY
According to one general aspect, a system includes a primary evaporator operable to facilitate heat transfer by evaporating received liquid to obtain vapor, the primary evaporator including a first port for receiving the liquid from a liquid line, a second port for outputting the vapor to a vapor line, and a third port for outputting excess liquid received from the liquid line to an excess fluid line. A condensing system is operable to receive the vapor from the vapor line, to condense at least some of the vapor, and to output the liquid to the liquid line. A reservoir is in fluid communication with the condensing system, and the liquid is obtained at least partially from the reservoir. In the system, a primary loop includes the condensing system, the primary evaporator, the liquid line, and the vapor line, the primary loop being operable to provide a heat transfer path, and a secondary loop includes the condensing system, the primary evaporator, the liquid line, the vapor line, and the excess fluid line. The secondary loop is operable to provide a venting path for removing other vapor that is present within the liquid from the primary evaporator.
Implementations may include one or more of the following features. For example, the liquid in the primary evaporator and received from the liquid line may include the excess liquid in excess of a liquid amount necessary to maintain saturation of a primary wick within a core of the primary evaporator. In this case, the primary evaporator may include a secondary wick that is operable to perform phase separation of the other vapor from the liquid for output through the excess fluid line. Further, the primary wick and the secondary wick of the primary evaporator may maintain capillary pumping of the liquid, the excess liquid, and the vapor, so as to maintain flow control to and through the primary evaporator.
A mechanical pump may be included that is operable to facilitate the heat transfer by actively pumping the liquid for evaporation by the primary evaporator, and for output as the excess liquid flows through the third port to the excess fluid line. In this case, the reservoir may be positioned between an output of the condensing system and an input of the mechanical pump, or the mechanical pump may be positioned between an input of the condensing system and an output of the primary evaporator.
A bypass valve may be included in parallel with the mechanical pump, and may be operable to bypass the mechanical pump during a passive pumping operation of the liquid for evaporation by the primary evaporator. The mechanical pump may include a liquid pump that is oriented in series with the liquid line and positioned between the condensing system and the primary evaporator, or a vapor compressor that is oriented in series with the vapor line and positioned between the primary evaporator and the condensing system.
A sensor may be included that is operable to communicate a saturation level of a wick of the primary evaporator to the mechanical pump, wherein a pumping pressure delivered by the mechanical pump is adjusted, based on the saturation level, so as to maintain saturation of the wick with the liquid. A liquid bypass valve may be connected between the liquid line and the vapor line and may be operable to maintain constant pump speed operations of the mechanical pump. The primary evaporator may include a primary wick and a secondary wick, compositions of which may comprise metal.
A priming system may be included within the secondary loop, and the priming system may include a secondary evaporator coupled to the vapor line, and a secondary reservoir may be in fluid communication with the secondary evaporator and coupled to the primary evaporator by the excess fluid line, wherein the priming system may be operable to provide the liquid to the primary evaporator at least partially from the secondary reservoir. The condensing system may include a first condenser within the primary loop and coupled to the liquid line and to the vapor line, and a second condenser within the secondary loop and coupled to the excess fluid line and to the secondary reservoir.
The third port of the primary evaporator may be primarily used to output the excess liquid to the excess fluid line, and the third port may include a subport for outputting the other vapor to a vapor line, such that the vapor line is included within the secondary loop.
The liquid line may be coaxial to and contained within the excess fluid line. A second primary evaporator may be connected in parallel with the primary evaporator within the primary loop. A back pressure regulator may be oriented in series with the vapor line and positioned between the primary evaporator and the condensing system, and may be operable to substantially equalize heat load between the primary evaporator and the secondary primary evaporator. In this case, the back pressure regulator may restrict vapor from reaching the condensing system until a vapor space of the primary evaporator and of the second primary evaporator is substantially devoid of liquid.
A second primary evaporator may be oriented in series with the primary evaporator within the primary loop. The condensing system may include a plurality of condensers connected in parallel to one another. In this case, liquid outputs may be associated with each of the plurality of condensers and may be operable to output the liquid to the primary evaporator, and condenser regulators may be coupled to the liquid outputs and operable to regulate liquid flow therefrom.
A second primary evaporator may be connected with the primary evaporator within the primary loop, and a thermal storage unit may be coupled to the second primary evaporator. A second primary evaporator may be connected with the primary evaporator within the primary loop, and first and second flow controllers may be connected to the primary evaporator and the second primary evaporator, respectively, and may be operable to regulate liquid flow to the primary evaporator and the second primary evaporator, respectively, so as to ensure a substantially equal heat load distribution between the evaporators.
A second primary evaporator may be connected with the primary evaporator within the primary loop, and a condensing heat exchanger may be coupled to the second primary evaporator. A spray-cooled evaporator may be coupled to the condensing heat exchanger by way of a mechanical pump. The condensing system may include a body-mounted radiator, or may include a deployable or steerable radiator.
According to another general aspect, liquid is evaporated from a primary wick of a primary evaporator to thereby obtain vapor, the vapor is output through a vapor line coupled to the primary evaporator, and the vapor from the vapor line is condensed within a condensing system. The liquid is returned to the primary evaporator through a liquid line coupled to the primary evaporator, where a saturation amount of the liquid is provided so as to maintain a saturation of the primary wick during the evaporating. Excess liquid beyond the saturation amount is provided to the primary evaporator at least partially from a reservoir, through the liquid line, and the excess liquid and other vapor within the primary evaporator is swept to the condensing system.
Implementations may include one or more of the following features. For example, in evaporating liquid from the primary wick of the primary evaporator capillary pumping of the liquid, the excess liquid, and the vapor may be maintained, so as to maintain flow control to and through the primary evaporator.
Also, in outputting the vapor, the vapor may be output through a first port of the primary evaporator. In returning the liquid and providing excess liquid, the liquid and excess liquid may be returned through a second port of the primary evaporator. In sweeping the excess liquid and undesired vapor, the excess liquid and undesired vapor may be swept from a third port of the primary evaporator.
Outputting the vapor may include outputting the vapor through a first port of the primary evaporator. Returning the liquid and providing excess liquid may include returning the liquid and excess liquid through a second port of the primary evaporator, and sweeping the excess liquid and other vapor may include sweeping the excess liquid from a third port of the primary evaporator, and sweeping the other vapor from a fourth port of the primary evaporator.
Sweeping the excess liquid and other vapor may include separating the liquid and excess liquid from the other vapor with a secondary wick of the primary evaporator. Providing the excess liquid may include pumping the excess liquid from the reservoir using a mechanical pump. In this case, the mechanical pump may be bypassed using a bypass valve in parallel with the mechanical pump, during a passive pumping operation of the liquid for evaporation by the primary evaporator.
Pumping the excess liquid may include pumping the liquid and the excess liquid using a liquid pump that is oriented in series with the liquid line and positioned between the condensing system and the primary evaporator, or may include pumping the vapor to the condensing system using a vapor compressor that is oriented in series with the vapor line and positioned between the primary evaporator and the condensing system.
Providing excess liquid may include providing the excess liquid from a priming system in which the reservoir is in fluid communication with a secondary evaporator, where the reservoir may be coupled to the primary evaporator. In this case, condensing the vapor may include condensing the vapor within a first condenser of the condensing system, the first condenser being coupled to the liquid line and to the vapor line, and sweeping the excess liquid and undesired vapor may include condensing undesired vapor within a second condenser of the condensing system, where the second condenser may be coupled to a mixed fluid line and to the reservoir.
According to another general aspect, a system includes a heat transfer system including a main evaporator having a core, a primary wick, a secondary wick, a first port, a second port, and a third port, as well as a condenser coupled to the main evaporator by a liquid line and a vapor line. A heat transfer system loop is defined by the condenser, the liquid line, the vapor line, the first port, and the second port. A venting system is configured to remove vapor bubbles from the core of the main evaporator. The venting system includes a pumping system operable to provide excess liquid to the main evaporator beyond a saturation amount of liquid needed for saturating the primary wick, and a reservoir in fluid communication with the pumping system and providing the excess liquid. The vapor bubbles are vented from the core of the main evaporator through the third port, and a venting loop is defined by the condenser, the liquid line, the vapor line, the first port of the main evaporator, and the third port of the main evaporator.
Implementations may include one or more of the following features. For example, the pumping system may include a mechanical pump.
The primary wick and the secondary wick of the main evaporator may maintain capillary pumping of the liquid, the excess liquid, and the vapor, so as to maintain flow control to and through the primary evaporator. In this case, the pumping system may include a secondary evaporator in fluid communication with the reservoir and coupled to the vapor line. Further, the reservoir may be in fluid communication with the secondary wick of the main evaporator through a mixed fluid line coupled to the third port of the main evaporator. The excess liquid may be substantially removed from the core of the main evaporator through a fourth port of the main evaporator.
Other features will be apparent from the description, the drawings, and the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a heat transport system.
FIG. 2 is a diagram of an implementation of the heat transport system schematically shown by FIG. 1 .
FIG. 3 is a flow chart of a procedure for transporting heat using a heat transport system.
FIG. 4 is a graph showing temperature profiles of various components of the heat transport system during the process flow of FIG. 3 .
FIG. 5A is a diagram of a three-port main evaporator shown within the heat transport system of FIG. 1 .
FIG. 5B is a cross-sectional view of the main evaporator taken along dashed section line 5 B- 5 B of FIG. 5A .
FIG. 6 is a diagram of a four-port main evaporator that can be integrated into a heat transport system illustrated by FIG. 1 .
FIG. 7 is a schematic diagram of an implementation of a heat transport system.
FIGS. 8A , 8 B, 9 A, and 9 B are perspective views of applications using a heat transport system.
FIG. 8C is a cross-sectional view of a fluid line taken along dashed section line 8 C- 8 C of FIG. 8A .
FIGS. 8D and 9C are schematic diagrams of the implementations of the heat transport systems of FIGS. 8A and 9A , respectively.
FIG. 10 is a schematic diagram of another implementation of a heat transport system.
FIG. 11 is a schematic diagram of an implementation of an actively pumped heat transport system.
FIGS. 12-16 are schematics of implementations of the system of FIG. 11 that demonstrate various examples of thermal management components and features.
FIGS. 17A-17E are examples of mechanical pumps that may be used in the systems of FIGS. 11-16 .
FIGS. 18A-18C illustrate examples of different evaporator and condenser architectures for use with the systems of FIGS. 11-16
FIG. 19 is a diagram of an example of a condenser flow regulator.
FIG. 20 is a diagram of an example of a back pressure regulator.
FIGS. 21 and 22 are diagrams of evaporator failure isolators.
FIGS. 23 and 24 illustrate examples of capillary pressure sensors.
FIG. 25 is a pressure drop diagram for a thermal management system.
Like reference symbols in the various drawings generally indicate like elements.
DETAILED DESCRIPTION
As discussed above, in a loop heat pipe (LHP), the reservoir is co-located with the evaporator, the reservoir is thermally and hydraulically connected with the evaporator through a heat-pipe-like conduit. In this way, liquid from the reservoir can be pumped to the evaporator, thus ensuring that the primary wick of the evaporator is sufficiently wetted or “primed” during start-up. Additionally, the design of the LHP reduces depletion of liquid from the primary wick of the evaporator during steady-state or transient operation of the evaporator within a heat transport system. Moreover, vapor and/or bubbles of non-condensable gas (NCG bubbles) vent from a core of the evaporator through the heat-pipe-like conduit into the reservoir.
Conventional LHPs require liquid to be present in the reservoir prior to start-up, that is, application of power to the evaporator of the LHP. However, liquid will not be present in the reservoir prior to start-up if, prior to start-up of the LHP, the working fluid in the LHP is in a supercritical state in which a temperature of the LHP is above the critical temperature of the working fluid. The critical temperature of a fluid is the highest temperature at which the fluid can exhibit a liquid-vapor equilibrium. For example, the LHP may be in a supercritical state if the working fluid is a cryogenic fluid, that is, a fluid having a boiling point below −150° C., or if the working fluid is a sub-ambient fluid, that is, a fluid having a boiling point below the temperature of the environment in which the LHP is operating.
Conventional LHPs also require liquid returning to the evaporator to be subcooled, that is, cooled to a temperature that is lower than the boiling point of the working fluid. Such a constraint makes it impractical to operate LHPs at a sub-ambient temperature. For example, if the working fluid is a cryogenic fluid, the LHP is likely operating in an environment having a temperature greater than the boiling point of the fluid.
Referring to FIG. 1 , a heat transport system 100 is designed to overcome limitations of conventional LHPs, which may include those noted above. The heat transport system 100 includes a heat transfer system 105 and a priming system 110 . The priming system 110 is configured to convert fluid within the heat transfer system 105 into a liquid, thus priming the heat transfer system 105 . As used in this description, the term “fluid” is a generic term that refers to a substance that may be both a liquid and a vapor in saturated equilibrium.
The heat transfer system 105 includes a main evaporator 115 , and a condenser 120 coupled to the main evaporator 115 by a liquid line 125 and a vapor line 130 . The condenser 120 is in thermal communication with a heat sink 165 , and the main evaporator 115 is in thermal communication with a heat source Q in 116 . The heat transfer system 105 also may include a hot reservoir 147 coupled to the vapor line 130 for additional pressure containment, as needed. In particular, the hot reservoir 147 increases the volume of the heat transport system 100 . If the working fluid is at a temperature above its critical temperature, that is, the highest temperature at which the working fluid can exhibit liquid-vapor equilibrium, its pressure is proportional to the mass in the heat transport system 100 (the charge) and inversely proportional to the volume of the system. Increasing the volume with the hot reservoir 147 lowers the fill pressure.
The main evaporator 115 includes a container 117 that houses a primary wick 140 within which a core 135 is defined. The main evaporator 115 includes a bayonet tube 142 and a secondary wick 145 within the core 135 . The bayonet tube 142 , the primary wick 140 , and the secondary wick 145 define a liquid passage 143 , a first vapor passage 144 , and a second vapor passage 146 . The secondary wick 145 provides phase control, that is, liquid/vapor separation in the core 135 , as discussed in U.S. application Ser. No. 09/896,561, filed Jun. 29, 2001, now U.S. Pat. No. 6,889,754, issued May 10, 2005, which is incorporated herein by reference in its entirety. As shown, the main evaporator 115 has three ports, a liquid inlet 137 into the liquid passage 143 , a vapor outlet 132 into the vapor line 130 from the second vapor passage 146 , and a fluid outlet 139 from the liquid passage 143 (and possibly the first vapor passage 144 , as discussed below). Further details on the structure of a three-port evaporator are discussed below with respect to FIGS. 5A and 5B .
The priming system 110 includes a secondary or priming evaporator 150 coupled to the vapor line 130 and a reservoir 155 co-located with the secondary evaporator 150 . The reservoir 155 is coupled to the core 135 of the main evaporator 115 by a secondary fluid line 160 and a secondary condenser 122 . The secondary fluid line 160 couples to the fluid outlet 139 of the main evaporator 115 . The priming system 110 also includes a controlled heat source Q sp 151 in thermal communication with the secondary evaporator 150 .
The secondary evaporator 150 includes a container 152 that houses a primary wick 190 within which a core 185 is defined. The secondary evaporator 150 includes a bayonet tube 153 and a secondary wick 180 that extends from the core 185 , through a conduit 175 , and into the reservoir 155 . The secondary wick 180 provides a capillary link between the reservoir 155 and the secondary evaporator 150 . The bayonet tube 153 , the primary wick 190 , and the secondary wick 180 define a liquid passage 182 coupled to the secondary fluid line 160 , a first vapor passage 181 coupled to the reservoir 155 , and a second vapor passage 183 coupled to the vapor line 130 . The reservoir 155 is thermally and hydraulically coupled to the core 185 of the secondary evaporator 150 through the liquid passage 182 , the secondary wick 180 , and the first vapor passage 181 . Vapor and/or NCG bubbles from the core 185 of the secondary evaporator 150 are swept through the first vapor passage 181 to the reservoir 155 and condensable liquid is returned to the secondary evaporator 150 through the secondary wick 180 from the reservoir 155 . The primary wick 190 hydraulically links liquid within the core 185 of the secondary evaporator 150 to the controlled heat source Q sp 151 , permitting liquid at an outer surface of the primary wick 190 to evaporate and form vapor within the second vapor passage 183 when heat is applied to the secondary evaporator 150 .
The reservoir 155 is cold-biased, and thus, it is cooled by a cooling source that will allow it to operate, if unheated, at a temperature that is lower than the temperature at which the heat transfer system 105 operates. In one implementation, the reservoir 155 and the secondary condenser 122 are in thermal communication with the heat sink 165 that is thermally coupled to the condenser 120 . For example, the reservoir 155 can be mounted to the heat sink 165 using a shunt 170 , which may be made of a heat conductive material, such as aluminum. In this way, the temperature of the reservoir 155 tracks the temperature of the condenser 120 .
FIG. 2 shows an example of an implementation of the heat transport system 100 . In this implementation, the condensers 120 and 122 are mounted to a cryocooler 200 , which acts as a refrigerator, transferring heat from the condensers 120 , 122 to the heat sink 165 . Additionally, in the implementation of FIG. 2 , the lines 125 , 130 , 160 are wound to reduce space requirements for the heat transport system 100 .
Though not shown in FIGS. 1 and 2 , elements such as, for example, the reservoir 155 and the main evaporator 115 , may be equipped with temperature sensors that can be used for diagnostic or testing purposes.
Referring also to FIG. 3 , the heat transport system 100 performs a procedure 300 for transporting heat from the heat source Q in 116 and for ensuring that the main evaporator 115 is wetted with liquid prior to startup. The procedure 300 is particularly useful when the heat transfer system 105 is at a supercritical state. Prior to initiation of the procedure 300 , the heat transport system 100 is filled with a working fluid at a particular pressure, referred to as a “fill pressure.”
Initially, the reservoir 155 is cold-biased by, for example, mounting the reservoir 155 to the heat sink 165 (step 305 ). The reservoir 155 may be cold-biased to a temperature below the critical temperature of the working fluid, which, as discussed, is the highest temperature at which the working fluid can exhibit liquid-vapor equilibrium. For example, if the fluid is ethane, which has a critical temperature of 33° C., the reservoir 155 is cooled to below 33° C. As the temperature of the reservoir 155 drops below the critical temperature of the working fluid, the reservoir 155 partially fills with a liquid condensate formed by the working fluid. The formation of liquid within the reservoir 155 wets the secondary wick 180 and the primary wick 190 of the secondary evaporator 150 (step 310 ).
Meanwhile, power is applied to the priming system 110 by applying heat from the controlled heat source Q sp 151 to the secondary evaporator 150 (step 315 ) to enhance or initiate circulation of fluid within the heat transfer system 105 . Vapor output by the secondary evaporator 150 is pumped through the vapor line 130 and through the condenser 120 (step 320 ) due to capillary pressure at the interface between the primary wick 190 and the second vapor passage 183 . As vapor passes through the condenser 120 , it is converted to liquid (step 325 ). The liquid formed in the condenser 120 is pumped to the main evaporator 115 of the heat transfer system 105 (step 330 ). When the main evaporator 115 is at a higher temperature than the critical temperature of the fluid, the liquid entering the main evaporator 115 evaporates and cools the main evaporator 115 . This process (steps 315 - 330 ) continues, causing the main evaporator 115 to reach a set point temperature (step 335 ), at which point the main evaporator 115 is able to retain liquid and be wetted and to operate as a capillary pump. In one implementation, the set point temperature is the temperature to which the reservoir 155 has been cooled. In another implementation, the set point temperature is a temperature below the critical temperature of the working fluid. In a further implementation, the set point temperature is a temperature above the temperature to which the reservoir 155 has been cooled.
Once the set point temperature has been reached (step 335 ), the system 100 operates in a main mode (step 340 ) in which heat from the heat source Q in 116 that is applied to the main evaporator 115 is transferred by the heat transfer system 105 . Specifically, in the main mode, the main evaporator 115 develops capillary pumping to promote circulation of the working fluid through the heat transfer system 105 . Also, in the main mode, the temperature of the reservoir 155 may be reduced below the set point temperature of the main evaporator 115 . The rate at which the heat transfer system 105 cools down during the main mode depends, in part, on the cold-biasing of the reservoir 155 because the temperature of the main evaporator 115 closely follows the temperature of the reservoir 155 . Additionally, though not necessarily, a heater can be used to further control or regulate the temperature of the reservoir 155 during the main mode (step 340 ). Furthermore, in the main mode, the power applied to the secondary evaporator 150 by the controlled heat source Q sp 151 is reduced, thus bringing the heat transfer system 105 down to a normal operating temperature for the fluid. For example, in the main mode, the heat load from the controlled heat source Q sp 151 to the secondary evaporator 150 is kept at a value equal to or in excess of heat conditions, as defined below. In one implementation, the heat load from the heat source Q sp is kept to about 5 to 10% of the heat load applied to the main evaporator 115 from the heat source Q in 116 .
Thus, in the FIG. 3 implementation, the main mode is triggered by the determination that the set point temperature has been reached at the main evaporator 115 (step 335 ). In other implementations, the main mode may begin at other times or due to other triggers. For example, the main mode may begin after the priming system 110 is wet (step 310 ) or after the reservoir 155 has been cold-biased (step 305 ).
At any time during operation, the heat transfer system 105 can experience heat conditions that cause formation of vapor on the liquid side of the evaporator, such as those resulting from heat conduction across the primary wick 140 and parasitic heat applied to the liquid line 125 . Specifically, heat conduction across the primary wick 140 can cause liquid in the core 135 to form vapor bubbles, which, if left within the core 135 , would grow and block off liquid otherwise supplied to the primary wick 140 , thus causing the main evaporator 115 to fail. One such heat condition is caused by parasitic heat input into the liquid line 125 (referred to as “parasitic heat gains”), which causes liquid within the liquid line 125 to form vapor.
To reduce the adverse impact of heat conditions such as those discussed above, the priming system 110 operates at a power level Q sp 450 that is greater than or equal to the sum of the head conduction and the parasitic heat gains. As mentioned above, for example, the priming system 110 can operate at 5 to 10% of the power to the heat transfer system 105 . In particular, fluid that includes a combination of vapor bubbles and liquid is swept out of the core 135 for discharge into the secondary fluid line 160 leading to the secondary condenser 122 . In particular, vapor that forms within the core 135 travels along the bayonet tube 143 and directly into the fluid outlet port 139 . Furthermore, vapor that forms within the first vapor passage 144 travels into the fluid outlet port 139 by either traveling through the secondary wick 145 (if the pore size of the secondary wick 145 is large enough to accommodate vapor bubbles) or through an opening (not shown) at an end of the secondary wick 145 near the outlet port 139 that provides a clear passage from the first vapor passage 144 to the outlet port 139 . The secondary condenser 122 condenses the bubbles in the fluid and pushes the fluid to the reservoir 155 for reintroduction into the heat transfer system 105 .
Similarly, to reduce parasitic heat input to the liquid line 125 , the secondary fluid line 160 and the liquid line 125 can form a coaxial configuration such that the secondary fluid line 160 surrounds and insulates the liquid line 125 from surrounding heat. This implementation is discussed further below with reference to FIGS. 8A and 8B . As a consequence of this configuration, it is possible for the surrounding heat to cause vapor bubbles to form in the secondary fluid line 160 , instead of in the liquid line 125 . As discussed, by virtue of capillary action effected at the secondary wick 145 , fluid flows from the main evaporator 115 to the secondary condenser 122 . This fluid flow, and the relatively low temperature of the secondary condenser 122 , causes a sweeping of the vapor bubbles within the secondary fluid line 160 through the condenser 122 , where they are condensed into liquid and pumped into the reservoir 155 .
As shown in FIG. 4 , data from a test run is shown. In this implementation, prior to startup of the main evaporator 115 at time 410 , a temperature 400 of the main evaporator 115 is significantly higher than a temperature 405 of the reservoir 155 , which has been cold-biased to the set point temperature (step 305 ). As the priming system 110 is wetted (step 310 ), power level Q sp 450 is applied to the secondary evaporator 150 (step 315 ) at a time 452 , causing liquid to be pumped to the main evaporator 115 (step 330 ), the temperature 400 of the main evaporator 115 drops until it reaches the temperature 405 of the reservoir 155 at time 410 . Power Q in 460 is applied to the main evaporator 115 at a time 462 , when the heat transport system 100 is operating in LHP mode (step 340 ). As shown, power input Q in 460 to the main evaporator 115 is held relatively low while the main evaporator 115 is cooling down. Also shown are the temperatures 470 and 475 , respectively, of the secondary fluid line 160 and the liquid line 125 . After time 410 , temperatures 470 and 475 track the temperature 400 of the main evaporator 115 . Moreover, a temperature 415 of the secondary evaporator 150 follows closely with the temperature 405 of the reservoir 155 because of the thermal communication between the secondary evaporator 150 and the reservoir 155 .
As mentioned, in one implementation, ethane may be used as the fluid in the heat transfer system 105 . Although the critical temperature of ethane is 33° C., for the reasons generally described above, the heat transport system 100 can start up from a supercritical state in which the heat transport system 100 is at a temperature of 70° C. As power Q sp is applied to the secondary evaporator 150 , the temperatures of the condenser 120 and the reservoir 155 drop rapidly (between times 452 and 410 ). A trim heater can be used to control the temperature of the reservoir 155 and thus the condenser 120 to −10° C. To startup the main evaporator 115 from the supercritical temperature of 70° C., a heat load or power input Q sp of 10 W is applied to the secondary evaporator 150 . Once the main evaporator 115 is primed, the power input from the controlled heat source Q sp 151 to the secondary evaporator 150 and the power applied to and through the trim heater both may be reduced to bring the temperature of the heat transport system 100 down to a nominal operating temperature of about −50° C. For instance, during the main mode, if a power input Q in of 40 W is applied to the main evaporator 115 , the power input Q sp to the secondary evaporator 150 can be reduced to approximately 3 W while operating at −45° C. to mitigate the 3 W lost through heat conditions (as discussed above). As another example, the main evaporator 115 can operate with power input Q in from about 10 W to about 40 W with 5 W applied to the secondary evaporator 150 and with the temperature 405 of the reservoir 155 at approximately −45° C.
Referring to FIGS. 5A and 5B , in one implementation, the main evaporator 115 is designed as a three-port evaporator 500 (which is the design shown in FIG. 1 ). Generally, in the three-port evaporator 500 , liquid flows into a liquid inlet 505 and into a core 510 , defined by a primary wick 540 , and fluid from the core 510 flows from a fluid outlet 512 to a cold-biased reservoir (such as reservoir 155 ). The fluid and the core 510 are housed within a container 515 made of, for example, aluminum. In particular, fluid flowing from the liquid inlet 505 into the core 510 flows through a bayonet tube 520 , into a liquid passage 521 that flows through and around the bayonet tube 520 . Fluid can flow through a secondary wick 525 (such as secondary wick 145 of main evaporator 115 ) made of a wick material 530 and an annular artery 535 . The wick material 530 separates the annular artery 535 from a first vapor passage 560 . As power from the heat source Q in 116 is applied to the evaporator 500 , liquid from the core 510 enters a primary wick 540 and evaporates, forming vapor that is free to flow along a second vapor passage 565 that includes one or more vapor grooves 545 and out a vapor outlet 550 into the vapor line 130 . Vapor bubbles that form within first vapor passage 560 of the core 510 are swept out of the core 510 through the first vapor passage 560 and into the fluid outlet 512 . As discussed above, vapor bubbles within the first vapor passage 560 may pass through the secondary wick 525 if the pore size of the secondary wick 525 is large enough to accommodate the vapor bubbles. Alternatively, or additionally, vapor bubbles within the first vapor passage 560 may pass through an opening of the secondary wick 525 formed at any suitable location along the secondary wick 525 to enter the liquid passage 521 or the fluid outlet 512 .
Referring to FIG. 6 , in another implementation, the main evaporator 115 is designed as a four-port evaporator 600 , which is a design described in U.S. application Ser. No. 09/896,561, filed Jun. 29, 2001. Briefly, and with emphasis on aspects that differ from the three-port evaporator configuration, liquid flows into the evaporator 600 through a fluid inlet 605 , through a bayonet 610 , and into a core 615 . The liquid within the core 615 enters a primary wick 620 and evaporates, forming vapor that is free to flow along vapor grooves 625 and out a vapor outlet 630 into the vapor line 130 . A secondary wick 633 within the core 615 separates liquid within the core from vapor or bubbles in the core (that are produced when liquid in the core 615 heats). The liquid carrying bubbles formed within a first fluid passage 635 inside the secondary wick 633 flows out of a fluid outlet 640 and the vapor or bubbles formed within a vapor passage 642 positioned between the secondary wick 633 and the primary wick 620 flow out of a vapor outlet 645 .
Referring to FIG. 7 , a heat transport system 700 is shown in which the main evaporator is a four-port evaporator, such as that illustrated 600 in FIG. 6 . The system 700 includes one or more heat transfer systems 705 and a priming system 710 configured to convert fluid within the heat transfer systems 705 into a liquid to prime the heat transfer systems 705 . The four-port evaporators 600 are coupled to one or more condensers 715 by a vapor line 720 and a fluid line 725 . The priming system 710 includes a cold-biased reservoir 730 hydraulically and thermally connected to a priming evaporator 735 .
Whether using a three-port or four-port evaporator design, design considerations of heat transport systems such as the heat transport systems 100 and 700 may include various advantageous features. For example, with specific reference to elements of the heat transport system 100 (although similar comments may generally apply to the heat transport system 700 of FIG. 7 , with reference to the corresponding elements as shown therein), such advantages may include startup of the main evaporator 115 from a supercritical state, management of parasitic heat leaks, heat conduction across the primary wick 140 , cold biasing of the cold reservoir 155 , and pressure containment at ambient temperatures that are greater than the critical temperature of the working fluid within the heat transfer system 105 . To accommodate these design considerations, the body or container (such as container 515 ) of the main evaporator 115 or secondary evaporator 150 can be made of extruded 6063 aluminum and the primary wicks 140 and/or 190 can be made of a fine-pored wick. In one implementation, the outer diameter of the main evaporator 115 or secondary evaporator 150 is approximately 0.625 inch and the length of the container is approximately 6 inches. The reservoir 155 may be cold-biased to an end panel of the heat sink 165 using the aluminum shunt 170 . Furthermore, a heater (such as a KAPTON™ heater) can be attached at a side of the reservoir 155 .
In one implementation, the vapor line 130 is made with smooth-walled stainless steel tubing having an outer diameter (OD) of 3/16″ and the liquid line 125 and the secondary fluid line 160 are made of smooth-walled stainless steel tubing having an OD of ⅛″. The lines 125 , 130 , 160 may be bent in a serpentine route and plated with gold to minimize parasitic heat gains. Additionally, the lines 125 , 130 , 160 may be enclosed in a stainless steel box with heaters to simulate a particular environment during testing. The stainless steel box can be insulated with multi-layer insulation (MLI) to minimize heat leaks through panels of the heat sink 165 .
In one implementation, the second condenser 122 and the secondary fluid line 160 are made of tubing having an OD of 0.25 inch. The tubing is bonded to the panels of the heat sink 165 using, for example, epoxy. Each panel of the heat sink 165 is an 8×19 inch direct condensation, aluminum radiator that uses a 1/16-inch thick face sheet. KAPTON™ heaters can be attached to the panels of the heat sink 165 , near the secondary condenser 120 to prevent inadvertent freezing of the working fluid. During operation, temperature sensors such as thermocouples can be used to monitor temperatures throughout the heat transport system 100 .
The heat transport system 100 may be implemented in any circumstances where the critical temperature of the working fluid of the heat transfer system 105 is below the ambient temperature at which the heat transport system 100 is operating. The heat transport system 100 can be used to cool down components that require cryogenic cooling. Referring to FIGS. 8A-8D , the heat transport system 100 may be implemented in a miniaturized cryogenic system 800 . In the miniaturized system 800 , the lines 125 , 130 , 160 are made of flexible material to permit coil configurations 805 , which save space. The miniaturized system 800 can operate at −238° C. using neon fluid. Power input Q in 116 is approximately 0.3 to 2.5 W. The miniaturized system 800 thermally couples a cryogenic component Q in (or heat source that requires cryogenic cooling) 816 to a cryogenic cooling source such as a cryocooler 810 coupled to cool the condensers 120 , 122 .
The miniaturized system 800 reduces mass, increases flexibility, and provides thermal switching capability when compared with traditional thermally switchable vibration-isolated systems. Traditional thermally switchable, vibration-isolated systems require two flexible conductive links (FCLs), a cryogenic thermal switch (CTSW), and a conduction bar (CB) that form a loop to transfer heat from the cryogenic component to the cryogenic cooling source. In the miniaturized system 800 , thermal performance is enhanced because the number of mechanical interfaces is reduced. Heat conditions at mechanical interfaces account for a large percentage of heat gains within traditional thermally switchable, vibration-isolated systems. The CB and two FCLs are replaced with the low-mass, flexible, thin-walled tubing used for the coil configurations 805 of the miniaturized system 800 .
Moreover, the miniaturized system 800 can function in a wide range of heat transport distances, which permits a configuration in which the cooling source (such as the cryocooler 810 ) is located remotely from the cryogenic component Q in 816 . The coil configurations 805 have a low mass and low surface area, thus reducing parasitic heat gains through the lines 125 and 160 . The configuration of the cooling source 810 within the miniaturized system 800 facilitates integration and packaging of the miniaturized system 800 and reduces vibrations on the cooling source 810 , which becomes particularly important in infrared sensor applications. In one implementation, the miniaturized system 800 was tested using neon, operating at 25 to 40K.
Referring to FIGS. 9A-9C , the heat transport system 100 may be implemented in an adjustable mounted or gimbaled system 1005 in which the main evaporator 115 and a portion of the lines 125 , 160 , and 130 are mounted to rotate about an elevation axis within a range of ±45° and a portion of the lines 125 , 160 , and 130 are mounted to rotate about an azimuth axis within a range of ±220°. The lines 125 , 160 , 130 are formed from thin-walled tubing and are coiled around each axis of rotation. The system 1005 thermally couples a cryogenic component (or heat source that requires cryogenic cooling) 1016 such as a sensor of a cryogenic telescope to a cryogenic cooling source 1010 such as a cryocooler coupled to cool the condensers 120 , 122 . The cooling source 1010 is located at a stationary spacecraft 1060 , thus reducing mass at the cryogenic telescope. Motor torque for controlling rotation of the lines 125 , 160 , 130 , power requirements of the system 1005 , control requirements for the spacecraft 1060 , and pointing accuracy for the sensor 1016 are improved. The cooling source 1010 and the radiator or heat sink 165 can be moved from the sensor 1016 , reducing vibration within the sensor 1016 . In one implementation, the system 1005 was tested to operate within the range of 70 to 115K when the working fluid is nitrogen.
The heat transfer system 105 may be used in medical applications, or in applications where equipment must be cooled to below-ambient temperatures. As another example, the heat transfer system 105 may be used to cool an infrared (IR) sensor that operates at cryogenic temperatures to reduce ambient noise. The heat transfer system 105 may be used to cool a vending machine, which often houses items that preferably are chilled to sub-ambient temperatures. The heat transfer system 105 may be used to cool components such as a display or a hard drive of a computer, such as a laptop computer, handheld computer, or a desktop computer. The heat transfer system 105 can be used to cool one or more components in a transportation device such as an automobile or an airplane.
Other implementations are within the scope of the following claims. For example, the secondary condenser 120 and heat sink 165 can be designed as an integral system, such as, a radiator. Similarly, the secondary condenser 122 and heat sink 165 can be formed from a radiator. The heat sink 165 can be a passive heat sink (such as a radiator) or a cryocooler that actively cools the condensers 120 , 122 .
In another implementation, the temperature of the reservoir 155 is controlled using a heater. In a further implementation, the reservoir 155 is heated using parasitic heat. In another implementation, a coaxial ring of insulation is formed and placed between the liquid line 125 and the secondary fluid line 160 , which surrounds the insulation ring.
FIG. 10 is a schematic diagram of an implementation of a heat transport system 1000 . In FIG. 10 , four-port evaporators 600 are arranged in a serial orientation.
More particularly, the heat transport system 1000 includes multiple heat transfer systems 1005 and a priming system 1011 configured to convert fluid from within the heat transfer systems 1005 into a liquid capable of priming the heat transfer systems 1005 . The heat transfer systems 1005 each include four-port evaporators 600 that are coupled to one or more condensers 1015 by a vapor line 1020 and a fluid line 1025 . The priming system 1011 includes a cold-biased reservoir 1030 hydraulically and thermally connected to a priming evaporator 1035 .
Similarly to the four-port, parallel arrangement shown in FIG. 7 , and in accordance with the general principles associated with an operation of the heat transport system 100 described above with respect to FIG. 1 , the heat transport system 1000 is capable of starting the main evaporators 600 from a super critical state, managing parasitic heat leaks, sweeping excess vapor and non-condensable gas bubbles (NCG) from the cores of the main evaporators 600 , and various other features and advantages described herein.
Moreover, as illustrated by FIGS. 7 and 10 , various implementations of heat transport systems may be used in many different operating environments, providing flexibility and a wide scope of use to designers of heat transport systems. For example, arrangements may be optimized to account for, for example, locations and types of heat sources, heat load sharing between the evaporators 600 , a type of fluid used in the system(s), and various other operating parameters. Of course, it should be understood that the parallel and serial evaporator configurations of FIGS. 7 and 10 also may be implemented using three-port evaporators, such as, for example, the three-port evaporator 500 of FIGS. 5A and 5B .
FIG. 11 is a schematic diagram of an implementation of an actively pumped heat transport system 1100 . In FIG. 11 , active loop pumping is enabled for the purpose of, for example, supporting improved waste heat rejection and heat transport capability when compared to heat transport systems that rely solely on passive (e.g., capillary) pumping.
More particularly, the actively pumped heat transport system 1100 includes multiple heat transfer systems 1105 , having evaporators 600 , and a mechanical pump 1110 that is arranged in series between a condenser 1115 (and a vapor line 1120 feeding the condenser 1115 ) and the evaporators 600 , along a liquid line 1125 . A reservoir 1130 is disposed between the mechanical pump 1110 and the condenser 1115 , where the reservoir 1130 may be used for, for example, managing excess fluid flow, fine temperature control through cold-biasing, and other features and uses as described herein and as are known.
The actively pumped heat transport system 1100 including the mechanical pump 1110 shares certain features and advantages with the passive heat transport systems described above with respect to FIGS. 1-10 . For example, the heat transport system 1100 includes a primary loop including the vapor line 1120 and the liquid line 1125 , as well as secondary loop(s) defined by the secondary fluid outlets 640 and the secondary vapor outlet 645 (where it should be understood that the outlets 640 and 645 may be replaced with the secondary fluid line 160 of FIG. 1 in a system using the three-port evaporator 500 ).
The mechanical pump 1110 thus provides a source of pumping power for moving fluid through the primary loop and/or the secondary loop of the heat transport system 1100 . This pumping power may be used during various operations of the heat transport system 1100 , and may be in addition to, or in the alternative to, other sources of pumping power.
For example, the pumping power provided by the mechanical pump 1110 may be used to provide liquid to the evaporators 600 during a start-up operation of the evaporators 600 , perhaps in conjunction with a separate priming system. Such a priming system may include, for example, the priming system 110 of FIG. 1 , or some other, conventional priming system (not shown).
The mechanical pump 1110 also may be used during steady-state operation of the actively pumped heat transport system 1100 , either continuously or intermittently, as needed to maintain a desired operational state of the heat transport system 1100 . For example, the mechanical pump 1110 may be activated during start-up of the heat transport system 1100 , and then may be bypassed or otherwise de-activated during steady-state operation of the heat transport system 1100 , unless and until a secondary pumping source (e.g., passive pumping supplied by capillary pressure) is insufficient to provide adequate heat transfer. In this sense, the heat transport system 1100 may be considered a dual-pumping system, in which mechanical pumping, capillary pumping, or some combination of both, is available on an as-needed basis to an operator or designer of the heat transport system 1100 . In particular, for instance, when the heat transport system 1100 is used to provide heat transfer over relatively large distances (e.g., 10 meters or more), the mechanical pump 1110 may be required to be used continuously to ensure adequate pumping power.
As a final example, and as discussed in more detail below, pumping power of the mechanical pump 1110 also may be used to ensure sweeping or venting of vapor bubbles from the cores of the evaporators 600 . As such, a use or extent of the pumping power of the mechanical pump 1110 may be dependent on the extent to which such vapor bubbles exist (or are thought to exist) within the evaporator cores or, similarly, may be dependent on the extent to which conditions for creating such vapor bubbles within the evaporator cores exist within and around the heat transport system 1100 .
As just referenced, and as described above in detail, the construction of three- and/or four-port evaporators permit control and management of liquid and vapor phases within the evaporator core(s). Specifically, for example, fluid within the cores 615 of evaporators 600 that includes a combination of liquid and vapor bubbles may be swept out of the cores 615 for discharge into the secondary fluid outlets 640 and vapor outlets 645 (or into the mixed secondary fluid line 160 in a three-port evaporator configuration).
As also described above, such mixed-phase fluid within the core 615 may result from various causes. For example, the mixed-phase fluid may result from heat conduction across the primary wick 620 and/or parasitic heat gains through the liquid line 1125 (e.g., when routing the liquid line through a “hot” environment). Whatever the cause of the mixed-phase flow, the heat transport system 1100 (using the mechanical pump 1110 ), and the systems described above (using the priming or secondary evaporators 150 / 710 / 1011 and associated reservoirs), are operable to provide excess liquid to the evaporators 600 , above and beyond the minimum needed to maintain operation of the heat transport system (e.g., an amount needed to maintain saturation of the wicks and associated capillary pumping).
As a result, the heat transport system 1100 , and the systems described above, are able to use this excess liquid to vent or sweep the gaseous portion of the mixed-phase flow from the evaporators 600 , using the secondary flow loops that include the secondary fluid/liquid outlets 640 / 645 or the secondary fluid line 160 . In this way, excess vapor enters the secondary loop either through the secondary wick 635 (if feasible for a given pore size of the secondary wick 635 ), or through an opening at an end of the secondary wick near an outlet port for the secondary loop(s), and is returned to the condenser 1115 for condensation and subsequent return through the liquid line 1125 and/or to the reservoir 1130 .
In one implementation, an amount of excess liquid provided to the cores of the evaporators 600 is optimized. In this implementation, the amount of excess liquid is sufficient to sweep all of the evaporator cores present in the system, but not substantially more than this amount, since excess fluid in the heat transport system 1100 may affect performance and reliability of the heat transport system 1100 . However, sweeping all of the evaporators 600 may be problematic, particularly, for example, when the evaporators 600 are not powered equally or, in the limiting case, where one of the evaporators 600 receives no heat (or actually acts as a condenser).
One technique for optimizing an amount of excess fluid flow to the evaporators 600 includes an appropriate selection of line diameters of the evaporator wicks, and/or for the liquid line 1125 or the vapor line 1120 . By selecting these line diameters appropriately, an amount of excess fluid beyond that required for operation of the evaporators 600 may be reduced or minimized, while still ensuring that the amount of excess fluid is sufficient to completely sweep or vent all of the evaporators 600 .
More particularly, in an implementation such as the one just described, such line sizing may be a factor in determining an efficiency of the sweeping of the evaporators 600 . In the case of FIG. 11 , this sweeping efficiency may determine how much more liquid must be supplied to the evaporators 600 through the liquid line 1125 than what is required to satisfy the heat load(s) of the evaporators 600 . Similarly, in the case of FIG. 1 or FIG. 7 , the sweeping efficiency may determine how much power must be applied to the secondary evaporator in excess of what is required to satisfy the heat load of the main evaporators 115 or 600 , respectively.
One parameter for describing the appropriate sizing criteria includes a ratio of the flow resistance of the secondary fluid/vaport outlets 640 / 645 (or, in FIG. 1 , the mixed secondary fluid line 160 ) to a sum of the resistances of the liquid line 1125 ( 125 in FIG. 1 ) outside of the evaporator 600 and the liquid flow passage in the evaporator core 615 ( 135 in FIG. 1 ). In general, a relatively large value of this ratio is preferred, and serves to decrease a sweepage power required to completely sweep all evaporator cores.
With such complete sweepage being provided, the heat transport system 1100 may use a narrow-diameter, small-pore, metal wick (e.g., 1 micron pore metal wick), which provides high thermal conductivity and increased pumping capability, relative to the polyethylene wicks that often are used in conventional heat transport systems. Such polyethylene wicks may be used despite their reduced pumping capacity, in part due to their relatively wide diameter and large pore size, which tends to reduce their thermal conductivity and, therefore, tends to reduce a presence of vapor within the liquid line 1125 and liquid 615 .
In other words, since the structure and function of the heat transport system 1100 enable venting or sweeping of such undesirable vapor from the core 615 , the heat transport system 1100 may not be required to resort to disadvantageous measures to avoid the presence of this vapor in the first place. As a result, the system 110 may enjoy the advantages of narrow-diameter, small-pore, metal wicks, and, in particular, increased pumping against gravity by a factor of ten, relative to polyethylene wicks, for example. Similarly, the heat transport system 1100 may not require subcooled liquid to be returned to the core 615 , such that the liquid line 1125 may be routed through hotter environments than are feasible with conventional systems that do not offer vapor sweepage, as it is described herein.
Accordingly, the heat transport system 1100 may provide many advantageous features for the transport and disposal of heat. For example, in addition or as an alternative to one or more of the features just described, the mechanical pump 1110 of the heat transport system 1100 may provide increased flow, increased flow controllability, and increased waste heat transportation and rejection, relative to passive systems (for example, heat transport may occur on the order of 50 kW or more, over a distance of 10 meters or more). As another example, the mechanically pumped heat transport system 1100 may greatly reduce temperature gradients across phased array antennas that may include thousands of elements arranged in complex arrays, thereby reducing an overall size of such arrays and reducing or eliminating the need for separate heat pipes to maintain acceptable element temperatures within the arrays.
The heat transport system 1100 offers one or more of the following or other advantages over conventional actively pumped systems as well, including those that have been deployed, for example, in geosynchronous communication satellites. For instance, the two-phase nature of the heat transport system 1100 is beneficial to heat transfer at the thermal interfaces, and reduces required pumping power. Additionally, the sweepage of excess vapor and its complete condensation within the condenser 1115 may reduce an amount of mixed fluid (i.e., two-phase) flow experience by the mechanical pump 1110 . As a result, a lifetime and reliability of the mechanical pump 1110 may be improved, since vapor within a liquid mechanical pump such as the mechanical pump 1110 tends to provide excessive stress within the pump.
In addition to some or all of these and other advantages, the heat transport system 1100 is compatible with a wide variety of thermal management components and features. Accordingly, FIGS. 12-16 are schematics of implementations of the heat transport system 1100 of FIG. 11 that demonstrate examples of such thermal management components and features.
In FIG. 12 , a system 1200 operates essentially as described above with respect to the heat transport system 1100 . The mechanical pump 1110 is illustrated as a liquid pump 1202 that is in series with a liquid line 1204 that is connected to evaporators 1206 . The evaporators 1206 vent or sweep two-phase fluid flow from their respective liquid cores through a mixed fluid line 1208 , as already described. The evaporators 1206 also output vapor through a vapor line 1210 to a condenser 1212 , which, in FIG. 12 , includes a body-mounted radiator (discussed in more detail below).
The mixed fluid line 1208 is shown as a dashed line in FIG. 12 to indicate the variety of forms it may take within the system 1200 . For example, the mixed fluid line 1208 may be implemented in a coaxial fashion with respect to the liquid flow line 1204 , as described above with respect to, for example, FIG. 8C . Such an implementation assists in protecting the liquid line 1204 from parasitic heat effects that may cause vapor and/or NCG bubbles within the liquid line 1204 , and allows the liquid line 1204 to be routed through relatively hot environments without experiencing parasitic heat gain.
Further, the mixed fluid line 1208 may be used in conjunction with a secondary evaporator 1214 , which, when used with a (cold-biased) two-phase reservoir 1216 in one of the various manners described above, provides for advantages such as, for example, operation of the system 1200 (or the heat transport system 1100 ) in a passive mode, in which the mechanical pump 1202 (or 1110 ) is bypassed, perhaps using a pump bypass valve 1218 , and the system 1200 (or 1100 ) relies solely on capillary pumping for fluid flow.
To the extent that the system 1200 uses fine-pore metal wicks, as described above with respect to FIG. 11 , its passive pumping capacity in this mode may be improved relative to other passive, capillary-pumped loops. Although the secondary evaporator is shown only conceptually in FIGS. 12-15 , its use should be apparent based on the above descriptions of secondary evaporators or priming systems 150 , 710 , and 1011 . Moreover, a particular implementation for using such a secondary evaporator in the context of a mechanically pumped heat transfer system is discussed in detail with respect to FIG. 16 .
As referred to above with respect to FIG. 11 , the secondary evaporator 1214 is not required for the system 1200 to operate in passive mode. For example, in such a passive mode, a conventional priming system may be used for starting the system 1200 (e.g., for wetting the primary wicks of the evaporators 1206 ). Alternatively, the liquid pump 1202 may be used to prime the evaporator(s) 1206 initially for starting, and/or may be used to maintain saturation of the primary wicks of the evaporators 1206 intermittently thereafter. The choice of which startup method(s) to use, or whether or when to use the system 1200 in a passive mode at all, is, of course, dependent on various operational and environmental factors of the system 1200 , such as, for example, one or more of the type of working fluid, a critical temperature of the working fluid, an ambient operating temperature of the system 1200 , the amount of heat to be dissipated, and various other factors.
The above discussion of a general operation of the system 1200 included reference to the evaporators 1206 , similar in structure and function to one or more of the various evaporators discussed herein, and using a cold plate as a heat transfer surface. However, it is a strength of the system 1200 that multiple types and arrangements of evaporators and heat transfer surfaces may be used.
For example, in FIG. 12 the system 1200 includes an evaporator 1220 that is interfaced with a thermal storage unit 1222 . In one implementation, the thermal storage unit 1222 may be used as a heat load transformer for pulsed power applications, such as, for example, space-based laser applications. The thermal storage unit may include, for example, 250 W-hr graphite hardware and a paraffin-based, lightweight composite design.
Further in FIG. 12 , the system 1200 may include an evaporator 1224 that is interfaced with a condensing heat exchanger 1226 , which is used to couple a spray-cooled evaporator 1228 into the system 1200 . The heat exchanger 1226 may be, for example, a high efficiency, two-phase/two-phase heat exchanger. A liquid pump 1230 is used to pump liquid from the condensing heat exchanger 1226 through the spray-cooled evaporator 1228 , to thereby form a separate loop coupled to the loop(s) of a primary thermal bus of the system 1200 .
In particular, such a separate loop may be used to connect the spray-cooled evaporator 1228 to the system 1200 , due to the fact that a nozzle pressure drop (e.g., 0.7 bar) of the spray-cooled evaporator 1228 relative to a capillary pressure rise (e.g., 0.4 bar) in the system 1200 may make parallel arrangement of the spray-cooled evaporator 1228 difficult in some use environments. In other implementations, however, the spray-cooled evaporator 1228 may be integral to the system 1200 , instead of being coupled through the condensing heat exchanger 1226 .
The spray-cooled evaporator 1228 may be used for efficient thermal control of high heat flux sources. For example, 500 W/cm 2 has been demonstrated with a heat transport system using ammonia as the working fluid. A loop using the spray-cooled evaporator 1228 may be operated near saturation in order to maximize heat transfer.
Such a spray-cooled evaporator 1228 may be particularly useful, for example, in spacecraft thermal management. For instance, in spacecraft electronics, heat fluxes at transistor gates are approaching 1 MW/in 2 . As component size continues to shrink and heat fluxes rise further, state-of-the-art systems may be used to offset the associated increases in local temperature drops. The significantly higher heat-transfer coefficient afforded by spray cooling, using the spray-cooled evaporator 1228 , may be advantageous in this respect.
Factors to consider in using the spray-cooled evaporator 1228 include, for example, nozzle optimization and scalability of the spray-cooled evaporator 1228 to extended surface areas. In one implementation, the spray-cooled evaporator 1228 may be used for cooling laser diode applications.
In FIGS. 11 and 12 , and in light of the above discussion, it should be understood that the capillary pumping developed by the evaporator wicks, as described above, may generally maintain phase separation at each heat source interface of the evaporators, and thereby assure excellent heat transfer characteristics and automatic flow control among the evaporators, even when no flow controllers are used. A pressure diagram illustrating this phenomenon is described in more detail below with respect to FIG. 25 .
Also, it should be apparent from FIG. 12 and the above discussion that many variations exist with respect to a number, type, and arrangement of evaporators that may be used in the system 1200 . Further examples of evaporator configurations are discussed below with respect to FIGS. 18A-18C .
Similarly, many types of condenser configurations may be used. For example, the condenser 1212 referred to above may include a body-mounted radiator, while a condenser 1232 may include a multi-fold, deployable or steerable radiator. Particularly in high-power spacecrafts, these radiators may be direct condensation or may use discrete heat pipes, depending on, for example, system reliability factors and/or a mass of micro-meteoroid shielding. As just mentioned, the condenser 1232 also may be made steerable for non-geostationary applications, in order, for example, to minimize radiator backloading. Gimbaled heat transport systems used in conventional telecom satellite systems may be used to enable such steerable radiators. Further, passive two-phase loops (e.g., LHPs) also may be incorporated into two-axis gimbaled systems. Other examples of condenser configurations are discussed below with respect to FIGS. 18A-18C .
Finally with respect to FIG. 12 , a liquid bypass valve 1234 is illustrated that may be used, for example, to maintain constant pump speed operations with the liquid pump 1202 , and which may improve a pump lifetime of the pump 1202 . Further, flexible elements 1236 are illustrated in order to indicate that the various elements of the system 1200 may be routed over and through a wide variety of use environments.
FIG. 13 is a schematic illustrating a heat transport system 1300 that shares many elements with the system 1200 of FIG. 12 (indicated in FIG. 13 by like-numbered elements). In FIG. 13 , however, the mechanical pump 1102 of FIG. 11 is represented by a vapor compressor 1302 , which may be a variable-speed vapor compressor. A liquid/vapor separator 1304 (or a vapor superheater, not shown) may be used to prevent liquid from entering the compressor and, similarly to the pump bypass valve 1218 of FIG. 12 , a compressor bypass valve 1306 may be used to operate the system 1300 in a passive (capillary) pumping mode.
The choice of whether to use the liquid pump 1202 or the vapor compressor 1302 is typically a design consideration. Generally, the liquid pump 1202 offers lighter weight and increased pumping power relative to the vapor compressor 1302 (due to, for example, the lower volumetric flow rate of the former). On the other hand, the vapor compressor 1302 offers heat pumping (i.e., an increased condensation temperature), which may reduce radiator heat and overall system mass and, additionally, may offer a longer operational lifetime.
The liquid pump 1202 may include, for example, a hermetically sealed, magnetically driven, centrifugal design. Other liquid pumps for space station applications, e.g., waste water and carbon dioxide, also may be used.
The vapor compressor 1302 may be a variable-speed compressor, and may include, for example, a hermetically sealed, oil-less centrifugal compressor with gas or magnetic bearings. A low-lift heat pump, which includes a similar compressor, also may be used. Further examples of specific types of pumps are provided below, and, in particular, with respect to FIGS. 17A-17E .
As also illustrated in FIG. 13 , a vapor compressor 1308 may be used in the loop formed by the spray-cooled evaporator 1228 and the condensing heat exchanger 1226 , instead of the liquid pump 1230 . The choice between the liquid pump 1230 and the vapor compressor 1308 may be driven by, for example, design choices similar to those just described.
Further in FIG. 13 , flow controllers 1310 may be used to ensure a desired heat load distribution between the evaporators 1206 , 1220 , and 1224 . For example, the flow controllers 1310 may be used to route more or less liquid to a particular evaporator, depending on, for example, an amount of heat present at that evaporator or, in the case of the evaporator 1220 , an amount of heat to be stored in the thermal storage unit 1222 . In order to provide equal heat load distribution, for example, feedback may be provided from an output of each of the evaporators 1206 , 1220 , and 1224 to the flow controllers 1310 . An example of this implementation is illustrated in more detail below, with respect to FIG. 15 . The flow controllers 1310 are shown in FIG. 13 as liquid flow controllers, but also may include other types of flow controllers, such as, for example, vapor flow controllers.
Referring to FIG. 14 , an implementation of a system 1400 is shown that includes condenser capillary flow regulators 1402 . The capillary flow regulators 1402 are included to increase or maximize condenser efficiency, reduce or minimize condenser size, and ensure subcooled liquid return to the liquid pump 1202 . The capillary flow regulators 1402 are discussed in more detail below with respect to FIG. 19 .
Also in FIG. 14 , a vapor bypass line 1404 is shown in conjunction with a low temperature heat source 1406 (and/or the spray-cooled evaporator 1228 ). Specifically, the vapor bypass line 1404 bypasses the vapor compressor 1308 and facilitates operation of the condensing heat exchanger 1226 .
Referring to FIG. 15 , an implementation 1500 is shown that includes superheat feedback flow controllers 1502 for regulating evaporator flow control. A regenerator 1504 is connected to the vapor compressor 1302 , and generally is operable to reuse the latent heat in the steam that leaves the compressor 1302 to assist in operation of the compressor 1302 . An expansion valve 1506 is included to meter the liquid flow that enters the evaporators from the liquid line 1204 , such that the liquid flow enters the evaporators at a desired rate, e.g., a rate that matches the amount of liquid being evaporated in the evaporators.
Referring to FIG. 16 , an implementation of a system 1600 is shown that includes a secondary evaporator 1602 , which is used similarly to the secondary evaporator 150 of FIG. 1 , the secondary evaporator 710 of FIG. 7 , and the secondary evaporator 1011 of FIG. 10 . That is, the secondary evaporator 1602 is used as a priming evaporator for ensuring successful start-up of the system 1600 , and for ensuring sufficient excess flow through the primary evaporator cores to enable venting of excess vapor and NCG bubbles therefrom, particularly during a passive (capillary) operation of the system 1600 .
More specifically, as should be apparent from the above discussion, the secondary evaporator 1602 is thermally and hydraulically connected to a cold-biased reservoir 1604 . As described with respect to FIG. 3 , application of power (heat) to the secondary evaporator 1602 causes evaporation therefrom, which travels through a back pressure regulator (BPR) 1606 (discussed in more detail below) and is condensed within one or more condensers 1608 . Flow regulators 1610 (similar to the regulators 1402 discussed above, and co-located with one another or with their respective condensers) regulate the condensed liquid flow from the condensers 1608 through a mechanical pump 1612 . From there, the condensed liquid flows through an inner liquid flow line of a coaxial flow line 1614 . In this way, the liquid reaches cold plate evaporator(s) 1616 , as well as a thermal mass (storage unit) 1618 and a remote evaporator 1620 .
Further, an isothermalized plate or structure 1622 may be included. Such a structure may be useful, for example, in settings where a constant temperature surface is desired or required, such as, for example, some laser systems. To the extent that such systems require a constant temperature surface, it may be efficient to use the (waste) heat being transported by the system 1600 to keep the structure 1622 at a constant temperature. When the structure 1622 is used, a flow regulator 1624 (perhaps similar to the regulators 1402 of FIG. 14 ) may be used to ensure that a proper amount of vapor from a vapor return line 1626 is provided to the structure 1622 .
A liquid line heat exchanger 1628 is used to provide subcooling of the liquid before it is routed to the evaporators. Also, as just referred to, the vapor return line 1626 returns vapor to the secondary evaporator 1602 and to the BPR 1606 . The BPR 1606 , generally speaking, ensures that no vapor reaches the condensers unless a vapor space for all evaporators in the system is devoid of liquid. As such, heat load sharing among the many parallel (or series) evaporators may be increased. An example of the BPR 1606 is discussed in detail below with respect to FIG. 20 .
FIGS. 11-16 illustrate various implementations of actively pumped thermal management systems, which include different combinations and arrangements of thermal management components. In order to further illustrate the flexibility of design and use of such thermal management systems, additional examples of such thermal components and their uses are provided below with respect to FIGS. 17-25 . It should be understood that such thermal components, and others, may be used in conjunction with some or all of the implementations of FIGS. 11-16 , or in other implementations.
FIGS. 17A-17E are examples of mechanical pumps that may be used in the systems of FIGS. 11-16 . Specifically, FIG. 17A illustrates a bellows pump, while FIG. 17B illustrates a centrifugal pump. FIG. 17C illustrates a diaphragm pump, and FIG. 17D illustrates a gear pump. Finally, FIG. 17D illustrates a peristaltic pump. It should be understood that the illustrated pumps are merely examples of known pumps that may be used in an actively pumped thermal management system, and other types of pumps also may be used.
FIGS. 18A-18C illustrate examples of different evaporator and condenser architectures for use with the systems of FIGS. 11-16 . As already discussed, such architectures may be characterized by virtually any parallel or series arrangement of evaporators and condensers. In FIG. 18A , a heat flow arrangement involving a centralized thermal bus 1802 is used for defense space applications requiring on-orbit servicing. In this concept, multiple parallel evaporators 1804 are used to cool internal electronics 1806 , thermal storage units 1808 , on-gimbal evaporator 1810 on a gimbaled payload 1812 that is connected to the bus 1802 by a coil 1814 , and on-orbit replaceable electronics modules 1816 . Spot coolers 1818 may be used as needed, and the bus 1802 is connected to a deployable or steerable direct condensation radiator 1820 by a coil 1822 . The deployable radiator 1820 may include a secondary loop heat pipe evaporator/reservoir mounted on the radiator 1820 to ensure that the radiator 1820 is cold-biased.
In FIG. 18B , an evaporator section 1824 includes multiple cold plates 1826 connected in parallel to a starter pump 1828 and thermal storage units (TSUs) 1830 . A two-axis gimbaled cold plate 1832 is also connected to the evaporator section 1824 , by way of a coil 1834 . The cold plate 1826 may feature equipment mounting locations 1836 having an advanced interface design, as well as additional spot cooler loops 1838 . In this example, a two-axis gimbaled condenser 1840 is connected to the evaporator section 1824 by a coil 1842 , and is connected to a pump 1844 and reservoir 1846 . Additional cooling may be supplied by a chiller 1848 that is connected to the condenser 1840 .
In FIG. 18C , a possible design for use in a space shuttle bay is illustrated, in which an evaporator section 1850 includes a deployable evaporator section 1852 with a coil or hinge 1854 , modular electronic boxes 1856 , and thermal storage units 1858 . A deployable radiator 1860 includes a pump 1862 and reservoir 1864 , as well as a coil or hinge 1866 .
FIG. 19 is a diagram of an example of the condenser flow regulator 1402 of FIGS. 14-16 . In FIG. 19 , a capillary structure 1902 receives a combined liquid/vapor flow 1904 from an associated condenser, and ensures liquid return to an associated liquid line. As discussed above, the regulator 1402 may thus increase a performance, and reduce a size of, associated parallel condensers.
FIG. 20 is a diagram of an example of the back pressure regulator (BPR) 1606 of FIG. 16 . As discussed above, the BPR 1606 typically is added to a condenser inlet in order to enable heat load sharing in either an active or passive (capillary) pumping mode of a thermal management system, such as the systems of FIGS. 11-16 .
In FIG. 20 , the BPR 1606 is attached at a vapor transport line 2002 on one end and at a radiator or condenser inlet header 2004 at the other end. The BPR 1606 includes a tubular shell external structure 2006 that has an internal annular wick 2008 . The wick 2008 has a first, sealed end 2010 and a second, unsealed (open) end 2012 . The sealed end 2010 of the wick 2008 is surrounded by an annular gap 2014 filled with vapor. The unsealed end 2012 of the wick 2008 is surrounded by an annular gap 2016 filled with liquid. As shown, the annular gaps 2014 / 2016 extend only a portion of the length of the BPR 1606 . In a central (low conductance) portion 2018 of the BPR 1606 , the tubular shell 2006 makes contact with the wick outer surface, and thereby seals the annular gap 2014 from the annular gap 2016 .
Thus, the BPR 1606 typically is positioned at the inlet to the condenser, where the vapor transport line 2002 meets the condenser inlet header 2004 . As such, the unsealed open end 2012 of the internal wick 2008 is thermally linked to a cooling source 2020 (e.g., radiator or other heat sink), and is connected to the condenser inlet header 2004 end of the BPR 1606 . The other end 2010 (sealed end of the internal wick 2008 ) is connected in series to the vapor transport line 2002 .
The BPR 1606 ensures that no vapor reaches the condenser unless the vapor space for all evaporators in the system is devoid of liquid. As such, heat load sharing among the many parallel or series evaporators in the system may be increased. The BPR 1606 typically uses pores 2022 selected such that the pore size is larger than the pore size(s) of any of the system evaporators. Thus, as vapor is produced, it is contained within all the evaporator vapor side space, and is thereby given an opportunity to condense. The vapor clears all evaporator vapor side space of liquid and, once that condition is achieved, pushes through the BPR wick 2008 and allows flow to reach the connected condenser.
FIGS. 21 and 22 are diagrams of evaporator failure isolators 2100 and 2200 , respectively, which may be used in any multi-evaporator implementations of the systems of FIGS. 11-16 . The isolators 2100 and 2200 generally are operable to prevent evaporator pump failures at any particular evaporator from propagating throughout an associated thermal management system.
In FIG. 21 , the isolator 2100 includes a first port 2102 for receiving liquid flow from a liquid line 2104 supplying liquid to a plurality of evaporators. A liquid return port 2106 outputs liquid to other isolators, and a liquid outlet port 2108 outputs liquid to an associated capillary pump (evaporator).
A tube 2110 defines a body of the isolator 2100 that includes a wick 2112 and a flow annulus 2114 . Along with a swage seal 2116 , the wick 2112 and flow annulus 2114 enable isolation of the liquid flow to an associated evaporator, through the liquid outlet port 2108 . If the associated evaporator experiences pump failure, it may be bypassed by the isolator 2100 until repair may be effected.
Similarly, in FIG. 22 , an evaporator failure isolator 2200 includes a liquid flow annulus 2202 through which subcooled liquid flows from an associated reservoir to remaining pumps. Isolation seals 2204 ensure that liquid flow to associated pumps is maintained through ports 2206 , such that only currently functioning pumps receive liquid flow.
FIGS. 23 and 24 illustrate examples of capillary pressure sensors 2300 and 2400 , respectively. Such capillary pressure sensors, generally speaking, provide feedback control for a mechanical pump (e.g., the mechanical pump 1102 of FIG. 11 ), and enable heat load sharing among multiple evaporators.
In FIGS. 23 and 24 , a liquid line 2302 and vapor line 2304 are coupled hydraulically to the capillary pressure sensors 2300 and 2400 . Particularly, in FIG. 23 , the liquid and vapor lines are adjacent to one or more evaporators, and the capillary pressure sensor 2300 includes a hermetic envelope 2306 , an internal wicking structure 2308 , and multiple temperature sensors 2310 .
The internal wicking structure 2308 includes a continuous wick element 2312 with the same capillary pumping radius 2314 (r pevap ) as an evaporator wick that hydraulically links the liquid line 2302 to one or more wick segments 2316 , 2318 , and 2320 with larger capillary pumping radii (r p1 , r p2 , and r p3 ). The capillary sensor 2300 is thermally coupled to one or more heat sources 2322 .
In operation, the temperature sensors 2310 measure envelope temperature above each wick segment 2316 , 2318 , 2320 , and/or temperature differences between the envelopes above each wick segment 2316 , 2318 , 2320 . Temperature increases on the envelope indicate that the wick segment below the envelope may no longer be saturated with liquid, due to inability of the wick segment to support the pressure difference between the vapor line 2304 and the liquid line 2302 . Thus, temperature feedback may be used to adjust a pumping pressure delivered by the mechanical pump 1102 by, for example, adjusting pump speed or adjusting a position of an associated pump bypass valve, in order to maintain saturation of the appropriate wick segment(s).
In FIG. 24 , a heat sink 2402 provides cold bias between the wick segments 2316 , 2318 , and 2320 , and multiple temperature sensors 2310 are used to measure temperature in the cold-biased zone(s). The wick segments 2316 , 2318 , and 2320 may be arranged in sequence, with the wick segment with the largest capillary radius nearest as associated vapor manifold.
In operation, temperature increases on the envelope indicate that the wick segment between the sensor and the vapor manifold may no longer be saturated with liquid due to, for example, an inability of the wick segment to support a pressure difference between the vapor line 2304 and the liquid line 2302 . Then, temperature feedback may be used to adjust the pumping pressure delivered by the mechanical pump, by either adjusting pump speed or the position of a pump bypass valve, to maintain saturation of the appropriate wick segment(s).
FIG. 25 is a pressure drop diagram 2500 for a thermal management system, such as the various implementations of thermal management systems discussed above. In FIG. 25 , the mechanical pump 1110 provides a pressure difference ΔP pump 2502 that is slightly higher than the low pressure point 2504 of the system at the reservoir. Pressure difference ΔP Flow Reg 2506 , the pressure differences provided by the flow regulators 1402 , are lower than the pressure difference ΔP LHP 2508 of the Loop Heat Pipe. Other than the pressure differences ΔP visc 5,6 2510 , 2512 , where a viscous pressure drop may dominate in effect, pressure differentials ΔP cap 1, 2, 3 2514 , 2516 , 2518 demonstrate the positive pressure differentials that enable capillary back pressure(s) the evaporators of the thermal management system, using the evaporator wicks, that allow excellent heat transfer and flow control, in conjunction with the mechanical pump 1110 . Finally, a pressure difference ΔP cap 4 2520 illustrates a pressure difference maintained for regulating flow through the condenser(s) 1115 .
As shown in FIGS. 11-25 , many different implementations exist for actively pumped thermal management systems. Such systems include capillary and/or mechanically pumped two-phase thermal management systems that combine the low input power, passive system advantages (e.g., heat load sharing, no moving parts) of small pore wick (capillary) pumped two-phase loop systems with the operational flexibility advantages (e.g., fluid flow-heat flow decoupling and flow controllability) of mechanically pumped two-phase loop systems.
As described, such thermal management systems absorb waste heat from a wide range of sources, including, for example, waste heat of electronics and power conditioning equipment, high-powered spacecraft, antennas, batteries, and laser systems. Military applications, such as space-based radar and lasers, offer a wide suite of potential heat sources and the elements required for their thermal management. Accordingly, such military applications such as those requiring counterspace detection and offensive force projection capabilities, may benefit from such thermal management systems, which provide high heat transport capability and high heat rejection, as well as high flux heat acquisition and efficient thermal storage, all the while minimizing system mass and maintaining operational reliability over the mission life. Commercial applications, such as, for example, soda-dispensing machines and notebook computers, also may benefit from the implementations of heat transport systems discussed herein, or variations thereof. | A system including a primary evaporator facilitating heat transfer by evaporating liquid to obtain vapor is disclosed. The primary evaporator receives a liquid from a liquid line and outputs the vapor to a vapor line. The primary evaporator also outputs excess liquid received from the liquid line to an excess fluid line. A condensing system receives the vapor from the vapor line, and outputs the liquid and excess liquid to the liquid line. The excess liquid is obtained at least partially from a reservoir. A primary loop includes the condensing system, the primary evaporator, the liquid line, and the vapor line, and provides a heat transfer path. Similarly, a secondary loop includes the condensing system, the primary evaporator, the liquid line, the vapor line, and the excess fluid line. The secondary loop provides a venting path for removing undesired vapor within the liquid or excess liquid from the primary evaporator. | 5 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to solid surface sheet material having improved physical and aesthetic properties. More particularly, the invention relates to providing solid surface sheet material comprised of highly filled acrylic resin containing a controlled amount of a selected synthetic mica.
[0002] U.S. Pat. No. 4,480,060 discloses composite pressed boards containing at least 50% mica mixed with an organic resin such as epoxy, polyimide, melamine or phenolic resin. The boards are useful in electrical applications and have an opaque, lusterless appearance.
[0003] International Publication WO98/38244, published Sep. 3, 1998 discloses products said to contain oriented pearlescent flakes of mica.
[0004] The inclusion of natural occurring mica with resins and fillers in preparing composite materials is disclosed in general terms in a number of publications.
SUMMARY OF THE INVENTION
[0005] The subject invention provides a solid surface sheet material having excellent physical properties and a lustrous, sparkling appearance which comprises an acrylic resin, from about 20 to about 75% by weight of a filler, based on the total weight of the material, and from about 0.1 to about 5% by weight of a selected synthetic mica based on total weight of the material.
DETAILED DESCRIPTION OF THE INVENTION
[0006] The resins useful in the present invention are not specially limited as long as they can be formed into a solid surface material by curing. Examples of useful acrylic resins include various kinds of conventional acrylic group monomers, acrylic group partial polymers, vinyl monomers for copolymerization other than acrylic group monomers, or oligomers. As the arylic group monomer, (meth)acrylic ester is preferable.
[0007] A particularly good and especially preferred polymer which meets all of the above properties is poly(methyl methacrylate). In a castable composition, it is often introduced as a sirup of polymer in methyl methacrylate monomer. Methods of preparing such a sirup are described in the prior art. Another method of preparing a sirup is to simply dissolve polymer in the monomer. This latter method is quite useful for adjusting viscosity of the castable composition since molecular weight of polymer as well as concentration can be varied in such a way as to control the rheology.
[0008] The amount of fluid polymerizable constituent required in the castable composition is at least 30% by volume. Methyl methacrylate monomer is preferred as a major constituent.
[0009] Other monomers useful as fluid polymerizable constituents are alkyl acrylates and methacrylates in which the alkyl groups can be from 1-18 carbon atoms, but preferably 1-4 carbon atoms. Suitable acrylic monomers are methyl acrylate; ethyl acrylate and methacrylate; n-propyl and i-propyl acrylates and methacrylates; n-butyl, 2-butyl, i-butyl and t-butyl acrylates and methacrylates; 2-ethylhexyl acrylate and methacrylate; cyclohexyl acrylate and methacrylate; omega-hydroxyalkyl acrylates and methacrylates; N,N-dialkylaminoalkyl acrylates and methacrylates; N-[t-butyl]aminoethyl acrylate and methacrylate.
[0010] Other unsaturated monomers include such compounds as bis-[beta-chloroethyl] vinylphosphonate; styrene; vinyl acetate; acrylonitrile; methacrylonitrile; acrylic and methacrylic acids; 2-vinyl- and 4-vinylpyridines; maleic acid, maleic anhydride and esters of maleic acid; acryl amide and methacrylamide; itaconic acid, itaconic anhydride and esters of itaconic acid and multifunctional monomers for crosslinking purposes such as unsaturated polyesters; alkylene diacrylates and dimethacrylates; allyl acrylate and methacrylate; N-hydroxymethylacrylamide and N-hydroxymethylmethacrylamide; N,N′-methylene diacrylamide and dimethacrylamide; glycidyl acrylate and methacrylate; diallyl phthalate; divinylbenzene; divinyltoluene; trimethylolpropane triacrylate and trimethacrylate; pentaerythritol tetraacrylate and tetramethacrylate; triallyl citrate and triallyl cyanurate.
[0011] The synthetic mica useful in providing the products of this invention are fluoro-phlogopites such as KMg 3 (AlSi 3 O 10 )F 2 . They are described in detail and a process for their preparation is disclosed in U.S. Pat. No. 5,094,852 which is incorporated herein by reference. Other useful forms of synthetic include fluoro-tetrasilicicmica (KMg 2.5 Si 4 O 10 )F 2 , sodium-fluoro-tetrasilicicmica (NaMg 2.5 Li(Si 4 O 10 )F 2 , sodium-taeniolite (NaMg 2 2Li(Si 4 O 10 )F 2 , and fluoro-hectorite Na 1/3 Mg 8/3 Li 1/3 (Si 4 O 10 ) F 2 .
[0012] Fillers useful in the present invention include, for example, aluminum trihydrate, calcium carbonate, barium sulfate, Bayer hydrate, magnesium hydroxide, talc, wolastonite, as a list that is not exhaustive and not intended to limit the invention. Fillers can be present in effective amounts from as low as about 20% by weight to about 75% by weight. Preferably, amounts from 30 to 67% by weight are used.
[0013] It is known to include in solid surface materials other additives such as pigments, dyes, flame retardant agents, parting agents, fluidizing agents, viscosity control agents, curing agents (chemical and thermal), antioxidants, toughening agents and the like as known to those of ordinary skill in the art.
[0014] Solid surface materials of this invention can be prepared by cell cast, continuous casting or by reactive extrusion using a multi-feeder twin-screw extruder equipped with vacuum and a sheet die of proper dimensions. The sheets produced can be transferred either onto a double belt press or into an oven for curing. The preferred method is continuous casting. The production of filled poly(methyl methacrylate) compositions is well known in the art, see for instance U.S. Pat. Nos. 3,847,865; 4,413,089; and 4,406,662, which are hereby incorporated by reference. Light pressure may be needed for maintaining sheet gauge or profile during curing. The resulting solid surface material is thermoformable.
[0015] The invention can be further understood by reference to the following examples in which parts and percentages are by weight unless otherwise indicated.
EXAMPLES
Example 1
[0016] Alumina trihydrate, approximately 60% by weight, was mixed with ingredients a. through f. as shown in Table 1 at a temperature of 27-29 deg C. After mixing for 1 minute, approximately 0.3 parts per hundred of water (based on the weight of the sirup) was added to the mixture. The mixture was then evacuated under vacuum (24-25 in Hg) using a pump and a suitable condensing vapor trap. At 3½ minutes and 4½ minutes into the evacuation, small amounts of calcium hydroxide and ethylene glycol dimercaptoacetate (GDMA) were added by syringe. After 5 minutes of total mixing and evacuation, the mixture was poured into a container of square design to form a layer of approximately {fraction ( 1 / 2 )}″ thickness and allowed to cure.
[0017] One control article (Control A) and four “synthetic mica containing” articles were made using the described procedure. In Control A, the pearlescent pigment was a 22% solids dispersion of natural mica (muscovite) in butylmethacrylate (BMA). Articles 1-4 used a synthetic fluoro-phlogopite mica (SH-100) purchased from TOPY Industries (dry) with an adjustment in sirup to account for the residual BMA.
TABLE 1 Articles 1 Control A, Articles 2-5 Synthetic Mica (2) (3) (4) (5) (1) Synthetic Synthetic Synthetic Synthetic Control A Article #1 Article #2 Article #3 Article #4 a. Alumina Trihydrate (ATH) * 59.9% 59.9% 60.0% 59.7% 60.3% b. Sirup (24% PMMA in 31.8% 34.2% 34.2% 34.2% 34.2% MMA) c. MMA Monomer 2.9% 2.9% 2.9% 2.9% 2.9% d. PMA 25 paste (t- 0.9% 0.9% 0.9% 0.9% 0.9% butylperoxy maleic acid) e. Trimethylol propane 0.3% 0.3% 0.3% 0.3% 0.3% trimethacrylate (TRIM) f. Dioctyl sodium 0.1% 0.1% 0.1% 0.1% 0.1% sulfosuccinate g. Phosphated propylene glycol 0.1% 0.1% 0.1% 0.1% 0.1% methacrylate h. Ca(OH) 2 Slurry (34% in 0.3% 0.3% 0.3% 0.3% 0.3% sirup) I. Ethylene glycol dimercapto 0.1% 0.1% 0.1% 0.1% 0.1% acetate (GDMA) j. Distilled Water 0.1% 0.1% 0.1% 0.1% 0.1% k. Yellow Pigment Dispersion # 0.4% 0.4% 0.4% 0.4% 0.4% PC-9Y139 (0.1% in Sirup) ** l. White Pigment Dispersion # 0.2% 0.2% 0.2% 0.2% 0.2% PC-11W1185 ** m. Muscovite Natural Pearl 3.0% — — — — Dispersion # PC-9Z319 ** n. Synthetic Pearl Flake — 0.6% 0.5% 0.8% 0.2% #SH100 (Ultimica by TOPY) Total: 100% 100% 100% 100% 100%
[0018] Samples 1-4 were tested on a Series IX Automated Materials Testing System (Instron Corporation v4.06) for strength and flexibility. The results of the testing are tabulated in Table 2. It will be noted that the structures containing synthetic mica support greater loads (lbs) and stresses (psi) prior to yield and increased force (energy) to break. In addition to increased strength, it was also noted that samples 2-4 displayed greater visual pearlescence than the control despite the lower levels of mica pigment (solids basis). Samples 2-5 were also found to be free of objectionable reddish-brown contamination present in the control sample and in the mica supplied by EM Industries (Ruby muscovite).
TABLE 2 Flexural 3-Pont Bend Analysis of Samples 1-5: Stress Force to Strain @ Load at @ Yield Modulus to Break Break Yield Specimen (psi) (psi) (lbs-in) (%) (lbs) Sample 1 (Control A) 8502 1276541 1.8 0.72 45.98 Sample 2 (Synthetic Article #1) 9634 1239000 2.6 0.88 51.02 Sample 3 (Synthetic Article #2) 10240 1257000 2.9 0.93 54.27 Sample 4 (Synthetic Article #3) 9846 1286000 2.7 0.87 52.21 Sample 5 (Synthetic Article #4) 9378 1223000 2.4 0.85 49.23
Example 2
[0019] Articles #5, #6, and Control B were prepared using equivalent methods to that as described above for Example 1, except that large scale, commercial continuous casting equipment and techniques were employed as described in U.S. Pat. Nos. 3,570,056 and 3,600,490 which are hereby incorporated by reference. Pigment flows were adjusted to achieve near equal color, pearlescence and appearance.
TABLE 3 Process Conditions and Formulations for Control B, Articles 5 and 6 (7) (8) (6) Synthetic Synthetic Control B Article #5 Article #6 a. Alumina Trihydrate (ATH)* 60.0% 60.0% 60.0% b. Sirup (24% PMMA in MMA) 32.2% 34.1% 34.3% c. MMA Monomer 2.6% 2.2% 2.2% d. PMA 25 paste (t-butylperoxy 0.8% 0.8% 0.8% maleic acid) e. Trimethylol propane 0.3% 0.3% 0.3% trimethacrylate (TRIM) f. Dioctyl sodium sulfosuccinate 0.2% 0.2% 0.2% g. Phosphated propylene glycol 0.1% 0.1% 0.1% methacrylate h. Ca(OH)2 Slurry (34% in sirup) 0.3% 0.3% 0.3% i. Ethylene glycol dimercapto 0.1% 0.1% 0.1% acetate (GDMA) j. Distilled Water 0.1% 0.1% 0.1% k. Yellow Pigment Dispersion 0.3% 0.4% 0.5% # Pc-9Y139 (0.2% in Sirup)** l. White Pigment Dispersion # PC- 0.2% 0.2% 0.2% 11W1185 (90% in Sirup)** m. Muscovite Natural Pearl 3.0% — — Dispersion # PC- 9Z319 (22% in BMA) ** n. Synthetic Pearl Flake Dispersion — 1.0% 1.0% # PC-9Z412 (22% in BMA)** Total: 100% 100% 100%
[0020] Samples 6-8 were tested on a Series IX Automated Materials Testing System (Instron Corporation v4.06) for strength and flexibility. The results of the testing are tabulated in Table 4. It will be noted that the structures containing synthetic mica support greater loads (lbs) and stresses (psi) prior to yield and increased force (energy) to break. Stain resistance (ANSI Z124 for Stain, Chemical, and Cigarette resistance) was improved in addition to Gardner Impact Performance and the ability of this product to resist discoloration at high temperatures using methods such as NEMA-LD-3.3.6. Improved weatherability was demonstrated in ASTM G24 using an Atlas Ci3000 weatherometer for products of this invention over those incorporating natural mica, e.g. reduced discoloration (dECIE94) at equivalent exposure conditions. In addition to increased strength, stain, temperature resistance, impact, and accelerated weatherability, extensive inspection of production found improved cleanliness of the synthetic formulation (reduced objectionable reddish-brown contamination) present in the control samples and in the natural mica formulations supplied by EM Industries (Ruby muscovite). Improved production yields are achieved.
TABLE 4 Analysis of Samples 6-8 Sample Sample Sample 6 7 8 Natu- Syn- Syn- ral thetic thetic Appearance Color Absolute L′ 89.91 90.36 a′ −0.10 −0.23 b′ 5.73 5.62 Flexural Properties Instron/Sintech Stress (MPa) 58.8 73.5 74.8 (Room Temp) Modulus (MPa) 8759 9244 8305 Force to Break (J) 215 346 414 Strain at Break (%) 0.7360 0.9340 1.0590 Physical Properties Hardness Rockwell 89.0 90.3 87.7 25 Item Stain Sanded finish 83 73 77 Gardner Impact (J) 7-9 9-11 | The subject invention provides a solid surface sheet material having excellent physical properties and a lustrous, sparkling appearance which comprises an acrylic resin, from about 20 to about 75% by weight of a filler and from about 0.1 to about 30% by weight of synthetic mica. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for recording and reading information on a magnetic disk provided with a plurality of recording tracks which are concentric with respect to the axis of rotation of the disk.
The apparatus is of the type comprising means for rotating the magnetic disk, at least one magnetic head for recording and reading the information on the recording tracks, means for translating the magnetic head radially with respect to the disk and for positioning it on a selected recording track, and means for controlling the translation means.
In accordance with a known technique, in order to achieve a high degree of packing of the recording tracks, burst information is prerecorded on each of the tracks; when such information is read by the magnetic head, it is such as to give rise to the generation of electrical signals which are indicative of precise positioning of the head with respect to the selected track, or the error in positioning that may occur as between the head and the track.
An apparatus is known, which is provided with two stepping motors connected to a carriage on which the magnetic recording and reading head is mounted. One of the stepping motors, which has an elementary step equal to the radial distance between one recording track and the other is controlled in conventional manner, in a stepwise mode, to cause translatory movement of the magnetic head radially with respect to the disk. The second one of the stepping motors however has a much smaller elementary step and is operable to produce micro-movements of the carriage for the purposes of correcting the position reached by the carriage by operation of the first motor.
Since such apparatus, uses two stepping motors, one for coarse positioning and the other for fine positioning, it is inevitably very expensive.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an apparatus which is capable of reading and recording information on a magnetic disk with tracks having a high degree of packing, which is very economical and at the same time highly reliable.
In accordance with that aim, the apparatus according to the invention is characterised in that the translation means comprise a single stepping motor capable of effecting both multiple rotational movements of an elementary step for displacing the magnetic head from one recording track to the other and micro-rotational movements which are sub-multiples of the elementary step, in response to the information recorded on the selected recording track.
BRIEF DESCRIPTION OF THE INVENTION
The invention will be described in more detail, by way of example, and with reference to the accompanying drawings, in which:
FIG. 1 is a side view of an apparatus embodying the invention.
FIG. 2 is a plan view of the apparatus in FIG. 1,
FIG. 3 is a diagrammatic representation of one of the recording tracks of a magnetic disk handled by the apparatus,
FIG. 4 is a detail view on an enlarged scale of a part of the recording track shown in FIG. 3,
FIG. 5 is a first diagram representing a first group of information which is prerecorded on the track shown in FIG. 3,
FIG. 6 is a second diagram representing a second group of information which is prerecorded on the track shown in FIG. 3,
FIG. 7 is a block diagram of an electrical circuit of the apparatus shown in FIG. 1,
FIG. 8 is a third diagram representing the configuration of some electrical signals of the circuit shown in FIG. 7,
FIG. 9 is an electrical diagram representing a detail of the circuit shown in FIG. 7, and
FIG. 10 is a diagrammatic representation of one of the motors of the apparatus shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an apparatus 10 according to the invention comprises a base 11 which rotatably mounts a spindle 12 connected to an electric motor 13 operable to rotate at least one magnetic disk 14 at constant angular velocity. The disk 14 may be for example of flexible type, known commercially as a "floppy disk".
Two magnetic heads 16 and 17 are mounted to the ends of two arms 18 of a carriage 19 which is slidable radially with respect to the disk 14 by means of guides 21 (FIGS. 1 and 2).
An electric motor 22 of the stepping type is fixed to the base 11 and is operable to control the displacement of the carriage 19 and the heads 16 and 17 by means of a hub 23 and a pair of flexible strips or blades 24 of known type, for example of the type described in our published Eurpoean Patent application No. EP 0,052,477.
The stepping motor 22 is of the two-pole type, is provided with a rotor 26 (FIG. 10) and pole pieces 27 energisable by means of currents I 1 and I 2 , and is capable of performing 400 steps per revolution, that is to say, an elementary step corresponds to a rotary movement of 0.9°, to which corresponds a linear movement of the carriage 19 of 132 μm (FIG. 2).
Each magnetisable surface 30 of each disk 14 which can be recorded on and/or read by the apparatus 10 according to the invention is subdivided into a plurality of tracks 32 which are concentric with respect to the axis of rotation 29 of the disk 14; in addition each surface 30 is subdivided into a plurality of sectors 33. In a particular embodiment, on a floppy disk 14 with a standardised diameter of 5.25 inches, which is equal to about 134 mm, there are one hundred and sixty tracks 32, from 000 to 159, and there are twenty six sectors 33, from 01 to 26; in that way each surface 30 is subdivided into 4160 blocks 34, in each of which binary information can be recorded in serial form.
The distance "d" (see FIG. 4) between the centre lines 44 of the tracks 32 is 132 μm which is equal to the linear elementary movement of the carriage 19 produced by means of the stepping motor 22, whereby the packing density, expressed in terms of tracks per inch (tpi) is 192.
Each track 32 is about 130 μm in width, being substantially equal to the width of the air gap 45 of each of the magnetic heads 16 and 17.
In accordance with a characteristic aspect of the present invention, pilot information or servo information is prerecorded at the beginning of each of the 4160 blocks 34 (FIGS. 2, 3 and 4); such pilot information, when read by the magnetic heads 16 and 17, is suitable for producing micrometric rotary adjusting movements of the stepping motor 22 to maintain the magnetic heads 16 and 17 precisely aligned with the respective recording track 32 selected.
Each track 32 which is shown in FIG. 3 in linearly developed format, rather than around a circumference as is the real situation, is subdivided into 26 blocks 34, one for each sector 33, and each block 34 is in turn subdivided into a data block 35 and a service or servo block 36.
In addition, provided for each track 32 is a block 37 which is indicative of the beginning of the track (index gap) and a breather block 38 (track gap) in which no information is written. A further servo block 36 is provided between the index gap 37 and the adjoining data block 34; in that way there are twenty seven servo blocks 36 in each track 32.
Each servo block 36 carries the servo information recorded thereon, which comprises key information 40 and burst information 41. Both the information 40 and the information 41 are in turn divided into two groups which are disposed in succession relative to each other, but on opposite sides with respect to the centre lines 44 of the recording tracks 32.
The length "1" of each servo block 36 varies according to the radial position of the corresponding track 32 on the disk 14 but it is such as to provide that each servo block 36 can always be read by the magnetic head 16, 17 in a certain time T 1 , for example in a time of 528 μsec. The lengths "k" and "b" of the individual groups of information 40 and 41 and the distance "a" between the groups 40 and 41 are such that each group 40 is read in a time T k of around 76 μsec, each group 41 is read in a time T b of around 156 μsec and the distance "a" is covered in a time T a of around 16 μsec. An example of the content of the information groups 40 and 41 is represented in FIGS. 5 and 6 respectively.
As can be seen therefrom, the key information 40 (see FIG. 5) in this example comprises a first series of pulses with a half-period T 1 of 1.5 μsec, which are followed by a second series of pulses with a half-period T 2 of 4 μsec, which in turn is followed by a third series of pulses with a half-period T 3 of 2 μsec, to finish with a final pulse with a half-period of T 2 . The items of information 41 on the other hand are formed by a single series of pulses with a half-period T 3 of 2 μsec.
The apparatus 10 further comprises an electrical circuit 50 (see FIG. 7) which is operable to control the positioning of the magnetic heads 16 and 17 with respect to the recording tracks 32, by means of rotary movements of the stepping motor 22, both multiple movements of an elementary step and micrometric adjusting movements in response to the command coming from an external controller 64 which is known per se, by means of an interface 63, and the pilot information which is read by the heads 16 and 17 in the servo blocks 36, as will be described in detail hereinafter.
The circuit 50 comprises a circuit 51 for reading/writing the binary information, which is connected to the magnetic heads 16 and 17 and to the interface 63 from which it receives the data to be written WD and to which it passes the read data RD, a circuit 52 for detecting the amplitude of the signals RD coming from the circuit 51 and for generating corresponding signals AM, a circuit 53 for interpreting the key information 40, and a timer 54 for generating a series of timing signals TA, TB, TC and TD (see FIG. 8) and activated by an output signal SK from the circuit 53.
The circuit 50 (see FIG. 7) further comprises a sample and hold circuit 55 which is actuated by the timing signal TA and which is capable of sampling and storing the output signals AM from the circuit 52, a comparator circuit 58 which is actuated by the timing signal TC and which is capable of comparing the output signals SH from the circuit 55 to the output signals AM from the circuit 52 to generate a logic signal μDIR which determines whether the amplitude of the signals which are read on the first block 41 (FIG. 4) of burst information is greater than the amplitude of the signals which are read on the second block 41 of burst information (μDIR=1) or vice-versa (μDIR=0). In other words, the signal μDIR is at level 1 when the reading head 16 or 17 has been moved towards the first block 41 that it meets, during the rotary movement of the disk 14, wherein the term first block 41 is used to mean that which is most closely adjacent to the blocks 40 containing the key information.
A circuit 59 (see FIG. 7) which is also actuated by the timing signal TC is operable to compare the signals SH and AM to each other to determine if the difference between the amplitude values of the two signals, in relation to the amplitude of one of the two, is higher than a predetermined value to which there corresponds a positioning error of ±3 μm in respect of the magnetic head 16 or 17 with respect to the centre line 44 of the selected track 32 (see FIG. 4): in the affirmative situation, the circuit 59 (see FIG. 7) generates a logic enabling signal EN at level 1.
A circuit 60 is operable to generate a signal μSTEP indicative of the fact that a micro-rotational movement has to be performed by the stepping motor 22 in response to the timing and enabling signals TD and EN respectively outputted by the circuits 54 and 59.
The circuit 50 further comprises a circuit 61 for controlling and actuating the stepping motor 22 and a circuit 62 for generating an enabling signal OK for transmission of the data RD read by the circuit 51 to the interface unit 63 by means of a NAND-gate 65.
The enabling circuit 62 is operable to prevent the generation of the signal OK and thus to prevent the information RD read by the head 16 or 17 from passing to the interface 63, whenever the interface 63 itself supplies a signal STEP which is indicative of the fact that a movement from one track 32 to another is to be performed, and that the stepping motor 22 is thus to be operated, or a signal SIDE which is indicative of the fact that the surface 30 of the magnetic disk 14 on which the information is to be written or read is to be changed. In the absence of the signals STEP and SIDE, the signal OK can also be blocked by the signal EN which is indicative of an unacceptable positioning error of the head 16 or 17 which is in the reading mode, with respect to the corresponding selected recording track 32.
The circuit 61 (see FIGS. 7 and 9) in turn comprises a binary six-bit counter 70 (b 0 -b 5 ), a tracking circuit 71 and a digital-analog converter 72. The inputs of the counter 70 receive a clock signal CK which is associated with the signal μSTEP, and an initial positioning signal PRESET directly from the interface 63. The circuit 71 receives the signal μDIR, the signal μSTEP and the outputs b 0 -b 4 of the counter 70. The output b 5 of the counter 70 is unused.
The circuit 61 further comprises a circuit 73 for determining the mode (FULL STEP or MICRO STEP) with which the stepping motor 22 is to be the subject of pilot control, and the input thereof receives signals STEP and DIR from the interface 63 and the signal μDIR from the circuit 58. The circuit 73 is connected to a translator 74 which is operable to generate the phase signals FA, FB, FC and FD which, by means of a power circuit 75, are passed to the stepping motor 22. The translator 74 and the power circuit 75 control the energisation currents I 1 and I 2 (see FIG. 10) for the windings of the stepping motor 22 in the switching mode by means of two logic signals DT1 and DT2 (see FIG. 9).
Finally, the circuit 61 comprises a circuit 76 for adjusting the useful cycle (DUTY CYCLE) of the currents I 1 and I 2 to be passed to the stepping motor 22, and an OR-gate 77 whose input receives the signal STEP and a signal RC (RIPPLE COUNTER) outputted by the counter 70.
The circuit 76 is connected to the power circuit 75 to receive two reference voltages V REF1 and V REF2 , the converter 72 to receive two adjusting voltages V 1 and V 2 and to the translator 74 to which it passes two control voltages SENS1 and SENS2, the values of which determine the duration of the pulses of the logic signals DT1 and DT2.
The circuit 71 (see FIG. 9) in turn comprises an EX-OR-gate 80 whose inputs receive the phase signals FA and FC outputted by the translator 74, an EX-OR-gate 81 whose inputs receive a signal AC generated by the gate 80 and the output signal b 4 from the counter 70, and an EX-OR-gate 82 whose inputs receive a signal AS generated by the gate 80 and the signal μDIR; the gate 82 generates a signal DIRSE for determining whether the counter 70 is to count in the up direction (DIRSE=0) or the down direction (DIRSE=1), as will be described hereinafter. The circuit 71 further comprises four EX-OR-gates 83, 84, 85 and 86, an input of which receives the output signal b 3 from the counter 70; the other input of the gates 83, 84, 85 and 86 respectively receive signals b 0 , b 1 and b 2 from the counter 70 and the signal AC from the gate 80. An AND-gate 87 having four inputs receives the output signals DAC1, DAC2 and DAC3 from the gates 83, 84 and 85 and the signal b 4 from the counter 70. The signals DAC1, DAC2 and DAC3 and an output signal SIGN from the gate 86 are applied to the digital-analog converter 72. The signal b 3 which is inverted by an inverter 88 and the signal DIRSE are also the inputs of an EX-OR-gate 89, the output of which is connected to one of the two inputs of a NAND-gate 90, the other input of which has the output of the AND-gate 87 connected thereto. The output of the NAND-gate 90 is connected to one of the two inputs of another NAND-gate 91, the other input of which receives the signal μSTEP which is inverted by an inverter 92. The output of the NAND-gate 91 generates the clock signal CK for the binary counter 70.
The circuit 73 in turn comprises a monostable multivibrator 95 whose input receives the signal STEP from the interface 63 and a first NAND-gate 96, an input of which receives the signal μDIR, and having its other input connected to the output of the multivibrator 95. A second NAND-gate 97 has an input connected to the output of an inverter 99, having its input connected to the output of the multivibrator 95, and at the other input receives the signal DIR from the interface 63. A third NAND-gate 98 which has its inputs connected to the outputs of the gates 96 and 97 outputs a signal MV which is indicative of the direction in which the stepping motor 22 is to be rotated.
The circuit 61 is operable to produce both multiple rotary movements of one step, to move the magnetic heads 16 or 17 onto the selected recording track 32, operating in the FULL STEP mode, and micrometric rotary adjusting movements to position the magnetic head 16 or 17 in precisely centered relationship with the centre line 44 of the recording track 32 which has already been reached, by operating in the MICRO STEP mode. In both those modes, the currents I 1 and I 2 (FIG. 10) which energise the windings of the stepping motor 22 are supplied by the power circuit 75, by way of the translator 74.
The mode of operation of the apparatus 10 as described hereinbefore is as follows:
It will be assumed that a magnetic disk 14 (see FIGS. 1 and 2) has been positioned on the spindle 12 and that one of the magnetic heads 16 or 17 is to be positioned on a given recording track, starting from a rest position which is memorised in the controller 64.
The controller 64 (see FIG. 7) passes to the circuit 50, by means of the interface 63, the signals STEP and DIR which are indicative of the elementary steps that the motor 22 is to perform in order to reach the selected track 32 and the direction, clockwise or anticlockwise, in which the motor 22 is to rotate.
The signal STEP (see FIG. 9), on passing into the circuit 73, actuates the monostable multivibrator 95 with the result that the output of the latter goes to level 0 for a predetermined time sufficient to cause the motor 22 to perform a rotary movement of one step. With the output of the multivibrator 95 at level 0, the motor 22 is actuated in the FULL STEP mode and the signal MV assumes the same value as the signal DIR.
The controller 64 (FIG. 7) also supplies the circuit 50 with the signal PRESET which conditions the counter 70 to present at its outputs b 0 -b 4 the starting configuration of 01000, with the least significant bit b 0 on the right and the most significant bit b 4 on the left. That configuration provides that the signals DAC1, DAC2 and DAC3 are all at level 1 and that the output voltages V 1 and V 2 from the converter 71 are equal to each other.
That means that, in that initial phase, the stepping motor 22 is pilot-controlled in conventional manner, with the energisation currents I 1 and I 2 (see FIG. 10) being maintained at the same value. That permits the rotor 26 of the motor 22 to stop at intermediate positions between the pole pieces 27 (positions P 1 , P 2 , P 3 and P 4 in FIG. 10). The stop positions P 1 and P 3 , to which corresponds for example positioning of the heads 16 and 17 at the odd tracks 32, are attained when the phase signals FA and FC (FIG. 9) are different from each other, while the stop positions P 2 and P 4 (see FIG. 10) to which corresponds positioning of the heads 16 and 17 at the even tracks 32, are attained when the signals FA and FC are equal to each other.
It is assumed that, when pilot-controlled in that way, the stepping motor 22 has moved the head 16 or 17 to the recording track 001 (see FIG. 4). At that point it is the circuit 50 which directly provides for the micrometric pilot control of the stepping motor 22 to move the selected head 16 or 17 into precisely centered relationship with the track 32 which has been reached, and to hold it in that position.
The selected head 16 or 17 reads the information contained in the recording track and transfers it to the reading/writing circuit 51 which outputs the reading signals RD which are passed to the circuit 52 and to the circuit 53. When the latter recognises that the information read by the magnetic head 16 or 17 belongs to the key information 40 of a servo block 36, it puts the signal SK at level 1 (time t 0 in FIG. 8) and holds it at that level for the entire period of time T c required for reading the burst information of the two blocks 41.
The timing circuit 54 (FIGS. 7 and 8), before enabling the circuit 52 with the signal TB (time t 3 ), enables the circuit 55 with the signal TA for a period of time T s between the times t 1 and t 2 . The circuit 52 is then enabled for a time T u between the times t 3 and t 6 . The period of time T d between the times t 0 and t 3 is so selected that it is greater than the value of T k +2T a , and less than the value of T b +T a -T u .
The circuit 55 is also enabled for a period of time T s between the times t 4 and t 5 , during enablement of the circuit 52, so that the circuit 55 samples the signals AM received between the times t 4 and t 5 , related to the values of the signals received between the times t 1 and t 2 .
The timer circuit 54, at the time t 7 after a period of time T b from the time t 6 , again enables the circuit 52 with the signal TB and, by means of the signal TC between the times t 8 and t 9 enables the comparison circuits 58 and 59. At the time t 9 , when enablement of the circuits 58 and 59 is terminated, a negative pulse of the signal TD is generated, which at the time t 10 returns the signal SK to level 0, thus terminating the phase of reading the servo information 40 and 41 contained in the servo block 36.
If the circuit 59 detects that the difference between the amplitudes of the signals AM which are read in the first block 41 (times t 4 -t 5 ) and those of the signals AM which are read in the second block 41 (times t 8 -t 9 ) is smaller than the predetermined value and that there is therefore not a positioning error of greater than ±3 μm in respect of the magnetic head 16 or 17 relative to the centre line 44 of the selected track 001, no pulse μSTEP is generated and the stepping motor 22 is held stationary in the position that it had previously reached. Concurrently, the signal OK is generated, which enables transfer of the information which is read in the data block 35 to the controller 64 by means of the interface 63.
If however the circuit 59 detects that the difference between the amplitudes of the signals AM is greater than the predetermined value, a negative pulse is generated on the signal μSTEP, by means of the signal EN, and a micro-rotation of the stepping motor 22 is produced.
In particular, the signal μSTEP (see FIG. 9), on going from level 1 to level 0, also causes the clock signal CK for the counter 70 to go to level 0, which changes the configuration of the counter outputs b 0 -b 4 .
The binary counter 70 is controlled to count in the up or down direction by the signal DIRSE which takes account of the level of the phase signals FA and FC with which the motor 22 was caused to perform the last step, and the level of the signal μDIR which is indicative of the direction in which the magnetic head 16 or 17 is displaced with respect to the centre line 44 of the selected track 001 (see FIG. 4).
As has been noted hereinbefore, the signal μDIR is at level 1 when the magnetic head 16 or 17 is displaced towards the first of the two burst information blocks 41 which it encounters.
It may be assumed for example that the magnetic head 16 or 17 is moved towards the first of the blocks 41 which it has read and that it is then displaced towards the track 002 with which it partially interferes; in that case the signal μDIR is at level 1.
The signal μDIR, by means of the circuit 73 (see FIG. 9), also conditions the signal MV. In fact, in that phase, as there are no pulses of the signal STEP, the signal MV assumes the same value as μDIR. Therefore, without pulses of the signal STEP, the circuit 73 is predisposed to provide for control of the stepping motor 22 in the MICRO STEP mode.
In the example set out above, with the magnetic head 16 or 17 positioned on the track 001, the phase signals FA and FC are different from each other; the signal AC is thus at level 1 and, the signal b 4 being initially at level 0, the signal AS is also at level 1. The signal μDIR being at level 1, the signal DIRSE is at level 0 and the counter 70 is operated to count in the up direction.
The outputs b 0 -b 3 of the binary counter 70 change whenever a negative pulse of the signal μSTEP is generated and, by means of the signals DAC1, DAC2, DAC3 and SIGN associated therewith, condition the converter 72 in such a way as to vary the values of the voltages V 1 and V 2 . At each pulse of the signal μSTEP the difference between V 1 and V 2 is incremented up to a certain point, and then reduced. In particular the outputs b 0 , b 1 and b 2 are such as to determine the value that the difference between the voltages V 1 and V 2 is to assume, while the output b 3 is such as to determine the sign of the voltages V 1 and V 2 .
The outputs b 0 -b 3 are capable of taking on a configuration in sixteen different conditions, to which correspond sixteen different combinations of values of V 1 and V 2 , whereby, within the limits of each of the elementary steps of 0.9° of the stepping motor 22, to which there corresponds a movement of the heads 16 and 17 from one recording track 32 to another, sixteen micro-steps may be performed, each of which corresponds to a movement of the carriage 19 and the magnetic heads 16 and 17 of around 8 μm.
For each of the micro-steps to be produced, the voltages V 1 and V 2 are varied in such a way that the current I 1 and I 2 which energise the windings of the motor 22 also change. In the hypothetical case envisaged, the voltage V 2 is increased and the voltage V 1 is reduced in such a way that in a similar fashion the current I 1 falls and the current I 2 rises (FIG. 10). In that way the rotor 26 of the motor 22 performs a rotary micro-motion in the anticlockwise direction and the heads 16 and 17 move towards the track 000 (see FIG. 4).
The above-indicated adjustment movements are carried out until the magnetic head detects that it is in precisely centered relationship to the centre line 44 of the selected track 001.
In accordance with a further feature of the present invention, the rotary micro-steps may be sixteen in one direction and sixteen in the opposite direction whereby the travel of the heads 16 and 17 in "searching for" precise positioning with respect to the centre line 44 of the selected track is of more or less a complete track, that is to say, ±132 μm.
In order to make that mode of operation possible, the binary counter 70 generates a pulse of the signal RC when eight micro-steps have been performed, in one direction or the other, from the initial position (for example position P 1 in FIG. 10).
It may be assumed for example that, in order to reach the optimum position of the magnetic head 16 or 17 on the selected track 001, the stepping motor 22 must perform ten micro-steps.
In the first operation of reading the servo information 40 and 41 the circuit 50 detects the positional error and a first pulse of the signal μSTEP is generated: the voltage V 1 is reduced and the voltage V 2 is increased, in the manner described hereinbefore.
Reading of the servo information 40 and 41 contained in the servo block 36 subsequent to that which had been previously read also provides for detection of the positional error and a second pulse of the signal μSTEP is generated so that a second pulse of the clock signal CK is applied to the counter 70 which again changes the configuration of its outputs. In particular, while the configuration of the outputs b 0 , b 1 and b 2 changes to indicate, by means of the signals DAC1, DAC2 and DAC3, the new value that is to be assumed by the difference between the voltages V 1 and V 2 , the output b 3 which is indicative of the fact that V 1 is greater than V 2 or vice-versa is intended not to change for the first eight clocks arriving at the counter. In that way, the difference between the energisation currents I 1 and I 2 is also further incremented.
Operation continues in a similar fashion until the eighth pulse of the signal μSTEP is generated, and thus until the rotor 26 has performed eight micro-steps. As it performs the eight micro-step the rotor 26 moves with its pole N almost into a position of correspondence with the pole piece 27 intermediate between the stop positions P 1 and P 4 (position P 8 in FIG. 10), the current I 1 having become very small and the current I 2 in the meantime having become very great.
The subsequent pulse of the signal μSTEP which causes the ninth clock pulse CK to be generated enables the counter 70 (see FIG. 9) to generate a pulse of the signal RC which, by means of the OR-gate 77, passes into the translator 74, causing a change in the configuration of the phase signals FA, FB, FC and FD, obviously taking account of the signal MV which is indicative of direction.
In other words, the pulse of the signal RC, just like a pulse of the signal STEP, would cause the motor 22 to perform an elementary step of 0.9° (see FIG. 10) until the rotor 26 moved from position P 8 to position P 10 . However that step is not performed. In fact, since the phase signals FA and FC change due to the effect of the pulse of the signal RC (see FIG. 9), now being in the condition of FA=FC, the signal AC outputted from the gate 80 also changes in value. Concurrently with generation of the pulse of the signal RC, the counter 70 also changes the configuration of the outputs b 0 -b 3 . In particular the output b 3 changes in value with the result that the output signal SIGN from the gate 86 does not change in value. In that way the currents I 1 and I 2 which would be changed by virtue of the change in the signals FA and FC remain at the values that they had previously. In addition, with the change in the phase signals, the current I 1 also changes in direction while the current I 2 still continues with the same direction as before (see FIG. 10).
By virtue of those simultaneous changes, the rotor 26 of the motor 22, rather than performing a complete rotational movement of 0.9°, performs a micro-step and moves to a position slightly beyond the pole piece 27 between the stop positions P 1 and P 4 (position P 9 in FIG. 10). By suitable selecting the limit values of the currents I 1 and I 2 , a micro-step of the rotor 26 which is equal to those produced previously is also effected in this case.
In addition, concurrently with the ninth clock CK, the counter 70 also changes the value of the output b 4 in such a way that, in spite of the change in the value of the signal AC, the signal DIRSE does not change in value.
The subsequent pulse of the signal μSTEP generates the tenth clock pulse CK and conditions the counter 70 to change the values of the outputs b 0 , b 1 and b 2 to reduce the difference between the voltages V 1 and V 2 , to which there corresponds a similar reduction in the difference between the currents I 1 and I 2 , to cause the rotor 26 of the motor 22 to perform a further micro-step in an anticlockwise direction, thus positioning the head 16 or 17 with respect to the centre line 44 of the selected track 001.
In that MICRO STEP mode, it would be possible to provide for pilot control of the motor 22 for n steps, for example for the entire travel movement of the carriage 19, but in the particular embodiment described herein, after sixteen micro-steps in each of the two directions of rotation, starting from the initial stop position (P 1 in the example stated), the circuit 71 is predisposed to block the generation of the clock pulses CK. The purpose of that is to ensure that a magnetic head 16 or 17 cannot, by error, be positioned on the centre line 44 of the tracks 32 which are immediately adjacent to the selected track (000 or 002 in the embodiment described), rather than on the actual selected track 001. To achieve that, after sixteen pulses have been received, the counter 70 is disposed with the outputs b 0 -b 4 in the final configuration 10111 if the counter 70 was counting in the up direction (DIRSE=0) or in the configuration 11000 if the counter was counting in a down direction (DIRSE=1). In that way the output of the AND-gate 87 is also put to level 1 in each case while the output of the NAND-gate 89 goes to level 1 whereby generation of the pulses CK is blocked. Such blocking of the pulses CK occurs only if the signal μDIR does not change in level, otherwise, the signal DIRSE also changing in level, the block is removed.
The currents I 1 and I 2 which are modulated in that way are also kept as they are during subsequent actuation of the motor 22 in the FULL STEP mode. That means that, when the circuit 55 receives another pulse of the signal STEP from the interface 63, rotary movement through an elementary step of 0.9° occurs from the position previously reached with modulation of the currents I 1 and I 2 .
That therefore means that there is a high probability that once the magnetic head 16 or 17 has been accurately positioned on one of the tracks 32, with movements of the carriage 19 which are a multiple of the elementary step, the same head 16 or 17 is already positioned at the centre of the new track selected.
Verification of the correct positioning of the magnetic head 16 or 17 with respect to the selected track 32 is effected twenty seven times for each revolution of the disk 14, once for each servo block 36 that the magnetic head 16 or 17 encounters. In that way, the position of the magnetic recording and reading head is continuously checked and possibly corrected, providing for highly precise and accurate tracking, which also makes it possible to remedy any errors in regard to eccentricity in the disk 14 or the spindle 12.
Whenever the circuit 50 detects correct positioning of the magnetic head 16 or 17 relative to the selected recording track, the binary information contained in the block 35 immediately following the servo block 36 which has been read, is read and transferred to the controller 64 or fresh data can be recorded in that block 35.
It will be clear therefore that the apparatus 10 comprises means 12 and 13 for rotating the disk 14, at least one magnetic head 16, 17 for recording and reading the information on the recording tracks 32, means 19, 22, 23 and 24 for translating the magnetic head 16 or 17 radially with respect to the disk 14 and positioning it with respect to a selected recording track, and means 50-62 for controlling the translation means, that the translation means comprise a single stepping motor 22 capable of effecting both multiple rotary movements of a step and rotary micro-movements which are submultiples of such step, and that the control means 50-62 are capable of controlling the rotary micro-movements of the stepping motor in response to the information recorded on the selected recording track.
It will be appreciated that the apparatus as described hereinbefore may be the subject of modifications and addition of parts, without thereby departing from the scope of the claims.
For example, the circuit 50 for controlling the stepping motor 22, rather than being on an apparatus for recording and reading information on a magnetic disk, may be applied to an apparatus for magnetic cards or tapes in which the recording tracks, rather than being circular and concentric, are straight and parallel to each other. | The apparatus records and reads binary information on a magnetic disk having magnetizable surfaces subdivided into a plurality of concentric tracks in which the information is recorded in block form (sectors). A first electric motor rotates the magnetic disk at a substantially constant angular velocity, and a second motor (22) of stepping type is operable to position the magnetic recording and reading heads (16, 17) with respect to the recording tracks of the disk. On each track, each block of binary information contains prerecorded burst information which, when read by the corresponding magnetic head, is capable of causing micrometric rotary adjusting movements of the stepping motor to bring the magnetic head into precise alignment with the selected recording track and to hold it in that position. Thus amplitude information from two bursts either side of the center line of the track is compared (52, 55, 59, 58) to provide a signal (μSTEP) when the amplitude discrepancy exceeds a threshold, and a signal (μDIR) indicating the sense of the discrepancy. A motor control circuit (61) effects micro-steps by applying pulses to the stepping motor (22) with duty cycle modulation. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 08/679,350, filed Jul. 10, 1996, now U.S. Pat. No. 5,985,838 which is a continuing application of U.S. patent application Ser. No. 08/371,723, filed Jan. 12, 1995, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 08/055,051, filed Apr. 29, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to peptide analogs that are interleukin-1β protease inhibitors. More particularly, the invention provides a-substituted methyl ketones derived from aspartic acid and the closed hemi-ketal forms thereof as inhibitors of interleukin 1-β protease.
2. Reported Developments
Enzymes involved in the catalytic degradation of proteins by hydrolyzing peptide bonds are known as proteases or proteinases. Proteinases are believed to be involved in various disease states including inflammation, metastasis, tissue damage, bone resorption and muscle degeneration in dystrophic diseases. Proteinases are divided into classes according to their catalytic mechanisms, such as serine-, cystein-, aspartic- and metallo-proteinases. For each class of proteinases, the catalytic site of the enzyme lies in the cleft on the surface of the enzymes in which reside the specificity subsites that bind amino acid side chains and the polypeptide backbone. In designing proteinase inhibitors, it is important to optimize the subsite binding characteristics with appropriate amino acid substrate analogs.
This invention relates to peptide substrates modified with affinity labels that inhibit interleukin-1β protease (hereinafter IL-1β protease). These inhibitors are thought to act by alkylating the cysteine sulfhydryl group (cys 285) within the catalytic site of IL-1β protease. Affinity labeling has been used since the 1960's to prepare irreversible peptide-based inhibitors which act to alkylate the active sites of cysteine proteases. A variety of affinity labels and amino acid sequences have been synthesized to improve the binding of these modified peptide inhibitors to the enzyme's active site. These affinity labels include peptidyl halomethyl ketones, peptidyl diazomethyl ketones, epoxysuccinyl peptides and peptidyl methylsulphonium salts as reviewed by D. Rich in Chapter 4 of “Proteinase Inhibitors”, Barret, A. J. and Salvesen, G., eds., Elsevier, 1986. More recently, peptide acyloxymethyl and aryloxymethyl ketons have also been described as affinity lables (Krantz, A. et al, Biochemisty, 30, p. 4678-4687, 1991). Current research (see for example European Patent Application, Pub. No. 015,748 A2; PCT International Publication No. WO 91/15577; Chapman, K. T., Biorganic & Medicinal Chem. Lett. 1992, 2, 613-618) has been directed towards understanding the enzyme binding specificity requirements in designing novel small molecular weight protease inhibitors that are efficacious, safe and have specificity for IL-1β protease which is believed to play an important role in many disease states (see Epstein, F. H., New Engl. Jrl. of Med., 32 p. 106-113, 1993).
Disease states in which IL-1β protease inhibitors may be useful as therapeutic agents include: infectious diseases, such as meningitis and salpingitis, septic shock, respiratory diseases; inflammatory conditions, such as arthritis, cholangitis, colitis, encephalitis, endocerolitis, hepatitis, pancreatitis and reperfusion injury, immune-based diseases, such as hypersensitivity, autoimmune diseases, such as multiple sclerosis; bone diseases; and certain tumors
The following publications illustrate that IL-1β inhibitors and antagonists are useful in modifying certain disease states in vivo.
1) IL-1 is present in affected tissues in ulcerative colitis in humans. In animal models of the disease, IL-1β levels correlate with severity. In the model, administration of 1-L-1ra reduced tissue necrosis and the number of inflammatory cells in the colon. Cominelli, F., Nast, C. C, Clark, B. D., Schindler, R., Llerena, R., Eysselein, V. E., Thompson, R. C., and Dinarello, C. A. “Interleukin-1 gene expression, synthesis, and effect of specific IL-1 receptor blockade in rabbit immune complex colitis” J. Clin. Investigations (1990) Vol. 86, pp, 972-980.
2) IL-1ra supresses joint swelling in the PG-APS model of arthritis in rats. Schwab, J. H., Anderle, S. K., Brown, R. R., Dalldorf, F. G. and Thompson, R. C. “Pro-and Anti-Inflammatory Roles of Interelukin-1 in Recurrence of Bacterial Cell Wall-Induced Arthritis in Rats”. Infect Immun. (1991) 59; 4436-4442.
3) IL-1ra shows efficacy in an small open-label human RA trial. Lebsack, M. E., Paul, C. C., Bloedow, C. C., Burch, F. X., Sack, M. A., Chase, W., and Catalano, M. A. “Subcutaneous IL-1 Receptor Antagonist in Patients with Rheumatoid Arthritis” Arth. Rheum. (1991) 34; 545.
4) IL-1 appears to be an autocrine growth factor for the proliferation of CML cells. Both IL-1ra and sIL-1R inhibit colony growth in cells removed from leukemia patients. Estrov, Z., Kurzrock, R., Wetzler, M., Kantarjian, H., Blake, M, Harris, D., Gutterman, J. U., and Talpaz, M. “Supression of chronic myelogenous leukemia colony growth by interleukin-1 (IL-1) receptor antagonist and soluble IL-1 receptors: a novel application for inhibitors of IL-1 activity”. Blood (1991) A; 1476-1484.
5) As in 4) above, but for acute myelogenous leukemia rather than chronic myelogenous leukemia. Estrov, Z., Kurzrock, R., Estey, E., Wetzler, M., Ferrajoli, A., Harris, D., Blake, M. Guttermann, J. U., and Talpaz, M. “Inhibition of acute myelogenous leukemia blast proliferation by interleukin-1 (IL-1) receptor antagonist and soluble IL1 receptors”. (1992) Bloods; 79; 1938-1945.
It is an object of the present invention to provide novel peptidyl substrate analogs modified with electronegative leaving groups that bind at the active site of IL-1β protease and inhibit IL-1β protease activity. IL-1β protease cleaves a biologically inactive 34 kD precursor of IL-1β to form the biologically active 17kD cytokine. This cleavage occurs at the peptidyl sequence of Val-His-Asp/-Ala-Pro-Val.
It is another object of the present invention to provide compositions comprising the above-referred to compounds.
It is a further object of the present invention to provide a method of use of the composition for the treatment of the above-identified disease states.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a compound of the formula (I) and a pharmaceutically acceptable salt thereof:
wherein
n=0-4;
m=0,1;
R 3 =a singularly or multiply substituted aryl wherein aryl is a phenyl or naphthyl ring wherein the substituents are independently selected from the group consisting of
(1) H
(2) halogen
(3) OH
(4) CF 3
(5) NO 2
(6) OR 5
(7) COR 9
(8) NR 6 COR 10
(9) CONR 5 R 6
(10) SO 2 NR 5 R 6
(11) SO 2 R 6
(12) COOR 11
and
(14) lower alkyl and lower cycloalkyl;
R=(1) lower straight chain or branched alkyl, lower cycloalkyl
(2) (CR 6 R 7 ) 0-6 -aryl
(3) (CR 6 R 7 ) 0-6 -heteroaryl or
(4) (CR 6 R 7 ) 2-6 —R 8 ;
R 6 and R 7 are independently H, lower straight chain or branched alkyl, benzyl, aryl, cycloalkyl and aryl is defined as above and heteroaryl includes pyridyl, thienyl, furyl, thiazolyl, imidazolyl, pyrazolyl, isoxazolyl benzimidazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, isothiazolyl, benzofuranyl, isoxazolyl, triazinyl and tetrazolyl;
R 8 =(1) OCH 2 CH 2 OR 6
(2) OCH 2 CH 2 NR 6 R 7
(3) NR 6 CH 2 CO 2 R 6
(6) NR 6 R 7 wherein R 6 and R 7 are as above defined;
R 9 =(1) lower straight chain or branched alkyl, lower cycloalkyl
(2) (CR 6 R 7 ) 0-6 -aryl;
(3) (CR 6 R 7 ) 0-6 -heteroaryl; or
(4) (CR 6 R 7 ) 0-6 —R 8 , wherein R 6 , R 7 and R 8 are as above defined;
R 10 =(1) R 9
(2) OR 11
(3) NR 6 R 11 ,
wherein
R 11 =(1) lower straight chain or branched alkyl, lower cycloalkyl
(2) (CR 6 R 7 ) 1-6 -aryl;
(3) (CR 6 R 7 ) 1-6 -heteroaxyl; or
(4) (CR 6 R 7 ) 2-6 —R 8 , and R 6 , R 7 and R 8 are as above defined;
R 4 =H or deuterium;
R 2 =(1) OR 6
(2) NR 6 OR 7 or
(3) NR 6 R 7 , and R 6 and R 7 are as above-defined;
A=(1) an amino acid of the formula (II)
wherein R 6 and R 7 are as defined above;
R 12 is independently
(1) H or
(2) (CR 6 R 7 ) 1-6 —R 13 , and R 6 and R 7 are as above-defined;
R 13 =(1) H
(2) F
(3) CF 3
(4) OH
(5) OR 11
(6) NR 6 R 14
(7) cycloalkyl
(8) aryl
(9) heteroaryl
(10) SH
(11) SR 11
(12) CONR 5 R 6
(13) COOR 5 or
R 14 =(1) R 7
(2) COR 10
(3) SO 2 NR 5 R 6 or
or
A=(2) an amino acid selected from the group consisting of
R 1 is an acyl group of the formula (III)
wherein
R 12 is
(1) OR 5
(2) NR 5 R 6
(3) R 5
(4) —CH═CHR 5
wherein R 15 =single bond, (CH 2 ) 2-6 —NR 6 —, (CH 2 ) 2-6 —O— and
R 5 and R 6 are as above defined; or
a sulfonyl group of the formula (IV)
wherein
wherein R 5 and R 6 are as above-defined.
As used herein the term pharmaceutically acceptable salts include the acid and base addition salts.
The term acid addition salts refers to those salts which retain the biological effectiveness and properties of the free bases and which are not biologically or otherwise undesirable, formed with inorganic acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and the like, and organic acids such as acetic acid, propionic acid, glycolic acid, pyruvic acid, oxalic acid, maleic acid, malonic acid, succinic acid, fumaric acid, tartaric acid,citric acid, benzoic acid, cinnamic acid, mandelic acid, methanesulfonic acid, ethanesulfonic acid, p-toluenesulfonic acid, salicylic acid and the like.
The term base addition salts include those derived from inorganic bases such as sodium, potassium, lithium, ammonium, calcium, magnesium, iron, zinc, copper, manganese, aluminum salts and the like. Particularly preferred are the ammonium, potassium, sodium, calcium and magnesium salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion exchange resins, such as isopropylamine, trimethylamine, diethylamine, triethylamine, tripropylamine, ethanolamine, 2-dimethylaminoethanol, 2-diethylaminoethanol, trimethamine, dicyclohexylamine, lysine, arginine, histidine, caffeine, procaines, hydrabamine, choline, betaine, ethylenediamine, glucosamine, methylglucamine, theobromine, purines, piperazine, piperidine, N-ethylpiperidine, polyamine resins and the like. Particularly preferred organic non-toxic bases are isopropylamine, diethylamine, ethanolamine, trimethamine, dicyclohexylarine, choline and caffeine.
“Alkyl” means a saturated or unsaturated aliphatic hydrocarbon which may be either straight- or branched-chain. Preferred groups have no more than about 12 carbon atoms and may be methyl, ethyl and structural isomers of propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl and dodecyl.
“Lower alkyl” means an alkyl group as above, having 1 to 7 carbon atoms. Suitable lower alkyl groups are methyl ethyl n-propyl isopropyl, butyl tert-butyl, n-pentyl neopentyl n-hexyl, and n-heptyl.
“Substituted phenyl” means a phenyl group in which one or more of the hydrogens has been replaced by the the same or different substituents including halo, lower alkyl nitro, amino, acylamino, hydroxyl, lower alkoxy, aryl, heteroaryl, lower alkoxy, alkylsulfonyl, trifluoromethyl, morpholinoethoxy, morpholino-sulfonyl, and carbobenzoxy-methyl sulfamoyl.
“Halogen” means chloride, fluoride, bromide or iodide.
“Lower cycloalkyl” means cycloalkyl having C 3 to C 6 carbon atoms.
The present invention also concerns the pharmaceutical composition and method of treatment of IL-1β mediated disease states or disorders in a mammal in need of such treatment comprising the administration of IL-1β inhibitors of formula (I) as the active agent. These disease states and disorders include: infectious diseases, such as meningitis and salpingitis; septic shock, respiratory diseases; inflammatory conditions, such as arthritis, cholangitis, colitis, encephalitis, endocerolitis, hepatitis, pancreatitis and reperfusion injury, immune-based diseass, such as hypersensitivity; auto-immune diseases, such as multiple sclerosis; bone diseases; and certain tumors.
In the practice of this invention an effective amount of a compound of the invention or a pharmaceutical composition thereof is administered to the subject in need of, or desiring, such treatment. These compounds or compositions may be administered by any of a variety of routes depending upon the specific end use, including orally, parenterally (including subcutaneous, intraarticular, intramuscular and intravenous administration), rectally, buccally (including sublinguaully), transdermally or intranasally. The most suitable route in any given case will depend upon the use, the particular active ingredient, and the subject involved. The compound or composition may also be administered by means of controlled-release, depot implant or injectable formulations as described more filly herein.
In general, for the uses as described in the instant invention, it is expedient to administer the active ingredient in amounts between about 0.1 and 100 mg/kg body weight, most preferably from about 0.1 to 30 mg/kg body weight for human therapy, the active ingredient will be administered preferably in the range of from about 0.1 to about 20-50 mg/kg/day. This administration may be accomplished by a single administration, by distribution over several applications or by slow release in order to achieve the most effective results. When administered as a single dose, administration will most preferably be in the range of from about 0.1 to 10 mg/kg of body weight.
The exact dose and regimen for administration of these compounds and compositions will necessarily be dependent upon the needs of the individual subject being treated, the type of treatment, and the degree of affliction or need. In general, parenteral administration requires lower dosage than other methods of administration which are more dependent upon absorption.
A further aspect of the present invention relates to pharmaceutical compositions comprising as an active ingredient a compound of the present invention in admixture with a pharmaceutically acceptable, non-toxic carrier. As mentioned above, such compositions may be prepared for use for parenteral (subcutaneous, intraarticular, intramuscular or intravenous) administration, particularly in the form of liquid solutions or suspensions; for oral or buccal administration, particularly in the form of tablets or capsules; or intranasally, particularly in the form of powders, nasal drops or aerosols.
When administered orally (or rectally) the compounds will usually be formulated into a unit dosage form such as a tablet , capsule, suppository or cachet. Such formulations typically include a solid, semi-solid or liquid carrier or diluent. Exemplary diluents and vehicles are lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, mineral oil, cocoa butter, oil of theobroma, alginates, tragacanth, gelatin, syrup, methylcellulose, polyoxyethylene sorbitar monolaurate, methyl hydroxybenzoate, propyl hydroxybenzoate, talc, and magnesium stearate.
The compositions may be prepared by any of the methods well-known in the pharmaceutical art, for example as described in Remington's Pharmaceutical Sciences , 17th edition, Mack Publishing Company, Easton, Pa., 1985. Formulations for parenteral administration may contain as common excipients sterile water or saline, alkylene glycols such as propylene glycol, polyalkylene glycols such as polyethylene glycol, oils of vegetable origin, hydrogenated naphthalenes and the like. Examples of vehicles for parenteral administration include water, aqueous vehicles such as saline, Ringer's solution, dextrose solution, and Hank's solution and nonaqueous vehicles such as fixed oils (such as corn, cottonseed, peanut, and sesame), ethyl oleate, and isopropyl myristate. Sterile saline is a preferred vehicle and the compounds are sufficiently water soluble to be made up as a solution for all foreseeable needs. The vehicle may contain minor amounts of additives such as substances that enhance solubility, isotonicity, and chemical stability, e.g., antioxidants, buffers, and preservatives. For oral administration, the formula can be enhanced by the addition of bile salts and also by the addition of acylcarnitines ( Am. J. Physiol . 251:332 (1986)). Formulations for nasal administration may be solid and contain as excipients, for example, lactose or dextran, or may be aqueous or oily solutions for administration in the form of nasal drops or metered spray. For buccal administration typical excipients include sugars, calcium stearate, magnesium stearate, pregelatinated starch, and the like.
When formulated for nasal administration the absorption across the nasal mucous membrane is enhanced by surfactant acids, such as for example, glycocholic acid, cholic acid, taurocholic acid, desoxycholic acid, chenodesoxycholic acid, dehydrocholic acid, glycodeoxy-cholic acid, and the like (See, B. H. Vickery, “LHRH and its Analogs-Contraception and Therapeutic Applications”, Pt. 2, B. H. Vickery and J. S. Nester, Eds., MTP Press, Lancaster, UK, 1987).
DETAILED DESCRIPTION OF THE INVENTION
Compounds of the present invention are prepared using the procedure described generally in Schemes I, II and III and in more detail described in the Examples.
wherein A, R 3 and m are as defined in formula (I) and Z is benzyloxycarbonyl.
wherein Z, A, R 1 , R 3 , m and n are as defined in formula (I).
Methods of Preparation
The synthesis of the disclosed interleukin enzyme (ICE) inhibitors was conducted by one of two methods depicted in Schemes I and II. For inhibitors which contained an N-terminal benzyloxycarbonyl group (“Z” group), N-benzyloxycarbonyl-L-aspartic acid mon t-butyl ester or other benzyloxycarbonyl protected aspartic acid-based peptides (Formula A) were used as starting materials. The synthesis of the requisite peptides are readily carried out by a variety of methods known to those practicing in the art of peptide chemistry. The aspartic acid-based peptide (Formula A) is reacted with ethyl chloroformate and N-methyl morpholine in tetrahydrofuran (THF) at low temperature (ca. −15° C.) for approximately 30 min. This generates a mixed anhydride in solution thereby activating the free carboxylate toward nucleophilic attack. Other activating reagents (e.g. isopropyl chloroformate), solvents (diethyl ether, dioxane), and tertiary amine bases (diisopropyl ethyl amine, triethyl amine) can be used in place of the above preferred reagents to form a reactive carboxylate species. The pre-formed mixed anhydride is treated (without isolation) with a solution of diazomethane in diethyl ether. The diazomethane reagent is prepared under standard conditions from DIAZALD® using a commercially available (Aldrich) diazomethane generator. A one to two molar excess of diazomethane is added and the reaction mixture is warmed from −15° C. to 25° C. over a 20 min period. During this time, diazomethane reacts with the mixed anhydride to form an a-diazoketone. The a-diazoketone is not isolated by the reaction mixture is treated directly with an excess of a 1:1 solution of 48% hydrobromic (HBr) and glacial acetic (HOAc) acids. The mixture of acids are added dropwise to the a-diazoketone and the reaction mixture is subsequently stirred for at least 15 minutes. This treatment with 1:1 48% HBr and glacial HOAc decomposes the a diazoketone to yield the desired N-benzyloxycarbonyl-L-aspartic acid mono t-butyl ester a-bromoketone (Formula B) and nitrogen gas as a by-product The bromomethyl ketone is typically isolated as an oil using standard procedures which are apparent to those skilled in the art. The a-bromoketone so obtained is of sufficient purity to be used in all subsequent reactions. However, the ketone can be further purified by high pressure liquid chromatography (HPLC), if analytically pure material is desired.
The t-butyl ester a-bromoketone (Formula B) is subsequently reacted with a variety of phenols, naphthols, and arylcarboxylic acids. This is conducted by exposing the bromomethyl ketone to an excess of the phenol or arylcarboxylic acid in dimethylformamide containing sodium or potassium hydride or potassium fluoride. The reaction can be conveniently monitored by thin layer chromatography (TLC) and once the TLC indicates that displacement of the bromide with the phenol or carboxylate is completed, the product is isolated using standard procedures. The desired aspartic acid mono t-butyl ester a-aryloxymethyl- or a-arylacyloxymethyl ketone (Formula C) may be purified by conventional methods including recrystallization and silica gel column chromatography.
The remaining synthetic transformation to generate the ICE inhibitors is the hydrolysis of the t-butyl ester function. This is conducted by exposing the t-butyl ester (Formula C) to a 25% solution of trifluoroacetic acid (ITA) in methylene chloride at 25° C. The de-esterification is typically complete within 3 hrs. Removal of the volatile TFA and organic solvent affords the aspartic acid (Formula 1). The yield of the reaction is quantitative in most instances, providing the t-butyl ester starting material is of high purity. Purification, if required, can be performed by recrystallization or chromatographic techniques which are well known to those skilled in the art The concentration of TFA may range from 5%-100% and other organic solvents may be used such as chloroform. Alternatively, a solution of three molar anhydrous hydrochloric acid in ethyl acetate may be used in place of the TFA-methylene chloride solution with equal efficiency. the 1 H NMR spectra of these acids of Formula 1 indicate that they exist in equilibrium as the closed hemiketal form shown in Formula 1A and that the ratio of Formula 1 versus Formula 1A is solvent dependent.
In Scheme II, the synthesis of aryloxy- and arylacyloxymethyl ketones (Formula 2) which possess an N-terminal group other than the Z-group are described. The aspartic acid derivatives of Formula C are the starting material for the synthesis of inhibitors of Formula 2. First the Z-group is removed to generate the N-terminal amine (Formula D) under hydrogenolytic conditions. The reagents and conditions typically used to carry out the hydrogenolytic removal of the Z-group are hydrogen gas, ambient temperature conditions and pressure, 5% palladium on carbon as the catalyst in an alcoholic solvent eg., methanol, optionally containing two equivalents of hydrochloric acid. It is not necessary to purify the intermediate fire amine (or the hydrochloride salt if hydrochloric acid is used in the hydrogenolysis), though this material needs to be dry and free of alcohol for the subsequent coupling reaction to proceed in good yield.
The N-terminal amine is then condensed with a carboxylic acid to yield intermediates of Formula E. It is generally necessary to first activate the acid as an acid chloride or mixed anhydride and then react it with the free amine (or hydrolchloride salt) in the presence of an organic base, e.g., N-methylmorpholine. Alternatively, coupling with acid with the intermediate amine is conducted using amide coupling reagents/conditions employed in peptide coupling chemistry (“The Practice of Peptide Synthesis”, M. Bodanszky, Springer-Verlag, NY, 1984; “The Peptides”, Vol 1-3, E. Gross and J. Meienhofer, Eds. Academic Press, NY, 1981). Lastly, the t-butyl ester in Formula E is removed with trifluoroacetic acid (as described above) to give the aspartic acid analogs of Formula 2. As in the case of the compounds of Formula 1, the 1 H NMR of components of Formula 2 appear to exist in equilibrium with their corresponding closed hemiketal counterparts of Formula 2A.
The phenols, naphthyls and arylcarboxylic acids used in the reaction with the bromomethyl ketones can be either purchased form commercial sources or synthesized by adopting known procedures. Their synthesis would be readily deduced by those skilled in the art of organic synthesis. By way of example, the preparation of the 2,6-dichloro-3-sulfonamido benzoic acids are presented in Scheme III. Thus, 2,6-dichlorobenzoic acid (Formula F; available from Aldrich Chemical Co.) is reacted with chlorosulfonic acid to yield the intermediate sulfonyl chloride (Formula G). The electrophilic sulfonyl chloride is reacted with a variety of amines to give the substituted benzoic acids (Formula 3).
Intermediate compounds for use in making the final compounds of the present invention are described in Examples 1-37.
EXAMPLE 1
N-Benzyloxycarbonyl-L-aspartic Acid Bromomethyl Ketone b-tert-Butyl Ester
To a solution of N-benzyloxycarbonyl L1 aspartate b-tert-butyl ester (Formula A; 10 g, 31 mmol) in. 70 ml of anhydrous THF at −15° C. was added N-methyl morpholine (4.7 ml, 43.4 mmol) followed by the dropwise addition of ethyl chloroformate (3.9 ml, 40.5 mmol). The reaction mixture was stirred for 30 min at −15° C. and the suspension treated with diazomethane in ether (160 ml of a 0.4 in solution in ether, prepared from “DIAZALD®” [Aldrich]) and warmed to room temperature.
The bromomethyl ketone was formed in the same pot by cooling the intermediate diazoketone above followed by the dropwise addition of a 1:1 solution of 48% hydrobromic acid and glacial acetic acid (62 ml). After stirring for 15 min the reaction mixture was poured into a separatory funnel. The aqueous layer was drawn off and discarded. The remaining organic phase was washed with water, saturated aqueous NaHCO 3 , brine and dried (MgSO 4 ). The solvents were removed in vacuo and the title compound so obtained (m.p. 41-43° C.) was used in the subsequent displacement reactions without further purification.
EXAMPLE 2
N-Benzyloxycarbonyl-L-aspartic Acid 2,6-Dichlorobenzoyloxymethyl Ketone b-tert-Butyl Ester
N-Benzyloxycarbonyl-L-aspartic acid bromomethyl ketone b-tert-butyl ester (0.30 g; 0.76 mM) was dissolved in 12 ml of anhydrous DMF. To this solution was added powdered potassium fluoride (0.11 g, 19 mmol) and 2,6-dichlorobenzoic acid (0.17 g, 0.91 mmol) and the reaction mixture was stirred overnight. The solution was diluted with Et 2 O and washed with water, aqueous saturated NaHCO 3 , brine and dried (MgSO 4 ). The ketone so obtained was purified by silica gel chromatography using ethyl acetate/hexane as the eluting solvent ( 1 H NMR (CDCl 3 ) d 7.35 (m, 8H)), 5.90 (d, 2H each), 5.20 (m, 4H), 4.70 (m, 1H), 3.00 and 2.75 (doublet of doublets, 1H each), 1.42 (m, 9H).
In a similar manner, the following compounds of formula B were prepared:
EXAMPLE 3
N-Benzyloxycarbonyl-L-aspartic acid 2,6-difluorophenoxy-methyl Ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-difluorophenol (mp 50-51° C.).
EXAMPLE 4
N-Benzyloxycarbonyl-L-aspartic acid 2,6-ditrifluoromethyl benzyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-ditrifluoromethyl benzoic acid (mp 62-63° C.).
EXAMPLE 5
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichlorophenoxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dichloro-phenol.
EXAMPLE 6
N-Benzyloxycarbonyl-L-aspartic acid 2-fluoro-4-(N-morpholinylsulfonamido)phenoxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2-fluoro-4-(N-morpholinylsulfonamido)phenol.
EXAMPLE 7
N-Benzyloxycarbonyl-L-aspartic acid 2-chloro-4-(N-thiomorpholinylsulfonamido)phenoxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2-chloro-4-(N-thiomorpholinylsulfonamido)phenol.
EXAMPLE 8
N-Benzyloxycarbonyl-L-aspartic acid 2,6-chloro-3-(2-N-morpholinylethoxy)benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dichloro-3-(2-N-morpholinylethoxy)benzoic acid.
EXAMPLE 9
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dimethoxybenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dimethoxy-benzoic acid.
EXAMPLE 10
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-3-(benzyloxy)benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dichloro-3-(benzoyloxy)benzoic acid.
EXAMPLE 11
N-Benzyloxycarbonyl-L-aspartic acid 2-acetamido-6-chloro benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2-acetamido chlorobenzoic acid.
EXAMPLE 12
N-Benzyloxycarbonyl-L-aspartic acid 2,6-difluorobenzoyloxy-methyl ketone βtert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-difluorobenzoic acid.
EXAMPLE 13
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-butylsulfonamido)-2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 3-(N-butylsulfonamido)-2,6-dichlorobenzoic acid.
EXAMPLE 14
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-3-sulfonamido benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dichloro-3-sulfonamidobenzoic acid.
EXAMPLE 15
N-Benzyloxycarbonyl-L-aspartic acid-3-(N-benzylsulfonamido)-2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 3-(N-benzylsulfonamido)benzoic acid.
EXAMPLE 16
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-[2-aminoacetamidoyl]sulfonamido)-2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 3-(N-[2-aminoacetamidoyl]sulfonamido)-2,6-dichlorobenzoic acid.
EXAMPLE 17
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro3-(N-morpholinylsulfonamido)benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester and 2,6-dichloro-3-N-morpholinylsulfonamido)benzoic acid.
EXAMPLE 18
N-Methoxycarbonyl-L-alanine-L-aspartic Acid 2,6-Dichloro-benzoyloxymethyl Ketone β-tert-Butyl Ester and other Compounds of Formula E
Part A: N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester (1.02 g, 2 mmol) was dissolved in absolute ethanol (100 ml) containing 6 N aqueous HCl (0.67 ml, 4 mmol). 10% Palladium on carbon (96 mg) was added and the reaction mixture was stirred under an ambient atmosphere of hydrogen gas for approximately 1 hour (thin layer chromatography [5% MeOH—CH 2 Cl 2 ] indicated the disappearance of starting material). The solution was filtered and the solvent was removed in vacuo to give L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert butyl ester-HCl salt (Formula D) which was used immediately in the subsequent reaction described in Part B.
Part B: A solution of N-methoxycarbonyl-L-alanine (301 mg, 2.05 mmol) in CH 2 Cl 2 (10 ml) was cooled to −20° C. and isobutylchloroformate (0.28 ml, 2.05 mmol) and N-methylmorpholine (0.23 ml, 2.05 mmol) were added sequentially. The reaction mixture was stirred for 15 minutes and a solution of aspartic acid 2,6-dichlorobenzoyl methyl ketone β-tert-butyl ester-HCl salt (prepared in Part A above) followed by a second addition of N-methyl morpholine (0.23 ml, 2.05 mmol).
The reaction mixture was stirred for 30 minutes and was then diluted with EtOAc, washed with water, aqueous saturated NaHCO 3 , brine and dried (MgSO 4 ). The solvents were removed in vacuo and the product purified by silica gel chromatography using 40% EtOAc-hexane as eluent to give N-methoxycarbonyl-L-alanine-L-aspartic acid 2,6-dichlorobenzoyl methyl ketone tert ester (0.72 g; 80%).
In a similar fashion the following compounds of Formula E were prepared:
EXAMPLE 19
N-(2-Thienyl)carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and 2-thiophene carboxylic acid.
EXAMPLE 20
N-Methoxycarbonyl glycine-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone β-tert-butyl ester and N-methoxycarbonyl glycine.
EXAMPLE 21
N-Methoxycarbonyl-L-phenylalanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone 5-tert-butyl ester and N-methoxycarbonyl-L-phenyl alanine.
EXAMPLE 22
N-Methoxycarbonyl-L-β-(2-thienyl)alanine-L-aspartic acid 2,6-dichloro-benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-methoxycarbonyl-L-β-(2-thienyl)alaine.
EXAMPLE 23
N-Methoxycarbonyl-L-valine-L-aspartic acid 2,6-dichlorobenzoyl-oxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-methoxycarbonyl-L-valine.
EXAMPLE 24
N-Methoxycarbonyl-L-histidine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxy-carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-methoxycarbonyl-L-histidine.
EXAMPLE 25
N-Benzyloxycarbonyl-L-alanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxy-carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-benzyloxycarbonyl-L-valine.
EXAMPLE 26
N-Benzyloxycarbonyl-L-alanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxy-carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-benzyloxycarbonyl-L-alanine.
EXAMPLE 27
i) Benzyloxycarbonyl-L-valine-L-alanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and N-benzyloxycarbonyl-L-valine-L-alanine
EXAMPLE 28
N-2-Furoyl-L-aspartic Acid 2,6-Dichlorobenzoyloxymethyl Ketone β-tert-Butyl Ester
Part A. N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester (1.02 g, 2 mmol) was dissolved in absolute ethanol (100 ml) containing 6 N aqueous HCl (0.67 ml, 4 mmol). 10% Palladium on carbon (96 mg) was added and the reaction mixture was stirred under an ambient atmosphere of hydrogen gas for approximately 1 hour (thin layer chromatography [15% MeOH—CH 2 Cl 2 ] indicated the disappearance of starting material). The solution was filtered and the solvent was removed in vacuo to give L-aspartic acid 2,6-diclorobenzoyloxymethyl ketone β-tert-ester-HCl salt (Formula D) which was used immediately in the subsequent reaction described in Part B.
Part B: To a solution of L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester-HCl salt (2.0 mmol, prepared in Part A above) in CH 2 Cl 2 (10 ml) at 0° C. was added 2-furoyl chloride (0.21 ml, 2.05 mmol). N-methylmorpholine (0.25 ml; 2.10 mmol) was then added and the reaction mixture stirred for 1 hour as it slowly was allowed to warm to room temperature. The solution was diluted with EtOAc, washed with water, saturated aqueous NaHCO 3 , brine and dried (MgSO 4 ). The solvents were removed in vacuo. The product was purified by silica gel chromatography using 30% EtOAc-hexane as eluent to give N-2-furoyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester (mp 73-74° C.).
In a similar fashion the following compounds of Formula E were prepared:
EXAMPLE 29
N-2-Furonylcarbonyl-L-aspartic acid 2,6-dichloro3-(N-morpholinylsulfonamido) benzoyloxymethyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichloro3-(N-morpholinylsulfonamido) benzoyloxymethyl ketone β-tert-butyl ester and 2-furoic acid chloride.
EXAMPLE 30
N-(3-Phenylpropionyl)-L-aspartic acid 2,6-chlorobenzoyloxy-methyl ketone β-tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-benzoyloxymethyl ketone β-tert-butyl ester and 3-phenylpropionyl chloride.
EXAMPLE 31
N-Methoxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone tert-butyl ester from N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and methyl chloroformate.
EXAMPLE 32
N-(N,N-4-Dimethylaminomethyl)benzoyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester (mp. 63-65° C.) from 2,6-dichlorobenzoyloxymethyl ketone β-tert-butyl ester and 4-(N,N-dimethylaminomethyl)benzoyl chloride.
EXAMPLE 33
3-(N-Butylsulfonamidoyl)-2,6-dichlorobenzoic Acid and Other Compound of Formula 3
Part A: Under an atmosphere of nitrogen gas, a reaction vessel was charged with 2,6-dichlorobenzoic acid (10 g, 53.55 mmol) (Formula F) and chlorosulfonic acid (3 ml, 472 mmol). The reaction mixture was refluxed for 1 hour and cooled to 10° C. The contents of the reaction vessel were poured slowly into 3 L of ice water. The white solid which precipitated was collected by filtration and dried in vacuo (10 mm) at 35° C. for 48 hours to give 3-(chlorosulfonyl)-2,6-dichlorobenzoic acid (Formula G) (9.2 g, 61% yield).
Part B: 3-(Chlorosulfonyl)-2,6-dichlorobenzoic acid (1.5 g; 5.2 mmol) was dissolved in anhydrous toluene (35 ml) to which was added powdered K 2 CO 3 (1.44 g: 10.4 mmol) and n-butylamine (1.0 ml, 10.4 mmol). The reaction mixture was stirred at 25° C. for 12 hours. The solution was diluted slowly with 1 M ethereal HCl (20 ml) and was then stirred for 30 minutes. The solution was filtered and the resulting filtrate was evaporated to dryness to give crude product. Further purification of the material by silica gel chromatography using EtOAc as the eluent provided 3-(N-butylsulfonamidoyl)-2,6-dichlorobenzoic acid (Formula 3) (1.43 g, 85%. 1 H NMR (DMSO) d 8.11 (t, 1H), 7.98 and 7.71 (doublets, 1H each), 2.75 (m, 2H), 1.55 (m, 2H), 1.32 (m 2H), 0.87 (t, 3H).
In a similar manner, the following compounds were prepared:
EXAMPLE 34
2,6-Dichloro-3-sulfonamidoylbenzoic acid ( 1 H NMR (DMSO) d 8.11 (t, 1H), 7.42 and 7.15 (doublets, 1H each), 7.26 (d, 2H) from 3-chlorosulfonyl-2,6-dichlorobenzoic acid and 40% aqueous ammonium hydroxide.
EXAMPLE 35
3-(N-Benzylsulfonamidoyl)-2,6-dichlorobenzoic acid ( 1 H NMR (DMSO) d 8.70 (t, 1H), 7.90 and 7.65 (doublets, 1H each), 7.25 (m, 5H), 4.15 (m, 2H) from 3-chlorosulfonyl-2,6-dichlorobenzoic acid and benzyl amine.
EXAMPLE 36
3-(N-[2-Aminoacetamido]sulfonamidoly)-2,6-dichlorobenzoic acid from 3-chlorosulfonyl-2,6-dichlorobenzoic acid and glycinamide (m.p. 210-213° C.
EXAMPLE 37
3-(N-Morpholino)sulfonamidoyl)-2,6-dichlorobenzoic acid from 3-chlorosulfonyl-2,6-dichlorobenzoic acid and morpholine.
EXAMPLE 38
N-Benzyloxycarbonyl-L-aspartic Acid 2,6-Dichlorobenzoyloxymethyl Ketone and Other Compounds of Formula I
A solution of β-tert-butyl ester of N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (Example 2) in methylene chloride containing 25% v/v trifluoroacetic acid (20 ml) was stirred for 2 hours at 0° C. The solvent was removed in vacuo and the residue azeotroped three times with methylene chloride to give analytically pure N-benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (high resolution mass spectrum for C 20 H 17 Cl 2 NO 7 found 453.1572).
In a similar fashion, the following compounds of Formulas 1 and 2 were prepared:
EXAMPLE 39
N-Benzyloxycarbonyl-L-aspartic acid 2,6-difluorophenoxymethyl ketone (high resolution mass spectrum for C 19 H 17 F 2 NO 6 found 393.3562) from the β-tert-butyl ester of Example 3.
EXAMPLE 40
N-Benzyloxycarbonyl-L-aspartic acid 2,6-ditrifluoromethyl benzoyloxymethyl ketone (high resolution mass spectrum for C 22 H 17 O 7 F 6 found 521.1452) from the β-tert-butyl ester of Example 4.
EXAMPLE 41
N-Benzyloxycarbonyl-L-aspartic acid 2,6 dichlorophenoxymethyl ketone (mass spectrum m/z 426 (M+H) from the β-tert-butyl ester of Example 5.
EXAMPLE 42
N-Benzyloxycarbonyl-L-aspartic acid 2-fluoro-4-(N-morpholinylsulfonamido)phenoxymethyl ketone (m.p. 65-66° C.) from the β-tert-butyl ester of Example 6.
EXAMPLE 43
N-Benzyloxycarbonyl-L-aspartic acid 2-chloro(N-thiomorpholinylsulfonamido)phenoxymethyl ketone (m.p. 180-181° C.) from the β-tert-butyl ester of Example 7.
EXAMPLE 44
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro3-(2-N-morpholinylethoxy)benzoyloxymethyl ketone (high resolution mass spectrum for C 26 H 29 O 9 N 2 Cl 2 found 583.1245) from the β-tert-butyl ester of Example 8.
EXAMPLE 45
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dimethoxybenzoyloxy methyl ketone (high resolution mass spectrum for C 22 H 24 O 9 N found 446.1430 ) from the β-tert-butyl ester of Example 9.
EXAMPLE 46
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-3-(benzyloxy)benzoyloxymethyl ketone (high resolution mass spectrum for C 27 H 24 O 8 NCl 2 found 560.0865 ) from the β-tert-butyl ester of Example 10.
EXAMPLE 47
N-Benzyloxycarbonyl-L-aspartic acid 2-acetamido-6-chloro-benzoyloxymethyl ketone (high resolution mass spectrum for C 22 H 22 O 8 N 2 Cl 2 found 477.1044) from the β-tert-butyl ester of Example 11.
EXAMPLE 48
N-Benzyloxycarbonyl-L-aspartic acid 2,6-difluorobenzoyloxymethyl ketone (high resolution mass spectrum for C 20 H 18 O 7 NF 2 found 422.1046) from the β-tert-butyl ester of Example 12.
EXAMPLE 49
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-butylsulfonamido)-2,6-dichlorobenzoyloxymethyl ketone (m.p. 48-50° C.) from the β-tert-butyl ester of Example 13.
EXAMPLE 50
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-3-sulfonamidobenzoyloxymethyl ketone (m.p. 44-46° C.) from the β-tert-butyl ester of Example 14.
EXAMPLE 51
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-benzylsulfonamido)-2,6-dichlorobenzoyloxymethyl ketone (m.p. 66-68° C.) from the β-tert-butyl ester of Example 15.
EXAMPLE 52
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-[2-aminoacetamidoyl]sulfonamido)-2,6-dichlorobenzoyloxymethyl ketone (m.p. 54-56° C.) from the β-tert-butyl ester of Example 16.
EXAMPLE 53
N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichloro-3-(N-morpholinylsulfonamido)benzoyloxymethyl ketone (high resolution mass spectrum for C 24 H 25 O 10 N 2 Cl 2 found 603.0594) from the β-tert-butyl ester of Example 17.
EXAMPLE 54
N-Methoxycarbonyl-L-alanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (Anal. calc. for C 17 H 18 O 8 Cl 2 N 2 : C, 45.45; H, 4.04; N, 6.24. Found. C, 45.20, H, 4.06; N, 5.98) from the β-tert-butyl ester of Example 18.
EXAMPLE 55
N-(2-thienyl)carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (mass spectrum m/z 430 (M+)) from the β-tert-butyl ester of Example 19.
EXAMPLE 56
N-Methoxycarbonyl-glycine-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone (Anal. calc. for C 16 H 16 O 8 Cl 2 N 2 : C, 44.16; H, 3.17; N, 6.44. Found: C, 44.24; H, 3.15; N, 6.12) from the β-tert-butyl ester of Example 20.
EXAMPLE 57
N-Methoxycarbonyl-L-phenylalanine-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (Anal. calc. for C 23 H 22 O 8 Cl 2 N 2 : C, 52.59; H, 4.22; N, 5.33. Found: C, 52.98; H, 4.38; N, 5.21) from the β-tert-butyl ester of Example 21.
EXAMPLE 58
N-Methoxycarbonyl-L-β-(2-thienyl)alanine-L-aspartic acid 2,6-di-chlorobenzoyloxymethyl ketone (mass spectrum m/z 531 (M+)) from the β-tert-butyl ester of Example 22.
EXAMPLE 59
N-Methoxycarbonyl-L-valine-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone (m.p. 119-120° C.) from the β-tert-butyl ester of Example 23.
EXAMPLE 60
N-Methoxycarbonyl-L-histidine-L-aspartic acid 2,6-dichlorobenzoyl-oxymethyl ketone (Anal. calc. for C 22 H 21 O 10 F 3 Cl 2 N 4 : C, 41.99; H, 3.36; N, 8.90. Found: C, 42.08; H, 3.48; N, 8.67; mass spectrum m/z 515 (M+)) from the β-tert-butyl ester of Example 24.
EXAMPLE 61
N-Benzyloxycarbonyl-L-valine-L-aspartic acid 2,6-dichlorobenzoyloxy-methyl ketone (Anal. calc. for C 25 H 26 O 8 Cl 2 N 2 : C, 54.26; H, 4.47; N, 5.06. Found: C, 54.06; H, 4.74; N, 4.91) from the β-tert-butyl ester of Example 25.
EXAMPLE 62
N-Benzyloxycarbonyl-L-alanine-L-aspartic acid 2,6-dichlorobenzoyl-oxymethyl ketone (mass spectrum m/z 525 (M+)) from the β-tert-butyl ester of Example 26.
EXAMPLE 63
N-Benzyloxycarbonyl-L-valine-L-alanine-L-aspartic acid 2,6-di-chlorobenzoyloxymethyl ketone (Anal. calc. for C 28 H 31 O 9 Cl 2 N 3 : C, 53.85; H, 5.00, N, 6.73. Found: C, 54.00; H, 5.04; N, 6.66) from the β-tert-butyl ester of Example 27.
EXAMPLE 64
N-(2-Furonyl)carbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (mass spectrum m/z 414 (M+)) from the β-tert-butyl ester of Example 28.
EXAMPLE 65
N-(2-Furonyl)carbonyl-L-aspartic acid 2,6-dichloro-3-(N-morpholinylsulfonamido)benzoyloxymethyl ketone (mass spectrum m/z 563 (M+)) from the β-tert-butyl ester of Example 29.
EXAMPLE 66
N-(3-Phenylpropionyl)-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone ( 1 H NMR (CDCl 3 ) d 7.40 (m, 9H), 5.05 (2×dd, 4H), 4,70 (m, 1H), 2.85 (m, 2H), 2.65 (dd, 1H), 2.60 (dd, 1H), 2.50 (m,2 from the β-tert-butyl ester of Example 30.
EXAMPLE 67
N-Methoxycarbonyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone ( 1 H NMR (DMSO) d 7.60 (m, 6H), 5.24 (m, 4H), 4.51 (m, 1H), 3.58 (s, 3H), 2.75 (dd, 1H), 2.55 (dd, 1H) from the β-tert-butyl ester of Example 31.
EXAMPLE 68
N-(4-N,N-dimethylaminomethyl)benzoyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (m.p. 55-57° C.) from the β-tert-butyl ester of Example 32.
EXAMPLE 69
N-Benzyloxycarbonyl-D-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (high resolution mass spectrum for C 20 H 17 Cl 2 NO 7 , found 453.1583) from N-benzyloxycarbonyl-D-aspartic acid β-tert-butyl ester and 2,6-dichlorobenzoic acid using the procedures described in Examples 1, 2 and 38.
EXAMPLE 70
N-(2-[2,6-dichlorobenzoyloxy)acetyl-L-aspartic acid 2,6-dichlorobenzoyloxymethyl ketone (mass spectrum m/z 551 (M + ) from N-Benzyloxycarbonyl-L-aspartic acid 2,6-dichlorobenzyloxymethyl ketone and 2-(2,6-dichlorobenzoyloxy])acetic acid using the procedures described in Examples 18 and 38.
EXAMPLE 71
N-Benzyloxycarbonyl-L-valine-L-aspartic acid 4-(N,N-diethyl-sulfonamido)-2,3,5,6-tetrafluorophenoxymethyl ketone (mass spectrum m/z 664 (M+H) from N-Benzyloxycarbonyl-L-aspartic acid bromomethyl ketone β-tert-butyl ester, N-benzyloxycarbonyl-L-valine and 4-(N,N-diethylsulfonamido)-2,3,5,6-tetrafluorophenol using the procedures described in Examples 2, 18 and 38. The 4-(N,N-diethyl-2,3,5,6-tetrafluorophenol was prepared by reacting 2,3,5,6-tetrafluorophenol with chlorosulfonic acid followed by reaction with diethylamine, analogous to the procedure described in Scheme III and Example 33.
Compounds of the present invention were tested for IL-1β protease inhibition activity according to the following protocol:
Partially purified IL-1β protease is stored at −80° C., thawed on ice, and preincubated for 10 minutes at 37° C. with 2.5 mM dithiothreitol in a buffer solution containing 10 mM Tris-HCl (pH 8.0) and 25% (v/w) glycerol. Inhibitors are prepared as stock solutions in dimethyl sulfoxide (DMSO). The protease is preincubated with inhibitor in a volume of 20 ml in a 1.5 ml polypropylene microcentrifuge tube for 15 minutes at 37° C. The volume of compound added to the assay is adjusted to yield a DMSO concentration in the preincubation of <15% (v/v). The enzyme assay is then initiated by the addition of substrate (TRITC-AYVHDAPVRS-NH 2 ) to yield a final concentration of 67 mM in a final volume of 30 mL. The reaction are carried out for 60 minutes at 37° C. in the dark and are terminated by the addition of 10 ml of 10% trifluoroacetic acid (TFA). Following the addition of 115 ml of 0.1% TFA, the samples are analyzed by high pressure liquid chromatography using a reverse phase (C18) column and elution with an acetonitrile/water/FA gradient. Substrate and product are monitored by their absorbance at 550 nm and elute at 4.2 and 5.2 minutes, respectively.
TABLE I
Ex-
ample
No.
Name of Compound
IC 50 μm
38
N-Benzyloxycarbonyl-L-aspartic acid
0.05
2,6-dichlorobenzoyloxymethyl ketone
40
N-Benzyloxycarbonyl-L-aspartic acid
0.10
2,6-ditrifluoromethylbenzoyloxymethyl ketone
41
N-Benzyloxycarbonyl-L-aspartic acid
0.10
2,6-dichlorophenoxymethyl ketone
42
N-Benzyloxycarbonyl-L-aspartic acid
0.32
2 fluoro-4-(N-morpholinyl
sulfonamido)phenoxymethyl ketone
49
N-Benzyloxycarbonyl-L-aspartic acid 3-(N-
0.09
butylsulfonamido)-2,6-dichlorobenzoyloxymethyl
ketone
52
N-Benzyloxycarbonyl-L-aspartic acid 3-
0.06
(N-[2-aminoacetamidoyl]sulfonamido)-
2,6-dichlorobenzoyloxymethyl ketone
53
N-Benzyloxycarbonyl-L-aspardic acid
0.09
2,6 dichloro-3-(N-morpholinylsulfonamido)-
benzoyloxylmethyl ketone
54
N-Methoxycarbonyl-L-alanine-L-aspartic acid
0.06
2,6-dichlorobenzoyloxymethyl ketone
57
N-Methoxycarbonyl-L-phenylalanine-L-aspartic
0.07
acid 2,6-dichlorobenzoyloxymethyl ketone
64
N-(2-furonyl)carbonyl-L-aspartic acid 2,6-
0.14
dichlorobenzoyloxymethyl ketone
67
N-Methoxycarbonyl-L-aspartic acid
0.08
2,6-dichlorobenzoyloxymethyl ketone
68
N-(4-N,N-dimethylaminomethyl)benzoyl-L-aspartic
0.3 acid 2,6-dichlorobenzoyloxymethyl ketone
70
N-(2-[2,6-dichlorobenzoyloxy])acetyl-L-aspartic acid
2,6- 0.2 dichlorobenzoyloxymethyl ketone
Compounds of the present invention were tested for their ability to block mature IL-1β release from cells (monocytes) as described in the following protocol:
Protocol for Monitoring Release of Mature IL-1β-From Human Monocytes
Human monocytes were isolated from heparinized leukopheresis units obtained through Biological Specialty Corporation (Lansdale, Pa.). Monocytes were purified by Ficoll-Hupaque (Pharmacia Fine Chemicals, Piscataway, N.J.) gradient centrifugation and more than 95% pure monocyte populations obtained by centrifugal elutriation. The assay was performed on duplicate samples of freshly isolated human monocytes, cultured in suspension at 37° C. and rotated gently in conical bottom polypropylene tubes (Sardstedt Inc., Princeton, N.J.). Human monocytes at a concentration of 5×10 6 cells/mL were resuspended in 1 mL of RPMI 1640 (a common tissue buffer from M.A. Bioproducts, Walkersyille, Md.) containing 1% fetal calf serum (FCS) (HyClone, Logan, Utah) and 50 μg/mL gentamycin (Gibco, Grand Island, N.Y.). The cells were treated either with a compound of the invention (i.e. test compound) or with a non-inhibitor (control compound, typically 0.03% DMSO) for 15 minutes and then activated with 0.01% fixed Staphylococcus aureus (The Enzyme Center, Malden, Mass.) for 1 hour. The cells were then centrifuged and resuspended in 1 mL of cysteine, methionine-free RPMI media containing 1% dialyzed FCS (Hyclone). The cells were pretreated with a test compound or control compound for 15 minutes after which 0.01% fixed S. aureus plus 100 μCi Tran 35-S label (ICN, Irvine, Calif.) was added and the cells incubated at 37° C. for 1 hour. After incubation, cells were centrifuged, washed once in phosphate buffer saline and resuspended in 1 ML RPMI containing 1% fetal calf serum The cells were again pretreated with a test or control compound for 15 minutes and then 0.01% S. aureus for 2 hours. At the end of the incubation, cells were centrifuged and supernates saved for immunoprecipitation. Cells were washed once in phosphate buffer saline and then lysed in RIPA, a continuous cell media buffer containing 2 mM phenylmethylsulfonyl fluoride, 10 mM iodoacetate, 1 μg/mL pepstatin A, 1 μg/mL leupeptin and 0.5 TIU aprotinin.
For the immunoprecipitations, an equal volume of 1% dry milk in RIPA buffer plus 50 μL of resuspended protein A sepharose CL-4B (Pharmacia, Piscataway, N.Y.) was added to supernates and 1 mL of 4% dry milk containing protein A sepharose CL-4B to cell lysates and samples rotated for 30 minutes at 4° C. Beads were then centrifuged down, samples transferred to fresh tubes and incubated overnight with 40 μg rabbit antihuman IL1B polyclonal antibody (Genzyme, Cambridge, Mass.). The IL-1β proteins were then precipitated with 70 μL protein A sepharose, resuspended in 60 μL SDS sample buffer and run on 15% SGDPAGE gels. Autoradiography was performed on dried gels and the amount of radioactivity (counts per minute, cpm) quantitated using a Betascope 603 analyzer.
Data Analysis
In the monocyte pulse chase assay, each test parameter was run in duplicate. Data was collected from the Beta Scope using a personal computer, then transferred to the VAX system for calculation of mean cpm and standard deviation of the mean. When test compounds were evaluated, the percent inhibition of release of mature IL1β was calculated as follows:
100×[1−(cells treated with stimuli+test compound−unstimulated cells)/(cells teed with stimuli+control compound−unstimulated cells)]
These % inhibition values were then used to calculate IC 50 value for each compound. Since the human monocyte pulse chase assay uses primary cells from different donors, each test compound was run in 2-3 separate experiments, using monocytes from 2-3 different donors.
Results
Example
in vivo IC 50 (μM)
38
10
45
ca. 100
48
ca. 100
59
10
61
0.9
63
0.5
65
30
69
10
71
5
SEQUENCE LISTING
(1) GENERAL INFORMATION:
(iii) NUMBER OF SEQUENCES:1
(2) INFORMATION FOR SEQ ID NO:1:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH:10 Amino Acids
(B) TYPE:Amino Acid
(C) STRANDEDNESS:
(D) TOPOLOGY:Linear
(ii) MOLECULE TYPE:Peptide
(ix) FEATURE:
(A) NAME/KEY: Modified-site
(B) LOCATION: -1
(D) OTHER INFORMATION: /label=TRITC
/note=“TRITC is tetramethylrhodamine isothiocyanate”.
(x) FEATURE:
(A) NAME/KEY: Modified-site
(B) LOCATION: 11
(D) OTHER INFORMATION:
(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 1:
Ala Tyr Val His Asp Ala Pro Val Arg Ser
1 5 10 | Disclosed are compounds, compositions, and methods for inhibiting interleukin-1β protease activity, wherein the compounds are α-substituted methyl ketones having formula (I) as set forth herein. These compounds are inhibitors of IL-1β converting enzyme and as such are useful as therapeutic agents for certain infectious diseases. | 2 |
BACKGROUND OF THE INVENTION
In the operation of hydraulic equipment and, particularly, earth moving and excavating apparatus, the operator is faced with a peculiar problem. When he moves the operating handle of the valve which controls the flow of pressure fluid to the cylinder being operated, the valve suddenly opens in the intermediate part of the handle stroke. This causes the fluid to flow to the cylinder suddenly and to begin operation of the apparatus with a jerk. Furthermore, if he tries to hold the handle with the valve slightly open to permit slow movement of the apparatus, or even for the purpose of jogging the apparatus, he is faced with the fact that the vehicle on which the apparatus is mounted may be traveling over rough terrain. Similarly, even if the vehicle is in a fixed position adjacent an excavation, for instance, the erratic forces to which the apparatus is being subjected as it moves through earth and rock causes the operator to be so moved about on the vehicle, so that it is difficult for him to maintain the handle in a fixed position relative to the valve. The result of this motion of the operator in the vehicle and the difficulty in holding the handle fixed relative to the valve, is that the operation of the cylinder and of the excavation apparatus is erratic, so that not only is the operation carried on in less than a smooth manner, but the entire hydraulic system is being subjected to force and pressure changes that cause more wear than is necessary. These and other difficulties experienced with the prior art devices have been obviated in a novel manner by the present invention.
It is, therefore, an outstanding object of the invention to provide a control system which permits an operator to regulate a hydraulic cylinder to operate smoothly despite jarring of the vehicle in which he is seated.
A further object of the present invention is the provision of a control apparatus for a hydraulic actuator that eliminates erratic behavior of the apparatus for reasons not connected with the work being performed.
It is another object of the instant invention to provide a control system for providing an operator with a strong indication of the point in valve motion when flow of pressure fluid begins to take place to a hydraulically operated apparatus.
A still further object of the invention is the provision of a control system including apparatus to permit an operator to control hydraulically-actuated apparatus smoothly despite the movement of the vehicle to which the apparatus is attached moving over rough terrain.
It is a further object of the invention to provide a control system associated with hydraulically-actuated apparatus permitting an operator to select and maintain the flow of fluid to a cylinder at a selected amount.
It is a still further object of the present invention to provide a control system including sensing apparatus that can readily be applied to pre-existing equipment.
Another object of the invention is the provision of a control system including sensing apparatus that is rugged in construction, relatively simple to manufacture, and which is capable of a long life of useful service with a minimum of maintenance even in dusty conditions.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
In general, the invention consists of a control system having a hydraulic cylinder, having a valve connected to the cylinder for directing pressure fluid thereto, the valve having a longitudinally-slidable plunger, and having a lever mounted for pivotal motion relative to the valve about an axis. A link joins the plunger to a point on the lever spaced a substantial distance from the said axis.
A stop is fixedly related to the valve and a contact element is mounted on the lever at a point spaced a substantial distance from the said axis and is adapted to engage the said stop at a point in the pivotal motion, while allowing pivotal motion passed that point despite such engagement.
More specifically, the contact element consists of a pin mounted in the lever for sliding motion transversely thereof, the pin having a washer at one side of the lever to limit the motion in the direction toward the stop. The pin has a head on the other end for engagement with the stop and a coil spring lies around the pin and is maintained under compression between the said head and the adjacent side of the lever.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which;
The single FIGURE of drawing shows a control system constructed in accordance with the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, it can be seen that the control sytem indicated generally by the reference numeral 10, contains a hydraulic cylinder 11 which is connected by suitable conduits to a valve 12, having a longitudinally slidable plunger 13. A lever 14 is mounted for pivotal movement relative to the valve about an axis A, while a link 15 joins the plunger 13 to the lever 14 at a point B spaced a substantial distance from the said axis A. A stop element 16 is fixed rigidly relative to the body of the valve 12 and of the pivotal axis A. A contact element 17 is mounted on the lever 14 at a point spaced a substantial distance from the pivotal axis A and is adapted to engage the stop element at a point in the pivotal motion, while allowing further pivotal motion passed that point despite such engagement.
It can be seen that the lever 14 is mounted as a first degree lever with the axis A constituting the fulcrum and the link 15 acting as the load. The contact element 17 consists of a pin 18 slidably carried in the lever for motion transversely thereof and provided in one end with a washer 19 and a nut 21 engaging a threaded end of the pin. The other end of the pin is provided with a head 22 having a semi-spherical shape. Between the head and the side of the lever 14 lies a coil spring 23 which is slightly under compression, but which is capable of being compressed to a much greater extent.
The stop element 16 consists of a finger extending upwardly from a bracket 24, which is fastened to the housing of the valve 12 by means of a bolt 25. The bracket 24 has a horizontally extending fork 26 with one tine lying on either side of the lever 14 and a hinge pin 27 extending transversely through the lever to act as a hinge pin operating about the axis A. Another finger 28 extends downwardly from the bracket 24 and acts as a stop element in connection with a pin 29. This pin is capable of sliding motion through the lower end of the lever 14 and is provided at its outer side with a washer 31 and is threaded to receive a nut 32. The other end of the pin 29 is provided with a semi-spherical head 33 adapted to engage a vertical surface of the finger 28. A coil spring 34 lies between the head 33 and the facing surface of the lever 14. The upper end of the lever is provided with a hand grip 35, formed of a suitable elastomer plastic such as Teflon.
The operation of the invention will now be readily understood in view of the above description. It will be understood that the difficulty with the old arrangements was that as one rides in the vehicle and it bounces over the ground, it is very difficult to find the exact point where the plunger 13 is located within the valve 12 to start the motion of the cylinder 11 properly. It will be understood that the location of the head 17 on the pin 18 and the location of the head 33 on the pin 29 can be adjusted by use of the nut 21 and 32 respectively. When the operator grasps the hand grip 35 and presses it to the left in the drawing, this serves to draw the plunger 13 to the right which eventually will cause pressure fluid to pass to the left-hand end of the cylinder 11. The head 17 of the pin 18 has been adjusted so that as the handle is moved just as oil has started to flow through the passages in the valve to the left-hand end of the cylinder 11, the head 17 strikes the stop element 16. The operator feels this and he knows then that oil pressure has started. He then can press the handle slightly more to the left and produce full flow of oil or he can leave the handle in the position that it is where he can feel the head 17 engaging the stop element 16 and allow for slow motion of the cylinder or for jogging. In other words, when the head of the pin 18 strikes the stop element 16, the operator knows that he has reached a position where the plunger has just opened up the ports to allow the flow of oil to the cylinder. The reverse, of course, is true if the operator wishes the cylinder to receive pressure oil at the right-hand end, and of course connect the other end to exhaust. He moves the hand grip 35 and the lever 14 to the right (clockwise) and this moves the plunger 13 to the left. Eventually, the head 33 of the pin 29 engages the surface of the stop element or finger 28 and indicates to the operator that oil has just started to flow to the cylinder. In this way, the fact that the operator is being bounced around on the top of the vehicle, either by moving over rough terrain, or because the operating elements of the vehicle are cutting a non-homogeneous material, so that the forces vary from time to time does not prevent him from holding the flow of oil to the cylinder at a constant rate. The apparatus is inexpensive and can be applied as an accessory to existing equipment. It is simple in construction and quite rugged in design, so that it will not be made inoperational by dust and the like.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed. | Control system including an hydraulic valve and cylinder and including apparatus for indicating to the operator the exact point when pressure fluid starts to flow to the cylinder. | 4 |
RELATED APPLICATIONS
The present application is a continuation of U.S. Provisional Patent Application Ser. No. 60/009,436 filed Dec. 29, 1995 and entitled "Reduction of Power Used by Transceivers in a Data Transmission Loop," by Lawrence G. Pignolet and Daniel Castel, incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a data network having data processing devices linked for data transmission. In particular, the present invention relates to obtaining a reduction in the power consumed by data transceivers in such a network.
2. Background Art
Data transmission loops have been used in local area networks of data processing devices for coupling data terminals to a central processor. The loop topology permits each data terminal to monitor data transmitted over the loop, and to insert data into the loop. More recently, the loop topology has been proposed for connecting disk drives to a storage controller in a storage subsystem. In this application, the loop interfaces in a simple way to optical fibers interconnecting the storage controller to the disk drives, and the number of pin connections to the disk drives is reduced for enhanced reliability. Manufacturers of data processing devices and disk drives are presently cooperating in the development of standards for the transceivers, cables and connectors to be used in connecting loops of disk drives to data processing equipment. The data transmission loop has been named Fibre Channel Arbitrated Loop, and the current standards are described in Kurt Chan, FC-AL Direct Disk Attach Profile (Private Loop) Version 1.2, Hewlett-Packard, 9000 Foothills Blvd., Roseville, Calif. 95747-5601, Preliminary Draft Version, 1.20 (Jan. 4, 1995), incorporated herein by reference. One disadvantage of the Fiber Channel Arbitrated Loop is that all of the transceivers in the loop are running continuously. To avoid skews and to minimize the number of connections, data is transmitted serially over the loop. Consequently, it is desirable to transmit data at the highest practical rate, such as at 265.625 MHz, 531.25 MHz, or preferably 1.0625 GHz. Consequently, transceivers must consume a substantial amount of power in order to serialize and deserialize the data at such a high rate. For example, a 3 and 1/2 inch disk drive employing a standard SCSI interconnect consumes about 15 watts. The 3 and 1/2 inch drive, when adapted with Fiber Channel transceivers available in the first quarter of 1996, is expected to require no less than about 18 watts. Consequently, a disk array cabinet designed for the standard SCSI drives cannot be fully populated due to power supply and cooling limitations. The option of increasing the power supply and cooling capacity is undesirable since it would require a re-design of the power supply and cabinets, and would increase the cost of ownership, cost of air conditioning, and the cost of power.
SUMMARY OF THE INVENTION
The basic objective of the present invention is to reduce the power consumption of transceivers in a data transmission loop interconnecting a multiplicity of data processing devices.
In accordance with a basic aspect of the invention, a data network has a data transmission loop including a multiplicity of data processing devices, each of which is linked to the loop by a transceiver, and passes data from a previous device in the loop to a next device in the loop when not transmitting data onto the loop. The power consumed by the transceiver is reduced by selectively activating and deactivating the transceiver, and passing data from the previous device in the loop to the next device in the loop when the transceiver is deactivated. The transceiver can be designed to continuously regenerate data and to avoid delays in establishing communication after the transceiver is activated by continuously powering a bit clock oscillator or bit synchronizer circuits used by the transceiver. In one embodiment, an auxiliary data channel from a loop controller in the loop to each device in the loop is used to send a transceiver activation or deactivation signal to an addressed one of the transceivers.
In an alternative embodiment, when a device detects that communication is occurring with another device for a predetermined period of time, the device selectively deactivates its transceiver for that predetermined period of time. For example, a loop controller in the data transmission loop periodically sends a word synchronization code followed by an address of a device that is to communicate with the loop controller. When another device finds that the word synchronization code is not followed by its address, it deactivates its transceiver for a fixed period of time. Alternatively, a message length parameter could follow the address, and the device could deactivate its transceiver for a period of time determined by the message length parameter.
In accordance with another aspect of the invention, the data network has dual redundant data transmission loops, each linking a respective one of two transceivers in each device, only one of which is powered on at any given time. If a failure of the powered-on transceiver occurs, the failed transceiver is bypassed and the other transceiver for the device is activated. For example, the transceiver failure is detected by a loop controller in the data transmission loop, and upon detecting the transceiver failure, the loop controller addresses the failed transceiver and sends a bypass and deactivation signal over an auxiliary data channel. One-half of the transceivers are initially activated in each of the dual redundant loops so that along each loop, the transceivers are alternately activated or deactivated and bypassed. This initial state minimizes the guaranteed recovery time from a loop failure by activating all of the inactive transceivers in the functioning loop, and best insures data regeneration through the loop by the transceivers that are activated.
In a specific embodiment, the data processing devices are disk drives in a storage subsystem, and the loop controller is a storage controller of the storage subsystem. Disk adapters in the storage controller are linked to strings of the disk drives by optical fibers and shielded twisted pair cable ("twinax") in accordance with industry group standards for a Fiber Channel Arbitrated Loop. The disk drives can also be given the capability of selecting among multiple power sources (such as 5 volts or 12 volts) for providing a regulated voltage (such as 3.3 volts) to the disk drive circuits, in order to reduce the need for excess power supply capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description with reference to the accompanying drawings wherein:
FIG. 1 is a block diagram showing a conventional configuration of a data network applying a data transmission loop for linking data processing devices;
FIG. 2 is a conventional protocol used in the network of FIG. 1 for permitting a loop controller to read data from a selected loop device in the data network of FIG. 1;
FIG. 3 is a conventional protocol used by the loop controller for writing data to a selected loop device in the data network of FIG. 1;
FIG. 4 is a block diagram showing details of a port bypass circuit and a data transceiver associated with a loop device in the data network of FIG. 1;
FIG. 5 is a block diagram illustrating the use of Fiber Channel Arbitrated Loops for interconnecting disk drives in an array to disk adapters in a storage controller;
FIG. 6 is a schematic diagram illustrating the use of an additional optical link to permit a disk adapter to address a selected disk drive and port bypass circuit in order to turn on and off a loop transceiver in the disk drive;
FIG. 7 is a flow chart of steps in a storage controller program for setting up an initial configuration of the transceivers in the disk drives in the system of FIG. 5;
FIG. 8 is a flow chart of steps in a storage controller program performed upon detecting a failure of a drive to respond to the storage controller including steps for de-activating a faulty one of the transceivers in the disk drive and activating the other one of the transceivers in the disk drive;
FIG. 9 is a schematic diagram of a transceiver configured to permit a major portion of the circuits in the transceiver to be powered down without disrupting synchronization of the transceiver to the data transmitted over a data transmission loop;
FIG. 10 is a timing diagram illustrating the periodic insertion of word sync and addresses in the data stream transmitted over the data transmission loop by the loop controller;
FIG. 11 is a schematic diagram of circuitry added to the transceiver for providing a data valid signal when word synchronization is obtained after powering up a transceiver;
FIG. 12 is a flow chart of a timer interrupt routine for permitting the controller of the loop device to periodically power down a transceiver and to power it up only during brief intervals when the loop controller transmits a word sync code and a loop device address according to the transmission format shown in FIG. 10; and
FIG. 13 is a schematic diagram showing how a disk drive can be given the capability of selecting among multiple power sources for providing a regulated voltage to disk drive circuits.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 1, there is shown a block diagram of a data network including a number of data processing devices linked by a data transmission loop. The data transmission loop includes a loop controller 21, and loop devices 22, 23, 24, 25, 26, and 27. Each of the devices 21-27 in the data transmission loop has a transceiver including a transmitter port (Tx) and a receiver port (Rx).
A loop controller 21 acts as an arbitrator that addresses selected ones of the loop devices 22-27 to enable the addressed loop device to transmit data over the transmission loop. When the loop device is not transmitting data over the transmission loop, it merely acts as a repeater to transmit data that it receives. The loop controller 21 in particular controls the loop to satisfy requests from host computers or network clients 28, 29 that are also linked to the loop controller 21.
The network topology shown in FIG. 1 has been used for local area networks. More recently, the loop topology has been proposed for linking disk drives to a storage controller. In this case, the storage controller would be the loop controller 21 and the disk drives would be the loop devices 22-27.
Turning now to FIG. 2, there is shown a data transmission protocol for permitting the loop controller (21 in FIG. 1) to read data from an addressed one of the loop devices (22-27 in FIG. 1). The loop controller transmits a read command addressing one of the loop devices. The addressed one of the loop devices responds by transmitting single or multiple sequences of data requested by the loop controller. At the end of data transmission, the loop device transmits a response signal (RSP).
Turning now to FIG. 3, there is shown a data transmission protocol used by the loop controller to write data to a loop device. The loop controller transmits a write command addressing one of the loop devices. When a loop device is ready to receive data from a loop controller, the loop device returns a transfer ready (XFR -- RDY) signal. Then the loop controller transmits a sequence of data to the loop device, and waits for another transfer ready signal from the loop device. Upon receiving another transfer ready signal, the loop controller transmits a remaining sequence of data to the loop device. Once the loop device has received the remaining sequence of data, the loop device returns a response signal (RSP) to the loop controller, indicating that all of the data has been successfully received.
Turning now to FIG. 4, there are shown a conventional port bypass circuit and components in a conventional transceiver of a loop device. The port bypass circuit has been used for maintaining the continuity of the data transmission loop when a loop device is removed from the data transmission loop. The port bypass circuit includes a multiplexer 31, such as Motorola Part No. MC10SX1189. The port bypass circuit 30 is wired to a female connector 32 which receives a male connector 33 mounted to the loop device 22. When the loop device 22 is removed so that the connector 33 disengages from the connector 32, a select line 34 of the multiplexer 31 assumes a logic low state so that the multiplexer 31 maintains continuity of the loop from the previous loop device (k-1) to the next loop device (k+1). The receiver port (Rx) is provided by a differential receiver 35, and the transmitter port (Tx) is provided by a differential transmitter 36. In this regard, the links 37, 38 of the data transmission loop are made of shielded twisted pair wire, commonly known as "twinax."
The transceiver circuits in the loop device 22 include clock and word sync recovery circuits 39. These circuits typically include a phase-locked loop for clock recovery and a decoder or framing circuit for word sync recovery, although oversampling-type clock recovery circuits could be used in lieu of a phase-locked loop. The oversampling type circuits permit faster acquisition of bit sync, although the phase-locked loop type circuits offer improved noise rejection.
The bit clock from the clock recovery circuits 39 clocks a shift register 40 performing parallel-to-serial conversion of data from a device controller 41 for transmission over the data transmission loop. The shift register 40 also performs serial-to-parallel conversion of data received from the transmission loop. Parallel data from the shift register 40 is received in a register 42 for transmission to the controller 41. The register 42 isstrobed by a bit counter 43 that counts the number of bits per data word, and generates a data clock received by the controller 41. An AND gate 44 combines the carry out of the bit counter 43 with a transmit enable signal (XMIT) to provide a parallel load enable signal to the shift register 40 during data transmission from the controller 41 to the data transmission loop. The bit counter 43 is reset when the clock and word sync recovery circuits 39 detect a word sync so long as the controller 41 is not transmitting. For this purpose, an AND gate 45 and an inverter 46 generate a reset signal to the bit counter 43 from a word sync signal (W) from the sync recovery circuits 39 and the transmit enable signal (XMIT).
Turning now to FIG. 5, there is shown a block diagram of a disk array storage subsystem for which the present invention is particularly useful. The storage subsystem includes a storage controller 51 in a disk drive array 52. The storage controller 51 receives data access requests from a number of host central processing units 53, 54. The storage controller attempts to satisfy these data access requests by accessing a cache memory 55. If the desired data are not found in the cache memory 55, then the data are obtained from the disk drives in the disk drive array 52.
The storage controller 51 has a number of channel adapter processors 56, 57 for interfacing the host computers 53, 54 to the cache memory 55. The storage controller 51 has a number of disk adapter processors 58, 59 for staging data from the disk drives to the cache memory 55 when requested data is not available in the cache memory. The disk adapters 58, 59 also perform a destage operation to write new or modified data from the cache memory 55 back to the disk drives in the disk drive array 52. For redundancy, each of the channel adapters 56, 57 and disk adapters 58, 59 are interconnected to the cache memory by dual busses 61, 62. Further details of the preferred construction for the storage controller 51 are found in Yanai et al., U.S. Pat. Nos. 5,381,539; 5,341,493; 5,335,352, 5,255,270; 5,269,011; and 5,206,939; all incorporated herein by reference.
In the storage subsystem shown in FIG. 5, the disk array 52 is stored in a cabinet that is separate from the storage controller 51. In situations where space close to the host processing units 53, 54 is scarce, the disk array 52 can be mounted a considerable distance from the storage controller 51. To provide a high degree of immunity from electrical interference, the disk drive array 52 is linked to the storage controller 51 by a number of optical fibers generally designated 63. As shown in FIG. 5, for example, each disk adapter 58 is interconnected via two data transmission loops to two respective strings of six disk drives. (In practice, a larger number of disk drives could be included in each string.) For redundancy, each of the twelve disk drives in the disk drive array 52 has two loop transceivers. The first loop transceiver for each disk drive has a transmit port (Tx1) and a receiver port (Rx1), and the second loop transceiver for each disk drive has a transmitter port (Tx2) and a receiver port (Rx2). The first transceiver links the disk drive to the first disk adapter 58, and the second transceiver links the disk drive to the second disk adapter 59. Therefore, the storage subsystem can continue to operate when either a single disk adapter fails or a single transceiver fails.
A problem with linking the disk drives in the disk array 52 into the data transmission loops of the optical fibers 69 is that the transceivers require a good deal of power to handle the high serial data rates of the loops. In accordance with the present invention, the power consumed by the transceivers is reduced by selectively reducing the power to the transceivers so that each transceiver is at some time incapable of providing data to or transmitting data from the controller in the disk drives. The present invention provides a mechanism for selectively activating the transceivers so that when necessary a transceiver becomes capable of providing data to or transmitting data from its associated disk drive controller. As will be further described below, a transceiver can be activated by providing an alternative link for receiving an activation command from the storage controller, or by activating the transceiver at a programmed time in the future.
Turning now to FIG. 6, there is shown a schematic diagram of an alternative data link for selectively activating or deactivating a transceiver 71 associated with a controller 72 of a disk drive generally designated 70. This circuit uses an additional link 73 in the connectors 74 and 75 connecting the disk drive 70 to the cabinet of the disk drive array. The pin connections 73 convey an enable signal from the storage controller. A NAND gate 76 shuts off the transceiver 71 when either the signal on the connection 73 is a logic 0, or when the controller provides a logic 0. In a similar fashion, a NAND gate 77 combines the activation signal from the storage controller with the activation signal from the disk drive controller 72 to provide a select signal to a bypass multiplexer 78 so that the transceiver 71 is bypassed in the data transmission loop when the transceiver is shut off. Moreover, when the disk drive 70 is removed from the disk drive array, a resistor 79 provides a logic low signal to the NAND gate 77 causing the multiplexer 78 to bypass the opened transceiver data path.
To provide the activation signal from the storage controller, an additional optical link 81 interconnects an additional receiver 82 in the disk drive array to the disk adapter 58, 59 included in the data transmission loop of the transceiver 71. The receiver 82 converts serial data on the optical link 81 to parallel data words providing bits for an address bus 84 and a bit for a data line 85. The receiver also provides a clock line 86 conveying a clock synchronized to the new data words from the receiver 82. The disk drive array is also provided with an address decoder 87 for each transceiver in the loop of the disk adapter 58, 59 and each of these address decoders decodes a unique address for the transceiver 71. A single bit register 88 is clocked by the clock line 86 and enabled by the address decoder 87 to receive the data bit on the data line 85 when addressed by the address on the address bus 84. In this fashion, the disk adapter 58, 59 can address any transceiver to which it is connected, to either set or reset the activation signal to the transceiver.
The circuitry shown in FIG. 6 could be used to activate a transceiver in a disk drive only when data is to be transmitted to or received from that particular transceiver. However, if power to that transceiver is entirely shut off, then a good deal of time will be required for the transceiver to stabilize before it is capable of transmitting or receiving data. One solution to this problem is to shut off power only to those circuits in the transceiver that are not essential for maintaining bit synchronization, as will be further described below with reference to FIG. 10. Another solution to this problem, however, is to recognize that only one of the transceivers in each disk drive need be active at any given time, and that one transceiver need be shut off only in the unlikely event of a malfunction in the transceiver or in the disk adapter to which it is linked.
Turning now to FIG. 7, there is a flow chart of steps in software executed by the storage controller 51 to initially configure the transmission loops from the disk adapters to the disk drive array. In a first step 101, the storage controller initializes disk adapter configuration tables to indicate that odd numbered disk drives are to be accessed via the first transceiver in each drive, and the even numbered disk drives are to be accessed via the second transceiver in each of the disk drives. Then in step 102, the storage controller activates the first transceiver in each odd numbered disk drive, and activates the second transceiver in each even numbered disk drive. Execution of the software for the storage controller then continues until there is a failure of the storage controller to communicate with a disk drive. When the communication fault is isolated to a particular disk drive, the storage controller executes a routine shown in FIG. 8.
As shown in FIG. 8, when the Nth disk drive fails to respond to the storage controller, the storage controller determines in step 111 whether the number N is odd or even. If N is odd, then execution branches to step 112. In step 112, the storage controller checks the configuration tables to determine whether the first transceiver is indicated for the disk drive. If not, then execution branches to step 113 to signal a total failure of the disk drive. For example, an operator of the storage subsystem would be informed that the disk drive should be replaced, and the system may attempt to reconstruct the data in the failed disk drive if the system has sufficient redundancy information for reconstructing the disk drive using so-called "RAID" techniques. Next, in step 114, the storage controller bypasses the indicated transceiver of the disk drive by addressing the single-bit control register (88 in FIG. 6) for the indicated transceiver of the disk drive. Then in step 115, the storage controller changes the configuration table to indicate that the disk drive is inoperative. Execution then continues.
If in step 112 the configuration table indicates the first transceiver for the disk drive, then execution continues from step 112 to step 117 where the storage controller signals a partial failure of the disk drive. For example, an operator or user of the storage subsystem would be informed that the disk drive should be replaced, and a background task may be scheduled for copying data from the disk drive in anticipation of the disk drive being replaced. Then in step 118, the first transceiver for the drive is deactivated, and the second transceiver for the drive is activated. Finally, in step 119, the configuration table is changed to indicate that the second transceiver for the disk drive should be used.
If in step 111 the number N is even, then execution branches to step 121. In step 121, the storage controller checks the configuration table to find whether the second transceiver is indicated for the disk drive. If not, then execution branches from step 121 to 113 to signal a total failure of the disk drive. Otherwise, execution continues from step 121 to step 122 where the storage controller signals a partial failure of the disk drive. Next, in step 123, the second transceiver for the disk drive is deactivated, and the first transceiver for the disk drive is activated. Finally, in step 124, the storage controller changes the configuration table to indicate that the first transceiver should be used for the disk drive.
As mentioned above, the circuitry in FIG. 6 could be used for activating the transceiver in a disk drive only when the disk drive needs to communicate with the storage controller. If all of the power is shut off to the bit clock generator of a transceiver, however, considerable time is required for bit synchronization to be achieved. The time for bit synchronization would include the time for the frequency of the bit clock to stabilize, as well as the time for the bit clock to become synchronized to the data transmitted over the transmission loop. To minimize these delays, the transceiver circuits could be partitioned so that the bit synchronization circuits are always powered up, but the other circuits would only be powered up when needed.
Turning now to FIG. 9, there is shown a schematic diagram of a transceiver in which bit synchronization circuits of the transceiver are shown above a dashed line 130 and the other circuits are shown below the dashed line. The circuits above the dashed line 130 are always energized, but the circuits below the dash line are energized only when a PWR -- UP signal is active. The use of such circuitry for each of the transceivers in the disk drive would permit the storage controller to use the circuitry of FIG. 6 to quickly power up all of the circuits in the transceiver only when the storage controller needs to communicate with the transceiver.
As shown in FIG. 9, the bit synchronization circuits include a phase-locked loop. The phase-locked loop includes a transition detector having an exclusive OR gate 131 and a delay line 132 having a delay of approximately one-half of the period of the bit rate of the data transmitted over the data transmission loop. The output of the exclusive OR gate 131 activates a tri-state driver 133, such as a N-channel FET which acts as a phase detector to provide an error signal to a loop filter. The loop filter includes a series resistor 134 and a shunt capacitor 135. The voltage on the shunt capacitor 135 provides a frequency control signal to a voltage controlled oscillator 136 which generates the bit clock. The bit clock is delayed by one-quarter period of the bit rate in a delay line 137 before being applied to the tri-state gate 133. The delays of the delay lines 132 and 137 should proportionally match each other, and these delay lines could each include a string of inverters. To insure that the complete activation of a transceiver will not disrupt the bit synchronization of other transceivers in the data transmission loop, the circuits always powered up include a multiplexer 138 and a d-type flip-flop 139. The flip-flop 139 regenerates the data from the receiver port (Rx) for transmission from the transmitted port (Tx) unless the transceiver is fully energized and transmitting, as controlled by a NAND gate 140.
The circuits in the lower part of FIG. 9 which are similar to the circuits in FIG. 4 are designated with similar but primed reference numerals. The circuits energized by the PWR -- UP signal also include a word sync decoder 141 which recognizes the presence of a word sync code in the shift register 40'. In this regard, the data transmitted over the transmission loop is encoded to ensure that there will always be transitions in the data to facilitate bit synchronization, and to insure that the word sync code will appear in the shift register 40' only when intended. Suitable encoding schemes are well known in the art, such as a conventional eight bit to ten bit encoding technique proposed in the Fiber Channel specification cited above.
The transceiver circuitry shown in FIG. 9 would also be useful in a power reduction scheme whereby the transceiver circuits are fully energized only at programmed times in order to search whether the disk drive is being accessed by the storage controller. As shown in FIG. 10, for example, the word sync code (Ws) and the address (A0, A1, A2, etc.) of the loop device presently being accessed is periodically transmitted over the transmission loop by the storage controller. Therefore, unless a transceiver is addressed, it can be shut off for a period of time Ts between the word sync and address codes.
For a transceiver to be periodically powered down and powered up, the transceiver should also give an indication of whether or not word sync has been achieved, in order to permit the microcontroller to look for the transceiver address. As shown in FIG. 11, the circuitry includes a d-type flip-flop 141 providing a set signal continuing for a controller clock cycle after the POWER -- ON signal is asserted. This set signal sets a flip-flop 142. The flip-flop 142 is reset by a NAND gate 143 in response to the word sync signal (W) from the word sync decoder (141 in FIG. 9).
Turning now to FIG. 12, there is shown a flow chart of a timer interrupt routine for the device controller to permit the device controller to power up and power down the transceiver of FIG. 9 at the periodic intervals required for scanning for the transceiver address. When the timer interrupt occurs at the end of the period Ts as shown in FIG. 10, the controller powers up the loop transceiver in a first step 151. Then in step 152 the controller waits for the data valid signal to be asserted by the transceiver circuitry in FIG. 11. Next in step 153 the controller looks for an address command in the data from the transceiver. Step 153 is also accessed by an "end of command software interrupt" entry point, and is also used as an initial entry point when the system is initially powered up. Next, in step 154, the controller checks the address of the address command to determine whether the loop device is being addressed. If so, then execution branches from step 154 to step 155 to set up a return to the start of a command service task. This command service task will decode the data following the address command as a command from the loop controller. Then in step 156, the controller disables the timer interrupt, and execution returns.
If in step 154 the controller found that it was not being addressed, then in step 157 the controller powers down the loop transceiver. Next, in step 158, the controller resets the timer interrupt so that the interrupt will occur after the duration of time Ts, and execution returns. The duration of time Ts could be constant. Alternatively, the duration of time Ts could be variable. If the duration of time Ts were variable, then the loop controller could insert after each address on the data stream of FIG. 10, a parameter indicating the duration of time Ts to the next word sync and address code. In this case, in the routine of FIG. 12, the controller would read the parameter in step 157 before powering down the loop transceiver, and in step 158 the controller would use the parameter to reset the interrupt timer with a variable time value causing the next timer interrupt of the controller to occur just before the next word sync and address code in the data stream.
Turning now to FIG. 13, there is shown a schematic diagram illustrating how the disk drive 70 can be given the capability of selecting among multiple power sources (Vs1 and Vs2) to provide a regulated voltage (3.3 volts) to disk drive electronics 160. For example, Vs1 and Vs2 can be independent 5 volt sources, or Vs1 could be a 5 volt source and Vs2 could be a 12 volt source. The disk drive has two 3.3 volt regulators 161 and 162. The regulator 161 is powered by Vs1, and the regulator 162 is powered by Vs2. The regulators, for example, are part No. M1C5156 sold by MICREL Corp., 1849 Fortune Drive, San Jose, Calif. The regulator 161 is constructed to work with an N-channel enhancement-mode MOSFET 163 and a current sensing resistor 164. A resistor 165 is added to the circuit of the regulator 161 and an "open source" output of the controller 72 is connected to the current sense (Is) input of the regulator. Therefore, the controller can enable or disable the regulator 161 by asserting or de-asserting a select signal S1, active low. In a similar fashion, the regulator 162 has an associated N-channel pass transistor 166, current sensing resistor 167, and an additional resistor 168 for permitting the current sensing input (Is) of the regulator 162 to be connected to an open-source output of the controller.
Although only two power sources Vs1 and Vs2 are shown in FIG. 13, a Fiber Channel compatible disk drive should have input pins on its connector 75 for two independent 5 volt power sources and two independent 12 volt power sources. Therefore, so that the controller 72 could select any of these four power sources, the disk drive 70 could have two additional 3.3 volt regulator circuits, so that each power source would have a respective regulator circuit. During configuration of the disk drives in the storage subsystem, the storage controller would select which supply should power the disk drive electronics in each disk drive. Preferably the storage controller would attempt to balance the load on each of the 5 volt supplies, and if the capacity of the 5 volt supplies would be reached, then storage controller would select and balance between the 12 volt supplies. In this fashion, the storage controller would attempt to minimize power usage and enhance reliability.
Various modifications of the invention will become apparent to persons of ordinary skill in the art from the foregoing description. For example, the different embodiments of the invention described above could be combined in a single system. In particular, the timer interrupt method of FIG. 12 could be used together with the method of FIGS. 7 and 8 in a system employing redundant loops. In this case, the transceivers de-activated in FIGS. 7 and 8 would have all of their circuits shut off, and the transceivers activated in FIGS. 7 and 8 would have their bit synchronization and regeneration circuits (top half of FIG. 9) continuously powered up, and their other circuits (bottom half of FIG. 9) selectively powered up and powered down by the timer interrupt routine of FIG. 12. | Transceivers are selectively activated to reduce power in a network of data processing devices linked by a data transmission loop. Each of the devices is linked by a transceiver, and passes data from a previous device in the loop to a next device in the loop when not transmitting data onto the loop. For example, the data processing devices are disk drives in a storage subsystem. Delays in establishing communication after transceiver activation can be avoided by continuously powering a bit clock oscillator or bit synchronizer. In one embodiment, a loop controller in the loop sends activation and deactivation signals to addressed transceivers via an auxiliary channel. In another embodiment, when a device detects that communication is occurring between other devices for a certain period of time, the device selectively deactivates its transceiver for the certain period of time. For redundancy, the data processing devices can be connected via dual loops, and then power is further reduced by activating at most one of the two transceivers in a device at any given time. In this case, if a transceiver failure occurs, the failed transceiver is bypassed and the other transceiver for the device is activated. For example, when a loop controller detects a transceiver failure, the loop controller sends transceiver activation and deactivation signals over the auxiliary channel. | 8 |
BRIEF DESCRIPTION OF THE INVENTION
[0001] This invention relates generally to the transmission of serial signals, such as in a transition minimized differential signaling system. More particularly, this invention relates to a clock-edge modulated serial link incorporating direct current (DC) balancing control signals.
BACKGROUND OF THE INVENTION
[0002] Mobile devices, such as cellular phones, Personal Digital Assistants (PDAs) and portable game consoles continue to grow in popularity. FIG. 1 illustrates an example of such a mobile device. In particular, FIG. 1 illustrates a mobile device 100 connected to a mobile display 102 via an interface 104 . The mobile device 100 includes a central processing unit 106 and a graphic controller 108 . The mobile display 102 includes a display controller 110 and a display 112 , such as a liquid crystal display. A battery 114 powers the mobile device 100 and the mobile display 102 . Low power design is critical in mobile applications of this type.
[0003] A conventional mobile device interface 104 uses parallel channels with single-ended full-swing signaling. The channels are composed of many lines, for example, 22 lines with 18-bit video pixel data lines and control signal lines, such as dot-clock, data enable (DE), horizontal sync (HSYNC), vertical sync (VSYNC), and other display-specific configuration settings. These signal lines consume power and space. In addition, they produce excessive electromagnetic radiation. To reduce the number of lines, a serial link with low-voltage swing differential signaling may be used. As known in the art, this type of signaling amplifies difference signals, while rejecting common-mode signals.
[0004] Popular display interfaces, such as Low Voltage Differential Signaling (LVDS) and Digital Visual Interface (DVI) use 3 channels of serialized differential signals for 18-bit or 24-bit pixel color data. In addition, a separate channel is used for clock transmission. In such an application, the voltage swing is reduced to about 400 mV.
[0005] In certain applications, such as a mobile display, relatively low video resolution is acceptable. In such a case, it is possible to use a single data channel. However, in this situation, the prior art has relied upon a separate clock channel. Since the dedicated channel solely for clock transmission increases hardware costs and power, it would be desirable to remove the dedicated clock channel and use only a single channel for transmitting the clock, data and control signals. However, if conventional network protocols, such as 802.3z Gigabit Ethernet are employed, a number of problems arise. For example, a local reference clock must be used at the receiver. This increases hardware costs and reduces flexibility in transmission bandwidth.
[0006] In view of the foregoing, it would be desirable to provide a low-power mobile device with a serial channel that supports clock, data and control signals, such as DC balancing control signals.
SUMMARY OF THE INVENTION
[0007] The invention includes a battery powered computing device with a channel configured as a single direct current balanced differential channel. A signal transmitter is connected to the channel. The signal transmitter is configured to apply clock edge modulated signals to the channel, where the clock edge modulated signals include direct current balancing control signals. A signal receiver is connected to the channel. The signal receiver is configured to recover the direct current balancing control signals.
[0008] The invention includes a signal transmitter. The signal transmitter has a channel node to interface with a single direct current balanced differential channel. Circuitry is connected to the channel node, the circuitry being configured to multiplex clock, data and control signals and apply them to the channel node. The clock signal is pulse width modulated to incorporate direct current balancing control signals.
[0009] The invention also includes a signal receiver. A channel node interfaces with a channel configured as a single direct current balanced differential channel. Circuitry is connected to the channel node. The circuitry is configured to de-multiplex clock, data and control signals from the channel node. The circuitry identifies direct current balancing control signals within a pulse width modulate clock signal.
[0010] The invention allows many parallel channels to be reduced to a single serial channel, which reduces power consumption. To further reduce power dissipation, the invention may be implemented with voltage-mode drivers. Still additional power reduction can be achieved by removing the source transmission channel termination and relying solely upon receiver side source transmission channel termination. The invention includes a delay-locked loop (DLL) data-recovery circuit that operates robustly in a high jitter environment.
BRIEF DESCRIPTION OF THE FIGURES
[0011] The invention is more fully appreciated in connection with the following detailed description taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 illustrates a mobile device and a mobile display that may be configured in accordance with an embodiment of the invention.
[0013] FIG. 2A illustrates DC-balanced clock-edge modulation in accordance with an embodiment of the invention.
[0014] FIG. 2B illustrates special character embedded clock-edge modulation utilized in accordance with an embodiment of the invention.
[0015] FIG. 3 illustrates a clock-edge modulated transmitter configured in accordance with an embodiment of the invention.
[0016] FIG. 4 illustrates a multiplexer that may be used in the clock-edge modulated transmitter of FIG. 3 .
[0017] FIG. 5 illustrates a voltage mode driver utilized in accordance with an embodiment of the invention.
[0018] FIG. 6 illustrates a clock-edge modulated receiver configured in accordance with an embodiment of the invention.
[0019] FIG. 7 illustrates clock-edge modulated decoder that may be used in accordance with an embodiment of the invention.
[0020] FIG. 8A illustrates a phase detector circuit configured in accordance with an embodiment of the invention.
[0021] FIG. 8B illustrates the use of a coarse-up signal in accordance with an embodiment of the invention.
[0022] FIG. 8C illustrates various signals processed in accordance with an embodiment of the invention.
[0023] Like reference numerals refer to corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The invention includes a single-channel serial link using clock edge modulation (CEM). This scheme, also known as pulse-width modulation (PWM), encodes data information onto a periodic clock by varying the position of a selected edge (i.e., the rising edge or falling edge); thus, the pulse-width of the clock is altered or modulated. The invention provides techniques to transfer a clock signal, data and control signals over a single channel.
[0025] By way of example, the invention may be implemented by varying the falling edge of the clock signal. As shown in FIG. 2A , data are encoded as a variation of the clock falling edge position, while the position of the rising edge is fixed. The periodic occurrence of the rising edges enables easy extraction of the clock signal, from which the receiver can generate the “dot-clock” simply by dividing down the incoming signal (e.g., by 18) with no further clock recovery mechanism. The modulation of the falling edge position or the clock pulse width allows one to embed data and control signals in the clock, therefore reducing the pin count.
[0026] U.S. Pat. No. 6,463,092 (the '092 patent) utilizes a pulse width modulation technique of this type. The '092 patent, which is assigned to the assignee of the current invention, is hereby incorporated by reference. The current invention builds upon the disclosed scheme of the '092 patent to achieve DC-balancing. In one embodiment, DC-balancing is achieved by inserting DC-balancing control signals into the serial link. The DC-balancing control signals may include signals to maintain DC-balance, increase DC-balance, and decrease DC-balance. Standard techniques are used to generate and process the DC-balance control signals. An aspect of the invention is directed toward incorporating the DC-balance control signals into a single serial link along with clock and data signals.
[0027] In one embodiment of the invention, the bit “ 0 ” is coded as a 50% duty cycle clock, indicating that no changes are necessary to keep balance. On the other hand, the bit “ 1 ” is coded as either a 25% or a 75% duty cycle clock, denoted as “1−” and “1+”, respectively, in FIG. 2 ( a ). Whether to use a 25% or a 75% duty cycle is determined by the DC value of the bits transmitted so far. If the DC value is lower than nominal, the bit “ 1 ” is coded as 75%, and vice versa. With this encoding, the maximum disparity counted in unit pulse length (i.e., 25% pulse width) is only 2 and good DC-balance is achieved.
[0028] The serial link may also be used to transmit control signals, such as HSYNC and VSYNC. In one embodiment, these control signals are transmitted when DE is unasserted. Leveraging this fact, the state of DE being 0 is coded as two consecutive “1+”'s or “1−”'s, as shown in FIG. 2 ( b ), which is an impossible sequence while the normal pixel data are being sent (i.e., DE is 1). This special sequence indicates that the following 16 pulse-width modulated symbols represent control characters. In this way, the control signals can be transmitted without requiring any additional channels. That is, the invention leverages the DE 0 state (when data is not being sent) to send DC-balance and other control information on a single channel.
[0029] FIG. 3 illustrates a transmitter 300 configured in accordance with an embodiment of the invention. The transmitter 300 includes an encoder 302 that receives data and control signals. For example, the data may be 6 bits of red pixel data, 6 bits of green pixel data, and 6 bits of blue pixel data. The control signals may include HSYNC, VSYNC, and DE signals. The output of the encoder 302 is applied to a serializer circuit 304 , which serializes the data and control information for the serial link. The encoder 302 or the serializer circuit 304 may be used to generate a DC-balance control signal.
[0030] The serialized data is then applied to a multiplexer, which receives control inputs form a phase-locked loop 310 . The output of the multiplexer 306 is applied to a channel driver 308 , in this case a voltage mode driver, which produces differential clock-edge modulated signals. In particular, the channel driver 308 applies a positive CEM signal (CEM+) and a negative CEM signal (CEM−) to a channel node 309 .
[0031] In one embodiment, the phase detector 312 of the phase-locked loop 310 multiplies the reference clock by 18 and operates with a voltage controlled oscillator 313 to generate 4 clock phases: 0(φ0), 90(φ1), 180(φ2), and 270(φ3). A divider 314 divides the multiplied clock signal and provides a feedback input to the phase detector 312 . The transmitter operates as if it is sending 4 Non-Return to Zero (NRZ) bits per symbol using these clock phases. The phase signals are processed by the multiplexer 306 .
[0032] FIG. 4 illustrates a pulse width modulated 4-to-1 multiplexer configured in accordance with an embodiment of the invention. Note that the first bit 400 and the last bit 402 are fixed at 1 and 0, respectively. Only the middle two bits (b and c in FIG. 4 ) need to vary to express the three different falling edge positions. The encoder 302 and serializer 304 may be used to generate these two bits from the parallel pixel data and control signals.
[0033] Since power consumption is a significant concern in a mobile device, an embodiment of the invention uses a voltage mode driver 308 for off-chip signaling in the CEM transmitter. FIG. 5 illustrates a known voltage mode driver that may be used in accordance with an embodiment of the invention. Unlike other prior art drivers, the voltage mode driver does not have a current source stack, hence it is capable of low voltage operation. To reduce the power consumption, the voltage mode driver is designed to operate at 1.2V supply and the voltage swing is also reduced to 80 mV. Since the link span of the mobile display is short (less than several inches) and the CEM signal is relatively immune to inter-symbol interference, an 80 mV swing is enough to guarantee proper operation of the receiver. Using the voltage mode driver with reduced swing, the CEM transmitter has been implemented to consume less than 1 mW when operating at 270 Mbps.
[0034] For the proposed CEM link, the data is delivered on the clock signal, making the receiver architecture much simpler. That is, the receiver does not require an NRZ phase detector nor a local frequency reference, as is the case in many serial link receivers. In one embodiment, the invention uses a delay locked loop (DLL) for data recovery, as shown in FIG. 6 .
[0035] The receiver 600 has a front-end limiting amplifier 602 which receives differential input signals CEM+ and CEM− at channel node 603 . The amplifier 602 facilitates an adequate signal level for the DLL input. A voltage-controlled delay line (VCDL) 604 generates 8-phase delayed clocks to sample and decode the CEM data. FIG. 2 ( a ) shows a timing relationship between sampling clocks and input CEM data. In one embodiment, the sampler 606 examines the CEM data at two different phases (φ3 and φ5, as shown in FIG. 2A ) to identify the location of the clock falling edge.
[0036] FIG. 7 illustrates a sampler and pulse-width modulated decoder 606 implemented with two flip-flops 700 and 702 . Each flip-flop receives the φ0 signal, while flip flop 700 receives the φ3 signal and flip flop 702 receives the φ5 signal. Using the sampled results, the CEM decoder extracts the data and disparity information. From the disparity information, the receiver can detect the pixel boundary and special sequences indicating DE, HSYNC, and VSYNC.
[0037] As shown in FIG. 6 , the input CEM data is sampled by its own delayed version. So, the DLL can recover data even if the input clock has a large amount of jitter. To ensure enough lock range of the DLL, a phase detector 608 with false-lock detection may be used. FIG. 8A illustrates a phase detector 608 configured in accordance with an embodiment of the invention. If the initial delay of VCDL is larger than 2× T CLK , i.e., the rising edge of the φ1 clock is located in the shaded area of FIG. 8 ( b ), the coarse_up signal is asserted to prevent harmonic lock. On the other hand, when the initial delay is so small that the VCDL delay would be stuck to its minimum value, the PD_reset signal is asserted to deactivate the false up signal. This is accomplished by comparing rising edges of φ0 and φ4, as shown in FIG. 8 ( c ). If the rising edge of φ4 is found between φ0 and φ8, the phase detector no longer generates an up signal, but makes the VCDL slow down.
[0038] The clock-edge modulated serial link of the invention has been fabricated in a standard 0.18 μm CMOS technology. The fabricated chip consumes 3.12 mW at 1.2 V supply voltage when operating at 270 Mb/s.
[0039] Those skilled in the art will appreciate that the invention may be implemented with various modifications. For example, the serial link may be augmented with multiple links to increase throughput. In addition, the invention can be utilized in a bidirectional (full-duplex) mode. Also, since differential mode signals are used, there is a common mode signal that may be used for other purposes. For example, the common mode signal may be used to exchange configuration data. The configuration data may specify such parameters as data format, data destination (when multiple transmitters/receivers are connected on the bus), data directionality, and the like.
[0040] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obviously, many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, they thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention. | A battery powered computing device has a channel configured as a single direct current balanced differential channel. A signal transmitter is connected to the channel. The signal transmitter is configured to apply clock edge modulated signals to the channel, where the clock edge modulated signals include direct current balancing control signals. A signal receiver is connected to the channel. The signal receiver is configured to recover the direct current balancing control signals. | 7 |
FIELD OF THE INVENTION
This invention relates to an all terrain drill unit of the kind comprising an all terrain vehicle chassis carrying a drilling mast which may be moved between a horizontal position overlying the chassis and a vertical position at one end of the chassis, the vehicle chassis being used to bring the drill to a desired location and also carrying a power source for the drill.
BACKGROUND OF THE INVENTION
In conventional units of this kind, it has been known to carry out various of the vehicle functions using hydraulic motors or actuators, but the relatively high cost of such techniques has restricted their use to selected functions only. We have found however that the advantages gained by using hydrostatic drives for essentially all of the vehicle functions outweigh the extra cost involved, particularly in the respect that with proper application of conventional hydrostatic engineering techniques, we find that a more versatile and effective unit can be produced which is nevertheless substantially easier to operate than conventional units.
SUMMARY OF THE INVENTION
As compared with conventional units, a drill unit in accordance with the invention, in which all major functions are performed hydraulically, and in which the controls for these functions are appropriately integrated and interlocked, can have the advantages of being able to drill at any angle to the vertical (available conventional mobile drills of this type can only drill vertically), of being exceptionally simple to operate (most conventional units require extensive operator training), and reliability and easy maintenance in that all of the major drive parts may be readily available standard items. To this end, hydraulic drive units are used both to provide traction for the vehicle chassis and drive for the drilling unit; the use of a hydraulic drive in the drilling head eliminates the need for the mechanical drive conventionally used for this purpose and enables the drilling head to be operated at any angle to the vertical at full efficiency.
Moreover, the use of hydraulic operation enables exceptionally simple controls to be utilized. In accordance with a further feature of the invention, a single pump controlled by a lever with a central neutral position is preferably utilized to determine the rate of forward and reverse movement of the vehicle in accordance with the degree of forward or rearward movement of the lever which is connected to appropriate proportioning valves in hydraulic circuits of the vehicle. By means of another control, the output of this pump may be switched so that instead of determining forward and reverse movement of the vehicle, it determines forward or reverse rotation of the drill. In a preferred arrangement, the control lever is duplicated both in a driving cab of the vehicle to control movement of the vehicle and at a control console adjacent the drilling head at the rear end of the vehicle to control rotation of the drill.
In accordance with a further preferred feature, and in order to allow for the different drilling speed ranges required for different types of drilling operation, the hydraulic drive to the drilling head incorporates a change speed gearbox which may have a hydraulically controlled shift. Preferably the gears are selected by two position selectors which are both normally centered in a neutral position by springs and displaced into gear selecting positions by independently controlled hydraulic cylinders so that the selectors may be operated in any desired combination.
According to a further preferred feature of the invention, each wheel of the vehicle is driven by an independent hydraulic motor, and a flow limiting valve is provided in the supply line to each hydraulic motor so that in the event of any wheel slipping or lifting clear of the ground, power will still be available at the other wheels, and the slipping wheel will not spin uncontrollably and thus worsen the lack of adhesion. Drive power may be applied either to the wheels of only one axle, or to all four wheels; the application of drive to all four wheels may be achieved by hydraulically controlling variable capacity drive motors on two of the wheels to change between idling and powered states.
The drilling mast is preferably pivotally mounted on a sub-frame which may be moved horizontally by hydraulic actuating means to provide exact positioning of the drill. The vehicle chassis is preferably further equipped with three hydraulically extensible legs whereby, on reaching a desired drilling station, it may be anchored firmly on the ground and appropriately levelled. The drilling mast, as well as hydraulic drive means for drill bits and hydraulic means for advancing the drive means relative to the mast as drilling proceeds, may also have associated with it hydraulic winches operating conventional block and tackle means for handling drill bits, corers and the like.
Preferably, the drill head itself comprises a hydrostatic motor, a change speed gearbox, and a reduction gear drive to an output shaft through which the drilling torque is applied. Although contrary to normal practice, the use of geared drive throughout instead of the more usual chain drive has the advantage of providing a compact assembly in which adequate thrust bearings may readily be applied to the output shaft. It is found in practice that the drilling heads of such drill units are subjected to considerable abuse, and the compact assembly which can be provided by a geared drive can more easily be engineered to withstand the abnormal stresses to which the head may be subjected when used for purposes which it was not intended.
Further features and details of the invention will be apparent from the following description of a preferred embodiment of the invention.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the drilling unit,
FIG. 2 is a side elevation of the unit,
FIG. 3 is a rear elevation of the unit,
FIG. 4 is a fragmentary vertical section on the centre line of a rear wheel of a vehicle chassis of the unit,
FIG. 5 is a view from the direction of the arrow F in FIG. 4, with the wheel and parts of the wheel hub removed for the sake of clarity,
FIG. 6 is a fragmentary vertical section on the centre line of a front wheel of the vehicle chassis,
FIG. 7 is a fragmentary plan view from the direction of the arrow E in FIG. 6,
FIG. 8 is a schematic diagram of the hydraulic circuits of the unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 to 3, the drill unit is built upon a ladder-type chassis comprising longitudinal members 2 and cross members 4 and 6, supported on front and rear wheels 8 and 10. Outrigger portions of the cross members 4 and 6 support a cab 12, fenders 14 and 16 and lockers 18 for carrying drills and other accessories. Guided for longitudinal motion relative to the rear of the chassis upon a bed formed by the longitudinal members 2 is a subframe 20 having uprights 22 which support, through pivots 24, brackets 26 attached to a cradle 28 forming part of a drilling mast indicated generally by the reference 30. The mast is normally supported in a horizontal position over the chassis by additional rests 32 and 34 carried by the chassis.
Also carried on the chassis frame is a prime mover in the form of an internal combustion engine 36 supplied with fuel from a tank 37 and coupled to several hydraulic pumps, these pumps being shown generally as an assembly 38.
The various functions of the drilling unit are best described in conjunction with their associated hydraulic circuits, as shown in FIG. 8. A primary hydraulic circuit, providing motive power for the vehicle chassis of the unit and for a drilling head 40 carried by the mast 30 is shown on the right hand side of FIG. 8 and comprises a variable displacement pump unit 42 forming part of the assembly 38. A secondary hydraulic circuit supplied by a constant displacement pump 44 incorporated in the assembly 38 comprises all of the auxiliary functions associated with the drilling function of the rig. These various auxiliary functions will be described further below. An auxiliary pump 46 is provided for use during movement of the vehicle to provide the steering function.
Referring now in more detail to FIG. 8, the pump unit 42 includes a variable displacement pump 48 having output lines 50 and 52 and receiving input oil from a return line 5. In order to provide various control functions described below, an auxiliary pump 56 is provided drawing oil through a filter 58 from a tank 60 (see also FIGS. 1 and 2). The various sumps shown in the diagram are all returned to this tank 60 via an oil cooler 72 (see FIGS. 1 and 2) and a return line filter 70. The output pressure from pump 56 on the line 66 is controlled by means of a relief valve 68. Other details of the pump unit, apart from the control functions discussed below, need not be described in detail since the unit shown is a conventional proprietary item (Eaton transmission pump No. 5420-024).
The lines 50 and 52 are connected to a change-over valve 54 operated by a double acting actuator 73. The control pressure for the actuator 73 is applied through two control lines 74a and 74b either to the line 66 or to a return line 76 by means of a manually operated changeover valve 78. When the pressure from line 66 is applied to the line 74b, the valve 54 is moved to the opposite position from that shown, and the lines 50 and 52 are connected by lines 80 and 82 to a constant volume hydraulic motor unit 84, which drives the drill head 40 through a gearbox 86 and reduction gears 87 and 89. Overloads on the gearbox and motor transferred back from the drill head are prevented by back-to-back pressure relief valves 88.
When pressure from the line 66 is applied to the line 74a, the valve 54 assumes the position shown, thus connecting the lines 50 and 52 to fixed volume hydraulic motors 94 and variable volume hydraulic motors 96 through lines 90 and 92. The motors 94 drive the front wheels 8 through reduction hubs 102, and the motors 96 drive the rear wheels 10 through reduction hubs 104 (see FIGS. 4 and 5). A manually operated changeover valve 108 connected to the line 66 controls double acting actuators operating the flow controls on the motors 96 so as to move these between neutral and full flow, so as to provide either two or four wheel drive. The maximum flow of oil to the motors 94, 96 driving the individual wheels is limited by flow restrictors 106. In the event of one driven wheel losing adhesion, the presence of the flow restrictor 106 associated with that wheel prevents its associated motor from hogging the entire oil supply, and ensures that traction is maintained on the other wheel or wheels. Obviously, the relative calibrations of the various restrictors may be varied should it be desired to redistribute the maximum oil flows permitted to each wheel.
The line 66 also supplies, via the valve 78 and line 114, a brake valve 116 by means of which hydraulic pressure may be applied to or released from cylinders 118 operative to release normally applied disc brakes 120 (see FIG. 5) acting on brake discs 122 attached to the hubs 104 (see FIGS. 4 and 5) As will be seen from FIGS. 4 and 5, the hubs 104 and motors 96 for the rear wheels 10 are supported by brackets 124 on the longitudinal members 2 of the chassis. Since pressure is applied via the valve 78, the brakes can only be released when this valve is positioned so that the valve 54 applies fluid pressure to the wheel motors 94, 96.
The valve 116 is actuated by a cam 110 having a center dwell and ganged with a two way proportioning valve 112 which also has pressure applied thereto via the valve 78 and the line 114. The arrangement is such that the valve 116 is closed when the proportioning valve is closed, and open when the proportioning valve is opened in either direction. The proportioning valve acts upon opening so as to move a control valve 111 in the pump unit 42 proportionately in a corresponding direction so as in turn to set up a proportionate pressure differential between the lines 50, 52, the sense of the differential being in accordance with the direction of opening of the valve 112. Hence movement of the valve 112 out of its closed position releases the brakes 120 and progressively applies power to the vehicle wheels so as to drive the vehicle in either direction according to the direction of movement of the valve.
When the valve 78 is reversed, control pressure is applied to a two way proportioning valve 113 ganged with the valve 112, which then operates in the same way as the valve 112 to apply the variable and reversible differential output from the pump 48 to the drill head motor 84. Two way check valves 115 act to isolate that one of the valves 112, 113 to which pressure is not applied.
Referring now to the lower center portion of FIG. 8, the pump 46 draws oil from the tank 60 through a filter 59, and delivers it to a steering control unit 126 (see also FIG. 2) through a line 128 in which the pressure is controlled by a relief valve 130. The steering control unit 126 is conventional, and selectively supplies oil to two steering actuators 132 (see FIG. 7). Referring to FIGS. 6 and 7, the actuators 132 act between a bracket 134 and steering knuckles 136 welded to the sides of cylindrical drums 138 which house the motors 94. Diametrically opposite points at the top and bottom of the drums are connected by king pins 140 and forks 142 to a front axle 144 to the center point of which the bracket 134 is attached. The knuckles 136 are connected by a tie rod 146 so as to complete an Ackerman steering linkage, and the bracket 134 is pivotally connected to a cross member 4 of the chassis by a pivot pin 148 so as to permit the axle to rock laterally relative to the chassis. Since the rear wheels are fixed relative to the chassis, this enables the front axle to move to accommodate unevenness in the terrain without influencing the steering. The steering unit 126 is connected to a steering wheel 127 appropriately positioned relative to a driver's seat 150 in the cab 12, and an appropriate feedback connection is established between the front wheels and the steering unit 126 to control the pressure applied to the cylinders 132.
Referring now to the left hand portion of FIG. 8, the pump 44 draws oil from the tank 60 through a filter 61, and supplies pressurized oil via the line 152 to the various auxiliary functions associated with operation of the unit in its drilling mode. Oil from the line 152 is applied to the various auxiliaries by means of valves assembled into banks 154, 155 and 156. These valve bank assemblies are mounted on a control panel 158 at the rear of the vehicle chassis adjacent the operating position of the drilling mast 30. The control panel 158 also carries a lever 161 operating the valves 112 and 113 for the variable volume pump unit 42 via a cable, a further lever 160 also operating the valves 112 and 113 via a cable 163 being provided in the cab 12. The control function is such that in the mid position of the control levers 160, 161, the output pressure from the pump 48 is the same on both lines 50 and 52, and movement in opposite directions from the central position produces a pressure differential between the two lines in a sense depending on the direction of movement of the lever. The valve 78, determines whether the levers 160, 161 control the drill head 40 or the motors 94, 96.
All the auxiliary functions save the water pump referred to below are powered by double acting linear hydraulic actuators or reversible hydraulic motors. The individual valves in the banks 154, 155 and 156 each have three positions, a first position in which one output line is connected to the line 152 and the other line to a return line 164, an intermediate position in which both output lines are either blocked, and a third position in which the one line is connected to the line 164 and the other line to the line 152.
The valves in the bank 156 control various functions mainly associated with the operation of the drilling head 40. A valve 166 controls two actuators 168 which move the head 40 longitudinally of the mast 30 on guides 170 (see FIGS. 1 and 2). A second valve 172 is connected in parallel with the valve 166 but is in series with a flow restrictor 174 and a relief valve 173; the valve 172 may be used when it is desired to move the drill head at a lower rate, as during actual drilling, whilst the valve 173 limits the thrust applied to the drill. A fourth position of the valve 166 allows the actuators to permit the drill head to move downwards under gravity, but not in the opposite direction.
Valves may be provided to control double acting cylinders which operate the selectors in the change speed gearbox 86 so as to alter the ratio of the gearing between the motor 84 and the output shaft 184 of the drill head 40, or these selectors may be operated manually.
The valve 186 controls a cat head winch 188 mounted on the cross member 6, which is used in conjunction with a cat head 190 in the fitting and removal of drill bits and the like in and from the drilling head 40.
Two valves 192 control two boom winches 194, and a valve 196 controls a further winch 198 on the carriage 20. All of these three winches are used in connection with the handling of drill bits, tubes, corers and the like in association with the drilling mast.
Considering now valves comprised by the valve bank 155, the valve 202 controls a levelling jack 204 at the front of the vehicle, whilst valves 206 and 208 control levelling jacks 210 at the rear of the vehicle and extending through the cross member 6.
A valve 212 in the bank 156 controls an actuator 214 controlling longitudinal movement of the carriage 20, and a valve 216 controls two actuators 218 acting between the platform 20 and the bracket 26 so as to tilt the mast 30 to any desired angle.
The valve 220 in the bank 154 controls an additional winch 222 at the front of the vehicle, and the valve 224 in the bank 156 controls a hydraulic motor 226 driving a water pump 228 used either to supply water for use during a drilling operation, or for extracting excess water as necessary. A variable restrictor valve 230 is provided in series with the pump motor so as to control the pump output.
In use, the drilling unit is driven to a drilling site in the condition shown in FIGS. 1 to 3, that is with the drilling mast resting horizonally on the supports 32. The valve 78 is positioned so that the output of the pump 48 is applied to the wheel motors, the valve 108, which is located in the cab, being positioned either so as to cause the rear wheel motors 96 to idle, or to cause both the motors 96 and the front wheel motors 94 to be powered if four wheel drive is required by terrain conditions. The velocity of the vehicle is controlled by the lever 160 in the cab, which is disposed so that forward movement of the lever causes the vehicle to move forward at a rate dependent on the degree of movement of the lever, and rearward movement causes the vehicle to move rearward according to the degree of rearward movement of the lever. Any additional braking effort which may be required to bring the vehicle to a halt is automatically applied by the brakes 120 when the pressure in the brake cylinders is released by the valve 116 as the lever 160 is returned to its center position. Thus the brakes cannot be released unless the vehicle is powered. On arrival at the site, the vehicle is manoeuvered, using either the lever 160 or the lever 161, as is convenient, so that the rear of the mast 30 is in line with the desired point of entry of the drilling to be made, and the operator then reverses the valve 78. The levelling jacks 204 and 210 are extended so as to support the vehicle firmly on the ground and level the chassis, using the appropriate control valves in the bank 155, and the control valve 216 is used to extend the actuators 218 to whatever extent is necessary to bring the mast 30 to a desired drilling angle. This will normally be vertical, with the cradle at 28 adjacent the supports 22, but it is an important advantage of the unit that other angles may equally readily be employed if desired. When the required angle has been reached, the mast is locked in position by returning the valve to its intermediate, locked position. Drill bits and the like, according to the operation being carried out, may be fitted to the drill head 40 using the various winches 188, 194 and 198, and an appropriate ratio selected in the change speed gearbox 86 by use of selectors. The lever 161 may then be used to control clockwise and anti-clockwise rotation of the drill shaft 184 in a similar manner to that described with reference to the forward and rearward movement of the vehicle, the valve 78 having previously been operated so as to connect the pump 48 to the motor unit 84. The drill may be advanced to a drilling position by means of the valve 166, and precisely positioned over the required point of entry by using the valve 212 to control the actuator 214 moving the carriage 20. During drilling, the drill may be advanced by the actuators 168 under the control of the valve 172, or by gravity under the control of the valve 166 in its fourth position. When it is required to change or extend a drill or the like, the drill head may be withdrawn up the mast by the actuators 168 under control of the valve 166, and the necessary exchange of bits or insertion of extensions handled using the various winches. Any necessary supply or removal of water or mud during the drilling operation can be carried out using the pump 228.
On completion of the drilling operation, the drills and the like may be stowed in the lockers 18, the platform 20 retracted, and the drilling mast returned to its horizontal position, the jacks 204 and 210 retracted, and the valve 78 again reversed so that pressurized oil is available for supply to the wheel motors so that the unit may be moved to another drilling site or returned to base. The winch 222 may be utilized if necessary to assist in crossing particularly difficult terrain, or in clearing sites prior to drilling. | A self-propelled all terrain drill unit having propulsion means for the chassis, a drilling mast mounted on the latter for movement between horizontal and vertical positions and a drilling head carried by the mast wherein all major functions are performed hydraulically, the hydraulic functions being divided into two groups; those of propelling the vehicle to a drilling site and operating the drill at the site provided by a variable displacement pump and those of adjusting the position of the machine at the site and aligning and positioning the drilling head provided by an independent pump. | 4 |
BACKGROUND
[0001] Embodiments of the present disclosure relate generally to the field of drilling and processing of wells. More particularly, present embodiments relate to a system and method for measuring a tubular internal stress or force introduced by a tubular grappling system.
[0002] In conventional oil and gas operations, a well is typically drilled to a desired depth with a drill string, which includes drill pipe and a drilling bottom hole assembly (BHA). Once the desired depth is reached, the drill string is removed from the hole and casing is run into the vacant hole. In some conventional operations, the casing may be installed as part of the drilling process. A technique that involves running casing at the same time the well is being drilled may be referred to as “casing-while-drilling.”
[0003] Casing may be defined as pipe or tubular that is placed in a well to prevent the well from caving in, to contain fluids, and to assist with efficient extraction of product. When the casing is run into the well, the casing may be internally gripped by a grappling system of a top drive. Specifically, the grappling system may exert an internal pressure or force on the casing to prevent the casing from sliding off the grappling system. With the grappling system engaged with the casing, the weight of the casing is transferred to the top drive that hoists and supports the casing for positioning down hole in the well.
[0004] When the casing is properly positioned within a hole or well, the casing is typically cemented in place by pumping cement through the casing and into an annulus formed between the casing and the hole (e.g., a wellbore or parent casing). Once a casing string has been positioned and cemented in place or installed, the process may be repeated via the now installed casing string. For example, the well may be drilled further by passing a drilling BHA through the installed casing string and drilling. Further, additional casing strings may be subsequently passed through the installed casing string (during or after drilling) for installation. Indeed, numerous levels of casing may be employed in a well. For example, once a first string of casing is in place, the well may be drilled further and another string of casing (an inner string of casing) with an outside diameter that is accommodated by the inside diameter of the previously installed casing may be run through the existing casing. Additional strings of casing may be added in this manner such that numerous concentric strings of casing are positioned in the well, and such that each inner string of casing extends deeper than the previously installed casing or parent casing string.
BRIEF DESCRIPTION
[0005] In accordance with one aspect of the disclosure, a system includes a tubular grappling system having a mandrel, an actuator disposed about and coupled to the mandrel, and a plurality of grapples coupled to the actuator, wherein the actuator is configured to translate the plurality of grapples along angled surfaces of the mandrel, and the plurality of grapples is configured to engage with an inner diameter of a tubular. The system also includes a tubular stress measurement system having a first sensor configured to detect a parameter indicative of an axial or circumferential position of the plurality of grapples and a calculation system configured to calculate an internal stress on the tubular based on the parameter.
[0006] Another embodiment includes a method including detecting a first parameter indicative of an axial or circumferential position of a plurality of grapples configured to engage with an inner diameter of a tubular, calculating a radial travel distance of the plurality of grapples based on the parameter indicative of the axial or circumferential position of the plurality of grapples using one or more processors of a calculation system, and calculating an internal stress on the tubular based on the radial travel distance of the plurality of grapples using the one or more processors of the calculation system.
[0007] In accordance with another aspect of the disclosure, a system includes a data collection system having a magnet coupled to a plurality of grapples configured to engage with an inner diameter of a tubular, a magnetometer coupled to an actuator housing of an actuator, wherein the actuator is configured to axially actuate the plurality of grapples, wherein the magnetometer is axially aligned with the magnet, and a signal transmitter coupled to the actuator and configured to transmit a measurement detected by the magnetometer to a calculation system.
DRAWINGS
[0008] These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0009] FIG. 1 is a schematic of a well being drilled, in accordance with present techniques;
[0010] FIG. 2 is a cross-sectional schematic of a tubular grappling system and tubular stress measurement system, in accordance with present techniques;
[0011] FIG. 3 is a graph illustrating pressure measurements of an actuator of the tubular grappling system and a radial travel distance of grapples of the tubular grappling system with respect to time, in accordance with present techniques;
[0012] FIG. 4 is schematic of a data collection system of the tubular stress measurement system, in accordance with present techniques; and
[0013] FIG. 5 is a schematic of a calculation system of the tubular stress measurement system, in accordance with present techniques.
DETAILED DESCRIPTION
[0014] Present embodiments provide a tubular (e.g., casing) stress measurement system for a top drive system. Specifically, the tubular stress measurement system is configured to measure a stress or force acting on a string of tubular when a grappling system of the top drive system is engaged with the tubular. The grappling system includes grapples and a mandrel that are positioned within the tubular prior to hoisting. As described in detail below, the grapples are translated downward along angled surfaces of the mandrel to force the grapples radially outward such that the grapples engage with the internal diameter of the tubular. With the grapples engaged with the tubular, the grapples may apply a force or pressure on the tubular and thereby block the tubular from sliding off the grappling system when the tubular is hoisted and run into a well or hole by the top drive system. As the grapples are translated downward along the mandrel, the tubular stress measurement system measures an axial travel distance of the grapples. In the manner described in detail below, the measured axial travel distance of the grapples may be used to calculate a radial travel distance of the grapples. The radial travel distance of the grapples may then be used to calculate a stress (e.g. internal stress) on the tubular caused by the grapples.
[0015] Turning now to the drawings, FIG. 1 is a schematic of a drilling rig 10 in the process of drilling a well in accordance with present techniques. The drilling rig 10 features an elevated rig floor 12 and a derrick 14 extending above the rig floor 12 . A supply reel 16 supplies drilling line 18 to a crown block 20 and traveling block 22 configured to hoist various types of drilling equipment above the rig floor 12 . The drilling line 18 is secured to a deadline tiedown anchor 24 , and a drawworks 26 regulates the amount of drilling line 18 in use and, consequently, the height of the traveling block 22 at a given moment. Below the rig floor 12 , a casing string 28 extends downward into a wellbore 30 and is held stationary with respect to the rig floor 12 by a rotary table 32 and slips 34 . A portion of the casing string 28 extends above the rig floor 12 , forming a stump 36 to which another length of tubular 38 (e.g., casing) may be added. In certain embodiments, the tubular 38 may include 30 foot segments of oilfield pipe having a suitable diameter (e.g., 13⅜ inches) that are joined as the casing string 28 is lowered into the wellbore 30 . As will be appreciated, in other embodiments, the length and/or diameter of segments of the casing 16 (e.g., tubular 38 ) may be other lengths and/or diameters. The casing string 28 is configured to isolate and/or protect the wellbore 30 from the surrounding subterranean environment. For example, the casing string 28 may isolate the interior of the wellbore 30 from fresh water, salt water, or other minerals surrounding the wellbore 30 .
[0016] When a new length of tubular 38 is added to the casing string 28 , a top drive 40 , hoisted by the traveling block 22 , positions the tubular 38 above the wellbore 30 before coupling with the casing string 28 . The top drive 40 includes a grappling system 42 that couples the tubular 38 to the top drive 40 . In operation, the grappling system 42 is inserted into the tubular 38 and then exerts a force on an internal diameter of the tubular 38 to block the tubular 38 from sliding off the grappling system 42 when the top drive 40 hoists and supports the tubular 38 .
[0017] As described in detail below, the grappling system 42 further includes a tubular stress measurement system 44 . The tubular stress measurement system 44 is configured to measure a stress (e.g., internal stress) in the tubular 38 caused by the force exerted on the tubular 38 by the grappling system 42 . As shown, the tubular stress measurement system 44 includes a data collection system 46 and a calculation system 48 . The data collection system 46 is coupled to the grappling system 42 and collects data for use in calculating the stress in the tubular 38 . The data collected by the data collection system 46 is described in further detail below. The calculation system 48 of the tubular stress measurement system 44 receives (e.g., by wired or wireless transmission) the collected data from the data collection system 46 and calculates the stress in the tubular 38 using the collected data. In the illustrated embodiment, the calculation system 48 is separate from the data collection system 46 . However, in other embodiments, both systems 46 and 48 may be combined and resident on the top drive 40 .
[0018] It should be noted that the illustration of FIG. 1 is intentionally simplified to focus on the top drive 40 and grappling system 42 with the tubular stress measurement system 44 described in detail below. Many other components and tools may be employed during the various periods of formation and preparation of the well. Similarly, as will be appreciated by those skilled in the art, the orientation and environment of the well may vary widely depending upon the location and situation of the formations of interest. For example, rather than a generally vertical bore, the well, in practice, may include one or more deviations, including angled and horizontal runs. Similarly, while shown as a surface (land-based) operation, the well may be formed in water of various depths, in which case the topside equipment may include an anchored or floating platform.
[0019] FIG. 2 is a cross-sectional side view of the grappling system 42 and the tubular stress measurement system 44 of the top drive 40 . In the illustrated embodiment, the grappling system 42 includes an actuator 50 , a mandrel 52 , and grapples 54 (e.g., dies, gripping surfaces, friction surfaces, etc.). To grip the tubular 38 , the mandrel 52 and the grapples 54 , which are disposed about the mandrel 52 , are inserted or “stabbed” into the tubular 38 . After the mandrel 52 and grapples 54 are disposed within the tubular 38 , the grapples 54 may be translated downward, in a direction 56 , by hydraulic actuation of the actuator 50 . However, in other embodiments, the grapples 54 may be translated rotationally by mechanical actuation of the actuator 50 . In the manner described below, the grapples 54 are forced radially outward, as indicated by arrows 58 , and engaged with an inner diameter 60 of the tubular 38 when the grapples 54 are pushed downward by the actuator 50 . Similarly, in embodiments where the actuator 50 rotates the grapples 54 , the grapples 54 may similarly be forced radially outward to engage with the inner diameter 60 of the tubular 38 .
[0020] In the illustrated embodiment, the actuator 50 is a hydraulic actuator. However, in other embodiments, the actuator 50 may be a mechanical actuator, electromechanical actuator, pneumatic actuator, or other type of actuator. The illustrated actuator 50 includes a hydraulic cylinder 62 coupled to the mandrel 52 and a piston 64 disposed within the hydraulic cylinder 62 and about the mandrel 52 . The piston 64 is coupled to a piston sleeve 66 that extends around an outer diameter 68 of the mandrel 52 . Additionally, the piston sleeve 66 extends out of the hydraulic cylinder 62 at a base 70 of the hydraulic cylinder 62 and couples to the grapples 54 disposed about the mandrel 52 , as indicated by juncture 72 .
[0021] To actuate the actuator 50 (e.g., the piston 64 ) in the illustrated embodiment, a hydraulic fluid (e.g., oil) is pumped into a piston chamber 74 of the actuator 50 from a hydraulic fluid source 76 . For example, after the mandrel 52 and the grapples 54 are inserted into the tubular 38 , hydraulic fluid may be pumped into the piston chamber 74 on a first side 78 of the piston 64 through a first port 80 . As the hydraulic fluid is pumped into the piston chamber 74 on the first side 78 of the piston 64 , pressure on the first side 78 builds, thereby forcing the piston 64 and the piston sleeve 66 downward (i.e., in the direction 56 ). As the grapples 54 are rigidly coupled to the piston sleeve 66 at the juncture 72 , the grapples 54 also translate downward in the direction 56 when the hydraulic fluid is pumped into the piston chamber 74 on the first side 78 of the piston 64 .
[0022] As mentioned above, when the grapples 54 are translated downward, the grapples 54 are forced radially outward by the mandrel 52 , which remains stationary. Specifically, each of the grapples 54 includes one or more angled surfaces 82 that engage with one or more corresponding angled surfaces 84 of the mandrel 52 . In the illustrated embodiment, each grapple 54 includes three angled surfaces 82 . However, other embodiments of the grapples 54 may include a fewer or greater number of angled surfaces 82 , where each angled surface 82 corresponds with one of the angled surfaces 84 of the mandrel 52 . Each of the angled surfaces 84 of the mandrel 52 has a profile disposed at an outward angle 86 relative to a central axis 88 of the mandrel 52 . In certain embodiments, the outward angle 86 may be approximately 1 to 10, 2 to 8, or 3 to 6 degrees. As will be appreciated by those skilled in the art, the magnitude of outward angle 86 (e.g., an angle of approximately 1 to 10, 2 to 8, or 3 to 6 degrees) may enable gradual radially outward movement of the grapples 54 , thereby enabling improved control and/or operation of the grappling system 42 . Furthermore, each angled surface 82 of the grapples 54 has a profile disposed at an inward angle 90 relative to the central axis 88 of the mandrel 52 , where the inward angle 90 has a magnitude equal or similar to the outward angle 86 of the angled surfaces 84 of the mandrel 52 . As the grapples 52 are forced downward by the actuator 50 , the angled surfaces 82 of the grapples 54 will engage with the corresponding angled surfaces 84 of the mandrel 52 to force the grapples 54 radially outward (e.g., in the direction 58 ).
[0023] Each of the grapples 54 has a radially outward surface 92 that engages with the inner diameter 60 of the tubular 38 when the grapples 54 are forced radially outward by a sufficient amount using the actuator 50 . When the radially outward surfaces 92 of the grapples 54 engage with the inner diameter 60 of the tubular 38 , friction between the grapples 54 and the tubular 38 is increased, thereby blocking the tubular 38 from moving or slipping relative to the grapples 54 when the top drive 40 hoists and supports the tubular 38 during a well forming operation. In certain embodiments, the radially outward surfaces 92 may have coarse surfaces or may include surface treatments to increase friction between the grapples 54 and the inner diameter 60 of the tubular 38 .
[0024] As mentioned above, the embodiments disclosed herein describe the actuator 50 having a hydraulic actuation mechanism. However, it will be appreciated that the actuator 50 may have other actuation mechanisms in other embodiments. For example, the actuator 50 may be mechanically actuated to rotate the grapples 54 . In such an embodiment, the angled surfaces 82 of the grapples 54 and the angled surfaces 84 of the mandrel 52 may have horizontal orientations, as compared to the vertical orientations of the angled surfaces 82 and 84 shown in FIG. 2 . In other words, the outward and inward angles 86 and 90 of the angled surfaces 82 and 84 , respectively, may have a horizontal orientation. Additionally, in such an embodiment, the angled surfaces 82 and 84 may be curved to extend (e.g., partially extend) around a circumference of the mandrel 52 . When the actuator 50 mechanical actuates (e.g., rotates) the grapples 54 , the angled surfaces 82 of the grapples 54 will engage with the angled surfaces 84 of the mandrel 52 to radially expand the grapples 54 such that the grapples 54 engage with the inner diameter 60 of the tubular 38 , as similarly described above.
[0025] After the tubular 38 is positioned above and coupled to the casing string 28 , the grappling system 42 may release the tubular 38 . Specifically, in the illustrated embodiment, hydraulic fluid may be pumped from the hydraulic fluid source 76 into the piston chamber 74 on a second side 94 of the piston 64 through a second port 96 . The actuator 50 may include seals 97 disposed between the piston 64 and the cylinder 62 to block hydraulic fluid from flowing from the second side 94 to the first side 78 . Similarly, the actuator 50 may include additional seals 99 disposed between the piston sleeve 66 and the cylinder 62 to block hydraulic fluid from exiting the piston chamber 74 . As hydraulic fluid is pumped into the piston chamber 74 on the second side 94 of the piston 64 , pressure may build on the second side 94 of the piston 64 to force the piston 64 upwards in a direction 98 . As the piston 74 is forced upwards, the hydraulic fluid previously pumped into the piston chamber 74 on the first side 78 of the piston 64 (i.e., to engage the grapples 54 with the tubular 38 ) may exit the piston chamber 74 through the first port 80 and return to the hydraulic fluid source 76 . As the piston 64 is actuated upwards, the piston sleeve 66 and the grapples 54 are also translated upwards (i.e., in the direction 98 ). As a result, the angled surfaces 82 of the grapples 54 may slide inwards and upwards along the angled surfaces 84 of the mandrel 52 , and the radially outward surfaces 92 of the grapples 54 may disengage with the inner diameter 60 of the tubular 38 . Thereafter, the grapples 54 and the mandrel 52 may be removed from the tubular 38 , and the grappling process described above may be repeated to grab and hoist another length of tubular 38 .
[0026] As will be appreciated, it may be desirable to monitor the stress (e.g., internal stress) on the tubular 38 that is caused by the grappling system 42 (e.g., the grapples 54 ). For example, if the force applied by the grapples 54 to the tubular 38 during the grappling process exceeds a threshold (e.g., a yield pressure of the tubular 38 ), the tubular 38 may deform and/or degrade. Accordingly, the top drive 40 and the grappling system 42 include the tubular stress measurement system 44 mentioned above. The tubular stress measurement system 44 includes the data collection system 46 , which collects measurements associated with the operation of the grappling system 42 . For example, the data collection system 46 includes a distance sensor system 100 and a pressure sensor system 102 . The distance sensor system 100 may be configured to measure an axial travel distance of the piston sleeve 66 while the grapples 54 are engaged with the tubular 38 . In other embodiments, such as embodiments where the actuator 50 mechanically rotates the grapples 54 , the distance sensor system 100 may be configured to measure a rotational travel distance of the piston sleeve 66 and/or grapples 54 . The axial or rotational travel distance of the piston sleeve 66 (or grapples 54 ) measured by the distance sensor system 100 may then be used to calculate an internal stress of the tubular 38 . The components of the distance sensor system 100 are described in further detail below with reference to FIG. 4 .
[0027] The pressure sensor system 102 includes two pressure sensors (e.g., a first pressure sensor 104 and a second pressure sensor 106 ) to measure pressures inside the piston chamber 74 . Specifically, the first pressure sensor 104 is exposed to the piston chamber 74 on the first side 78 of the piston 64 . Similarly, the second pressure sensor 106 is exposed to the piston chamber 74 on the second side 94 of the piston 64 . The pressure measurements collected by the first and second pressure sensors 104 and 106 may be used to help determine when the grapples 54 are engaged with the inner diameter of the tubular 38 . For example, in the illustrated embodiment, the grapples 54 are not yet engaged with the inner diameter 60 of the tubular 38 . Accordingly, during initial actuation of the actuator 50 (e.g., when hydraulic fluid is first pumped into the piston chamber 74 on the first side 78 of the piston 64 ), the pressure of the piston chamber 74 measured by the first pressure sensor 104 may be relatively low. After the hydraulic fluid forces the piston 64 downward to the point where the grapples 54 are engaged with the inner diameter 60 of the tubular 38 , the pressure measured by the first pressure sensor 104 will increase more sharply as the tubular 38 provides resistance.
[0028] FIG. 3 is a graph 120 that illustrates the measurements of the first pressure sensor 104 and the radial travel distance of the grapples 54 when the grappling system 42 is actuated by the actuator 50 . Specifically, the graph 120 includes an X-axis 122 representing time, a first Y-axis 124 representing the radial travel distance of the grapples 54 , and a second Y-axis 126 representing pressure measured by the first pressure sensor 104 . A first line 128 represents the radial travel distance of the grapples 54 during actuation of the grappling system 42 as a function of time. A second line 130 represents the pressure measured by the first pressure sensor 104 during actuation of the grappling system 42 as a function of time.
[0029] As mentioned above, after the mandrel 52 and grapples 54 are initially inserted into the tubular 38 , the grapples 54 may not be in contact with the inner diameter 60 of the tubular 38 . As a result, when the actuator 50 is first actuated by pumping hydraulic fluid into the piston chamber 74 on the first side 78 of the piston 64 , the pressure measured by the first pressure sensor 104 may be relatively low. For example, at a time 132 , hydraulic fluid may begin pumping into the piston chamber 74 on the first side 78 of the piston 64 . During a first time period 134 when the hydraulic fluid is pumping into the piston chamber 74 , the piston 64 and the piston sleeve 66 may translate downwards, and the grapples 54 may begin moving radially outwards toward the inner diameter 60 of the tubular 38 , as indicated by segment 136 of the first line 128 . During the first time period 134 , the pressure measured by the first pressure sensor 104 is relatively low and increases marginally, as indicated by segment 138 of the second line 130 , because the piston 64 moves with little resistance as the grapples 54 have not yet contacted the inner diameter 60 of the tubular 38 .
[0030] At a time 140 , the grapples 54 contact the inner diameter 60 of the tubular 38 . When the grapples 54 contact the inner diameter 60 of the tubular 38 , movement of the grapples 54 , and therefore the piston 64 , is resisted by the tubular 38 . Accordingly, the pressure inside the piston chamber 74 on the first side 78 of the piston 64 will increase more rapidly, as indicated by segment 140 of the second line 130 . Additionally, as radially outward movement of the grapples 54 is resisted by the tubular 38 when the grapples 54 contact the tubular 38 , the travel distance of the grapples 54 will increase more slowly, as indicated by segment 142 of the first line 128 . Indeed, the radially outward travel distance of the grapples 54 when the grapples 54 are in contact with the inner diameter 60 of the tubular 38 may equal or approximately equal a radially outward travel distance (e.g., expansion) of the tubular 38 . Accordingly, as described in detail below, the data collection system 46 of the tubular stress measurement system 44 is configured to measure the axial travel distance of the piston sleeve 66 , which may then be used to calculate the radially outward travel distance of the grapples 54 after the grapples 54 have contacted the inner diameter 60 of the tubular 38 . As will be appreciated, once the radially outward travel distance (e.g., expansion) of the tubular 38 is determined, a stress (e.g., internal stress) on the tubular 38 may be calculated.
[0031] FIG. 4 is a schematic representation of the data collection system 46 of the tubular stress measurement system 44 . As mentioned above, the data collection system 46 may be configured to measure an axial travel distance (or a rotational travel distance) of the piston sleeve 66 during actuation of the actuator 50 with the distance sensor system 100 . To this end, the data collection system 46 or distance sensor system 100 includes a variety of sensors that enable measurement of the axial travel distance of the piston sleeve 66 . For example, in the illustrated embodiment, the data collection system 46 includes a magnetometer 160 (e.g., Hall effect sensor) disposed above a magnet 162 (e.g., a cylindrical or rectangular rare earth magnet) that is positioned on an axial end 164 of the piston sleeve 66 . As will be appreciated by those skilled in the art, the magnetometer 160 (e.g., Hall effect sensor) may be configured to precisely and accurately measure a magnetic field strength of the magnet 162 . The magnetometer 160 and the magnet 162 may also be resistant to extreme temperatures, debris, or other environmental conditions to which the data collection system 46 may be exposed. However, in other embodiments, the distance sensor system and/or data collection system 46 may include other sensors and components, such as lasers, optical sensors, ultrasonic sensors, acoustic sensors, radio-frequency identification (RFID) chips or tags, etc. For example, in such embodiments, an emitter (e.g., laser, ultrasonic device, etc.) may be positioned in the location of the magnetometer 160 , and the emitter may emit a wave (e.g., light wave or sound wave) that reflects off of the axial end 164 of the piston sleeve 66 . The wave reflecting off of the piston sleeve 66 may then be detected by a detector, which may be integrated with the emitter or positioned next to the emitter (e.g., at or near the position of the magnetometer 160 ).
[0032] In the illustrated embodiment, the magnetometer 160 is mounted to a sensor mount 166 (e.g., an aluminum bracket) coupled to the cylinder 62 of the actuator 50 . The magnetometer 160 is a transducer that varies its output voltage in response to a magnetic field measurement, and the magnet 162 is a permanent magnet that emits a strong magnetic field. For example, the magnet 162 may be a neodymium magnet or a samarium-cobalt magnet. The centers of the magnetometer 160 and the magnet 162 are axially aligned or positioned relative to one another to enable the magnetometer 160 to reliably measure the magnetic field strength of the magnet 162 . For example, the magnetometer 160 may measure the magnetic field strength of the magnet 162 at a frequency of approximately 100 Hertz.
[0033] When the piston sleeve 66 (and thus the grapples 54 ) move axially, the magnetic field of the magnet 162 measured by the magnetometer 160 will change, as the magnetometer 160 remains fixed to the cylinder 62 of the actuator 50 , while the magnet 162 moves with the piston sleeve 66 . For example, when the piston sleeve 66 and the grapples 54 move downward during actuation of the actuator 50 , the magnetic field of the magnet 162 measured by the magnetometer 160 may decrease as the magnet 162 moves away from the magnetometer 160 . Conversely, when the piston sleeve 66 and the grapples 54 move upward during release of the grapples 54 from the tubular 38 , the magnetic field of the magnet 162 measured by the magnetometer 160 may increase as the magnet 162 moves closer to the magnetometer 160 . As mentioned above, the magnetometer 160 outputs a voltage indicative of the measured magnetic field strength of the magnet 162 . Thus, a change in the voltage output of the magnetometer 160 is indicative of a change in axial position of the magnet 162 .
[0034] In embodiments where the actuator 50 mechanically rotates the grapples 54 , the magnet 162 may be disposed on a side (e.g., outer circumference) of the piston sleeve 66 and the magnetometer 160 may be radially offset from the piston sleeve 66 and mounted to the sensor mount 166 . In such an embodiment, the magnetometer 160 may similarly measure a change in the measured magnetic field of the magnet 162 as the grapples 54 , the piston sleeve 66 , and the magnet 162 rotate. For example, as similarly described above, when the grapples 54 , piston sleeve 66 , and magnet 162 rotate, the magnet 162 may rotate away from the magnetometer 160 , and the voltage output of the magnetometer 160 may decrease. Conversely, when the grapples 54 , piston sleeve 66 , and magnet 162 , the magnet 162 may rotate toward from the magnetometer 160 , and the voltage output of the magnetometer 160 may increase. As similarly described above, a change in the measured magnetic field of the magnet 162 is indicative of a change in rotational position of the magnet 162 , and thus the grapples 54 .
[0035] The data measurements obtained by the magnetometer 160 may be transmitted to the calculation system 48 of the tubular stress measurement system 44 . In the illustrated embodiment, the magnetometer 160 is coupled to electrical components disposed inside a junction box 168 that is mounted to an exterior 170 of the cylinder 62 of the actuator 50 . The electrical components include a printed circuit board 172 , a battery 174 , and a signal transmitter 176 . The printed circuit board 172 receives the measured data from the magnetometer 160 , and the signal transmitter 176 transmits the measured data to the calculation system 48 of the tubular stress measurement system 44 . For example, the signal transmitter 176 may include an antenna that transmits the data as a radio signal to a signal receiver of the calculation system 48 . The signal transmitter 176 may also transmit measurements obtained by the first and second pressure sensors 104 and 106 to the calculation system 48 . In other embodiments, the data collection system 46 and the calculation system 48 may be hard wired to one another. For example, the data collection system 46 and the calculation system 48 may be integrated or combined with one another and may both be positioned on the top drive 40 .
[0036] The data collection system 46 further includes additional magnetometers (e.g., magnetic latching switches) 178 coupled to the sensor mount 166 . More particularly, the additional magnetometers 178 are positioned approximately 90 degrees from the magnetometer 160 . Accordingly, the additional magnetometers 178 are positioned on a lateral side of the magnet 162 . In certain embodiments, the additional magnetometers 178 may be positioned a distance of approximately one-third the total stroke of the piston sleeve 66 from the magnetometer 160 (e.g., approximately 1 to 2 inches). In other words, the additional magnetometers 178 may be positioned one above the other, where the average distance of the additional magnetometers 178 is approximately one-third the total stroke of the piston sleeve 66 from the magnetometer 160 .
[0037] The additional magnetometers 178 enable calibration of the magnetometer 160 . While the illustrated embodiment includes two additional magnetometers 178 for redundancy, other embodiments may include fewer or more additional magnetometers 178 , including no additional magnetometers 178 . In FIG. 4 , the piston sleeve 66 is shown in a baseline or “zeroed out” position when the actuator 50 is not actuated. In this baseline position, axial distances 180 between the magnet 162 and each of the additional magnetometers 178 may be known. When the piston sleeve 66 moves downward during actuation of the actuator 50 , the magnet 162 may pass the one or both of the additional magnetometers 178 . As each of the additional magnetometers 178 have an orientation perpendicular to the orientation of the magnet 162 , the magnetic field of the magnet 162 measured by the additional magnetometers 178 will switch (e.g., from north to south) when the magnet 162 passes each of the additional magnetometers 178 . Thus, when the measured magnetic field switches for one of the additional magnetometers 178 , an operator or user will know the precise axial position of the magnet 162 and the piston sleeve 66 at that time. Therefore, each stroke of the piston 64 may be used to calibrate the measurements of the magnetometer 160 .
[0038] FIG. 5 is a schematic representation of the calculation system 48 of the tubular stress measurement system 44 . The calculation system 48 includes one or more microprocessors 200 , a memory 202 , a signal receiver 204 , and a display 206 . The memory 202 is a non-transitory (not merely a signal), computer-readable media, which may include executable instructions that may be executed by the microprocessor 200 . Additionally, the memory 202 may be configured to store data collected by the calculation system 48 . For example, the signal receiver 204 may receive data measurements from the data collection system 46 . These data measurements may include voltage output data from the magnetometer 160 and/or additional magnetometers 178 , pressure measurements from the first and second pressure sensors 104 and 106 , or other data. Using the collected data, the microprocessor 200 may calculate an axial position (or rotational position) of the magnet 162 , the piston sleeve 66 , and the grapples 54 . In certain embodiments, one or more of the components described above (e.g., microprocessors 200 , memory 202 , signal receiver 204 , and/or display 206 ) may be additionally and/or alternatively located within the junction box 168 coupled to the actuator 50 . Similarly, the components of the junction box 168 may additionally and/or alternatively be included with the calculation system 48 .
[0039] Based on the measured axial (or rotational) position of the magnet 162 , the radially outward travel distance of the grapples 54 can be calculated. Specifically, as described above, when the piston sleeve 66 and the grapples 54 are actuated axially downward (or rotationally around), the angled surfaces 84 of the mandrel 52 force the grapples 54 radially outward toward the inner diameter 60 of the tubular 38 . As the angle 86 of the angled surfaces 84 of the mandrel 52 is known, the radial travel distance of the grapples 54 can be calculated based on the axial travel distance (or rotational travel distance) of the piston sleeve 66 and grapples 54 measured by the magnetometer 160 . In particular, the radial travel distance of the grapples 54 once the grapples 54 have contacted the inner diameter 60 of the tubular 38 (i.e., once the pressure measured by the first pressure sensor 104 begins to increase rapidly) may be calculated. Thereafter, the internal stress of the tubular 38 may be calculated based on the radial travel distance of the grapples 54 after the grapples 54 have contacted the inner diameter 60 of the tubular 38 . In certain embodiments, a threshold internal stress valve may be stored in the memory 202 . If the calculated internal stress meets or exceeds the threshold internal stress value, an alarm 208 , such as an auditory and/or visual alarm, of the tubular stress measurement system 44 may be activated to alert a user or operator that the calculated internal stress of the tubular 38 has exceeded the threshold.
[0040] As discussed in detail above, the present embodiments provide the tubular stress measurement system 44 . Specifically, the tubular stress measurement system 44 is configured to measure a stress or force acting on a length of tubular 38 when the grappling system 42 of the top drive 40 is engaged with the tubular 38 . The grappling system 42 includes the grapples 54 and mandrel 52 that are positioned within the tubular 38 prior to hoisting. Within the tubular 38 , the grapples 54 are translated downward or rotationally (e.g., by actuator 50 ) along angled surfaces 84 of the mandrel 52 to force the grapples 54 radially outward such that the grapples 54 engage with the internal diameter 60 of the tubular 38 . With the grapples 54 engaged with the tubular 38 , the grapples 54 may apply a force or pressure on the tubular 38 and thereby block the tubular 38 from sliding off the grappling system 42 when the tubular 38 is hoisted and run into the wellbore 30 by the top drive 40 . As the grapples 54 are translated downward or rotationally along the mandrel 52 , the tubular stress measurement system 44 measures an axial or rotational travel distance of the grapples 54 . Specifically, the tubular stress measurement system 44 includes magnetometers 160 and 178 that measure the magnetic field strength of the magnet 162 coupled to the piston sleeve 66 actuating the grapples 54 . The measured magnetic field strength is then used to calculate the axial or rotational travel distance of the grapples 54 . Thereafter, the axial or rotational travel distance of the grapples 54 may be used to calculate a radial travel distance of the grapples 54 . More specifically, the radial travel distance of the grapples 54 after the grapples 54 have contacted the inner diameter 60 of the tubular 38 is calculated using the method described above. Once the radial travel distance of the grapples 54 is determined, a stress (e.g. internal stress) in the tubular 38 caused by the grapples 54 may be calculated.
[0041] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | Present embodiments are directed to a tubular stress measurement system including a first sensor configured to detect a parameter indicative of an axial or circumferential position of the plurality of grapples and a calculation system configured to calculate an internal stress on the tubular based on the parameter. | 4 |
RELATED APPLICATIONS
This is a divisional application of Ser. No. 08/752,202, Nov. 19, 1996, U.S. Pat. No. 5,961,008.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a method and an apparatus for pouring liquid from a vessel, more particularly to a pouring head for pouring alcoholic beverages from individual bottles such as frequently seen in bars, night clubs, and restaurants.
2. The Prior Art
The prior art in pouring heads for pouring from bottles is exemplified by the following:
U.S. Pat. No. 3,321,113 Conroy 5/67
U.S. Pat. No. 3,630,419
This prior art, both in documental patent form and in commercial embodiment, has been the subject of various shortcomings. The pertinent prior art is characterized in having a pouring spout using at least one of normally two metal balls to provide a hydraulically controlled shut-off of the dispense pour for giving a predetermined quantity of liquid per pour. A specific example is a one (1) ounce pour which is routinely referred to as a "shot."
The prior art has a history of erratic variation in poured quantity between successive pours, a history of delivering frequent or occasional "short-shots", and a history of structural and breakage problems.
These pourers typically have a body with a front spout and a rear inlet pipe, a ball valve in the inlet pipe, a dump cap secured to the back end of the inlet pipe, a latch ball in the dump cap, and a cork to secure the pourer in the mouth of a beverage bottle. The beverage bottle is normally upright and is inverted over a glass to pour a unit of beverage into the glass. The body and dump cap usually have an air vent pipe for allowing air into the bottle. Frequently the spout outlet is covered by a normally closed flap to prevent insect egress and evaporation of liquid product. Among the specific problems of these pourers are the following:
Firstly, the corks are used solely to seal the body to the bottle, and hold the pourer in the bottle. In order to extract a pourer from the bottle, the spout of the pourer is grasped and pulled. Some pourers are provided with collars that go over the bottle neck in which case the collar is grasped and pulled. In both instances the inlet pipe is frequently stretched, cracked, bent or broken, usually at the liquid ports which are usually inside the collar and the weakest structure of the pourer. There is no way to apply a torque or pull to the collar other than firstly applying the torque or pull to the spout. When any stretching, cracking, bending, or breaking occurs, the pourer is functionally destroyed. The prior art pourers have also been difficult to remove, particularly for smaller people, and have been fingernail breakers and finger cutters.
Within the function and structure of the pourers, the dump cap has historically been a problem. Firstly the existing art is to injection mold the body and the dump cap of the same or similar plastics, and solvent weld them together with a solvent such as MEK, or to sonic weld them together. There has historically been problems with solvent overflow, not enough solvent, too much solvent, melt overflow from sonic welding, air and/or liquid leakage in the joints, incomplete bonding or welding, and breakage of the dump cap. The solvent or sonic welded area has been vulnerable to subsequent attack by alcohol and the relatively exotic trace chemicals in liquor. Subsequent stress cracking is well known. Further, the typical dump cap has used a four finger molded retainer to capture the latch ball valve. The four fingered ball valve retainer is not 100% reliable, and when bottle and pourer are slammed back down upon a counter the latch ball valves have fallen out and into the bottle of beverage. There has been litigation wherein such a fallen out latch ball valve was served to a consumer in purchased beverage, probably poured after the broken pourer was removed from the bottle. It has also become known to applicant that one of the many reasons for short-shot pours, is that the latch ball valve has had an implied angle of ninety (90°) degrees, has been in a relatively hard and rigid plastic material, and that the latch ball valve is not properly and immediately seating, but rather is jumping around on and off of the latch valve seat in the dump cap. Further yet it has been found that the shut-off ball valve is sticking to its seat in the dump cap and is never falling and therefore the pourer never shuts-ff. It has also been found that any one of the four fingers jointly holding the latch ball valve may break off, and the pourer is destroyed.
It has also been found that control of the ball shut-off valve in the body has been erratic. The causes have been found to be erratic fluid sealing of the ball to the base of the inlet pipe.
Further, prior structure has required hand labor intensive assembly processes relying upon the discretion and repetitive capabilities of assemblers. Quality has been erratic and defects excessive.
The methods and structure for admission of air into the bottle as liquid is poured out have been found to be too variable, and the cause of variation in shot size. Most prior art has an always open air pipe. One example of prior art has a solenoid controlled air valve.
The prior flapper valves on the spout outlet have also caused problems, sticking either open or closed, and occasionally interfering with flow out of the spout.
It has also been fount that because of the control or latch valve seat, the pourer has to be tilted at least forty-five (45°) degrees or one half of the included angle of the valve seat before the control valve will positively operate, if the valve does not properly close the pourer will short shot.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a new and improved liquid pouring apparatus and components therefore, and methods of operation and provision thereof.
If is an object of this invention to provide an improved liquid pouring head having an improved mechanical mechanism for automatic shut off.
It is an object of this invention to provide an improved liquid pouring head having an improved dump cap and assembly of the cap to the pourer body.
It is an object of this invention to provide an liquid pouring head having a new and improved air flow control.
It is an object of this invention to provide a liquid pouring head having improved method and structure for removal of the head from a beverage bottle.
It is an object of this invention to provide a new cork per se, as well as a new combination of a cork and collar for easier injection and extraction of a pourer into and out of a bottle.
It is an object of this invention to provide several new improvements in ball valve control structure and function in a pouring head.
SUMMARY OF THE INVENTION
A method of installing and extracting a pourer from a bottle has the steps of providing a sealing cork with an annular flange of larger diameter than the pouring spout and grasping the cork flange to twist and pull the pourer out of the bottle.
A method of installing and extracting a pourer to and from a bottle, wherein the pourer has a collar, has the steps of providing a splined radial connection between the collar and a sealing cork, and twisting the collar in or out of the bottle with the collar.
A method of providing a liquid pourer for pouring liquid from a bottle has the steps of providing a pourer body, providing a pourer dump cap, and assembling and sealing and retaining the cap to the body with mechanical retainer and without the use of solvent, adhesive, sealant or welding.
A liquid pourer for pouring liquid from a bottle has a body, a tubular cork, and an annular ring on the cork with a perimeter larger than the body, enabling grasping of the ring and extraction of the pourer by the cork.
A liquid pourer for pouring liquid from a bottle has a body, a cork, and a collar; the cork and collar are radially splined to each other enabling the collar to turn the cork in the bottle during extraction of the pourer.
A liquid pourer for pouring liquid from a bottle has a body, a dump cap, and connecting means for mechanically connecting the cap to the body without solvent or adhesive.
A liquid pourer for pouring liquid from a bottle has a body, a dump cap, a shut-off valve with the body, and a liquid sump around a normally open valve support.
A liquid pourer for pouring liquid from a bottle has a body, a dump cap, a shut-off valve in the body, a control valve in the dump cap, and a control valve seat having an included angle of less than ninety (90°) degrees,
A liquid pourer for pouring liquid from a bottle has a body, a dump cap, a shut-off valve in the body, a control valve in the dump cap, and a control valve retainer on a distal end of the valve cap, the control valve retainer is a circumfrentially complete tube with a plurality of inward extending abutments through which the control valve has been pressed.
A liquid pourer for pouring liquid from an inverted bottle has a body with a liquid bore and an air pipe, within the air pipe is a normally open control valve for controlling air pressure inside the bottle during pouring.
A liquid pourer for pouring liquid from an inverted bottle has a body with a pouring spout, a normally closed flap over an outlet of the pouring spout, and a thumb actuator on the flap for manually opening the flap while inverting the pourer and bottle.
A new cork per se for a liquid pourer has a relatively larger annular ring with grasping knobs enabling direct grasping and turning and pulling of the cork for insertion and/or extraction of the pourer without structural loading of the body.
A new cork and collar combination has the collar splined to the cork, enabling turning of the cork in the bottle during insertion and/or extraction of the pourer.
A new dump cap per se is of relatively soft pliable material, and has integral sealing assembly structure enabling subsequent assembly without solvent, adhesive, sealant or welding.
Other aspects of prior problems, objectives of the invention and manifestations of the invention will become known upon the knowledge and use of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the preferred embodiment of the liquid pourer of this invention;
FIG. 2 is a section through lines II--II of FIG. 1;
FIG. 3 is a section through lines III--III of FIG. 2;
FIG. 4 is a frontal end view of the dump cap;
FIG. 5 is a back end view of the dump cap;
FIG. 6 is a detail side section of the cork;
FIG. 7 is a back end view of FIG. 6;
FIG. 8 is a detail side section of the cork and collar combinations;
FIG. 9 is an underside view of the collar; and
FIG. 10 is a top view of the cork for the collar in FIGS. 8 & 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-10 show the preferred embodiment of this invention. In FIG. 1, a liquid pouring head is generally identified by the numeral 10. This head 10 is specifically for pouring liquid, usually alcoholic beverage, out of a bottle 12. The bottle 12 is typically a one quart or one liter size. The adjoining head 10 and bottle 12 normally sit upright on a counter or bottle rack and are jointly inverted to pour a unit of liquid from the bottle 12.
The head 10 includes a main body 14 injection molded of a relatively rigid plastic, and a sealing cork 16, 16A, an optional collar 18 which is combined within the optional collar 16A.
The body 14 has a liquid inlet pipe 20 and an air vent pipe 22. A dump cap 24 is secured to a rear distal end 26 of the inlet pipe 20 and air pipe 22 and retains a shut-off ball valve 28 in a liquid bore 30 of the body 14. The dump cap 24 also contains a function control ball valve 32. The dump cap 24 provides an air valve chamber 34 for an air control ball valve 36.
The body 14, has a front or top pouring spout 38 with a diametric outer perimeter 40, and a liquid outlet 42. Behind the spout 38 is the inlet pipe 20 and the air pipe 22, the inlet pipe 20 has its distal end 26 and the liquid bore 30, which includes a precision valve bore 44, an enlarged valve pocket 46, liquid ports 48 into the liquid bore 30, and a shut-off valve seat 50, leading outward to the spout outlet 42. The air pipe 22 has an air inlet 52 in the pour spout 38. The spout 38 has an internal top cavity 54 in which a label or a function light may be placed. Just rearward of the pour spout 38 is a cork retainer 56 which extends around the liquid inlet pipe 20 and the air pipe 22.
An important feature of this invention is embodied in the dump cap 24, shown in detail in FIGS. 2 & 3, having a front section 58 sealed and secured to the liquid inlet pipe 20, and a rear section 60 containing the control valve 32. The distal end 26 of the liquid inlet pipe 20 and the air pipe 22 is precisely sized. The dump cap front section 58 has a front outer tubular section 62 having a precisely sized internal surface which is a light press fit upon the distal end 26. The front section of dump cap 58 also has a shorter internal tubular section 64 which is precisely fitted to provide a light press fit into the distal end valve pocket 46. While the body 14 is of relatively hard and rigid plastic, the entire dump cap 24 is of a different, softer and relatively pliable plastic, such as high density polypropylene which enables the dump cap 24 to pliably conform to the body 14. The distal end 26 is pressed into and bottomed out in an annular receptor 66 between the tubular sections 62, 64. Inside the front section of dump cap 58 is a non-round, in this case square, valve support 68 upon which the shut-off valve 28 normally rests. Between the valve support 68 and the internal tubular section 64 is a liquid sump 70 for wetting and priming liquid inside of the valve pocket 46. On the outside of the inlet pipe distal end 26 is an opposed press of retainer abutments 72 having angled entry cams over which the pliant dump cap outer tubular section 62 can be pressed, until bottoming out in the annular receptor 66 whereupon the retainer abutments 72 snap into a pair of complementary retainer acceptors 74, whereupon the dump cap 24 is permanently sealed and secured to the body 14.
In the dump cap rear section 60 is a control valve chamber 76 containing the function control valve 32. There are two significant improvements here, the first being a frustro-conical control valve seat 78 having an included angle of less than ninety (90°) degrees, specifically an included angle in the range of forty to sixty (40° to 60°) degrees has been found to immediately seat the control valve 32 and prevent it from rolling around on the seat. Secondly, the rear section has a new control valve retainer 80 wherein the retainer 80 has the rear distal end of the dump cap 24 is a complete circumferential ring 82 within which is a plurality of inward projecting valve retainer abutments 84 through which the function control valve 32 is pressed. In between the control valve seat 78 and the shutoff valve support 68, is the portion control aperture 86.
FIG. 3 best illustrates the air pressure control valve 36 inside of the air valve chamber 34. The dump cap 24 has a rear vent portion 88 of the air vent pipe 22. In the front of the rear vent portion 88 is an expanded diameter forming the air valve chamber 36, and into which an extended air pipe distal end 90 is telescoped, and press fitted and fluid tightly sealed. The air pipe distal end 90 has a rearward facing air valve seat 92 for the air control valve 36. The rearward or downward end of the air valve chamber 34 has at least one and preferably a pair of open air valve supports 94 which are ramped to bias the air control valve 36 downward during pouring and inward toward the liquid bore 30 during upright rest of the pourer 10.
The air control valve 36 is a precision ball of stainless steel, ceramic, or plastic. The air control valve 36 is always open when the pourer 10 is upright, and is normally closed when the pourer 10 is inverted into a pouring position.
Another important feature of this invention is the new cork 16 shown best in FIGS. 6 & 7. The cork 16 has the conventional tubular section 96 and seals 98. Atop the cork 16 is a new annular ring 100 that has an outer perimeter 102 that is larger than the spout outer perimeter 40. In the cork outer perimeter 102 is a forward facing spout gripping lip 104 which is normally slip-fitted on the spout perimeter 40. On an underside of the cork perimeter 102 is a continuous plurality of convex grasping knobs 106, which have an outer diameter larger than the spout perimeter 40 and larger than a neck of the bottle 12. The cork 16 is retained to the body 14 by a barb section 108 snapped over the cork retainer 56.
When the pourer 10 is installed in a bottle, the cork seals 98 are wetted and the cork perimeter 102 is grasped with three fingers while the palm pushes on the spout 38. What is new in both function and structure is that the cork 16 can now be turned as it is being inserted in the bottle 12 to reduce the force required to insert and connect the pourer 10.
Then, when extracting the pourer 10 from the bottle 12, the cork 16 is grasped directly either with 3 fingers or with a wrap of the thumb and first finger, and the entire pourer 10 is extracted by pulling and turning directly upon the cork 16, rather than on the spout 38 as in the prior art. The lip 104 compresses inward against the spout perimeter 40 and the entire pourer 10 with its cork 16 can now be rotated in the bottle 12 during extraction which significantly reduces the force required to pull out the pourer 10. No more broken off spouts 38, and fewer broken/cracked fingernails.
FIGS. 8-10 illustrate a further important improvement in the pourer 10, wherein the pourer 10 is provided with a collar 18, and a collar cork 16A. The collar 18 is from the exterior conventional and covers the bottle outlet, specifically the threads and security seal. Inside the collar 18, which is a relatively rigid plastic component, is an inward facing radial spline 110 around the entire inside of the collar 18. The cork annular ring 100A has a peripheral spline 112 that is connected to and engaged to the collar spline 110. Now, during insertion and/or removal of the pourer 10 with the collar 18, the cork 16A can be rotated in the bottle by turning the collar 18, which significantly relieves the force needed to insert or to extract the pourer 10. Note that the rigid collar 18 has acute teeth 114 while the soft and pliable cork 16A has obtuse teeth 116 for preventing deformation of the teeth.
Note than either the cork 16 per se, or the cork 16A and collar 18 combination will work on any pourer 10, be it of the portion-control type having the dump cap 24 as shown, or a free pour type without a dump cap 24, or an electronic pourer as shown in my U.S. Pat. No. 5,255,819.
One of the distinguishing features of the pourer 10 of this invention, in that the dump cap 24 is permanently assembled and sealed to the body 14 without solvents, adhesives, sealants, or welding. It is ideally suited for robotic and/or low-skill manual assembly, with extremely high quality and reliability. The dump cap 24 is no longer susceptible to stress cracking from alcohol and chemicals in beverages, and is no longer susceptible to failing and dropping the control valve 32 out of the pourer 10.
The new spout flap 118 shown only in FIG. 1, is pivotally secured to the spout 38 by a hinge pin 120. The flap 118 is provided with a thumb actuator 122 that is engageable by a user's thumb and enables manual opening of the flap 118 during inversion of the pourer 10.
In the use and operation of the pourer 10, it is normally in a bottle 12 sitting upright on a support surface. As the pourer sits, control valve 32 rests upon the retainer abutments 84 and valve seat 78 is open for drainage of liquid out of the pourer 10 and back into the bottle 12. After the pourer 10 has drained empty, the sump 70 retains a quantity of priming and wetting liquid in the underside of the valve pocket 46. The air control valve 36 is open and is supported by the open air valve supports 94.
When the connected bottle 12 and pourer 10 are picked up and inverted, the control valve 32 moves into and closes the control valve seat 78. The air control valve 36 moves into and closes the air valve seat 92. The sump 70 drops its liquid onto the shut-off valve 28 sealing it to the liquid bore 30. Whereupon the shut-off valve 78 is held up by a partial vacuum in the valve pocket 46. Controlled flow of liquid into the liquid bore 30 through the portion control aperture 86 controls the rate and time of the fall of the shut-off valve 28, until the liquid ports 48 are reached, whereupon the shut-off valve 28 falls upon its seat 50 and the pour is terminated. The bottle 12 and pourer 10 are then turned upright to drain and reset the valves 28, 32. During pouring of liquid from the bottle 12, air pressure inside the bottle 12 drops and eventually a pressure differential sufficient to lift the air control valve 36 off its seat 78 is reached. The air control valve 36 opens and closes repetitively to control the pressure in the bottle 12, at a predetermined and constant partial pressure for an even flow rate of pours.
It has been found that with the new reduced angle in the control valve seat 78, the pourer 10 now needs to be inverted past horizontal only one-half of the include angle, to be positively operable, rather that the forty-five (45°) degrees required by the prior embodiments.
Further, it has been found that the cork per se, and the combination of the new cork and collar, and the new dump cap per se, are each an invention including patentable utility individually usable on pourer of all/most types.
Many other advantages and values may be found and realized, and various modifications will be suggested by those versed and working in the art, but be it understood that I embody within the scope of the patent hereon, all such embodiments as reasonably and properly come within the scope of my contribution to the art and industry. | A liquid pourer for pouring liquid from a bottle, most likely liquor, has a new sealing cork enabling much easier insertion and extraction of the pourer into and out of a bottle, a new cork and collar combination enabling similar easier insertion and extraction, and a new dump cap for portion control pouring wherein a new assembly and sealing method and structure is provided, and numerous new improvements making the pourer provide higher quality pouring. | 1 |
RELATED APPLICATIONS
This application is a continuation claiming priority benefit of U.S. Ser. No. 13/541,536 filed Aug. 8, 2015 and U.S. Ser. No. 61/504,873, filed Jul. 6, 2011 incorporated herein by reference.
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
This disclosure relates to the field of fabric (i.e. clothes) washing apparatus which are portable, and operable without a running source of water, and without a power source. The washing apparatus operates with a volume of liquid cleaner (water) and manual manipulation of a handle.
SUMMARY OF THE DISCLOSURE
Disclosed herein is a portable washing apparatus for the washing of fabrics. The washing apparatus in one example comprising: a base member configured to fit within a watertight container; a frame extending vertically from and removably attached to the base member; a cross support extending horizontally across the frame and removably attached thereto; and an agitator having a lower end attached to the base member so as to freely rotate thereupon. The agitator having an upper end attached to the cross support so as to freely rotate there under. The washing apparatus may also include a driving portion having a user-engagement handle, a shaft, and an agitator engagement portion. The driving portion may utilize a system of detents and grooves whereupon oscillating vertical movement of the driving portion by the user is translated to rotary movement of the agitator.
In one form, the portable washing apparatus as disclosed is arranged wherein the base member comprises a plurality of identical base portions which are removably connected to each other to form the base member.
The portable washing apparatus may also be arranged wherein the frame comprises a plurality of vertical supports. Each vertical support having a lower end removably attached to the base and an upper end removably attached to an upper ring.
The frame of the portable washing apparatus may comprise: a cross support having a surface defining a non-cylindrical hole therein; wherein the driving portion comprises a non-cylindrical shaft; and wherein the non-cylindrical hole engages the non-cylindrical shaft an prohibits rotation of the driving portion relative to the frame.
The driving portion of the portable washing apparatus as may also comprise at least one detent extending radially therefrom. Wherein the agitator comprises a surface defining a bore; and wherein the bore comprises surfaces defining at least one spiral indent which receive the detents extending radially from the driving portion such that linear oscillation of the driving portion results in rotational movement of the agitator.
The portable washing apparatus also may include at least one spiral indent which is arranged such that linear oscillation of the driving portion results in rotational oscillation of the agitator.
The portable washing apparatus in one form is configured to fit entirely or substantially within a portable fluid container (rigid or collapsible) during operation.
The portable washing apparatus may be formed wherein the base member comprises a plurality of raised portions extending longitudinally therefrom so as to maintain a significant portion of the base member above the lower inner surface of a portable fluid container during operation to function as a dirt trap.
The portable washing apparatus as disclosed may include a plurality of extensions protruding from a longitudinal central member.
The portable washing apparatus may also be arranged wherein the frame comprises a plurality of clamp arms which engage the upper surface of a rigid portable fluid container so as to maintain position of the frame relative to the rigid portable fluid container.
The portable washing apparatus as disclosed may utilize a cover substantially enclosing the apparatus with or without a separate cross member.
The portable washing apparatus as disclosed may utilize a collapsible bag, a rigid bucket, or other fluid container or reservoir. The collapsible bag may be positioned radially within a plurality of vertical supports, or may be positioned external of the vertical supports.
A portable washing apparatus for the washing of fabrics is disclosed. The washing apparatus comprising: a bottom plate configured to fit external of a watertight container; a base member configured to fit within the watertight container; a frame extending vertically from and removably attached to the bottom plate. A cross support may be included, extending horizontally across the frame and removably attached thereto. An agitator having a lower end attached to the base member so as to freely rotate thereupon is positioned within the watertight container. The agitator having an upper end attached to the cross support so as to freely rotate there under. A driving portion having a user-engagement handle, a shaft, and an agitator engagement portion is also included. The driving portion and agitator having a system of detents and grooves whereupon oscillating vertical movement of the driving portion by the user is translated to rotary movement of the agitator.
In one form, the cross member comprises a cover substantially enclosing the apparatus.
In one configuration, the bottom plate comprises a plurality of identical plate components; and the cover comprises a plurality of the identical plate components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the disclosed apparatus in one configuration.
FIG. 2 is an isometric view of the apparatus of FIG. 1 within a container.
FIG. 3 is a plan view of the apparatus of FIG. 1 in a disassembled configuration.
FIG. 4 is an end view of the configuration of FIG. 3 .
FIG. 5 is a side view of an agitator component of the apparatus of FIG. 1 .
FIG. 6 is an end view of the component of FIG. 5 .
FIG. 7 is a side cutaway view of the component of FIG. 6 taken along line 7 - 7 .
FIG. 8 is a side view of an operating handle component of the apparatus of FIG. 1 .
FIG. 9 is an isometric view of the top side of a split base component of the apparatus of FIG. 1 .
FIG. 10 is an isometric view of the bottom side of the component of FIG. 9 .
FIG. 11 is a top (plan) view of a cross member component of the disclosed apparatus.
FIG. 12 is a side hidden line view of the cross member component shown in FIG. 11 .
FIG. 13 is a bottom hidden line view of the cross member component shown in FIG. 11 .
FIG. 14 is an isometric view of the disclosed apparatus with a top cover and additional bottom plate.
FIG. 15 is a front view of the apparatus as shown in FIG. 14 .
FIG. 16 is a first vertical view of a plate component of the disclosed apparatus.
FIG. 17 is a side view of the plate component shown in FIG. 16 .
FIG. 18 is a second vertical view of the plate component shown in FIG. 16 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before beginning a detailed description, an axes system 10 is shown in FIG. 1 comprising a vertical axis 12 , and a radial axis 14 which is centered upon the center of the long axis of the agitator component 22 and is directed radially outward. This axes system is intended to aid in description of the disclosed apparatus and is not intended to be limiting.
Looking again to FIG. 1 , one configuration of a portable washing apparatus 20 is shown. The portable washing apparatus 20 generally comprises three independent but interoperating portions: a driving portion 24 , a frame portion 26 , and an agitator portion 28 . Each of these portions are assembled together for a washing device which does not require running water to operate, and also does not require a power source such as wind, hydro, electric, or other outside power sources. While the apparatus may be mechanized, it operates well with a user (human) simply filling the machine with a cleaning fluid and then manipulating the handle.
Looking to FIG. 2 , the apparatus is configured wherein a fluid holding container 102 is also provided. The container 102 in this configuration surrounds the frame portion 26 , and agitator portion 28 . In another configuration, the container 102 may be provided between the frame portion 28 and agitator portion 28 . This fluid container 102 may be a rigid element such as a bucket, barrel, or similar apparatus, or may be a flexible container such as for example a bag. Collapsible buckets may be especially useful as they are easily collapsed and thus take up less space for shipping or storage.
Returning to FIG. 1 , the frame portion generally comprises a base 30 which in one form comprises a first portion 32 and second portion 34 with a seam 36 therebetween. The configuration of these portions can be more easily seen in FIGS. 9 and 10 where it can be seen that to reduce manufacturing and replacement costs, the first portion 32 and second portion 34 may be formed as identical components. By using the illustrated semicircular portions, interconnected by way of a plurality of surfaces defining holes 38 and interoperating detents 40 a single molded component can form both of these first and second portions 32 / 34 . In addition, the bottom side 42 may comprise a plurality of raised portions 44 providing a fluid gap between the base 30 and the lower inner surface of the container 30 to increase the cleaning action of the apparatus. Additionally, a plurality of channels 46 may be formed in the upper surface 48 of the base 30 to further increase cleaning action, as well as provide additional rigidity and support to the overall apparatus. In one form, the raised portions 44 fit within channels 46 to improve stackability of the apparatus. In the drawings, the mating surface 50 between individual components is planar, although other shapes could alternatively be utilized.
A plurality of vertical supports 52 may be provided as shown in FIGS. 1, 3 , and 4 which provide vertical separation between the base 30 and an upper ring 54 . One of the vertical supports is not shown in FIG. 1 , so that the surfaces defining holes 58 and 60 can more clearly be seen. The upper ring 54 may also be comprised of separate and interconnecting components. In the drawings, the components are semicircular, but other shapes may also be used. In one configuration, the lower end 56 of the vertical supports 52 fits into one of several surfaces defining holes 58 in the base 30 . These surfaces defining holes 58 may also be seen in FIGS. 9 and 10 . In FIG. 1 , one of the vertical supports 52 is removed to show the holes 58 in the base 30 , as well as one of several holes 60 in the upper ring 54 .
In one configuration, the upper end 62 of the vertical supports 52 comprises a pin 64 to interconnect the individual components of the upper ring 54 , and maintain relative position between the upper ring 54 and the vertical supports 52 .
In one configuration, a cross support 66 is utilized as shown in FIGS. 1 and 2 comprising a surface defining a central void 68 for receiving of the driving portion 24 . In FIGS. 11-13 it can be seen how in this embodiment, the void 68 is non-circular so as to prohibit rotation of the driving portion 24 relative to the cross support 66 .
In one configuration, the cross support 66 comprises recesses 70 for maintaining proper position upon the upper ring 54 , as well as surfaces 72 for maintaining the apparatus 20 in relative position to the container 30 . In one form as shown in FIG. 2 , the cross support 66 comprises clamp arms 74 which further hold the container 30 in position relative to the cross support 66 . In this embodiment, both the cross support 66 and clamp arms 74 are also held in position by the pins 64 on to which they are pressed.
In one form, a collapsible bag 108 may be utilized which fits over the apparatus and comprises grommets 110 , holes, strings, etc. which fit over the pins 64 . The upper ring 54 is then installed over the grommets, and this assembly holds the bag in place. In another form, the bag may fit within the vertical supports 52 in the same manner.
Looking to FIG. 5 , a detail view of the agitator 22 in one configuration is shown. While this configuration comprises a plurality of four extensions 76 (three of which can be seen in this figure) and each extension 76 comprises hills 78 and valleys 80 . Each of the extensions 76 being attached to or formed as extensions of a central member 104 . The particular arrangement of these surfaces is not critical as many different configurations could be utilized for aesthetic or functional purposes. An end view of the four arm embodiment, is shown in FIG. 4 . As shown in FIG. 5 , a recess 82 is provided in the upper end of the agitator 22 which fits upon a matching surface 98 of the cross support 66 as can be seen in FIGS. 12 and 13 . Additionally, on the other vertical end, a bearing 84 is provided which fits within and revolves upon a surface 86 defining a bore or bearing surface as shown in FIGS. 9 and 10 . This bearing 84 as shown in FIG. 7 may also provide a cap to prohibit pumping action of cleaning water through the center 86 of the agitator 22 during operation. These surfaces 82 / 84 at the upper and lower vertical ends of the agitator 22 maintain the agitator 22 in relative position to the other components or portions of the apparatus 20 as it is being rotated (actuated).
Looking to FIG. 7 , a cross sectional view of this configuration of the agitator 22 is shown wherein the inner surface 86 of the agitator 22 is configured to receive detents extending from the driving portion 24 . In particular, looking to FIG. 8 it can be seen how the driving portion 24 comprises a shaft 88 which may be non-cylindrical, and a handle 90 which is configured to be grasped by the user while being moved (actuated) in an oscillating vertical motion as shown by the arrow 92 . Non-cylindrical being defined herein as a longitudinal extrusion of a geometric shape, wherein the geometric shape is not a circle. At the lower end of the driving portion 24 , a plurality of detents 94 may be provided which are configured to engage a plurality of helical “rifling” channels 96 formed within the inner surface 86 of the agitator 22 as seen in FIG. 7 . In this embodiment, the cross support 66 as already described does not permit relative rotation of the driving portion 24 , and also does not permit vertical movement of the agitator 22 . Thus, as the handle 90 is oscillated vertically, the detents 94 rotate the agitator 22 back and forth in direction of travel 100 shown in FIG. 1 as can be understood by one of ordinary skill in the art.
In an alternate configuration, the components are reversed such that the shaft 88 comprises the helical rifling portion, and the engaging surface of the agitator 22 is linear. Other mechanisms such as a system of gears may be utilized instead of the helical rifling portion.
In yet another alternate configuration, the detents may be formed in a spiral shape and engage grooves in the opposing component.
Looking to FIGS. 3 and 4 , it can be seen how the entire apparatus can be disassembled into its component parts easily, and in some configurations without tools. This makes the apparatus particularly useful where shipping and/or storage is difficult, while backpacking, and in other environments where more industrialized ways of cleaning clothing are commonplace.
FIGS. 14-15 show a configuration wherein a bottom plate and top cover 114 are provided. The bottom plate 112 is placed under the base member 30 and the top cover 114 may operate with a cross member similar to that shown in FIGS. 11-13 or may serve the same function. As shown, a bag 108 is provided and places radially inward of the supports 52 and external of the base member 30 and agitator 22 . Again, the bag 108 may have grommets 110 or similar fasteners to attach to the upper end of the frame, such as at the upper end of the supports 52 .
FIGS. 16-18 show one example of the disclosed cover 114 and bottom plate 112 which again may be formed of a single cast. For example a plurality of the plate components 126 may be provided wherein a single cast component forms both sides of each of the cover 114 and bottom plate 112 . In this example, the surface 98 ′ functions in the same way as the surface 98 previously disclosed. A plurality of holes 118 ′ are provided for attachment to either the upper or lower end of the supports 52 . A groove 120 is provided to assist in alignment of the supports 52 during assembly. Groove 120 also serves as a lip to fit over the outer edge of solid containers and to minimize splashing of water outside of the container while operating the handle. The groove may also be shaped to snap lock onto the side of a solid container such as a lid for a standard 5 gallon bucket. Each plate component 126 in this example also comprises a recess 122 and a projection 124 which engage opposing surfaces of an adjacent component 126 to form the bottom plate 112 or top cover 114 .
One added benefit of this example is the ease in which a component may e replaced. As several identical supports 52 , several identical plates 126 , and several identical base portions 32 are used in each assembly, there are fewer unique parts. A single replacement plate 126 may be used to replace one of the four plates used in this example if broken or damaged.
One form of assembling this example is to assemble the bottom plate 112 by connecting two plate components 126 with the grove side up, then attaching a number of the supports 52 to the bottom plate. The bag 108 may then be positioned within the supports 52 and attached at the top thereof. The base member 30 may then be assembled and placed into the bag 108 . The agitator 22 and driver 24 may then be attached to the base member 30 . The bag 108 may then be filled with cleaning fluid and fabric (i.e. clothes). The cover 114 may then be assembled about the shaft 88 and attached to the upper end of the supports 52 . As previously mentioned, the handle 90 may then be manipulated to rotate the agitator 22 and clean the fabric.
In one form, each of the components could be made of plastics or plastic equivalents to reduce in cost, or alternatively could be made of metals or natural materials where such materials are more plentiful and replacement parts are easier to manufacture when made of these materials. Generally, ease of manufacture by casting has been taken into account, and the majority of the parts can easily and cheaply be cast either in plastics, metals, or other such materials.
While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants' general concept. | This disclosure relates to the field of washing apparatus which are portable, and operable without a running source of water, and without a power source. The washing apparatus operates with a volume of liquid cleaner (water) and manual manipulation of a handle. The apparatus may also be dis-assembled by a user without tools for shipping or storage in a much smaller space. | 3 |
This is a divisional application of application Ser. No. 08/629,729, filed Apr. 9, 1996, now U.S. Pat. No. 5,726,934.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of integrated circuit design, specifically to analog signal recording and playback utilizing non-volatile memory integrated circuits.
2. Prior Art
For analog signal recording and playback utilizing non-volatile memory integrated circuits, as described in the patent numbered 5,220,531 by Trevor Blyth and Richard Simko, EEPROM (electrically erasable programmable read only memory) memory cells are used. These cells are comprised of a floating gate device having a source, a drain, a gate and a floating gate wherein the threshold of the device as measured between the gate and the source of the device is determined (controlled) by the charge on the floating gate. These cells are erased using Fowler-Nordheim tunneling by applying a high voltage, e.g. 21V on the gate, zero volts on the source, and zero volts on the drain. The high voltage on the gate capacitively couples to the floating gate, which creates a high electric field through the tunnel oxide between the floating gate and the drain. This electric field causes electrons to tunnel to the floating gate, which effectively raises the Vt (threshold voltage) to about 6V. Next the cell is programmed using the same Fowler-Nordheim tunneling mechanism by applying a high voltage on the drain, e.g. 9 to 19 volts, zero volts on the gate, and 6V on the source. The high voltage on the drain causes a high electric field through the tunnel oxide between the floating gate and the drain in the reverse direction. This causes electrons to tunnel from the floating gate to the drain, causing the threshold voltage to be lower (depleted), e.g. -1V to +3V, depending on the voltage level on the drain and the pulse width.
In U.S. Pat. No. 5,220,531, the program "pulse" is divided into a series of coarse pulses and a series of fine pulses to store an analog signal in the non-volatile memory cell. After each programming pulse, the content of the cell is read using a read cycle and compared with the analog signal to be stored, with the coarse pulses terminating when the desired programmed level is approached, and the fine pulses terminating when the desired programmed level is reached. The coarse write/read/compare series followed by the fine write/read/compare series provides superior analog signal resolution in the stored signal.
In the above patent, the dynamic range of the cell is about 3V, with an analog resolution of about 12 millivolts, giving an effective resolution equivalent to a digital storage of 8 bits (each cell has a resolution of 12/3000, or about 1 part in 250). Each coarse pulse or fine pulse is divided into a ramp up time portion and a flat time portion equally of the high voltage, and a sample and compare enable time portion. The compare time portion is used to read back the voltage stored in the memory cell after each incremental coarse or fine programming pulse to see if it reaches a desired value. The sample time portion is used to sample the next sample of input signal and hold it. The sample and compare time portion is the quiet time, i.e. the high voltage source such as the charge pump is disabled for noise reasons. The step voltage between successive coarse levels is approximately 220 millivolts and the step voltage between successive fine levels is approximately 22 millivolts, which is equivalent to a resolution of 12 mV in the stored voltage in the memory cell. The large step voltage for the coarse levels is required to cover the full range of the cell programming threshold window plus an additional voltage margin, which ranges from approximately 9 to 19 volts on the drain of the memory cell, corresponding to about 0-3v of the memory cell threshold voltage, approximately the analog dynamic range of the memory cell. The number of coarse pulses available is chosen to be 45, which translates into 45×220 mV=10 volts full range. The large coarse step is used to achieve the short writing time. The fine ramp full range is chosen to be about 2V. 90 fine pulses are available, giving a writing resolution of about 22 mV. Thus the number of column sample and hold/high voltage drivers is defined by the sampling rate together with the cell programming time. For example, for sampling rate of 8 Khz (typical audio signal), and a cell programming time of 12.5 ms with the above coarse and fine pulses, the number of column sample and hold/high voltage drivers are 12.5 ms/125 μs=100. This also means the cell writing is happening for 100 columns at the same time.
In the read mode, the storage cell is configured as a source follower with a constant load current from the drain to ground. The gate and the source of the memory cell are connected together, the drain of the memory cell is connected to a constant bias current, the gate of the select transistor is connected to an intermediate voltage, e.g. 10V, to eliminate the gate voltage drop effect and the resistive effect from the small size of the select gate. A regulated power supply, e.g. 4V, is connected to the gate/source of the memory cell to avoid the variation of the gate/source voltage on the cell readout voltage. The voltage at the drain is the memory cell readout voltage. Thus the cell is connected as a source follower with the drain and source interchanged. This results in a linear relationship between the threshold of the cell and the cell readout voltage. The storage cell is thus operated in the saturation region since the gate and source are effectively tied together.
In this read configuration, severe disadvantages are encountered when used in a configuration wherein there are series parasitic resistive effects on the source node or the drain node, or there are large variations in the transistor conductances such as are caused by mobility or threshold voltage variations over temperature, process variations or power supply variations. The series parasitic resistive effects, for example, come from the source diffusion resistance of the memory cells, or from other series transistors as in a string memory cell structure such as in a NAND flash memory cell. The source line is typically strapped, e.g., for every 32 cells, by metal or select transistors to reduce resistance from the source line diffusion. Even so, the resistance from the source line diffusion is still very significant, especially for multilevel storage wherein each discrete storage level is to be discernible on readout from each other discrete level. Furthermore, the more effective the strap in reducing these effects, the more strap area is used, resulting in a larger die size.
The NAND memory cell consists of a string of, for example, 8 memory cells in series, and 2 select transistors to select the memory string, one select transistor contact being shared with another memory cell string. Since in effect there is only one-half a bitline contact and one-half a common source line for the 8 memory cells, the per-cell area of the NAND configuration is much smaller. However the series parasitic resistances and transistor conductance variations of this configuration cause voltage drops along the source or drain nodes which lower the dynamic range of the memory cell. More severe in the NAND structure, if considered for analog storage, is the fact that this voltage drop causes the output voltage of one particular cell in a string to be different in the read-back mode of the read/compare/write programming sequence than in the actual read mode for output or playback purposes, since the threshold voltages of other memory cells in the same string are frequently to be further modified depending on the signal inputs. Thus, a first cell in a string can appear to be properly programmed, but one or more other cells in the string require further programming by further programming pulses, so that these cells will have a different resistance when the contents of the first cell are to be later read out during playback from the resistance that existed when the first cell was determined to be properly programmed.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to utilize the small cell size of the NAND storage cell structure in an analog storage and playback device. This is achieved, in part, by using a special, zero current source follower storage cell, in which in the read mode, the cell loading current is waveshaped to attain an optimal dynamic range and to avoid the resistive effects of series parasitic resistances of other transistors in the source node or drain node, and to avoid the transistor conductance variations of all the transistors in the read path. The loading current is waveshaped to reduce possible overshoot and settling effects to achieve the fine output voltage resolution in an optimal sensing time.
For the purpose of illustration, a typical NAND memory string consisting of 8 series connected memory cells, one bitline select NMOS and one source line select NMOS is described. In a typical device, many such strings are connected in parallel and possibly in series to create a sector. A memory array could have one P-substrate for all sectors, or several P-substrates with each P-substrate shared across a few sectors to minimize capacitive loading in erase. In particular, in erase, the same P-substrate HV is applied to all the unselected rows to inhibit erasing. Fowler-Nordheim tunneling is used for both erase and programming. The erase is done by applying a high voltage HV, e.g. 20V, on the P-substrate and a low voltage, e.g. 0V, on the gates of the 8 memory cells for typically 1 ms. The electric fields across the tunnel oxides between the substrate and the floating gates are high enough to cause electrons to tunnel from the floating gates to the substrate. The net result is the reduction of the cell threshold voltage from a high value, for example, 2V, to a low value, for example -1.0V. The erase is normally done for one sector or many sectors, depending on the array architecture. The erase is selectively inhibited by not applying a high voltage to the substrates of the other sectors, or by applying the same high voltage at the same time to the gates of the inhibited memory cells in the same sector.
The programming is done in an iterative and incremental manner by grounding the substrate and the bitline and applying a series of incremental high voltage (HV) pulses, e.g., from 10V to 18V on the gate of the selected cell. The high voltage pulses will capacitively couple the floating gates to a high voltage. The resulting high electric field between the floating gates and the substrate will cause Fowler-Nordheim electron tunneling from the channel on the substrate to the floating gates. A column is unselected by causing the channels of the unselected string to be coupled to a high voltage, thus reducing the field across the unselected cells. An intermediate level, for example 9V, is applied to the gates of the unselected cells to inhibit programming when a high level is on the channel of the unselected cells. The net result is the incremental increase in the selected cell threshold voltage. A verify read cycle is done after each incremental HV programming pulse. When the desired output voltage is reached, the bitline is switched to an inhibit voltage, for example, 9V, to stop programming. The desired threshold resolution is typically traded off for programming time. For example, given a programming pulse width and an operating threshold window, more pulses are needed to cover the threshold programming window if the incremental programming level is smaller.
In the read-back mode, the storage cell is connected in a source follower mode with a waveshaped current load. The source line is biased at VREF1, a current Iload is connected to the bitline, the gate of the selected cell is biased at VREF2, the gates of the other unselected cells are biased at VREF3, and the gates of the bitline and source line select transistors are biased at VREF4. (VREF1 and VREF2 may in general be different voltages, though could be made equal to each other depending on the threshold of programmed cells.) The conditions for the voltage levels are such that the selected cell is operating in the saturation mode and the unselected cells and the select transistors are operating in the linear mode. Since the final value of the load current is practically zero amps, the voltage drop across the parasitic resistors is substantially equal to zero volts. Also since the final value of the load current is practically zero and the select transistors and the unselected memory cells are operating in the linear region, the voltage drop across them is also substantially equal to zero volts. And since the selected memory cell is operating in the saturation region with the load current substantially equal to zero amps, the source voltage, i.e. the memory cell output voltage of the selected cell, is equal to its gate voltage minus the threshold voltage. Hence a linear relationship is obtained between the threshold voltage and the cell output voltage. Since the cell threshold voltage is incrementally controlled by the incremental programming, the cell output voltage is also controlled incrementally to reach a desired programmed voltage. Thus no voltage variation on the drain or source is possible due to different threshold voltages of the unselected memory cells, different values of the parasitic resistance, or due to transistor conductance variation of all the transistors in the storage cell string. Note also that in NAND structures with multiple memory cells in series, the gate voltages of the unselected memory cells cannot be taken arbitrarily high to reduce the resistive effect due to disturb effects (undesired threshold shifts in the nonselected cells), but a similar result is achieved by the substantially zero load current of the present invention during a read.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating a NAND storage cell structure in the read mode.
FIG. 2 is a diagram illustrating an array of NAND storage cell structures.
FIG. 3 is an illustration of the load current and associated signal waveforms during the read of the NAND storage cells of the present invention.
FIG. 4 illustrates the connection of data converters to an analog memory in accordance with the present invention to provide the storage and playback of a multi-bit digital value as a single analog voltage.
DETAILED DESCRIPTION OF THE INVENTION
The storage cell structure used in the present invention is a typical NAND flash memory string similar to that described for digital memory storage by K. Suh et al., in ISSCC Digest of Technical Papers, pp. 128-129, Feb., 1995 and by K. Imamiya et al., in the ISSCC Digest of Technical Papers, pp. 130-131, Feb., 1995. As shown in FIG. 1, the memory string of the preferred embodiment consists of 8 memory cells ME0 through ME7 in series and two select transistors, one select transistor MD to select the bitline and one select transistor MS to select the source line. Typically many such strings are connected in parallel to create a sector, and many such sectors are connected to create a full memory array, as shown in FIG. 2.
The primary purpose of using such a string structure is to reduce the number of contacts per memory cell. Here only one-half a contact is needed for 8 memory cells instead of one-half a contact for one memory cell as in a NOR structure, which has only one memory cell and no select transistors. Only one-half a contact is needed since two strings share the same contact. The vertical dimension along the bitline is now mainly limited by stacked poly pitch instead of contact size, contact to stacked poly gate, stacked poly pitch, and source width as in a NOR structure. The horizontal dimension along the wordline is limited as in a NOR structure, mainly by contact size, metal to metal and diffusion to diffusion spacing. The overall effect is a dramatic reduction in the chip area per memory cell. The tradeoff is slower access time due to memory cells in series and the complexity of the programming algorithm to avoid various disturb modes. Typically extensive cell characterization is needed to optimize various conditions. The slower access time is circumvented by doing a page read, i.e. reading multiple cells at the same time, hence the structure is normally well suited for serial read applications such as mass storage, but not well suited for random access read applications.
Here method and apparatus for using the NAND storage cell for analog memory storage in a source follower configuration with a zero current load is described.
Floating gate devices ME0 through ME7 are the memory cells, device MD is the select transistor for the bitline and device MS is the select transistor for the source line. RD is the parasitic resistance due to the source line diffusion, and RS is lumped parasitic resistance due to the interconnections. Devices M0 through M7 are the typical column select based on the column decoding. Device MH is the typical sample and hold switch. (Known techniques for charge canceling and feedthrough reduction could be employed.) Capacitor CH is the hold capacitor for the sample and hold, and I1 is a typical MOS analog differential op amp buffer. The buffer is part of the column driver circuit which provides the enabling and inhibiting voltages into the column in programming and also serves to read the voltage out of the memory cell. The bias current and the reference voltages are supplied from a reference circuit such as a standard CMOS bandgap reference.
In FIG. 1, device ME5 is shown to be selected for read. Also shown are exemplary waveforms for the load current and relevant voltages. The read cycle begins with the load current Iload ramping up rapidly to Imax at t0 (see FIG. 3) to stabilize the output node voltage VOUT at a voltage close to the final voltage. Then Iload ramps down from Imax at t1 to Imin at t2 to minimize possible overshoot and settling. After some time t2, the output node VOUT is well stabilized, and the hold switch MH is opened to hold the output voltage on the hold capacitor CH, completing the read cycle.
Also shown is a signal called QUIET, which effectively shuts down all possible circuits on the integrated circuit except the Iload and its associated circuits during the critical read period. Shutting down other circuits minimizes any possible noise coupling from the other active circuits on the chip to provide a more accurate read.
The timing should be optimized for a particular array architecture and circuit configuration. For example, t1, t2 and t3 relative to t0 could be nanoseconds to hundreds of nanoseconds to a few microseconds, depending on factors such as the bitline capacitance and desired output voltage resolution. Longer times result in finer output voltage resolution. The time duration t2 -t1 is limited on the minimum side by the possibility of overshoot, and if overshoot is not encountered, the change from Iload=Imax to Iload=Imin may be a rapid step.
Shown in FIG. 3 is the output voltage VOUT, which is not to actual scale. During the duration of Imax (from time t0 to time t1) the output voltage VOUT will rather quickly rise toward a stable level with a reasonably low RC time constant because of the various devices being turned on relatively firmly to conduct the current Imax. However the output voltage VOUT will be somewhat low and not an accurate measure of the threshold of the selected cell because of the inconsistent and unknown voltage drop through the other cells connected in series. Between time t1 and t2, the current is reduced to Imin in a manner to avoid overshoot, during which time VOUT increases because of the reduced voltage drop in the series devices. After time t2, the voltage VOUT will rise somewhat further toward a new, somewhat higher stable level, this time with a considerably higher RC time constant because of the device being read being biased at its threshold and not being turned on very firmly.
The conditions for voltage levels are such that the dynamic range is optimized while disturb is minimized. VREF1, VREF2 determine the output dynamic range directly. To ensure the selected cell is in saturation for linearity reasons, VREF2≦VREF1+Vtmin, where Vtmin is the minimum threshold voltage of the memory cell. VREF3 should be ≧VREF1+Vtmax, where Vtmax is the maximum threshold voltage of the memory cell. VREF4≧VREF1 +VtMD. The conditions for VREF3 and VREF4 are needed to ensure minimum voltage drop from the gate voltages along the series transistor chain. Normally some overdrive (voltages over the minimum specified) is needed to enhance the reading speed. In addition, VREF3≦VDISTURB for the unselected cells, as VDISTURB will cause undesired threshold shifts for the erased unselected cells. VDISTURB is normally determined by characterization of single cell performance over the expected disturb time period.
For purposes of explanation, disturb effects are defined as the undesired condition under which the cell threshold shifts a certain amount. For digital non-volatile memory, 100-500 mV is typically used. For analog storage, a typical number on the order of 8 mV is used. The undesired condition happens during read, program, or erase of a selected cell or cells. It could happen for unselected cells or selected cells. For example, to read one cell, the cell is also disturbed at the same time. Obviously, different disturb effects exists for different technologies (EEPROM, NAND, DINOR, AND, NOR , etc. . . ), different array and circuit implementations, and different applications.
The disturb time period is dependent on the array architecture, circuit implementation, and the product application. For example, Information Storage Devices, Inc. (ISD) guarantees 10 years of storage retention. This means the fixed disturb time is 10 years if reading continuously on one cell. Normally no one reads one cell continuously for 10 years. However, 10 years is still used as the worst case for read disturb for the unselected cells.
As an exemplary set of values, let VREF1=3V, VREF2=2.5V, VREF3=5.5V, VREF4=5.5V, for Vtmin=-0.5V, and Vtmax=2.0V, wherein the Vt (threshold) numbers include the body effect of the memory cell. A dynamic range of 2.5V, from 0.5V to 3.0V, will be expected, wherein 0.5=VREF2-Vtmax=2.5-2.0, and 3.0V=VREF2-Vtmin=2.5-(-0.5). Imax could be several microamps, and Imin could be tens to hundreds of nanoamps, or possibly zero nanoamps. Some nonzero current in the nanoamp range is preferred however, to sink, for example, some possible field leakage or some weak noise coupling. A nonzero Imin also helps to stabilize the final output voltage without causing any significant voltage drop since the current magnitude is minuscule, 3 orders of magnitude smaller than Imax, i.e., nanoamps compared to microamps.
As the current Iload is reduced, the gate bias voltage for each of the current load devices across the memory array also reduces. Due to non-uniformity, the precise small current values and current-time profiles are different across the array. However each current load will ultimately reduce to substantially zero, the precise time at which the substantially zero current is reached not being important because the sensing of VOUT is done after that.
The present invention is compatible with various of the other aspects of the existing ISD analog storage devices. For instance, the variation of the memory cell output voltage over temperature could be minimized by utilizing a reference scheme as described by Richard T. Simko in the U.S. Pat. No. 5,126,967.
Table 1 shows various operating conditions for erase, programming, and read modes. In programming, the source line select transistor MS is needed to isolate the inhibit bitline voltage, =˜9V, on the adjacent unselected bitlines of the same sector from the source line voltage, which would be zero volts if there is no transistor MS, since all the rows on the erased sector are on, equal to 9V or 10-18V, and the selected bitline is at 0V. In programming, the bitline select transistor MD is also needed to isolate the inhibit bitline voltage, =˜9V, on the adjacent unselected bitlines of the same sector from the drains of the first memory cells of other sectors sharing the same unselected bitlines. This would cause unwanted erasing of those memory cells. Select transistor MS also allows all the source lines to be strapped together by metal lines since the source line of any sector is now individually selected by the transistor MS.
TABLE 1______________________________________CONDITIONS FOR ERASING CELLS 0 THROUGH 7AND FOR PROGRAMMING AND READING CELL 5 OFAN EIGHT NAND CELL STRING PROGRAM ERASE PROGRAMMING INHIBIT READ______________________________________SL FL 0 0 VREF1BL FL 0 9 IloadROW 5 0 10-18 10-18 VREF2ROW 0-4,6-7 0 9 9 VREF3SSL FL 0 0 VREF4BSL FL 9 9 VREF4other BLs FL VINHIBIT VINHIBIT FL e.g. 9V. e.g. 9V.P-substrate 20 0 0 0______________________________________
Where:
FL=electrically floating
Iload=waveshaped load current (read bias current applied through column multiplexer).
In the present invention, the NAND memory cell configuration is used in an analog storage device in spite of the unpredictable resistances to be encountered in the NAND connected cells during playback. This is achieved by reading a cell by a two step, or multi-step read wherein a high read current is first used to obtain a quickly settling, though inaccurate readout voltage, followed by a very low, substantially zero readout current to allow the readout voltage to resettle at a more accurate readout voltage because of the now negligible voltage drops across the other resistances in the NAND connection because of the very low current.
As an alternative, a similar effect can be obtained by discharging the hold capacitor CH before each read by momentarily shorting the capacitor to ground through an n-channel device. Then when a read operation is initiated, the read current will be initially relatively high because of the output driving the load capacitor starting from ground level. Now as the output voltage approaches the threshold of the cell being read, the current will automatically decrease toward a substantially zero value. After a few time constants the current will decrease to substantially zero and the output voltage will be an accurate read of the cell being read. The cell should be read in any event while the current is still on the order of or above the expected field leakage and noise so that the output does not drift above a true cell output reading. In that regard, the ultimate near zero read current is preferably at least one order of magnitude below the initial read current, more preferably at least two, and can be on the order of three orders of magnitude below the initial read current. Further, depending on the characteristics and direction of the field leakage and noise coupling, Imin as defined in FIG. 1 may be made to be equal to zero and still obtain a stable cell read voltage accurately reflecting the cell programming unaffected by the other resistances in the NAND cell connection.
It should be noted that analog storage devices used to store and playback audio signals of the type manufactured by Information Storage Devices are a form of sequential access device, limited random access type capabilities only being used to point to the start of a free recording region or the start of a recorded message, not to individual cells. Consequently one can define the order in which cells are accessed for recording, and of course playback will need to be in the same sequence. Referring to FIG. 1, this allows designing for the programming of cell ME0 of a NAND string of cells first, then cell ME1, then cell ME2, etc. This way, one is assured that the programming of cells physically between the cell being presently programmed and the source follower read circuitry will not change between the time the cell being presently programmed is determined to be properly programmed and programming of the cell stops, and the time the same is read out during playback. Thus, in the NAND structure, the cell readout value is not affected by cells programmed in subsequent programming cycles. When the foregoing programming sequence is followed, the zero current read of the present invention further improves the accuracy of recording and readback in such devices.
The present invention has been described with respect to its use and advantages in conjunction with analog storage in floating gate NAND structure storage cells. The very low or zero current during read of the present invention is also advantageous in enhancing read accuracy during playback or output of storage cells realized in other configurations and other technologies such as NOR and DINOR configurations, two transistor and one transistor cells and EPROM cells. Enhanced read-back accuracy is important not only in the storage and playback of analog signals, such as analog samples of an audio or other time varying analog signal on a one sample per cell basis, but also in the storage of digital signals, particularly in the storage and playback of digital signals stored as multi levels in each storage cell so as to store the equivalent of two or more bits of information in each cell. This may be achieved by the addition of an A/D converter at the input to the storage device and a D/A converter at the output of the device, as shown in FIG. 4. The magnitude of the number, or the number of bits in the digital word, is given by the voltage range of the stored analog level, divided by the guaranteed accuracy of storage. The accuracy of storage considers not only the increment during the programming sequence, but also factors such as noise, worst case programming increment, long term voltage retention characteristics of the cell and the effects of ambient temperature and operating voltage. An analog memory of the type described in the present invention should able to resolve a voltage to about 10 millivolts over a range of 2.5 Volts. While this allows about 250 distinct levels and a representation of up to 8 bits of binary information, after consideration of the above factors, the number of bits may be reduced to, say, 4 bits (16 levels spaced approximately 150 millivolts apart). Nevertheless, 4 bits to a single cell provides a significant improvement in the information storage density that can be achieved in a memory array, compared to the conventional digital storage which provides for only 1 bit per cell. In such a system, each N bit input signal, shown in FIG. 4 as a parallel signal though a serial signal could also be used, is converted to one of 2 N discrete voltage levels and stored as the respective level in a respective storage cell as described. Then on readout, the one of 2 N discrete voltage levels is reconverted to an N bit output signal, again shown in FIG. 4 as a parallel signal though a serial signal could also be used.
Thus while the present invention has been disclosed and described with respect to a certain preferred embodiment thereof, it will be understood to those skilled in the art that the present invention may be varied without departing from the spirit and scope thereof. | This invention utilizes the small cell size of the NAND storage cell structure in an analog storage and playback device. This is achieved, in part, by using a special, zero current storage cell, in which in the read mode, the cell loading current is waveshaped to attain an optimal dynamic range and to avoid the resistive effects of series parasitic resistances of other transistors in the source node or drain node, and to avoid the transistor conductance variations of all the transistors in the read path. The loading current is waveshaped to reduce possible overshoot and settling effects to achieve the fine output voltage resolution in an optimal sensing time. Details of the method and alternate embodiments are disclosed. | 6 |
This is a continuation of copending application Ser. No. 07/467,868 filed on Jan. 22, 1990, allowed.
BACKGROUND OF THE INVENTION
This invention relates generally to a method for preparing noncarbon Group IV main group element compounds that contain two reactive sites. More specifically, the method involves cleavage of a cyclic noncarbon Group IV main group element-nitrogen bond with a reactive halide moiety to yield reactive halo and amide functional groups in the same molecule
The pursuit of a synthetic pathway for incorporating free radical curable functionality onto the siloxane backbone has been long and difficult. For example, it is noted that organosilicon compounds that contain silicon-bonded acylamino-substituted hydrocarbon radicals are known and have been described in publications such as U.S. Pat. No. 4,608,270 to I5 Varaprath, which is herein incorporated by reference. As noted in Varaprath U.S. Pat. No. 4,608,270 and as taught in U.S. Pat. No. 2,929,829 to Morehouse, Japan 51/108022 to Furuya et al., Japan 56/74113 to Takamizawa, and West German DE 2365272 to Koetzsch et al., acylaminoorganopolysiloxanes can be synthesized by reacting aminosiloxanes with the corresponding acid chloride in the presence of a tertiary amine such as triethylamine. Such a synthesis has several disadvantages. First, the removal of the voluminous precipitate of triethylamine hydrochloride by filtration is tedious. Second, even when an excess of amine is used, a small amount of HCl is liberated that is detrimental to the stability of the polymer, especially when the acid chloride has other reactive vinyl functionality such as where the acid chloride is methacrylyl chloride.
An alternative method for the preparation for the acylaminoorganopolysiloxanes involves the reaction of aminosiloxanes and silanes with an acid anhydride or ester at elevated temperature. This is taught in U.S. Pat. No. 4,507,455 to Tangney and Ziemelis, assigned to the assignee of the present invention. Unfortunately at the elevated temperatures of the reaction, acrylamide derivatives undergo Michael addition and amidation of the acrylic double bond, resulting in unwanted byproducts and crosslinkage of the desired product which ultimately causes the polymer to gel.
As taught in the above-mentioned U.S. Pat. No. 4,608,270 to Varaprath, these problems can be overcome by reacting the aminosilanes and siloxanes with acid chlorides in the presence of aqueous sodium hydroxide. The HCl that is produced on addition of acyl chloride is neutralized by hydroxide in the aqueous phase. However, a problem arises from the fact that this reaction is carried out in a two-phase system in which the aminosiloxane is dissolved in an organic solvent that is immiscible with water. Because the amide function is generally highly polar and hydrophilic, it has a tendency to absorb moisture. Incorporation of these units into the siloxane backbone increases water miscibility causing the polymers to emulsify easily thus making phase separation difficult.
To some extent, this problem can be overcome by using chlorinated solvents such as methylene chloride or chloroform but, unfortunately, such solvents are toxic. Moreover, when larger amounts of amide functionality or a more resinous structure or both are used, it is almost impossible to prepare such compounds using a two-phase system even when chlorinated solvents are used.
Accordingly, a need remains for an improved method for preparing organosilicon amide compounds that avoids the phase separation and solvent toxicity problems previously encountered.
A need remains for an expanded method that permits use of silane starting materials having hydrolytically unstable groups such as Si--O--CH 3 . A need remains for an improved method of preparing organosilicon amide compounds that minimizes the production of by-products that must be phase separated, filtered, and/or washed from the product. A need exists to avoid amine and acrylylamide functionality in the starting materials for preparing siloxane polymers and in the starting siloxane polymer itself. Instead the monomeric acrylylamide functionality should be coupled to the silicon polymer as a concluding step. All of these problems and attendant needs strongly suggest that there is still a need for an easy synthetic pathway to incorporate free radical curable functionalities onto the silioxane backbone.
A method for making nitrogen derivatives of a variety of elements is known:
Y.sub.3 MNRR'+R"X→Y.sub.3 MX+R"NRR'
where Y is alkyl, aryl, or a halide; M is silicon, germanium, or tin; NRR' is --NRR' (where R and R' are organic radicals), --NCO, NHSi, imidazole, --N═S═N--, --N═CPh 2 , --N 3 , --NSO, --N═PR 3 , --NSO 2 R, --NPhCSMe, or --NRBEt 3 ; and R"X is acyl halide, alkyl halide, phosgene, PhSO 2 Cl, SO 2 Cl 2 , SOCl 2 , S 2 ,Cl 2 , ClSO 2 NCO, RN═SF 2 , RN=SCl 2 , R 2 NSCl, ClSO 2 NCO, PCl 3 , OPCl 3 , PhPOCl 2 , (Cl 3 P═N) 2 SO 2 , BCl 3 , PhBCl 2 , R 2 BCl, AlCl 3 , FeCl 3 , BeCl 2 , SbCl 5 , PhN═CCl 2 ,NOCl, PR 2 F 3 , R 2 AsCl, Me 2 NSOCl, S 3 N 2 Cl 2 , CF 3 SF 3 , (ClSO 2 ) 2 NH, Mn(CO) 5 Br, Mo(C 5 H 5 )(CO) 3 Cl, W(C 5 H 5 )(CO) 3 Cl, or Ph 2 PCl. This general reaction has been used by German inorganic chemists such as H. Roesky and B. Kuhtz, Chem. Ber. (107) 1 (1974), R. Mews and O. Glemser, Inorg. Chem. (11) 2521 (1972), I. Ruppert, V. Bastian, and R. Appel, Chem. Ber. (108) 2329 (1975), U. Wannagat, Angew. Chem. (77) 626 (1965) and British inorganic chemists such as E. W. Abel and I.D. Towle J. Organomet. Chem. (122)253 (1976) and D. Armitage and A. Sinden J. Inorg. Nucl. Chem. (36) 993 (1974) to make nitrogen derivatives of the elements Be, B, Al, C, Si, Ge, Sn, Ti, P, As, Sb, Nb, Ta, S, Mo, W, Mn, Fe, Rh from complex element halides and usually the trimethylsilyl derivative of the nitrogen compound. The driving force of the reaction is the easy removal of byproduct halosilane, the preferential pairing of the electropositive Si with electronegative halide, and the delocalization of the nitrogen lone pair in most reaction products.
This reaction proceeds rapidly in high yields at low temperatures. For example, ##STR1## K. Farmery, M. Kilner and C. Midcalf, J. Chem. Soc. (A) 2279 (1970);
Si(NMe.sub.2).sub.4+ 4PhCOCl---reflux, no solvent→4PhCONMe.sub.2 +SiCl.sub.4,
H. H. Anderson, J. Amer. Chem Soc. (74) 1421 (1962);
Me.sub.2 NSiMe.sub.3 +NOCl (excess)---25° C., exothermic, no solvent, 73% yield→Me,NNO+Me.sub.3 SiCl
J. E. Byrne and C. R. Russ, J. Organometal. Chem. (22) 357 (1970); and ##STR2## J. R. Bowser, P. J. Williams, and K. Kurz, J. Org. Chem. (48) 4111 (1983).
However, the general reaction does not produce interesting organosilicon compounds and thus has been of little interest to the organosilicon chemist. There have been no reports of this type of reaction being run with acrylyl chloride or methacrylyl chloride nor has there ever been mention of using a heterocyclic form of the noncarbon Group IV main group element-nitrogen linkage as part of this reaction. Certainly it has never been suggested that this type of reaction could serve as a synthetic pathway to incorporate free radical curable functionalities onto a silioxane backbone.
BRIEF SUMMARY OF THE INVENTION
The need to find a clean and simple synthetic pathway to incorporate free radical curable functionalities onto the silioxane backbone has been met by the present invention which is directed to a very general synthetic pathway to a general class of difunctional halo amide element (M) bonded nitrogen monomers and polymers of formula X--MY 2 --R--NR'--R" where X is a halogen; M is a noncarbon Group IV main group element, R is a divalent radical, R' is a monovalent radical and R" is a group bonded to nitrogen and containing any one of at least eighteen different elements in the periodic table. The method combines the inorganic methods used to prepare various nitrogen derivatives with a cyclic noncarbon Group IV main group element-nitrogen heterocycle to yield an interesting variety of noncarbon Group IV main group compounds. The method also solves the solvent toxicity, phase separation, stability, byproduct and polymerization problems previously faced in the preparation of organosilicon derivatives.
This general class of difunctional halo amide compounds is prepared by cleaving the nitrogen-noncarbon Group IV main group element bond heterocyclic ring with a reactive halide moiety according to the following general scheme: ##STR3##
The cyclic nitrogen-noncarbon Group IV main group element compound can have any structure so long as it contains at least one cyclic noncarbon Group IV main group atom bonded to a cyclic nitrogen atom. The terminal or acyclic bonds of the cyclic noncarbon Group IV main atom are satisfied by organic radicals or by divalent, noncarbon Group IV main group-linking oxygen or nitrogen atoms. The terminal or acyclic bond of the cyclic nitrogen is satisfied by an organic radical, an inorganic radical or a hydrogen atom. The R"X compound is any compound with a halide moiety that will cleave the cyclic noncarbon Group IV main group element-nitrogen bond.
The noncarbon Group IV main group element may be silicon, germanium or tin and preferably is silicon. The noncarbon Group IV main group element-nitrogen heterocycle may be of any size and contain carbon and other noncarbon elements. Preferably the heterocyclic ring contains four to six atoms. Preferably the noncarbon Group IV main group element and nitrogen are linked by a divalent hydrocarbon radical such as an isobutylene radical The terminal valences of the noncarbon Group IV main group element are satisfied by organic radicals, alkoxy radicals, nitrogen radicals, hydrogen atoms, halogen atoms or divalent noncarbon Group IV main group element linking oxygen or nitrogen atoms. The terminal valence of the cyclic nitrogen is satisfied by such groups as an alkyl radical, an aryl radical, an inorganic radical or a hydrogen atom.
The reactive halide moiety is used to open the cyclic noncarbon Group IV main group element-nitrogen ring by cleaving the noncarbon Group IV main group element-nitrogen bond in a by-product free reaction that yields an N-aminoalkyl noncarbon Group IV main group moiety while simultaneously adding a reactive halogen on the noncarbon Group IV main group element in one step and in high yield Preferably the halide moiety is provided by a covalently bonded halide compound that yields a hydrogen halide on hydrolysis. Typically such compounds are the halides of Group II through Group VI main group elements and transition metal elements such as acyl halide, alkyl halide, phosgene, PhSO 2 Cl, SO 2 Cl 2 , SOCl 2 , S 2 Cl 2 , ClSO 2 NCO, RN═SF 2 , RN═SCl 2 , R 2 NSCl, ClSO 2 NCO, PCl 3 , OPCl 3 , PhPOCl 2 , (Cl 3 P═N) 2 SO 2 , BCl 3 , PhBCl 2 , R 2 BCl, AlCl 3 , FeCl 3 , BeCl 2 , SbCl 5 , PhN═CCl 2 , NOCl, PR 2 F 3 , R 2 AsCl, Me 2 NSOCl, S 3 N 2 Cl 2 , CF 3 SF 3 , (ClSO 2 ) 2 NH, Mn(CO) 5 Br, Mo(C 5 H 5 )(CO) 3 Cl, W(C 5 H 5 )(CO) 3 Cl, or Ph 2 PCl. Preferably the halide compound is an acyl halide such as acrylyl chloride.
A cyclic nitrogen-silicon compound is given by formula I ##STR4## where Y denotes a divalent, silicon-linking oxygen or nitrogen atom, an organic radical, an alkoxy radical, a hydrogen atom or a halogen atom; R typically denotes a divalent hydrocarbon radical; and R' denotes a hydrocarbon radical or hydrogen atom. Preferably the cyclic ring contains four to six atoms. The formula R"X denotes a reactive halide compound where R" typically denotes a monovalent organic radical bonded to a carbonyl radical, i.e., an acyl radical, and X denotes a halide.
Advantageously the reactions and workup of the reaction of cyclic silicon-nitrogen compounds with acyl halides are straight forward with no intermediates or byproducts that require separation, filtering, washing, or other special treatment. Usually the reactions are carried out at room temperature. However, when the acyl halide is an acrylyl halide, the reaction is carried out preferably at about -10 to 10° C. to minimize byproduct formation.
Typically the cyclic compound and an acyl halide are reacted in equimolar amounts by adding the halide to the cyclic compound Any nonreactive solvent may be used. Preferably a nonaqueous solvent is used. Since solvent requirements are minimal, chlorinated solvents can be avoided thereby reducing toxicity problems The reaction is typically carried out with agitation in a dry atmosphere.
The halo functionality of the reaction product may be reacted with various reactants to produce useful derivatives. For example, the reaction of the halo noncarbon Group IV main group element group with an amide salt produces a difunctional diamide silicon compound. The reaction of the halo noncarbon Group IV main group element group with an acid salt yields an acid derivative. The reaction of the halo noncarbon Group IV main group element group with an amine gives an amino derivative. And the reaction of the halo noncarbon Group IV main group element group with a base yields a disiloxane.
The halocsilicon group and certain of its derivative functionalities are capable of capping any SiOH group When the other functionality of the difunctional compound is an acrylamide, the capped entity may be crosslinked by free-radicals through the acrylamide functionality thereby producing useful products such as paper release coatings and photoresists.
Accordingly, it is an object of the present invention to provide an improved method for preparing organosilicon compounds that contain, in addition to the silicon-bonded acylamino-substituted hydrocarbon radicals of the type described in the Varaprath Pat No. 4,608,270, a second reactive halosilicon functionality. These and other objects of and advantages of the invention will become apparent from the following description and the appended claims
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The reactant heterocyclic noncarbon Group IV main group element (M)-nitrogen compound has the general formula: ##STR5## where M is a noncarbon Group IV main group element such as silicon germanium or tin. Preferably M is silicon The terminal "Y" radicals on the noncarbon Group IV main group element (M) include organic radicals and divalent, silicon-linking, oxygen and nitrogen atoms Examples of organic radicals include, but are not limited to, (1) divalent radicals such as alkylene radicals such as --CH 2 CH 2 --, ##STR6## --CH 2 CH 2 CH 2 --, --CH 2 CH(CH 3 )CH 2 --, and --(CH 2 ) 6 -- and arylene radicals such as --C 6 H 4 --, --CH 2 C 6 H 4 --, and --CH 2 ,C 6 H 4 CH 2 -- and halogenated derivatives thereof; and (2) monovalent radicals such as an alkyl radical such as methyl (Me), ethyl (Et), propyl, butyl (Bu), hexyl, and octyl; cycloaliphatic radicals such as cyclohexyl; aryl radicals such as phenyl (Ph), benzyl, styryl (cinnamenyl, i.e., PhCH═CH--), tolyl, and xenyl; and alkenyl radicals such as vinyl and allyl and halogenated derivatives thereof, alkoxy radicals such as methoxy and ethoxy radicals, aryloxy radicals, nitrogen radicals and hydrogen and halogen atoms.
When M is silicon and the terminal bonds of the cyclic silicon are satisfied by divalent organic radicals or by divalent, silicon-linking oxygen atoms, the heterocyclic silicon-nitrogen compound can be a silane, a siloxane, a silcarbane, or a silcarbanesiloxane. Preferably monovalent organic radicals containing no more than 6 carbon atoms, such as methyl, 3,3,3 trifluoropropyl, phenyl and vinyl radicals and, most preferably, methyl radicals are used.
The heterocycle that is to be reacted with the acyl halide can have any structure as long as it contains at least one cleavable cyclic noncarbon Group IV main group element-nitrogen bond. The divalent R radical which completes the noncarbon Group IV main group element-nitrogen heterocycle includes, but is not limited to alkylene radicals such as --CH 2 CH 2 --, ##STR7## --CH 2 CH 2 CH 2 --, --CH 2 CH(CH 3 )CH'--, and --(CH 2 ) 6 --; oxy radicals such as --OCH(CH) 3 CH 2 --; and arylene radicals such as C 6 H 4 , --CH 2 C 6 H 4 --, and --CH 2 C 6 H 4 CH 2 --. Preferably the cyclic heterocycle is a 4, 5, or 6 membered ring.
The terminal R' group on the cyclic nitrogen atom includes hydrocarbon radicals such as, but not limited to, alkyl radicals such as methyl, ethyl, propyl, butyl, hexyl, and octyl; cycloaliphatic radicals such as cyclohexyl; aryl radicals such as phenyl, benzyl, styryl (cinnamenyl), tolyl, and xenyl; and alkenyl radicals such as vinyl and allyl. The terminal R' group may also be an inorganic radical such as --SiMe 2 CH 2 CHMeCH 2 Cl and a hydrogen atom.
Cyclic aminosilicon compounds and their preparation are well known in the organosilicon art. J. L. Speier, C. A. Roth and J. W. Ryan, "Synthesis of (3-Aminoalkyl) silicon Compounds" J. Org. Chem. 36, 3120 (1970). Some are commercially available. Such compounds include, but are not limited to, the following representative compounds: ##STR8##
The reactive halide R"X can have any structure that provides a reactive halide that will cleave the cyclic nitrogen-silicon bond. Typically such compounds are the halides of Group II through Group VI main group elements and the transition metal elements. Suitable reactive halides are typically any primarily covalent linked halides that are hydrolyzable on exposure to water at room temperature, preferably over a period of less than about 24 hours to give hydrogen halide as a product. For example, the reactive halide can be, but is not limited to, phosphorus trihalide, alkyl or aryl sulfonyl halide, aluminum chloride, antimony pentachloride, ethylchloroformate, manganese chloropentacarbonyl, or an acyl halide. An acyl halide R"X can have any structure such as a linear, branched, or cyclic structure having aromatic, heterocyclic, olefinic or paraffinic bonding and containing one or more carbon-bonded --COX radicals, where X denotes a halogen atom. Examples of acyl halide R"X containing more than one carbon bonded --COX include succinyl chloride and suberoyl chloride. Preferably the acyl halide has the structure R"X where X denotes a halogen atom, preferably chlorine, and the acyl R" group includes but, as noted above, is not limited to a substituted or unsubstituted monovalent hydrocarbon radical bonded to a carbonyl group.
Examples of unsubstituted acyl R" group hydrocarbon radicals include, but are not limited to, monovalent radicals such as alkyl radicals such as methyl, ethyl, propyl, butyl, hexyl, and octyl; cycloaliphatic radicals such as cyclohexyl; aryl radicals such as phenyl, benzyl, styryl (cinnamenyl), tolyl, and xenyl; and alkenyl radicals such as vinyl, isopropenyl and allyl. Examples of substituted acyl R" group hydrocarbon radicals include, but are not limited to, halogenated R radicals such as --CF 3 and --C 6 H 4 Cl, and other substituted radicals which are stable under the reaction conditions employed in the method of this invention such as --CH 2 CH 2 CN, --C 6 H 4 NO 2 and --C(CN)═CH 2 . Examples of corresponding acyl halide R"X include acetyl chloride, benzoyl chloride and, most preferably, acrylyl chloride, methacrylyl chloride and cinnamoyl chloride. Other compounds of general formula R"X which provide a reactive halide are compounds otherwise corresponding thereto and having the same general properties thereof wherein the acyl group R" is replaced by other common moieties containing Group II through Group VI main group elements such as beryllium, boron, aluminum, carbon, silicon, germanium, tin, phosphorus, arsenic, antimony, niobium or sulfur of a transition metal such as tungsten, iron, rhodium, manganese, molybdenum, tantalum or titanium, e.g., where PCl 3 , AlCl 3 , FeCl 3 or NOCl is used instead of an acyl halide.
The solvent can be any suitable liquid that will not react with the components of the reaction Dry, nonaqueous solvents are used since the reactants are typically moisture sensitive. Preferably the solvent is also a solvent for the organosilicon product of the reaction Examples of suitable solvents include, but are not limited to, hydrocarbons such as toluene, xylene, hexane, cyclohexane and hydrocarbons such as methylene chloride, chloroform, trichloroethylene and trichloroethane; and oxygenated compounds such as ethyl ether and ethyl acetate. Mixtures of two or more solvents can also be used, it only being required that the mixture, and not necessarily all of the components in the mixture, be a solvent for all the starting materials. Preferably, a non-toxic solvent such as toluene or diethyl ether is used. The amount of solvent that is used should be sufficient to dissolve the starting materials and, preferably, the halosilicon amide product as well. Except when the acyl halide is an acrylyl halide, the method of this invention can be practiced at any reasonable temperature. Advantageously this method proceeds readily at room temperature. When an acrylyl halide is used, this method should be practiced at a relatively low temperature to minimize the formation of byproducts. Accordingly, when using the method of this invention to prepare acrylyl-substituted aminosilicon compounds, the reaction should be conducted at a temperature of from about -10 to about 10° C. Higher reaction temperatures substantially reduce the yield of desired product.
The usual low shear means such as stirrers, paddles, and impellers are sufficient to maintain sufficient agitation. Agitation is maintained until the acylation reaction is finished, typically within an hour.
After the reaction is finished, the solvent can be removed from the product using conventional means such as a rotary evaporator. When acrylyl-substituted products are to be separated from the solvent, it is desirable to add a polymerization inhibitor such as sodium nitrite to the solution prior to any separating action such as distilling or fractionation.
Derivatives of the difunctional halosilicon amide are prepared by reacting the halo functionality of the product halosilicon amide with various reactants such as an alkali metal amide, an alkali metal salt of an organic acid, an alkali metal amine salt or an alkali metal hydroxide to give the corresponding diamide, acid derivative, amine derivative, or oxy dimer. Since the halosilicon amide product and its derivatives except the oxy dimer will convert any SiOH unit to acylamide functionality, they are all useful as endcapping agents. When the acyl halide is an acryl halide, the product halosilicon acrylamide and its derivatives not only serve as endcapping agents but also serve to introduce the free radical polymerizable acrylamide functionality onto the endcapped silicon unit. These encapped silicon units with a polymerizable acrylamide functionality are useful in the production of various cross-linked products including photoresists, moisture and radiation dual cure conformal coatings, coupling agents, paper release coatings, among others.
The products of this method are useful as polar silicon-containing additives for cosmetic compositions, coating compositions, textile treating compositions, and paints. The compositions are useful as comonomers with polymerizable vinyl monomers such as styrene, butadiene, methyl methacrylate, ethyl acrylate, vinyl acetate, vinyl chloride, vinylidene chloride and acrylonitrile. In particular the compounds having acrylamide radicals are useful as a reactive component in free radical curable compositions such as radiation curable compositions used for paper, resin protective, and optical fiber coatings.
The following examples are disclosed to further teach the practice of the invention and are not intended to limit the invention as it is delineated in the claims.
EXAMPLE 1
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with acrylyl chloride.
A two liter three necked flask equipped with a nitrogen inlet, dropping funnel, thermometer and a magnetic stir bar was charged with 196.0 g (1.37 moles) of 1,2,2,4tetramethyl-1-aza-2-silacyclopentane and 600 ml of anhydrous diethyl ether. The mixture was stirred and was cooled externally in an ice bath. To this 123.6 g (1.37 moles) of acrylyl chloride dissolved in 400 ml of anhydrous ether was slowly added with stirring. The temperature of the reaction mixture was maintained at 5±1° C. Addition took approximately 5 hrs. The mixture was stirred overnight. Solvent was removed under reduced pressure to yield the product, N-methyl-N-[2-methyl-3-(chlorodimethylsilyl) propyl]-2-propenamide, (ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )COCH═CH 2 ), in quantitative yield The product was characterized by gas-liquid chromotography (glc), IR and NMR spectra. 1 H NMR (CDCl 3 , 400 MHz): 6.5-5.5 (CH 2 ═CH), 3.25-3.0(N-CH 2 ), 2.9-2.75 (N--CH 3 ), 2.0 (CH--CH 2 ), 0.85-0.80 (CH--CH 3 ), 0.3-0.5 (SiCH 2 ), and 0.3 (Si--CH 3 ); 13 C NMR (CDCl.sub. 3): 166.4 and 166.3 (C═O), 127.5 (CH 2 ═CH), 127.3 (CH 2 ═CH), 57.87 and 55.7 (N--CH 2 --), 35.8 and 34.1 (N-CH 3 ), 28.5 and 27.3 (CH 2 --CH), 23.8 and 23.5 (--SiCH 2 --CH), 19.8 and 19.4 (CH 3 --CH); 29 Si (CDCl 3 ): 31.34 and 30.87. IR (neat): 1650 cm -1 (C═O) and 1620 cm -1 (C═C).
EXAMPLE 2
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with acetyl chloride.
A one liter three-necked flask was equipped with a thermometer, nitrogen inlet, 125 ml capacity pressure equalizing dropping funnel and a magnetic stir bar. The cyclic silazane (100.0 g; 0.6993 mmoles) dissolved in 250 g of dry ether was transferred into the flask. The flask was cooled externally using an ice bath. When the temperature of the solution reached 5 ° C., acetyl chloride (54.89 g; 0.6993 moles) dissolved in 50 g of dry ether was gradually added to the stirred solution. Addition took approximately one hour. After the addition was over, the mixture was stirred for another 4 hrs. The solvent was removed under reduced pressure. The product, ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )COMe, was distilled (70-80° C./0.1 mm Hg). The product was characterized by proton NMR, Carbon-13 NMR, Silicon-29 NMR, and IR. H 1 NMR (CDCl 3 ) 3.2-3.0 (N--CH 2 ,(m)), 2.9-2.8 (N--CH 3 ), 2.0 (COCH 3 and CH), 1.0 (CH--CH 3 (d)), 0.8-0.5 (SiCH 2 ); 0.3 (SiCH 3 ). 13 C NMR (CDCl 3 ): 170 (C═O), 58.3 and 54.9 (N--CH 2 --), 36.0 and 32.7 (N-CH 3 ), 27.6 and 26.9 (CH--CH 3 ), 23.4 and 23.1 (--SiCH 2 --CH), 21.2 and 20.9 (COCH 3 ), 19.4 and 19.0 (CH--CH 3 ), 2.0 (si--CH 3 ). 29 Si NMR (CDCl 3 ): 31.38, 30.91. IR (neat): 1655 CM -1 (C═O).
EXAMPLE 3
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with methacrylyl chloride or with ethyl chloroformate.
Using the general method outlined in Example 2, ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )COC(CH 3 )═CH 2 was prepared by the reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with methacrylyl chloride and ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )COOEt was prepared by the reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with ethyl chloroformate. Removal of solvent under reduced pressure afforded the liquid product.
EXAMPLE 4
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with benzoyl chloride.
A 500 ml three-necked flask equipped with a thermometer, nitrogen inlet, dropping funnel and a magnetic stir bar was charged with 39.32 g (0.275 moles) of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane dissolved in 100 ml of ether. The flask was colled externally in an ice bath. Benzoyl chloride (38.64 g; 0.275 moles) dissolved in 50 ml of ether was gradually added over a period of 2 hrs to the solution of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane. The mixture was stirred for an additional 2 hrs. Solvent was removed under reduced pressure The product, ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )COPh, was isolated and characterized by 1 H NMR which correlated with the expected structure.
EXAMPLE 5
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with benzene sulfonyl chloride
A 250 ml three-necked flask was equipped with a thermometer. To the flask a solution of 10.0 g (69.9 mmoles) of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane in 40 ml of dry ether was added. The flask was cooled in an ice bath and 12.3 g (69.9 mmoles) of benzene sulfonyl chloride (C 6 H 5 SO 2 Cl) dissolved in 10 ml of ether was gradually added over a period of 30 minutes. The mixture was stirred for two hrs and solvent removed under reduced pressure The product was characterized by 200 MHz proton NMR (CDCl 3 ; tetramethylsilane (TMS)): 8.0-7.3 (m, 6.0, C 6 H 5 ), 2.90-2.58 (m, 5.7, N--CH 2 , N--CH 3 ), 2.0-1.9(m, 1.2, CH--CH 2 ), 1.2-0.9 (m, 4.6, CH--CH 3 ), 0.7-0.5(m, 0.96, SiCH 2 ), 0.4 (s, 5.5, Si--CH 3 ).
EXAMPLE 6
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with succinyl chloride.
Cyclic silazane (1,2,2,4 tetramethyl-1-aza-2-silacyclopentane, 18.45 g, 129.0 mmoles) was dissolved in 125 ml of dry ether and placed in a 250 ml three-necked flask fitted with a magnetic stir bar, nitrogen inlet, thermometer and a dropping funnel. The reaction mixture was stirred and cooled to 0 ° C. using a dry-magnetic ice/isopropanol bath. To this stirred mixture, 10.0 g (64.5 mmoles) of succinyl chloride dissolved in 35 ml of dry ether was added dropwise After the addition of succinyl chloride was over, the mixture was stirred for an additional 1 hr. Solvent was removed under reduced pressure and the isolated product, [(ClSi(Me) 2 CH 2 CH(CH 3 )CH 2 N(CH 3 )),COCH 2 ] 2 , was characterized by 1 H HMR and IR.
EXAMPLE 7
Reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane with suberoyl chloride
The reaction of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane and suberoyl chloride was carried out in a similar manner as that for the reaction with succinyl chloride in Example 6 except that an ice water bath was used instead of the dry-ice/isopropanol bath. In this case 10.0 g (69.9 mmoles) of 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane and 7.38 g (35.0 mmoles) of suberoyl chloride was used
EXAMPLE 8
Reaction of N-methyl-N-[2-methyl-3-(chlorodimethylsilyl)propyl]-2-propenamide with the sodium salt of N-methylacetamide.
Chlorosilane, i.e., 3I9.2 g (1.37 moles) N-methyl-N-[2-methyl-3-(chlorodimethylsilyl)propyl]-2propenamide, was placed in a dropping funnel and diluted with 200 ml of dry toluene. The chlorosilane solution was gradually added to a slurry of a sodium salt of N-methylacetamide in xylene. The reaction was slightly exothermic with the temperature increasing from about 23° to 30 ° C. The mixture was stirred overnight. Sodium chloride was removed by centrifugation and most of the solvent was removed under reduced pressure. The product N-methyl acetamide derivative was characterized by Fourier transform infrared spectroscopy (FTIR) and 29 Si NMR techniques.
EXAMPLE 9
Reaction of N-methyl-N-[2-methyl-3-(chlorodimethylsilyl)propyl]-2-propenamide with sodium acetate.
Sodium acetate (1.9 g; 23.2 mmoles) was added to 5 g (21.4 mmoles) of N-methyl-N-[2-methyl-3-(chlorodimethylsilyl)propyl]-2-propenamide in 50 ml of hexane. The mixture was stirred and heated to reflux for 24 hr. The reaction mixture was allowed to cool. The salt was filtered and solvent removed to obtain the acetate derivative.
EXAMPLE 10
Preparation of disiloxane from N-methyl-N-[2-methyl-3(chlorodimethylsilyl)propyl]-2-propenamide.
To an ethereal solution of 2 g (8.5 mmoles) of N-methyl-N-[2-methyl-3-(chlorodimethylsilyl)propyl]-2-propenamide was added dilute sodium hydroxide solution. The mixture was stirred for 10 minutes, the ether layer was separated, washed with water, dried over anhydrous sodium sulfate and solvent removed to obtain the confirmed by 1 H NMR and IR spectra.
EXAMPLE 11
Using known methods for cleaving acyclic silicon-nitrogen bonds with various complex element halides R"X where R" is a complex element moiety (Roesky and B. Kuhtz, Chem. Ber. 107, 1 (I974), U. Wannagat, Angew. Chem. 77, 626 (1965), E. W. Abel and I. D. Towle, J. Organomet. Chem., 122, 253 (1976), and D. Armitage and A. Sinden, J. Inorg. Nucl. Chem. 36, 993 (1974)), the following equivalent products are made by reacting the indicated equivalent complex element halides with 1,2,2,4 tetramethyl-1-aza-2-silacyclopentane:
__________________________________________________________________________R"X Reaction Products__________________________________________________________________________COCl.sub.2 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)COCl (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 COSO.sub.2 Cl.sub.2 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SO.sub. 2 ClSOCl.sub.2 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SOClAlCl.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)AlCl.su b.2SbCl5 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SbCl.su b.4FeCl.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)FeCl.su b.2BeCl.sub.2 (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 BePOCl.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)POCl.su b.2Mn(CO).sub.5 Cl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)Mn(CO). sub.5R'.sub.2 AsCl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)AsR'.su b.2ClSO.sub.2 NCO ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SO.sub. 2 NCOalkyl-X ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)alkylR' N═SF.sub.2 (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 S═NR'ClSO.sub.2 NCO ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SO.sub. 2 NCOCl.sub.3 P═NSO.sub.2 N═PCl.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)Cl.sub. 2 P═NSO.sub.2 N═PCl.sub.3R'.sub.2 NSCl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SNR'.su b.2PhPOCl.sub.2 (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 POPhPhBCl.sub.2 (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 BPhPhN═CCl.sub.2 (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)).sub. 2 C═NPhPR'.sub.2 F.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)PR'.sub .2 F.sub.2R'.sub.2 AsCl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)AsR'.su b.2S.sub.3 N.sub.2 Cl.sub.2 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)ClN.sub .2 S.sub.3Me.sub.2 NSOCl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)OSNMe.s ub.2(ClSO.sub.2).sub.2 NH (ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)SO.sub .2).sub.2 NHPh.sub.2 PCl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)PPh.sub .2W(C.sub.5 H.sub.5)(CO).sub.3 Cl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)W(CO).s ub.2 (C.sub.5 H.sub.5)Mo(C.sub.5 H.sub.5)(CO).sub.3 Cl ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)Mo(CO). sub.2 (C.sub.5 H.sub.5)PCl.sub.3 ClSi(Me).sub.2 CH.sub.2 CH(CH.sub.3)CH.sub.2 N(CH.sub.3)PCl.sub .2__________________________________________________________________________ | Difunctional halo silicon amide compounds are prepared by cleaving the nitrogen-silicon bond in a nitrogen-silicon heterocycle with a reactive halide. The reaction is straight forward with no intermediates or byproducts. The halo functionality is capable of capping any SiOH group. When the other functionality is an acrylamide, the capped entity may be polymerized or crosslinked by free radical initiators of the acrylamide functionality thereby producing useful products such as paper release coatings and photoresists. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to an engagement device particularly for at least one lens of a pair of sunglasses or spectacles.
Eyeglasses are currently constituted by a front that supports a single lens or a pair of lenses; hinges for connection to temples are associated with the ends of said front.
It is thus known to manufacture hinges which are constituted by two elements which are mutually associated so that they can rotate with respect to each other and the free ends of which can be embedded for example in the temple and in the front or are obtained or formed directly at the ends of said temple and said front.
The manufacture and use of these conventional eyeglasses entails high manufacturing costs and drawbacks, such as the need to provide appropriate seats on the front to associate the lenses therewith by deforming said front or by using coupling screws, with consequent difficulty in lens replacement.
The use of these conventional eyeglasses furthermore forces, during their design, to determine a preset position of the lens with respect to the temples and therefore with respect to the facing surface of the user's face; in other words, it is necessary to preset the pantoscopic angle without being able to modify it in any way.
SUMMARY OF THE INVENTION
The aim of the present invention is therefore to solve the described technical problems, eliminating the drawbacks of the prior art and thus providing a pair of eyeglasses in which it is possible to rapidly and easily assemble the lens or lenses to the remaining parts that constitute the pair of eyeglasses to allow better industrialization.
Within the scope of the above aim, an important object is to provide a pair of eyeglasses that allows to simply and quickly interchange its individual components without using particular tools.
Another important object is to provide a pair of eyeglasses that allows to vary the pantoscopic angle according to specific requirements of the manufacturing process or of the user.
Another object is to provide a device that associates with the preceding characteristics that of being reliable and safe in use and has low manufacturing costs.
With the foregoing and other objects in view, there is provided an engagement device, particularly for at least one lens of a pair of sunglasses or spectacles, characterized in that it comprises means for temporary engagement between at least one end of said lens and the corresponding end of a temple or of a front, said means allowing to preset or vary the pantoscopic angle of said at least one lens.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the invention will become apparent from the detailed description of some particular but not exclusive embodiments, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a partially sectional side view of an end of a lens and of the corresponding end of a temple or of a front or of a support that can be connected to the front;
FIG. 2 is a top view of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 3 is a view, similar to FIG. 1, of another embodiment;
FIG. 4 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 5 is a view, similar to FIG. 1, of another embodiment;
FIG. 6 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 7 is a view, similar to FIG. 1, of another embodiment;
FIG. 8 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 9 is a view, similar to FIG. 1, of another embodiment;
FIG. 10 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 11 is a view, similar to FIG. 1, of another embodiment;
FIG. 12 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 13 is a view, similar to FIG. 1, of another embodiment;
FIG. 14 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 15 is a view, similar to FIG. 1, of another embodiment;
FIG. 16 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 17 is a view, similar to FIG. 1, of another embodiment;
FIG. 18 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 19 is a view, similar to FIG. 1, of another embodiment;
FIG. 20 is a view, similar to FIG. 2, of the end of the temple or of the front or of the support to be connected to the lens or lenses;
FIG. 21 is a view, similar to FIG. 5, of another solution in which the user himself can vary the pantoscopic angle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the above figures, the reference numeral 1 designates the engagement device, which is particularly usable to mutually connect at least one first end 2 of a lens portion 3 of a pair of sunglasses or spectacles and a second end 4 of a frame portion 5. As used herein, the term "lens portion" refers to a single lens or to a pair of lenses. Moreover, as used herein, the term "frame portion" refers to a temple, to a front, or to a support which is associated or associable to a front.
The device comprises means to allow temporary mutual engagement of said first and second ends; said means are constituted by a first seat 6 which is formed longitudinally with respect to said first end 2 and is connected to a second seat 7 which advantageously has a circular plan.
Complementarily shaped temporary securing elements can be arranged at said first and second seats and are constituted by a longitudinal bridge 8 and by a cylinder 9 which are interposed transversely between two wings 10 and 11 formed at the second end 4 of the frame portion.
The functions of said bridge, cylinder, first seat, and second seat are to connect the lens portion 3 to the frame portion 5 and to allow to vary the inclination of the lens or lenses of the lens portion 3 with respect to said frame portion.
These functions are allowed by the shape of the cylinder 9 and of the second seat 7, whereas the pantoscopic angle and, accordingly, the angle that forms approximately between the planes of arrangement of the lens or lenses and of the user's face are determined by the shape of the first seat 6.
This angle is determined, for the illustrated embodiment, during the manufacture of the pair of eyeglasses, in that it is preset by the manufacturer.
The pantoscopic angle can furthermore be changed directly by the user: for example, if the first seat 6 is shaped like a truncated cone with its apex directed away from the first seat, then the lens 3 can be given a desired upward or downward tilt according, e.g., to a specific sports practice.
For example, in fact, in cycling the cyclist leans more or less towards the handlebar depending on whether he is performing a time trial or racing; this position forces him to rotate his eyes upward in order to see the track.
The possibility to vary the angular position of the lens thus allows the cyclist to see the track in optimum conditions, as the airflow correctly strikes the surface of the lens instead of the cyclist's eyes.
It has thus been observed that the device according to the invention has achieved the intended aim and objects, it is possible to rapidly and easily correctly assemble the lens or lenses for example to the front even without using particular tools and accordingly replace the lens or lenses in an equally rapid and easy manner.
Furthermore, the possibility to vary the pantoscopic angle allows the user to practice his sport in an optimum manner as the conditions of said sport vary.
The device according to the invention is of course susceptible to numerous modifications and variations, all of which are within the scope of the same inventive concept.
Thus, for example, FIGS. 3 and 4 illustrate a device 101 in which the second end 104 of the frame portion 105 comprises temporary securing elements which are constituted by a longitudinal bridge 108 that ends, towards the lens portion 103, with a cylinder 109; said securing elements are interposed transversely between a first wing 110, which is formed at the second end 104, and a second wing 111, which is arranged parallel to the first wing and is directly associated with the cylinder and with the bridge.
In this embodiment, too, said securing elements interact with means that allow to temporarily engage the second end 104 with the first end 102 of a lens portion 103; said means are constituted by a first seat 106 which is formed longitudinally with respect to said first end 102 and is connected to a second seat 107 which is advantageously shaped complementarily to the cylinder 109.
In this case, too, it is possible to obtain the desired pantoscopic angle during the manufacture of the pair of eyeglasses.
FIGS. 5 and 6 illustrate another embodiment, constituted by a device 201 in which two first seats 206a and 206b are formed at the first end 202 lens portion 203, are arranged longitudinally with respect to said first end 202 and parallel to each other, and are connected to two second seats 207a and 207b which have an essentially circular plan.
Complementarily shaped temporary securing elements interact with said pairs of first and second seats and constitute means for temporary engagement between said first end 202 and a second end 204 of a frame portion 205; said securing elements are constituted by two cylinders 209a and 209b which are arranged transversely between the wings 210 and 211 formed at the second end 204.
The center distance between the cylinders 209a and 209b, which are preferably arranged at a same plane that lies transversely to the wings 210 and 211, is equal to the center distance between the pair of first seats 206a and 206b.
in this case, too, it is possible to achieve, during manufacture, the desired pantoscopic angle.
FIGS. 7 and 8 illustrate another embodiment of a device 301 which has, at a first end 302 of a lens portion 303, means for temporary coupling to a second end 304 of a portion 305 or of a front or of a support which is associated or associable with said front.
Said coupling means are constituted by a first seat 306 which is formed longitudinally with respect to the lens 303 at the first end 302 and is connected to two second seats 307a and 307b which respectively have a longitudinal shape arranged along an axis that is inclined with respect to the first seat 306 and an essentially circular plan in a plane that lies below the plane of arrangement of the first seat 306.
Together, the first and second seats form an essentially Y-shaped seat at the first end 302; temporary securing elements interact with said seat and are constituted by two cylinders 309a and 309b which are interposed transversely between two wings 310 and 311 formed at the second end 304.
The two cylinders 309a and 309b are arranged so as to allow to insert both of them at the first seat 306 and then, as a consequence of a rotation applied to the temple 305, to place them respectively at the second seats 307a and 307b.
In this case, too, the temple and the lens are engaged in a manner that allows to preset the pantoscopic angle.
FIGS. 9 and 10 illustrate another embodiment of a device 401 which has, at a first end 402 of a lens portion 403, means that allow to mutually engage said first end and a second end 404 of a temple 405 or of a said first end and a second end 404 of a frame portion 405.
Said means are constituted by two first seats 406a and 406b which are formed at the lower perimetric edge 412 of the lens 403 and have an essentially circular plan.
Complementarily shaped temporary securing means can be arranged at the first seats and are constituted by two cylinders or bridges 409a and 409b which are arranged transversely between the wings 410 and 411 of the temple 405.
In this case, too, it is therefore possible to mutually couple the temple and the lens, as the center distance between the cylinders or bridges of the first seats is the same and their coupling can occur for example in a snap-together manner.
In this case, too, it is possible to obtain a desired pantoscopic angle during the manufacture of the pair of eyeglasses.
FIGS. 11 and 12 illustrate another embodiment for a device 501 which is constituted by a lens portion 503 which has a first end 502 that can be associated at a second end 504 of a frame portion 505.
Means for temporary engagement with the second end 504 are provided at the first end 502 and are constituted by a first seat 506 which is formed longitudinally with respect to the first end 502 and is connected to a second seat 507 which advantageously has a circular plan.
Multiple preferably semicircular third seats 513 are furthermore formed at the perimetric edge 512 of the lens 503 that is adjacent to the first seat 506.
Complementarily shaped temporary securing elements interact with said first, second, and third seats and are constituted by a bridge or cylinder 509, which is interposed transversely between the wings 510 and 511 formed at the second end 504 and at the temple 505, and by a lug 514 which protrudes from the base 515 that connects the wings 510 and 511.
The center distance between the bridge or cylinder 509 and the lug 514 is approximately equal to the center distance between the second seat 507 and the third seats 513; this allows not only to mutually engage the two parts of the pair of eyeglasses but also to vary the pantoscopic angle, as the user can vary the arrangement of the lug 514 in one of the several third seats 513.
FIGS. 13 and 14 illustrate another engagement device 601 which is suitable to mutually connect a first end 601 of a lens portion 603 of a pair of sunglasses or spectacles and a second end 604 of a frame portion 605.
Said device comprises means that allow to temporarily mutually engage the first and second ends; said means are constituted by a first seat 606 which is formed longitudinally with respect to the first end 602 and is connected to a second seat 607 which preferably has a circular plan.
Said means furthermore comprise third seats 613 which are formed at the inner and/or outer lateral surface of the lens 603, partially affect its thickness, and are arranged along a circular arc which is centered approximately in the second seat 607.
Complementarily shaped temporary securing elements can be arranged at said first, second, and third seats and are constituted by a bridge or cylinder 609, which is interposed transversely between the wings 610 and 611 formed at the second end 604 of the temple, and by a lug 614, which protrudes from the inner lateral surface of one of said wings 610 and 611 at a distance from the bridge or cylinder 609 that causes it to affect one of the third seats 613.
This embodiment, too, therefore allows not only to mutually engage two components of the pair of eyeglasses but also allows the user to modify the pantoscopic angle.
FIGS. 15 and 16 illustrate another embodiment of a device 701 which can be used to mutually connect a first end 702 of a lens portion 703 of a pair of sunglasses or spectacles and a second end 704 of a frame portion 705.
Said device 701 comprises means for temporary engagement between the first end and the second end and also comprises means for varying the pantoscopic angle which are constituted by a first seat 706 that consist of a hole formed at the first end 702 of the lens 703.
A complementarily shaped temporary securing element can be detachably arranged at said seat 706 and is constituted by a cylinder 709 that protrudes from a wing 710 that forms the second end 704 of the temple 705; said cylinder 709 has a head 716 that gives it a mushroom-like shape that is elastically compressible for removable insertion within the first seat 706.
The means for varying the pantoscopic angle are constituted by multiple ridges 717 which protrude transversely from the base 715 of the temple 705 from which the wing 710 protrudes.
Said ridges 717 are shaped like an arc that is centered approximately at the axis of the cylinder 709.
The center distance between the first one of said ridges 717 and the cylinder 709 is equal to the distance between the axis of the first seat 706 and the perimetric edge 712 of the lens 703, whereas the other ridges are arranged gradually further away from the cylinder 709, so as to allow the perimetric edge 712 of said lens to interact with one of said ridges when the temple is rotated with respect to the lens.
A temporary position of the lens with respect to the temple is thus produced, providing the desired pantoscopic angle.
FIGS. 17 and 18 illustrate another embodiment of an engagement device 801 which can be used particularly to mutually connect at least one first end 802 of a lens portion 803 of a pair of sunglasses or spectacles and a second end 804 of a frame portion 805.
The device comprises means that allow temporary engagement between the first end and the second end, as well as means for varying the pantoscopic angle; said means are constituted by a first seat 806, which is constituted by a through hole formed on the lens 803 at the first end 802, and by second seats 807, which partially affect the thickness of the lens and are formed at the inner and/or outer surface thereof in the interspace between the first seat 806 and the perimetric edge 812 of said lens.
Advantageously, said second seats 807 are arranged at a circular arc that is centered on the axis of the first seat 806.
Complementarily shaped temporary securing elements can be arranged at said first and second seats and are constituted by a bridge 809 which has an elastically compressible head 816; said cylinder protrudes from a wing 810 that forms the second end 804 of the temple 805.
There is also a lug 814 which also protrudes from the wing 810 in the same direction as the cylinder 809; the center distance between the lug and the cylinder is approximately equal to the center distance between the first seat 806 and the second seat 807.
This embodiment, too, therefore allows to mutually engage two components of the pair of eyeglasses and also allows to vary the pantoscopic angle by arranging the lug 814 in the desired one of the various second seats 807.
FIGS. 19 and 20 illustrate another embodiment of a device 901 which is particularly usable to mutually connect at least one first end 902 of a lens portion 903 of a pair of sunglasses or spectacles and a second end 904 of a frame portion 905.
The device comprises means for temporarily engaging the first and second ends as well as means for varying the pantoscopic angle; said means are constituted by a first through seat 906 which is formed at the first end 902 and is constituted by multiple preferably circular holes which are connected along a circular arc whose concavity is directed towards the perimetric edge 912 that is associable with the temple 905.
There are also second seats 907 that partially affect the thickness of the inner and/or outer lateral surface of the lens, are formed in the interspace between the perimetric edge 912 and the first seat 906, and are arranged at a same axis.
Complementarily shaped temporary securing elements can be arranged at said first and second seats and are constituted by a cylinder 909, which has a head 916 that can be compressed elastically to place it inside the first seat 906, and by a lug 914; said cylinder and said lug protrude from a wing 910 that forms the second end 904 of the temple 905.
The center distance between the bridge and the lug is approximately equal to the center distance between the first seat 906 and the second seats 907.
In this case, too, it is therefore possible to mutually associate the components of a pair of eyeglasses, varying both the position of the head 916 of the cylinder 909 within the first seat 906 and the position of the lug 914 with respect to the desired second seat 907 so as to accordingly vary the pantoscopic angle.
FIG. 21 illustrates another embodiment, constituted by a device 1001 in which two first seats 1006a and 1006b are formed at the first end 1002 of the lens portion 1003 and are arranged longitudinally with respect to said first end 1002 and parallel to each other.
Said two first seats are connected to multiple pairs of second seats 1007a and 1007b which are arranged sequentially with respect to each other and have an essentially circular plan.
Complementarily shaped temporary securing elements interact with said multiple pairs of second seats, which constitute means for temporary engagement between said first end 1002 and a second end 1004 of a frame portion 1005; said securing elements are constituted by two cylinders 1009a and 1009b which are arranged transversely between the wings formed at the second end 1004.
The center distance between the cylinders 1009a and 1009b, which are preferably arranged on a same plane that lies transversely to said wings, is equal to the center distance between the two first seats 1006a and 1006b.
Depending on the position of the cylinders in the desired pair of the pairs of second seats 1007a and 1007b, it is possible to connect the elements that constitute the pair of eyeglasses, furthermore varying the useful length of the temple; if instead the user places the cylinders so that they are staggered with respect to two adjacent pairs of second seats, he can change the pantoscopic angle.
For this purpose, the center distance between the pairs of second seats 1007a and 1007b is such as to also allow to simultaneously arrange the cylinders in individually different pairs of second seats.
The materials and the dimensions that constitute the individual components of the device may of course be the most pertinent according to the specific requirements. | The engagement device has a first seat having a longitudinal extension and formed in a first end of a lens of a pair of eyeglasses. A second seat, also formed in the first end of the lens, has an essentially circular configuration and communicates with the first seat. The engagement device also has a longitudinal bridge connected to a second end of a temple and a cylinder connected to the bridge. The bridge and the cylinder are interposed transversely between two wings formed at the second end of the temple. The bridge is accommodated in the first seat and the cylinder is accommodated in the second seat. The walls laterally delimiting the first seat may be manufactured at mutually different angles to each other according to the desired angle of the lens with respect to the temple. | 6 |
BACKGROUND OF THE INVENTION
A good sturdy camera tripod, however excellent it may be for much indoor and some outdoor photography, is often seriously at a loss out-of-doors in rough terrain or when performing close-up or copy work indoors or out. When close-up nature photography especially is undertaken in wooded or overgrown country, it is difficult or impossible to maneuver the typical tripod so that it is both stabile and convenient to hand as well as sufficiently close to what is to be pictured. Even indoors, where there are no terrain problems, the usual tripod is too large and inflexible for close-up copy work of various kinds without special attachments for those purposes. One I know of amounts to little more than an addition to the tripod for lowering the camera. Another is a low, "spider-like" stand with three or four legs. But more to the point is the one shown in U.S. Pat. No. 3,586,278. This, however, consists of a rather elaborate and cumbersome array of legs and interconnected rods, all not readily assembled or disassembled for transport or storage besides being not really suitable for much inside or outside work. For some nature photography especially it would doubtless take too long to set up before the "subject" would have vanished. Probably it would be too noisy as well, for silence is one of the requisites of nature photography in those cases. At any rate, until my present invention, I am aware of no camera support system specifically addressed to the problems concerned, one which is particularly adapted to indoor and outdoor close-up and copy photography, which is also useful for general photography, and which at the same time is light in weight, silent, flexible and compact.
SUMMARY OF THE INVENTION
The camera support system of my invention, which I deem best described as an "adjustable apex camera system", incorporates a pair of supports, each of which is essentially a bipod. One of the bipods is larger than the other and consists of a pair of legs adjustably pivoted to a fixture at their upper ends, one of the legs being of channel shape and the other cylindrical, the lower end of the former having a transverse base whose outer ends and the lower end of the cylindrical leg provide supporting feet. The pivot fixture between the legs, constituting the apex of the larger bipod, carries the smaller of the two bipods which is basically a duplicate of the larger and can be employed apart from the latter in a similar manner for extreme close-up or copy work as well as for ordinary time and other exposures. Various camera mounts are adjustably attached to the apices of either or both bipods and/or to a leg of the larger. The legs themselves of the two bipods can be folded upon each other and the transverse base detached and secured along one leg so that the entire system is in a compact and handy form for transport and storage. When folded the larger of the bipods can also be used in a horizontal position in the manner of an "optical bench" with the camera supported on the one mount and the object to be photographed supported on a small table or in a small vise carried on another of the mounts.
Other and further features and advantages of the invention will become apparent from the drawings and the more detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an upright perspective view of the two bipods which comprise my apex camera support system, the smaller being shown dismounted from the larger for separate use.
FIG. 2 is also an upright perspective view of my system with the smaller bipod shown in one position on the larger.
FIG. 3 is similar to FIG. 2 except that the smaller bipod is shown in another position on the larger.
FIG. 4 is likewise a perspective view showing my system horizontally disposed for use as an "optical".
FIG. 5 is a further perspective view showing my system folded for transport and storage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 through 3 the larger of the two bipods of my system, generally indicated at 10, is illustrated in the form of a channel shaped leg 11 having side walls 12 between the upper ends of which is secured a first fixture 13 in the form of a mounting block pivoted at one end about an axis defined by a transverse clamp bolt 14. The fixture 13 is bored to slidably receive the upper end of a cylindrical leg 15 which is adjusted lengthwise relative to the fixture 13 by a clamp screw 16. A transverse cylindrical base member 17, parallel to the axis of the clamp bolt 14 and normal to the channeled leg 11, is removably secured as shown at 18 to a tongue formed on the lower end of the leg 11. The lower end of the leg 15 and the outer ends of the base member 17 are preferably fitted with rubber-like tips 19. The latter function as feet for the bipod 10 and support it upright as shown on whatever underlying terrain or surface 20 is involved, whence the fixture 13 forms the apex of the bipod 10. By releasing the clamp bolt 14 and spreading the legs 11 and 15 and/or releasing the clamp screw 16 and sliding the leg 15 through the fixture 13, the overall height of the apex of the bipod 10 can be adjusted relative to the surface 20. These two manners in which the height of the bipod 10 can be adjusted is especially helpful in out-of-doors nature photography where space or obstacles may limit the spread of the legs 11 and 15. Indeed, the leg 15 can be swung sufficiently far about the clamp bolt 14 so that the device in effect doubles its ordinary height and becomes a monopod.
The other end of the fixture 13 is provided with a transverse bore 21 (see FIG. 4) through its upper and lower faces which receives a clamp screw up therethrough to removably engage a typical camera panning head 26. The latter is a well-known proprietary item and features a fixing screw 27 which is adjustably swiveled relative to the body 28 of the head by a clamp screw 29. One side face and the outer end face of the fixture 13 are provided with respective threaded bores 30 and 31 intersecting the bore 21 so that other items, such as a camera flash, reflector, timing equipment, etc., can be mounted on the fixture 13 and so that the latter can be employed in the manner later described in connection with FIG. 4. A similar panning head 35 may be mounted on the leg 15 by means of a second fixture 36. The latter comprises a base block 37 slidably receiving the leg 15 and adjusted therealong by a clamp screw 38. Between a pair of plates 39 fixed as shown to and extending from the free end of the block 37 a second block 40 is adjustably pivoted relative thereto about a clamp bolt 41 and carries the head 35. The fixture 36 thus provides an alternate position for a camera whose height can be adjusted independently of the height of the bipod 10. This feature is especially useful in nature work as well as indoors when the bipod 10 is used in the manner later described in connection with FIG. 4.
The smaller of the two bipods of my system is also illustrated in FIGS. 1 through 3 and generally indicated at 50. It includes a channel shaped stub leg 51 having side walls 52 between the lower ends of which a mounting block 53 is pivoted about a clamp bolt 54 and provided with a bore 55 therethrough for mounting the bipod 50 upon the fixture 13, as later described. Between the upper ends of the channel side walls 52 is pivoted a base block 56 about a clamp bolt 57 parallel to the bolt 54. The block 56 which constitutes the apex of the bipod 50 may, as shown, support another panning head 58 secured by a suitable clamp screw 59 (shown in FIG. 5 in its storage position after removal of the head 58) up through the block 56. The other stub leg of the bipod 50 takes the form of a pair of parallel rods 60 threaded at their upper ends into the lower face of the base block 56 and fixed by wing nuts 61. Slidably disposed on both rods 60 is a tie block 62, whose position is adjusted by clamp screws 63, which helps stabilize the two rods 60. The lower ends of the rods 60 are cranked in opposite directions laterally of the channeled leg 51, the cranked ends being fitted with elastomeric sleeves 64. The latter and the mounting block 53 thus function as feet and support the bipod 50 upright as shown in FIG. 1. The overall height of the apex of the bipod 50 can be adjusted by the spread of the stub legs 51 and 60 and secured by the clamp bolt 57.
The bipod 50 may be used in the manner shown in FIG. 1, wholly apart from the bipod 10, for extreme close-up or copy work in the field or studio when the object to be photographed is not to be disturbed from its setting or need not be specially mounted for photographing. The bipod 50 is also useful by itself as a small, compact camera support when taking ordinary time exposures or when camera stability is needed in any situation, especially where the underlying area available is very limited, such as a rock, a tree stump, and so forth. It can even be used against one's chest to support a camera. The bipod 50 may also be combined with the bipod 10 and employed in the manners shown in FIGS. 2 and 3, the bipod 50 in effect then becoming a third fixture on the bipod 10. For this purpose the mounting block 53 is adjustably attached to the outer end of the fixture 13 by means of a clamp screw 65 through the bore 55 and threaded into the end bore 31 of the fixture 13. In these positions the bipod 50 in effect provides a cantilevered extension of the bipod 10 in a multitude of directions for pictures that cannot be taken from the bipod 10 alone owing to intervening obstacles or in other situations which restrict the location or adjustment of the bipod 10.
The leg 15 of the bipod 10, after loosening the clamp bolt 14, can be folded scissors-like into the channel of the leg 11 and then the latter laid in a horizontal or reclining position as shown in FIG. 4, whereupon it is supported by the upper end of the leg 11 and the outer tipped ends 19 of the base member 17 and becomes a kind of "optical bench". In order to increase the rigidity of the bipod 10 in this position, the width of the base block 37 of the fixture 36 is made a close fit between the channel leg side walls 12. A panning head 70 may then be screwed into the bore 31 of the fixture 13 to support a camera and the panning head 35 adjusted to support either a small rectangular table 72 or vise clip 74 mounted on a block 75 screwed on to the head 35. The mounting block 75 may also include a transverse rod 76 therethrough, adjusted by a clamp screw 77, whose outer nutted ends 78 carry a semi-circular transparent wind screen or shield 79. The location of the table 72 or the vise clip 74 relative to the panning head 70 can be adjusted by loosening the clamp screw 38 and sliding the fixture 36 along the leg 15. Of course the positions of the camera and the table 72 or clip 74 on the heads 35 and 70 could be reversed. The table 72 or the clip 74 can also be mounted on the head in the case of the set-up shown in FIG. 2 and then adjusted to a level position. With a camera on the head 58, overhead shots of mounted subjects can thus be taken.
When the system is to be transported or stored, the bipod 10 is folded in the same manner as in FIG. 4 and the fasteners 18 are removed from the base member 17. The latter is then placed alongside the leg 11 and reattached with the fasteners 18 to one side wall 12 in holes 80 (see FIG. 2) provided for that purpose. The bipod 50 is next folded to the position shown in FIG. 5 by loosening the clamp bolts 54 and 57, and then the wing nuts 61 and the clamp screws 63 so that the rods 60 may be rotated to turn their cranked ends 64 inwardly. One or more of the panning heads 26, 35, 58 or 70 may be removed or simply stored in place, as shown in the case of the head 35, whereupon the system will assume more or less the configuration shown in FIG. 5. The bipod 50, if detached from the fixture 13, can be folded up for storage or transport in the same manner.
All the metal parts (except the various clamp screws and bolts) are readily fabricated from light-weight material such as aluminum, the leg 15 and the base member 17 being tubular. Insofar as suitable dimensions are concerned, the legs 11 and 15 of a working prototype of the bipod 10 are each about 24 inches in length and the base member 17 about 12 inches in length, while the stub legs 51 and 60 of the bipod 50 are each about 6 inches in length. If desired, in order to increase the adaptability of the bipod 10 to various terrain, the connection between the channel leg 11 and the base member 17 could be a pivotal one and an additional clamp bolt employed so that the angle between the two can be adjusted. My invention therefore provides an apex camera system which is light-weight and compact as well as readily adapted to various conditions indoors and out. While many of its features are designed for close-up and copy photographic work, it is also readily adapted to general photography indoors and out owing to its flexibility and convenience. Hence, though my invention has been described in terms of a particular embodiment, being the best mode known of carrying out my invention, it is not limited to that embodiment alone. Instead the following claims are to be read as encompassing all adaptations and modifications of my invention falling within its spirit and scope. | A camera support system, particularly for close-up and copy photography, features a light-weight larger bipod consisting essentially of a pair of foldable legs, a transverse lower end member on one leg and the lower end of the other leg providing supporting feet for the system. The legs carry various adjustable mounts for one or more cameras, or accessories, one of the mounts being essentially a smaller bipod which can be similarly employed when detached from the larger. Both the larger and smaller bipods can be used in either upright or reclining positions and are readily foldable into compact form for carriage and storage. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
Pursuant to 35 USC § 119(e), this application claims priority to U.S. Provisional Application Ser. No. 60/641,218, filed Dec. 31, 2004, the contents of which are incorporated herein by reference.
BACKGROUND
Cancer treatment can be approached by several modes of therapy, including surgery, radiation, chemotherapy, or a combination of any of these treatments. Among them, chemotherapy is indispensable for inoperable or metastatic forms of cancer.
The microtubule system of eukaryotic cells is an important target for developing anti-cancer agents. More specifically, tubulin polymerization/depolymerization is a popular target for new chemotherapeutic agents. A variety of clinically used compounds (e.g., paclitaxel, epothilone A, vinblastine, combretastatin A-4, dolastatin 10, and colchicine) target tubulin polymerization/depolymerization and disrupt cellular microtubule structures, resulting in mitotic arrest and inhibition of the growth of new vascular epithelial cells. See, e.g., Jordan et al. (1998) Med. Res. Rev. 18: 259-296. Thus, those compounds may have the ability to inhibit excessive angiogenesis, which occurs in diseases such as cancer (both solid and hematologic tumors), cardiovascular diseases (e.g., atherosclerosis), chronic inflammation (e.g., rheutatoid arthritis or Crohn's disease), diabetes (e.g., diabetic retinopathy), macular degeneration, psoriasis, endometriosis, and ocular disorders (e.g., corneal or retinal neovascularization). See, e.g., Griggs et al. (2002) Am. J. Pathol. 160(3): 1097-103.
Take combretastatin A-4 (CA-4) for example. CA-4, isolated by Pettit and co-workers in 1982 ( Can. J. Chem. 60: 1374-1376), is one of the most potent anti-mitotic agents derived from the stem wood of the South African tree Combretum caffrum . This agent shows strong cytotoxicity against a wide variety of human cancer cells, including multi-drug resistant cancer cells. See, e.g., Pettit et al. (1995) J. Med. Chem. 38: 1666-1672; Lin et al. (1989) Biochemistry 28: 6984-6991; and Lin et al. (1988) Mol. Pharmacol. 34: 200-208. CA-4, structurally similar to colchicines, possesses a higher affinity for the colchicine binding site on tubulin than colchicine itself. Pettit et al. (1989) Experientia 45: 209-211. It also has been shown to possess anti-angiogenesis activity. See Pinney et al. WO 01/68654A2. The low water-solubility of CA-4 limits its efficacy in vivo. See, e.g., Chaplin et al. (1999) Anticancer Research 19: 189-195; and Grosios et al. (1999) Br. J. Cancer 81: 1318-1327.
Identification of compounds that also target the microtubule system (e.g., tubulin polymerization/depolymerization) can lead to new therapeutics useful in treating or preventing cancer or symptoms associated with cancer.
SUMMARY
This invention is based on a surprising discovery that a group of fused bicyclic heteroaryl compounds effectively inhibit the growth of certain cancer cells.
In one aspect, this invention features fused bicyclic heteroaryl compounds.
One subset of the fused bicyclic heteroaryl compounds have the following formula:
in which each is a single bond or a double bond; A is C(═O), CRR′, O, NR, S, SO, or SO 2 ; D is aryl or hetereoaryl; R 1 is selected from H, alkyl, aryl, alkoxy, hydroxy, halo, amino, or alkylamino; each of Q, U, V, and Y, independently, is CR or N; X is N, CR, or NR′; Z is C; and each of T and W is C or N, at least one of T and W being C; provided that when T is C and W is N, the bond between T and W is a single bond, the bond between T and Z is a double bond, the bond between Y and Z is a single band, the bond between X and Y is a double bond, the bond between W and X is a single bond, and X is N or CR; when T is N and W is C, the bond between T and W is a single bond, the bond between T and Z is a single bond, the bond between Y and Z is a double band, the bond between X and Y is a single bond, the bond between W and X is a double bond, and X is N or CR; and when T is C and W is C, the bond between T and W is a double bond, the bond between T and Z is a single bond, the bond between Y and Z is a double band, the bond between X and Y is a single bond, the bond between W and X is a single bond and X is NR and Y is N, or X is NR, Y is CR, and at least one of Q, U and V is N. Each of R and R′, independently, is H, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cyclyl, heterocyclyl, SO 3 R a , SO 2 R a , SO 2 NR a R b , COR a , COOR a , or CONR a R b ; each R a and R b , independently, is H, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cyclyl, or heterocyclyl.
Referring to this formula, the compounds may have the following feature: each of T and X is N, W is C, each of Q, U, and V is CH, and Y is CR; each of T and W is C, X is NH, Y is N, and each of Q, U, and V is CH; each of T and W is C, each of Q and U is CH, V is N, X is NH, and Y is CR; T is C, W is N, each of Q, U, V, and X is CH, and Y is CR; T is N, W is C, each of Q, U, V, and X is CH, and Y is CR; T is C, W is N, each of Q, U, and V, is CH, X is N, and Y is CR; each of T and W is C, each of Q, U, and V is CH, X is O, and Y is N; each of T and W is C, Q is CH, or each of U and V is N, X is NH, and Y is CR; or T is C, each of W, V, and X is N, each of Q and U is CH, and Y is CR. Further, the compounds may have one or more of the following features: D is substituted phenyl, e.g., 3,4,5-trimethoxyphenyl; A is C(O); and A is CH 2 , NH, O, S, or SO 2 .
Another subset of the fused bicyclic heteroaryl compounds have the following formula:
in which each is a single bond or a double bond; A is C(═O), CRR′, O, NR, S, SO, or SO 2 ; D is aryl or hetereoaryl; R 1 is selected from alkyl, aryl, alkoxy, hydroxy, halo, amino, or alkylamino; each of Q, U, or V, independently, is CR or N; X is O or S; Y is CR″ or N; each of T, W, and Z is C; the bond between T and W is a double bond; the bond between T and Z is a single bond; the bond between Y and Z is a double band; the bond between X and Y is a single bond; and the bond between W and X is a single bond. Each of R and R′, independently, is H, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cyclyl, heterocyclyl, SO 3 R a , SO 2 R a , SO 2 NR a R b , COR a , COOR a , or CONR a R b , and R″ is H, alkyl, alkenyl, alkynyl, heteroaryl, cyclyl, heterocyclyl, SO 3 R a , SO 2 R a , SO 2 NR a R b , COR a , COOR a , or CONR a R b ; each R a and R b , independently, is H, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cyclyl, or heterocyclyl.
Referring to the above formula, the compounds may have one or more of the features: each of Q, U, and V is CH, and Y is CR; D is substituted phenyl, e.g., 3,4,5-trimethoxyphenyl; A is C(O); and Y is CH, CNH 2 , CCH 3 , or CCH 2 CH 3 .
The term “alkyl” herein refers to a straight or branched hydrocarbon, containing 1-10 carbon atoms. Examples of alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and t-butyl. The term “alkenyl” refers to a straight or branched hydrocarbon, containing 1-10 carbon atoms and one or more double bonds. The term “alkynyl” refers to a straight or branched hydrocarbon, containing 1-10 carbon atoms and one or more triple bonds. The term “alkoxy” refers to an —O-alkyl. The term “amino” refers to a nitrogen radical which is bonded to two hydrogen, or one hydrogen and one alkyl groups, or two alkyl groups.
The term “aryl” refers to a 6-carbon monocyclic, 10-carbon bicyclic, 14-carbon tricyclic aromatic ring system wherein each ring may have 1 to 4 substituents. Examples of aryl groups include, but are not limited to, phenyl, naphthyl, and anthracenyl. The term “aryloxy” refers to an —O-aryl. The term “aralkyl” refers to an alkyl group substituted with an aryl group.
The term “cyclyl” refers to a saturated and partially unsaturated cyclic hydrocarbon group having 3 to 12 carbons. Examples of cyclyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl, and cyclooctyl.
The term “heteroaryl” refers to an aromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heteroaryl groups include pyridyl, furyl, imidazolyl, benzimidazolyl, pyrimidinyl, thienyl, quinolinyl, indolyl, and thiazolyl. The term “heteroaralkyl” refers to an alkyl group substituted with a heteroaryl group.
The term “heterocyclyl” refers to a nonaromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heterocyclyl groups include, but are not limited to, piperazinyl, pyrrolidinyl, dioxanyl, morpholinyl, and tetrahydrofuranyl.
Alkyl, alkenyl, alkynyl, cyclyl, heterocyclyl, aryl, heteroaryl, and alkoxy mentioned herein include both substituted and unsubstituted moieties. Examples of substituents include, but are not limited to, halo, hydroxyl, amino, cyano, nitro, mercapto, alkoxycarbonyl, amido, carboxy, alkanesulfonyl, alkylcarbonyl, carbamido, carbamyl, carboxyl, thioureido, thiocyanato, sulfonamido, alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl, cyclyl, heterocyclyl, in which alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl cyclyl, and heterocyclyl are optionally further substituted.
Shown below are some examples of the bicyclic heteroaryl compounds of this invention:
Some other examples of the compounds of this invention are shown below:
The bicyclic heteroaryl compounds described above inhibit cancer cell growth. Thus, in another aspect, this invention also features a method for treating cancer. The method includes administering to a subject in need thereof an effective amount of one of the above-mentioned compounds.
In still another aspect, this invention features a method for inhibiting tubulin polymerization, or treating an angiogenesis-related disorder. The method includes administering to a subject in need thereof an effective amount of one or more of the above-mentioned compounds.
Also within the scope of this invention is a composition containing one or more of the above-described compounds for use in treating cancer or an angiogenesis-related disorder, as well as the use of such a composition for the manufacture of a medicament for treating cancer or an angiogenesis-related disorder.
The details of many embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and the claims.
DETAILED DESCRIPTION
The fused dicyclic heteroaryl compounds described above can be prepared by methods well known in the art. For example, synthesis of indazole, imidazo[1,2-a]pyridine, 1H-pyrrolo[2,3-b]pyridine, indolizine, pyrazolo[1,5-a]pyridine, benzo[d]isoxazole, and 7H-pyrrolo[2,3-d]pyrimidine has been described in the literature. See, e.g., Chemistry of Heterocyclic Compounds, Vol. 22, Edited by Richard H. Wiley, Published by Interscience Publishers, New York, 1967. One skilled in the art can modify these methods and make the fused dicyclic heteroaryl compounds of this invention. Shown in Schemes 1-4 are synthetic routes for compounds 1, 2, 3, and 7, respectively.
To synthesize the compounds of this invention, suitable synthetic chemistry transformations and protecting group methodologies (protection and deprotection) may be used. These transformations and methodologies are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons (1999); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
A synthesized fused bicyclic heterocyclic compound can be further purified by flash column chromatography, high performance liquid chromatography, or crystallization.
Also within the scope of this invention is a pharmaceutical composition that contains an effective amount of at least one fused bicyclic heterocyclic compound of this invention and a pharmaceutically acceptable carrier. Further, this invention covers a method for inhibiting tubulin polymerization or treating cancer or an angiogenesis-related disorder. The method includes administering to a subject an effective amount of a fused bicyclic heterocyclic compounds described in the “Summary” section.
As used herein, the term “treating” refers to administering a fused bicyclic heteroaryl compound to a subject that has a disorder, e.g., cancer or an angiogenesis-related disorder, or has a symptom of such a disorder, or has a predisposition toward such a disorder, with the purpose to cure, heal, alleviate, relieve, alter, remedy, ameliorate, improve, or affect the disorder, the symptoms of the disorder, or the predisposition toward the disorder. The term “an effective amount” refers to the amount of the active agent that is required to confer the intended therapeutic effect in the subject. Effective amounts may vary, as recognized by those skilled in the art, depending on route of administration, excipient usage, and the possibility of co-usage with other agents.
As used herein, the term “cancer” refers to cells having the capacity for autonomous growth, i.e., an abnormal state or condition characterized by rapidly proliferating cell growth. In addition, cancer can be a drug resistance phenotype wherein cancer cells express P-glycoprotein, multidrug resistance-associated proteins, lung cancer resistance-associated proteins, breast cancer resistance proteins, or other proteins associated with resistance to anti-cancer drugs. Examples of cancers include, but are not limited to, carcinoma and sarcoma such as leukemia, sarcomas, osteosarcoma, lymphomas, melanoma, ovarian cancer, skin cancer, testicular cancer, gastric cancer, pancreatic cancer, renal cancer, breast cancer, prostate cancer, colorectal cancer, cancer of head and neck, brain cancer, esophageal cancer, bladder cancer, adrenal cortical cancer, lung cancer, bronchus cancer, endometrial cancer, nasopharyngeal cancer, cervical or hepatic cancer, or cancer of unknown primary site.
The term “angiogenesis” refers to the growth of new blood vessels—an important natural process occurring in the body. In many serious diseases states, the body loses control over angiogenesis. Angiogenesis-dependent diseases result when new blood vessels grow excessively. Examples of angiogenesis-related disorders include cardiovascular diseases (e.g., atherosclerosis), chronic inflammation (e.g., rheutatoid arthritis or Crohn's disease), diabetes (e.g., diabetic retinopathy), macular degeneration, psoriasis, endometriosis, and ocular disorders (e.g., corneal or retinal neovascularization).
To practice the method of the present invention, the above-described pharmaceutical composition can be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional and intracranial injection or infusion techniques.
A sterile injectable composition, e.g., a sterile injectable aqueous or oleaginous suspension, can be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as Tween 80) and suspending agents. The sterile injectable preparation can also be a sterile injectable solution or suspension in a non-toxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or diglycerides). Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long-chain alcohol diluent or dispersant, or carboxymethyl cellulose or similar dispersing agents. Other commonly used surfactants such as Tweens or Spans or other similar emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms can also be used for the purposes of formulation.
A composition for oral administration can be any orally acceptable dosage form including, but not limited to, capsules, tablets, emulsions and aqueous suspensions, dispersions and solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added. A nasal aerosol or inhalation composition can be prepared according to techniques well-known in the art of pharmaceutical formulation and can be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. A fused bicyclic heterocyclic compound-containing composition can also be administered in the form of suppositories for rectal administration.
The carrier in the pharmaceutical composition must be “acceptable” in the sense of being compatible with the active ingredient of the formulation (and preferably, capable of stabilizing it) and not deleterious to the subject to be treated. For example, solubilizing agents such as cyclodextrins, which form specific, more soluble complexes with the fused bicyclic heterocyclic compounds, or one or more solubilizing agents, can be utilized as pharmaceutical excipients for delivery of the fused bicyclic heterocyclic compounds. Examples of other carriers include colloidal silicon dioxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow # 10.
Suitable in vitro assays can be used to preliminarily evaluate the efficacy of one or more of the fused bicyclic heterocyclic compounds in inhibiting growth of cancer cell lines. The compounds can further be examined for its efficacy in treating cancer by in vivo assays. For example, the compounds can be administered to an animal (e.g., a mouse model) having cancer and its therapeutic effects are then assessed. Based on the results, an appropriate dosage range and administration route can also be determined.
The fused bicyclic heterocyclic compounds described above can be screened for the efficacy in inhibiting tubulin polymerization and inhibiting angiogenesis by the methods described in the specific examples below.
Without further elaboration, it is believed that the above description has adequately enabled the present invention. The following specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. All of the publications cited herein are hereby incorporated by reference in their entirety.
EXAMPLES
Example 1
Synthesis of (7-methoxy-imidazo[1,2-a]pyridin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 1)
7-Methoxyimidazo[1,2-a]pyridine was prepared according to the method described in Loeber, S., et al., Bioorg Med Chem Lett 1999, 9 (1), 97-102.
7-Methoxyimidazo[1,2-a]pyridine (621 mg, 4.2 mmol) was mixed with POCl 3 (16.8 mmol) in dimethylformamide (4 mL). The reaction mixture was heated at 90° C. for 24 h and then cooled to room temperature. After the solvent was removed in vacuo, an oil was obtained. The oil was purified on a silica gel column eluting with EtOAc/Hexane (1:1) to afford 7-methoxyimidazo[1,2-a]pyridine-3-carbaldehyde (508 mg, 69%).
To a dry flask equipped with a condenser, an addition funnel, and a magnetic stirrer were added magnesium turnings (2.5 mmol), 0.5 mL of anhydrous tetrahydrofuran (THF), and a small piece of iodine. To this was added via the addition funnel approximately ⅓ of 3,4,5-trimethoxybromobenzene (2.5 mmol) in 1.3 mL of THF. When the solution became colorless (heating may be needed), the remaining 3,4,5-trimethoxybromobenzene solution was added dropwise to the solution under mild refluxing. The reaction mixture was stirred for 1 h at room temperature and then slowly added to 7-methoxyimidazo[1,2-a]pyridine-3-carbaldehyde (0.094 g, 0.53 mmol) in THF (3 mL) at 0° C. After the addition, the solution was allowed to stir at room temperature for another 20 min. Then, a saturated NH 4 Cl solution (5 mL) was slowly added at 0° C., and the mixture was stirred for 10 min. The aqueous layer was separated and extracted with Et 2 O (3×10 mL). The combined organic layers were washed with brine, dried over MgSO 4 , and filtered. The filtrate was concentrated in vacuo and the residue was purified by column chromatography to provide benzhydrol (0.119 g).
MnO 2 (0.444 g, 5.1 mmol) was added to a solution of benzhydrol (0.115 g, 0.33 mmol) in 5 mL anhydrous CH 2 Cl 2 at 0° C. with stirring. After the addition, the mixture was stirred at room temperature for 8 h. The mixture was diluted with anhydrous ether (50 mL) and filtered through a pad of Celite. The filtrate was concentrated in vacuo and the residue was purified by flash chromatography to give compound 1 (0.087 g, 76%).
1 H NMR (300 MHz, CDCl 3 ) δ 3.92 (s, 9H, —OCH 3 ), 3.94 (s, 3H, —OCH 3 ), 6.83 (dd, 1H, J=7.5, 1.5 Hz), 7.11 (s, 2H), 7.12 (d, 1H, J=1.5 Hz), 8.16 (s, 1H), 9.49 (d, J=1H, 7.5 Hz)
Example 2
Synthesis of (7-methoxy-2-methyl-imidazo[1,2-a]pyridin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 2)
A mixture of 4-methoxy-2-aminopyridine (1.07 g, 8.6 mmol) and ethyl 2-chloroacetoacetate (5.4 g) in EtOH (50 mL) was refluxed for 24 h. The reaction mixture was then concentrated to half its volume, extracted with CH 2 Cl 2 , washed with brine and then water, and dried over anhydrous MgSO 4 . The solvent was removed in vacuo and the residue was purified on a silica gel column eluting with EtOAc and then MeOH/CH 2 Cl 2 (1:9) to give ethyl 7-methoxy-2-methylimidazo[1,2-a]pyridine-3-carboxylate (2.71 g, 90%).
A mixture of the resulting product (0.340 g, 1.04 mmol) in THF (15 mL) was stirred for 10 min at 0° C. under N 2 . Lithium aluminum hydride (LAH) was added and the mixture stirred overnight at room temperature under N 2 . An aqueous NH 4 Cl solution (5 mL) was then added. The mixture was concentrated to half its volume and extracted with EtOAc. The combined organic layers were washed with brine and water, dried over anhydrous MgSO 4 , and evaporated to give a residue. MnO 2 (0.783 g, 9 mmol) was added to the residue in anhydrous CH 2 Cl 2 (15 mL) at 0° C. with stirring. After the addition, the mixture was stirred at room temperature for 8 h, diluted with anhydrous ether (50 mL) and filtered through a pad of Celite. The filtrate was concentrated in vacuo and the residue was purified by flash chromatography to give 7-methoxy-2-methylimidazo[1,2-a]pyridine-3-carbaldehyde (0.070 g, 53%).
The resulting product was then reacted with 3,4,5-trimethoxybromobenzene and then oxidized by MnO 2 in a manner similar to that described in Example 1 to afford compound 2 at a yield of 55%.
1 H NMR (300 MHz, CDCl 3 ) δ 2.22 (s, 3H, —CH 3 ), 3.89 (s, 6H, —OCH 3 ), 3.92 (s, 3H, —OCH 3 ), 3.93 (s, 3H, —OCH 3 ), 6.71 (dd, 1H, J=7.8, 2.4 Hz), 6.92 (s, 3H), 9.24 (d, 1H, J=7.8 Hz).
Example 3
Synthesis of (6-methoxy-3a,7a-dihydro-1H-indazol-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 3)
A mixture of 6-methoxy-1H-indazole-3-carboxylic acid (0.200 g, 1.04 mmol) in THF (15 mL) was stirred for 10 min at 0° C. under N 2 . LAH was added and the mixture was stirred overnight at room temperature under N 2 . Then, an aqueous NH 4 Cl solution (5 mL) was added and the reaction mixture was concentrated to half its volume and extracted with EtOAc. The organic layer was washed with brine and water, dried over anhydrous MgSO 4 , and the solvent removed in vacuo to give a residue. MnO 2 (0.680 g, 7.8 mmol) was added to the residue in anhydrous CH 2 Cl 2 (15 mL) at 0° C. with stirring. After the addition, the mixture was stirred at room temperature for 8 h. The mixture was diluted with anhydrous ether (50 mL) and filtered through a pad of Celite. The filtrate was concentrated in vacuo and the residue was purified by flash chromatography to give 6-methoxy-1H-indazole-3-carbaldehyde (0.100 g, 56%).
The resulting product was coupled with 3,4,5-trimethoxybromobenzene and subsequently oxidized by MnO 2 in a manner similar to that described in Example 1 to afford compound 3 at a yield of 54%.
1 H NMR (300 MHz, CDCl 3 ) δ 3.89 (s, 3H, —OCH 3 ), 3.93 (s, 6H, —OCH 3 ), 3.94 (s, 3H, —OCH 3 ), 6.90 (d, 1H, J=2.1 Hz), 7.01 (dd, 1H, J=9, 2.1 Hz), 7.665 (s, 2H), 8.27 (d, 1H, J=9 Hz), 10.44 (s, 1H).
Example 4
Synthesis of (6-methoxy-indolizin-1-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 4)
Potassium tert-butoxide (5.4 g, 48 mmol) was added to 3-methyl-pyridin-3-ol (5 g, 45.87 mmol) in THF (200 mL) at 0° C. The mixture was stirred at room temperature for 30 min. MeI (3.2 mL, 48 mmol) was added dropwise at 0° C. and stirring was continued at room temperature for 8 h. Water was added and the mixture was evaporated to half its volume and extracted with EtOAc. The organic layer was washed with brine and water, dried over anhydrous MgSO 4 , and filtered. The filtrate was concentrated in vacuo, and the residue was purified by flash chromatography to give 5-methoxy-2-methyl-pyridine (4.8 g, 85%).
n-BuLi in hexane (1.6 M, 7.6 mL, 11.9 mmol) was added dropwise to a solution of diisopropylamine (1.089 g, 10.9 mmol) in THF (25 mL) at −60 to −70° C. under N 2 . The mixture was stirred for 10 min. A solution of 5-methoxy-2-methyl-pyridine (1.274 g, 10.35 mmol) in THF (5 mL) was added dropwise to the above mixture. Stirring was continued for another 10 min and 3,4,5-trimethoxybenzonitrile (1.88 g, 9.74 mmol) in THF (5 mL) was added at −70° C. The mixture was stirred at −78° C. for 1 h and then allowed to warm to room temperature. Stirring was continued for another 2 h and the reaction mixture was poured into an ice-cold aqueous NH 4 Cl solution. The organic layer was separated and the aqueous phase was extracted with ether. The combined organic layers were extracted with a dilute HCl solution. The aqueous layer was washed with ether, neutralized with 10% aqueous NaOH, and extracted with ether. The organic layer was washed with water and dried. The residue was purified by chromatography eluting with CH 2 Cl 2 to give 2-(5-methoxypyridin-2-yl)-1-(3,4,5-trimethoxyphenyl)ethanone (2.31 g, 75.0%).
A mixture of the resulting pyridine derivative (0.200 g, 0.631 mmol), chloroacetaldehyde (0.099 g, 1.3 mmol), and NaHCO 3 (0.212 g, 2.6 mmol) in acetone (5 mL) was refluxed for 20 h. The precipitate was removed by filtration. The filtrate was concentrated to give a residue, which was purified on a silica gel column eluting with CH 2 Cl 2 to afford compound 4 (0.184 g, 95%).
1 H NMR (300 MHz, CDCl 3 ) δ 3.86 (s, 3H, —OCH 3 ), 3.91 (s, 6H, —OCH 3 ), 3.93 (s, 3H, —OCH 3 ), 7.00 (dd, 1H, J=9.6, 1.5 Hz), 7.08 (d, 1H, J=3 Hz), 7.10 (s, 2H), 7.62 (d, 1H, J=1.5 Hz), 8.37 (d, J=1H, 9.6 Hz).
Example 5
Synthesis of (6-methoxy-2-methyl-indolizin-1-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 5)
A mixture of 2-(5-methoxypyridin-2-yl)-1-(3,4,5-trimethoxyphenyl)ethanone (0.200 g, 0.631 mmol), 1-bromo-2-propanone (0.171 g, 1.3 mmol), and NaHCO 3 (0.212 g, 2.6 mmol) in acetone (5 mL) was refluxed for 20 h. The precipitate was removed by filtration. The filtrate was concentrated to give a residue, which was purified on a silica gel column eluting with CH 2 Cl 2 to afford compound 5 (0.213 g, 95%).
1 H NMR (300 MHz, CDCl 3 ) δ2.29 (s, 3H, —CH 3 ), 3.81 (s, 3H, —OCH 3 ), 3.85 (s, 6H, —OCH 3 ), 3.92 (s, 3H, —OCH 3 ), 6.74 (dd, 1H, J=9.6, 2.1 Hz), 6.97 (s, 2H), 7.08 (s, 1H), 7.40 (d, 1H, J=9.6 Hz), 7.50 (d, 1H, J=2.1 Hz).
Example 6
Synthesis of (2-ethyl-6-methoxy-indolizin-1-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 6)
A mixture of A mixture of 2-(5-methoxypyridin-2-yl)-1-(3,4,5-trimethoxyphenyl)ethanone (0.200 g, 0.631 mmol), 1-bromo-2-butanone (0.190 g, 1.3 mmol), and NaHCO 3 (0.212 g, 2.6 mmol) in acetone (5 mL) was heated under reflux for 20 h. The precipitate was removed by filtration. The filtrate was concentrated to give a residue, which was purified on a silica gel column eluting with CH 2 Cl 2 to afford compound 6 (0.213 g, 92%).
1 H NMR (300 MHz, CDCl 3 ) δ 1.23 (t, 3H, —CH 2 CH 3 , J=7.5 Hz), 2.79 (q, 2H, —CH 2 CH 3 , J=7.5 Hz), 3.81 (s, 3H, —OCH 3 ), 3.84 (s, 6H, —OCH 3 ), 3.92 (s, 3H, —OCH 3 ), 6.71 (dd, 1H, J=9.9, 2.1 Hz), 6.97 (s, 2H), 7.13 (s, 1H), 7.31 (d, 1H, J=9.9 Hz), 7.52 (d, 1H, J=2.1 Hz).
Example 7
Synthesis of (7-methoxy-2-methyl-indolizin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 7)
Methylzinc chloride in THF (2 M, 10.489 mL, 21 mmol) was added to a solution of 2-chloro-4-methoxypyridine (0.500 g, 3.48 mmol) and Pd(PPh 3 ) 4 (0.161 g, 0.14 mmol) in THF (10 mL). The mixture was refluxed for 40 h and then poured into an aqueous solution (10 mL) containing ethylenediaminetetraacetic acid (1.5 g). The resulting mixture was neutralized with K 2 CO 3 and extracted with Et 2 O. The organic layer was concentrated to give a residue, which was purified on a silica gel column eluting with MeOH:EtOAc (1:10) to give 4-methoxy-2-methylpyridine (0.213 g, 50.0%).
4-Methoxy-2-methylpyridine (0.123 g, 1 mmol) and bromoacetone (0.16 mL, 1 mmol) were heated at 95° C. under N 2 for 2 h. 1,8-Diazabicyclo-[5.4.0]-undec-7-ene (0.34 mL, 2.2 mmol) in benzene (10 mL) was added. The mixture was then refluxed under N 2 for 1 h, poured into ice water, and then extracted with EtOAc. The combined organic layers were washed with water and dried. After the solvent was removed in vacuo, the residue was purified on a silica gel column eluting with EtOAc:Hexane (1:9) and EtOAc to give 7-methoxy-2-methylindolizine (0.050 g, 31%).
A mixture of the indolizine 7-methoxy-2-methylindolizine (0.040 g, 0.25 mmol, 1 eq.), substituted benzoyl chloride (2.0 eq.), and Et 3 N (5.0 eq.) was heated at 90° C. (bath temperature) for 2-8 h. The reaction mixture was cooled to room temperature, and EtOAc was added. The organic layer was separated and washed with dilute HCl and water and dried. After the solvent was removed, the residue was purified on a silica gel column eluting with EtOAc:hexane (1:9) to give compound 7 (0.065 g, 74%).
1 H NMR (300 MHz, CDCl 3 ) δ 1.97 (s, 3H, —CH 3 ), 3.91 (s, 3H, —OCH 3 ), 3.88 (s, 9H, —OCH 3 ), 6.15 (s, 1H), 6.54 (dd, 1H, J=7.8, 2.7 Hz), 6.69 (d, 1H, J=2.7 Hz), 6.85 (s, 2H), 9.62 (s, 1H)
Example 8
Synthesis of (6-methyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 8)
6-Chloro-1-(phenylsulfonyl)-1H-pyrrolo[2,3-b]pyridine was prepared by the method described in Samuel C. et al., Heterocycles, 1990, 30 (1), 627-633.
A solution of methylzinc chloride in THF (2 M) (9 mL, 12 mmol) was added to 6-chloro-1-(phenylsulfonyl)-1H-pyrrolo[2,3-b]pyridine (0.600 g, 2.05 mmol) and Pd(PPh 3 ) 4 (0.095 g, 0.08 mmol) in THF (30 mL). The mixture was refluxed for 40 h, cooled to 0° C., quenched with water and extracted with Et 2 O. The organic layer was concentrated and the residue was purified over a silica gel column eluting with EtOAc/hexane (1:5) to give N-protected 6-methyl-7-azaindole (0.495 g, 88%).
A solution of 50% NaOH (0.573 g) was added to N-protected 6-methyl-7-azaindole (0.390 g, 1.43 mmol) in Ethanol (10 mL). After refluxed for 8 h, the mixture was concentrated and was extracted with CHCl 3 . The organic layer was washed with water and dried. The solvent was evaporated in vacuo and the residue was purified on a silica gel column eluting with EtOAc/hexane (1:3) to give 6-methyl-1H-pyrrolo[2,3-b]pyridine (0.148 g, 78%).
Ethylmagnesium bromide (3.0 M solution in diethyl ether, 0.43 mL) was added to a mixture of 6-methyl-1H-pyrrolo[2,3-b]pyridine (0.127 g, 0.969 mmol) and anhydrous zinc chloride (0.263 g, 1.94 mmol) in dry CH 2 Cl 2 (20 mL) over 10 min at room temperature. The suspension was stirred for 1 h and then a solution of 3,4,5-trimethoxybenzoyl chloride (0.335 g, 1.45 mmol) in dry CH 2 Cl 2 (10 mL) was added dropwise over 5 min. After 1 h, aluminum chloride (0.129 g, 0.969 mmol) was added. The resulting thick mixture was vigorously stirred for 5 h. The reaction was quenched with water (10 mL) and extracted with CH 2 Cl 2 (20 mL). The organic layer was dried over anhydrous MgSO 4 and concentrated to give a brown oil, which was further purified on a silica gel column (MeOH:CH 2 Cl 2 =1:25) to give compound 8 (0.150 g, 48%) as a white solid.
1 H NMR (300 MHz, CDCl 3 ) δ 2.76 (s, 3H, —CH 3 ), 3.92 (s, 6H, —OCH 3 ), 3.96 (s, 3H, —OCH 3 ), 7.17 (s, 2H), 7.21(d, 1H, J=8.1 Hz), 7.90 (s, 1H), 8.59 (d, 1H, J=8.1 Hz), 13.29 (s, 1H)
Example 9
Synthesis of (6-methoxy-1H-pyrrolo[2,3-b]pyridin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 9)
7-Azaindole N-oxide was prepared by the method described in Minakata et al., Synthesis, 1992, 7, 661-663.
A mixture of 7-azaindole N-oxide (5.55 g, 8.6 mmol) in Ac 2 O (30 mL) was refluxed for 12 h. The reaction mixture was concentrated to half its volume, extracted with CH 2 Cl 2 , washed with water, dried over anhydrous MgSO 4 , and evaporated to give a residue, which was purified on a column of silica gel eluting with EtOAc/hexane (1:6) to give 1-acetyl-1H-pyrrolo[2,3-b]pyridin-6-yl acetate (4.55 g, 70%).
A mixture of 1-acetyl-1H-pyrrolo[2,3-b]pyridin-6-yl acetate (0.635 g, 2.9 mmol) and K 2 CO 3 (1.6 g, 12 mmol) in MeOH/H 2 O (20 mL/20 mL) was stirred at room temperature for 12 h. The reaction mixture was concentrated to half its volume and extracted with CHCl 3 . The organic layer was dried over anhydrous MgSO 4 and evaporated to give a residue, which was further purified on a silica gel column to give 1H-pyrrolo[2,3-b]pyridin-6-ol (0.233 g, 60%).
A mixture of 1H-pyrrolo[2,3-b]pyridin-6-ol (0.200 g, 1.49 mmol) and K 2 CO 3 (1 g, 7.45 mmol) in acetone (30 mL) was stirred under N 2 at room temperature for 1 h. MeI (0.166 g, 1.192 mmol) was added. The reaction mixture was stirred under N 2 at 50° C. for 12 h and then filtered. The filtrate was concentrated to half its volume, diluted with water, and extracted with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , and evaporated to give a residue, which was purified on a column of silica gel eluting with EtOAc/hexane (1:4) to give 6-methoxy-1H-pyrrolo[2,3-b]pyridine (159 mg, 89%).
Ethylmagnesium bromide (3.0 M solution in diethyl ether, 0.33 mL) was added to a mixture of 6-methoxy-1H-pyrrolo[2,3-b]pyridine (0.108 g, 0.73 mmol) and anhydrous zinc chloride (0.201 g, 1.46 mmol) in dry CH 2 Cl 2 (20 mL) over 10 min at room temperature. The suspension was stirred for 1 h and 3,4,5-trimethoxybenzoyl chloride (0.252 g, 1.09 mmol) in dry CH 2 Cl 2 (10 mL) was then added dropwise over 5 min. After the reaction mixture was stirred for 1 h, aluminum chloride (0.097 g, 0.73 mmol) was added. The resulting thick mixture was vigorously stirred for 5 h. The reaction was quenched with water (10 mL) and extracted with CH 2 Cl 2 (20 mL). The combined organic layers were dried over anhydrous MgSO 4 and evaporated to give a brown oil, which was purified on a silica gel column eluting with EtOAc/hexane (1:1) to compound 9 (0.189 g, 76%).
1 H NMR (300 MHz, CDCl 3 ) δ 3.91 (s, 6H, —OCH 3 ), 3.94 (s, 3H, —OCH 3 ), 3.99 (s, 3H, —OCH 3 ), 6.78(d, 1H, J=8.7 Hz), 7.12 (s, 2H), 7.64(d, 1H, J=3 Hz), 8.49(d, 1H, J=8.7 Hz), 9.09 (s, 1H)
Example 10
Synthesis of (6-ethoxy-1H-pyrrolo[2,3-b]pyridin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 10)
Compound 10 was prepared by the same method described in Example 9 except EtI, instead of MeI, was used.
1 H NMR (300 MHz, CDCl 3 ): δ 1.45(t, 1H, —OCH 2 CH 3 , J=6.9 Hz), 3.91 (s, 3H, —OCH 3 ), 3.93 (s, 3H, —OCH 3 ), 3.94 (s, 3H, —OCH 3 ), 4.39(q, 2H, —OCH 2 CH 3 , J=6.9 Hz), 6.76(d, 1H, J=9 Hz), 7.12 (s, 2H), 7.62(d, 1H, J=3 Hz), 8.48(d, 1H, J=9 Hz), 8.93 (s, 1H)
Example 11
Synthesis of (6-methoxy-3a,7a-dihydro-benzofuran-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 11)
A mixture of (6-methoxy-benzofuran-3-yl)-acetic acid (2 g, 9.7 mmol) and H 2 SO 4 (0.3 mL) in methanol (40 mL) was refluxed for 8 h and then concentrated. An aqueous NaHCO 3 solution was added, followed by extraction with CH 2 Cl 2 . The combined organic layers were dried over anhydrous MgSO 4 and evaporated to give a brown oil, which was purified on a silica gel column eluting with EtOAc/hexane (1:10) to give methyl 2-(6-methoxybenzofuran-3-yl)acetate (2.1 g, 98%)
A mixture of methyl 2-(6-methoxybenzofuran-3-yl)acetate (0.500 g, 2.27 mmol) and SeO 2 (0.303 g, 2.73 mmol) in 1,4-dioxane (10 mL) was refluxed for 2 days and then filtered. The filtrate was concentrated in vacuo and the residue was purified on a silica gel column to give methyl 2-(6-methoxybenzofuran-3-yl)-2-oxoacetate (0.452 g, 85%)
LAH (0.093 g, 2.39 mmol) was added to a mixture of methyl 2-(6-methoxybenzofuran-3-yl)-2-oxoacetate (0.280 g, 1.196 mmol) in THF (10 mL) at 0° C. under N 2 , and the mixture was stirred overnight at room temperature under N 2 . An aqueous NH 4 Cl solution (5 mL) was added, and the reaction mixture was concentrated to half its volume and extracted with EtOAc. The organic layer was washed with brine and water, dried over anhydrous MgSO 4 , and evaporated to give 1-(6-methoxy-benzofuran-3-yl)-ethane-1,2-diol.
NaIO 4 (0.204 g, 1.12 mmol) was added to 1-(6-methoxy-benzofuran-3-yl)-ethane-1,2-diol (0.180 g, 1.196 mmol) in THF (50 mL) and water (1 mL) with stirring. The mixture was stirred overnight at room temperature under N 2 . Water (10 mL) was added, and the mixture was concentrated to half its volume and extracted with EtOAc. The organic layer was washed with brine and water, dried over anhyd. MgSO 4 , and evaporated to give a residue, which was purified on a silica gel column eluting with EtOAc/hexane (1:10) to give 6-methoxybenzofuran-3-carbaldehyde (0.110 g, 73%).
To a dry flask equipped with a condenser, an addition funnel, and a magnetic stirrer were added magnesium turnings (2.5 mmol), THF (0.5 mL), and a small piece of iodine. To this was added via the addition funnel approximately ⅓ of 3,4,5-trimethoxybromobenzene (2.5 mmol) in 1.3 mL of THF. When the solution became colorless (heating may be needed), the remaining 3,4,5-trimethoxybromobenzene solution was added dropwise to the solution under mild refluxing. Stirring was then continued for 1 h at room temperature. The resulting solution was then slowly added to 6-methoxybenzofuran-3-carbaldehyde (0.100 g, 0.176 mmol) in anhydrous THF (5 mL) at 0° C. After the addition, the solution was allowed to stir at room temperature for another 20 min. Then, a saturated NH 4 Cl solution (5 mL) was slowly added at 0° C., and the mixture was stirred for 10 min. The aqueous layer was separated and extracted with Et 2 O (3×10 mL). The combined organic layers were washed with brine, dried over MgSO 4 , and filtered. The filtrate was concentrated in vacuo and the residue was purified by column chromatography to provide benzhydrol (0.097 g, 50%).
MnO 2 (0.193 g, 1.88 mmol) was added to a solution of benzhydrol (0.050 g, 0.145 mmol) in 5 mL anhydrous CH 2 Cl 2 at 0° C. with stirring. After the addition, the mixture was stirred at room temperature for 8 h. The mixture was diluted with anhydrous ether (50 mL) and filtered through a pad of Celite. The filtrate was concentrated in vacuo and the residue was purified by flash chromatography to give compound 11 (0.043 g, 87%)
1 H NMR (300 MHz, CDCl 3 ) δ 3.89 (s, 3H, —OCH 3 ), 3.92 (s, 6H, —OCH 3 ), 3.95 (s, 3H, —OCH 3 ), 7.03(dd, 1H, J=8.4, 2.1 Hz), 7.08(d, 1H, J=2.1 Hz), 7.16 (s, 2H), 8.03(s, 1H), 8.05 (d, 1H, J=9.3 Hz).
Example 12
Synthesis of (6-methoxy-2-methyl-3a,7a-dihydro-benzofuran-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 12)
A mixture of 6-methoxybenzofuran-3-carbaldehyde (0.600 g, 3.41 mmol), HOCH 2 CH 2 OH (3.17 g, 51 mmol) and p-toluenesulfonic acids (0.001 g) in benzene (20 mL) was refluxed for 8 h using a Dean-Stark water trap. The mixture was concentrated under reduced pressure and then diluted with EtOAc. The organic solution was washed with water, dried over anhydrous MgSO 4 , and concentrated to give 3-(1,3-dioxolan-2-yl)-6-methoxybenzofuran (0.711 g, 95%)
3-(1,3-Dioxolan-2-yl)-6-methoxybenzofuran (0.144 g, 0.65 mmol) was dissolved in THF (5 mL) at −30 to −20° C. To this solution was added dropwise tert-butyllithium (15% in pentane, 0.56 mL, 1.31 mmol). The reaction mixture was continuously stirred at −30° C. for 30 min and then allowed to warm to 0° C. and stir for another 20 min. The reaction mixture was cooled to −30° C. again and iodomethane (0.138 g, 0.98 mmol) was added dropwise. After stirring at −30° C. for another 1 h, it was allowed to warm to room temperature overnight. After the solvent was removed under reduced pressure, the residue was dissolved in EtOAc and washed with saturated NaHCO 3 . The aqueous layer was extracted with EtOAc (3×20 mL). The combined organic layers were dried over anhydrous MgSO 4 and concentrated under reduced pressure to provide 3-[1,3]dioxolan-2-yl-6-methoxy-2-methyl-benzofuran.
2N HCl (5 mL) was added to 3-[1,3]dioxolan-2-yl-6-methoxy-2-methyl-benzofuran in THF (5 mL) at 0° C. After stirring for 1 h at room temperature, the solvent was removed under reduced pressure. The residue was dissolved in EtOAc and washed with saturated NaHCO 3 . The aqueous layer was extracted with EtOAc (3×20 mL). The organic layers were combined and dried over anhydrous MgSO 4 . After the solvent was removed, the residue was purified on a silica gel column eluting with EtOAc/hexane (1:9) to give 6-methoxy-2-methylbenzofuran-3-carbaldehyde (0.090 g, 81%).
6-Methoxy-2-methylbenzofuran-3-carbaldehyde was coupled with 3,4,5-trimethoxybromobenzene and subsequently oxidized by MnO 2 in a manner similar to that described in Example 11 to afford compound 12.
1 H NMR (300 MHz, CDCl 3 ) δ 2.55 (s, 3H, —CH 3 ), 3.85 (s, 6H, —OCH 3 ), 3.86 (s, 3H, —OCH 3 ), 3.95 (s, 3H, —OCH 3 ), 6.85 (dd, 1H, J=9, 2.4 Hz), 7.01(d, 1H, J=2.4 Hz), 7.12 (s, 2H), 7.34 (d, 1H, J=9 Hz).
Example 13
Synthesis of (6-methoxy-3a,7a-dihydro-benzo[b]thiophen-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 13)
6-Methoxy-3-methylbenzo[b]thiophene was prepared using the method described in Campaigne et al., J Heterocycl Chem, 1970, 7, 695.
A mixture of 6-methoxy-3-methylbenzo[b]thiophene (2.753 g, 15.5 mmol) and SeO 2 (2.06 g, 18.55 mmol) in 1,4-dioxane (30 mL) was refluxed for 2 days and then filtered. The filtrate was concentrated in vacuo, and the residue was purified on a silica gel column eluting with EtOAc/hexane (1:10) to give 6-methoxybenzo[b]thiophene-3-carbaldehyde (2.3 g, 80%).
The resulting product was then coupled with 3,4,5-trimethoxybromobenzene and then oxidized by MnO 2 in a manner similar to that described in Example 11 to afford compound 13 at a yield of 54%.
1 H NMR (300 MHz, CDCl 3 ) δ 3.89 (s, 6H, —OCH 3 ), 3.91 (s, 3H, —OCH 3 ), 3.95 (s, 3H, —OCH 3 ), 7.13 (dd, 1H, J=9, 2.4 Hz), 7.14 (s, 2H), 7.36(d, 1H, J=2.4 Hz), 7.85 (s, 1H), 8.37 (d, 1H, J=9 Hz).
Example 14
Synthesis of (6-methoxy-2-methyl-3a,7a-dihydro-benzo[b]thiophen-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 14)
6-Methoxybenzo[b]thiophene-3-carbaldehyde was converted to 3-(1,3-dioxolan-2-yl)-6-methoxybenzo[b]thiophene according to the method described in Example 12.
The resulting product was then coupled with 3,4,5-trimethoxybromobenzene and then oxidized by MnO 2 in a manner similar to that described in Example 11 to afford compound 14 at a yield of 79%.
1 H NMR (300 MHz, CDCl 3 ) δ 2.49 (s, 3H, —CH 3 ), 3.82 (s, 6H, —OCH 3 ), 3.87 (s, 3H, —OCH 3 ), 3.95 (s, 3H, —OCH 3 ), 6.92 (dd, 1H, J=9, 2.4 Hz), 7.12 (s, 2H), 7.26(d, 1H, J=2.4 Hz), 7.44 (d, 1H, J=9 Hz).
Example 15
Synthesis of (6-methoxy-pyrazolo[1,5-b]pyridazin-3-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 15)
A solution of 3,4,5-trimethoxybenzaldehyde (1.0 g, 5.0 mmol) in THF (50 mL) was stirred at 0° C. Sodium acetylide (18% w.t. slurry in xylene, 1.63 g, 6.1 mmol) was added via syringe. The reaction mixture was stirred overnight at room temperature and quenched by water. It was then extracted with EtOAc (30 mL×3). The combined organic layers were washed with brine, dried over anhydrous MgSO 4 , filtered, and concentrated to give a crude product, which was purified by flash column chromatography eluting with EtOAc/n-hexane (1:2) to afford 1-(3,4,5-trimethoxyphenyl)prop-2-yn-1-ol as a white solid (815 mg, 72%).
To a stirred solution of 1-(3,4,5-trimethoxyphenyl)prop-2-yn-1-ol (100 mg, 0.44 mmol) in acetone (10 mL), aqueous Jones reagent was added dropwise at 0° C. until the red color persisted. The reaction mixture was quenched by 2-propanol, and the precipitate was were removed by filtered through Celite. The filtrate was diluted with EtOAc, washed several times with a saturated aqueous NaHCO 3 solution, water and brine, dried over MgSO 4 , and concentrated to give crude product, which was purified by flash chromatography eluting with EtOAc/n-hexane (1:4) to afford 1-(3,4,5-trimethoxyphenyl)prop-2-yn-1-one as a colorless oil (74 mg, 75%).
A mixture of 3-chloro-6-methoxypyridazine (1.0 g, 6.9 mmol) in methanol (50 mL) with 33% palladium on carbon (100 mg) was hydrogenated under 45 psi overnight. The catalyst was removed by filtration through a pad of Celite. The filtrate was concentrated and dissolved in EtOAc. The solution was washed several times with a saturated NaHCO 3 solution and brine, dried over MgSO 4 , concentrated to give a crude product, which was purified on a silica gel column eluting with EtOAc/n-hexane (1:2) to give 3-methoxypyridazine as a pale yellow solid (662 mg, 87%).
1 H NMR (300 MHz, CDCl 3 ): δ 4.14 (s, 3H), 6.98 (dd, J=1.2, 9.0 Hz, 1H), 7.36 (dd, J=4.5, 8.7 Hz, 1H), 8.84 (dd, J=1.2, 4.5 Hz, 1H).
Potassium bicarbonate (2.5 M) was added to a solution of hydroxylamine-O-sulfonic acid (64.7 mg, 0.57 mmol) until the pH value turned to 5. Then, 3-methoxypyridazine (42 mg, 0.38 mmol) was added at 70° C. over 10 min. The mixture was stirred at 70° C. for 2 h and then cooled to room temperature. The pH value of the mixture was adjusted to 8 by addition of 2.5M potassium bicarbonate. 1-(3,4,5-Trimethoxyphenyl)prop-2-yn-1-one (42 mg, 0.19 mmol) in CH 2 Cl 2 (10 mL) and potassium hydroxide (40 mg, 0.71 mmol) were added. The mixture was stirred at room temperature overnight, and then was extracted with CH 2 Cl 2 , and the combined organic layers were washed with brine, dried over MgSO 4 , and concentrated to give a crude product, which was purified on a silica gel column eluting with CH 2 Cl 2 /MeOH (20:1) to afford compound 15 as a white solid (31 mg, 48%).
1 H NMR (300 MHz, CDCl 3 ): δ 3.93 (s, 6H), 3.95 (s, 3H), 4.11 (s, 3H), 7.00 (d, J=9.3 Hz, 1H), 7.15 (s, 2H), 8.23 (s, 1H), 8.56 (d, J=9.6 Hz, 1H).
Example 16
Synthesis of (2-methoxy-7H-pyrrolo[2,3-d]pyrimidin-5-yl)-(3,4,5-trimethoxy-phenyl)-methanone (compound 16)
10% Pd/C (1.000 g, 11.6 mmol) was added to a solution of 4-chloro-2-methoxy-7H-pyrrolo[2,3-d]pyrimidine (0.200 g, 1.09 mmol) in 20 mL anhydrous MeOH under H 2 at room temperature. The mixture was stirred for 8 h and then filtered through a pad of Celite. The filtrate was concentrated in vacuo to give 2-methoxy-6,7-dihydro-5H-pyrrolo[2,3-d]pyrimidine as a major product.
MnO 2 (1.720 g, 20 mmol) was added to 2-methoxy-6,7-dihydro-5H-pyrrolo[2,3-d]pyrimidine in 20 mL of anhydrous CH 2 Cl 2 at room temperature. The mixture was stirred for 8 h, diluted with anhydrous ether (50 mL), and filtered through a pad of Celite. The filtrate was concentrated in vacuo, and the residue was purified on a silica gel column eluting with MeOH/CH 2 Cl 2 (1:9) to give 2-methoxy-7H-pyrrolo[2,3-d]pyrimidine (0.149 g, 90%).
To a mixture of 2-methoxy-7H-pyrrolo[2,3-d]pyrimidine (0.220 g, 1.476 mmol) and anhydrous zinc chloride (0.407 g, 2.953 mmol) in dry CH 2 Cl 2 (20 mL), ethylmagnesium bromide (0.65 mL, 3.0 M solution in diethyl ether) was added over 10 min at room temperature. The suspension was stirred for 1 h, and then 3,4,5-trimethoxybenzoyl chloride (0.510 g, 2.2 mmol) in dry CH 2 Cl 2 (10 mL) was added dropwise over 5 min. The reaction mixture was stirred for another 1 h and then aluminum chloride (0.196 mg, 1.476 mmol) was added. The resulting thick mixture was vigorously stirred for 5 h. The reaction was quenched with water (10 mL) and extracted with CH 2 Cl 2 (20 mL). The combined organic layers were dried over anhydrous MgSO 4 and evaporated to give a brown oil, which was purified on a silica gel column (EtOAc:Hexane=1:1 to MeOH:CH 2 Cl 2 =1:20) to give compound 16 (0.081 g, 20%).
1 H NMR (300 MHz, CDCl 3 ) δ 3.93 (s, 6H, —OCH 3 ), 3.95 (s, 3H, —OCH 3 ), 4.09 (s, 3H, —OCH 3 ), 7.13 (s, 2H), 7.71(d, 1H, J=2.4 Hz), 9.38 (s, 1H), 9.79 (s, 1H).
Example 17
Cell Growth Inhibition Assay
KB cells (a cell line derived from a human carcinoma of the nasopharynx) and MKN-45 cells (a gastric cancer cell line) were maintained in plastic dishes in RPMI 1640 medium supplemented with 5% fetal bovine serum. The KB cells were seeded in 96-well plates at a final cell density of 7,000 cell/mL. The MKN-45 cells were seeded in 96-well plates at a final cell density of 20,000 cell/mL. The cells were treated with a test compound (at least five different concentrations for the test compound), and incubated in a CO 2 incubator at 37° C. for 72 h. The number of viable cells was estimated using the MTS assay (or the methylene blue assay) and absorbance was measured at 490 nm. Cytotoxicity of the test compounds was expressed in terms of IC 50 values. The values represent averages of three independent experiments, each with duplicate samples.
Compounds 1-14 were tested in the above assay. All of them effectively inhibited growth of KB cells and MKN-45 cells. Unexpectedly, most of them exhibited IC 50 values lower than 1 mM, some even lower than 100 nM.
Example 18
Tubulin Polymerization Assay
Turbidimetric assays of microtubule are performed according to the procedure described by Lopes et al. (1997, Cancer Chemother. Pharmacol. 41: 37-47) with some modifications. MAP-rich tubulin (2 mg/ml) is preincubated in a polymerization buffer (0.1 M PIPES, pH 6.9, 1 mM MgCl 2 ) with a test compound at 4° C. for 2 min before the addition of 1 mM GTP. The samples are then rapidly warmed to 37° C. in a 96-well plate thermostatically controlled spectrophotometer and measuring the change at 350 nm with time.
Example 19
Cell Growth Inhibition Assay on Multiple-Drug Resistant Human Cancer Cell Lines
Several fused bicyclic heteroaryl compounds of this invention are tested against several panels of drug-resistant cell lines. It is well known that several anti-mitotic agents, including vinca alkaloid (e.g., vincristine and vinblastine) and taxol, have been used to treat various human cancers. Vinca alkaloid resistance has been attributed to a number of mechanisms associated with the multi-drug resistance (MDR) phenotype, including overexpression of p-glycoprotein and multi-drug resistant-associated protein (MRP). The mechanisms responsible for taxol resistance include overexpression of p-glycoprotein and mutation of tubulin. For comparison, five anti-mitotic agents, i.e., vincristine, VP-16, cisplatin, camptothecin, and taxol, are also tested against several panels of drug-resistant cell lines e.g., KB-Vin10 (a vincristine-resistant cell line), KB100 (a camptotnecin-resistant cell line), and CPT30 (a camptothecin-resistant cell line).
Example 20
CAM Assay for Antiangiogenic Potency
Each test compound is dissolved in a 2.5% aqueous agarose solution (final concentration: 1-20 mg/mL). 10 μL of the solution are applied dropwise on circular Teflon pallets of 3 mm in diameter and then cooled to room temperature at once. After incubation at 37° C. and relative humidity of 80% for 65-70 h, fertilized hen eggs are positioned in a horizontal position and rotated several times. Before opening the snub side, 10 mL of albumin are aspirated from a hole on the pointed side. At two-third of the height (from the pointed side), the eggs are traced with a scalpel and the shells are removed with forceps. After the aperture (cavity) has been covered with keep-fresh film, the eggs are incubated at 37° C. at a relative humidity of 80% for 75 h. When the chorioallantoic membrane approximates a diameter of 2 cm, one pellet (1 pellet/egg) is placed on it. The eggs are incubated for 1 day and subsequently evaluated under the stereomicroscope.
Other Embodiments
All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. For example, compounds structurally analogous to the fused bicyclic heteroaryl compounds of this invention also can be made, screened for their inhibitory activities against cancer cell growth, and used to practice this invention. Thus, other embodiments are also within the claims. | Compounds of the following formula:
wherein A, D, Q, T, U, V, W, X, Y, Z, R 1 , and | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/736,856, filed Dec. 13, 2012 and to U.S. Provisional Patent Application No. 61/820,231 filed on May 7, 2013. The contents of the entirety of each of the foregoing are hereby incorporated in their entireties herein by this reference.
TECHNICAL FIELD
[0002] This disclosure relates to the targeted stable integration of foreign polynucleotides into one particular locus of the maize genome through the use of zinc finger nucleases.
REFERENCE TO SEQUENCE LISTING SUBMITTED ELECTRONICALLY
[0003] The official copy of the sequence listing is submitted electronically via EFS-Web as an ASCII formatted sequence listing with a file named “74381_ST25.txt”, created on Nov. 26, 2013, and having a size of 23.7 kilobytes and is filed concurrently with the specification. The sequence listing contained in this ASCII formatted document is part of the specification and is herein incorporated by reference in its entirety.
BACKGROUND
[0004] The genomic locus of Corn Event DAS-59132 is described in U.S. Pat. No. 8,273,535, METHODS FOR DETECTION OF CORN EVENT DAS-59132. The transgene expression cassette integrated into chromosome 8 of the B73 maize genome derived region of Hi-II maize germplasm (D. D. Songstad, W. L. Petersen, C. L. Armstrong, American Journal of Botany , Vol. 79, pp. 761-764, 1992) as a full length T-strand insert. In addition, the genomic DNA surrounding the transgenic locus lacked any large deletions relative to the native B73 sequence, and was generally devoid of repetitive elements except for a single, small repetitive element. Extensive field studies revealed that the presence of the event did not adversely affect normal growth and development of plants that carried the event. Moreover, corn lines bearing the event retained the agronomic and breeding characteristics comparable in agronomic performance to non-transformed isolines. Hence the genomic locus in which Corn Event DAS-59132 integrated represents an excellent endogenous genomic locus in maize for the targeted integration of other transgenic constructs and hereinafter is referred to as the E32 or Event32 locus.
[0005] Targeted genome modification of plants has been a long-standing and elusive goal of both applied and basic research. Methods and compositions to target and cleave genomic DNA by site specific nucleases are being developed to reach this goal. Site specific nucleases include but are not limited to (Zinc Finger Nucleases (ZFNs), Meganucleases, TALENS and CRISPR/Cas with an engineered crRNA/tracr RNA, see Burgess; et al; Nature Reviews Genetics 14, 80-81 (February 2013)). The site specific cleavage of genomic loci by ZFNs can be used, for example, to induce targeted mutagenesis, induce targeted deletions of cellular DNA sequences, and facilitate targeted recombination of an exogenous donor DNA polynucleotide within a predetermined genomic locus. See, for example, U.S. Patent Publication No. 20030232410; 20050208489; 20050026157; 20050064474; and 20060188987, and International Patent Publication No. WO 2007/014275, the disclosures of which are incorporated by reference in their entireties for all purposes. U.S. Patent Publication No. 20080182332 describes use of non-canonical zinc finger nucleases (ZFNs) for targeted modification of plant genomes and U.S. Patent Publication No. 20090205083 describes ZFN-mediated targeted modification of a plant EPSPs genomic locus. In addition, Moehle et al. (2007) Proc. Natl. Acad. Sci. USA 104(9): 3055-3060 describe using designed ZFNs for targeted gene addition at a specified genomic locus. Current methods of targeting typically involve co-transformation of plant tissue with a donor DNA polynucleotide containing at least one transgene and a site specific nuclease which is designed to bind and cleave a specific genomic locus. This causes the donor DNA polynucleotide to stably insert within the cleaved genomic locus resulting in targeted gene addition at a specified genomic locus.
BRIEF SUMMARY OF THE INVENTION
[0006] The presently claimed invention is a method for integrating one or more functional exogenous nucleic acid sequences into the genome of a maize cell having an E32 locus. The method comprises making a double-stranded cleavage in the E32 locus using one or more zinc finger nucleases comprising a zinc finger binding domain that binds to a target site selected from the group shown in Table 1B. This results in the integration of a functional polynucleotide comprising the one or more exogenous sequences into the genome of the maize cell within the E32 locus. The method optionally includes expressing a gene product encoded and controlled by the one or more exogenous sequences.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 depicts the relation of the ZFNs designed to bind the E32 locus of. Six ZFNs (E32 ZFN1-6) were indentified from the yeast assay and four ZFNs were advanced for evaluation in plants.
[0008] FIG. 2 is a plasmid map of pDAB105906.
[0009] FIG. 3 is a plasmid map of pDAB111809.
[0010] FIG. 4 is a plasmid map of pDAB100655 and represents a typical donor construct in which other desirable coding sequences, including but not limited to PAT can be substituted for the AAD-1 region.
[0011] FIG. 5 is a ZFN locus disruption graph of the E32 locus with arrows indicating a disrupted genomic locus.
[0012] FIG. 6 is a plasmid map for pDAB108688 (control vector).
[0013] FIG. 7 is a plasmid map for pDAB108690 (targeting vector).
[0014] FIG. 8 shows the primer and probe location for the ZFN disruption qPCR.
[0015] FIG. 9 is a ZFN disruption assay graph (upper brackets indicate non-disrupted events and lower brackets show disrupted events).
[0016] FIG. 10 is a plasmid map of pDAB104179.
[0017] FIG. 11 shows the primer and probe location for the ZFN disruption qPCR.
[0018] FIG. 12 is a ZFN disruption assay graph (upper brackets indicate non-disrupted events negative and lower brackets show disrupted events).
[0019] FIG. 13 shows the primer location for in/out PCR.
[0020] FIG. 14 is a Southern analysis strategy showing the location of enzyme cut sites and primers for probe generation.
[0021] FIG. 15 is a plasmid map of pDAB107855.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The full length DNA molecule (PHI17662A) used to transform Corn Event DAS-59132, the 3′ end of the genomic flanking sequence, and the PHI17662A/3′ maize genome junction are described in the disclosure of U.S. Pat. No. 8,273,535. The E32 locus is described by SEQ ID NO:1 and relates to the genomic flanking regions of Corn Event DAS-59132 that were used to identify genomic target sequences for designing zinc finger protein binding domains for exogenous gene insertion. These target sites include but are not limited to those described in Table 1B. After having identified the E32 locus as a highly desirable location for inserting exogenous genes which is one embodiment of this invention, it is well within the skilled artisans purview to identify and use other target sites within the E32 locus.
[0023] SEQ ID NO:1 is provided as the following sequence;
[0000]
agttgggaaggcaaaacgaatataagtgcattcggattactgtttagtcg
agtcatatttaaggaattcattgtaaatgttctaacctaacctaagtatt
aggcagctatggctgatatggatctgattggacttgatttatccatgata
agtttaagagcaactcaaagaggttaggtatatatggttttgtaaaggta
aatttagttaatattagaaaaaaaaagtgtatccaataggctctataaac
aactcttcaaatttagtggctttctatccatccacctttgctctctattt
ttggatagcctgatttactctctattcagtccgtaggtttaatgagtctg
ttggattagcctacactttttctgtaaaatctattttagatagtagctaa
atcagtaaatttggctagtatttttagctattctcttggagtttgctata
agaccagaacatgtaaattggaagtttgtggacccggacgagaatgcatg
acaaatccagagtattgatgatggaattcacctattttacccgactcttc
cattgtgtccatttctcatcatccccgggcgctttctgcatccggtacag
ctgacatgacacgttcacgcgttacatggctgatggctcacaagtcaccc
ccacatgtctagtgttcgcccaggcagatcgtcctcggcctgcgctgccg
tgctcttgccgccgcttgcttgggccctgctggcgcccgctgccgatcac
acggcctacgcggtgcaggcagcgccaccgaacccgcagtcttgttgtgc
cgataggtggcagtggcagtggcactggcacggcacgcgatcgatcgctc
cgctcatctgctgacagtggatagagcagcgttggccgttggggccggat
ctccgtgaagcggtcgtccctgctgtactgtgccgctatggcgtgtcgct
ttcgccatgttttcttttcttttttttttctttttctttttgctagggcg
gtttctcgttcgctggtaacagggaccacttcggttgatccgttgaattt
actgaaagagatgggaatggtcgctgtgcccgggacattgaatgagatgt
tgtgtaagtgaatatggctttagccttttgcgagtggggcggcaatgcac
ggcatgaactataatttccggtcaaacttttgtgtggaaatggatgctaa
acgaacacaaaccgggtttaaaccagaggccgacacggcacacacggcga
cattcaccgccggcttcctccgtcgccactcggcacaaggctcatcagtc
gccgatgcccgatgcgatcaacggaagcggatggcccgcttctttagaat
tggcacaggaacactggccactgcccttgatgtgcaattatgcctgcgaa
agcctaggcaacacacgcgaataaacgagcgaatgacacggaaagctgat
gtggtatgaattatacaacattatgggccaaaatattattctatccacca
ttgtgtagccacagcatcggtatttgagttgtgcgaggacaaatccctcg
tgaggtcaaaaacagcaaataataaacccatctcctgaagacaccaaaaa
aaaggagcagctcctcgtgtcaatgaacaagcgtcacaagaaaagggagc
acgtaaataacctcttcaattgcttcagcatgaaaagaacgggaagaaat
gcaagtctacagaggaaagtgcagctgtttcggctgccatggcaagttcc
tacatgggcgaggaaaagctgaactggattccagtcttcgcgctgtcatg
ctcagcttgctttaggatgcggcaatagttcacctggatgaaaaagatac
aagttagtcttgaagcagtcgagtggacatccaaagtatcaaaatcgaaa
gcttgtaaatggggaaggaaatatacctctacccggaaaagtttggtagg
caaaataatcccaacgccagcagagctccggaacgtttgccgaaattcag
aagccgaaaagttcttgtactcaccctccgacagtttcgcaaggtttcca
gcagtaaggaatgcgtggccatggattccagcgtctctgaatatcttgag
gggcagatcaaaagaaaggtcagcgaaggcagacacggccagatcacctc
ccaagtaatcccttccagggtcagccgagccactctccgagttattaagg
acatgcctccgcgcctctgttgggccaactccccttaatctgaaacccag
cagagatgacggtccgcccaagctgcacactggagaagaattacctccaa
gataaaacctctctggcactgatgaagtcgaattcatgaatccccctgca
agcggtaaaatgacacccgctcctacaccaacgttgagagcagcactata
aaatcccaaaggcacagcaccacgtacatcgaactcctgagagcaaaccc
aacggcaatatttttgtaatagtgatggtcagaactgagaagatcagata
aaattatacactgatgcaattatttcatagtttcgcccatgaactgtaag
ggctagacaaagcaaaaagtaagacatgaagggcaagagaataacctgcc
ggaaatatctcaatcctttgctattccatagaccaccaacttgagaagtt
gactgaaacgcatatcctttcgttggcctaagatgtgaatccctcttatc
aatcttgtatgtgtacttcaatgcagaaagaaggttatgccctaactgcc
tccttatggcctttgatgagacacgtgatggatcagttaaggtacgccac
gcaaggttgtatgacaagtcatggttccttgttgacagcaaaccaaatga
aaggccaagtaggcgctccttgtatgatgaaaacttcagccaatcttgtg
atgacaaagatgcccgagccatcaatggtgttggtattgatttaaacctc
ggtaggcagactccaacaccaacctctgttgtttggtcccaaccaaagga
tcctgatgcatcccagatgtcaccatagccaaacaagttcttcaacttaa
gtgacccttccagcgaccaagatcttgcctacaagagtggcaagcacagt
ca
[0024] The present disclosure further relates to methods and compositions for targeted integration into the maize E32 locus using ZFNs and a gene donor construct. Practice of the methods, as well as preparation and use of the compositions disclosed herein employ, unless otherwise indicated, conventional techniques in molecular biology, biochemistry, chromatin structure and analysis, computational chemistry, cell culture, recombinant DNA and related fields as are within the skill of the art. These techniques are fully explained in the literature. See, for example, Sambrook et al. MOLECULAR CLONING: A LABORATORY MANUAL, Second edition, Cold Spring Harbor Laboratory Press, 1989 and Third edition, 2001; Ausubel et al., CURRENT PROTOCOLS IN MOLECULAR BIOLOGY, John Wiley & Sons, New York, 1987 and periodic updates; the series METHODS IN ENZYMOLOGY, Academic Press, San Diego; Wolfe, CHROMATIN STRUCTURE AND FUNCTION, Third edition, Academic Press, San Diego, 1998; METHODS IN ENZYMOLOGY, Vol. 304, “Chromatin” (P. M. Wassarman and A. P. Wolfe, eds.), Academic Press, San Diego, 1999; and METHODS IN MOLECULAR BIOLOGY, Vol. 119, “Chromatin Protocols” (P. B. Becker, ed.) Humana Press, Totowa, 1999.
[0025] The terms “polypeptide,” “peptide” and “protein” are used interchangeably to refer to a polymer of amino acid residues. The term also applies to amino acid polymers in which one or more amino acids are chemical analogues or modified derivatives of corresponding naturally-occurring amino acids.
[0026] “Binding” refers to a sequence-specific, non-covalent interaction between macromolecules (e.g., between a protein and a nucleic acid). Not all components of a binding interaction need be sequence-specific (e.g., contacts with phosphate residues in a DNA backbone), as long as the interaction as a whole is sequence-specific. Such interactions are generally characterized by a dissociation constant (Kd) of 10 −6 M or lower. “Affinity” refers to the strength of binding: increased binding affinity being correlated with a lower binding constant (Kd).
[0027] A “binding protein” is a protein that is able to bind non-covalently to another molecule. A binding protein can bind to, for example, a DNA molecule (a DNA-binding protein), a RNA molecule (an RNA-binding protein) and/or a protein molecule (a protein-binding protein). In the case of a protein-binding protein, it can bind to itself (to form homodimers, homotrimers, etc.) and/or it can bind to one or more molecules of a different protein or proteins. A binding protein can have more than one type of binding activity. For example, zinc finger proteins have DNA-binding, RNA-binding and protein-binding activity.
[0028] A “zinc finger DNA binding protein” (or binding domain) is a protein, or a domain within a larger protein, that binds DNA in a sequence-specific manner through one or more zinc fingers, which are regions of amino acid sequence within the binding domain whose structure is stabilized through coordination of a zinc ion. The term zinc finger DNA binding protein is often abbreviated as zinc finger protein or ZFP.
[0029] Zinc finger binding domains can be “engineered” to bind to a predetermined nucleotide sequence. Non-limiting examples of methods for engineering zinc finger proteins are design and selection. A designed zinc finger protein is a protein not occurring in nature whose design/composition results principally from rational criteria. Rational criteria for design include application of substitution rules and computerized algorithms for processing information in a database storing information of existing ZFP designs and binding data. See, for example, U.S. Pat. Nos. 6,140,081; 6,453,242; 6,534,261 and 6,794,136; see also WO 98/53058; WO 98/53059; WO 98/53060; WO 02/016536 and WO 03/016496.
[0030] “Cleavage” refers to the breakage of the covalent backbone of a DNA molecule. Cleavage can be initiated by a variety of methods including, but not limited to, enzymatic or chemical hydrolysis of a phosphodiester bond. Both single-stranded cleavage and double-stranded cleavage are possible, and double-stranded cleavage can occur as a result of two distinct single-stranded cleavage events. DNA cleavage can result in the production of either blunt ends or staggered ends. In certain embodiments, fusion polypeptides are used for targeted double-stranded DNA cleavage. A “cleavage domain” comprises one or more polypeptide sequences which possesses catalytic activity for DNA cleavage. A cleavage domain can be contained in a single polypeptide chain or cleavage activity can result from the association of two (or more) polypeptides.
[0031] A “target site” or “target sequence” is a nucleic acid sequence that defines a portion of a nucleic acid to which a binding molecule will bind, provided sufficient conditions for binding exist.
[0032] An “exogenous” molecule is a molecule that is not normally present in a cell, but can be introduced into a cell by one or more genetic, biochemical or other methods. “Normal presence in the cell” is determined with respect to the particular developmental stage and environmental conditions of the cell. Thus, for example, a molecule induced by heat shock is an exogenous molecule with respect to a non heat-shocked cell. An exogenous molecule can comprise, for example, a coding sequence for any polypeptide or fragment thereof, a functioning version of a malfunctioning endogenous molecule or a malfunctioning version of a normally-functioning endogenous molecule. Additionally, an exogenous molecule can comprise a coding sequence from another species.
[0033] Nucleic acids include DNA and RNA, can be single- or double-stranded; can be linear, branched or circular; and can be of any length. Nucleic acids include those capable of forming duplexes, as well as triplex-forming nucleic acids. See, for example, U.S. Pat. Nos. 5,176,996 and 5,422,251. Proteins include, but are not limited to, DNA-binding proteins, transcription factors, chromatin remodeling factors, methylated DNA binding proteins, polymerases, methylases, demethylases, acetylases, deacetylases, kinases, phosphatases, integrases, recombinases, ligases, topoisomerases, gyrases and helicases.
[0034] A “product of an exogenous nucleic acid” includes both polynucleotide and polypeptide products, for example, transcription products (polynucleotides such as RNA) and translation products (polypeptides) and the products of gene expression and gene products.
[0035] A “fusion” molecule is a molecule in which two or more subunit molecules are linked, for example, covalently. The subunit molecules can be the same chemical type of molecule, or can be different chemical types of molecules. Examples of the first type of fusion molecule include, but are not limited to, fusion proteins (for example, a fusion between a ZFP DNA-binding domain and a cleavage domain) and fusion nucleic acids (for example, a nucleic acid encoding the fusion protein described supra). Examples of the second type of fusion molecule include, but are not limited to, a fusion between a triplex-forming nucleic acid and a polypeptide, and a fusion between a minor groove binder and a nucleic acid.
[0036] Expression of a fusion protein in a cell can result from delivery of the fusion protein to the cell or by delivery of a polynucleotide encoding the fusion protein to a cell, wherein the polynucleotide is transcribed, and the transcript is translated, to generate the fusion protein. Trans-splicing, polypeptide cleavage and polypeptide ligation can also be involved in expression of a protein in a cell. Methods for polynucleotide and polypeptide delivery to cells are presented elsewhere in this disclosure.
[0037] For the purposes of the present disclosure, a “gene,” includes a DNA region encoding a gene product (see infra), as well as all DNA regions which regulate the production of the gene product, whether or not such regulatory sequences are adjacent to coding and/or transcribed sequences. Accordingly, a gene includes, but is not necessarily limited to, promoter sequences, terminators, translational regulatory sequences such as ribosome binding sites and internal ribosome entry sites, enhancers, silencers, insulators, boundary elements, replication origins, matrix attachment sites and locus control regions.
[0038] “Gene expression” refers to the conversion of the information, contained in a gene, into a gene product. A gene product can be the direct transcriptional product of a gene (e.g., mRNA, tRNA, rRNA, antisense RNA, interfering RNA, ribozyme, structural RNA or any other type of RNA) or a protein produced by translation of a mRNA. Gene products also include RNAs which are modified, by processes such as capping, polyadenylation, methylation, and editing, and proteins modified by, for example, methylation, acetylation, phosphorylation, ubiquitination, ADP-ribosylation, myristilation, and glycosylation.
[0039] The disclosed methods and compositions include fusion proteins comprising a cleavage domain and a DNA-binding domain (ZFP) in which the DNA-binding domain by binding to a sequence in the E32 locus directs the activity of the cleavage domain to the vicinity of the sequence and, hence, induces a double stranded break) in the E32 locus. As set forth elsewhere in this disclosure, a zinc finger domain can be engineered to bind to virtually any desired sequence. Accordingly, one or more DNA-binding domains can be engineered to bind to one or more sequences in the E32 locus. Expression of a fusion protein comprising a DNA-binding domain and a cleavage domain in a cell, effects cleavage at or near the target site.
[0040] Selection of a target site in the E32 locus for binding by a zinc finger domain can be accomplished, for example, according to the methods disclosed in U.S. Pat. No. 6,453,242 that also discloses methods for designing ZFPs to bind to a selected sequence. It will be clear to those skilled in the art that simple visual inspection of a nucleotide sequence can also be used for selection of a target site. Accordingly, any means for target site selection can be used in the methods described herein.
[0041] For ZFP DNA-binding domains, target sites are generally composed of a plurality of adjacent target subsites. A target subsite refers to the sequence, usually either a nucleotide triplet or a nucleotide quadruplet which may overlap by one nucleotide with an adjacent quadruplet, that is bound by an individual zinc finger. See, for example, WO 02/077227. The strand with which a zinc finger protein makes most contacts is designated the target strand “primary recognition strand,” or “primary contact strand,” some zinc finger proteins bind to a three base triplet in the target strand and a fourth base on the non-target strand. A target site generally has a length of at least 9 nucleotides and, accordingly, is bound by a zinc finger binding domain comprising at least three zinc fingers. However binding of, for example, a 4-finger binding domain to a 12-nucleotide target site, a 5-finger binding domain to a 15-nucleotide target site or a 6-finger binding domain to an 18-nucleotide target site, is also possible. As will be apparent, binding of larger binding domains (e.g., 7-, 8-, 9-finger and more) to longer target sites is also consistent with the invention.
[0042] It is not necessary for a target site to be a multiple of three nucleotides. In cases in which cross-strand interactions occur (see, e.g., U.S. Pat. No. 6,453,242 and WO 02/077227), one or more of the individual zinc fingers of a multi-finger binding domain can bind to overlapping quadruplet subsites. As a result, a three-finger protein can bind a 10-nucleotide sequence, wherein the tenth nucleotide is part of a quadruplet bound by a terminal finger, a four-finger protein can bind a 13-nucleotide sequence, wherein the thirteenth nucleotide is part of a quadruplet bound by a terminal finger, etc.
[0043] The length and nature of amino acid linker sequences between individual zinc fingers in a multi-finger binding domain also affects binding to a target sequence. For example, the presence of a so-called “non-canonical linker,” “long linker” or “structured linker” between adjacent zinc fingers in a multi-finger binding domain can allow those fingers to bind subsites which are not immediately adjacent. Non-limiting examples of such linkers are described, for example, in U.S. Pat. No. 6,479,626 and WO 01/53480. Accordingly, one or more subsites, in a target site for a zinc finger binding domain, can be separated from each other by 1, 2, 3, 4, 5 or more nucleotides. To provide but one example, a four-finger binding domain can bind to a 13-nucleotide target site comprising, in sequence, two contiguous 3-nucleotide subsites, an intervening nucleotide, and two contiguous triplet subsites.
[0044] Distance between target sites refers to the number of nucleotides or nucleotide pairs intervening between two target sites as measured from the edges of the sequences nearest each other. In certain embodiments in which cleavage depends on the binding of two zinc finger domain/cleavage half-domain fusion molecules to separate target sites, the two target sites can be on opposite DNA strands. In other embodiments, both target sites are on the same DNA strand.
[0045] For targeted integration into the E32 locus, one or more ZFPs are engineered to bind a target site at or near the predetermined cleavage site, and a fusion protein comprising the engineered DNA-binding domain and a cleavage domain is expressed in the cell. Upon binding of the zinc finger portion of the fusion protein to the target site, the DNA is cleaved, preferably via a double-stranded break, near the target site by the cleavage domain.
[0046] The presence of a double-stranded break in the Event32 locus facilitates integration of exogenous sequences via homologous recombination or via non-homology directed repair mechanisms. Thus, the polynucleotide comprising the exogenous sequence to be inserted into the Event32 locus will include one or more regions of homology with E32 to facilitate homologous recombination.
[0047] In addition to the fusion molecules described herein, targeted replacement of a selected genomic sequence also involves the introduction of a donor sequence. The donor sequence can be introduced into the cell prior to, concurrently with, or subsequent to, expression of the fusion protein(s). The donor polynucleotide contains sufficient homology to E32 to support homologous recombination between it and the E32 genomic sequence to which it bears homology. Approximately 25, 50, 100, 200, 500, 750, 1,000, 1,500, 2,000 nucleotides or more of sequence homology between a donor and a genomic sequence, or any integral value between 10 and 2,000 nucleotides or more, will support homologous recombination. In certain embodiments, the homology arms are less than 1,000 base pairs in length. In other embodiments, the homology arms are less than 750 base pairs in length.
[0048] Donor sequences can range in length from 10 to 50,000 base pairs or any integral value of nucleotides between or longer. It will be readily apparent that the donor sequence is typically not identical to the genomic sequence that it replaces. Additionally, donor sequences can comprise a vector molecule containing sequences that are not homologous to the replaced region. Generally, the homologous region(s) of a donor sequence will have at least 50% sequence identity to a genomic sequence with which recombination is desired. In certain embodiments, 60%, 70%, 80%, 90%, 95%, 98%, 99%, or 99.9% sequence identity is present. Any value between 1% and 100% sequence identity can be present, depending upon the length of the donor polynucleotide.
[0049] A donor molecule can contain several, discontinuous regions of homology to cellular chromatin. For example, for targeted insertion of sequences not normally present in a region of interest, said sequences can be present in a donor nucleic acid molecule and flanked by regions of homology to a gene sequence in the region of interest.
[0050] Donor molecules can also be inserted into the E32 locus to serve as a reservoir for later use. For example, a donor molecule containing a mutation of interest may be inserted in the E32 locus. Next, ZFNs specific to the gene of interest can be introduced which will cleave both the endogenous locus and the donor molecule in the E32 locus which contains the mutation of interest. The resulting double stranded break in the genome can then become the integration site for the donor molecule released from the E32 locus. In this way, the efficiency of targeted integration of a donor sequence at any region of interest can be greatly increased since the method does not rely on simultaneous uptake of both the nucleic acids encoding the ZFNs and those donor sequences.
[0051] Donor molecules can also be inserted into the E32 locus to serve as a target site for subsequent insertions. For example, a donor molecule comprised of DNA sequences that contain recognition sites for additional ZFN designs may be inserted into the locus. Subsequently, additional ZFN designs may be generated and expressed in cells such that the original donor molecule is cleaved and modified by repair or homologous recombination. In this way, reiterative integrations of donor molecules may occur at the E32 locus.
[0052] Any exogenous sequence can be introduced into the E32 locus as described herein. Exemplary exogenous sequences include, but are not limited to any polypeptide coding sequence (e.g., cDNAs), promoter, enhancer and other regulatory sequences (e.g., interfering RNA sequences, shRNA expression cassettes, epitope tags, marker genes, cleavage enzyme recognition sites and various types of expression constructs. Such sequences can be readily obtained using standard molecular biological techniques (cloning, synthesis, etc.) and/or are commercially available.
[0053] To express ZFNs, sequences encoding the fusion proteins are typically subcloned into an expression vector that contains a promoter to direct transcription. Suitable bacterial and eukaryotic promoters are well known in the art and described, e.g., in Sambrook et al., Molecular Cloning, A Laboratory Manual (2nd ed. 1989; 3.sup.rd ed., 2001); Kriegler, Gene Transfer and Expression: A Laboratory Manual (1990); and Current Protocols in Molecular Biology (Ausubel et al., supra. Bacterial expression systems for expressing the ZFNs are available in, e.g., E. coli, Bacillus sp., and Salmonella (Palva et al., Gene 22:229-235 (1983)). Kits for such expression systems are commercially available. Eukaryotic expression systems for mammalian cells, yeast, and insect cells are well known by those of skill in the art and are also commercially available.
[0054] The particular expression vector used to transport the genetic material into the cell is selected with regard to the intended use of the fusion proteins, e.g., expression in plants, animals, bacteria, fungus, protozoa, etc. (see expression vectors described below). Standard bacterial and animal expression vectors are known in the art and are described in detail, for example, U.S. Patent Publication 20050064474A1 and International Patent Publications WO05/084190, WO05/014791 and WO03/080809.
[0055] Standard transfection methods can be used to produce bacterial, mammalian, yeast or insect cell lines that express large quantities of protein, which can then be purified using standard techniques (see, e.g., Colley et al., J. Biol. Chem. 264:17619-17622 (1989); Guide to Protein Purification, in Methods in Enzymology, vol. 182 (Deutscher, ed., 1990)). Transformation of eukaryotic and prokaryotic cells are performed according to standard techniques (see, e.g., Morrison, J. Bact. 132:349-351 (1977); Clark-Curtiss & Curtiss, Methods in Enzymology 101:347-362 (Wu et al., eds., 1983).
[0056] Any of the well known procedures for introducing foreign nucleotide sequences into such host cells may be used. These include the use of calcium phosphate transfection, polybrene, protoplast fusion, electroporation, ultrasonic methods (e.g., sonoporation), liposomes, microinjection, naked DNA, plasmid vectors, viral vectors, both episomal and integrative, and any of the other well known methods for introducing cloned genomic DNA, cDNA, synthetic DNA or other foreign genetic material into a host cell (see, e.g., Sambrook et al., supra). It is only necessary that the particular genetic engineering procedure used be capable of successfully introducing at least one gene into the host cell capable of expressing the protein of choice.
[0057] As noted above, DNA constructs may be introduced into the genome of a desired plant species by a variety of conventional techniques. For reviews of such techniques see, for example, Weissbach & Weissbach Methods for Plant Molecular Biology (1988, Academic Press, N.Y.) Section VIII, pp. 421-463; and Grierson & Corey, Plant Molecular Biology (1988, 2d Ed.), Blackie, London, Ch. 7-9.
[0058] A DNA construct may be introduced directly into the genomic DNA of the plant cell using techniques such as electroporation and microinjection of plant cell protoplasts, or the DNA constructs can be introduced directly to plant tissue using biolistic methods, such as DNA particle bombardment (see, e.g., Klein et al. (1987) Nature 327:70-73). Alternatively, the DNA construct can be introduced into the plant cell via nanoparticle transformation (see, e.g., US Patent Publication No. 20090104700, which is incorporated herein by reference in its entirety). Alternatively, the DNA constructs may be combined with suitable T-DNA border/flanking regions and introduced into a conventional Agrobacterium tumefaciens host vector. Agrobacterium tumefaciens -mediated transformation techniques, including disarming and use of binary vectors, are well described in the scientific literature. See, for example Horsch et al. (1984) Science 233:496-498, and Fraley et al. (1983) Proc. Nat'l. Acad. Sci. USA 80:4803.
[0059] In addition, gene transfer may be achieved using non- Agrobacterium bacteria or viruses such as Rhizobium sp. NGR234 , Sinorhizoboium meliloti, Mesorhizobium loti , potato virus X, cauliflower mosaic virus and cassava vein mosaic virus and/or tobacco mosaic virus, See, e.g., Chung et al. (2006) Trends Plant Sci. 11(1):1-4.
[0060] The virulence functions of the Agrobacterium tumefaciens host will direct the insertion of a T-strand containing the construct and adjacent marker into the plant cell DNA when the cell is infected by the bacteria using binary T DNA vector (Bevan (1984) Nuc. Acid Res. 12:8711-8721) or the co-cultivation procedure (Horsch et al. (1985) Science 227:1229-1231). Generally, the Agrobacterium transformation system is used to engineer dicotyledonous plants (Bevan et al. (1982) Ann. Rev. Genet. 16:357-384; Rogers et al. (1986) Methods Enzymol. 118:627-641). The Agrobacterium transformation system may also be used to transform, as well as transfer, DNA to monocotyledonous plants and plant cells. See U.S. Pat. No. 5,591,616; Hernalsteen et al. (1984) EMBO J. 3:3039-3041; Hooykass-Van Slogteren et al. (1984) Nature 311:763-764; Grimsley et al. (1987) Nature 325:1677-179; Boulton et al. (1989) Plant Mol. Biol. 12:31-40; and Gould et al. (1991) Plant Physiol. 95:426-434.
[0061] Alternative gene transfer and transformation methods include, but are not limited to, protoplast transformation through calcium-, polyethylene glycol (PEG)- or electroporation-mediated uptake of naked DNA (see Paszkowski et al. (1984) EMBO J. 3:2717-2722, Potrykus et al. (1985) Molec. Gen. Genet. 199:169-177; Fromm et al. (1985) Proc. Nat. Acad. Sci. USA 82:5824-5828; and Shimamoto (1989) Nature 338:274-276) and electroporation of plant tissues (D'Halluin et al. (1992) Plant Cell 4:1495-1505). Additional methods for plant cell transformation include microinjection, silicon carbide mediated DNA uptake (Kaeppler et al. (1990) Plant Cell Reporter 9:415-418), and microprojectile bombardment (see Klein et al. (1988) Proc. Nat. Acad. Sci. USA 85:4305-4309; and Gordon-Kamm et al. (1990) Plant Cell 2:603-618).
[0062] The disclosed methods and compositions can be used to insert exogenous sequences into a predetermined location such as the E32 locus. This is useful inasmuch as expression of an introduced transgene into the maize genome depends critically on its integration site. Accordingly, genes encoding herbicide tolerance, insect resistance, nutrients, antibiotics or therapeutic molecules can be inserted, by targeted recombination.
[0063] Transformed plant cells which are produced by any of the above transformation techniques can be cultured to regenerate a whole plant which possesses the transformed genotype and thus the desired phenotype. Such regeneration techniques rely on manipulation of certain phytohormones in a tissue culture growth medium, typically relying on a biocide and/or herbicide marker which has been introduced together with the desired nucleotide sequences. Plant regeneration from cultured protoplasts is described in Evans, et al., “Protoplasts Isolation and Culture” in Handbook of Plant Cell Culture, pp. 124-176, Macmillian Publishing Company, New York, 1983; and Binding, Regeneration of Plants, Plant Protoplasts, pp. 21-73, CRC Press, Boca Raton, 1985. Regeneration can also be obtained from plant callus, explants, organs, pollens, embryos or parts thereof. Such regeneration techniques are described generally in Klee et al. (1987) Ann. Rev. of Plant Phys. 38:467-486.
[0064] One skilled in the art will recognize that after the exogenous sequence is stably incorporated in transgenic plants and confirmed to be operable, it can be introduced into other plants by sexual crossing. Any of a number of standard breeding techniques can be used, depending upon the species to be crossed.
[0065] A transformed maize cell, callus, tissue or plant may be identified and isolated by selecting or screening the engineered plant material for traits encoded by the marker genes present on the transforming DNA. For instance, selection can be performed by growing the engineered plant material on media containing an inhibitory amount of the antibiotic or herbicide to which the transforming gene construct confers resistance. Further, transformed cells can also be identified by screening for the activities of any visible marker genes (e.g., the beta-glucuronidase, luciferase, B or C1 genes) that may be present on the recombinant nucleic acid constructs. Such selection and screening methodologies are well known to those skilled in the art.
[0066] Physical and biochemical methods also may be used to identify plant or plant cell transformants containing inserted gene constructs. These methods include but are not limited to: 1) Southern analysis or PCR amplification for detecting and determining the structure of the recombinant DNA insert; 2) Northern blot, 51 RNase protection, primer-extension or reverse transcriptase-PCR amplification for detecting and examining RNA transcripts of the gene constructs; 3) enzymatic assays for detecting enzyme or ribozyme activity, where such gene products are encoded by the gene construct; 4) protein gel electrophoresis, Western blot techniques, immunoprecipitation, or enzyme-linked immunoassays (ELISA), where the gene construct products are proteins. Additional techniques, such as in situ hybridization, enzyme staining, and immunostaining, also may be used to detect the presence or expression of the recombinant construct in specific plant organs and tissues. The methods for doing all these assays are well known to those skilled in the art.
[0067] Effects of gene manipulation using the methods disclosed herein can be observed by, for example, northern blots of the RNA (e.g., mRNA) isolated from the tissues of interest. Typically, if the mRNA is present or the amount of mRNA has increased, it can be assumed that the corresponding transgene is being expressed. Other methods of measuring gene and/or encoded polypeptide activity can be used. Different types of enzymatic assays can be used, depending on the substrate used and the method of detecting the increase or decrease of a reaction product or by-product. In addition, the levels of polypeptide expressed can be measured immunochemically, i.e., ELISA, RIA, EIA and other antibody based assays well known to those of skill in the art, such as by electrophoretic detection assays (either with staining or western blotting). As one non-limiting example, the detection of the AAD-1 (aryloxyalkanoate dioxygenase; see WO 2005/107437) and PAT (phosphinothricin-N-acetyl-transferase (PAT), EC 2.3.1.183) proteins using an ELISA assay is described in U.S. Patent Publication No. 20090093366 which is herein incorporated by reference in its entirety. The transgene may be selectively expressed in some tissues of the plant or at some developmental stages, or the transgene may be expressed in substantially all plant tissues, substantially along its entire life cycle. However, any combinatorial expression mode is also applicable.
[0068] The present disclosure also encompasses seeds of the transgenic plants described above wherein the seed has the transgene or gene construct. The present disclosure further encompasses the progeny, clones, cell lines or cells of the transgenic plants described above wherein said progeny, clone, cell line or cell has the transgene or gene construct.
[0069] Administration of effective amounts is by any of the routes normally used for introducing fusion proteins into ultimate contact with the plant cell to be treated. The ZFPs are administered in any suitable manner, preferably with acceptable carriers. Suitable methods of administering such modulators are available and well known to those of skill in the art, and, although more than one route can be used to administer a particular composition, a particular route can often provide a more immediate and more effective reaction than another route.
EXAMPLES
Example 1
Production of Zinc Finger Proteins Designed to Bind the Genomic Locus for Corn Event DAS-59132
[0070] Zinc finger proteins directed against DNA sequences which comprise the genomic locus for Corn Event DAS-59132 (see, FIG. 1 ) were designed per the methods described in Urnov et al. (2005) Nature 435:646-651. Exemplary target sequence and recognition helices are shown in Table 1A (recognition helix regions designs) and Table 1B (target sites). In Table 1B, nucleotides in the target site that are contacted by the ZFP recognition helices are indicated in uppercase letters; non-contacted nucleotides are indicated in lowercase.
[0000]
TABLE 1A
Genomic locus for Corn Event DAS-59132-binding
zinc finger designs.
ZFP#
F1
F2
F3
F4
F5
25716
RSDDLSK
QSGSLTR
RSDNLRE
QSGDLTR
DTGARLK
SEQ ID
SEQ ID
SEQ ID
SEQ ID
SEQ ID
NO: 43
NO: 44
NO: 45
NO: 46
NO: 47
25717
RSADRKT
DRSHLSR
TSGNLTR
RSDDLSR
QSANRTK
SEQ ID
SEQ ID
SEQ ID
SEQ ID
SEQ ID
NO: 48
NO: 49
NO: 50
NO: 51
NO: 52
[0000]
TABLE 1B
Target Sequences for zinc finger proteins.
Zinc
SEQ
Finger
ID
Number
NO:
Target Sequence
25686
2
caCAACAAGACtGCGGGTtcggtggcgc
25687
3
gaTAGGTGGCAGTGGCAgtggcactggc
25688
4
taTCGGCACAACAAGACtgcgggttcgg
25689
5
tgGCAGTGGCAGTGGCActggcacggca
25692
6
caGCAGATGAGcGGAGCGatcgatcgcg
25693
7
caGTGGATAGAGCAGCGttggccgttgg
25710
8
agGAAGCCGGCGGTGAAtgtcgccgtgt
25711
9
cgTCGCCAcTCGGCACAAggctcatcag
25712
10
atCGGGCATCGGCGACTgatgagccttg
25713
11
gaTCAACGGAAGCGGATGGCccgcttct
25716
12
tgATCGCAtCGGGCATCGgcgactgatg
25717
13
cgGAAGCGGATGGCCCGcttctttagaa
[0071] The E32 zinc finger protein designs were incorporated into vectors encoding a protein having at least one finger with a CCHC structure. See, U.S. Patent Publication No. 2008/0182332. In particular, the last finger in each protein had a CCHC backbone for the recognition helix. The non-canonical zinc finger-encoding sequences were fused to the nuclease domain of the type IIS restriction enzyme FokI (amino acids 384-579 of the sequence of Wah et al. (1998) Proc. Natl. Acad. Sci. USA 95:10564-10569) via a four amino acid ZC linker and an opaque-2 nuclear localization signal derived from Zea mays to form Corn Event DAS-59132 zinc-finger nucleases (ZFNs). The optimal zinc fingers were verified for cleavage activity using a budding yeast based system previously shown to identify active nucleases. See, e.g., U.S. Patent Publication No. 20090111119; Doyon et al. (2008) Nat Biotechnol. 26:702-708; Geurts et al. (2009) Science 325:433. Zinc fingers for the various functional domains were selected for in-vivo use. Of the numerous ZFNs that were designed, produced and tested to bind to the putative Corn Event DAS-59132 genomic polynucleotide target sites, six pairs of ZFNs were identified as having in vivo activity at high levels, and selected for further experimentation. See, Table 1A. The selected ZFN pairs which optimally bound the E32 locus were advanced for testing in a transient corn transformation assay.
[0072] FIG. 1 shows the genomic organization of the E32 locus in relation to the ZFN polynucleotide binding/target sites of the six ZFN pairs. The first three ZFN pairs (E32 ZFN1, E32 ZFN2, and E32 ZFN3) bind upstream of the Corn Event DAS-59132 transgenic insert, the second three ZFN pairs (E32 ZFN4, E32 ZFN5, and E32 ZFN6) bind downstream of the Corn Event DAS-59132 transgenic insert. Four ZFNs were characterized as being capable of efficiently binding and cleaving Corn Event DAS-59132 genomic polynucleotide target sites in planta.
Example 2
Zinc Finger Nuclease Constructs and AAD-1 Gene Donor Construct
[0073] Plasmid vectors containing ZFN expression constructs of the six exemplary zinc finger nucleases were designed and constructed using skill commonly practiced in the art. Each zinc finger-encoding sequence was fused to a sequence encoding an opaque-2 nuclear localization signal (Maddaloni et al. (1989) Nuc. Acids Res. 17(18):7532), that was positioned upstream of the zinc finger nuclease.
[0074] The opaque-2 nuclear localization signal and zinc finger nuclease fusion sequence was paired with the complementary opaque-2 nuclear localization signal and zinc finger nuclease fusion sequence. As such, each construct consisted of a single open reading frame comprised of two opaque-2 nuclear localization signals and zinc finger nuclease fusion sequences separated by the 2A sequence from Thosea asigna virus (Mattion et al. (1996) J. Virol. 70:8124-8127). Expression of the ZFN coding sequence was driven by the highly expressing constitutive Zea mays Ubiquitin 1 promoter (Christensen et al. (1992) Plant Mol. Biol. 18(4):675-89) and flanked by the Zea mays Per 5 3′ polyA untranslated region (U.S. Pat. No. 6,699,984). The resulting six plasmid constructs were confirmed via restriction enzyme digestion and via DNA sequencing. FIGS. 2 and 3 provide a graphical representation of the completed plasmid constructs. The ZFN expressed in plasmid construct, pDAB105906 ( FIG. 2 ), contains “Fok-Mono” which is a wild type FokI endonuclease. The ZFN expressed in plasmid construct, pDAB111809 ( FIG. 3 ), contains “Fok1-ELD” which is a modified Fold endonuclease. The modified Fok1 endonuclease contains alterations as described in Doyon Y., Vo T., Mendel M., Greenberg S., Wang J., Xia D., Miller J., Urnov F., Gregory P., and Holmes M. (2010) Enhancing zinc-finger-nuclease activity with improved obligate heterodimeric architecture. Nature Methods, 8(1); 74-79.
[0075] A donor construct was designed to integrate into the ZFN cleaved genomic DNA of the E32 locus. FIG. 4 illustrates the donor construct, pDAB100655, which consists of a single gene expression cassette. This single gene expression cassette is comprised of the Zea mays Ubiquitin 1 promoter (ZmUbi1 promoter), the AAD-1 coding sequence (U.S. Pat. No. 7,838,733) and the Zea mays Per 5 3′ untranslated region (ZmPer5 3′ UTR). The construct contains a pair of repeated Corn Event DAS-59132 ZFN6 binding sequences which were included downstream of the AAD-1 gene expression cassette. The various gene elements were assembled in a high copy number pUC based plasmid.
Example 3
Transient Transformation of Maize Hi-II Cultures to Determine ZFN Efficiency
Transformation of ZFN Genes
[0076] Maize Hi-II embryogenic cultures were produced as described in U.S. Pat. No. 7,179,902 and were used to evaluate and test the efficiencies of the different ZFNs. Plasmid DNA consisting of pDAB105901, pDAB105902, pDAB105903, pDAB105904, pDAB105905 and pDAB105906 were transiently transformed into maize callus cells to compare the cutting frequency of different ZFNs against a standard tested ZFN, pDAB7430, which was designed to the inositol polyphosphate 2-kinase gene locus within the maize genome as described in U.S. Patent Application No. 2011/0119786.
[0077] From Hi-II cultures, 12 mL of packed cell volume (PCV) from a previously cryo-preserved cell line plus 28 mL of conditioned medium was subcultured into 80 mL of GN6 liquid medium (N6 medium (Chu et al., (1975) Sci Sin. 18:659-668), 2.0 mg/L 2, 4-D, 30 g/L sucrose, pH 6.0) in a 500 mL Erlenmeyer flask, and placed on a shaker at 125 rpm at 28° C. This step was repeated two times using the same cell line, such that a total of 36 mL PCV was distributed across three flasks. After 24 hours, the contents were poured into a sterile PETRI™ dish and the GN6 liquid media was removed. Slightly moistened callus was transferred to a 2.5 cm diameter circle on GN6 S/M solid medium (N6 Medium (Chu et al., (1975) Sci Sin. 18:659-668), 2.0 mg/L 2,4-D, 30 g/L sucrose, 45.5 g/L sorbitol, 45.5 g/L mannitol, 100 mg/L myo-inositol, 2.5 g/L Gelrite™, pH 6.0) containing filter paper. The plates were incubated in the dark for 4 hours at 28° C.
[0078] Microparticle gold (0.6 micron, BioRad, Hercules, Calif.,) was prepared for DNA precipitation by weighing out 21 mg into a sterile, siliconized 1.7 mL microcentrifuge tube (Sigma-Aldrich, St. Louis, Mo.) and 350 μL of ice cold 100% ethanol was added and vortexed for 1 minute. The gold was pelleted by centrifugation at 10,000 rpm for 15 seconds using a MINISPIN™ centrifuge (Eppendorf, Hauppauge, N.Y.). After removing the supernatant, 350 μL of ice cold, sterile water was added, mixed up and down with the pipette and centrifuged at 10,000 rpm for 15 seconds. The wash step was repeated one more time prior to suspending the gold in 350 μL of ice cold, sterile water. The washed gold was then stored at −20° C. until needed.
[0079] For each DNA precipitation, 3 mg of gold in 50 μL of water was aliqouted into a siliconized 1.7 mL microcentrifuge tube (Sigma-Aldrich, St. Louis, Mo.). Plasmid DNA (2.5 μg E32 ZFN in plasmids pDAB105901, pDAB105902, pDAB105903, pDAB105904, pDAB105905 or pDAB105906 and 2.5 μg IPK1 ZFN in plasmid pDAB7430) was premixed in 0.6 mL microcentrifuge tubes (Fisher Scientific, Nazareth, Pa.) and added to the gold suspension gently pipetting up and down 5-10 times to mix thoroughly. Twenty microliters (20 μL) of cold 0.1 M spermidine was then added and gently mixed by pipetting up and down 5-10 times. Fifty microliters (50 μL) of ice cold 2.5 M calcium chloride was added slowly and gently mixed by pipetting up and down 5-10 times. The tube was then capped and allowed to incubate at room temperature for 10 minutes. After centrifuging for 15 seconds at 10,000 rpm, the supernatant was carefully removed and 60 μL of ice cold, 100% ethanol was added. The gold DNA mixture was resuspended by gently pipetting up and down 5-10 times.
[0080] For microparticle bombardment, sterilized macrocarriers (BioRad, Hercules, Calif.) were fit into stainless steel holders (BioRad, Hercules, Calif.) and autoclaved. Nine microliters (9 μL) of gold/DNA suspension was evenly spread in the center of the macrocarrier being sure to pipette up and down so as to keep the suspension well mixed between aliquots. Macrocarriers were then placed onto a piece of sterile 125 mm Whatman #4 filter paper (GE Healthcare, Buckinghamshire, UK) on a bed of 8-mesh DRIERITE™ (W.A Hammond Drierite Co., Xenia, Ohio) in a 140×25 mm glass PETRI™ dish. The gold/DNA was allowed to dry completely for about 5-10 minutes. Rupture discs (1,100 psi, BioRad, Hercules, Calif.) were sterilized by soaking for a few seconds in isopropyl alcohol then loaded into the retaining cap of a microparticle bombardment devise (PDS-1000, BioRad, Hercules, Calif.). An autoclaved stopping screen (BioRad, Hercules, Calif.) and a loaded macrocarrier was placed into the launch assembly, the lid was screwed on and placed into the bombardment chamber just under the nozzle. The PETRI™ dish containing target was uncovered and placed in the bombardment chamber 6 cm below the nozzle. A vacuum was pulled (−0.9 bar) and the devise was fired. The above described steps were repeated for each target blasted. Targets were incubated in dark at a temperature of 28° C. for 24 hours on the same blasting medium. Blasted cells were transferred to recovery GN6 solid recovery medium (N6 medium (Chu et al., (1975) Sci Sin. 18:659-668), 2.0 mg/L 2, 4-D, 30 g/L sucrose, 2.5 g/L Gelrite, pH 6.0) and incubated for additional 48 hours at 28° C. in the dark. Seventy-two hours post bombardment, the cells were harvested into 2 mL EPPENDORF MICROFUGE SAFE LOCK TUBES™ and lyophilized for 48 hours in a VIRTIS MODEL #50L VIRTUAL XL-70 LYOPHILIZER™ (SP Scientific, Gardiner N.Y.).
Next Generation Sequencing (NGS) Analysis of Transiently Transformed Maize
[0081] The transiently transformed maize callus tissue was analyzed to determine the cleavage efficiency of the zinc finger nuclease proteins.
Sample Preparation
[0082] Maize callus tissue transiently transformed with the ZFN constructs and two control vectors, pDAB100664 and pDAB100665 were collected in 2 mL EPPENDORF™ tubes and lyophilized for 48 hr. Genomic DNA (gDNA) was extracted from lyophilized tissue using the QIAGEN PLANT DNA EXTRACTION KIT™ (Valencia, Calif.) according to manufacturer's specifications. The isolated gDNA was resuspended in 200 μL of water and the concentration was determined using a NANODROP® spectrophotometer (Invitrogen, Carlsbad, Calif.). Integrity of the DNA was estimated by running samples on a 0.8% agarose E-gels (Invitrogen). gDNA samples were normalized (25 ng/μL) for PCR amplification to generate amplicons which would be analyzed via ILLUMINA™ sequencing (San Diego, Calif.).
[0083] PCR primers for amplification of the genomic regions which span each tested ZFN cleavage site and the control samples were purchased from Integrated DNA Technologies (Coralville, Iowa). Optimum amplification conditions for the primers were identified by temperature gradient PCR using 0.2 μM appropriate primers, ACCUPRIME PFX SUPERMIX™ (1.1×, Invitrogen) and 100 ng of template genomic DNA in a 23.5 μL reaction. Cycling parameters were initial denaturation at 95° C. (5 min) followed by 35 cycles of denaturation (95° C., 15 sec), annealing (55-72° C., 30 sec), extension (68° C., 1 min) and a final extension (72° C., 7 min). Amplification products were analyzed on 3.5% TAE agarose gels. After identifying an optimum annealing temperature, preparative PCR reactions were carried out to validate each set of PCR primers and for generating the ILLUMINA™ sequencing amplicon.
[0084] For preparative PCR, 8-individual small scale PCR reactions were performed for each template using conditions described above and the resulting PCR products were pooled together and gel purified on 3.5% agarose gels using the QIAGEN MINELUTE GEL EXTRACTION/PURIFICATION KIT™ per manufacturer's recommendations. Concentrations of the gel purified amplicons were determined by NANODROP™ and the ILLUMINA™ sequencing samples were prepared by pooling approximately 100 ng of PCR amplicons from ZFN targeted and corresponding wild type controls. Primers used for the PCR amplicon generation are shown in Table 2 below.
[0000]
TABLE 2
Oligonucleotides for amplification of ZFN
binding sites.
Corn Event
DAS-59132
Direc-
Zinc Finger
tion//SEQ
Number
ID NO:
Primer Sequence
25686/25687 and
Forward//SEQ
CAGGCAGCGCCACCGAAC
25688/25689
ID NO: 14
Reverse//SEQ
CGATCGATCGCGTGCCGT
ID NO: 15
256892/256893
Forward//SEQ
CTGGCACGGCACGCGATC
ID NO: 16
Reverse//SEQ
CGGAGATCCGGCCCCAAC
ID NO: 17
25710/25711
Forward//SEQ
GACACGGCACACACGGCG
ID NO: 18
Reverse//SEQ
TCGGGCATCGGCGACTGA
ID NO: 19
25712/25713 and
Forward//SEQ
ACTCGGCACAAGGCTCAT
25716/25717
ID NO: 20
Reverse//SEQ
CCTGTGCCAATTCTAAAG
ID NO: 21
9149/9215
Forward//SEQ
GCAGTGCATGTTATGAGC
ID NO: 22
Reverse//SEQ
CAGGACATAAATGAACTG
ID NO: 23
AATC
ILLUMINA™ Sequencing and Analysis
[0085] The ZFNs were designed to recognize, bind and modify specific DNA sequences within the genomic locus of transgenic Corn Event DAS-59132. The efficiency by which the six ZFNs cleaved the genomic locus were assayed to determine which ZFN cleaved most efficiently. ILLUMINA™ sequencing was performed at Cofactor Genomics (St. Louis, Mo.) and sequences were analyzed using a sequence analysis script. Low quality sequences were filtered out and the remaining sequences were parsed according to unique DNA sequences identifiers. The unique DNA sequences identifiers were then aligned with the reference sequence and scored for insertions/deletions (indels). To determine the level of cleavage activity, the region surrounding the ZFN cleavage site was scored for the presence of sequence variants which resulted from the indels. Cleavage activity for each ZFN in the study was calculated as the number of sequences with indels/1M high quality sequences or as a percentage of high quality sequences with indels. The levels of cleavage efficiency were determined by normalizing the ZFN level of cleavage activity with the activity of a ZFN directed to the IPP2-K gene as described in U.S. Patent Publication No. 2011/0119786.
[0086] The E32 ZFN6 which contains the 25716 and 25717 zinc finger binding domains cleaved the genomic locus of transgenic Corn Event DAS-59132 with the highest efficiency. This ZFN functioned at 3.8 times the efficiency of the control IPPK2 zinc finger nuclease. Given the high levels of cleavage activity of E32 ZFN6, this ZFN was selected for use in integrating the donor DNA fragment into the genomic locus via non homologous end-joining.
[0000]
TABLE 3
Cleavage efficiency of the tested eZFNs.
E32 ZFN Number
% IPPK2 ZFN Activity
25686/25687
32
25688/25689
108
25712/25713
69
25716/25717
380
Example 4
Transient Expression of E32 ZFNs in Maize Protoplasts to Demonstrate NHEJ Targeting to the E32 Locus
[0087] A rapid testing system for gene targeting was established to target the endogenous genomic loci of Corn Event DAS-59132 and to optimize donor targeting parameters in maize. Double strand breaks were generated within the genome at Corn Event DAS-59132 and repaired by either the non-homologous end joining (NHEJ) or homology dependent repair (HDR).
Protoplast Isolation
[0088] Maize Hi-II embryogenic suspension cultures were maintained on a 3.5 day subculturing schedule. A 10 mL solution of sterile 6% (w/v) cellulase and a 10 mL solution of sterile 0.6% (w/v) pectolyase enzyme solutions was pipetted into a 50 mL conical tube. Next, 4 mL of pack cell volumes (PCV) of Hi-II suspension cells were added into the 50 mL tube containing the digest solution and wrapped with Parafilm®. The tubes were placed on a platform rocker at room temperature for about 16-18 hr. Next, the cells and enzyme solution were slowly filtered through a 100 μM cell strainer placed in a 50 mL conical tube. The cells were then rinsed using a 100 μM cell strainer by pipetting 10 mL of W5 media through the strainer. The cells and enzyme solution were slowly filtered through a 70 μM cell strainer. This straining step was followed by another straining step, wherein the cells and enzyme solution were slowly filtered through a 40 μM cell strainer placed in a 50 mL conical tube. Using a 10 mL pipette tip, the 40 μM cell strainer was rinsed with 10 mL of W5 media to give a final volume of 40 mL and the tube was inverted. Very slowly, 8 mL of a sucrose cushion solution was added to the bottom of the protoplast/enzyme solution. Using a centrifuge with a swing arm bucket rotor, the tubes were spun for 15 minutes at 1,500 rpm. The protoplast cells were removed using a 5 mL narrow bore pipette tip. These cells (7-8 mLs) which were observed as a protoplast band were removed very slowly and put into a sterile 50 mL conical tube. Next, 25 mL of W5 media was used to wash the tubes. The W5 wash media was added to the protoplasts and the tubes were inverted slowly and centrifuged for 10 minutes at 1,500 rpm. The supernatant was removed and 10 mL of MMG solution was added with slow inversion of the tube to resuspend the protoplast pellet. The density of protoplasts were determined using a haemocytometer. Four PCVs yield about 30 million protoplasts.
Protoplast Transformation
[0089] The protoplast cells were diluted to 1.6 million protoplasts per mL using MMG solution. The protoplasts were gently resuspended by slowly inverting the tube. Next, 300 μL of protoplasts (about 500 k protoplasts) were added to a sterile 2 mL tube and the tubes were inverted to evenly distribute the protoplast cells. Plasmid DNA at a concentration of 40-80 μg in TE buffer was added to the protoplasts. The experimental conditions are described in Table 4. The tubes were slowly rolled to suspend the DNA with the protoplasts and the tubes were incubated for 5-10 minutes at room temperature. Next, 300 μL of a PEG solution was added to the protoplast/DNA solution. Once all the PEG solution had been added, the PEG solution was mixed with the protoplast solution by gently inverting the tube. The cocktail was incubated at room temperature for 15-20 minutes with periodic inverting of the tube(s). After the incubation, 1 mL of W5 solution was slowly added to the tubes and the tubes were gently inverted. Finally, the solution was centrifuged at 1,000 rpm for 15 minutes. The supernatant was carefully removed so as not to disturb the cell pellet. One milliliter of washing/incubating solution was added. The tubes were gently inverted to resuspend the cell pellet. The tubes were covered with aluminum foil to eliminate any exposure to light, and were laid on a rack on their side to incubate overnight. The cells were harvested 24 hours post-transformation for molecular analysis.
[0000]
TABLE 4
Treatment groups for protoplast transformation.
Salmon
Donor DNA
E32-ZFN6
Sperm
pDAB100651
pDAB105906
pUC19
DNA
Total DNA
Treatment Groups
(μg)
(μg)
Filler (μg)
Filler (μg)
(μg)
E32 Donor alone +
pDAB100651
N/A
pUC19
N/A
80
No enzyme control
(40 μg)
(0 μg)
(40 μg)
(0 μg)
(filler-1)
E32 Donor alone +
pDAB100651
N/A
N/A
ssDNA
80
No enzyme control
(40 μg)
(0 μg)
(0 μg)
(40 μg)
(filler-2)
E32 Donor alone
pDAB100651
N/A
N/A
N/A
40
control (no filler)
(40 μg)
(0 μg)
(0 μg)
(0 μg)
E32-ZFN6 alone
N/A
pDAB105906
pUC19
N/A
80
control (no donor)
(0 μg)
(4 μg)
(76 μg)
(0 μg)
filler1
E32-ZFN6 alone
N/A
pDAB105906
N/A
ssDNA
80
control (no donor)
(0 μg)
(4 μg)
(0 μg)
(76 μg)
filler2
E32-ZFN6 wt Fokl
N/A
pDAB105906
N/A
N/A
40
alone control (no
(0 μg)
(40 μg)
(0 μg)
(0 μg)
donor) No filler
E32-ZFN6 wt Fokl +
pDAB100651
pDAB105906
pUC19
N/A
80
E32 Donor (1:10)
(40 μg)
(4 μg)
(36 μg)
(0 μg)
filler1
E32-ZFN6 wt Fokl +
pDAB100651
pDAB105906
N/A
ssDNA
80
E32 Donor (1:10)
(40 μg)
(4 μg)
(0 μg)
(36 μg)
filler2
Sequence Validation of Targeting Using NGS
[0090] ZFN cleavage activity in maize protoplasts was determined using the Next Generation Sequencing method described in EXAMPLE 3. The sequenced PCR amplified fragments were scored for the presence of sequence variants resulting from indels. The relative frequency of indels from each of E32 ZFN6 treatment cleaved the genomic locus of transgenic Corn Event DAS-59132 at about 1.5% of the DNA molecules in the amplicons.
Demonstration of Targeting Using In-Out PCR
[0091] Targeting of an AAD-1 gene-containing donor cassette into the genomic locus of transgenic Corn Event DAS-59132 into the Hi-II maize transgenic cell suspensions via NHEJ was confirmed via a in-out PCR reactions. The in-out PCR reactions amplified fragments containing the junction of the AAD-1gene donor and genomic locus of transgenic Corn Event DAS-59132. The resulting amplicon was subjected to a second PCR reaction, wherein primers were designed to bind internally within the first amplicon. The combination of two independent PCR reactions resulted in the removal of background amplifications which may be false-positives.
[0092] The in-out PCR results of the protoplast transformation experiments demonstrated that the genomic locus of transgenic Corn Event DAS-59132 could be reproducibly targeted with a 5.3 kb AAD-1gene plasmid donor and the E32-ZFN6 zinc finger nuclease at a ratio of 1:10 μg of DNA Targeting via a NHEJ method was evidenced by the insertion of the AAD-1gene donor cassette in both orientations. Sequence of the in-out PCR amplicons showed three instances of perfect integration of the donor DNA.
Example 5
WHISKERS™ Mediated Stable Transformation of ZFN and Donor for Targeted Integration Via NHEJ in Maize Hi-II Cultures
[0093] Transgenic events were targeted to the endogenous genomic locus of Corn Event DAS-59132. Constructs as described in Example 1 include the donor sequence (pDAB100655) and Event 32 ZFN 6 (E32 ZFN6; pDAB105906).
[0094] Maize callus cells, consisting of 12 mL of packed cell volume (PCV) from a previously cryo-preserved Hi-II cell line, plus 28 mL of conditioned medium was subcultured into 80 mL of GN6 liquid medium (N6 medium (Chu et al., (1975) Sci Sin. 18:659-668), 2.0 mg/L of 2, 4-D, 30 g/L sucrose, pH 5.8) in a 500 mL Erlenmeyer flask, and placed on a shaker at 125 rpm at 28° C. This step was repeated two times using the same cell line, such that a total of 36 mL PCV was distributed across three flasks. After 24 hours, the GN6 liquid media was removed and replaced with 72 mL GN6 S/M osmotic medium (N6 Medium, 2.0 mg/L 2,4-D, 30 g/L sucrose, 45.5 g/L sorbitol, 45.5 g/L mannitol, 100 mg/L myo-inositol, pH 6.0). The flask was incubated in the dark for 30-35 minutes at 28° C. with moderate agitation (125 rpm). During the incubation period, a 50 mg/mL suspension of silicon carbide WHISKERS™ (Advanced Composite Materials, LLC, Greer, S.C.) was prepared by adding 8.1 mL of GN6 S/M liquid medium to 405 mg of sterile, silicon carbide WHISKERS™.
[0095] Following incubation in GN6 S/M osmotic medium, the contents of each flask were pooled into a 250 mL centrifuge bottle. After all cells in the flask settled to the bottom, the content volume in excess of approximately 14 mL of GN6 S/M liquid was drawn off and collected in a sterile 1 L flask for future use. The pre-wetted suspension of WHISKERS™ was mixed at maximum speed on a vortex for 60 seconds, and then added to the centrifuge bottle.
[0096] In this example, 159 μg of pDAB100655 (donor sequence) and 11 μg of pDAB10506 (ZFN) plasmid DNA were added to each bottle. Once the plasmid DNA was added, the bottle was immediately placed in a modified RED DEVIL 5400™ commercial paint mixer (Red Devil Equipment Co., Plymouth, Minn.), and agitated for 10 seconds. Following agitation, the cocktail of cells, media, WHISKERS™ and plasmid DNA were added to the contents of a 1 L flask along with 125 mL fresh GN6 liquid medium to reduce the osmoticant. The cells were allowed to recover on a shaker set at 125 rpm for 2 hours. About 6 mL of dispersed suspension was filtered onto Whatman #4 filter paper (5.5 cm) using a glass cell collector unit connected to a house vacuum line such that 60 filters were obtained per bottle. Filters were placed onto 60×20 mm plates of GN6 solid medium (same as GN6 liquid medium except with 2.5 g/L glufosinate).
Identification and Isolation of Putative Targeted Events
[0097] One week post-DNA delivery, filter papers were transferred to 60×20 mm plates of GN6 (1H) selection medium (N6 Medium, 2.0 mg/L 2, 4-D, 30 g/L sucrose, 100 mg/L myo-inositol, 2.5 g/L Gelrite, pH 5.8) containing a selective agent. These selection plates were incubated at 28° C. for one week in the dark. Following 1 week of selection in the dark, the tissue was embedded onto fresh media by scraping ½ the cells from each plate into a tube containing 3.0 mL of GN6 agarose medium held at 37-38° C. (N6 medium, 2.0 mg/L 2, 4-D, 30 g/L sucrose, 100 mg/L myo-inositol, 7 g/L SEAPLAQUE® agarose, pH 5.8, autoclaved for 10 minutes at 121° C.).
[0098] The agarose/tissue mixture was broken up with a spatula, and then 3 mL of agarose/tissue mixture was evenly poured onto the surface of a 100×25 mm PETRI™ dish containing GN6 (1H) medium. This process was repeated for both halves of each plate. Once all the tissue was embedded, the plates were incubated at 28° C. under dark conditions for up to 10 weeks. Putatively transformed isolates that grew under these selection conditions were removed from the embedded plates and transferred to fresh selection medium in 60×20 mm plates. If sustained growth was evident after approximately 2 weeks, an event was deemed to be resistant to the applied herbicide (selective agent) and an aliquot of cells was subsequently harvested for genotype analysis. In this example, 24 events were recovered from 6 treated bottles. These events were advance for molecular analysis to confirm the integration.
Molecular Analysis of NHEJ Targeting to the E32 Locus
[0099] The 24 events that were recovered from the WHISKERS™ mediated transformation, as described above, were analyzed using several different molecular tools. As a result of the analysis, events which contained a copy of the AAD-1 transgene integrated within the E32 genomic locus were identified. The 24 various events were confirmed to contain a copy of the AAD-1 transgene and then it was determined if there was disruption of the E32 site by either indels or by the insertion of AAD-1 cassette. The events that were positive for the presence of the AAD-1 gene and a disrupted ZFN site were further characterized for the presence of the expected donor and target junction fragments (by In-Out PCR), and for expected molecular weight fragments that corresponded with band sizes in Southern blot that indicated a targeted insertion of the donor DNA region within the E33 genomic locus. These assays confirmed that events containing a copy of the AAD-1 transgene integrated within the E32 genomic locus via an NHEJ mechanism.
DNA Extraction
[0100] DNA was extracted from lyophilized maize callus tissue using a QIAGEN BIOSPRINIT 96™ DNA isolation kit per manufacturer's recommendations. A pre-defined program was used for the automation extraction and DNA was eluted in 200 μL of 1:1 TE Buffer/distilled water. Two microliters (2 μL) of each sample was quantified on THERMOSCIENTIFIC NANODROP 8000™ and samples were normalized to 100 ng/μL using QIAGEN BIOROBOT 3000™. Normalized DNA was stored at 4° C. until further analysis.
Copy Number Evaluation
[0101] Transgene copy number determination by a hydrolysis probe assay, analogous to a TAQMAN® assay, was performed by real-time PCR using the LIGHTCYCLER®480 system (Roche Applied Science, Indianapolis, Ind.). Assays were designed for AAD-1 and the internal reference gene, Invertase, using LIGHTCYCLER® Probe Design Software 2.0. For amplification, LIGHTCYCLER®480 Probes Master mix (Roche Applied Science, Indianapolis, Ind.) was prepared at 1× final concentration in a 10 μL volume multiplex reaction containing 0.4 μM of each primer and 0.2 μM of each probe (Table 5). A two step amplification reaction was performed with an extension at 60° C. for 40 seconds with fluorescence acquisition. Analysis of real time PCR copy number data was performed using LIGHTCYCLER® software release 1.5 using the relative quant module and is based on the ΔΔCt method. For this, a sample of gDNA from a single copy calibrator and a known two-copy check were included in each run.
[0000]
TABLE 5
Primer/Probe Sequences for hydrolysis probe
assay of AAD-1 and internal reference.
Primer
Name
Sequence
Detection
GAAD1F
SEQ ID NO: 24;
—
TGTTCGGTTCCCTCTACCAA
GAAD1R
SEQ ID NO: 25;
—
CAACATCCATCACCTTGACTGA
GAAD1R
SEQ ID NO: 26;
FAM
CACAGAACCGTCGCTTCAGCAACA
IVF-Taq
SEQ ID NO: 27;
—
TGGCGGACGACGACTTGT
IVR-Taq
SEQ ID NO: 28;
—
AAAGTTTGGAGGCTGCCGT
IV-Probe
SEQ ID NO: 29;
HEX
CGAGCAGACCGCCGTGTACTTCTACC
Corn Event DAS-59132 Genomic Locus Disruption Assay
[0102] A genomic locus disruption assay for Corn Event DAS-59132 was performed by real-time PCR using the LIGHTCYCLER®480 system (Roche Applied Science, Indianapolis, Ind.). Assays were designed to monitor the specificity for which E32 ZFN6 (25716/25717) bound and cleaved genomic sequences of the E32 locus and the internal reference gene invertase using the LIGHTCYCLER® Probe Design Software 2.0. For amplification, LIGHTCYCLER®480 Probes Master mix (Roche Applied Science, Indianapolis, Ind.) was prepared at 1× final concentration in a 10 μL volume multiplex reaction containing 0.4 μM of each primer and 0.2 μM of each probe (Table 6). A two step amplification reaction was performed with an extension at 55° C. for 30 seconds with fluorescence acquisition. Analysis for the disruption assay was performed using target to reference ratio ( FIG. 5 ). Four of the eight events were identified as containing an AAD-1 transgene integrated into the genomic locus of Corn Event DAS-59132. The following events, consisting of; Event 100655/105906[1]-001, Event 100655/105906[5]-013, Event 100655/105906[5]-015, and Event 100655/105906[3]-018, were advance for further molecular analysis to confirm the integration of the AAD-1 transgene within the genomic locus of Corn Event DAS-59132.
[0000] Event32 Locus Specific In-Out qPCR
[0103] The insertion of the AAD-1 donor DNA within the genomic locus of E32 via NHEJ can occur in one of two orientations. The integration of the AAD-1 transgene and the orientation fo the insert were confirmed with an in-out PCR assay. The in-out PCR assay utilizes an “out” primer that was designed to bind to the genomic locus of E32; an “in” primer was designed to bind to the AAD-1 donor sequence. The amplification reactions using these primers only amplify a donor gene which is inserted at the target site. The resulting PCR amplicons represent the junction fragments of the E32 target site and the donor DNA sequences at either the 5′ or 3′ ends of the insert. Positive and negative controls were included in the assay. Two positive control plasmids, pDAB100664 and pDAB100665, were constructed to simulate donor insertion at the genomic locus of E32 in each of the two different orientations.
[0104] For the in-out PCR, a DNA intercalating dye, SYTO-13®, was used in the PCR mix in order to detect amplification in real time on a thermocycler with fluorescence detection capability. In addition, a melting temperature (Tm) analysis program was attached to a regular PCR program so the amplified products could be analyzed for their Tm profiles. Any similarity between the Tm profiles of an unknown sample and the positive control sample would indicate that the unknown sample has the same amplified product as that of the positive control. The PCR reactions were conducted using 10 ng of template genomic DNA, 0.2 μM dNTPs, 0.2 μM forward and reverse primers, 4 μM SYTO-13® and 0.15 μL of Ex Taq HS. Reactions were completed in two steps: the first step consisted of one cycle at 94° C. (2 minutes) and 35 cycles at 98° C. (12 seconds), 66° C. (30 seconds) and 68° C. (1.3 minutes); the second step was a Tm program covering 60-95° C. followed by 65° C. (30 seconds) and 72° C. (10 minutes) (Table 6). The amplicons were sequenced to confirm that the AAD-1 gene had integrated within the genomic locus of E32.
[0105] The results of the real-time, in-out PCR amplicons were visualized using the ABI software. These results were further confirmed using a gel shift assay, wherein the amplicons were run on a 1.2% TAE gel. Expected amplicon sizes were approximately 1.8 kb for the orientation as depicted in pDAB100664 and about 2 kb for the orientation depicted in pDAB100665. The gel shift assay results confirmed the real-time, in-out PCR data.
[0106] The locus disruption data and in-out PCR suggested that a copy of the AAD-1 transgene had integrated via NHEJ into the E32 locus in some maize events recovered by selection on 2,4-D.
[0000]
TABLE 6
Primers for In-Out PCR to detect NHEJ mediated
targeting.
Expected
Primer
Amplicon
Name
Sequence
size/control
E32-3R2
Forward Primer
1.8 kb
NJ-AAD1-
SEQ ID NO: 30
pDAB100664
Pri2
GCC CTT ACA GTT CAT GGG CG
Reverser Primer
SEQ ID NO: 31
GAC CAA GTC CTT GTC TGG GAC
A
E32-5F1
Forward Primer
2.0 kb
NJ-AAD1-
SEQ ID NO: 32
pDAB100665
Pri2
ACA AAC ACG TCC TCC AAG GCT
Reverse Primer
SEQ ID NO: 33
GAC CAA GTC CTT GTC TGG GAC
A
Southern Blot Analysis
[0107] The maize callus events identified above as putatively targeted were further screened using a Southern blot assay to confirm that the AAD-1 transgene had integrated via NHEJ into the E32 locus. The Southern blot analysis experiments generated data which demonstrated the integration and integrity of the AAD-1 transgene within the maize genome.
DNA Extraction
[0108] Genomic DNA was extracted from the callus tissue harvested from each individual event. Initially, the tissue samples were collected in 2 mL tubes and lyophilized for 2 days. Tissue maceration was performed with a KLECO TISSUE PULVERIZER™ and tungsten beads (Kleco, Visalia, Calif.). Following tissue maceration the genomic DNA was isolated using the DNEASY PLANT MINI KIT™ (Qiagen, Germantown, Md.) according to the manufacturer's suggested protocol.
[0109] Genomic DNA (gDNA) was quantified using the QUANT-IT PICO GREEN DNA ASSAY KIT™ (Molecular Probes, Invitrogen, Carlsbad, Calif.). Quantified gDNA was adjusted to 4 μg for the Southern blot analysis. DNA samples were then digested using the NcoI restriction enzyme (New England BioLabs, Ipswich, Mass.) overnight at 37° C. and purified using QUICK-PRECIP™ (Edge BioSystem, Gaithersburg, Md.) according to the manufacturer's suggested protocol. DNA was resuspended in 1× dye and electrophoresed for 5 hours on a 0.8% SEAKEM LE AGAROSE™ (Lonza, Rockland, Me.) gel. The gel was denatured, neutralized, and then transferred to a nylon charged membrane (Millipore, Bedford, Mass.) overnight and DNA was crosslinked to the membrane using a UV STRATA LINKER 1800™ (Stratagene, La Jolla, Calif.), and blots were prehybridized with 20 mL of PERFECTHYB PLUS™ (Sigma, St. Louis, Mo.). The 226 bp probe SEQ ID NO:34 (GTGCATTCGGATTACTGTTTAGTCGAGTCATATTTAAGGAATTCATTGTAAATGTTCT AACCTAACCTAAGTATTAGGCAGCTATGGCTGATATGGATCTGATTGGACTTGATTT ATCCATGATAAGTTTAAGAGCAACTCAAAGAGGTTAGGTATATATGGTTTTGTAAAG GTAAATTTAGTTAATATTAGAAAAAAAAAGTGTATCCAATAGGCTCTATAAACA) was labeled using PRIME-IT RMT RANDOM™ (Stratagene, La Jolla, Calif.) according to manufacturer's suggested protocol and purified using PROBE QUANT G-50 MICRO COLUMNS™ (GE Healthcare, Buckinghamshire, UK) per the manufacturer's suggested protocol. Approximately, 20×10 6 cpm of the labeled probe was added to the blots and incubated overnight. Blots were washed twice for 15 minutes per wash and placed on a phosphor image screen for 24 hours and analyzed by a STORM 860 SCANNER™ (Molecular Dynamics).
[0110] The results from Southern blot analysis showed DNA from some events had NcoI bands of the size expected (2.9 and 5.5 kb) from integration of the donor DNA via NHEJ into the E32 locus.
[0111] The transformed maize tissue was regenerated into fertile corn plants bearing the true-breeding phenotype resistance to the 2,4-dichlorophenoxyacetic acid herbicides conferred by the AAD-1 gene introduced by the donor DNA.
Example 6
Targeting Event 32 Via Homology Directed Repair in Zea mays c.v. Hi-IIPlasmid Vectors
[0112] Plasmid vectors containing ZFN expression constructs were constructed as described in Example 2. The ZFN expressed in plasmid construct, pDAB105906 ( FIG. 2 ), contains “Fok-Mono” which is a wild type FokI endonuclease. The ZFN expressed in plasmid construct, pDAB111809 ( FIG. 3 ), contains “Fok1-ELD” which is a modified Fold endonuclease. The modified Fok1 endonuclease contains alterations as described in Doyon Y., Vo T., Mendel M., Greenberg S., Wang J., Xia D., Miller J., Urnov F., Gregory P., and Holmes M. (2010) Enhancing zinc-finger-nuclease activity with improved obligate heterodimeric architecture. Nature Methods, 8(1); 74-79.
[0113] A donor construct, pDAB107855 ( FIG. 15 ), was designed and built to integrate into the ZFN cleaved genomic DNA of the DAS-59132 genomic locus. This single gene expression cassette is comprised of the OsAct1 promoter, the phosphinothricin acetyl transferase (PAT) coding sequence:: and the ZmLip 3′ UTR. In addition, the donor plasmid was designed with 1 kb sequences (homology arms) on either end of the target PAT gene that were homologous to sequence on either end of the ZFN cut site in the DAS-59132 genomic locus. The homology arms served as the substrate that the homologous recombination machinery used to insert the transgene into the genomic ZFN cut site. The various gene elements were assembled in a high copy number pUC based plasmid.
Plant Transformation
[0114] WHISKERS™ transformations were done as described in EXAMPLE 5 using pDAB107855 (donor sequence) and pDAB105906 (ZFN) plasmid DNA.
[0000] Molecular Analysis to Confirm Targeted Integration of a Pat Gene Cassette into the E32 Locus of Hi-II
DNA Extraction
[0115] DNA extractions were done as described in EXAMPLE 5.
Targeted Locus Disruption Assay
[0116] WHISKERS™ mediated transformation of Hi-II callus cells with the DAS-59132-ZFN and donor plasmid resulted in targeted and random transgene insertions. To distinguish random insertion events from the targeted event populations, all 854 events generated were initially screened using a locus disruption assay (done as described in EXAMPLE 5 using primers in Table 7). This assay determined whether the ZFN binding site within the locus remains intact or had been disrupted through ZFN cleavage or donor insertion. Indication of a disruption within the genomic loci is initial evidence that the ZFN has cleaved the endogenous DAS-59132 target locus and indicates targeted insertion of the donor DNA molecule. Primers were designed to amplify the endogenous target region that contains the ZFN recognition sites, and samples were set up to be analyzed by qPCR. Amplification of the intact region, indicative of an untargeted event, resulted in a 140 base pair amplicon measured as a detectable qPCR signal. Successful targeted integration of the donor molecule results in disruption of the detectable qPCR signal and is shown as a lower overall signal compared to control.
[0000]
TABLE 7
Oligonucleotide Primer and Probe Sequences
for targeted Locus Disruption Assay.
Primer
SEQ ID
Detec-
Name
NO:
Sequence
tion
MAS604
SEQ ID
ACACGGCACACACGGCGACATTCA
—
NO: 35
MAS606
SEQ ID
AGGGCAGTGGCCAGTGTTCCTGTG
—
NO: 36
UPL 69
—
Roche Sequence
FAM
IVF-
SEQ ID
TGGCGGACGACGACTTGT
—
Taq
NO: 37
IVR-
SEQ ID
AAAGTTTGGAGGCTGCCGT
—
Taq
NO: 38
IV-
SEQ ID
CGAGCAGACCGCCGTGTACTTCTACC
HEX
Probe
NO: 39
[0117] The 854 events generated from precision transformation were screened with the disruption assay, and scored as disrupted based on a significant drop in the target to reference signal. The results indicated that 63 of the 854 events assayed had a disrupted signal at the targeted locus, indicative of targeted gene insertion or indels at the site.
Targeted Locus In-Out PCR Assay
[0118] The presence of an insert were further confirmed using in-out PCR as described in EXAMPLE 5 and using the primers in Table 8. Positive samples identified on the real-time system were further confirmed using a standard gel shift assay.
[0000]
TABLE 8
Primer and Probe Sequences for DAS-59132
Locus In-Out Assay.
Pri-
mer
SEQ ID
Name
NO:
Primer Sequence
5′
E32-
SEQ ID
GAAGGCAAAACGAATATAAGTGCATTCGG
Junc-
5F3
NO: 40
tion
E32-
SEQ ID
TCGTGGATAGCACTTTGGGCT
Se-
OLP-
NO: 41
quence
R1
3′
E32-
SEQ ID
TCTACAGTGAACTTTAGGACAGAGCCA
Junc-
OLP-
NO: 42
tion
F3
Se-
E32-
SEQ ID
GCCCTTACAGTTCATGGGCG
quence
3R2
NO: 30
[0119] The results of the disruption assay and the targeted locus in-out PCR assay were further confirmed via Southern blotting and sequencing (standard of Next Generation Sequencing).
[0120] In this example, 63 events out of a total of 854 samples submitted showed disruption of the E32 Locus. Of these, 8 targeted events were identified by in-out PCR and Southern analysis.
[0121] The transformed maize tissue was regenerated into fertile corn plants bearing the true-breeding phenotype, resistance to glufosinate and L-phosphinothricin, herbicides, of the donor DNA.
Example 7
Agrobacterium -Mediated Delivery of Plasmid Vectors for Event 32 Locus Disruption in Zea mays c.v. B104
Transformation
[0122] Zea mays c.v. B104 was transformed with binary constructs pDAB108688 (control vector, FIG. 6 ) and pDAB108690 (targeting vector, FIG. 7 ) using the superbinary transformation system (U.S. Pat. No. 5,591,616). As such, Agrobacterium was used for delivery of the ZFNs to the E32 genomic locus. Transgenic maize callus were obtained and analyzed via molecular confirmation assays to determine whether or not the E32 genomic locus of Zea mays c.v. B104 was disrupted. The results of the assays confirmed that Agrobacterium could be used to deliver ZFNs to cleave and disrupt the E32 genomic locus.
Binary Vectors
[0123] A binary construct, pDAB108690 (targeting vector, FIG. 7 ), was designed and built to contain a donor gene expression cassette and a ZFN gene expression cassette. This donor gene expression cassette was comprised of the Zea mays Ubiquitin 1 gene promoter (Zm Ubi1 promoter), the AAD-1 coding sequence and was terminated by the Zea mays lipase 3′ untranslated region (ZmLip 3′UTR). In addition, the donor plasmid was designed with 1 kb sequence (homology arms) on either end of the AAD-1 gene that are homologous to sequence on either end of the ZFN cut site in the E32 genomic locus to facilitate donor insertion by HDR. The ZFN gene expression cassette was comprised of the rice Actin1 gene promoter (OsAct1 promoter), the 25716 and 25717 ZFN coding sequences and the ZmPer5 3′ UTR.
[0124] In addition, a second control binary construct, pDAB108688 (control vector, FIG. 6 ), was designed and built to contain a gene expression cassette the same AAD-1 gene In addition, the donor plasmid was designed with 1 kb sequence (homology arms) on either end of the target aad-1 gene that is homologous to sequence on either end of the ZFN cut site in the E32 genomic locus.
[0000] Zea mays c.v. B104 Transformations
[0125] The constructs were transferred into Agrobacterium and used to transform Zea mays c.v. B104. The transformation procedure that was utilized is described in U.S. Pat. Pub. No. 2013/0157369. After completion of the transformation, isolated maize callus tissues were selected for and obtained from media containing the herbicide selectable agent. Table 9 shows the transformation frequency in the experiments. The resulting events were analyzed via molecular analysis to confirm ZFN mediated cleavage of the E32 Locus of Zea mays c.v. B104 following delivery of ZFN and donor via Agrobacterium -mediated transformation.
[0000] TABLE 9 Summary of transformation events produced using pDAB108688 (control vector) and pDAB108690 (targeting vector). Putative Number of immature events Transformation Construct embryos transformed produced frequency (%) pDAB108688 930 355 38.17 (control vector) pDAB108690 4789 1002 20.92 (targeting vector)
Genomic DNA Isolation for PCR from Callus Tissue
[0126] Genomic DNA was isolated as described in EXAMPLE 5.
Copy Number Determination
[0127] Transgene detection by hydrolysis probe assay, analogous to TaqMan® assay, was performed by real-time PCR using the LightCycler®480 system (Roche Applied Science). Assays were designed for detection of AAD-1 and ZFN disruption and were multiplexed with internal reference assays (Invertase) to ensure appropriate amount of gDNA was present in each assay. For amplification, LightCycler®480 Probes Master Mix™ (Roche Applied Science, Indianapolis, Ind.) was prepared at 1× final concentration in a 10 μL volume multiplex reaction containing 0.4 μM of each primer and 0.2 μM of each probe (Table 10). A two step amplification reaction was performed with an extension at 60° C. for 40 seconds (for the AAD1 reaction) or 60° C. for 30 seconds (for the ZFN disruption reaction) and with fluorescence acquisition.
[0128] Cp scores, the point at which the fluorescence signal crosses the background threshold using the fit points algorithm (Light Cycler® software release 1.5) and the Relative Quant module (based on the ΔΔCt method), was used to perform the analysis of real time PCR data.
[0129] The ZFN disruption qPCR assay determines if the ZFN target site is intact or has been modified during the experiment (by donor insertion or by NHEJ). This assay used the Roche UPL probe with primers designed to anneal outside of the ZFN cut site and probe hybridization region ( FIG. 8 ). If events are disrupted at both alleles, the target to reference ratio is reduced compared to controls. Analysis of non-targeted controls and events that are not disrupted showed a target to reference ratio in the 0.4 to 0.6 range; disrupted events showed a target to reference ratio in the 0.2 to 0.35 range ( FIG. 9 ).
[0130] This data demonstrates that the E32 Locus can be cleaved by introduction of the ZFN via Agrobacterium -mediated transformation.
[0000]
TABLE 10
Primers and probes for qPCR.
Probe
(Flouro-
SEQ ID
phore/quen-
Name
NO:
Oligo Sequence
cher)
MAS604
SEQ ID
ACACGGCACACACGGCGACATTCA
—
NO: 53
MAS606
SEQ ID
AGGGCAGTGGCCAGTGTTCCTGTG
—
NO: 54
UPL69
—
See Roche
See Roche
IVF-
SEQ ID
TGGCGGACGACGACTTGT
—
Taq
NO: 55
IVR-
SEQ ID
AAAGTTTGGAGGCTGCCGT
—
Taq
NO: 56
IV-
SEQ ID
CGAGCAGACCGCCGTGTACTTCTA
HEX/BHQ
Probe
NO: 57
CC
GAAD1F
SEQ ID
TGTTCGGTTCCCTCTACCAA
—
NO: 58
GAAD1R
SEQ ID
CAACATCCATCACCTTGACTGA
—
NO: 59
GAAD1P
SEQ ID
CACAGAACCGTCGCTTCAGCAACA
FAM
NO: 60
Example 8
Event 32 Locus Targeting Via Homology Directed Repair in Zea mays c.v B104
Vectors
[0131] Plasmid vectors for expression of ZFNs were described in EXAMPLE 2.
[0132] A donor construct, pDAB104179 ( FIG. 10 , SEQ ID NO:61), designed to integrate into the ZFN cleaved genomic DNA of the E32 genomic locus was a single gene expression cassette comprised of the OsAct1 promoter, the PAT coding sequence and the ZmLip 3′ UTR. In addition, the donor plasmid was designed with 1 kb sequence (homology arms) on either end of the target PAT gene that is identical to sequence on either end of the ZFN cut site in the E32 genomic locus to facilitate integration of the donor DNA region.
[0000] Transformation into B104 Using Particle Bombardment
[0133] Ears of the inbred line Zea mays c.v. B104 were self-pollinated and harvested when immature embryos were approximately 1.8-2.2 mm in length. De-husked ears were transported to the laboratory for sterilization. The end of a #4 stainless steel scalpel handle (lacking a blade) was placed into the distal portion of each ear. Ears were scrubbed with a nailbrush using liquid detergent (Liqui-Nox®, ALCONOX, Inc.) and surface-sterilized by immersion in 20% commercial bleach (Ultra Clorox® Germicidal Bleach, 6.15% sodium hypochlorite) for 20 minutes then rinsed with sterile deionized water 3 times inside a laminar flow hood. Immature zygotic embryos were aseptically excised from each ear and placed into an Eppendorf™ tube containing approximately 2.0 mL ‘LS-inf medium’ (LS salts, N6 vitamins, 68.5 g/L sucrose, 36 g/L D-glucose, 700 mg/L L-proline and 1.5 mg/L 2,4-D). The contents of the tube were poured onto plates of ‘resting medium’ (MS salts and vitamins, 30 g/L sucrose, 700 mg/L L-proline, 15 mg/L silver nitrate, 500 mg/L MES, 100 mg/L casein hydrolysate, 100 mg/L myo-inositol and 3.3 mg/L dicamba adjusted to pH 5.8 and solidified with 2.3 g/L Gelzan™), excess liquid was removed, and embryos were oriented with the scutellum facing upwards. Plates were placed at 28° C. with 24 hours continuous lighting at 50 μmoles/m 2 s for 3 days.
[0134] Four hours prior to bombardment, 30 embryos were arranged in the center of Petri dish of ‘osmolysis medium’ Cresting medium with the addition of 45.5 g/L sorbitol and 45.5 g/L mannitol) within a 2.5 cm diameter area with the scutella facing upwards. The embryos were incubated on this medium for 4 hours at 50 μmoles/m 2 s at 28° C. prior to bombardment.
[0135] To prepare gold microparticles for bombardment, 15 mg of 0.6 micron gold (Bio-Rad, Hercules, Calif., USA) were weighed into a siliconized microcentrifuge tube and 500 μL of cold ethanol (100%) was added. The tube was sonicated in an ultrasonic water bath for 15 seconds, allowed to sit at room temperature for 30 minutes, and then centrifuged for 60 seconds at 3,000 rpm. The supernatant was removed, and 1 mL cold, sterile water was added. The tube was finger-vortexed, allowed to settle for 3-5 minutes, and centrifuged for 60 seconds at 3,000 rpm. The supernatant was removed, and the water wash was repeated two additional times. After the second water wash, the gold was re-suspended in 500 μL cold water, sonicated for 15 seconds, and aliquoted 25 μL at a time into 10 sterile, siliconized microcentrifuge tubes. Individual tubes were frozen at −20° C. until use.
[0136] For precipitation of DNA onto prepared gold microparticles, one tube of gold was thawed for every 10 plates to be bombarded. The tube was sonicated in an ultrasonic water bath for 15 seconds, finger-vortexed, and then tapped on the laminar flow hood surface to gather all droplets to the bottom. To obtain a 20:1 molar ratio of donor to zinc finger constructs, 4.75 μg of donor DNA (pDAB104182) was pre-mixed with 0.25 μg of zinc finger (pDAB105941), then added to the gold, while pipetting up and down. Fifty μL of 2.5 M calcium chloride (anhydrous) was added, while pipetting up and down, and 20 μL of 0.1M spermidine (free base) was added, while pipetting up and down. The tube was placed on a Turbomix™ attachment for a Vortex-Genie® set at 2, and allowed to shake for 10 minutes at room temperature. The tube was removed from the shaker and allowed to settle for 3-5 minutes before being centrifuged for 15 seconds at 5,000 rpm. The supernatant was removed, 250 μL cold ethanol (100%) was added and the tube was finger vortexed to dislodge the pellet and ensure a uniform suspension. The DNA-coated microparticles settled for 3-5 minutes, and the tube was centrifuged again for 15 seconds at 5,000 rpm. The pellet was resuspended in 120 μL cold ethanol (100%), and finger vortexed to ensure dispersal. Macrocarriers were placed into macrocarrier holders, autoclaved for sterility, coated with 10 μL of the prepared solution and allowed to dry completely prior to bombardment.
[0137] Bombardment of embryos was done using a PDS-1000™ (Bio-Rad) per manufacturer's specifications at 900 psi under 28 inches vacuum at a distance of 6 cm from the stopping screen. Each sample was bombarded once, and then returned to 50 moles/m 2 s 24-hour lighting overnight at 28° C. The next day, embryos were transferred to fresh ‘resting medium’ for 7 days under the same temperature and lighting conditions. Embryos were subsequently transferred to ‘sel-5 Bi medium’ Cresting medium with the addition of 5 mg/L Bialaphos) for 7 days, transferred a second time to the same medium for 14 days and then transferred to ‘pre-regen medium’ (MS salts and vitamins, 30 g/L sucrose, 700 mg/L L-proline, 15 mg/L silver nitrate, 500 mg/L MES, 100 mg/L casein hydrolysate, 100 mg/L myo-inositol and 3.3 mg/L dicamba, 2.5 mg/L ABA, 1 mg/L BAP, 0.5 mg/L NAA and 5 mg/L Bialaphos adjusted to pH 5.8 and solidified with 2.3 g/L Gelzan) for 7 days under the same temperature and lighting conditions. Tissues were then transferred to ‘regen media’ (MS salts and vitamins, 30 g/L sucrose, 100 mg/L myo-insitol and 5 mg/L Bialaphos adjusted to pH 5.8 and solidified with 2.3 g/L Gelzan) under a 16/8 light/dark photoperiod with 90 moles/m 2 s lighting for 14 days at 28° C. Plantlets were transferred to ‘plant robusting medium’ (MS salts and vitamins, 30 g/L sucrose, 500 mg/L MES and 100 mg/L myo-insitol adjusted to pH 5.8 and solidified with 2.3 g/L Gelzan) under 150-200 moles/m 2 s lighting at 28° C. using the same photoperiod. Once plants grew to at least 8 cm, a 2 cm section of leaf tissue was collected on wet ice, and delivered to a 4° C. cold room for analysis. Plantlets were then transplanted into soil and transferred to the greenhouse and analyzed via molecular analysis.
Molecular Analysis Bialophos-Selected Events
[0138] Genomic DNA Isolation for qPCR from Callus Tissue
[0139] Tissue samples were collected in 96-well collection plates (Qiagen) and lyophilized for 48 hours. Tissue disruption was performed with a Kleco™ tissue pulverizer (Garcia Manufacturing, Visalia, Calif.) in Biosprint96 RLT lysis Buffer™ with one stainless steel bead. Following tissue maceration, genomic DNA was isolated in a high throughput format using the Biosprint96 Plant Kit™ (Qiagen) and the Biosprint96 extraction Robot™. Genomic DNA was then diluted to 2 ng/μL.
Copy Number Determination
[0140] Gene copy number and the disruption assay were done as described in EXAMPLE 7. Analysis of non-targeted controls and events that are not targeted or disrupted showed a target to reference ratio in the 0.4 to 0.6 range; disrupted or targeted events showed a target to reference ratio in the 0.2 to 0.35 range ( FIG. 12 ).
[0000]
TABLE 11
Primers and probes for qPCR.
Probe
SEQ
(Flouro-
ID
phore/quen-
Name
NO:
Oligo Sequence
cher)
MAS604
53
ACACGGCACACACGGCGACATTCA
—
MAS606
54
AGGGCAGTGGCCAGTGTTCCTGTG
—
UPL69
—
See Roche
See Roche
IVF-
55
TGGCGGACGACGACTTGT
—
Taq
IVR-
56
AAAGTTTGGAGGCTGCCGT
—
Taq
IV-
57
CGAGCAGACCGCCGTGTACTTCTACC
HEX/BHQ
Probe
TQPATS
62
ACAAGAGTGGATTGATGATCTAGAGA
—
GGT
TQPATA
63
CTTTGATGCCTATGTGACACGTAAAC
—
AGT
TQPATF
64
GGTGTTGTGGCTGGTATTGCTTACGC
CY5/BHQ2
Q
TGG
ZGP3S
65
CCTGCTCCACTACCAGTACAA
—
ZGP3A
66
GTCCAAGAAGGTGACCTTCTC
—
TQZGP3
67
AGATCACCGACTTTGCGCTCTTT
6FAM/BHQ1
Locus-Specific In-Out PCR
[0141] Locus-specific in-out PCR was done as described in EXAMPLE 5.
[0000]
TABLE 12
Primer sequences for in-out PCR.
SEQ ID
Name
NO:
Oligo Sequence
E32-
SEQ ID
GAAGGCAAAACGAATATAAGTGCATTCGG
5F3
NO: 68
E32-
SEQ ID
TCTACAGTGAACTTTAGGACAGAGCCA
OLP-F3
NO: 69
E32-
SEQ ID
TCGTGGATAGCACTTTGGGCT
OLP-R1
NO: 70
E32-3R2
SEQ ID
GCCCTTACAGTTCATGGGCG
NO: 71
[0142] Expected amplification sizes for the 5′ end amplicon was 1,874 bp and the 3′ end was 2,089 bp. The PCR bands were excised and sequenced. The resulting sequence data confirmed that the amplicons contained the expected genomic E32 locus-donor chromosomal junctional sequences.
Southern Blot
[0143] DNA from events that showed positive disruption and in-out PCR were analyzed by Southern blots to confirm intact donor insertion at the target. DNA was digested with NcoI and probed with flanking genomic DNA outside the homology arms ( FIG. 14 ). A band at 1,950 bp was predicted for the endogenous, non-targeted locus and a band of 4,370 bp was predicted for a targeted locus.
[0144] For Southerns, genomic DNA (from 1 μg to 5 μg) was digested in 1× Buffer 3 (New England BioLabs) with 50 Units of NcoI (New England BioLabs) in a final volume of 125 μL. Samples were incubated at 37° C. overnight. The digested DNA was concentrated by re-precipitation with Quick Precipitation Solution™ (Edge Biosystems) according to manufacturer's suggested protocol. Recovered digest was resuspended in 30 μL of 1× loading buffer and incubated at 65° C. for 30 minutes. Resuspended samples were loaded onto a 0.8% agarose gel prepared in 1×TAE (0.8M Tris-acetate [pH8.0]/0.04 mM EDTA) and electrophoresed in 1×TAE buffer. The gel was sequentially subjected to denaturation (0.2 M NaOH/0.6M NaCl) for 30 minutes, and neutralization (0.5 M Tris-HCl [pH7.5]/1.5M NaCl) for 30 minutes. Transfer of DNA fragments was performed by passively wicking 20×SSC solution overnight through the gel onto treated Immobilon NY+™ (Millipore) Following transfer, the membrane was briefly washed with 2×SSC, cross-linked with a StrataLinker 1800™ (Stratagene), and baked at 80° C. for 1 hour.
[0145] Blots were incubated with prehybridization solution (Perfect Hyb Plus™, Sigma) for 1 hour at 65° C. in glass roller bottles using a model 400 Hybridization Incubator™ (Robbins Scientific). For probe preparation, genomic sequence outside the donor homology region was PCR amplified with primers (Table 13) and purified from agarose gels using a QIAquick gel extraction Kit™ (Qiagen). The fragment was labeled with 3000 Ci/mmol α 32 P-dCTP (Perkin/Elmer/BLU513H) using Prime-IT® II Random Primer labeling Kit™ (Stratagene) according to manufacturer's suggested protocol. Blots were hybridized overnight at 65° C. with denatured probe at approximately 2×10 6 counts per mL/hybridization buffer. Following hybridization, blots were washed at 65° C. with 0.1×SSC/0.1% SDS for 40 minutes. Blots were exposed using phosphor imager screens (Molecular Dynamics) and imaged using a Storm Imaging System™ (Molecular Dynamics, Storm 860™).
[0000]
TABLE 13
Primers used to make Southern probe.
Name
SEQ ID NO:
Oligo Sequence
MAS600
SEQ ID NO: 72
TGTTTATAGAGCCTATTGGATACA
MAS603
SEQ ID NO: 73
AGTGCATTCGGATTACTGTTTAGTC
[0146] A total of 912 events were screened by disruption and in-out PCR and 16 were confirmed to be targeted based on Southern analysis. The targeting frequency for a donor fragment within the E32 genomic locus was calculated to be 1.8%.
[0147] Although disclosure has been provided in some detail by way of illustration and example for the purposes of clarity of understanding, it will be apparent to those skilled in the art that various changes and modifications can be practiced without departing from the spirit or scope of the disclosure. Accordingly, the foregoing descriptions and examples should not be construed as limiting. | The present invention claims methods for the stable integration of exogenous DNA into a specific locus, E32, in the maize genome through the use of zinc finger nucleases. Maize plants and plant parts that were transformed by the methods of the invention are claimed. The invention is useful for creating desirable traits such as herbicide resistance, herbicide tolerance, insect resistance, insect tolerance, disease resistance, disease tolerance, stress tolerance, and stress resistance in maize The E32 locus represents a superior site for inserting foreign genes because native agronomic phenotypes are not disturbed. | 2 |
FIELD OF THE INVENTION
This invention relates to a process for making paper or paperboard comprising the addition of any cationically substituted starch to the pulp fiber components of a papermaking furnish followed by the addition of an effective proportional amount of carboxymethyl cellulose or its additionally substituted derivatives. The process of this invention provides improved paper strength properties over prior art practices by increasing the extent of precipitation and retention of cationic starch on papermaking furnish fibers, thereby increasing the strength benefit from its use at a given level of addition and, particularly, at higher desired levels of cationic starch addition. Alternatively, the process of this invention may provide the papermaker with the ability to increase sheet filler loading for increased opacity or reduced fiber raw material cost while maintaining necessary sheet strength specifications which normally decrease with increased sheet filler content. The process of this invention also reduces the buildup of unretained cationic starch in the recirculating process filtrate circuit, thereby reducing production losses associated with excessive foaming and chemical slime deposition in the process. The process of this invention will also serve to reduce the Biological Oxygen Demand (BOD) loading contributed by unretained cationic starch in the process effluent.
BACKGROUND OF THE INVENTION
Paper or paperboard normally is made by producing a stock slurry or furnish, comprised mainly of cellulosic wood fibers but also often containing inorganic mineral fillers or pigments, depositing the slurry on a moving papermaking wire or fabric, and forming a sheet from the solid components by draining the water. This process is followed by pressing and drying operations. Many different organic and inorganic chemicals are often added to the furnish before the sheet forming process in order to make processing less costly or more rapid, or to attain special functional properties in the final paper or paperboard product.
The paper industry continuously strives for improvements in paper quality as well as reductions in manufacturing costs. Sheet strength is often a key factor in achieving or balancing these goals. Increases in strength potential of the fiber furnish, for example, enable the papermaker to improve sheet opacity and printability or reduce fiber furnish raw material cost through substitution of expensive fiber with elevated loadings of low cost filler. A stronger sheet also provides the opportunity for cost savings through a reduction in pulp refining energy.
Starches are used by the paper industry to increase the inter-fiber bond strength of paper or paperboard as typically characterized by standardized Tensile, Mullen Burst, or Scott Bond tests. Papermaking starches function to enhance the fiber furnish strength potential by creating additional hydrogen bonding sites between contiguous fiber surfaces when the sheet is formed and dried. Higher starch addition rates are often desired to achieve increases in bonding strength. However, starch adsorption on the fibers is incomplete, resulting in reduced starch efficiency, operating difficulties attributable to high levels of unabsorbed starch recirculating in the process filtrate circuit, and the resulting inability to further increase the starch addition level. These effects are evident even for the cationically derivatized starch products.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1F are scanning electron micrograph (SEM) photographs of several handsheets. The SEM photographs are Robinson backscatter images at 90X magnification. These photographs provide important insight into distribution of filler in the handsheets.
FIGS. 2A-2F are 35 mm camera photographs of the same handsheets. The handsheets were placed on a light box and illuminated for photographs taken at a fixed distance with a 35 mm Minolta camera and no magnification. These shots describe the sheet formation as observed by the naked eye.
DETAILED DESCRIPTION OF THE INVENTION
The present inventors have discovered that dilute solutions of a carboxymethyl cellulose including carboxymethyl cellulose (CMC) or its additionally substituted derivatives such as carboxymethyl methylcellulose (CMMC), carboxymethyl hydroxyethylcellulose (CMHEC), and carboxymethyl hydroxypropylcellulose (CMHPC) added to a papermaking furnish following, and in a particular weight ratio to the addition of cationic starch, effectively increases the adsorption and retention of cationic starch, resulting in proportionately increased sheet strength for a given level of cationic starch addition. The inventors have also discovered that in order to minimize macro-coagulation of the cationic starch/CMC complex and to achieve uniform distribution of the starch and maximum strength gain, it is critical that the CMC be added separately and following the addition of cationic starch. The inventors have also discovered that the strength increasing benefit of the present invention is preferably maximized when both the cationic starch and subsequent CMC additions are made to the longer fiber, chemically produced pulp prior to blending with short fiber, mechanically produced pulps when the fiber furnish is comprised of both types of pulp. Furthermore, the inventors have discovered that the process of the present invention is wholly compatible with, and further enhanced by, the subsequent use of typical papermaking fine solids retention aids such as medium and high molecular weight cationic and anionic polyacrylamide copolymers.
Cationically derivatized starches useful in the process of the present invention are most commonly produced from corn or potatoes, but may also be produced from tapioca, rice, and wheat. Their cationic character in aqueous solution is produced by the presence of either tertiary or quaternary amine groups which are substituted on the starch molecules during their manufacture. The cationicity of these starches is defined by the Degree of Substitution (DS) or average number of amine groups substituted for hydroxyl groups per anhydroglucose unit of starch, and may range from about DS=0.01 to DS=0.10.
The cationic starch preferably is first hydrated and dispersed in water before addition to the papermaking furnish. Either starches that have to be gelatinized or "cooked" at the use location or pre-gelatinized, cold water dispersible starches can be used. Preferably the starch dispersion will contain about 0.1% to 10% of cationic starch, based on the weight of the solution or dispersion.
The cationic starch may be added to the total furnish or it may preferably be added to the fiber furnish prior to blending in any inorganic fillers. The latter preferred method is intended to promote maximum starch adsorption on furnish fibers versus fillers, thereby promoting maximum inter-fiber bonding strength development and also minimizing the negative effect on sheet opacity by minimizing starch-induced filler coagulation.
For papermaking furnishes which are comprised of a combination of chemical pulp fibers such as those produced from either the Kraft or sulfite pulping processes and mechanical pulp fibers such as those from either the stone groundwood or thermomechanical pulping processes, the cationic starch may be added to the blended furnish or may be more preferably added to the chemical pulp prior to blending with one or more mechanical pulp components. The preferred method is intended to promote maximum starch adsorption on the long, chemically produced fibers, the strength development potential of which is limited by bonding area versus the short, mechanically produced fibers, the strength development potential of which is limited by the fiber length and not the lack of adequate inter-fiber bonding. This is particularly true of the stone groundwood pulps.
The anionic carboxymethyl cellulose (CMC) useful in the process of the present invention has a Degree of Substitution of up to the theoretical limit of 3.0 but preferably from about 0.30 to 1.40 carboxymethyl substituents per anhydroglucose unit of cellulose. The CMC can be unmodified or it can be additionally substituted with methyl or hydroxyalkyl groups, the latter functionality preferably containing 2 to 3 carbon atoms. Carboxymethyl methylcellulose (CMMC), carboxymethyl hydroxyethylcellulose (CMHEC), and carboxymethyl hydroxypropylcellulose (CMHPC) are examples of substituted carboxymethyl cellulose. Additionally, the CMC, CMMC, CMHEC, or CMHPC can possess an average Molecular Weight in the range of about 10,000 to 1,000,000 but preferably in the range of 90,000 to 700,000.
The carboxymethyl cellulose is preferably added to the pulp furnish following the addition of cationic starch with some mixing after each addition. The carboxymethyl cellulose is added in the form of an aqueous solution containing from about 0.1% to 5.0% CMC. The amount of carboxymethyl cellulose added to the furnish preferably is about 5% to 20%, most preferably about 6% to 14%, based on the weight of cationic starch added.
Papermaking retention aids are used to increase the retention of fine furnish solids in the web during the turbulent process of draining and forming the paper web. Without adequate retention of the fine solids, they are either lost to the process effluent or accumulate to excessively high concentrations in the recirculating white water loop and cause production difficulties including deposit buildup and impaired paper machine drainage. Additionally, insufficient retention of the fine solids and the disproportionate quantity of chemical additives which are adsorbed on their surfaces reduces the papermaker's ability to achieve necessary paper quality specifications such as opacity, strength, and sizing.
The extent to which typical papermaking retention aids can function to increase the incorporation of papermaking functional chemical additives into the paper sheet, thereby increasing the benefit and efficiency of their use, depends entirely upon the degree of adsorption or precipitation of the functional additives on the surfaces of the furnish solids. Therefore, the process of the present invention promotes the benefit of papermaking retention aids by promoting more complete adsorption and retention of cationic starch on the furnish solids.
Any known papermaking retention aid may be used in addition to the process of the present invention. Those most commonly employed are cationic or anionic polyacrylamide copolymers with Molecular Weights ranging from about 1 million to 18 million and charge densities ranging from about 1% to 40%, expressed as the mole % of charged moiety. They are normally applied as highly dilute aqueous solutions to the diluted papermaking furnish immediately prior to the paper machine headbox.
In U.S. Pat. No. 4,710,270 to Sunden et al., cationic starch and carboxymethyl cellulose are both added to a paper furnish to improve retention and binding of fillers. The patent calls for the preparation of a separate filler furnish by dispersing the starch and CMC together in water, adding the resultant mixture to an aqueous slurry of mineral fillers, and then incorporating an additional anionic or cationic colloidal inorganic polymer to the filler slurry. The filler furnish, described as a tertiary gel structure, is then mixed into the slurry of cellulosic fibers.
The present invention provides a substantially different and improved method of preparing such filler-containing paper furnishes although the present invention is just as useful in non-filler-containing furnishes. The present invention provides better distribution of both the starch and filler and, as a result, higher opacity values and more uniform sheet formation. These improvements result from the aforementioned novel and critical addition points and order of addition of the cationic starch and CMC as compared to the method of Sunden et al.
The process of the present invention will be better understood by considering the following examples. Unless otherwise noted, all parts and percentages reported therein are parts and percentages by weight.
EXAMPLE 1
Example 1 illustrates the incomplete adsorption of cationic starch on wood pulp fiber as the starch adsorption level is increased. The data presented in Table 1 were obtained through a laboratory starch adsorption procedure involving the use of a colorimeter. The test is based on the characteristic blue color formed when the amylose fraction of the starch molecule is complexed with KI/I 2 solution. The procedure involves the use of a dynamic retention test device (Britt Dynamic Retention jar) and applied vacuum to roughly simulate the forming table on a paper machine. A 200 mesh (125-P) screen is utilized in the Britt jar. Filtrate samples from mixing and draining furnish in the Britt jar are obtained as the test samples in this procedure. A colorimeter is then utilized to measure the filtrate for starch content after the filtrate is mixed and treated with a given volume of the starch reagent (KI/I 2 ). In order to accurately determine starch mass per filtrate volume, a calibration curve must first be generated via the colorimeter with known quantities of the particular starch to be utilized in the testing.
The initial testing medium added to the Britt jar consists of a 0.5% consistency bleached Kraft hardwood/softwood (50/50) fiber furnish refined to 350-400 ml Canadian Standard Freeness (CSF) and containing 0.75% papermaker's alum (pH 4.5). A fiber-only test furnish was selected for this test to eliminate the adverse effects of light-scattering pigments on the colorimeter and also to allow direct measurement of starch adsorption effects on the fiber fraction. This same test furnish was used in Example 1 to which increasing levels of Stalok 600 (Staley) potato starch were added. Stalok 600 is a cationic pre-gelatinized, cold water dispersable starch with a 0.032 degree of substitution (DS). This starch is a quaternary amine-substituted potato starch with a nitrogen content of 0.30 wt. %.
The data in Table 1 clearly demonstrate the incomplete adsorption of cationic starch. For example at a 10 lb/T starch addition level, only 60% of the starch was retained on the fiber.
TABLE 1______________________________________Starch Adsorption on Fiber at Various Addition LevelsStarch.sup.(1) Starch In Starch On StarchAdded Filtrate Fiber Adsorption(lb/T) (lb/T) (lb/T) (%)______________________________________10 4.0 6.0 60.020 9.5 10.5 52.530 16.8 13.2 44.040 24.2 15.8 39.650 32.5 17.5 35.160 39.7 20.3 33.870 48.2 21.8 31.280 55.1 24.9 31.190 62.7 27.3 30.3100 68.0 32.0 32.0______________________________________ .sup.(1) Staley Stalok 600
EXAMPLE 2A
In Table 2A the positive effect of CMC on cationic starch adsorption is demonstrated through various methods of addition of the starch and CMC.
The same test procedure, test furnish, and starch type described in Example 1 were utilized in this study. The CMC used was Hercules CMC-7LT with 0.7 DS.
The data show that starch adsorption is significantly increased over the starch-only case as the CMC dosage level is increased. The anionic CMC effectively destabilizes the cationic starch in solution and provides a more favorable condition for starch adsorption or retention on fiber. The largest improvement in starch retention is consistently obtained through the addition of a combined starch-CMC solution to the test furnish as the more concentrated effect provided by the pre-reaction of additives enables more starch to be destabilized and subsequently adsorbed onto the fiber surfaces. The data also demonstrate that cationic starch should precede CMC when added separately to the furnish allowing starch to contact the fiber prior to the addition of CMC.
TABLE 2A______________________________________CMC Effect on Starch Adsorption for Various Orders of AdditionStarch.sup.(1) CMC.sup.(2) % Starch AdsorptionAdded Added Combined Separate Addition**(lb/T) (lb/T) Addition* (Starch/CMC) (CMC/Starch)______________________________________30 0 52.0 -- --30 1.8 66.3 64.9 54.630 2.4 76.4 64.9 56.930 3.0 81.1 67.9 60.230 4.8 73.3 72.3 65.6______________________________________ *Starch and CMC prepared as individual solutions, combined, and added as one solution. **Starch and CMC solutions prepared and added separately. .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMC7LT
EXAMPLE 2B
A handsheet study was conducted to evaluate the effects of the starch and CMC additives on sheet properties. A complete paper furnish was made comprising 73.75% bleached Kraft fiber (50% hardwood/50% softwood blend), 20% Kaolin clay (Huber Hi-White), 5% titanium dioxide (SCM Glidden Zopaque RG), 0.75% papermaker's alum, and 0.50% rosin size (Hercules dry Pexol 200). The final furnish pH was 4.5. The pulp was first refined to 372 ml CSF. The same starch and CMC types used in Example 2A were utilized in this study, the results of which are summarized in Tables 2B and 2B-1.
Five handsheets were made at each condition listed in Table 2B. Handsheets were prepared from the resulting furnish using a Noble and Wood sheet forming apparatus. The pressing (20 psi) and drying (240° F.) steps were conducted with the same apparatus. After drying, the sheets were conditioned for 24 hours at approximately 50% relative humidity and 73° F. The sheets were then cut to a 7"×7" area, weighed, and evaluated individually for opacity, Mullen Burst, and tensile strength. An additional test was conducted to qualitatively determine starch distribution in the handsheet by applying the same KI/I 2 starch reagent to the surface of each sheet. Since the reagent stains starch-containing areas deep blue, a mottled or grainy sheet appearance indicates an uneven distribution of starch. The final sheet measurement was obtained when the remaining portion of each sheet was oven-dried, weighed, and ashed in a muffle furnace (930° C.) to determine ash content (wt. %).
The data of Table 2B are averages of replicated tests for all sheets per experimental condition. The tensile strength and Mullen Burst data are then standardized in Table 2B-1 to correct differences in sheet weight and ash content. The standardization procedure involves the division of the average burst or tensile value by the corresponding average grammage value. This value is then multiplied by the corresponding ratio of treated handsheet % ash/starch-only % ash so that each condition is standardized to a constant ash value. Table 2B-1 demonstrates significant mullen and tensile increases for the separate addition case of 30 lb/T starch followed by 3 lb/T CMC. However, the combined addition of the same dosage levels of starch and CMC did not increase the sheet strength. Combined addition involved the pre-mixing of starch-CMC either in powder form or from separate solutions to create a single solution.
Based on these results it is evident that the situation which enabled the maximum starch adsorption, pre-mixed cationic starch and CMC (10:1), did not provide strength increases. This result is explained through the qualitative observations of starch distribution summarized in Table 2B. The starch distribution test shows that either method of combined addition results in an uneven starch distribution in the sheet. This effect is a result of the strong affinity of cationic starch and CMC for each other, resulting in tenacious agglomerates when these additives are combined in solution in concentrated form. When the complexation reaction between additives takes place within the furnish (separate addition) after the starch has already begun to adsorb, the starch is more evenly distributed, as demonstrated by the even appearance of color in the distribution test. For starch to be effective at promoting or reinforcing fiber-fiber bonds, it is well known that it must be evenly distributed (separate addition) and not retained in localized areas in the sheet (combined addition).
The data of Table 2B demonstrate that the opacity was not adversely affected by the increased starch content of the separate addition case. Also, the filler retention was increased through separate addition, presumably due to the increased number of cationic sites on fiber provided by the additional starch. The filler retention and opacity values were reduced for both methods of combined addition. These effects were most likely a result of the uneven starch distribution in the sheet providing fewer and more poorly distributed cationic sites for filler retention.
TABLE 2B__________________________________________________________________________Handsheet Test Results Avg. Sheet Avg. Ash Avg. Mullen Avg. Tensile Wt/Area Content Avg. Burst Strength StarchCondition (g/m.sup.2) (%) Opacity (g/cm.sup.2) (g/cm) Distribution__________________________________________________________________________No Starch 40.48 5.13 67.69 315.0 1375.1 --Starch-Only.sup.(1) 48.40 16.97 80.18 346.6 1535.8 Even Color(30 lb/T)Separate Addition 50.61 18.75 80.60 444.4 1785.8 Even ColorStarch/CMC.sup.(2)(30 lb/T/3 lb/T)Combined Addition* 48.08 15.30 78.79 387.4 1464.4 MottledStarch/CMC (Small Spots)(30 lb/T/3 lb/T)Combined Addition** 46.50 13.87 77.33 361.4 1507.2 MottledStarch/CMC (Small Spots)(30 lb/T/3 lb/T)__________________________________________________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMC7LT *Starch and CMC prepared as individual solutions, combined, and added as one solution. **Starch and CMC mixed in powder form, and prepared and added as one solution.
TABLE 2B-1__________________________________________________________________________Standardized Mullen/Tensile Data From Table 2B Standardized Standardized Mullen Tensile (g/cm.sup.2) % Change vs. (g/cm) % Change vs.Condition (g/m.sup.2) Starch-Only (g/m.sup.2) Starch-Only__________________________________________________________________________Starch-Only 7.2 -- 31.7 --(30 lb/T)Separate Addition 9.7 +35% 39.0 +23%Starch/CMC(30 lb/T/3 lb/T)Combined Addition 7.3 -1% 27.5 -13%Starch/CMC(30 lb/T/3 lb/T)Combined Addition 6.4 -12% 26.5 -16%Starch/CMC(30 lb/T/3 lb/T)__________________________________________________________________________
EXAMPLE 2C
A second handsheet study was conducted in the same furnish described in Example 2B to further evaluate the methods of application of the cationic starch-CMC additive program and the resultant effects on handsheet properties. In this study the Stalok 600 starch addition level was raised to 60 lb/T while CMC-7LT was added at 6 lb/T to maintain the same 10:1 weight ratio. Five handsheets per condition were prepared and evaluated as described in Example 2B. Data from this study are summarized in Table 2C and 2C-1. The data again demonstrate that the separate addition of CMC (after starch) is the superior method of addition for handsheet quality. For example, the starch distribution was favorable, and the strength properties, ash retention, and opacity were all significantly improved over the starch only case. The same claims cannot be made for either method of combined addition.
TABLE 2C__________________________________________________________________________Handsheet Test Results Avg. Sheet Avg. Ash Avg. Mullen Avg. Tensile Wt./Area Content Avg. Burst Strength StarchCondition (g/m.sup.2) (%) Opacity (g/cm.sup.2) (g/cm) Distribution__________________________________________________________________________Starch-Only.sup.(1) 48.08 16.27 78.95 409.9 1582.2 Even Color(60 lb/T)Separate Addition 55.04 20.86 82.51 618.0 1610.8 Even ColorStarch/CMC.sup.(2)(60 lb/T/6 lb/T)Combined Addition* 50.93 17.76 79.96 523.8 1544.7 MottledStarch/CMC (Small Spots)(60 lb/T/6 lb/T)Combined Addition** 51.24 18.77 81.18 478.8 1562.6 MottledStarch/CMC (Few Large(60 lb/T/6 lb/T) Spots)__________________________________________________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMC7LT *Starch and CMC prepared as individual solutions, combined, and added as one solution. **Starch and CMC mixed in powder form, and prepared and added as one solution.
TABLE 2C-1__________________________________________________________________________Standardized Mullen/Tensile Data From Table 2C Standardized Standardized Mullen Tensile (g/cm.sup.2) % Change vs. (g/cm) % Change vs.Condition (g/m.sup.2) Starch-Only (g/m.sup.2) Starch-Only__________________________________________________________________________Starch-Only 8.5 -- 32.9 --(60 lb/T)Separate Addition 14.4 +69% 37.5 +14%Starch/CMC(60 lb/T/6 lb/T)Combined Addition 11.2 +32% 33.1 +1%Starch/CMC(60 lb/T/6 lb/T)Combined Addition 10.8 +27% 35.2 +7%Starch/CMC(60 lb/T/6 lb/T)__________________________________________________________________________
EXAMPLE 3A
A starch adsorption study conducted using the same procedure and fiber-only test furnish described in Example 1 demostrated the efficacy of additionally substituted cellulose derivatives. As summarized in Table 3A, carboxymethyl hydroxyethylcellulose (CMHEC) and carboxymethyl methylcellulose (CMMC) both exhibited a positive effect on starch adsorption when added separately after the Stalok 600 starch. The approximate molecular weight and anionic DS for CMHEC-37L (Hercules), and CMMC-2000 (Aqualon) were not available. Similar cellulose derivatives containing the anionic carboxymethyl substituent, such as carboxymethyl hydroxypropylcellulose (CMHPC) are also expected to exhibit positive effects on cationic starch adsorption.
TABLE 3A______________________________________Effect of Various Cellulose Derivatives on Starch AdsorptionStarch.sup.(1) AdditiveAdded Dosage % Starch Adsorption(lb/T) (lb/T) CMHEC.sup.(2) CMMC.sup.(3)______________________________________30 0 55.7 55.730 4.2 78.5 66.430 7.5 80.3 --30 9.0 82.0 70.030 12.0 -- 71.0______________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMHEC37L (carboxymethyl hydroxyethylcellulose) .sup.(3) Aqualon CMMC2000 (carboxymethyl methylcellulose)
EXAMPLE 3B
The importance of the anionic carboxymethyl substituent in the aforementioned cellulose derivatives is expressed by the data in Table 3B where the nonionic hydroxyethyl cellulose (HEC) and hydroxypropyl cellulose (HPC) are compared to CMC for their effects on starch adsorption. Table 3B is a compilation of data from individual starch adsorption studies conducted as described in Example 1. The same fiber-only test furnish and cationic starch type (Stalok 600) were utilized. Results indicate that the nonionic cellulose derivatives do not enhance the adsorption of cationic starch. The data also demonstrate that a maximum level of CMC for starch adsorption can be reached, usually 6-14% based on starch addition. The peak level of CMC performance is usually followed by a trend of diminishing starch adsorption with each subsequent increase in CMC addition. The CMC utilized in this work was Hercules CMC-12M8 containing 1.2 DS.
The HEC utilized was Hercules Natrosol 250 LR, a cellulose derivative with an average of 2.5 MS or moles of ethylene oxide substituted at the hydroxyl groups of each anhydroglucose unit. The HPC was Hercules Klucel E, a similar product in which propylene oxide is the substituent. Klucel E has an approximate molecular weight of 90,000. The average molecular weight of the Natrosol was not provided.
TABLE 3B______________________________________Effect of Various Cellulose Derivatives on Starch AdsorptionStarch.sup.(1) AdditiveAdded Dosage % Starch Adsorption(lb/T) (lb/T) HEC.sup.(2) HPC.sup.(3) CMC.sup.(4)______________________________________30 0 51.5 52.9 51.530 1.2 46.7 53.9 57.730 1.8 50.1 52.2 74.230 2.4 47.2 50.3 77.230 3.0 47.0 50.9 71.230 3.6 48.7 53.4 64.430 4.2 47.7 51.6 62.330 4.8 46.7 50.3 62.1______________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules Natrosol 250LR (hydroxyethyl cellulose) .sup.(3) Hercules KlucelE (hydroxypropyl cellulose) .sup.(4) Hercules CMC12M8 (carboxymethyl cellulose)
EXAMPLE 4A
Table 4A contains the results of two separate studies conducted to determine the compatibility of high molecular weight polyacrylamide (PAM) retention aids in combination with the starch and CMC additives. The data were obtained via the starch adsorption test and test furnish described in Example 1. In each case the polymers were last in the addition sequence after the addition of starch and CMC. The retention aids are both co-polymers: the anionic polymer, Betz® Polymer 1237, contains acrylamide and acrylic acid while the cationic polymer, Betz® Polymer CDP-713, contains acrylamide and a cationic moiety. The polymers both possess a molecular weight greater than 5,000,000.
As described in Table 4A, no adverse effects on starch adsorption resulted from the incorporation of typical dosage levels of the polymeric retention aids into the fiber-only test furnish. In fact, small additional increases in starch adsorption were obtained through the subsequent addition of either polymer. Stalok 600 cationic starch and Hercules CMC-7LT were utilized in this study.
TABLE 4A______________________________________Effect of Polymeric Retention Aids on Starch AdsorptionStarch.sup.(1) CMC.sup.(2) Polymer % Starch AdsorptionAdded Added Added With Cationic With Anionic(lb/T) (lb/T) (lb/T) Polymer.sup.(3) Polymer.sup.(4)______________________________________30 0 0 50.0 57.930 0 0.50 55.8 57.130 0 0.75 54.3 59.130 0 1.00 55.4 59.530 3 0 80.5 85.530 3 0.50 84.0 87.130 3 0.75 83.4 86.630 3 1.00 84.3 86.8______________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMC7LT .sup.(3) Betz Polymer CDP713 (Cationic Polyacrylamide) .sup.(4) Betz Polymer 1237 (Anionic Polyacrylamide)
EXAMPLE 4B
Table 4B summarizes a study conducted in the filler-containing furnish described in Example 2B to determine the effect of the starch and CMC on fines retention both with and without the cationic polymer (Betz Polymer CDP-713). Each test involved the addition of 500 ml of 0.47% consistency furnish to the Britt jar. The furnish was then agitated at high shear (1400 rpm) and dosed with appropriate aliquots of the additives (separate addition) prior to the filtering step. Fines retention was calculated by comparing the mass of fine solids per unit volume in the filtrate to the mass of fine solids per equivalent unit volume present in the original furnish.
The data in Table 4B shows that the addition of CMC provides significant improvements in fines retention over both starch-only and starch-polymer conditions. Retention improvements via CMC are a result of improved starch adsorption which provides the necessary increase in cationic attachment sites for the predominantly anionic filler and fiber fines. The maximum fines retention for each experimental condition in this study occurred consistently at 7% CMC based on starch content or 2 lb/T CMC: 30 lb/T starch. The optimum fines retention level at each condition occurred with the same starch and CMC combination regardless of polymer addition level. The experimental conditions achieving the highest fines retention in this study were those which included the polymeric retention aid. Although the polymer helped in each case, the preferred order of addition for fines retention was that in which the CMC followed the starch and preceded the last additive, cationic polymer. Stalok 600 cationic starch and Hercules CMC-7LT were utilized in this study.
TABLE 4B______________________________________Effect of Additives on Fines Retention Cationic Poly-Starch.sup.(1) CMC.sup.(2) mer.sup.(3) % Fines Retention ViaAdded Added Added Designated Order of(lb/T) (lb/T) (lb/T) Chemical Addition______________________________________ 0 0 0 19.8 Starch/CMC30 0 0 24.430 1 0 32.530 2 0 39.530 3 0 36.530 4 0 31.4 Starch/ Starch/ CMC/Polymer Polymer/CMC30 0 0.25 37.330 1 0.25 34.8 33.130 2 0.25 44.1 40.330 3 0.25 42.1 38.630 4 0.25 37.7 33.830 0 0.50 36.330 1 0.50 46.1 42.330 2 0.50 51.4 44.030 3 0.50 47.0 38.030 4 0.50 45.3 37.1______________________________________ .sup.(1) Staley Stalok 600 .sup.(2) Hercules CMC7LT .sup.(3) Betz Polymer CDP713
EXAMPLE 5
Example 5 illustrates the preferred method of addition of starch and CMC for papermaking furnishes containing a mixture of chemical and mechanical pulps. The handsheet study summarized in Table 5 was conducted in the same manner as described in Example 2B. However, the final furnish blend used in this study was comprised of 44% Kraft chemical pulp, 29% stone groundwood pulp, 15% thermomechanical pulp (TMP), and 12% Kaolin filler clay. The acid furnish (pH 4.5) also contained 1.0% papermaker's alum and 0.75% sodium aluminate, both based on total furnish solids.
The preferred method of addition involves the pre-treatment of the chemical pulp portion of the furnish with cationic starch followed by the CMC. The treated chemical pulp is then blended with the remaining mechanical pulp portion of the furnish and the filler. In this study, individual handsheets were prepared after each aliquot of treated Kraft chemical pulp was blended with the remaining furnish components The pre-treatment of chemical pulp with starch and CMC was compared directly to pre-treatment with equivalent levels of starch-only. The pre-treatment case was also compared to the case in which either the starch or starch and CMC were added to the total furnish after the blending of chemical pulp with the other pulp and filler components.
The starch used in this work was National Starch's Cato 217, an amphoteric corn starch carrying a net cationic charge. The degree of cationic substitution or % Nitrogen were not available. The type of CMC utilized was Hercules CMC-7LT as described in Example 2A. After handsheets prepared in this study were conditioned, cut, and weighed as described in Example 2B, they were evaluated for Mullen Burst and ash content.
The data in Table 5 demonstrate that the most positive effects on Mullen Burst result from the pre-treatment of chemical pulp with starch and CMC. Strength improvements over the starch-only condition (total furnish addition) become greater as the starch addition level is increased. This effect is explained by the fact that as the starch dosage is increased, more unabsorbed starch is present in the furnish for the CMC to destabilize. The addition of starch and CMC to the total furnish (no chemical pulp pre-treatment) resulted in a strength increase at only the high (40 lb/T) starch addition level. The apparent lack of strength improvement when starch and CMC were added to the total furnish was likely a result of starch adsorption being nearly complete before the CMC was added, and thus, the CMC had little unabsorbed starch to affect. Cationic starch adsorption is usually more complete in furnishes containing mechanical pulps due to the high surface area and abundance of anionic adsorption sites. However, even though starch adsorption is more thorough in these furnish types, the strength improvements provided by starch are not as great as in furnishes containing 100% chemical pulp. This effect is due to the fact that the strength development potential of chemically produced fiber is limited by bonding area while the strength development potential of mechanical pulp is limited by fiber length and not the lack of inter-fiber bonding. Thus, in this study the maximum strength benefit from starch was obtained by allowing the starch to preferentially adsorb onto the longer, chemical pulp fraction, aided by CMC. The largest increases in ash retention were also obtained via Kraft pre-treatment with starch and CMC.
The pre-treatment of chemical pulps should not be limited to just furnishes comprised in part by mechanical pulps. For example, the most efficient use of cationic starch in furnishes containing 100% chemical pulp may also be obtained through treatment of the fiber portion with starch and CMC prior to addition of filler and other additives.
TABLE 5__________________________________________________________________________Handsheet Properties Comparing Kraft Pulp Pre-Treatment to Total FurnishAddition Starch/CMC Standardized % Change vs. Dosage Avg. Sheet Avg. Ash Avg. Mullen Mullen Starch-Only Level Wt/Area Content Burst (g/cm.sup.2) (Total FurnishCondition (lb/T) (g/m.sup.2) (%) (g/cm.sup.2) (g/m.sup.2) Addition)__________________________________________________________________________Starch-Only (National Starch Cato 217)(Total 20 61.84 7.17 1707.8 27.6 --Furnish 30 63.10 7.44 1709.9 27.1 --Addition) 40 63.42 7.58 1759.2 27.8 --Starch/CMC (Hercules CMC-7LT)(Total 20/2 62.15 7.27 1649.5 26.9 -3%Furnish 30/3 62.00 7.19 1706.4 26.6 -2%Addition) 40/4 63.10 7.45 1856.2 28.9 +4%Starch-Only(Kraft Pulp 20 62.95 7.95 1622.1 28.6 +4%Pre-Treatment) 30 64.53 8.14 1728.2 29.3 +8% 40 63.42 8.14 1655.8 28.0 +1%Starch/CMC(Kraft Pulp 20/2 63.58 8.18 1668.5 29.9 +8%Pre-Treatment 30/3 64.53 8.43 1747.9 30.7 +13% 40/4 64.37 8.45 1957.4 33.9 +22%__________________________________________________________________________
EXAMPLE 6
A handsheet study was conducted to compare the aforementioned prior art to this novel method of application of starch and CMC. As previously described, U.S. Pat. No. 4,710,270 issued to Sunden et al. involves the use of cationic starch and CMC in paper furnishes to improve the retention and binding of fillers. The patent calls for the step-wise formation of a tertiary gel structure involving an aqueous slurry of mineral fillers to be utilized in the furnish. In short, a reaction product is first formed when a dry mixture of 2-3 parts CMC to 100 parts cationic starch is dispersed in water. This compound is then reorganized to a secondary structure upon direct addition to the filler slurry. The cationic starch and CMC mixture is generally added at 2-20% of the dry filler weight. Finally, a tertiary gel structure is formed when an anionic or cationic colloidal inorganic polymer is added to the filler slurry. The final reaction product is then added to a separate slurry of cellulosic fiber.
In Example 6, the Sunden patent method was closely simulated in the laboratory preparation of handsheets. The Sunden method was compared to the present invention involving the separate additions of cationic starch and CMC, in sequence, to the fiber. The treated fiber was subsequently blended with the filler and alum prior to the formation of individual handsheets. A basic outline of both the Sunden and present invention methods of furnish preparation is described in Table 6. A more detailed description of each addition scenario is provided to the following paragraphs.
This particular study involved handsheets prepared from an acid furnish (pH 4.8). The filler portion of the furnish was prepared from 80% clay (Huber Hi-White) and 20% TiO 2 (SCM Glidden Zopaque RG). Filler levels in the final furnish were varied at either 10% or 30% of furnish solids. Since the consistency of the final blended furnish was constant at 0.5%, the fiber fraction provided the balance of the furnish solids as the filler level was varied. The fiber segment was comprised of 50% bleached Kraft hardwood and 50% bleached Kraft softwood. As indicated in Table 6, the final additive was papermaker's alum added at 1.0% based on total furnish solids.
A. Sunden Furnish Preparation Method
The Sunden et al. method involved the aqueous dispersion of a dry mixture of cationic starch and CMC in a ratio of 10:0.25 which was considered the most efficient structure by the patentees. The starch and CMC utilized were Staley Stalok 600 and Hercules CMC-7LT, respectively, and are described in Examples 1 and 2A of this work. Both additives closely resemble the products described in Example 1 of the Sunden patent in regard to charge characteristics. Since the Sunden method required that the starch-CMC blend be added to a separate filler slurry before mixing with the fiber, the test furnish was prepared in two parts as individual filler and fiber slurries. The starch-CMC blend (10:0.25) was added to the filler at levels such that the starch content would be either 30 lb/T or 50 lb/T based on total furnish solids (fiber and filler). These two levels were utilized throughout the study. The starch levels were selected in part based on the range indicated by the Sunden patent (Claim No. 5) indicating the dry weight of starch and CMC should be 2-20% of the dry weight of the filler. After the proper starch-CMC dosage was added to the 20% solids filler slurry, the combination was mixed for 20 seconds at moderate shear on a magnetic stir plate. A colloidal solution polymer, formed from waterglass as described in Example 1 of the Sunden patent, was then added to the filler dispersion at a level corresponding to 3.0% SiO 2 on weight of the starch to form the tertiary gel structure. This addition level was selected based on the patent's claim 6 in which the colloidal solution polymer is added in amounts of 1-5% calculated as SiO 2 on weight of the starch added. The waterglass utilized was from PQ Corporation and had a weight ratio of 3.22 (SiO 2 /Na 2 O).
The final compound, the tertiary structure, was allowed to mix for 20 seconds on a magnetic stir plate at moderate shear prior to mixing with the cellulose fiber. The gel structure was then blended with the fiber slurry using an impeller-type mixer set at 1200 rpm for 20 seconds. Upon completion of the mixing step, alum was added at 1.0% based on total furnish solids. After an additional 20 seconds of mixing at 1200 rpm, the final stock blend was added to the sheet mold to form the sheet. This entire process was repeated in the preparation of each handsheet simulating the Sunden patent method.
B. New Method of Furnish Preparation
The handsheets produced via the Sunden method were compared to the sheets prepared by the new method of application of both the starch and CMC. This approach involved the separate addition of starch and CMC to the fiber slurry at starch dosage levels corresponding to 30 lb/T and 50 lb/T based on total furnish solids (fiber and filler). The CMC was added at a level equivalent to 10% of the starch dosage. The same starch and CMC types utilized in the Sunden method were used in this method.
Starch was added first to the fiber slurry and mixed for 20 seconds at 1200 rpm before the CMC aliquot was added under shear. After an additional 20 seconds of agitation at 1200 rpm, the appropriate quantity of filler slurry was blended with the treated fiber for 20 seconds followed by the addition of 1% alum and 20 seconds of mixing of the final furnish (1200 rpm). The final fiber:filler ratio and total furnish solids were equivalent to those utilized in the preparation of the Sunden method handsheets. As with the Sunden method, the entire furnish-blending process was repeated for each handsheet prepared.
C. Furnish Preparation for Blank Condition (Starch-Only)
Furnish preparation of the blank condition (starch-only) handsheets involved the same blending procedure described for the new method of starch and CMC application with the important exception being that CMC was not added. In other words, the fiber segment of the furnish was treated with starch (only) prior to the addition of filler and alum.
D. Handsheet Preparation and Testing
Handsheets for each condition were prepared, cut, and conditioned in the same manner described in Example 2B. Each handsheet was weighed and subsequently evaluated for opacity, brightness, and Mullen Burst. The remaining portion of each handsheet was then ashed in a muffle furnace at 903° C. to determine % sheet ash. Prior to the ashing step several handsheets were photographed by both a 35 mm camera and a scanning electron microscope (SEM) to provide important information regarding sheet formation and filler distribution. The SEM photos FIGS. 1A-1F are Robinson backscatter images at 90X magnification. The same exact handsheets were placed on a light box and illuminated for photographs taken at a fixed distance with a 35 mm Minolta camera and no magnification (FIGS. 2A-2F). Obviously, the magnified SEM photos provide insight into the distribution of filler in the handsheets while the 35 mm shots describe the sheet formation as observed by the naked eye.
Results of the handsheet evaluation are summarized in Table 6B. The Sunden method and the new method each demonstrated increases in Mullen Burst over the blank (starch-only) case at each experimental condition. However, handsheets prepared via the Sunden method exhibited significantly larger increases over the blank than the new method at the high furnish ash level (30% ash). This result is explained in the following paragraphs.
Burst increases associated with the new method were linked directly to higher starch adsorption/retention in the handsheets. This conclusion was made based on the fact that at each experimental condition the new method handsheets provided burst increases over each blank case while simultaneously increasing the sheet ash content and maintaining equivalent opacity and brightness levels. In addition, the SEM photographs of the new method and corresponding blank conditions both demonstrate even filler distribution across fiber surfaces. The photos of FIGS. 2A-2D show equivalent sheet formation of the same sheets prepared via the new method and blank conditions. Thus, since the new method demonstrated both higher Mullen Burst and ash content while maintaining equivalent sheet optical properties, filler distribution, and sheet formation, the increased burst strength had to result from enhanced starch adsorption. This conclusion is further supported by the knowledge that internal bond strength normally decreases with increased sheet filler content.
On the other hand, the increases in burst strength provided by the Sunden method could not be linked solely to the higher retention of starch in the handsheets. In fact, the substantial improvement in burst by the Sunden process over the new method at the 30% ash level was a direct result of the poor filler distribution in the sheets. For example, the direct reaction of the cationic starch-CMC complex with the filler slurry via the Sunden method resulted in coagulated filler particles which were subsequently retained in localized areas in the handsheets FIGS. 1E-1F.
The retention of filler as coagulated particles allowed less interruption of the fiber-fiber bonding process than when the filler was evenly distributed across the fiber surfaces in discrete particle form. In other words, the retention of filler in localized areas allowed more intimate fiber-fiber contact (bonding), and consequently led to higher burst values. Aside from the poor filler distribution exhibited by the Sunden method in the SEM photos, the effects of the coagulated filler were also reflected in reduced opacity and brightness data and relatively poor sheet formation (FIGS. 2E-2F).
Thus, when all sheet properties are considered, the new method provides a superior program for overall sheet quality. The Sunden method, however, provides increased strength at increased sheet ash content but all at the expense of the sheet optical properties. The adverse effects on the Sunden method on filler distribution, formation, and sheet optical properties were more significant at the higher furnish ash content (30%).
TABLE 6A__________________________________________________________________________Summary of Chemical Addition Sequence/Furnish Preparation Method forHandsheet Study Comparing Sunden Method to New MethodSUNDEN ET AL, METHOD(U.S. 4,710,270) NEW METHOD BLANK (STARCH-ONLY)__________________________________________________________________________Cationic Starch/CMC Mixture Cationic Starch Cationic Starch(2.5% CMC based on starch) ↓ ↓↓ Fiber Slurry Fiber SlurryFiller Slurry (50% B1 SW/50% B1 HW) (50% B1 SW/50% B1 HW)(80% Clay/20% TiO.sub.2) ↓ ↓↓ CMC Filler SlurryColloidal Solution Polymer (10% CMC based on starch) (80% Clay/20% TiO.sub.2)Prepared from waterglass ↓ ↓(3% SiO.sub.2 based on starch) Filler Slurry Alum↓ (80% Clay/20% TiO.sub.2) ↓Fiber Slurry ↓ Form Sheet(50% B1 SW/50% B1 HW) Alum↓ ↓Alum Form Sheet↓Form Sheet__________________________________________________________________________
TABLE 6B__________________________________________________________________________Handsheet Test ResultsAddition Starch Dosage Furnish Avg. Sheet Avg. Sheet Avg.Method (Furnish Basis) Ash Level Wt./Area Ash Avg. Avg. Mullen(See Table 6A) (lb/T) (%) (g/m.sup.2) (%) Opacity Brightness (g/cm.sup.2)__________________________________________________________________________Blank 30 10 122.73 8.79 91.4 82.3 6325.8Sunden 30 10 121.46 8.86 88.8 81.1 7211.0New 30 10 124.30 9.25 91.2 81.9 6955.1Blank 50 10 121.78 8.71 91.1 82.5 6427.7Sunden 50 10 121.15 8.88 88.8 80.9 7372.7New 50 10 124.63 9.30 91.0 81.7 7448.6Blank 30 30 115.45 24.27 95.0 82.5 3279.3Sunden 30 30 117.03 25.71 92.6 79.1 4835.9New 30 30 117.98 25.16 95.3 82.8 3377.0Blank 50 30 116.40 24.36 95.1 82.4 3382.6Sunden 50 30 118.62 25.04 92.5 79.0 5110.8New 50 30 118.93 25.22 95.2 82.8 3741.9__________________________________________________________________________
While this invention has been described with respect to particular embodiments therefore, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. | A process of making paper by forming a paper furnish comprised of cellulosic fibers or cellulosic fibers and mineral filler material suspended in water, depositing the furnish on a papermaking wire, and forming a sheet out of the solid components of the furnish while carried on the wire, the improvement wherein there is mixed into the furnish, prior to its being deposited on the wire, about 0.50 to 5 percent of cationic starch (based on the dry weight of total solids in the furnish) followed by about 5 to 20 percent of a water soluble carboxymethyl) cellulose (based on the weight of the cationic starch). | 3 |
[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/158,441 filed May 30, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to leather coating compositions, particularly those compositions for dyeing, staining, or otherwise modifying the color of leather.
[0004] 2. Background of the Prior Art
[0005] In recent years numerous advancements have been made in processes for coloring leather. U.S. Pat. No. 5,354,341 disclosed a mixture of at least 2 metal-free dyes having a trichromatic formulation that enhances the brilliance of the finished color on the leather. The dyes carry a single sulfo or carboxyl group and molecular weight of 450 to 700. The dyeing time routinely requires 30 to 180 minutes to dry.
[0006] U.S. Pat. No. 5,376,147 likewise disclosed improvements in the trichromatic technique by employing dyes having two sulfo or carboxyl groups and molecular weights between 790 to 1100, but the dyeing process still required 30 to 180 minutes to dry.
[0007] U.S. Pat. No. 6,290,866 disclosed that an aqueous coating composition comprising copolymerized acetoacetate or acetoacetamide monomer and copolymerized carboxylic acid monomer, in contact with metal oxide, hydroxide, or carbonate provided aesthetically pleasing and protective dried coatings on leather that had good embossability and wet-flex resistance. No enhancements in processing time at ambient temperature were noted; however, when drying at elevated temperatures of about 200° F. (93.3° C.), drying time still required at least 2.0 minutes.
[0008] U.S. Pat. No. 6,387,291 discloses raising the glass transition temperature of the above-described aqueous coating compositions by increasing the amount of copolymerized acetoacetate or acetoacetamide. Again the leather products required 2 minutes or 120 seconds to dry at elevated temperatures of 93.3° C.
[0009] U.S. Patent 6,471,885 discloses a multistage emulsion polymer for an aqueous leather coating composition, said polymer containing copolymerized monoethylenically-unsaturated nonionic monomer which are predominantly acrylic, i.e. monomers selected from, e.g. esters of (meth) acrylic acid. It also contains copolymerized monoethylenically-unsaturated carboxylic acid monomer. Again, however, the coated leather required 120 seconds to dry at 90° C.
[0010] Currently, state-of-the art aqueous coating compositions employed for dyeing leather employ dye mixtures of all types dispersed in propylene glycol monomethyl ether. Even with predominantly acrylic polymers, certain vehicles have been used for enhancing dye penetration, for example polytetrafluoroethylene, (i.e. teflon), and carboxylic acid derivatives such as dibutyl phthalate have been employed as an elastomeric plasticizer to help soften the leather. However, the enhanced dye penetration still requires, at ambient temperature, leather dyeing process times of 5 to 10 minutes and higher before dry surface is obtained. Also, the quality of the finish is not as soft and natural as desired, even though dibutyl phthalate is used.
[0011] An improved leather dyeing process with enhanced drying or “flash time” while still providing aesthetically pleasing soft natural coatings with good wet-flex resistance is a long felt need in the industry.
DETAILED DESCRIPTION
[0012] In the process of the present invention leathers are coated with dye mixtures prepared on a polyacrylate vehicle, dispersed in propylene glycol monomethyl ether, n-butyl acetate, and a mixture of C-3 and C-4 alcohols, thus negating the need for an aqueous composition, teflon dispersions and carboxylic acid derivatives such as dibutyl phthalate. The leather coating process results in improved dye penetration and processing at ambient conditions, surprisingly drying said leather in less than 1.0 minute, preferably 30 seconds.
[0013] Compositions of the present invention may be applied to all types of leather such as, for example, mineral tanned or vegetable tanned leather including full-grain leather, buffed or corrected-grain leather, and split leather with or without a prior treatment with an impregnating resin mixture and with or without the application of subsequent coatings using conventional coatings application methods such as, for example, curtain coater and spraying methods such as, for example, air-atomized spray, air-assisted spray, airless spray, high volume low pressure spray, and air-assisted airless spray.
[0014] The compositions of the present invention require at least one dye or pigment and a polyacrylate polymer vehicle. Additionally, conventional coating adjuvants may be contained in the composition. Such adjuvants may include, for example, emulsifiers, coalescing agents, buffers, neutralizers, thickeners, humectants, wetting agents, biocides, plasticizers, antifoaming agents, colorants, waxes, and anti-oxidants.
[0015] The polyacrylate vehicle may include, for example, a (meth)acrylic ester monomer including methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, methyl methacrylate, butyl methacrylate, isodecyl methacrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, aminoalkyl (meth)acrylates the polyacrylate and pigment will be substantially dissolved in from 30-65% by weight of a solvent, preferably n-butyl acetate capable of dissolving nitrocellulose (lacquer) as well as dyes and pigments, and which is compatible with leather.
[0016] The quick-drying compositions of the present invention comprises polyacrylate resin, n-butyl acetate, dye or pigment, propylene glycol monomethyl ether and C-3/C-4 alcohols.
[0017] In a preferred embodiment the composition of this invention may comprise an effective amount of dye or pigment constituents dispersed in, by weight, 20-32 parts propylene glycol monomethyl ether, preferably 28.0 parts; 10-15 parts isobutyl alcohol, preferably 12.0 parts; 8-12 parts isopropyl alcohol, preferably 10.0 parts; 3-5 parts n-butanol, preferably 4.0 parts; 20-25 parts n-butyl acetate, preferably 22.4 parts; 5-15 parts polyacrylate resin, preferably 5.5 parts. The overall amount of C3 and C4 alcohol is 21-32 parts.
[0018] The dyes can be either metallic or metal-free colorants of the type readily available in the prior art.
[0019] Especially preferred dye mixture and polyacrylate vehicle may be obtained from SPIES HECKER as Nos. 293 and 295.
[0020] To a dye mixture and polyacrylate vehicle such as Spies Hecker 293 or 295 comprising 100 parts by weight is added an equal portion of 100 parts of a solvent mixture such as Spies Hecker 8581, comprising 50-60% by weight propylene glycol monomethyl ether, 20-30% C-4 alcohol (preferably isobutyl alcohol), 15-25% C-3 alcohol (preferably isopropyl alcohol), and if desired additional minor amounts of other C-3 or C-4 alcohols such as n-butanol and n-propanol.
[0021] When coating the leather one must first clean the surface. The surface can be cleaned with ammonia water if extremely soiled. Then the leather may be cleaned (to return the leather to a bare state, removing all existing dyes, if desired) with the solvent mixture, such as SH 8581. Then the above-described composition of the invention is sprayed onto the leather, using 2-6 coats and allowing less than a minute, preferably 15-30 seconds flash time between coats.
[0022] The materials become dust free in 30 seconds. “Dust-free” identifies the condition in which the coating sets to the point that dust will not become trapped in it.
[0023] The materials exhibit tape time 30 seconds. Tape time is the condition where the materials are dry enough to tape on without leaving any tape marks.
[0024] When a leather dye is sprayed onto the leather, the “overspray” created from the spraying operation will normally set on the areas surrounding the actual surface point sprayed. The compositions of the present invention will absorb into the surrounding area, such that blending or repair is invisible. This condition is commonly referred to as “zero overspray”.
[0025] For purposes of this description and in the claims, parts and percentages are by weight unless otherwise specified.
EXAMPLE
[0026] SURE COAT NO. 1601, having a toner color of black was acquired from SEM Products, Inc. and applied to the surface of a control leather strip and the results are reflected below in Table 1. However, prior to application, the leather surfaces were cleaned with SURE COAT NO. 3635 which was clear of toner.
[0027] The Sure Coat specimen were cleaned with a clear Sure Coat prior to spraying the Sure Coat and toner.
[0028] Two compositions (A and B) of the present invention was prepared, composition A by admixing 1.0 part SPIES HECKER 293 and 1.0 part SPIES HECKER 8581 and the composition B by admixing 1.0 part SPIES HECKER 295 and 1.0 part SPIES HECKER 8581. Two identical leather surfaces were selected as specimen A and B, and each was first cleaned with the SPIES HECKER 8581 by liberal application and immediate wiping with a cloth so that the 8581 did not evaporate on the surface. The specimen were taped for similar masking of graphic patterns to be dyed. Composition A was sprayed onto specimen A in six (6) coatings. Also six (6) coatings of composition B was sprayed onto specimen B. Flash times between each coating for each specimen was from 15 to 30 seconds, which was sufficient time to allow the coating to become dry to the touch prior to applying the subsequent coating. The taping was removed. Neither specimen A or B showed any build up of dye or pigment, unlike the Sure Coat system.
[0029] The overspray for A and B was absorbed into the leather so that after merely 30 seconds no dust could be trapped within the coating. That is, it was dust free after 30 seconds.
[0030] The specimen A and B were each dry enough in 30 seconds to tape over without leaving tape marks. The specimen did not require clear overcoating because the original coating completely penetrated the leather.
[0031] Specimen A and B results and comparisons are as follows:
TABLE 1 TEST SURE COAT SPECIMEN A SPECIMEN B Flash time 300-600 seconds 30 seconds 30 seconds Dust free 1200 seconds 30 seconds 30 seconds Tape time 3,600 seconds 30 seconds 30 seconds Final clear Required to Not required Not required overcoating cover up surface because of because of dye imperfections dye absorption, absorption, re- thus resulting in resulting in more sulting in more hiding natural natural appearance natural appear- leather grain to leather and more ance to leather and giving a flexibility in the and more flexi- more vinyl-like leather. However, bility in the appearance. satin clear coating is leather. However, possible for added satin clear coating durability without is possible for losing appearance or added durability texture flexibility.* without losing appearance or texture flexibility.
[0032] [0032] TABLE 2 SH 8581 WEIGHT INGREDIENT CAS-NO PERCENT Propylene glycol monomethyl 107-98-2 56.0 ether Isobutyl alcohol 78-83-1 23.9 Isopropyl alcohol 67-63-0 20.0 n-butanol 71-36-3 0.1
[0033] [0033] TABLE 3 SH 295 INGREDIENT CAS-NO. PERCENT (WEIGHT) n-Butyl acetate 129-86-4 44.1-45.7 Polyacrylate resin 10.6-11.4 n-Butanol 71-38-3 7.0-8.2 Cellulose, acetate butanoate 9004-38-8 6.4-6.8 Butyl glycolate 7397-62-8 4.7-4.9 Mica 12001-26-2 4.2-8.2 Xylene 1330-20-7 3.4-3.6 2-Butoxyethyl acetate 112-07-2 3.0-3.2 Titanium dioxide 13463-67-7 2.8-6.4 White Spirit 64742-82-1 2.3-2.4 Melamine resin 2.1-2.2 Ethyl benzene 100-41-4 1.4-1.5 Dipropylene glycol 34590-94-8 1.5 methyl ether Isobutyl alcohol 78-83.1 1 Chromium oxide 1308-38-9 0-1.2 Iron oxide 1309-37-1 0-5.8 Formaldehyde 50-00-0 0.1 Suspected Human Carcinogen
[0034] [0034] TABLE 4 SH 293 INGREDIENT CAS-NO. PERCENT (WEIGHT) n-Butyl acetate 123-88-4 25.1-55.3 Polyacrylate resin additives 5.9-48.0 1-Ethoxy 2 Propanol 52126-53-6 0-10.3 n-Butanol 71-35-3 0.1-10.9 Cellulose acetate butanoate 9004-36-5 0-5.7 Xylene 1330-20-7 1.9-5.5 Aromatic hydrocarbons 54742-98 6 0.3-9.4 mixture (C9-G12) 1,2,4-Trimethyl-Benzene 95-63-6 0.3-5.2 Butoxypropanol 51331-86-8 0-4.0 White spirit 64742-82.1 1.2-3.9 Aluminum 7429-90-5 1.3-3.6 (inter alia)
[0035] [0035] TABLE 5 SURE COAT NO. 1601 COMPONENT PERCENT (WEIGHT) PGME 5-10 PTFE Dispersion 1-5 Dibutyl phthalate 1-5 C6-C13 acetates 0-5 Colorant 0-5 H 2 O >50%
[0036] [0036] TABLE 6 SH 8070 COMPONENT PERCENT (WEIGHT) n-butyl acetate 32.9 Polyester resin 27.7 Polyacrylate resin 13.7 Silica 8.9 Xylene 4.8 Methoxypropylene acetate 3.6 Aromatic hydrocarbons C9-C12 3.4 Ethyl benzene 2 1,2,4-Trimethyl benzene 1.7 2-(2H benzotriazol-2-yl) - 4,6-DTPP | An improved method for dying leather with propylene glycol monomethyl ether (PGME) systems comprising adding polyacrylate resin base, C3 and C4 alcohols, and n-butyl acetate and negating the need for teflon dispersions, dibutyl phthalate, and improves the dye penetration, hastens the flash times, improve the dust free time, and improves the tape time. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The application is a divisional of U.S. patent application Ser. No. 12/568,615, which was filed Sep. 28, 2009 now U.S. Pat. No. 8,215,115, and is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with government support under Contract No. N00019-06-C-0081 awarded by the United States Navy. The Government therefore may have certain rights in this invention.
BACKGROUND
This application relates generally to sealing an interface in the combustor section of a gas turbine engine.
Gas turbine engines are known and typically include multiple sections, such as a inlet section, a compression section, a combustor section, a turbine section, and an exhaust nozzle section. The inlet section moves air into the engine. The air is compressed in the compression section. The compressed air is mixed with fuel and is combusted in combustion areas within the combustor section. The products of the combustion are expanded through the turbine section to rotatably drive the engine.
The combustor section of the gas turbine engine typically includes a combustor liner that establishes combustion areas within the combustor section. The combustion areas extend circumferentially around a centerline of the engine. The combustion areas in a can combustor are separated from each other. The combustion areas in an annular combustor are connected. Turbine nozzles direct the products of combustion from the combustion area to the turbine section in both types of combustors. Substantial leaks at the interfaces between the turbine nozzles and the combustion chambers can cause irregularities in temperature and pressure. The irregularities can reduce the usable life of the turbine nozzles, turbine wheels and other components. Some leakage may be acceptable if the leakage is predictable and relatively uniform.
SUMMARY
An example method of sealing an interface within a gas turbine engine includes holding a sealing ring arrangement relative to a turbine nozzle using a flange extending from a combustor liner. The method further includes urging the sealing ring arrangement toward a sealed relationship with the turbine nozzle.
An example method of sealing a gas turbine engine interface includes holding a sealing ring arrangement against a turbine nozzle using a flange, and urging the sealing ring arrangement against the turbine nozzle to seal an interface between the turbine nozzle and a combustor liner.
These and other features of the example disclosure can be best understood from the following specification and drawings, the following of which is a brief description:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional schematic view of an example gas turbine engine.
FIG. 2 is a sectional side view of a portion of the combustor section in the FIG. 1 engine.
FIG. 3 is a close up view of area 3 in the FIG. 2 combustion section.
FIG. 4 is a sectional view of the combustor section in the FIG. 1 engine at line 4 - 4 of FIG. 2 .
FIG. 5 is a perspective view of the FIG. 2 sealing rings.
DETAILED DESCRIPTION
FIG. 1 schematically illustrates an example gas turbine engine 10 including (in serial flow communication) an inlet section 14 , a centrifugal compressor 18 , a combustion section 26 , a turbine wheel 30 , and a turbine exhaust 34 . The gas turbine engine 10 is circumferentially disposed about an engine centerline X. During operation, air is pulled into the gas turbine engine 10 by the inlet section 14 , pressurized by the compressor 18 , mixed with fuel, and burned in the combustion section 26 . The turbine wheel 30 extracts energy from the hot combustion gases flowing from the combustion section 26 .
In a radial turbine design, the turbine wheel 30 utilizes the extracted energy from the hot combustion gases to power the centrifugal compressor 18 . The examples described in this disclosure are not limited to the radial turbine auxiliary power unit described and may be used in other architectures, such as a single-spool axial design, a two spool axial design, and a three-spool axial design. That is, there are various types of engines that could benefit from the examples disclosed herein, which are not limited to the radial turbine design shown.
Referring to FIGS. 2-4 with continuing reference to FIG. 1 , within the combustion section 26 of the engine 10 an example combustor liner 50 is secured relative to a turbine nozzle 54 . The combustor liner 50 establishes a combustion area 58 . A fuel nozzle 62 is configured to spray fuel into the combustion area 58 . Air is delivered to the combustion area 58 through apertures 66 in the combustion liner 50 . As known, the air pressure within the combustion area 58 is less than the air pressure outside the combustion area 58 .
An igniter 70 ignites a mixture of fuel and air within the combustion area 58 to generate hot combustion gases G that are forced through the turbine nozzle 54 . The hot combustion gases G drive turbine wheel 30 .
In this example, eight fuel nozzles 62 are circumferentially arranged about the engine centerline X. The fuel nozzles 62 are arranged such that the spray pattern of fuel from one of the fuel nozzles 62 slightly overlaps the spray pattern of fuel from an adjacent one of the fuel nozzles 62 . Arranging the fuel nozzles 62 in this manner facilitates evenly driving the turbine wheel 30 with the hot combustion gas G moving through the turbine nozzle 54 .
The combustor liner 50 and the turbine nozzle 54 meet at an interface 74 . In this example, the turbine nozzle 54 provides an annular opening that is defined by spaced apart, concentric outer and inner walls 64 and 65 . The annular opening of the turbine nozzle 54 is configured to receive inner and outer collar portions 80 and 81 of the combustor liner 50 . In this example, the inner and outer collar portions 80 and 81 are placed within the annular turbine nozzle 54 between the outer and inner walls 64 and 65 . The inner collar portion 80 is placed adjacent to a radially outer surface 75 of the inner wall 65 in this example.
A flange 78 extends from a radially inward face of the combustor liner 50 and is configured to hold a plurality of axially aligned sealing rings 82 , such that the inner wall 65 of the turbine nozzle 54 is positioned radially between the inner collar portion 80 and the sealing rings 82 .
In this example, a portion of the flange 78 is secured directly to the combustor liner 50 . Welding secures the flange 78 to the combustor liner 50 in this example. Other adhesion techniques are used in other examples. The flange 78 is also formed from a single sheet of material, which, in this example, is the same type of material used to manufacture the combustor liner 50 .
Another portion of the flange 78 establishes a channel 86 that facilitates holding the sealing rings 50 . In this example, the flange 78 has a J-shaped portion 88 that establishes the channel 86 . The sealing rings 82 are not secured directly to the flange 78 in this example and are thus moveable within the channel 86 .
In this example the inner collar portion 80 , the outer collar portion 81 , the outer wall 64 , and the inner wall 65 are aligned with the engine centerline X.
The higher air pressure outside the combustion area 58 exerts forces F on the sealing rings 82 , which urges the sealing rings 82 against the flange 78 and the turbine nozzle 54 to seal the interface 74 . More specifically, the sealing rings 82 are urged against the flange 78 and an inner surface 83 of inner wall 65 . In one example, the inner surface 83 is machined to facilitate maintaining the seal with the sealing rings 82 .
Referring to FIG. 5 , the example sealing rings 82 have a break 90 . That is, the example sealing rings 82 are not continuous rings. As known, the interface 74 is exposed to extreme temperature variations, which can cause the sealing rings 82 , and surrounding components, to expand and contract. The break 90 accommodates movements of the sealing rings 82 as the sealing rings 82 expand and contract due to temperature fluctuations within the engine 10 . In another example, the sealing rings 82 are a continuous spiral snap ring.
In this example, the break 90 of one of the sealing rings 82 is circumferentially offset from the break 90 of another of the sealing rings 82 . Offsetting the breaks in this manner prevents the break 90 from becoming a significant leakage path for air through the interface 74 . That is, area of the break 90 in one of the sealing rings 82 is sealed by another of the sealing rings 82 .
Two sealing rings 82 are shown in this example. Other examples include using more or fewer sealing rings 82 . Five sealing rings 82 may be arranged together, for example. The radially outer and radially inner faces 94 of the example sealing rings 82 are rounded. In this example, the radially outer face facilitates sealing the sealing rings 82 against the turbine nozzle 54 . Pointed faces or flattened faces are used in other examples.
In one example, an axially directed face 98 of the sealing rings 82 includes features such as grooves or ribs that limit rotation of the sealing rings 82 relative to each other.
The example sealing rings 82 are made of a carbon-based material. Other examples include sealing rings 82 made of other materials. The example sealing rings 82 have a radial thickness Tr of about 0.25 inches (0.6 cm) and an axial thickness Ta of about 0.08 inches (0.2 cm). The diameter of the example sealing rings 82 is about 12 inches (30.5 cm).
Features of the disclosed examples include using a sealing ring to seal an interface between a combustor and a turbine nozzle. Using the sealing ring facilitates assembly of the interface between the combustor and the turbine nozzle because the sealing ring can be moved relative to the combustor liner. If leaks are found when using the sealing ring, the leaks are typically more predictable and uniform than leaks at interfaces in the prior art designs. Controlled leakage amounts can also be created by the sealing rings. Another feature of disclosed examples includes using breaks in the sealing rings to accommodate expansions and contractions.
Although a preferred embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | An example method of sealing an interface within a gas turbine engine includes holding a sealing ring arrangement relative to a turbine nozzle using a flange extending from a combustor liner. The method further includes urging the sealing ring arrangement toward a sealed relationship with the turbine nozzle. | 5 |
[0001] This application claims priority from Japanese Patent Application No. 2015-127114 filed on Jul. 24, 2015, the entire subject-matter of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to an iron-based sintered alloy to be suitably used as a die material and a cutter blade material for a pelletizer of a resin extruder in pairs, and a method for producing the same.
[0004] 2. Description of the Related Art
[0005] Since a cutter blade or the like for a pelletizer of a resin extruder is severely worn under a corrosive environment, excellent corrosion resistance and wear resistance are required. Also, a tool material to be used in the cutter blade and the like for a pelletizer of a resin extruder desirably has not only excellent corrosion resistance and wear resistance but also machinability for processing the material into the cutter blade or the like. To such a request, for example, JP-A-H11-92870 proposes a material which is machinable, has a predetermined level of hardness and excellent wear resistance, and is excellent in corrosion resistance, obtainable by dispersing appropriate amounts of carbides in high strength stainless steel. That is, there is proposed a highly corrosion-resistant carbide-dispersed material in which carbides of Ti and Mo are dispersed in a matrix, wherein the carbide-dispersed material contains, in terms of weight ratio, Ti; 18.3 to 24%, Mo; 2.8 to 6.6%, C; 4.7 to 7% as the carbides and contains Cr; 7.5 to 10%, Ni; 4.5 to 6.5%, Co; 1.5 to 4.5%, and 0.6 to 1% of one or more of Al, Ti, and Nb as the matrix, the balance being Fe and unavoidable impurities.
[0006] Moreover, JP-A-2000-256799 proposes a highly corrosion-resistant carbide-dispersed material in which carbides of Ti and Mo are dispersed in a matrix, wherein the carbide-dispersed material contains, in terms of weight ratio, Ti; 18.3 to 24%, Mo; 2.8 to 6.6%, C; 4.7 to 7% as the carbides and contains Cr; 7.5 to 10%, Ni; 4.5 to 6.5%, Cu; 1 to 4.5%, Co; 0 to 4.5%, and 0.6 to 1% of one or more of Al, Ti, and Nb as the matrix, the balance being Fe and unavoidable impurities. According to the example, the highly corrosion-resistant carbide-dispersed material has a hardness of 46.0 to 49.8 HRC after sintering, is machinable, and has a hardness of 58.0 to 63.5 HRC and a bending strength of 126 to 155 kgf/mm 2 after an aging treatment.
[0007] However, resin materials to be used in a resin extruder are various materials and application ranges thereof have been extended, so that the tool material to be used for the cutter blade and the like for a pelletizer is required to have higher corrosion resistance, wear resistance, machinability, or mechanical strength. The highly corrosion-resistant carbide-dispersed materials proposed in JP-A-H11-92870 and JP-A-2000-256799 have a problem that they cannot always cope with such requirements sufficiently.
SUMMARY
[0008] Illustrative aspects of the present disclosure provide an iron-based sintered alloy having remarkably excellent characteristics in corrosion resistance, wear resistance, machinability, or mechanical strength according to an application target of a resin extruder. The iron-based sintered alloy may be suitably used as die and cutter blade materials for a pelletizer of the resin extruder in pairs.
[0009] According to a first illustrative aspect, there may be provided a method for producing an iron-based sintered alloy that is used in sliding components in pairs, the iron-based sintered alloy having a composition comprising, in terms of percent by mass, Ti: 18.4 to 24.6%, Mo: 2.8 to 6.6%, C: 4.7 to 7.0%, Cr: 7.5 to 10.0%, Ni: 4.5 to 6.5%, Co: 1.5 to 4.5%, Al: 0.6 to 1.0%, the balance being Fe and unavoidable impurities, wherein the alloy has a structure in which hard particles are dispersed in an island shape in a matrix and, wherein the method comprises, while an area ratio of the hard particles is kept constant, controlling a maximum circle equivalent diameter of the hard particles to a predetermined value of 40 to 10 μM.
[0010] The area ratio of the hard particles may be 38% to 41% and standard deviation of the area ratio of the hard particles may be 2.5 to 3.5. Ti, Mo, and C forming the hard particles may be supplied as a TiC powder and a Mo powder.
[0011] The components used in pairs may be components to be used as a die and a cutter blade.
[0012] According to a second illustrative aspect, there may be provided an iron-based sintered alloy which is used in a die and a cutter blade for a pelletizer of a resin extruder, the iron-based sintered alloy having a composition comprising, in terms of percent by mass, Ti: 18.4 to 24.6%, Mo: 2.8 to 6.6%, C: 4.7 to 7.0%, Cr: 7.5 to 10.0%, Ni: 4.5 to 6.5%, Co: 1.5 to 4.5%, Al: 0.6 to 1.0%, the balance being Fe and unavoidable impurities, and the iron-based sintered alloy having a structure in which hard particles are dispersed in an island shape in a matrix, wherein a coefficient of friction after passing through a conforming stage is 0.12 or less in a friction test in water by a cutter blade-on-disk method simulating a die and a cutter blade.
[0013] According to a third illustrative aspect, there may be provided an iron-based sintered alloy that is used in sliding components in pairs, the iron-based sintered alloy having a composition comprising, in terms of percent by mass, Ti: 18.4 to 24.6%, Mo: 2.8 to 6.6%, C: 4.7 to 7.0%, Cr: 7.5 to 10.0%, Ni: 4.5 to 6.5%, Co: 1.5 to 4.5%, Al: 0.6 to 1.0%, the balance being Fe and unavoidable impurities, wherein the alloy has a structure in which hard particles are dispersed in an island shape in a matrix, an area ratio of the hard particles is within a constant range and a maximum circle equivalent diameter of the hard particles is a predetermined value of 40 μm to 10 μm.
[0014] According to a fourth illustrative aspect, there may be provided a method for producing the iron-based sintered alloy according to the third illustrative aspect, the method comprising: forming a compact by mixing material powders including TiC, Mo, Ni, Cr, Co, Al and Fe and subjecting the mixture by a cold isostatic pressing method; and subjecting the formed compact to a vacuum sintering, a solution treatment and an aging treatment.
[0015] The iron-based sintered alloy according to the present disclosure has remarkably excellent characteristics in corrosion resistance, wear resistance, machinability, or mechanical strength, has relatively low hardness after sintering, and has high bending strength after an aging treatment. The iron-based sintered alloy according to the disclosure has high wear resistance particularly in the case where the alloy is processed into a die and a cutter blade of a pelletizer to be provided on a resin extruder and they are used in pairs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a SEM photograph of an iron-based sintered alloy according to the disclosure;
[0017] FIG. 2 is a SEM photograph of a material of Comparative Example;
[0018] FIG. 3 is a graph showing maximum circle equivalent diameter and area ratio, and Rockwell hardness after sintering of an iron-based sintered alloy according to the disclosure;
[0019] FIG. 4 is a graph showing standard deviation of the maximum circle equivalent diameter and the area ratio shown in FIG. 3 ;
[0020] FIG. 5A to 5C are schematic views showing a test specimen shape for a wear test and a wear testing machine portion fitted therewith;
[0021] FIG. 6 is a graph showing wear weight of a cutter blade after a wear test; and
[0022] FIGS. 7A and 7B are graphs showing a changing state of a coefficient of friction during a wear test.
DETAILED DESCRIPTION
[0023] Illustrative embodiments will now be described with reference to the accompanying drawings. FIG. 1 is a scanning electron microscope (SEM) photograph showing a structure of an iron-based sintered alloy according to the disclosure. FIG. 2 is a SEM photograph showing a structure of a commercially available carbide-dispersed iron-based sintered alloy material (material of Comparative Example) widely used in a cutter blade for a pelletizer, a punch of a punching die, and the like. In FIGS. 1 and 2 , the black portions scattered in an island shape in a matrix are titanium carbide, molybdenum carbide, or a composite carbide of titanium and molybdenum and are particle (hard particle) portions having high hardness. As shown in FIG. 1 , the iron-based sintered alloy according to the disclosure is characterized in that the hard particles have a fine and relatively uniform shape and are homogeneously dispersed over the whole matrix.
[0024] The present iron-based sintered alloy is manufactured by forming a mixed powder, which has been obtained by mixing a predetermined powder (e.g., the predetermined power may contain 23 to 30.8 mass % of TiC powder, 2.8 to 6.6 mass % of Mo powder, 4.5 to 6.5 mass % of Ni powder, 7.5 to 10.0 mass % of Cr powder, 1.5 to 4.5 mass % of Co powder, 0.6 to 1.0 mass % of Al powder and 40.6 to 60 mass % of Fe powder) in a wet ball mill, by a cold isostatic pressing (CIP) method (e.g., by applying a pressure of 1,000 to 4,000 kgf/cm 2 ) and subjecting the formed compact (e.g., having a columnar shape having a diameter of 50 to 200 mm and a height of 25 to 60 mm or a cuboid shape having a length of 55 to 150 mm, a width of 100 to 275 mm and a height of 45 to 60 mm) to vacuum sintering, a solution treatment, and an aging treatment at predetermined temperatures (e.g., the vacuum sintering is performed at a sintering temperature of 1,360 to 1,400° C. (preferably, 1,380 to 1,400° C.) for 4 to 6 hours), the solution treatment is performed at a temperature of 800 to 1,050° C. for 3 to 8 hours, and the aging treatment is performed at a temperature of 440 to 530° C. for 4 to 10 hours). As shown in FIG. 3 , the iron-based sintered alloy is characterized in that it can be manufactured so that, while an area ratio of hard particles existing in the matrix is kept constant (is not changed), a maximum circle equivalent diameter (in terms of a projected area circle equivalent diameter) thereof is controlled to a predetermined value. In FIG. 3 , the horizontal axis shows sintering temperature in the vacuum sintering and the vertical axis shows the maximum circle equivalent diameter (equivalent diameter) or area ratio of the hard particles after the aging treatment is performed and Rockwell hardness (hardness) after the vacuum sintering. Incidentally, FIG. 3 shows an average of 5 test specimens at each point.
[0025] As shown in FIG. 3 , at a sintering temperature of 1,360 to 1,400° C., the area ratio of the hard particles (asterisk) is 38 to 41% (about 40%) and is constant and the maximum circle equivalent diameter (♦) decreases in reverse proportion to the sintering temperature. In the present iron-based sintered alloy, the structure is observed like a structure formed through gradual decay from large-diameter hard particles as if the maximum diameter of the hard particles that can exist at the sintering temperature is present. This is also understood from the fact that variation (standard deviation) in the area ratio and maximum circle equivalent diameter of the hard particles shown in FIG. 4 is small. In FIG. 4 , the horizontal axis shows the sintering temperature and the vertical axis shows standard deviation of the area ratio and maximum circle equivalent diameter of the hard particles. According to FIG. 4 , at a sintering temperature of 1,360 to 1,400° C., the standard deviation of the area ratio is about 2% (2.5 to 3.5%) and is constant. With regard to the maximum circle equivalent diameter, the standard deviation is 12 to 11 μm at a sintering temperature of 1,360 to 1,370° C. that is relatively large as compared to that at other sintering temperatures within 1,350 to 1,400° C. and is small at a sintering temperature of 1,380 to 1,400° C. At a sintering temperature of 1,380 to 1,400° C., the standard deviation of the maximum circle equivalent diameter is 6 to 4 μm and is very small.
[0026] According to FIG. 3 and FIG. 4 , at a sintering temperature of 1,350° C. or 1,350 to 1,360° C., a singular appearance in the average and standard deviation of the maximum circle equivalent diameter is observed. The following Table 1 shows the average, standard deviation, and a coefficient of variation of the maximum circle equivalent diameter at each sintering temperature. At a sintering temperature of 1,350 to 1,400° C., a singular point is observed in the coefficient of variation (standard deviation/average) at a sintering temperature of 1,350° C. According to this, it is understood that the case where the sintering temperature is 1,350° C. is structurally different from the sintering at a sintering temperature of 1,360 to 1,400° C.
[0000]
TABLE 1
Sintering
Standard
Coefficient
temperature
Average
deviation
of
(° C.)
(μm)
(μm)
variation
1,350
38.64
4.57
0.12
1,360
39.87
12.52
0.31
1,370
33.87
10.71
0.32
1,380
26.77
6.21
0.23
1,390
24.78
5.39
0.22
1,400
18.67
3.9
0.21
[0027] Moreover, according to FIG. 3 , Rockwell hardness (▴) of the present iron-based sintered alloy after sintering increases in proportion to the sintering temperature when the sintering temperature is in a range of 1,350 to 1,380° C. (31 to 46 HRC) and when the sintering temperature exceeds 1,380° C., it is observed that the hardness becomes a constant value or decreases. However, the highest value of the hardness is 46 HRC at a sintering temperature of 1,380° C. and thus the iron-based sintered alloy has sufficient machinability.
Example 1
[0028] An iron-based sintered alloy according to the present disclosure was manufactured. From the material, five disks and cutter blades were cut out and a wear test in water by a cutter blade-on-disk method was performed. FIGS. 5B and 5C show the shapes of the disk and the cutter blade used in the wear test, respectively. The disk and cutter blade were put into a wear testing machine (e.g., “EFM-III-1010-ADX”, a schematic diagram of which is shown in FIG. 5A ) having a rotation mechanism, pressurization mechanism and a temperature control mechanism and the wear test was performed. The hardness of the disk and the hardness of the cutter blade were both 57 HRC as hardness after an aging treatment. The wear test was performed under a contact face pressure of 5.8 kg/cm 2 at a peripheral speed of 5.2 m/sec and the test time was 10 hours. Volume of water bath was 1.8 L and temperature of water was 30° C. Incidentally, using the disk and cutter blade cut out from the material of Comparative Example, the same wear test as above was performed.
[0029] The iron-based sintered alloy was manufactured as shown below.
[0030] That is, a compounding powder of the powders shown in Table 2 were mixed in a ball mill, the resulting mixed powder was filled into a rubber mold having a space of φ100×50 mm so as to be formed into a columnar shape having a diameter of 100 mm and a height of 50 mm, and, after sealing, was formed by a CIP method by applying a pressure of 1,500 kgf/cm 2 , and the resulting compact was heated under vacuum at 1,380° C. for 5 hours, thereby performing vacuum sintering. Thereafter, a solution treatment was performed under a temperature at 850° C. for 4 hours and an aging treatment under a temperature at 500° C. for 6 hours was conducted. Table 3 shows maximum circle equivalent diameter and area ratio of the structure of the manufactured iron-based sintered alloy (Inventive Example). As shown in Table 3, Inventive Example (present iron-based sintered alloy) has a maximum circle equivalent diameter of hard particles of about 16 μm and the size is ½ or less of that of Comparative Example and the standard deviation of the maximum circle equivalent diameter is about 2 μm and is ¼ or less of that in Comparative Example. The inventive Example has an area ratio of hard particles of 40%, which is about the same as in the case of Comparative Example (43%) but the standard deviation of the area ratio is 1.2%, which is considerably smaller than that in the case of Comparative Example (4.5%). That is, Inventive Example is characterized in that small hard particles are homogeneously dispersed as a whole.
[0031] In the disclosure, with regard to the carbides, it is suitable that only TiC is supplied as a powder and the others are supplied as individual metal powders, for example, a Mo powder. As the TiC powder, a commercially available one having a particle size of 1 to 2 μm was used. Incidentally, as for materials of Comparative Example, Table 2 shows a chemical composition and Table 3 shows the maximum circle equivalent diameter and area ratio of the structure, as well.
[0000]
TABLE 2
Chemical composition (mass %)
TiC
Mo
Ni
Cr
Co
Al
Cu
Fe
Inventive
27
5
5.7
8.8
2.9
0.7
—
49.9
Example
Comparative
30 to 32
2 to 4
3 to 4.5
9 to 10
3 to 6.5
0 to 1
0 to 1
1 to 2
Example
[0000]
TABLE 3
Maximum circle equivalent
diameter (μm)
Area ratio (%)
Standard
Standard
Average
deviation
Average
deviation
Inventive
15.9
2.01
39.58
1.21
Example
Comparative
37.8
9.89
43.17
4.51
Example
[0032] FIG. 6 shows wear weight of the cutter blade by the wear test after the passage of 10 hours and FIGS. 7A and 7B show a changing state of the coefficient of friction during the wear test. According to FIG. 6 , the wear weight in Inventive Example is ⅕ or less of that in Comparative Example. According to FIG. 7A , the coefficient of friction in Inventive Example gradually increases until 1 hour from the start of the test (0.25 to 0.50), thereafter slightly decreases, after 2.1 hours, sharply decreases, subsequently fluctuates within the range of 0.15 to 0.45 until 4.2 hours, and is near to almost 0 (0.05 or less) after 4.2 hours. Incidentally, the coefficient of friction becomes about 0.1158 after 7.156 to 7.167 hours. That is, the present iron-based sintered alloy has a coefficient of friction of at least about 0.12 or less, mainly 0.1 or less and specifically, near to almost 0 in the wear test in water after passing through a certain conforming stage. On the other hand, the coefficient of friction of Comparative Example fluctuates within a certain range during the test time (0.3 to 0.6). | A method for producing an iron-based sintered alloy, which is used in sliding components in pairs and has a composition including, in terms of percent by mass, Ti: 18.4 to 24.6%, Mo: 2.8 to 6.6%, C: 4.7 to 7.0%, Cr: 7.5 to 10.0%, Ni: 4.5 to 6.5%, Co: 1.5 to 4.5%, Al: 0.6 to 1.0%, the balance being Fe and unavoidable impurities, wherein the method is carried out such that the alloy has a structure in which hard particles are dispersed in an island form in a matrix and, while an area ratio thereof is kept constant, a maximum circle equivalent diameter thereof is controlled to a predetermined value of 40 to 10 μm. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/676,694 filed Jul. 27, 2012, the disclosure of which is hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] Aspects of the invention include compounds related to the molecule inauhzin and methods of synthesizing and using the same to inhibit the growth of cells including cancer cells.
BACKGROUND AND SUMMARY
[0003] The p53 tumor suppressor protein can prevent the formation of tumors through several mechanisms, including the activation of cell-cycle checkpoints to prevent damaged cells from proliferation (cell-cycle arrest and DNA repair), the promotion of senescence (permanent cell-cycle arrest), and/or the triggering of cell death (apoptosis or autophagy). It can also impede cell migration, metabolism, or angiogenesis, which are needed for cancer cell progression and metastasis. Mutations of the tumor suppressor gene TP53 are detected in ˜50% of all types of human cancers, while the functions and stability of the p53 protein are often abrogated via posttranslational mechanisms in the rest of human cancers that contain wild type TP53. Therefore, the restoration or reactivation of wild-type p53 function can lead to rapid elimination of tumors. As such, compounds that target the p53 pathway have become promising anticancer drug candidates, and several of them have entered clinical trials. For instance, Nutlin-3 and MI-219 can increase p53 level and activity by interfering with the p53-MDM2 binding. Even though there have been extensive endeavors to find small molecules that target the p53 pathway, none has yet proven to be clinically effective therapeutics due to the inherent undesirable toxicity to normal cells and tissues.
[0004] Recent efforts in in silico screening and cellular-based assays have shown that Inauhzin (INZ) and some of its analogs ( FIG. 7 ) comprise a class of small molecules that effectively activate p53 and promote p53-dependent apoptosis of human cancer cells, apparently without causing genotoxic stress. In addition, INZ appears to stabilize p53 by increasing p53 acetylation and preventing MDM2-mediated ubiquitylation of p53 in cells. Remarkably, INZ inhibited cell proliferation, induced senescence and tumor-specific apoptosis, and repressed the growth of xenograft tumors derived from p53-harboring lung cancer H460 and colon cancer HCT116 +/+ cells without causing measurable toxicity to normal tissues.
[0005] INZ is an effective anti-cancer agent which can be used either alone or in combination with Nutlin treatment or DNA damage agents such as Cisplatin and Doxorubicin. A single treatment with Nutlin-3 is less efficient in inhibiting the growth or in promoting apoptosis of some cancer cells, such as HCT116 +/+ , H460, or A549, in xenograft tumor models even though these cells contain wild type p53. The combination of INZ with Nutlin-3 synergistically promotes apoptosis in HCT116 +/+ and H460 cell lines in a p53-dependent fashion. This combination also synergistically activates p53 in xenograft tumors derived from these cancer cells and significantly suppresses their growth.
[0006] To further characterize the structural features essential for the activity of this group of small molecules to induce p53 and to suppress cell proliferation, a structure-activity relationship (SAR) analyses of INZ analogs was performed. A number of new INZ analogs were synthesized and evaluated for their ability to induce p53 and inhibit cell growth using cell-based assays. This study not only revealed critical chemical groups for INZ activity, but also lead to the discovery of INZ derivative 37, a compound that displays better potency in p53 induction and cancer cell growth inhibition than does INZ.
[0007] Additional information regarding small molecule modulators of SIRT1 activity activating p53 and suppressing tumor growth can be found in International Patent Application Publication Number WO 2012/135149, published Aug. 20, 2009 base on PCT/US/2012/030619 having an International Filing Date of Mar. 26, 2012, which claims the benefit of US provisional patent Applications Nos. 61/467,511 filed on Mar. 25, 2011, 61/579,519 filed on Dec. 22, 2011, and 61/583,040 filed on Apr. 1, 2012, each of which are hereby incorporated by reference in their entirety.
[0008] According to one embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein, G 2 is:
[0000]
[0009] X is: CH 2 , O, NH, or S;
[0010] R1 is: CH 3 , CH 3 CH 2 , CH 3 CH 2 CH 2 , or CH 3 CH 2 CH 2 CH 2 ;
[0011] Y is: H,
[0000]
or R2;
[0012] R2 is:
[0000]
[0013] R3 is H, an alkyl group, or a halogen;
[0014] R4 is H, a halogen, or OCH 3 ; and
[0015] R5 is:
[0000]
[0016] In one particular embodiment, the compound according to Formula I is:
[0000]
[0000] or a pharmaceutically acceptable salt thereof. In another particular embodiment, the composition comprises a compound according to Formula (I), wherein G 2 is
[0000]
[0000] X is CH 2 , R1 is CH 3 CH 2 , Y is H, R3 is H, and R4 is H. In still another particular embodiment, the composition comprises a compound according to Formula (I), wherein G 2 is
[0000]
X is CH 2 , Y is R2, R1 is CH 3 CH 2 , R2 is
[0017]
R3 is H, and R4 is H.
[0018] In another embodiment, of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof,
[0000] wherein, G 2 is:
[0000]
[0019] X is: CH 2 , O, or S;
[0020] R1 is: CH 3 CH 2 ;
[0021] Y is: H;
[0022] R3 is H; and R4 is H, Cl, or OCH 3 .
[0023] In another embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof:
[0000] wherein, G 2 is:
[0000]
[0024] X is: S;
[0025] R1 is: CH 3 CH 2 , or CH 3 CH 2 CH 2 CH 2 ;
[0026] Y is: H;
[0027] R3 is H, OCH 3 , an alkyl group, or a halogen;
[0028] R4 is H.
[0029] In another embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof:
[0000] wherein G 2 is:
[0000]
[0030] X is: S;
[0031] R1 is: CH 3 CH 2 ;
[0032] Y is:
[0000]
[0033] R3 is H;
[0034] R4 is H; and
[0035] R5 is:
[0000]
[0036] In another embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof:
[0000] wherein, G 2 is:
[0000]
[0037] X is: S;
[0038] R1 is: CH 3 CH 2 ;
[0039] Y is: R2;
[0040] R2 is:
[0000]
[0041] R3 is H; and
[0042] R4 is H.
[0043] According to another embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein, G 2 is:
[0000]
[0044] X is: CH 2 , O, NH, or S;
[0045] R1 is: CH 3 , CH 3 CH 2 , CH 3 CH 2 CH 2 , or CH 3 CH 2 CH 2 CH 2 ;
[0046] Y is: H,
[0000]
CH 2 CH 2 OH, CH 2 CH 2 CCH;
[0047]
or R2;
[0048] R2 is:
[0000]
[0049] R3 is H, an alkyl group, OCH 3 or a halogen;
[0050] R4 is H, a halogen, or OCH 3 ; and
[0051] R5 is:
[0000]
[0052] In another embodiment of the present disclosure, a composition is provided, the composition comprising a compound according to Formula (I) or a pharmaceutically acceptable salt thereof: wherein, G 2 is:
[0000]
[0053] X is: CH 2 ;
[0054] R1 is: CH 3 CH 2 ;
[0055] Y is: H, CH 2 CH 2 OH, CH 2 CH 2 CCH; or R2;
[0056] R2 is:
[0000]
[0057] R3 is H, an alkyl group, OCH 3 , or a halogen; and
[0058] R4 is H.
[0059] In another embodiment, a method of increasing apoptosis is provided, the method, comprising the steps of contacting at least one eukaryotic cell with an effective amount of any of the above compositions containing a compound according to Formula (I) or a pharmaceutically acceptable salt thereof.
[0060] In another embodiment, a method of treating a patient is provided, the method comprising the steps of administering at least one therapeutically effective dose of any of the above compositions containing compound according to Formula (I) or a pharmaceutically acceptable salt thereof to a human or to an animal. In a particular embodiment, the compound of Formula I is co-administered to said human or said animal along with a therapeutically effective dose of at least one chemotherapeutic agent. In another particular embodiment, the human is diagnosed with cancer. In another particular embodiment, the human is diagnosed with lung cancer. In another particular embodiment, the chemotherapeutic agent is selected from the group consisting of: cisplatin and doxorubicin.
BRIEF DESCRIPTION OF THE SCHEMES, FIGURES, AND TABLES
[0061] FIG. 1 illustrates chemical structures of representative commercial analogs S1-S34.
[0062] FIGS. 2A-2D illustrate chemical structures of INZ synthetic analogs 6-36.
[0063] FIG. 3 illustrates the scheme 1 synthesis of INZ analogs 6-19.
[0064] FIG. 4 illustrates the scheme 2 synthesis of INZ analogs 20-27.
[0065] FIG. 5 illustrates the scheme 3 synthesis of INZ analogs 28-30.
[0066] FIG. 6 illustrates the scheme 4 synthesis of INZ analogs 31-36.
[0067] FIG. 7 illustrates the structure of Inauhzin (INZ).
[0068] FIGS. 8A and 8B show the cellular activity of INZ analogs S1-S34. Initial Inauhzin analogs were purchased and tested the activity on H460 and HCT116 p53+/+ by IB. Cells were treated with the compounds at 2 μM or 20 μM for 18 hrs and harvested for IB and their p53 induction activity as quantified from IB data as shown in FIG. 8A-FIG . 8 B.
[0069] FIGS. 9A and 9B show the cellular activities of INZ synthetic analogs 6-37. Cellular activity of INZ synthetic analogs 6-37 measured using IB that detects p53 levels and activity in H460 and HCT116 cells. FIG. 9A shows the results for cells that were harvested for IB with antibodies as indicated after being treated with each compound for 18 hrs as shown in representative blots (number denotes each compound; Inauhzin, INZ). FIG. 9B shows the p53 induction activity as quantified from IB data. 50 μg of total proteins was used per lane for the results shown in FIGS. 9A-9B .
[0070] FIG. 10A illustrates the structure of INZ synthetic analog 37.
[0071] FIG. 10B shows the cell growth inhibition by selected INZ Synthetic Analogs. FIG. 10B shows representative cell growth inhibition curves of INZ synthetic analogs 8, 30 and 37 in H460 and HCT116 cell lines.
[0072] FIG. 11 illustrates a summary of some of the Structure-Activity Relationships between compounds related to INZ.
[0073] FIGS. 12A and 12B show the comparative potency of INZ and compound 37 and observed toxicity in cell based and in vivo biochemical toxicity assays. FIG. 12A shows the cell growth inhibition curves of INZ and compound 37 in H460 cells. EC 50 and EC 90 values represent the average of triplicates within 10% relative standard deviation. The results were repeated in two independent experiments. FIG. 12B shows assay results for Alanine transferase and total bilirubin. Compound 37 was administered i.p. at 50 mg/kg once per day for two weeks in C57BL/6 and their blood was collected for Alanine transferase and total bilirubin biochemical assay.
[0074] FIGS. 13A and 13B show the effects of compound 37 on the growth of H460 orthotopic lung tumors. Each mouse was dosed once a day via i.p. with either vehicle or compound 37 (50 mg/kg) for 3 weeks starting 4 days after implantation of 5×10 5 H460-Luc tumor cells into the pleural space of the SCID mice. FIG. 13A shows the tumor burden in lung area measured by bioluminescent imaging (BLI) for each treatment group. Each value is a mean of five animals ±SD. FIG. 13B is bioluminescent imaging (BLI) of orthotopic lung tumors in SCID mice.
[0075] FIG. 14A illustrates the structure of INZ synthetic analog 38.
[0076] FIG. 14B illustrates the structure of INZ synthetic analog 39.
[0077] FIG. 14C illustrates the structure of INZ synthetic analog 40.
[0078] FIG. 14D illustrates the structure of INZ synthetic analog 41.
[0079] FIG. 14E illustrates the structure of INZ synthetic analog 42.
[0080] FIG. 14F illustrates the structure of INZ synthetic analog 43.
[0081] FIG. 15A shows mass spectrometry characterization data for INZ synthetic analog 42.
[0082] FIG. 15A shows liquid chromotography characterization data for INZ synthetic analog 42.
DESCRIPTION
[0083] For the purposes of promoting an understanding of the principles of the novel technology, reference will now be made to the preferred embodiments thereof, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel technology is thereby intended, such alterations, modifications, and further applications of the principles of the novel technology being contemplated as would normally occur to one skilled in the art to which the novel technology relates are within the scope of this disclosure and the claims.
[0084] As used herein, unless explicitly stated otherwise or clearly implied otherwise the term ‘about’ refers to a range of values plus or minus 10 percent, e.g. about 1.0 encompasses values from 0.9 to 1.1.
[0085] As used herein, unless explicitly stated otherwise or clearly implied otherwise the terms ‘therapeutically effective dose,’ ‘therapeutically effective amounts,’ and the like, refers to a portion of a compound that has a net positive effect on the health and well being of a human or other animal. Therapeutic effects may include an improvement in longevity, quality of life and the like these effects also may also include a reduced susceptibility to developing disease or deteriorating health or well being. The effects may be immediately realized after a single dose and/or treatment or they may be cumulatively realized after a series of doses and/or treatments.
[0086] Pharmaceutically acceptable salts include salts of compounds of the invention that are safe and effective for use in mammals and that possess a desired therapeutic activity. Pharmaceutically acceptable salts include salts of acidic or basic groups present in compounds of the invention. Pharmaceutically acceptable acid addition salts include, but are not limited to, hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, isonicotinate, acetate, lactate, salicylate, citrate, tartrate, pantothenate, bitartrate, ascorbate, succinate, maleate, gentisinate, fumarate, gluconate, glucaronate, saccharate, formate, benzoate, glutamate, methanesulfonate, ethanesulfonate, benzensulfonate, p-toluenesulfonate and pamoate (i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)) salts. Certain compounds of the invention may form pharmaceutically acceptable salts with various amino acids. Suitable base salts include, but are not limited to, aluminum, calcium, lithium, magnesium, potassium, sodium, zinc, and diethanolamine salts. For addition information on some pharmaceutically acceptable salts that can be used to practice the invention please reviews such as Berge, et al., 66 J. PHARM. SCI. 1-19 (1977), Haynes, et al, J. Pharma. Sci., Vol. 94, No. 10, October 2005, pgs. 2111-2120, the disclosures of which are hereby incorporated by reference in their entirety, and the like.
Design and Chemical Synthesis
[0087] Structurally, INZ (1) possesses two distinct chemical components: triazino[5,6-b]indol (G1) and phenothiazine (G2) moiety ( FIG. 7 ). Preliminary SAR studies were performed using 46 purchased analogous of INZ with diversities at G1 and G2. This study also investigated the activity of the compounds in cell-based assays for their ability to induce p53 levels in p53 containing human colon cancer HCT116 +/+ cells and/or human lung cancer H460 cells using immunoblotting (IB) ( FIG. 1 and FIG. 8 ). The results indicated that a unique structure scaffold might be required for the activity of INZ in cells. Removal of the ethyl group at R1 (S1-S3) or modification at both R 2 and R 3 positions on the indol moiety of INZ (S4) disabled the compound's ability to activate p53 in cells ( FIG. 8 ). Apparently, the R 2 position can be modified and substituted without loss of activity by replacing it with some alkyl groups, such as methyl, ethyl and allyl, but not propyl (S5-S8). Both triazino[5,6-b]indol (G1) and phenothiazine (G2) are essential functional groups for p53 induction. INZ analogs that included ethyl groups at the R 1 position but lacked either functional groups G1 (S9-S10), or G2 (S19-S22) failed to induce p53. Compounds S11-S18, S23-S28, and S29-S34 with substituted aromatic moieties other than triazino[5,6-b]indol at G1 and/or phenothiazine at G2 had very low or no activity. Overall, the results suggest that a specific chemical structure with the intact triazino[5,6-b]indol-3-ylthio)butanoyl]-10H-phenothiazine might be crucial for p53 activation in cells. Indeed, INZ (1) displayed more potent p53 activation and anticancer inhibition than either of its component fragments, compound 2′ or 3′ (Scheme 2, FIG. 4 , and data not shown). These results suggest that a synergism is achieved when these two structural units are combined within a single molecule. Therefore, further attention was focused on the structural modifications of the pharmacologically active core: triazino[5,6-b]indol or phenothiazine. Modifications included extension of carbon chain length on R1 (14) ( FIG. 2B ), the substitution on the phenothiazine ring (G2) (6-13) ( FIG. 2A ) or on the triazino[5,6-b]indol ring (G1) (15-36) ( FIGS. 2B-2D ).
[0088] The syntheses of these INZ derivatives are outlined in Schemes 1, 2, 3, and 4 ( FIGS. 3-6 ).
[0089] The synthesis of compounds INZ (1) and 6-19 is outlined as Scheme 1 ( FIG. 3 ). The 5H-[1,2,4]triazino[5,6-b]indole-3-thiol 3 was prepared from the commercial isatin according to the standard procedure. The bromide 5 was synthesized through refluxed thiophenol with the bromobutyryl bromide in toluene. Then the thiol 3 was reacted with bromide 5 in the presence of Et 3 N and afforded compound 1, and 6-19. Other bases were tested and some byproducts were produced, which gave rise to low yields.
[0090] The amide derivatives 20-27 were prepared in one step from INZ (1) in the presence of organic bases as depicted in Scheme 2 ( FIG. 4 ).
[0091] The amine derivative 28 was synthesized from INZ (1) and ethyl bromoacetate in the presence of K 2 CO 3 , which was depicted in Scheme 3 ( FIG. 5 ). Other organic bases, such as Et 3 N or DIPEA, were tested and the reaction proceeded very slowly with low yields. Compound 28 was hydrolyzed by 1 M NaOH and afforded the acid 29. The alcohol 30 was obtained through reduction of 28 by NaBH 4 . LiBH 4 was tested and several byproducts were produced as revealed by TLC analysis. Scheme 4 ( FIG. 6 ) shows the “click chemistry” for the synthesis of triazol derivatives. Triazols 34-36 were obtained in good yields through the reaction of azide derivative and the propargyl 31 and 32 under the standard conditions.
Biological Assessments of INZ Analogs
[0092] The synthetic analogs were then assayed for their potential to induce p53 level and activity in H460 cells and HCT116 +/+ cells by IB. Compounds were added into cultured H460 and HCT116 +/+ cells at 0.5, 2, 10 μM for 18 hrs and harvested for IB. The p53 activation was assessed by up-regulating the levels of MDM2, p53 and p53 acetylation. The induction level of p53 by each of the tested INZ analogs was normalized against the loading control of GAPDH and compared to the level of p53 in the cells treated with 2 μM INZ ( FIG. 9 ). Compounds showing good efficacy in p53 induction were further subjected to a 3-day WST assay to assess their ability to kill cancer cells. INZ was used along with the analogs as a positive control in each assay. The EC 50 values for their ability to inhibit cell growth were calculated through serial dilution of their concentrations with the highest concentration at 50 μM. Four-parameter or two-parameter Hill equation was employed to calculate and plot the dose-response curves as shown with some representative compounds in FIG. 10 and Table 1.
[0000]
TABLE 1
DOSE-RESPONSE DATA FOR SELECTED COMOUNDS
Cancer cells
Normal cells
H460
HCT116 +/+
H1299
HCT116 −/−
WI-38
p53 wild type
p53 wild type
p53 null
p53 null
p53 wild type
a EC 50 (μM)
b EC 90 (μM)
EC 50 (μM)
EC 90 (μM)
EC 50 (μM)
EC 90 (μM)
EC 50 (μM)
EC 90 (μM)
EC 50 (μM)
EC 90 (μM)
8
2.7 ± 0.3
3.5
1.3 ± 0.3
10.0
10.4 ± 1.6
223.9
5.9 ± 1.0
240.9
c n.d.
19
6.0 ± 0.6
26.5
2.2 ± 0.2
29.7
40.2 ± 7.4
172.8
44.2 ± 10.3
>1000
n.d.
20
2.9 ± 0.2
7.5
2.5 ± 0.6
18.3
21
4.3 ± 0.3
9.6
2.1 ± 1.0
21.9
12.6 ± 1.4
82.3
28.2 ± 1.4
>1000
22
4.9 ± 1.0
20.5
23
6.7 ± 0.7
22.6
24
5.7 ± 0.3
14.5
26
16.0 ± 0.9
38.2
27
3.4 ± 0.3
9.0
30 a
3.5 ± 0.4
7.7
0.8 ± 0.5
4.6
16.6 ± 4.1
921.6
7.8 ± 3.4
741.8
n.d.
37 b
0.7 ± 0.1
3.6
0.5 ± 0.1
5.0
11.2 ± 3.5
58.9
12.8 ± 1.7
91.7
n.d.
INZ
7.7 ± 1.1
39.9
2.7 ± 0.3
30.5
11.6 ± 3.4
217.4
13.3 ± 2.4
212.6
n.d.
a EC50 of the selected INZ analogs represent the average of triplicates. The EC50 values were determined by the two-parameter Hill equation where EC50 and the Hill coefficient were allowed to refine while the maximal and minimal values remain fixed.
b EC 90 values were calculated from the EC 50 and Hill slope by a web-based calculator: http://www.graphpad.com/quickcalcs/Ecanything1.cfm.
c Not be able to be determined.
Anti-Proliferative Effect of Synthetic INZ Analogs
[0093] In synthetic INZ analogs containing triazino[5,6-b]indol (G1), subtle and major modifications to phenothiazine ring (G2) generally led to less potent molecules. Though subtle changes on the branches of the phenothiazine ring were tolerated (for instance, compounds 6 and 7 with chlorine or methoxy remained active in p53 induction) ( FIGS. 2A and 9 ), they did not reach 50% p53 induction in H460 cells at 2 μM. The removal of any ring of G2, as shown for compound 10-13 ( FIG. 2A ), caused loss of activity, and those compounds were essentially inactive ( FIG. 9 ). The exception to this trend was substitution of the sulfur atom with methylene (8). 1-acridin-INZ derivative (8) drastically induced p53 at 0.5 μM, whereas compound 9, whose sulfur was substituted with oxygen, was inactive ( FIG. 9 ). It should be noted that 1-acridin-INZ (8) also exhibited more than 2 fold higher potency than did INZ in its inhibitory effect on H460 (EC 50 =2.7 μM) ( FIG. 10 ) and HCT116 +/+ cells (EC 50 =1.3 μM) ( FIG. 10 ). The EC 90 values of this analog were in the range of 3.5-10 μM, which were 3-10 fold lower than those for INZ.
[0094] Compound 14 ( FIG. 2B ) with the longer chain containing butyl at R1 position exhibited lower activity for p53 induction, which further indicated that the appropriate length of alkyl chain at R1 position is crucial for the activity of INZ, as INZ activity in p53 activation was reduced or lost when the chain was either longer than 2 carbons (14, FIG. 2B ) or removed (S2-S3, FIG. 1 ). Compounds 15-19 ( FIG. 2B ) were synthesized to determine the effect of different substituents, such as electron-withdrawing group (halogen atoms) and electron donating group (methyl or methoxy), at R 3 position of indole ring (G1) on p53 induction. Compounds 16 and 17, which have a chlorine and bromine atom, respectively, exhibited similar activity to that of INZ in HCT116 +/+ cells with a dose-dependent induction of p53 acetylation at lysine 382, p53 protein level and the up-regulation of MDM2 level. Compound 18 with a methoxy group displayed a marked decrease in p53 activation. In contrast, the methyl derivative 19 exhibited a significant effect on p53 induction compared to INZ at 0.5 μM. It also inhibited the proliferation of H460 and HCT116 +/+ with EC 90 values of ˜20-30 μM, which were 1.5 fold lower than that for INZ ( FIG. 10C ). These results indicate that the order of influence of these substituents on the antiproliferative activity of INZ is as follows: CH 3 >Cl=Br>F>OCH 3 .
[0095] The results from preliminary biological screening of INZ analogs (S5-S8, FIG. 1 ) suggested that R 2 position could be modified. Biotin was conjugated directly to INZ through the formation of the amide bond at the active hydrogen of R 2 in order to form compound 20 ( FIG. 2C ). This biotin-conjugated INZ was initially designed for target identification studies. Surprisingly, biotinylated INZ (20) was as effective as INZ in the induction of p53 acetylation and level in both H460 and HCT116 +/+ cells ( FIG. 9B ). Another biotin-conjugated compound derived from the inactive compound 15 was used as a negative control in the target identification screening (data not shown). In addition to compound 20, some other amide compounds (21-27) ( FIG. 2C ) were made through the same procedure. All these compounds with various aldehyde substitutions on R 2 exhibited good activities in p53 induction and cell growth inhibition in comparison with INZ ( FIGS. 9-10 ). Derivatives 20, 21 and 27 showed similar EC 90 values of 7.5, 9.6 and 9.0 μM, respectively whereas INZ is about 39.9 μM. Removal (25→32, FIGS. 2C-2D ) or separation (21→33, FIGS. 2C-2D ) of electron-withdrawing aldehyde atom from the indol resulted in a significant decrease in activity ( FIG. 9 ). Replacing the aldehyde with an ester group (28) or carboxylic acid (29) resulted in essentially inactive analogs, in striking contrast to its alcohol derivative 30, which was comparable to compound 8 in p53 activation and cell growth inhibition ( FIG. 2D , 10-11). The EC 90 values of compound 30 as tested in H460 and HCT116 +/+ cells, respectively, were ˜7.7 μM and 4.6 μM, which was 5 fold lower than that of INZ ( FIG. 10 ). Since compounds 8 and 30 displayed more potent activity compared than did INZ, the analog 37 which includes both substitution of the sulfur atom with methylene on G2 and alcohol substitution on G1 was synthesized. Remarkably, compound 37 was 10- and 5-fold more active than was INZ in growth inhibition of H460 and HCT116 +/+ cells (EC 50 =0.7 μM and 0.5 μM), respectively.
[0096] INZ displayed much higher toxicity to p53-containing human cancer cells than to p53-null cancer cells. This was evident in the EC 50 and EC 90 values for the compounds, which were 1.5 and 5-7 fold greater in p53-null cells than in p53-containing cell lines, respectively ( FIG. 10C ). The activity of INZ synthetic analogs was examined further by conducting in vitro cytotoxicity assays using p53 null lung cancer H1299 cells and colon cancer HCT116 −/− cells. Compounds 8, 19, 21, 30 and 37 were much less effective in H1299 cells and HCT116 −/− cells, in contrast to their inhibitory activity against p53-containing cells ( FIG. 10C ); the EC 50 values of compounds 8, 30 and 37 on H1299 were 10.4, 16.6 and 11.2 μM, respectively, which were 3-15 fold higher than those measured using H460 cells. The EC 90 values of compound 8, 30 and 37 on H1299 cells and HCT116 −/− cells were greater than 50 μM whereas those on H460 and HCT116 +/+ cells were 3.5 and 10, 7.7 and 4.6, and 3.6 and 5.0 μM, respectively. Remarkably, these synthetic analogs were much less toxic to normal human fiberbrast cell WI-38 ( FIG. 10 ), while they were much more potent than was INZ in killing p53-containing cancer cells. For example, the EC 50 value of compound 37 for WI-38 could not be determined at the highest concentration tested (50 μM) in comparison of its EC 50 values of 0.7 and 0.5 μM to p53-containing H460 and HCT116 +/+ cells, respectively. Together, these results indicate that these more potent INZ analogs, such as compounds 8, 30 and 37, possess strong p53-dependent cytotoxicity. Among them, compound 37 stands out as the most effective INZ analog identified in this study.
[0097] Initial studies on the 46 commercial analogs of INZ yielded information on the important functional groups at each of its two scaffolds identified as triazino[5,6-b]indol ring (G1) and phenothiazine ring (G2). The functional analyses of the commercial and synthetic analogs of INZ and their ability to activate p53 and to inhibit cell growth further as described above validates that each of the functional groups of INZs is critical for p53 activation and inhibition of cancer cell growth ( FIG. 11 ). Most modifications to phenothiazine ring G2, such as the branch substitutions (6-7, 9), or replacement with other rings (10-13, S19-S22), led to decreased activity in p53 induction, with the apparent exception that the substitution of sulfur in the G2 region by methylene (1→8) showed greater potency than compound 1 in both p53 induction and cancer cell inhibition. Analyses of analogs S1-S3, and 14 demonstrate that the ethyl group at R 1 is likely to be required for the activity of these compounds. The butyl group was tolerated. Modification of R 3 position at the region G1 with methyl, but not halide ormethoxy substitutions, increased activity in both of the assays (15-19). Most modifications on R 2 at the G1 region resulted in the impressive improvement in terms of p53 activation compared to compound 1 (20-27, 30-31). Overall, the best compound from this study was 1-acridin-INZ alcohol (37). The potency of this analog, compared to INZ, was improved nearly 5- to 10-fold in cancer growth inhibition. Interestingly and importantly, compounds 8, 30 and 37 were more potent in p53 activation than their parental compound INZ especially with the selective toxicity to p53-containing tumor cells, but not to normal cells.
[0098] Based on these SAR and cell-based analyses, 1-acridin-INZ alcohol (37) represented a candidate for further characterization of its biological activity against cancer by using orthotopic lung tumors derived from H460 cells (See FIGS. 12-13 ).
Experimental Section
Compounds S1-S34
[0099] INZ analogs S1-S34 were purchased from Asinex, ChemDiv and ChemBridge. Compounds S1-S5 were described in a preceding paper, re-validated by LC/MS on an Agilent 1200 LC/MS system (Agilent Technology) at the Chemical Genomics Core Facility of Indiana University School of Medicine. The minimum purity of all compounds is higher than 90%.
[0100] Cell Culture and Immunoblotting Analysis.
[0101] Human lung carcinoma H460, non-small-cell lung cancer H1299, human colon cancer HCT116 (HCT116 +/+ ), and human embryonic fibroblast WI-38 were bought from the American Type Culture Collection (ATCC). Human colon cancer HCT116 p53 null cell lines (HCT116 −/− ) were generously offered by Dr. Bert Vogelstein (Johns Hopkins University). Those cell lines were cultured in Dulbecco's modified Eagle's medium supplemented with 10% fetal bovine serum, 100 U per mL penicillin, and 100 U per mL streptomycin. Compounds were dissolved in DMSO and diluted directly into the medium to the indicated concentrations; 0.1% DMSO was used as a control. After incubation with the compounds for 18 h, cells were harvested and lysed in 50 mM Tris-HCl pH 8.0, 150 mM NaCl, 5 mM EDTA, 0.5% NP-40 supplemented with 1 mM DTT and 0.2 mM PMSF. An equal amount of protein samples (50 μg) was subjected to SDS-PAGE and transferred to a PVDF membrane (PALL Life Science). The membranes with transferred proteins were blocked with 1×TBST containing 5% non-fat, dried milk for 1 h at room temperature, and then incubated with anti-p53-acetylated (lys382, Cell Signaling), anti-p53 (mouse monoclonal, DO-1, Santa Cruz), anti-MDM2 (4B11)[14], or anti-GAPDH antibodies (Sigma) followed by a secondary antibody labeled with horseradish peroxidase (Pierce). The blots were developed by an enhanced chemiluminescence detection kit (Thermo Scientific), and signals were visualized by Omega 12iC Molcular Image System (UltraLUM).
[0102] Cell Viability Assay.
[0103] To assess cell growth, the cell counting kit (Dojindo Molecular Technologies Inc., Gaithersburg, Md.) was used according to manufacturer's instructions. Cell suspensions were seeded at 3,000 cells per well in 96-well culture plates and incubated overnight at 37° C. Compounds were added into the plates and incubated at 37° C. for 72 hrs. Cell growth inhibition was determined by adding WST-8 at a final concentration of 10% to each well, and the absorbance of the samples was measured at 450 nm using a Microplate Reader (Molecular Device, SpecrtraMax M5 e ). EC 50 values were determined by the Hill equation using Igor 4.01 (Lake Oswego, Oreg., USA).
[0104] General Chemistry.
[0105] All purchased chemicals were reagent-grade or better. Proton and carbon NMR spectra were recorded on a 500 MHz Bruker Avance II spectrometer. Chemical shifts are reported in δ (parts per million, ppm) with the δ 7.26 signal of CDCl 3 ( 1 HNMR), δ 2.50 signal of DMSO-d 6 ( 1 H NMR), or δ 77.2 signal of CDCl 3 ( 13 C NMR) as internal standards. All column chromatography was performed using Dynamic Adsorbents 230-400 mesh silica gel (SiO 2 ) with the indicated solvent system unless otherwise noted. TLC analysis was performed using 254 nm glass-backed plates and visualized using UV light (254 nm). HRMS data were obtained at the Mass Spectrometry Facility at IUPUI Chemistry Department on a Waters/Macromass LCT. All the synthetic compounds were analyzed by LC/MS on an Agilent 1200 LC/MS system (Agilent Technology) at the Chemical Genomics Core Facility of Indiana University School of Medicine and the purity was over 95%.
General Procedure for Synthesis of Compounds 1, 6-19
2-((5H-[1,2,4]triazino[5,6-b]indole-3yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (1, INZ)
[0106] 2-bromo-1-(10H-phenothiazin-10-yl)butan-1-one (3.675 g, 25 mmol) and 5H-[1,2,4]triazino[5,6-b]indole-3-thiol (2.125 g, 25 mmol) were dissolved in 50 ml anhydrous DMF and cooled to 0° C. 11.1 ml Et 3 N (250 mmol) was dropped to the above mixture. After stirring fort 0.5 h, TLC indicated that the reaction was completed and stopped. 300 ml ethyl acetate was added to the reaction mixture. The organic phase was washed by saturated NH 4 Cl for five times. It was dried by anhydrous Na 2 SO 4 and filtered. The organic phase was concentrated to about 15 ml and the pale solid was formed. The amorphous solid was collected and washed by a few ethyl acetate. 1 H NMR (500 MHz, DMSO-d 6 ) δ; 12.63 (br, 1H), 8.34 (d, J=7.5?, 1H), 7.89-7.96 (m, 1H), 7.56-7.73 (m, 4H), 7.37-7.47 (m, 5H), 7.29-7.22 (m, 1H), 5.27 (t, J=7.0, 1H), 1.86 (br, 1H), 1.74 (br, 1H), 0.85 (br, 3H). 13 C NMR (125 MHz, DMSO-d 6 ) δ 170.0, 146.8, 141.7, 140.9, 138.5, 138.3, 131.4, 128.6, 128.2, 128.0, 127.7, 127.4, 123.0, 122.0, 118.0, 113.2, 31.1, 25.9, 11.8. HRMS was calculated for C 25 H 19 N 5 OS 2 469.1031 and found 469.1047.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(2-chloro-10H-phenothiazin-10-yl)butan-1-one (6)
[0107] Compound 6 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.64 (d, J=17.5, 1H), 8.33-8.35 (m, 1H), 7.84-7.91 (m, 1H), 7.60-7.34 (m, 4H), 7.39-7.48 (m, 5H), 5.15-5.26 (m, 1H), 1.82 (br, 1H), 1.73 (br, 1H), 0.85 (br, 3H). HRMS calcd for C 25 H 18 ClN 5 OS 2 503.0641. found 503.0643.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(2-methoxy-10H-phenothiazin-10-yl)butan-1-one (7)
[0108] Compound 7 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.65 (d, J=22.5, 1H), 8.32-8.35 (m, 1H), 7.59-7.73 (m, 1H), 7.36-7.53 (m, 7H), 7.21 (br, 1H), 6.96-7.21 (m, 1H), 5.29 (t, J=7.0, 1H), 3.51-3.71 (m, 3H), 1.95 (br, 1H), 1.77 (br, 1H), 0.86 (br, 3H). HRMS calcd for C 26 H 21 N 5 O 2 S 2 499.1137. found 499.1144.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(acridin-10(9H)-yl)butan-1-one (8)
[0109] Compound 8 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.60 (br, 1H), 8.32 (d, J=7.5, 1H), 7.68-7.73 (m, 3H) 7.59 (d, J=8.0, 1H), 7.44-7.47 (m, 1H), 7.17-7.34 (m, 6H), 5.41 (s, 1H), 3.86 (s, 2H), 2.10 (br, 1H), 1.86 (br, 1H), 0.95 (br, 3H). 13 C NMR (125 MHz, DMSO-d 6 ) δ 169.9, 166.1, 146.7, 141.8, 140.9, 139.2, 135.2, 131.4, 127.8, 126.7, 126.6, 125.5, 122.9, 122.0, 117.9, 113.2, 47.3, 33.4, 26.2, 11.9. HRMS calcd for C 26 H 21 N 5 OS 451.146. found 451.1474.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenoxazin-10-yl)butan-1-one (9)
[0110] Compound 9 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.63 (br, 1H), 8.33 (d, J=8.0, 1H), 7.70-7.34 (m, 3H), 7.60 (d, J=8.0, 1H), 7.46 (d, J=7.5, 1H), 7.19-7.25 (m, 6H), 5.47 (t, J=7.0, 1H), 1.99-2.03 (m, 1H), 1.81-1.86 (m, 1H), 0.89 (t, J=7.5, 3H). HRMS calcd for C 27 H 19 N 5 O 2 S 453.1259. found 453.1270.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(2H-benzo[b][1,4]thiazin-4(3H)-yl)butan-1-one (10)
[0111] Compound 10 was synthesized similarly to 1. 1 H NMR (500 MHz, CDCl 3 ) δ 10.15 (s, 1H), 8.38 (d, J=7.5, 1H), 7.60-7.66 (m, 3H), 7.43 (t, J=7.5, 1H), 7.23 (br, 1H), 7.12-7.14 (m, 2H), 5.30 (br, 1H), 3.30 (br, 3H), 2.14 (d, J=7.0, 1H), 2.00 (br, 2H), 1.08 (br, 3H). HRMS calcd for C 21 H 19 N 5 OS 2 421.1031. found 421.1038.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(3,4-dihydroquinolin-1(2H)-yl)butan-1-one (11)
[0112] Compound 11 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.60 (br, 1H), 7.69-7.72 (m, 1H), 7.58 (d, J=8.0, 1H), 7.45 (t, J=7.0, 1H), 7.35 (br, 1H), 7.12-7.16 (m, 2H), 7.06 (t, J=7.5, 1H), 5.28 (t, J=6.5, 1H), 3.97 (br, 1H), 3.55 (br, 1H), 2.64-2.76 (m, 2H), 2.04 (br, 2H), 1.86 (br, 2H), 0.89 (br, 3H). HRMS calcd for C 22 H 21 N 5 OS 403.1467. found 403.1479.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-thiomorpholinobutan-1-one (12)
[0113] Compound 12 was synthesized similarly to 1. 1 H NMR (500 MHz, CDCl 3 ) δ 10.88 (br, 1H), 8.37 (d, J=8.0, 1H), 7.63-7.64 (m, 2H), 7.40-7.43 (m, 1H), 5.35 (t, J=7.0, 1H), 4.12-4.19 (m, 2H), 4.03-4.05 (m, 1H), 3.86-3.89 (m, 1H), 2.92-2.95 (m, 1H), 2.72-2.77 (m, 1H), 2.60-2.64 (m, 2H), 2.19-2.26 (m, 1H), 2.04-2.10 (m, 1H), 1.13 (t, J=7.0, 3H). HRMS calcd for C 17 H 19 N 5 OS 2 373.1031. found 373.1033.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(2,3-dihydro-1H-pyrrolo[3,2-b]pyridine-1-yl)butan-1-one (13)
[0114] Compound 13 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.56 (s, 1H), 8.28 (d, J=8.0, 1H), 8.08 (d, J=4.5, 1H), 7.67-7.71 (m, 2H), 7.56 (d, J=8.5, 1H), 7.42 (t, J=7.5, 1H), 7.00-7.03 (m, 1H), 6.59 (br, 1H), 4.05 (t, J=8.5, 2H), 3.12 (q, J=7.5, 2H), 2.10-2.15 (m, 1H), 1.98-2.04 (m, 1H), 1.07 (t, J=7.5, 3H). HRMS calcd for C 20 H 18 N 6 OS 390.1263. found 390.1274.
2-((5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)hexan-1-one (14)
[0115] Compound 14 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.62 (br, 1H), 8.35 (d, J=7.5, 1H), 7.96 (br, 1H), 7.58-7.74 (m, 4H), 7.37-7.48 (m, 5H), 7.26 (br, 1H), 5.32 (t, J=7.0, 1H), 1.86 (br, 1H), 1.83 (br, 1H), 1.09-1.24 (m, 4H), 0.73 (br, 3H). HRMS calcd for C 27 H 23 N 5 OS 2 497.1344. found 497.1348.
2-((7-fluoro-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (15)
[0116] Compound 15 was synthesized similarly to compound 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.70 (br, 1H), 8.17 (d, J=7.0, 1H), 7.89 (br, 1H), 7.56-7.64 (m, 4H), 7.37-7.43 (m, 4H), 7.22-7.25 (m, 1H), 5.26 (t, J=7.0, 1H), 1.95 (br, 1H), 1.74 (br, 1H), 0.85 (d, J=7.0, 3H). HRMS calcd for C 25 H 18 FN 5 OS 2 487.0937. found 487.0962.
2-((7-chloro-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (16)
[0117] Compound 16 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.79 (br, 1H), 8.38 (s, 1H), 7.88 (br, 1H), 7.73-7.79 (m, 1H), 7.49-7.63 (m, 3H), 7.37-7.43 (m, 4H), 7.23 (br, 1H), 5.26 (t, J=7.0, 1H), 1.86 (br, 1H), 1.74 (br, 1H), 0.86 (br, 3H). HRMS calcd for C 25 H 18 ClN 5 OS 2 503.0641. found 503.0641.
2-((7-bromo-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (17)
[0118] Compound 17 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.84 (br, 1H), 8.50 (s, 1H), 7.85 (d, J=8.0, 2H), 7.58 (d, J=8.5, 3H), 7.38-7.41 (m, 4H), 7.23 (br, 1H), 5.26 (s, 1H), 1.86 (br, 1H), 1.73 (br, 1H), 0.85 (br, 3H). HRMS calcd for C 25 H 18 BrN 5 OS 2 547.0136. found 547.0136.
2-((7-methoxy-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (18)
[0119] Compound 18 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ; 12.47 (br, 1H), 7.89 (br, 1H), 7.85 (br, 1H), 7.52-7.64 (m, 4H), 7.37-7.43 (m, 3H), 7.32-7.34 (m, 1H), 7.22 (br, 1H), 5.25 (t, J=7.0, 1H), 1.86 (br, 1H), 1.74 (br, 1H), 0.85 (br, 3H). HRMS calcd for C 26 H 21 N 5 O 2 S 2 499.1137. found 499.1136.
2-((7-methyl-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (19)
[0120] Compound 19 was synthesized similarly to 1. 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.50 (br, 1H); 8.13 (s, 1H), 7.87 (br, 1H), 7.49-7.61 (m, 5H), 7.37-7.42 (m, 3H), 7.22 (br, 1H), 5.25 (d, J=6.5, 1H), 2.52 (s, 3H), 1.90 (br, 1H), 1.74 (br, H), 0.86 (br, 3H). HRMS calcd for C 26 H 21 N 5 OS 2 483.1188. found 483.1196 General procedure for synthesis of compounds 20-27.
5-(5-oxo-5-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)pentyl)tetrahydro-1H-thieno[2,3-d]imidazole-2(5H)-one (20)
[0121] Biotin (100 mg, 0.410 mmol) was placed in 10 ml reaction flask and cooled to 0° C. 2.7 ml SOCl 2 was added to the flask and allowed to room temperature. The mixture was stirred for 1 h and excess SOCl 2 was evaporated. The residue was co-evaporated with 5 ml anhydrous toluene for three times to give the biotin acid chloride. The crude acid chloride was dissolved in 5 ml anhydrous THF. INZ (65 mg, 0.138 mmol) was dissolved in 3 ml anhydrous THF and injected to the above solution through syringe. The mixture was cooled to 0° C. and 100 μl Et 3 N (0.717 mmol) was dropped to the mixture. The solution was then allowed to room temperature. TLC was used to monitor the reaction. After 11 h, TLC indicated that the reaction was completed. The reaction mixture was diluted with 30 ml ethyl acetate and washed by saturated NaCl for two times. The organic phase was separated and dried by anhydrous Na 2 SO 4 . The organic phase was filtered, concentrated in vacuum and was purified by column (DCM/CH 3 OH, 55:1). The product was obtained as viscous oil. 1 HNMR (500 MHz, CDCl 3 ) δ 8.69 (d, J=8.5, 1H), 8.40 (d, J=7.5, 1H), 7.92 (br, 1H), 7.75-7.72 (m, 1H), 7.67 (d, J=7.0, 1H), 7.59-7.56 (m, 1H), 7.53 (d, J=3.0, 1H), 7.40 (br, 1H), 7.35-7.29 (m, 3H), 7.18 (br, 1H), 5.60 (d, J=39.5, 1H), 5.42-5.38 (m, 1H), 5.14 (s, 1H), 4.56-4.53 (m, 1H), 4.41-4.37 (m, 1H), 3.48-3.41 (m, 1H), 3.35-3.26 (m, 1H), 3.25-3.23 (m, 1H), 2.98-2.95 (m, 1H), 2.76 (d, J=12.5, 1H), 1.90-1.83 (m, 4H), 1.79-1.75 (m, 1H), 1.70 (br, 1H), 1.61-1.58 (m, 2H), 0.98-0.90 (m, 3H). 13 C NMR (125 MHz, CDCl 3 ) δ 173.1, 170.0, 167.7, 163.7, 146.7, 142.4, 139.5, 138.5, 138.3, 132.2, 127.7, 127.5, 127.3, 127.0, 126.8, 125.9, 121.4, 119.6, 117.8, 62.0, 60.4, 55.4, 55.3, 40.6, 39.1, 28.5, 28.4, 26.0, 24.2, 11.7. HRMS calcd for C 35 H 33 N 7 O 3 S 3 695.1807. found 695.1817.
2-((5-benzoyl-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (21)
[0122] Compound 21 was synthesized similarly to 20. 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.49 (d, J=7.5, 1H), 8.23 (d, J=8.5, 1H), 7.60-7.78 (m, 6H), 7.40-7.55 (m, 4H), 7.17-7.28 (m, 4H), 7.06 (br, 1H), 4.89 (t, J=6.5, 1H), 1.93 (t, J=6.5, 1H), 1.57-1.62 (m, 1H), 0.75 (t, J=7.0, 3H). HRMS calcd for C 32 H 23 N 5 O 2 S 2 573.1293. found 573.1298.
2-((5-nicotinoyl-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)-1-(10H-phenothiazin-10-yl)butan-1-one (22)
[0123] Compound 22 was synthesized similarly to 20. 1 H NMR (500 MHz, CDCl 3 ) δ 8.97 (s, 1H), 8.91 (d, J=4.0, 1H), 8.49 (d, J=8.0, 1H), 8.41 (d, J=8.5, 1H), 8.03-8.05 (m, 1H), 7.78-7.84 (m, 2H), 7.66 (t, J=7.5, 1H), 7.58 (d, J=7.0, 1H), 7.48-7.51 (m, 2H), 7.34 (br, 1H), 7.26-7.28 (m, 3H), 7.12 (br, 1H), 5.08 (t, J=6.0, 1H), 1.94-1.96 (m, 1H), 1.67-1.70 (m, 1H), 0.83 (t, J=6.5, 3H). 13 C NMR (125 MHz, CDCl 3 ) δ 169.9, 167.7, 166.4, 153.8, 150.6, 146.7, 141.9, 139.3, 138.4, 138.2, 137.3, 132.0, 129.6, 128.2, 127.7, 127.3, 127.2, 127.1, 126.9, 126.7, 126.2, 123.1, 121.9, 119.9, 116.5, 64.4, 25.8, 11.6. HRMS calcd C 31 H 22 N 6 O 2 S 2 574.1246. found 574.1257.
1-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)hexan-1-one (23)
[0124] Compound 23 was synthesized similarly to 20. 1 H NMR (500 MHz, CDCl 3 ) δ 8.70 (d, J=8.5, 1H), 8.42 (d, J=8.0, 1H), 7.89 (br, 1H), 7.68-7.76 (m, 2H), 7.51-7.60 (m, 2H), 7.40 (br, 1H), 7.27-7.35 (m, 3H), 7.18 (br, 1H), 5.37 (t, J=7.0, 1H), 3.26-3.41 (m, 2H), 2.13 (br, 1H), 1.81-1.90 (m, 3H), 1.28-1.46 (m, 4H), 0.98-1.00 (m, 6H). HRMS calcd for C 31 H 29 N 5 O 2 S 2 567.1763. found 567.1763.
1-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)pent-4-en-1-one (24)
[0125] Compound 24 was synthesized similarly to 20. 1 H NMR (500 MHz, CDCl 3 ) δ 8.71 (d, J=8.5, 1H), 8.43 (d, J=7.5, 1H), 7.89 (br, 1H), 7.73-7.77 (m, 1H), 7.68 (d, J=6.5, 1H), 7.58-7.61 (m, 1H), 7.51-7.53 (m, 1H), 7.41 (br, 1H), 7.34 (t, J=7.0, 1H), 7.26-7.28 (m, 2H), 7.18 (br, 1H), 5.90-5.98 (m, 1H), 5.36 (t, J=7.0, 1H), 5.10-5.20 (m, 2H), 3.48-3.53 (m, 1H), 3.37-3.43 (m, 1H), 2.57-2.62 (m, 2H), 2.12 (br, 1H), 1.89 (br, 1H), 0.98 (br, 3H). 13 C NMR (125 MHz, CDCl 3 ) δ 172.5, 169.9, 167.8, 146.7, 142.4, 139.5, 138.6, 138.3, 136.2, 132.2, 128.3, 127.7, 127.4, 127.3, 126.9, 126.8, 125.9, 121.5, 119.6, 117.8, 116.3, 100.0, 45.8, 38.8, 28.2, 26.1, 11.7. HRMS calcd for C 30 H 25 N 5 O 2 S 2 551.1450. found 551.1461.
1-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)pent-4-yn-1-one (25)
[0126] Compound 25 was synthesized similarly to 20. 1 H NMR (500 MHz, CDCl 3 ) δ 8.73 (d, J=8.5, 1H), 8.43 (d, J=7.5, 1H), 7.86 (d, J=7.0, 1H), 7.74-7.77 (m, 1H), 7.69 (d, J=7.0, 1H), 7.59-7.62 (m, 1H), 7.54 (d, J=7.5, 1H), 7.34-7.40 (m, 2H), 7.24-7.30 (m, 2H), 7.18 (br, 1H), 5.32 (t, J=7.0, 1H), 3.58-3.62 (m, 1H), 3.45-3.52 (m, 1H), 2.72-2.74 (m, 2H), 2.15 (br, 1H), 1.90 (br, 1H), 1.28 (t, J=7.5, 1H), 0.98-1.01 (m, 3H). HRMS calcd for C 30 H 23 N 5 O 2 S 2 549.1293. found 549.1294.
5-bromo-1-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)pentan-1-one (26)
[0127] Compound 26 was synthesized similarly to 20. 1 H NMR (500 MHz, CDCl 3 ) δ 8.71 (d, J=8.5, 1H), 8.43 (d, J=7.5, 1H), 7.92 (br, 1H), 7.76 (t, J=8.0, 1H), 7.68 (d, J=7.0, 1H), 7.60 (t, J=7.5, 1H), 7.52-7.54 (m, 1H), 7.41 (br, 1H), 7.30-7.36 (m, 3H), 7.19 (br, 1H), 5.39 (t, J=7.0, 1H), 3.31-3.51 (m, 5H), 2.11 (br, 1H), 1.93-1.98 (m, 2H), 1.85-1.91 (m, 4H), 0.98 (br, 3H). HRMS calcd for C 29 H 24 BrN 5 O 2 S 2 617.0555. found 617.0543.
Ethyl 5-oxo-5-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)pentanoate (27)
[0128] Compound 27 was synthesized similarly to 20. 1 H NMR (500 MHz, CD 3 Cl) δ 8.70 (d, J=8.5, 1H), 8.42 (d, J=7.5, 1H), 7.91 (br, 1H), 7.74-7.77 (m, 1H), 7.68 (d, J=7.5, 1H), 7.58-7.61 (m, 1H), 7.52-7.53 (m, 1H), 7.40 (br, 1H), 7.30-7.35 (m, 3H), 7.17 (br, 1H), 5.39 (t, J=6.5, 1H), 3.74 (s, 3H), 3.71-3.72 (m, 2H), 3.42-3.52 (m, 2H), 2.42-2.50 (m, 2H), 1.89-2.02 (m, 2H), 0.98 (br, 3H). 13 C NMR (125 MHz, CD 3 Cl) δ 173.3, 172.5, 169.9, 167.7, 146.6, 142.4, 139.4, 138.6, 138.3, 132.2, 128.3, 127.7, 127.5, 127.3, 127.1, 170.0, 126.8, 125.9, 121.4, 119.6, 117.7, 68.0, 51.8, 38.4, 32.9, 26.0, 19.5, 11.7. HRMS calcd for C 31 H 27 N 5 O 4 S 2 597.1504. found 597.1498.
General Procedure for Synthesis of Compounds 28-36
Ethyl 2-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)acetate (28)
[0129] Compound 5 (0.1407 g, 0.3 mmol) was dissolved in 5 ml anhydrous DMF. 50 mg K 2 CO 3 and ethyl 2-bromoacetate (0.2004 g, 1.2 mmol) were added to the above solution. This reaction was stirred at room temperature. After 6 h, TLC indicated there was no starting material remained and the reaction was stopped. 150 ml ethyl acetate was added to the above mixture. The organic phase was washed by saturated NH 4 Cl for five times. The organic phase was dried by Na 2 SO 4 and concentrated. The residue was purified by flash column chromatography (hexane/ethyl acetate-2:1) and viscous oil 28 was obtained. 1 H NMR (500 MHz, CDCl 3 ) δ 8.39 (d, J=7.5, 1H), 7.88 (br, 1H), 7.62-7.63 (m, 2H), 7.42-7.45 (m, 2H), 7.29-7.32 (m, 2H), 7.19-7.26 (m, 2H), 7.09 (br, 2H), 5.37 (t, J=7.0, 1H), 4.97 (s, 2H), 4.19 (q, J=7.0, 2H), 2.01 (br, 1H), 1.82 (br, 1H), 1.20-1.23 (m, 3H), 0.89-0.91 (m, 3H). HRMS calcd for C 29 H 25 N 5 O 3 S 2 555.1399. found 555.1405.
2-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)acetic acid (29)
[0130] Compound 28 (161 mg, 0.2901 mmol) was dissolved in 15 ml 1,4-dioxane and 0.58 ml 1 M NaOH was added to the solution. The reaction mixture was stirred at room temperature. After 14 h, TLC indicated that there was no starting material remained and the reaction was stopped. The pH of the reaction was adjusted to 4-5 using concentrated HAc. The mixture was extracted by ethyl acetate for three times and the organic phase was combined. The organic phase was dried by anhydrous Na 2 SO 4 and concentrated under vacuum. The residue was purified by column (DCM/MeOH-60:1) and the viscous oil 29 was obtained. 1 H NMR (500 MHz, CDCl 3 ) δ 8.42 (d, J=8.0, 1H), 7.94 (br, 1H), 7.62-7.68 (m, 2H), 7.35-7.49 (m, 4H), 7.24-7.30 (m, 3H), 7.07 (br, 1H), 5.40 (t, J=7.0, 1H), 5.01 (s, 2H), 2.03 (br, 1H), 1.84 (br, 1H), 0.92 (br, 3H). HRMS calcd for C 27 H 21 N 5 O 3 S 2 527.1086. found 527.1093.
2-((5(2-hydroxyethyl)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)thiol)-1-(10H-phenothiazin-10-yl)butan-1-one (30)
[0131] Compound 28 (95 mg, 0.1712 mmol) was dissolved in 4 ml MeOH/THF (3:1). The solution was cooled to 0° C. Then NaBH 4 (39 mg, 1.027 mmol) was added to the above solution. The reaction mixture was allowed to room temperature. After 6 h, TLC indicated there was no starting material remained and the reaction was stopped. Acetic acid was used to quench the reaction. The mixture was purified by column (hexane/ethyl acetate (5:1-3:1-1:1) and the viscous oil was obtained. 1 H NMR (500 MHz, CDCl 3 ) δ 8.44 (d, J=8.0, 1H), 7.99 (br, 1H), 7.72 (t, J=8.0, 1H), 7.66 (br, 1H), 7.59 (d, J=8.0, 1H), 7.47-7.51 (m, 2H), 7.40 (br, 1H), 7.27-7.34 (m, 3H), 7.18 (br, 1H), 5.37 (br, 1H), 4.45 (br, 2H), 4.09 (br, 2H), 2.28 (br, 1H), 2.12 (br, 1H), 1.88 (br, 1H), 0.96 (d, J=7.5, 3H). 13 C NMR (125 MHz, CDCl 3 ) δ 170.4, 146.7, 141.6, 138.6, 138.4, 130.9, 127.7, 127.3, 127.2, 126.9, 126.8, 123.1, 122.4, 110.6, 100.0, 60.7, 44.2, 25.9, 11.7. HRMS calcd for C 27 H 23 N 5 O 2 S 2 513.1293. found 513.1303.
1-(10H-phenothiazin-10-yl)-2-((5(prop-2-yn-1-yl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thiol)butan-1-one (31)
[0132] Compound 31 was synthesized similarly to 28 as amorphous powder. 1 H NMR (500 MHz, CDCl 3 ) δ 8.48 (d, J=7.5 1H), 7.59 (br, 1H), 7.75-7.78 (m, 1H), 7.67-7.70 (m, 2H), 7.51-7.55 (m, 2H), 7.40 (br, 1H), 7.31-7.34 (m, 3H), 7.17 (br, 1H), 5.43 (t, J=6.5, 1H), 5.08-5.13 (m, 2H), 2.40 (s, 1H), 1.92 (br, 1H), 1.89 (br, 1H), 0.92-1.01 (m, 3H). HRMS calcd for C 28 H 21 N 5 O 2 S 2 507.1188. found 507.1188.
2-((5(but-3-yn-1-yl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thiol)-1-(10H-phenothiazin-10-yl)butan-1-one (32)
[0133] Compound 32 was synthesized similarly to 28 as amorphous powder. 1 H NMR (500 MHz, CDCl 3 ) δ 8.46 (d, J=7.5, 1H), 7.97 (br, 1H), 7.68-7.74 (m, 2H), 7.48-7.59 (m, 3H), 7.40 (br, 1H), 7.31-7.34 (m, 2H), 7.18 (br, 1H), 5.41 (t, J=7.0, 1H), 4.45-4.52 (m, 2H), 2.77-2.80 (m, 2H), 2.14 (br, 1H), 1.89 (br, 1H), 0.98 (br, 3H). 13 C NMR (125 MHz, CD 3 Cl) δ 169.4, 165.9, 145.8, 140.9, 140.6, 137.9, 137.8, 130.9, 128.2, 127.8, 127.5, 127.2, 127.0, 123.0, 121.5, 117.3, 111.6, 80.6, 73.3, 25.7, 17.5, 11.3. HRMS calcd for C 28 H 21 N 5 O 2 S 2 507.1188. found 507.1188.
2-((5-(2-oxo-2-phenylethyl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thiol)-1-(10H-phenothiazin-10-yl)butan-1-one (33)
[0134] Compound 33 was synthesized similarly to 28 as amorphous powder. 1 H NMR (500 MHz, CDCl 3 ) δ 8.49 (d, J=7.5, 1H), 8.05 (d, J=7.5, 1H), 7.90 (br, 1H), 7.65-7.72 (m, 3H), 7.55-7.58 (m, 2H), 7.49-7.52 (m, 2H), 7.40-7.46 (m, 2H), 7.31-7.39 (m, 1H), 7.21-7.24 (m, 4H), 5.69-5.77 (m, 2H), 5.39 (t, J=6.5, 1H), 2.05 (br, 1H), 1.87 (d, J=5.5, 1H), 0.90-0.92 (m, 3H). HRMS calcd for C 33 H 25 N 5 O 2 S 2 587.1450. found 507.1461.
2-((5-((1-phenethyl-1H-1,2,3-triazol-4-yl)methyl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thiol)-1-(10H-henothiazin-10-yl)butan-1-one (34)
[0135] 2-bromoethylbenzene (3.083 g, 0.3 mmol) was dissolved in 17 ml anhydrous DMF. NaN 3 (2.1664 g, 33.329 mmol) and 56 mg KI were added to the above solution. The reaction mixture was heated to 90° C. for 18 h. TLC indicated that there was no starting material remained. The reaction was stopped and 200 ml DCM was added to the mixture. The organic phase was washed by 50 ml water and dried by anhydrous Na 2 SO 4 . The organic phase was concentrated and evaporated under vacuum. The crude azide was obtained and used for the next step directly.
[0136] Compound 32 (0.1268 g, 0.25 mmol) and azide (33.4 mg, 0.227 mmol) were dissolved in 3.6 ml t-BuOH/H 2 O/THF (v/v-1:1:1). Sodium ascorbate (98.9 mg, 0.4994 mmol) and CuSO 4 (11.3 mg, 0.0454 mmol) in 0.5 ml water were added to the above reaction mixture. The reaction mixture was heated to 55° C. After stirring for 24 h, TLC indicated that there was no starting material remained. The reaction was stopped and cooled to room temperature. 6 ml water was added to the mixture. The solid was collected and washed with a few water. Then, the solid was dissolved in 8 ml acetone and the solution was filtered. The filtrate was evaporated and the residue was dissolved in 3 ml ethyl acetate. The solution was heated and 5 ml hexane was added to the solution. After overnight, gray solid was formed and collected. The amorphous solid 34 was washed by 4 ml hexane and dried. 1 H NMR (500 MHz, CDCl 3 ) δ 8.44 (d, J=8.0, 1H), 8.03 (br, 1H), 7.66-7.77 (m, 3H), 7.48-7.51 (m, 2H), 7.41 (br, 1H), 7.32-7.33 (m, 2H), 7.18 (br, 1H), 7.06-7.13 (m, 4H), 6.93-6.95 (m, 2H), 5.46-5.56 (m, 3H), 4.53 (t, J=7.5, 2H), 3.14 (t, J=7 0.5?, 2H), 2.07 (br, 1H), 1.88 (br, 1H), 0.98 (br, 3H). HRMS calcd for C 36 H 30 N 8 OS 2 654.1984. found 654.1991.
2-((5-((1-phenethyl-1H-1,2,3-triazol-4-yl)ethyl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thiol)-1-(10H-phenothiazin-10-yl)butan-1-one (35)
[0137] Compound 35 was synthesized similarly to 34 as amorphous powder. 1 H NMR (500 MHz, CDCl 3 ) δ 8.43 (d, J=7.5, 1H), 8.00 (br, 1H), 7.64-7.67 (m, 2H), 7.42-7.50 (m, 4H), 7.23-7.33 (m, 6H), 7.18 (br, 1H), 7.00-7.02 (m, 2H), 6.92 (s, 1H), 5.44 (t, J=6.5, 1H), 4.62 (t, J=7.0, 2H), 4.48 (t, J=7.5, 2H), 3.24 (t, J=7.0, 2H), 3.06 (t, J=7.5, 2H), 2.04-2.08 (m, 1H), 1.87-1.89 (m, 1H), 0.92-1.01 (m, 3H). HRMS calcd for C 37 H 32 N 8 OS 2 668.2140. found 668.2135.
Ethyl 4-(4-(2-(3-((1-oxo-1-(10H-phenothiazin-10-yl)butan-2-yl)thio)-5H-[1,2,4]triazino[5,6-b]indol-5-yl)ethyl)-1H-1,2,3-triazol-1-yl)butanoate (36)
[0138] Compound 36 was synthesized similarly to 34 as amorphous powder. 1 H NMR (500 MHz, CDCl 3 ) δ 8.41 (d, J=8.0, 1H), 8.01 (br, 1H), 7.62-7.68 (m, 2H), 7.50 (d, J=7.5, 1H), 7.40-7.44 (m, 3H), 7.26-7.33 (m, 3H), 7.17 (br, 2H), 5.44 (t, J=6.5, 1H), 4.66 (t, J=7.0, 2H), 4.32 (t, J=7.0, 2H), 4.15 (q, J=7.0, 2H), 3.29 (t, J=7.0, 2H), 2.20 (t, J=7.5, 2H), 2.07-2.11 (m, 2H), 1.87 (br, 1H), 1.77 (br, 1H), 1.28 (t, J=7.0, 3H), 0.94-1.00 (m, 3H). HRMS calcd for C 35 H 34 N 8 O 3 S 2 678.2195. found 678.2197.
1-(acridin-10(9H)-yl)-2-((5-(2-hydroxyethyl)-5H-[1,2,4]triazino[5,6-b]indol-3-yl)thio)butan-1-one (37)
[0139] Compound 37 was synthesized similarly to 30 as viscous oil. 1H NMR (500 MHz, CDCl 3 ) δ 8.35 (d, J=7.5, 1H), 7.77 (br, 2H), 7.66-7.70 (m, 1H), 7.55 (d, J=8.0, 1H), 7.44 (t, J=8.0, 1H), 7.24-7.29 (m, 4H), 7.16 (br, 2H), 5.47 (br, 1H), 4.33-4.41 (m, 2H), 4.05-4.08 (m, 2H), 3.86 (br, 2H), 2.13-2.19 (m, 1H), 1.98-1.99 (m, 1H), 1.04 (br, 3H). HRMS calcd for C 28 H 25 N 5 O 2 S 495.1729. found 495.1731.
[0140] The structures of additional INZ analogs are provided in FIGS. 14A-14 F. FIG. 14A illustrates the structure of INZ synthetic analog 38, having a molecular weight of 465. FIG. 14B illustrates the structure of INZ synthetic analog 39, having a molecular weight of 537.6. FIG. 14C illustrates the structure of INZ synthetic analog 40, having a molecular weight of 481. FIG. 14D illustrates the structure of INZ synthetic analog 41, having a molecular weight of 503. FIG. 14E illustrates the structure of INZ synthetic analog 42, having a molecular weight of 495. FIG. 15A shows mass spectrometry characterization data for INZ synthetic analog 42. FIG. 15A shows liquid chromotography characterization data for INZ synthetic analog 42. FIG. 14F illustrates the structure of INZ synthetic analog 43, which has a molecular weight of 485.
[0141] The Effect of Compound 8 (Also Called INZ-14) on the Growth of H460 Orthotopic Lung Tumors.
[0142] By SAR analysis and chemical optimization, the solubility of INZ was improved and it was also found that INZ-14 (compound 8) was over 2 fold more active than INZ in growth inhibition of HCT116+/+ cells (EC 50 =1.41 μM and 3.52 μM, respectively). The EC 90 values of this analog were in the range of 10 μM, which were 5 fold lower than INZ ( FIG. 12 ). Compound 37 was found to be more potent than INZ without observed toxicity in cell based and in vivo biochemical toxicity assays. As shown in FIG. 12A , cell growth inhibition curves of INZ and compound 37 in H460 cells. EC 50 and EC 90 values represent the average of triplicates within 10% relative standard deviation. The results were repeated in two independent experiments. As shown in FIG. 12B , compound 37 was administered i.p. at 50 mg/kg once per day for two weeks in C57BL/6 and their blood was collected for Alanine transferase and total bilirubin biochemical assay.
[0143] In a preclinical trial experiment using the established orthotopic lung cancer model, INZ-14 (compound 8) was not only more potent in p53 activation and inhibition of cell proliferation than INZ, but also exhibited highly promising bioactivity against orthotopic lung cancers ( FIG. 13 ). The effects of compound 8 on the growth of H460 orthotopic lung tumors. Each mouse was dosed once a day via i.p. with either vehicle or 14 (50 mg/kg) for 3 weeks starting 4 days after implantation of 5×10 5 H460-Luc tumor cells into the pleural space of the SCID mice. As shown in FIG. 13A , tumor burden in lung area measured by bioluminescent imaging (BLI) for each treatment group. Each value is a mean of five animals ±SD. As shown in FIG. 13B , bioluminescent imaging (BLI) of orthotopic lung tumors in SCID mice.
[0144] While the novel technology has been illustrated and described in detail in the figures and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the novel technology are desired to be protected. As well, while the novel technology was illustrated using specific examples, theoretical arguments, accounts, and illustrations, these illustrations and the accompanying discussion should by no means be interpreted as limiting the technology. All patents, patent applications, and references to texts, scientific treatises, publications, and the like referenced in this application are incorporated herein by reference in their entirety. | Inauhzin (INZ) was identified as a novel p53 activator, which selectively and efficiently suppressing tumor growth without displaying genotoxicity and with little toxicity to normal cells. A panel of INZ analogs were synthesized and evaluated their ability to induce cellular p53 and to inhibit cell growth in cell-based assays. As described, this leads to the discovery of INZ analog 37, a molecule that exhibits much better potency than INZ in both of p53 activation and cell growth inhibition in several human cancer cell lines including H460 and HCT116 +/+ cells. This INZ analog exhibited a much lower effect on p53-null H1299 cells and importantly no toxicity towards normal human p53-containing WI-38 cells. Those results also reveal key chemical features for INZ activity, and identify the newly synthesized INZ analog 37 as a better small molecule for further development of anti-cancer therapies. | 0 |
This is a continuation of application Ser. No. 09/087,804, filed Jun. 1, 1998 now U.S. Pat. No. 6,274,597. This application is hereby incorporated herein by reference, in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of enhancing the activity of lysosomal α-Galactosidase A (α-Gal A) in mammalian cells and for treatment of glycosphingolipid storage diseases, in particular Fabry disease, by administration of 1-deoxy-galactonojirimycin and related compounds.
2. Background Information
Fabry disease (1) is a glycosphingolipid lysosomal storage disease caused by an X-linked inherited deficiency of lysosomal α-galactosidase A (α-Gal A), an enzyme responsible for the hydrolysis of terminal α-galactosyl residue from glycosphingolipids. A deficiency in the enzyme activity results in a progressive deposition of neutral glycosphingolipids, predominantly globotriaosylceramide (ceramide trihexoside, CTH), in vascular endothelial cells causing renal failure along with premature myocardial infarction and strokes in patients with this condition (2). This disorder is classified by clinical manifestations into two groups: a classic form with generalized vasculopathy and an atypical variant form, with clinical manifestations limited to heart. Recently, the atypical variant of the disease was found in 10% of adult male patients with unexplained left ventricular hypertrophy, increasing the estimation of frequency for the disorder (3). Like other glycosphingolipid lysosomal storage diseases, enzyme replacement therapy, gene therapy, bone marrow transplantation, and substrate deprivation are suggested as potential strategies for the treatment of this disease (4). However, at the moment the only treatment for this disorder is symptomatic management. Therefore, development of a new therapeutic strategy for this disease is urgently needed.
Studies (5) on residual α-Gal A activity of mutant enzymes revealed that some of mutant enzymes have similar kinetic properties to normal α-Gal A but with significant instability. This is considered as the case for most of atypical variant patients who generally showed higher residual α-Gal A activity than classical Fabry patients. For example (6), a purified mutant α-Gal A with a genotype of Q279E, found in a patient with atypical variant of Fabry disease, had the same Km and Vmax as the normal enzyme, but lost most of the enzyme activity by incubating the enzyme at pH 7.0 at 37° C. for 30 min while the normal enzyme was stable under the same condition. Both mutant and normal enzymes were stable at pH 5.0 at 37° C. Furthermore, the majority of the mutant enzyme protein in cells formed aggregate in endoplasmic reticulum (ER) and was quickly degraded (7), suggesting that the deficiency of the enzyme activity in this mutant maybe primarily caused by the unsuccessful exit of ER leading to excessive degradation of the enzyme protein. The present invention focuses on the aid of smooth escape of the enzyme from ER to prevent the degradation of the mutant enzyme.
SUMMARY OF THE INVENTION
The strategy of the invention is based on the following model. The mutant enzyme protein tends to fold in an incorrect conformation in ER where the pH is around 7. As a result, the enzyme is retarded from the normal transport pathway from ER through the Golgi apparatus and endosome to the lysosome, but instead is subjected to degradation. On the other hand, the enzyme protein with a proper conformation is transported to the lysosome smoothly and remains in an active form because the enzyme is more stable at a pH of less than 5. Therefore, a compound which is able to induce a proper conformation in mutant enzyme may serve as an enhancer for the enzyme. The present inventors have unexpectedly found that strong competitive inhibitors for α-Gal A at low concentrations enhance the mutant enzyme activity in cells, including mutant α-Gal A gene transfected COS-1 cells, fibroblasts from a transgenic mouse overexpressing mutant α-Gal A, and lymphoblasts from Fabry patients.
It is noted that while the above is believed to be the mechanism of operation of the present invention, the success of the invention is not dependent upon this being the correct mechanism.
Accordingly, it is one object of the present invention to provide a method of preventing degradation of mutant α-Gal A in mammalian cells, particularly in human cells.
It is a further object of the invention to provide a method of enhancing α-Gal A activity in mammalian cells, particularly in human cells. The methods of the present invention enhance the activity of both normal and mutant α-Gal A, particularly of mutant α-Gal A which is present in certain forms of Fabry disease.
In addition, the methods of the invention are also expected to be useful in nonmammalian cells, such as, for example, cultured insect cells and CHO cells which are used for production of α-Gal A for enzyme replacement therapy.
Compounds expected to be effective in the methods of the invention are galactose and glucose derivatives having a nitrogen replacing the oxygen in the ring, preferably galactose derivatives such as 1-deoxygalactonojirimycin and 3,4-diepi-α-homonojirimycin. By galactose derivative is intended to mean that the hydroxyl group at the C-3 position is equatorial and the hydroxyl group at the C-4 position is axial, as represented, for example, by the following structures:
wherein R 1 represents H, methyl or ethyl; R 2 and R 3 independently represent H, OH, a simple sugar (e.g. —O—galactose), a 1-3 carbon alkyl, alkoxy or hydroxyalkyl group (e.g. CH 2 OH).
Other specific competitive inhibitors for (x-galactosidase, such as for example, calystegine A 3 , B 2 and B 3 , and N-methyl derivatives of these compounds should also be useful in the methods of the invention. The calystegine compounds can be represented by the formula
wherein for calystegine A 3 : R 1 =H, R 2 =OH, R 3 =H, R 4 =H; for calystegine B 2 : R 1 =H, R 2 =OH, R 3 =H, R 4 =OH; for calystegine B 3 : R 1 =H, R 2 =H, R 3 =OH, R 4 =OH; for N-methyl-calystegine A 3 : R 1 =CH 3 , R 2 =OH, R 3 =H, R 4 =H; for N-methyl-calystegine B 2 : R 1 =CH 3 , R 2 =OH, R 3 =H, R 4 =OH; and for N-methyl-calystegine B 3 : R 1 =CH 3 , R 2 =H, R 3 =OH, R 4 =OH.
It is yet a further object of the invention to provide a method of treatment for patients with Fabry disease. Administration of a pharmaceutically effective amount of a compound of formula
wherein
R 1 represents H, CH 3 or CH 3 CH 2 ;
R 2 and R 3 independently represent H, OH, a 1-6 carbon alkyl, hydroxyalkyl or alkoxy group (preferably 1-3), or a simple sugar;
R 4 and R 5 independently represent H or OH; or a compound selected from the group consisting of 2,5-dideoxy-2,5-imino-D-mannitol, α-homonojirimycin, 3,4-diepi-α-homonojirimycin, 5—O—α-D-galactopyranosyl-α-homonojirimycin, 1-deoxygalactonojirimycin, 4-epi-fagomine, and 1-Deoxy-nojirimycin and their N-alkyl derivatives, will alleviate the symptoms of Fabry disease by increasing the activity of mutant α-Gal A in patients suffering from Fabry disease. Other competitive inhibitors of α-Gal A, such as calystegine compounds and derivatives thereof should also be useful for treating Fabry disease.
Persons of skill in the art will understand that an effective amount of the compounds used in the methods of the invention can be determined by routine experimentation, but is expected to be an amount resulting in serum levels between 0.01 and 100 μM, preferably between 0.01 and 10 μM, most preferably between 0.05 and 1 μM. The effective dose of the compounds is expected to be between 0.5 and 1000 mg/kg body weight per day, preferably between 0.5 and 100, most preferably between 1 and 50 mg/kg body weight per day. The compounds can be administered alone or optionally along with pharmaceutically acceptable carriers and excipients, in preformulated dosages. The administration of an effective amount of the compound will result in an increase in α-Gal A activity of the cells of a patient sufficient to improve the symptoms of the patient. It is expected that an enzyme activity level of 30% of normal could significatly improve the symptoms in Fabry patients, because the low range of enzyme activity found in apparently normal persons is about 30% of the average value (2).
Compounds disclosed herein and other competitive inhibitors for α-Gal A which will be known to those of skill in the art will be useful according to the invention in methods of enhancing the intracellular activity of α-Gal A and treating Fabry disease.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C. In vitro inhibition ( 1 A) and intracellular enhancement ( 1 B and 1 C) of α-Gal A by alkaloid compounds. The alkaloid compounds used were: (1) 2,5-Dideoxy-2,5-imino-D-mannitol, (2) α-Homonojirimycin, (3) 3,4-Diepi-α-homonojirimycin, (4) 5—O—α-D-Galactopyranosyl-α-homonojirimycin, (5) 1-deoxygalactonojirimycin, (6) 4-epi-Fagomine, (7) 1-Deoxy-nojirimycin, (Gal) Galactose. The intracellular α-Gal A activity in COS-1 cells transfected by cDNA of a mutant α-Gal A (R301Q) was assayed as described in “Methods”. (A) The inhibition assay was performed under the Methods. IC 50 ′s of the compounds were 1.3 mM (1), 2.6 mM (2), 2.9 μM (3), 0.62 mM (4), 4.7 nM (5), 0.25 mM (6), 0.8 mM (7), and 24 mM (Gal, galactose), respectively.
FIGS. 2A-2B. Enhancement of α-Gal A by DGJ in fibroblasts derived from Tg mice ( 2 A) and lymphoblasts derived from Fabry patients ( 2 B).
FIG. 3 . Time courses of enhancement of α-Gal A by DGJ in TgM fibroblasts (A) and lymphoblasts (B). The cell cultures were performed under the Methods section. DGJ concentration added was 20 μM. The genotype of the human lymphoblasts was R301Q. , mutant cell cultured without DGJ; ∘, mutant cell cultured with DGJ; ▴, normal lymphoblast cultured without DGJ; Δ, normal lymphoblast cultured with DGJ.
FIG. 4 . DGJ concentration dependence of α-Gal A enhancement in transfected COS-1 cells (A), TgM fibroblasts (B) and lymphoblasts with a genotype of R301Q (C). The cells were cultured at 37° C. in Ham's F-10 medium (COS-1 cells, TgM fibroblasts) or RPMI-1640 medium supplemented with 10% FCS (lymphoblasts) containing DGJ at a variable concentration for 4 days. The cDNA transfected into COS-l cells encoded a mutant α-Gal A (R301Q).
FIG. 5 . DE-HNJ concentration dependence of α-Gal A enhancement in transfected COS-1 cells.
FIG. 6 . Stabilization of DGJ enhanced α-Gal A in lymphoblasts. Δ, R301Q lymphoblasts cultivated without DGJ; ▴, R301Q lymphoblasts cultivated with DGJ.
FIG. 7 . TLC analysis of metabolism of [ 14 C]-CTH in TgN fibroblasts cultured with DGJ. The TgN fibroblasts were cultured at 37° C. in Ham's F-10 medium-10% FCS containing DGJ at 0 (lane 1), 2 (lane 2) and 20 μM (lane 3) for 4 days. After washing with the medium without DGJ, [ 14 C]-CTH (200,000 cpm) in 2.5 ml of Opti-MEM medium (Gibco, Gaithersburg, Md. U.S.A.) was added to the cells, and incubated for 5 hr. The cells were washed with 2 ml of 1% BSA and 2 ml of PBS three times each. The neutral glycolipids were extracted by CHCl 3 : MeOH (2:1), and purified by mild alkaline treatment, extraction with MeOH:n-hexane (1:1) and Folch extraction (19).
FIG. 8 A. Determination of mRNA of ax-Gal A in mutant lymphoblasts (R301Q) cultured with DGJ. The human mutant lymphoblasts (R301Q) were cultured with or without 50 μM DGJ for 4 days. The mRNAs of α-Gal A were determined by a compeititve RT-PCR method (15).
FIG. 8 B. Western blot of mutant α-Gal A (R301Q) expressed in TgM fibroblasts. The supernatant of cell homogenate containing 10 μg protein was applied to SDS-PAGE, and Western blot was performed with an anti-α-Gal A antibody raised in rabbit.
FIG. 9 . Percoll density-gradient centrifugation with TgM fibroblasts (A), TgM fibroblasts cultured with 20 μM DGJ (B), and TgN fibroblasts (C). The Percoll density-gradient centrifugation was performed with density markers (Sigma Chemical Co., St. Louis, Mo., U.S.A.) as previously described by Oshima et al. (8). β-Hexosaminidase, a lysosomal marker enzyme, was assayed with 4-methylumbelliferyl-β-N-actyl-D-glucosamine as substrate. Solid line, α-Gal A activity; broken line, β-hexosaminidase activity.
FIG. 10 . Enhancement of α-Gal A in transfected COS-1 cells by DGJ. The cDNA's transfected to COS-1 cells were α-Gal A's with the mutations on L166V, A156V, G373S and M2961. DGJ concentration added was 20 μM.
FIG. 11 . Enhancement of α-Gal A activity by administration of DGJ to TgM mice. DGJ solutions (0.05 mM or 0.5 mM) were placed as drink sources for TgM mice (four mice as a group). After 1 week administration, the organs were homogenized for the determination of the enzyme activity. The data were the subtraction of endogenous mouse α-Gal A activity obtained from non-Tg mice feeding with DGJ from the activity of TgM mice. The enzyme activities presented were the mean values and the standard deviations were less than 10%.
DETAILED DESCRIPTION OF THE INVENTION
Abbreviations
Abbreviations used herein are set forth below for convenience: α-Gal A, human lysosomal α-galactosidase A; TgN mouse, a transgenic mouse overexpressing normal human lysosomal α-galactosidase A; TgM mouse, a transgenic mouse overexpressing a mutant human lysosomal α-galactosidase A with a single amino acid replacement of Arg at 301 position by Gln (R301Q); TgN fibroblast, fibroblast generated from a TgN mouse; TgM fibroblast, fibroblast generated from a TgM mouse; DGJ, 1-deoxy-galactonojirimycin; DE-HNJ, 3,4-di-epi-(α-homonojirimycin; pNP-α-Gal, ρ-nitrophenyl-α-D-galactoside; 4-mU-α-Gal, 4-methylumbelliferyl-α-D-galactoside; FCS, fetal calf serum; PBS, phosphate-buffered saline; BSA, bovine serum albumin; TLC, thin-layer chromatography; CTH, globotriaosylceramide or ceramide trihexoside; CDH, ceramide dihexoside; CMH, ceramide monohexoside; ER, endoplasmic reticulum.
Materials and Methods
Materials. Alkaloidal compounds were either purified from plants or partial chemical modified derivatives of the plant products (9). TgN and TgM mice were generated as previously reported (10, 11). TgN or TgM fibroblasts were established from TgN or TgM mouse as routine. Human lymphoblasts were Epstein-Barr virus-transformed lymphoblast lines from a normal adult or patients with Fabry disease (6). Normal and mutant α-Gal A cDNAs for transient express in COS-1 cells were cloned as reported (12). α-Gal A for in vitro inhibition study of alkaloids was expressed and purified from the culture medium of Sf-9 cells infected by a recombinant baculovirus encoded normal α-Gal A gene (13). [ 14 C]-CTH was prepared by a combination of chemical and sphingolipid ceramide N-deacylase reactions (14).
Methods
Cell culture. COS-1 cells, TgN and TgM fibroblasts were cultured in Ham's F-10 medium supplemented with 10% FCS and antibiotics. Lymphoblasts were cultured in RPMI-1640 with 10% FCS and antibiotics. All cell cultures were carried out at 37° C. under 5% CO 2 . As a model for fibroblasts and lymphoblasts, cells (3x105 for fibroblasts and 5×10 5 for lymphoblasts) were cultured in 10 ml of the preferred medium with or without DGJ at 20 μM for 4 days before taken to the assay for intracellular enzyme activity.
Transient expression of α-Gal A in COS-1 cells. COS-1 cells (5×10 5 ) were transfected with 1 μg of plasmid DNA and 8 μl Lipofectamine (Gibco, Gaithersburg, Md. U.S.A.) in 1.2 ml Opti-MEM medium (Gibco) per 60-mm dish. After incubating at 37° C. for 6 hr, 1.2 ml of the same medium containing 20% FCS was added and the culture was incubated overnight. After replacing the medium with 2.4 ml complete Ham's F-10 medium, alkaloid was added at an appropriate concentration, and further incubated for 1 day, before taken to the assay for intracellular enzyme activity.
Intracellular enzyme assay for α-Gal A. After washing with phosphate-buffered saline twice, the cells were homogenized in 200 μl of H 2 O, and 10 μl of the supernatant obtained by centrifugation at 10,000×g was incubated at 37° C. with 50 μl of the substrate solution composed by 6 mM 4-mU-α-Gal and 90 mM N-acetylgalactosamine in 0.1 M citrate buffer (pH 4.5) for the enzyme assay. All the data are the averages of triplicate measurements with standard deviation less than 10%. One unit of enzyme activity was defined as one muol of 4-methylumbelliferone released per hour at 37° C.
In vitro inhibition assay of α-Gal A. The enzyme activity was assayed with pNP-α-Gal as substrate. A typical inhibition reaction was performed in a mixture of 200 nmol pNP-α-Gal, appropriate enzyme and inhibitor in a total volume of 120 μl with 0.05 M citrate buffer (pH 4.5). After incubation at 37° C. for 15 min, the reaction was terminated by addition of 1 ml of 0.2 M borate buffer (pH 9.8), and the amount of pNP released was measured as the absorbance at 490 nm.
EXAMPLE 1
A series of plant alkaloids (Scheme 1, ref. 9) were used for both in vitro inhibition and intracellular enhancement studies of α-Gal A activity. The results of inhibition experiments are shown in FIG. 1 A.
Among the tested compounds, 1-deoxy-galactonojirimycin (DGJ, 5) known as a powerful competitive inhibitor for α-Gal A, showed the highest inhibitory activity with IC 50 at 4.7 nM. α-3,4-Di-epi-homonojirimycin (3) was an effective inhibitor with IC 50 at 2.9 μM. Other compounds showed moderate inhibitory activity with IC 50 ranging from 0.25 mM (6) to 2.6 mM (2). Surprisingly, these compounds also effectively enhanced α-Gal A activity in COS-1 cells transfected with a mutant α-Gal A gene (R310Q), identified from an atypical variant form of Fabry disease with a residual α-Gal A activity at 4% of normal. By culturing the transfected COS-1 cells with these compounds at concentrations cat 3-10-fold of IC 50 of the inhibitors, α-Gal A activity was enhanced 1.5-4-fold (FIG. 1 C). The effectiveness of intracellular enhancement paralleled with in vitro inhibitory activity while the compounds were added to the culture medium at 10 μM concentration (FIG. 1 B).
EXAMPLE 2
DGJ, the strongest inhibitor in vitro and most effective intracellular enhancer, was chosen for more detailed characterization. DGJ was added to the TgM or TgN fibroblasts (FIG. 2A) and lymphoblasts derived from Fabry patients with genotypes of R301Q or Q279E mutations (FIG. 2 B). The enzyme activity found in TgM fibroblasts increased 6-fold by co-cultivation with 20 μM DGJ and reached 52% of normal. The DGJ also showed a similar effect on lymphoblasts in which the residual enzyme activity was enhanced by 8- and 7-fold in R301Q and Q279E, i.e., 48% and 45% of normal. The enzyme activity in Tg normal (TgN) fibroblasts and normal lymphoblasts also showed an increase by cultivation with DGJ.
EXAMPLE 3
The TgM fibroblasts and human lymphoblasts of normal and patient with a mutation on R301Q were cultured in the presence of DGJ at 20 μM. In the cultures without DGJ, the α-Gal A activity in TgM fibroblasts or mutant lymphoblasts was unchanged (FIG. 3 ). However, by including DGJ, the enzyme activity showed significantly increase in these cell cultures. The enzyme activity in mutant lymphoblasts reached to 64% of those found in normal lymphoblasts cultured without DGJ at the fifth day. The enzyme activity in normal lymphoblasts was also enhanced 30% after cultivation with DGJ.
EXAMPLE 4
DGJ concentration dependence of α-Gal A enhancement in transfected COS-1 cells, TgM fibroblasts and lymphoblasts with a phenotype of R301Q was examined.
As shown in FIG. 4, the enzyme activity increased with the increase in the concentration of DGJ in the range of 0.2-20 μM in transfected COS-1 cells (FIG. 4A) and lymphoblasts (FIG. 4 C), and between 0.2-200 μM in TgM fibroblasts (FIG. 4 B), respectively. A higher concentration of DGJ suppressed the enhancement effect.
DE-HNJ showed the same effect on the enhancement of α-Gal A in COS-1 cells transfected with a mutant cDNA of the enzyme (R301Q) at the higher concentrations (1-1000 μM) compared with DGJ (FIG. 5 ). It is clear that DE-HNJ at 1 mM in culture medium did not inhibit intracellular enzyme activity of COS-1 cells.
EXAMPLE 5
FIG. 6 shows an experiment to measure stabilization of DGJ enhanced α-Gal A in lymphoblasts. The cells were cultured at 37° C. in 10 ml RPMI-1640 medium supplemented with 10% FCS containing DGJ at 20 μM for 4 days, and 5×10 5 cells were transferred to 13 ml of RPMI1640 with 10% FCS without DGJ. Two ml of the medium was taken each day for the enzyme assay. The initial surplus of the total α-Gal A activity between pre-cultivation with and without DGJ was maintained for 5 days after replacement of the medium without DGJ (FIG. 6 ), suggesting that the enhanced enzyme is stable in the cells for at least 5 days.
EXAMPLE 6
To study the functioning of the enhanced enzyme in the cells, [ 14 C]-CTH was loaded to the culture of TgN fibroblasts.
The determination of glycolipid was performed by thin-layer chromatography using CHCl 3 :MeOH:H 2 O (65:25:4) as a developing solvent, and visualized by a Fuji-BAS imaging system (FIG. 7 ). The amount of ceramide di-hexoside (CDH), a metabolic product of CTH by α-Gal A, was comparable between the cells cultivated with 20 μM DGJ and without DGJ (4.5% vs. 4.3% of the total neutral glycolipids), indicating that the intracellular enzyme is not inhibited by DGJ at the concentration used.
EXAMPLE 7
In order to determine whether DGJ affects the biosynthesis of α-Gal A, the level of α-Gal A mRNA in mutant lymphoblasts (R301Q) cultured with DGJ were measured by a competitive polymerase chain reaction (PCR) method (15). FIG. 8A clearly shows that the mRNA of α-Gal A was unchanged by cultivation of lymphoblasts with 50 μM of DGJ.
On the other hand, Western blot analysis indicated a significant increase of the enzyme protein in TgM fibroblasts, and the increase corresponded to the concentration of DGJ (FIG. 8 B). More enzyme protein with lower molecular weight (ca. 46 kD) in the cells cultivated with DGJ suggested the higher level of matured enzyme (16). These results indicate that the effect of DGJ on enhancement of the enzyme is a post-transcriptional event.
EXAMPLE 8
To confirm the enhanced enzyme is transported to the lysosome, a sub-cellular fractionation was performed with Tg mice fibroblasts (FIG. 8 ). The overall enzyme activity in TgM fibroblasts was lower and eluted with a density marker of 1.042 g/ml which contained Golgi apparants fractions (20) (FIG. 9 A). By cultivation with 20 μM DGJ, the enzyme activity in TgM fibroblasts showed higher overall enzyme activity and the majority of the enzyme eluted with the same fraction of a lysosomal marker enzyme, β-hexosaminidase (FIG. 9 B). The elution pattern of (x-Gal A activity in TgM was also changed to those found in TgN fibroblasts (FIG. 9 C).
EXAMPLE 9
The genotypes of R301Q and Q279E were found from patients with atypical type of Fabry disease. The effectiveness of DGJ on enhancement of α-Gal A activity was examined with other genotypes and phenotypes of Fabry disease. In this experiment, three mutant α-Gal A cDNA's, L166V, A156V and G373S found in patients with classical type of Fabry disease and a mutation of M2961 found from patients with atypical form of the disease were used. FIG. 10 shows that the inclusion of DGJ increased enzyme activity in all four genotypes tested, especially for L166V (7-fold increase) and A156V (5-fold increase). The data indicated that this approach is useful not only for the atypical form, but also classical form of the disease.
EXAMPLE 10
DGJ was administrated to Tg mice by feeding 0.05 or 0.5 mM DGJ solutions as drinking source for a week corresponding to the dosage of DGJ at approximate 3 or 30 mg per kilogram of body weight per day. The enzyme activity was elevated 4.8- and 18-fold in heart, 2.0- and 3.4-fold in kidney, 3.1- and 9.5-fold in spleen and 1.7- and 2.4-fold in liver, respectively (FIG. 11 ). The increase of the enzyme activity in organs responded to the increase of DGJ dosage. Since the mutant gene (R301Q) was found in atypical variant type Fabry patients which have clinical symptoms limited to heart, the fact that oral adiministration of DGJ specifically enhances the α-Gal A activity in the heart of TgM mouse is particularly significant.
DISCUSSION
It is known that the ER possesses an efficient quality control system to ensure that transport to the Golgi complex is limited to properly folded and assembled proteins, and the main process of the quality control is enforced by a variety of chaperons (17). One explanation of the results presented in the present application is as follows: In some phenotypes of Fabry disease, the mutation causes imperfect, but flexible folding of the enzyme, while the catalytic center remains intact. Inhibitors usually have high affinity to the enzyme catalytic center, and the presence of the inhibitor affixes the enzyme catalytic center and reduces the flexibility of folding, perhaps leading to the “proper” conformation of the enzyme. As a result, the enzyme could be passed through the “quality control system”, and transported to Golgi complex to reach maturation. Once the enzyme is transported to lysosome where the pH is acidic, the enzyme tends to be stable with the same conformation, because the enzyme is stable under the acidic condition (6). In such cases, the inhibitor acts as chaperon to force the enzyme to assume the proper conformation. We propose to use “chemical chaperon” as a term for such low molecular weight chemical with such functions.
It is crucial for the functioning of the enzyme that the smooth dissociation of the compound from the enzyme catalytic center in lysosome could be taken. Since the compounds used in this study are competitive inhibitors, the dissociation of the inhibitors depends upon two factors: (i) the inhibitor concentration, and (ii) pH. Dale et al. (18) have shown that binding of 1-deoxynojirimycin to α-glucosidase is pH dependent where the inhibitor bound to the enzyme 80-fold more tightly at pH 6.5 compared to pH 4.5, suggesting that the nojirimycin derivatives function as an unprotonated form. This may explain the results on the functioning of α-Gal A in cells shown in FIG. 7, because the inhibitor can bind to the enzyme at neutral condition, and release from the enzyme at the acidic condition where DGJ tends to be protonated.
The results described herein show that DGJ can effectively enhance mutant α-Gal A activities in lymphoblasts of patients with atypical variant of Fabry disease with genotypes of R301Q and Q279E. The effectiveness of DGJ on other phenotypes of Fabry mutation including classical and atypical forms has also been examined. DGJ effectively enhanced the enzyme activity in all three genotypes of cell strains derived from patients diagnosed as atypical Fabry disease, and some of the cell strains with classical Fabry forms having high residual enzyme activity. According to the present invention, a strategy of administrating an α-Gal A inhibitor should prove tobe an effective treatment for Fabry patients whose mutation occurs at the site other than catalytic center, and also should be useful for other glycosphingolipid storage diseases.
References cited herein are hereby incorporated by reference and are listed below for convenience:
1. R. O. Brady, A. E. Gal, R. M. Bradley, E. Martensson, A. L. Warshaw, and L. Laster, N. Engl. J. Med. 276, 1163 (1967).
2. R. J. Desnick, Y. A. Ioannou, and C. M. Eng, in The Metabolic and Molecular Bases of Inherited Disease , eds. C. R. Scriver, A. L. Beaudet, W. S. Sly, and D. Valle (McGraw-Hill, New York), pp. 2741 (1995).
3. S. Nakao, T. Takenaka, M. Maeda, C. Kodama, A. Tanaka, M. Tahara, A. Yoshida, M. Kuriyama, H. Hayashibe, H. Sakuraba, and H. Tanaka, N. Engl. J Med. 333, 288 (1995).
4. E. Beutler, Science 256, 794 (1992); F. M. Platt, G. R. Neises, G. Reikensmeier, M. J. Townsend, V. H. Perry, R. L Proia, B Winchester, R. A. Dwek, and T. D. Butters, Science 276, 428 (1997).
5. G. Romeo, M. D'Urso, A. Pisacane, E, Blum, A. de Falco, and A. Ruffilli, Biochem. Genet 13, 615 (1975); D. F. Bishop, G. A. Grabowski, and R. J. Desnick, Am. J. Hum. Genet 33, 71A (1981).
6. S. Ishii, R. Kase, H. Sakuraba, and Y. Suzuki, Biochem. Biophys. Res. Comm. 197, 1585 (1993).
7. S. Ishii, R. Kase, T. Okumiya, H. Sakuraba, and Y. Suzuki, Biochem. Biophys. Res. Comm. 220, 812 (1996).
8. A. Oshima, K. Yoshida, K. Itoh, R. Kase, H. Sakuraba, and Y Suzuki, Hum Genet 93, 109( 1994).
9. N. Asano, K. Oseki, H. Kizu, and K. Matsui, J. Med. Chem. 37, 3701 (1994); N. Asano, M. Nishiba, H. Kizu, K. Matsui, A. A. Watson, and R. J. Nash, J. Nat. Prod. 60, 98 (1997).
10. M. Shimmoto, R. Kase, K. Itoh, K. Utsumi, S. Ishii, C. Taya, H. Yonekawa, and H. Sakuraba, FEBS Lett 417, 89 (1997).
11. S. Ishii, R. Kase, H. Sakuraba, C. Taya, H. Yonekawa, T. Okumiya, Y. Matsuda, K. Mannen, M. Tekeshita, and Y. Suzuki, Glycoconjugates J . in press (1998).
12. T. Okumiya, S. Ishii, T. Takenaka, R. Kase, S. Kamei, H. Sakuraba, and Y. Suzuki, Biochem. Biophys. Res. Comm. 214, 1219 (1995)
13. S. Ishii, R. Kase, H. Sakuraba, S. Fujita, M. Sugimoto, K. Tomita, T. Semba, and Y. Suzuki, Biochim. Biophys. Acta 1204, 265 (1994).
14. S. Neuenhofer, G. Schwarzmann, H. Egge, and K. Sandhoff, Biochemistry 24, 525 (1985); S. Mitsutake, K. Kita, N. Okino, and M. Ito, Anal. Biochem. 247, 52 (1997).
15. G. Gilliland, S. Perrin, K. Blanchard, and H. F. Bunn, Proc. Natl. Acad. Sci. USA 87, 2725 (1990); TaKaRa Bio Catalog Vol. 1, D-59 (1997).
16. P. Lemansky, D. F. Bishop, R. J. Desnick, A. Hasilik, K. Von Figura, J Biol. Chem. 262, 2062 (1987).
17. S. M. Hurtley, and A. Helenius, Annual Rev. Cell Biol. 5, 277 (1989).
18. M. P. Dale, H. E. Ensley, K. Kern, K. A. R. Sastry and L. D. Byers, Biochemistry 24, 3530 (1985).
19. Folch et al. J. Biol. Chem. 226:497 (1957).
20. Fleisher, S. and M. Kervina, Methods in Enzymology 31, 6 (1974).
It will be appreciated that various modifications may be made in the invention as described above without departing from the scope and intent of the invention as defined in the following claims wherein: | A method of enhancing the activity of lysosomal α-Galactosidase A (α-Gal A) in mammalian cells and for treatment of Fabry disease by administration of 1-deoxy-galactonojirimycin and related compounds. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a braking device disposed within a recess of a transmission case which contains an axle driving system for a working vehicle.
2. Prior Art
A conventional working vehicle is disclosed in U.S. Pat. No. 4,706,770 to Simon. This vehicle includes a drive system which transmits power from a prime mover to driven axles through a belt-type non-stage transmission and an axle driving system.
This axle driving system includes a forward-backward travel changeover device, a differential gear, and a front pair of driven axles, all housed within a transmission casing. Sprockets disposed on the axial ends of the front pair of driven axles transmit power through a chain to a rear pair of driven axles.
The forward-backward travel change-over device comprises an input shaft which selectively drives an intermediate shaft either forward through gears or backward through sprockets and a chain. The intermediate shaft drives the front pair of driven axles through a differential gear. The braking system comprises a disc brake disposed at one axial end of the intermediate shaft.
The disc brake is disposed along the drive route before the differential gear. As a result, the differential gear may operate while the brake is being applied if the loads on the axles are different. For example, if the brake is applied while traversing a slope, the differential gear tends to cause the vehicle to turn. Previous attempts to solve this problem provide a differential locking device disposed on the rear pair of axles, which locks the axles together during braking, making them rotate in unison. However, the durability and braking capacity of conventional solutions, such as differential locking devices, is less than optimal.
SUMMARY OF THE INVENTION
The present invention relates to a braking system for a working vehicle. The object of the present invention is to create a braking system that has better durability and braking capacity than previous systems. The braking system of the present invention enables the vehicle to stop without a tendency to turn, notwithstanding the presence of a differential gear. In addition, the braking system of the present invention is easier to assemble than the prior art, and also increases the support rigidity of the axles.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a side view of a working vehicle equipped with an axle driving system and a braking device;
FIG. 2 is a plan view of the driving system between a prime mover shaft and front and rear drive axles;
FIG. 3 is a side view of the axle driving system;
FIG. 4 is a plan view of the same;
FIG. 5 is a sectional rear view of the same;
FIG. 6 is a perspective view of a brake operating mechanism;
FIG. 7 is a sectional rear view of the axle driving system showing a differential locking mechanism;
FIG. 8 is a sectional side view of part of a forward-backward travel speed change mechanism of the axle driving system;
FIG. 9 is a perspective exploded view of a pair of transmission cases and the braking device; and
FIG. 10 is a perspective sectional view in part showing the mounting of the transmission case to a body frame.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a side view of a working vehicle with an axle driving system equipped with a braking device of the present invention. A front wheel 50 steers the vehicle. Two pairs of rear wheels, front drive wheels 47 and rear drive wheels 48, are driven by a pair of front driving axles 45 and a pair of rear driving axles 46, respectively.
A load carrying platform 49 is disposed on a vehicle body frame 54 above front drive wheels 47 and rear drive wheels 48. A seat S is disposed between front wheel 50 and front driving wheels 47. A brake pedal 32 is disposed to the left and below seat S. A hand brake lever 33 is also disposed to the left of seat S.
A prime mover pulley 40 is fixed to a prime mover shaft 42. Prime mover shaft 42 is disposed in a compartment 52 under seat S. Prime mover pulley 40 transmits driving power to a speed change pulley 41 through a V-belt 39. Speed change pulley 41 and prime mover pulley 40 can have different diameters, resulting in a drive ratio different than 1:1 between the two pulleys.
FIG. 2 shows a how power is transmitted from prime mover shaft 42 to driving axles 45 and 46. Speed change pulley 41 is fixed to an input shaft 2, which projects from a transmission case ML. Transmission case ML is coupled to transmission case MR. Within transmission cases ML and MR, input shaft 2 drives a pair of output shafts 1L and 1R which project laterally from transmission cases ML and MR respectively. Front driving axles 45 are connected to the output shafts 1L and 1R through joints 43.
Front driving axles 45 and rear driving axles 46 are journalled to body frame 54. Front driving axles 45 transmit power through sprockets 58, chain 44, and sprockets 59 to rear driving axles 46.
FIGS. 3, 4, and 5 show the axle driving system is disposed within transmission cases ML and MR. Specifically, input shaft 2 is journalled to transmission cases ML and MR. A forward gear 11 and a backward sprocket 12 are freely fitted on the input shaft 2. A forward-backward travel changeover element 22 is spline coupled to input shaft 2, and selectively engages either forward gear 11 or backward sprocket 12 with input shaft 2.
Forward gear 11 permanently engages with a gear 13 fixed to counter shaft 15. Backward sprocket 12 is permanently engaged with a sprocket 14 fixed to counter shaft 15 through a chain 21. When forward-backward travel change-over element 22 engages forward gear 11 with input shaft 2, input shaft 2 drives counter shaft 15 in the forward direction through gears 11 and 13. When forward-backward travel change-over element 22 engages backward sprocket 12 with input shaft 2, input shaft 2 drives counter shaft 15 in the backward direction through sprockets 12 and 14 and chain 21.
A gear 16 is fixed to counter shaft 15 and engages with a ring gear 17 of a differential gear 20. The rotation of counter shaft 15 is transmitted to left and right output shafts 1L and 1R by ring gear 17 and differential gear 20. Differential gear 20 can be locked by a differential lock slider 18 and a differential lock pin 19, making output shafts 1L and 1R integrally rotatable.
Transmission oil can be changed through oil change plug 51.
FIGS. 3, 5, and 6 show the braking device for output shafts 1L and 1R of the present invention. The following description is directed to the left brake, but also applies to the right brake. A recess 55 is formed on the outside transmission cases ML. An actuator 7, a drive side friction plate 8, and a brake side friction plate 9, are disposed within recess 55. Recess 55 is covered by a lid 5, so that the output shafts 1L and 1R and brake cam shafts 3 perforate lid 5 and project outwardly.
Output shaft 1L is journalled to transmission case ML by first bearing means 56, and protrudes from transmission case ML into recess 55. Output shaft 1L extends through recess 55, and is journalled to lid 5 by second bearing means 57.
A brake cam shaft 3 is journalled through lid 5. One axial end of brake cam shaft 3 is rotatably supported by transmission case ML. A brake cam 3a is formed on the part of brake cam shaft 3 that extends into recess 55. A brake arm 4 is fixed to the part of brake cam shaft 3 that projects outward from lid 5.
Drive side friction plates 8 are engaged with output shaft 1L by spline grooves 1a in output shaft 1L and corresponding spline bores in plates 8. Drive side friction plates 8 are disposed between brake side friction plates 9. Protrusions on the circumference of brake side friction plates 9 are fitted into corresponding grooves along the inner periphery of the recess 55. This arrangement allows drive side friction plates 8 and brake side friction plates 9 to slide in the direction of the axis of output shaft 1L. However, drive side friction plates 8 rotate integrally with output shaft 1L, while brake side friction plates cannot rotate relative to transmission case ML about the axis of output shaft 1L.
When actuator 7 is not actuated by a thrust generating mechanism as discussed below, friction is not generated between brake side friction plates 9 and drive side friction plates 8, and output shafts 1L and 1R and their associated friction plates 8 are freely rotatable.
Next, the thrust generating mechanism for biasing brake side friction plates 9 and drive side friction plates 8 against each other through actuator 7 will be explained. Actuator 7 is annular in shape, and fits into a cylindrical groove 5a in lid 5. A projecting engaging portion 7a of actuator 7 abuts against brake cam 3a. When brake arm 4 rotates brake cam shaft 3, the brake cam 3a pushes projecting engaging portion 7a, causing actuator 7 to rotate around output shaft 1L. Actuator 7 is separated from lid 5 by a cam member 6, which is held fixed relative to lid 5 by a holding bore 5b. Cam member 6 also abuts against a cam groove 7c in actuator 7. In one embodiment, cam member 6 is a steel ball, and cam groove 7c is shaped substantially like a teardrop, as shown by FIG. 3. As brake cam 3a rotates actuator 7, cam member 6 abuts against a shallower part of cam groove 7c, forcing actuator 7 farther away from lid 5 along the axis of output shaft 1L, toward drive side friction plates 8 and brake side friction plates 9. Actuator 7 then presses drive side friction plates 8 against brake side friction plates 9, resulting in friction which brakes the rotation of drive side friction plates 8 and output shaft 1L.
FIG. 7 shows the mechanism used by the operator to operate the brake. Brake pedal 32 is operably connected to an arm 35 by a rod, a wire or the like (not shown). Hand brake lever 33 is connected to an engaging pin 35a protruding from arm 35 by means of a slot shaped link 34. When hand brake lever 33 is in the non-braking position, engaging pin 35a can move vertically within a slot 34a, so that brake pedal 32, when depressed, can move arm 35 free from interference by hand brake lever 33 and slot shaped link 34. As a result, the operator can use either brake pedal 32 or hand brake lever 33 to rotate arm 35 about the axis of a rotary shaft 36.
Arm 35 is fixed to rotary shaft 36, as are a pair of arms 53. A pair of links 37 project through holes in arms 53. Links 37 are operably connected to arms 53 by a pair of biasing springs 38 which are sleeved around links 37. Links 37 are also attached to brake arms 4.
When the operator either depresses brake pedal 32 or pulls hand brake lever 33, arm 35 and rotary shaft rotate about the axis of rotary shaft 36. Arms 53, fixed to rotary shaft 36, also rotate. The rotation of arms 53 moves links 37 through biasing springs 38, causing brake arms 4 and brake cam shafts 3 to rotate about the axis of brake cam shafts 3, actuating the brake as described above.
The embodiment set forth above has several advantageous features. The operator is able to simultaneously operate all of the brakes by depressing a single pedal or pulling a single handle. In addition, any excessive operating force of brake pedal 32 is absorbed by biasing springs 38, preventing damage to the braking unit and other nearby parts. Furthermore, as seen from FIG. 3, brake cam shafts 3 and a shifter shaft 30 are mounted to transmission cases 1L and 1R at positions substantially symmetrical about a vertical imaginary line X--X running through output shafts 1L and 1R, resulting in a compact transmission.
FIGS. 5 and 8 show how differential lock slider 18 is operated. A control mechanism (not shown) controls the position of a wire 61. Wire 61 is attached to a biasing arm 29 which pivots around a bracket 31, and abuts against a shifter shaft 30. Differential lock pin 19 is fixed to differential lock slider 18 which is fixed to a differential lock shifter 28 which is in turn fixed to shifter shaft 30. When wire 61 is pulled, biasing arm 29 rotates about bracket 31 and depresses shifter shaft 30. When shifter shaft 30 moves, differential lock pin locks a differential side gear 62 to a differential case 63, making output shafts 1L and 1R integrally rotatable.
FIGS. 5 and 9 show how forward-backward travel change-over element 22 is operated. A forward-backward travel speed-change arm 24 rotates a forward-backward travel speed-change lever shaft 23, which controls the position of a shifter arm 26 and a shifter pawl 27. Shifter pawl 27 controls the axial position of forward and backward travel change-over element 22 along the axis of input shaft 2. The axial position of forward and backward travel change-over element 22 determines whether forward gear 11 or backward sprocket 12 rotates integrally with input shaft 2 as discussed above.
A forward-backward travel speed-change sensor 10 senses movement of shifter arm 26. Forward-backward travel speed-change sensor 10 detects when shifter arm 26 is in a neutral position, and operates as a switch so that the axle driving system can only be started when shifter arm 26 is in a neutral position.
FIGS. 3 and 10 show the means by which transmission cases ML and MR are mounted onto frame 54. A pair of mounting eyes are positioned underneath brake cam shafts 3 and shifter shaft 30, lower than output shafts 1L and 1R. A projection 101 extends laterally above each mounting eye 100. During assembly, transmission cases ML and MR housing the axle driving system are loaded onto body frame 54 and temporarily supported by projection 101. Transmission cases ML and MR are then slid longitudinally until a threaded bore in mounting eye 100 aligns with a bolt insertion bore 104 in body frame 54. A bolt 102 is then inserted and screwed into the threaded bore in mounting eye 100 and bolt insertion bore 104, completing assembly of the braking device. Using this method facilitates assembly work and reduces labor.
While preferred embodiments have been set forth, various modifications, alterations, and changes may be made without departing from the spirit and scope of tile present invention as defined in the appended claims. | The present invention relates to a braking system for an axle driving system for a working vehicle. The braking system comprises disc brake units which are disposed in recesses provided at the right and left sides of a transmission case, and a brake pedal and/or a hand-brake lever which can operate the disc brake units simultaneously. The construction of the present invention results in increased durability and braking capacity. The present invention allows the vehicle to travel in a straight line while stopping, notwithstanding the presence of a differential gear. In addition, the braking device is easily assembled and results in increased support rigidity for the axles. | 1 |
This application is a continuation of application No. 08/050,677, filed Apr. 21, 1993, now abandoned.
FIELD OF THE INVENTION
The present invention is concerned with an improved drinking cup that is especially suitable for use with hot liquids such as coffee or tea. The improved drinking cup of the present invention permits the user to drink hot liquids without discomfort or injury to the user's hand from the heat transmitted from the hot liquid through the cup sidewall. More particularly, the present invention is concerned with an improved cup which is characterized by a series of vertically oriented, generally triangular ribs which form a series of generally triangular liquid holding projections. The ribs are provided in sufficient number so that the user's hand will contact the ribs without coming into full contact with the sidewall of the body of the cup. Most particularly, the present invention provides a hot liquid cup which provides protection against discomfort or injury from the hot liquid within and improved sidewall strength to avoid crushing.
DESCRIPTION OF THE PRIOR ART
Disposable drinking cups of both paper and synthetic resin materials are well known. There are many simple paper or synthetic cups which are acceptable for holding cold or luke warm beverages. However, many of the prior art cups are unacceptable for use with hot drinks, such as coffee or tea, which frequently have temperatures in excess of 165° F.
In the case of paper cups, it is known that the cups will transmit the temperature through the cup sidewall. This temperature transmission generally makes it uncomfortable or painful to hold the cup about the sidewall. Many users will tend to gingerly grasp the cup at the upper or lower extremity in order to avoid direct contact with the hot sidewalls. While this is one solution to the problem of transferred heat, it is generally awkward and may contribute to spillage of the hot liquids. It is also known to provide paper cups with handles as one effort to avoid the problem associated with heat transmission through the sidewalls.
With respect to the synthetic resin cups, it is known to provide cups of a foamed synthetic material which has better insulating characteristics. While these cups may transmit some heat, they generally provide adequate protection for the hands of the user. However, the common synthetic cups, while providing insulation, are generally subject to being easily collapsed if squeezed by the user.
While the prior art cups have found many useful applications, they generally continue to exhibit two major problems. The first problem is associated with the insulating quality of the sidewalls. As the insulating quality of the sidewall is increased, the user's sense of the liquid's temperature is decreased. Accordingly, there is an increased potential for the user to attempt consumption of a beverage that is too hot to drink. Two, the prior art cups generally do not provide sufficient sidewall strength for use by older or geriatric consumers. Many geriatric users experience hand strength problems which lead to an unsure handling of cups. As a result, the geriatric user tends to squeeze the cup with a greater force than that which is necessary to secure the cup. In addition, the geriatric user's hands may have decreased sensitivity to heat. Under these conditions, the geriatric user may not appreciate the temperature of the liquid in a highly insulated cup and may attempt to consume the hot beverage. Alternatively, the geriatric user may not be able to sense the sidewall temperature until there has been some damage or burning of desensitized skin.
In view of the above problems with the prior art cups, it is the purpose of this invention to provide a cup which has increased sidewall strength along with increased temperature sensing and insulating abilities.
SUMMARY OF THE INVENTION
The preferred drinking cup has a bottom wall and an upwardly extending sidewall which are Connected to cooperatively form a liquid holding cavity. In general, the free end of the sidewall will terminate in a bead that forms the usual opening in the cup. The improved sidewall construction is characterized by a plurality of vertically oriented, generally triangular projections which extend from the sidewall of the cup and have an open base that is disposed towards the liquid holding cavity. The sidewalls of the triangular ribs extend away from the liquid holding cavity toward an intersection that is spaced from the main body of the cup. The ribs are provided in sufficient number to permit a user to grip the cup with the principle contact being made with the ribs rather than the body of the cup. The liquid which flows into the ribs provides the user with an initial temperature sensing for the liquid in the cup. In addition, the ribs provide increased sidewall strength which is particularly desired with geriatric users.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a ribbed cup in accordance with the present invention.
FIG. 2 is a section through the line 2--2 of FIG. 1.
FIG. 3 is a top plan view of the cup shown in FIG. 1.
FIG. 4 is a sectional view of an alternative embodiment of the rib configuration.
FIG. 5 is a section through the line 5--5 of FIG. 4.
FIG. 6 is a top plan view of the embodiment of FIG. 4.
FIG. 7 is a bottom plan view of the embodiment shown in FIG. 4.
FIG. 8 illustrates the shape of a prior art sidewall blank prior to being formed into a cup.
FIG. 9 illustrates the cup as formed in the prior art.
FIG. 10 illustrates a sidewall blank for a cup according to the present invention with the fold lines for the eight ribs illustrated thereon.
FIG. 11 illustrates a sidewall blank for a cup according to the present invention with the fold lines for the seven ribs illustrated thereon.
FIG. 12 illustrates three different rib configurations which are usable with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described with reference to the drawing figures. Like elements have been identified with the same numeral throughout the drawings.
With reference to FIG. 1, it can be seen that the cup 10 has a sidewall 12 which is joined at the first end 14 to a bottom wall 32 that forms the base of cup 10. The second or open end 16 of the cup 10 terminates in a bead 18 which provides a finished surface for the user's lips. The sidewall 12 includes a plurality of ribs 20. The ribs 20 are separated by sidewall segments 34. Each rib 20 has two sides, 22 and 24, which are joined with the segments 34. Sides 22 and 24 extend outwardly from the segments 34 at opposed angles of approximately 45°. The sides 22 and 24 intersect at 26. The ribs have an open base which is disposed toward the interior of the cup and the sides 22, 24 extend away from the interior of the cup. As a result of this configuration, fluid within the cup will enter into the triangular configuration of the ribs and the user will be able to sense the liquid temperature through contact with the ribs.
As can be seen from FIG. 1 each of the ribs 20 is spaced from the bead 18 by the circumferential ring 36. The circumferential ring 36 is dimensioned to permit the user's lips to contact the bead 18 without necessitating full contact with the ribs 20. The ribs 20 and the circumferential ring 36 meet at the blending points 40. The ribs 20 extend toward the base 14 and increase in depth as they approach base 14 until they reach the angled portion 28. At the end of angled portion 28 the sides 22 and 24 are brought into contact with each other at 29 to form the closed, flat rib portions 30 which continue to be Separated by the sidewall segments 34.
As can be seen with reference to FIG. 2, the interior portion 30 of ribs 20 and adjoining sidewall segments 34 are joined with the bottom wall 32 to form the closed end of the cup. It can also be seen from FIG. 2 that the cup 10 has a lower diameter 42 which is less than the upper diameter 44 of the cup 10. This allows the cups to be stacked in a nested fashion. As can be seen by reference to FIGS. 2 and 3, the increased rib size or taper from circumferential ring 36 toward the lower angular portions 28 causes the sidewall segments 34 to move inwardly. This configuration combines with the open base of the ribs 20 to facilitate stacking. FIGS. 1, 2, and 3 illustrate a cup with twelve ribs.
As will be apparent from the above description, a hot liquid placed within the cup 10 will enter into the open ribs 20. The user's hand will come into contact with the intersections 26. While the fluid within the ribs 20 will be at about the same temperature as the liquid in the cup, the reduced volume in the ribs and the airflow about the ribs 20 will prevent injury to the user's hands. In addition, the user will be able to exert greater force on the cup due to the reinforcement of the sidewall through the rib configuration. This allows the user to obtain a better grip on the cup and to sense the temperature of the liquid within the cup. As a result, the user will be able to obtain a securer grip on the cup while maintaining a comfortable hand temperature.
With respect to FIGS. 4-7, the alternative embodiment will be described. This embodiment is very similar to the prior embodiment and like numerals indicate like elements. The principle difference between the present embodiment and the prior embodiment is the disposition of the ribs 20. In the prior embodiment, the ribs were formed outwardly so that the sidewall segments 34, at the point adjacent the bottom wall 32, had substantially the same diameter as the bottom wall and the ribs extended outwardly. In this embodiment, the sidewall portions 54 extend inwardly and the ribs 20 are configured so that the interior portion 60 of the ribs 20 and the adjoining sidewall segments 54 have a common circumference. At this point, the diameter of the sidewall is substantially uniform and fits about the bottom wall 32. Accordingly, the ribs do not extend beyond the circumference defined by the sidewall. As in the prior embodiment, the sidewall is a slightly conical, tubular body which is truncated just after its union with bottom wall 32 and is terminated at the other end in the bead 18.
With reference to FIG. 4, it can be seen that the angled portion 58 of this second embodiment is disposed inwardly and the ribs 22 and 24 flair away from each other at the union 59 with bottom wall 32.
As can be seen by reference to the drawing figures, the embodiment of FIG. 1 will provide a cup interior which is substantially uniform while the exterior has undergone modifications to provide the rib structure. On the other hand, the exterior of the alternative embodiment, shown in FIG. 4, will be more uniform in shape and the rib configuration will result from the modification of the interior. At present, it is believed that both rib configurations will provide increased strength in the sidewall. However, it is also believed that the configuration of the second embodiment may, because of its interiorly disposed segments 54, provide a better griping surface.
With reference to FIG. 8, there is illustrated a prior art sidewall blank 70 for forming a cup that will be approximately 4 1/2 inches high with an outer diameter of 21/2 inches at the bottom and an outer diameter of 31/2 inches at the top. See FIG. 9. As shown in FIG. 8, the prior art blank has an arcuate bottom 74, an arcuate top 76 and joining sides which taper from 76 to 74. The arc length 76 in the prior art blank of this example is approximately 101/4 inches. The effective length is approximately 10 inches since approximately 1/4 of an inch is used to form the seam 75 as shown in FIG. 9. In such prior art cups, the blank is formed as shown in FIG. 8 and then is rolled about a mandrel and sealed at 75 to form a sidewall of the type shown in FIG. 9.
In the present invention, the blank for forming the sidewall is generally rectangular, as shown in FIGS. 10 and 11. With reference to FIG. 10, the blank 80 is approximately 101/4 inches long. As with the prior art, the vertical boarders 84 and 86 will be overlapped and sealed to close the sidewall. Spaced between the vertical boarders 84 and 86 is an area of approximately 10 inches. Within this 10 inches, there are a number of ribs 20 which are formed in the blank. As illustrated in FIG. 10, there are eight ribs formed between the vertical boarders 84 and 86. As illustrated in FIG. 11, there are seven ribs formed between vertical boarders 84 and 86. Each of the ribs 20 will have opposed, identical sides 22 and 24 that are joined at intersection 26. As can be seen from FIG. 10, the ribs will appear as elongated pyramids. As discussed earlier, the ribs are separated by sidewall segments 34.
Referring now to FIGS. 10, 11, and 12, some examples of rib and segment sizes will be described. If the rib 90 is an equilateral triangle of approximately 3/16 of an inch, the blank 80 will accommodate twelve ribs spaced by 1/2 inch segments. The rib size is measured adjacent to the first end or base 14 at the point where the sidewall meets the bottom wall 32. For the embodiment illustrated by rib 92 of FIG. 12, there will be eight ribs of 1/4 inch which are spaced by segments of 3/4 of an inch. For the rib 96, there will be eight ribs of 5/16 of an inch spaced by segments of 11/16 of an inch. From these examples, it can be seen that a ten inch blank may be divided into different combinations of ribs and segments. At present, it is preferred that a ten inch blank have at least eight ribs. More preferably, a ten inch blank will have eight 1/4 inch ribs spaced by 3/4 inch segments. It has been found that this combination will provide a sufficient spacing between the intersections 26 and the segments 34 to prevent an adult user from coming into close contact with the cup body. The use of an uneven number of ribs, as illustrated in FIG. 11, will assure that there are not two ribs which are directly opposite each other.
From the above description, it will be understood that the number and size of ribs will change in accordance with the cup size. For the example of a ten inch blank as provided above, the resulting cup will be a 20 ounce cup. It will also be seen from the above description that the present cup can be stacked or nested as is commonly desired in the art. In addition, the inclusion of circumferential ring 36 and the bead 18 permits the use of a dispenser with the present cup. | A drinking cup having bottom and sidewalls which define a liquid holding cavity. The sidewalls include a plurality of vertical ribs which are formed therein with an open base disposed toward the liquid holding cavity. The ribs are present in sufficient numbers to assure that the surfaces of the ribs are the primary contact point between the user's hand and the cup. The sidewall construction provides both improved insulation and strength characteristics. The cup finds particular use with geriatric users. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates generally to acetabular prosthetic devices and more particularly to an improved acetabular shell liner wherein the liner has a variable geometry rim surface.
BACKGROUND OF THE INVENTION
[0002] Artificial implants, including hip joints, shoulder joints and knee joints, are widely used in orthopedic surgery. Hip joint prostheses are common. The human hip joint acts mechanically as a ball and socket joint, wherein the ball-shaped head of the femur is positioned within the socket-shaped acetabulum of the pelvis. In a total hip joint replacement, both the femoral head and the surface of the acetabulum are replaced with prosthetic devices.
[0003] A first general class of hip prosthetic devices included an acetabular component in which the head of a prosthetic femoral component was intended to articulate relative to the acetabular component. Initial designs included an acetabular component with a thin bearing surface, or liner, which interfaced with a large femoral component head. This design allowed for good range of motion and a low incidence of dislocation or subluxation of the femoral component head, but the thin liners proved to wear poorly, requiring replacement.
[0004] Acetabular components generally comprise an assembly of a shell and a liner, but may comprise the liner alone. Generally, a metal shell and a polymeric liner are used. However, the liner may be made of a variety of materials, including but not limited to, polyethylene, ultra high molecular weight polyethylene, and ceramic materials. The shell is usually of generally hemispherical shape and features an outer, convex surface and an inner, concave surface that is adapted to receive a polymeric shell liner. The shell liner fits inside the shell and has a convex and concave surface. The shell liner is the bearing element in the acetabular component assembly. The convex surface of the liner corresponds to the inner concave surface of the shell or acetabulum, and the liner concave surface receives the head of a femoral component.
[0005] The liner concave surface, or internal concave surface, is characterized by features relative to an axis through the center of the concave surface. This axis may or may not be aligned with the central axis of the shell. In a typical liner the concave surface has a hemispherical geometry and is also referred to as the internal diameter. In such liners, the geometry is characterized by features that are concentric to an axis that runs through the center of the internal diameter.
[0006] The acetabular component is configured to be received and fixed within the acetabulum of a pelvis. Typically, the acetabular component comprises an assembly of a shell and a liner. If only a liner is used, it is most often fixed within the acetabulum with bone cement.
[0007] The femoral component generally comprises a spherical or near-spherical head attached to an elongate stem with a neck connecting the head and stem. In use, the elongate stem is located in the intramedullary canal of the femur and the spherical or near-spherical head articulates in the liner internal diameter.
[0008] Currently, a hip joint prosthesis may comprise an acetabular component having a thicker liner and a femoral component having a smaller sized head than the initial designs. Acetabular designs that include thicker liners provide more bearing support and less surface area for wear but presents problems with dislocation and subluxation, as well as reduced range of motion, due to the smaller head size. Thus, one of the critical concerns in designing total hip joint replacement components is how to design the components to minimize contact of the neck of the femoral component with the rim of the liner during articulation, thus reducing rim contact-induced subluxation, dislocation, and wear, while allowing a maximum desired range of motion. There are a variety of acetabular liners available for use in hip replacement procedures that seek to address the issues of limited range of motion, rim-contact wear, and dislocation or subluxation.
[0009] For example, the standard, non-anteverted liner, also called a flat or zero degree liner, has a wide rim, or impingement, surface. Typically, the center of rotation of the femoral head on a standard liner is concentric with the acetabular shell. This type of standard liner is used to provide a broad range of motion. Use of this liner requires optimal positioning of the acetabular component in the acetabulum in order to provide the required range of movement for a patient. While standard liners allow a broad range of motion, if malpositioned, they present an increased possibility of dislocation. To address this problem, a high wall liner may be used.
[0010] In contrast to standard liners, high wall liners, also known as shouldered or lipped liners, employ an extended, elevated portion over a segment of the periphery of the liner internal diameter in order to increase coverage of the femoral head and thus reduce the likelihood of dislocation and aid in reduction of the head should subluxation occur. The use of high wall liners may be beneficial in cases of tenuous stability in order to avoid dislocation. See e.g. T. Cobb, et al., The Elevated - Rim Acetabular Liner in Total Hip Arthroplasty: Relationship to Postoperative Dislocation , Journal of Bone and Joint Surgery, Vol. 78-A, No. 1, January 1996, pp. 80-86. However, high wall liners of all designs have a reduction in the arc of motion to contact in the direction of the elevated rim segment without a corresponding increase in motion in the opposing direction. Thus, there is a substantial loss of overall range of motion compared to a standard liner. This reduction in range of motion makes the rotational positioning or clocking of these designs in the acetabulum particularly important in order to reduce rim contact with the neck of the articulating femoral component and potential acceleration of polyethylene wear at the rim as a result of this contact.
[0011] In general, anteverted liners re-orient the central axis of the internal diameter of the liner relative to the central axis of the shell. Anteverted liners shift the capture area on the head of the femoral component in order to improve hip joint stability and decrease the risk of dislocation. However, use of an anteverted liner may reduce allowed range of motion.
[0012] Some liners have a constant geometry relieved rim surface around the circumference of the internal diameter of the acetabular liner. While a relieved rim surface increases range of motion, the constant geometry may not optimize the possible range of motion because it may not be correlated to the cross-section of the femoral component during a condition of femoral component neck-liner contact. At this point the femoral component is said to be in an impingement condition with the liner.
[0013] Prosthesis range of motion has been evaluated in the past by creating a cone that defines the limits of motion to contact, or impingement angles, for the prosthesis, as described in Thornberry, et al., The Effects of Neck Geometry and Acetabular Design on the Motion to Impingement in Total Hip Replacement , A Scientific Exhibit at the 1998 AAOS Meeting, New Orleans, La., 1998, the entire contents of which are hereby incorporated by reference. The size of the cone depends on the design of the components. Varying the orientation of the components allows a surgeon to shift the direction of the cone. In a successful component placement, the cone is positioned so that adequate range of motion for the patient is provided. The base of the cone provides information for flexion, extension, adduction, and abduction. The direction of flexion-extension, as well as abduction-adduction, can be drawn as a line on the base of the cone. The point where the line intersects the cone is the maximum motion of prosthesis in the respective direction. Designs that provide adequate range of motion generally correlate with good clinical results. See e.g. B. McGrory, et al., Correlation of Measured Range of Hip Motion Following Total Hip Arthroplasty and Responses to a Questionnaire , Journal of Arthroplasty, Vol. II, No. 5, 1996.
[0014] Thus, there is a need for a method of forming an acetabular shell liner that provides optimization of the maximum range of motion and minimum interference with the femoral component neck. There is also a need for a liner formed by such a method.
SUMMARY OF THE INVENTION
[0015] Methods and structures according to this invention include a method of producing an acetabular liner in which the rim surface geometry varies, rather than being set, in order to optimize the range of motion and minimize interference with the neck of the femoral component. This variable geometry rim surface is employed around the edge of the internal concave surface of the liner, i.e. around the circumference of a generally hemispheric acetabular liner inside diameter, and allows for delayed interference, or impingement, with the neck or stem portion of the femoral component, resulting in an increased range of motion. Thus, this variable geometry rim surface delays when the neck of the femoral component contacts the rim surface of the liner during articulation, allowing an increase in the range of motion of the femoral component and optimization of the liner.
[0016] Increasing the range of motion has many benefits and advantages. For example, increasing the range of motion allows a patient a greater range of movement. Second, an increase in the range of motion provides the surgeon with greater room for error in component positioning, or clocking, during surgery. Since it is not currently possible to accurately measure the precise angle required for implantation of an acetabular component in a particular patient, it is difficult to place an implant at precisely the correct angle. A surgeon generally relies on personal experience in making this assessment. While a locking mechanism, such as a spline interface between the liner and the shell, is beneficial because it allows for multiple reorientations of the liner, fine tuning the positioning of the acetabular component during the intraoperative assessment of range of motion and stability is difficult and often imprecise. Surgeons will benefit from a wider range, or larger target area for acetabular component orientation provided by the increased range of motion.
[0017] Third, a broader range of motion decreases the likelihood of dislocation or subluxation, as it is less likely the femoral component will contact the rim of the liner and lever out of the internal concave surface of the acetabular component. Finally, a broader range of motion aids in preventing wear on the liner or shell. If a femoral component regularly contacts the rim surface of the liner, the liner will wear, releasing polyethylene debris. This debris may cause osteolysis when it escapes into nearby bone and tissue, which may lead to aseptic loosening of the implant. Additionally, if the liner wears thin, the neck of the femoral component may contact the metal shell, resulting in fatigue to the metal that may cause the neck or shell to break, or metal debris to be released into nearby bone and tissue.
[0018] These and further advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a perspective view of a femoral component and acetabular shell liner of a hip prosthesis for a left hip according to an embodiment of the invention.
[0020] [0020]FIG. 2A is a perspective view of a variable geometry rim surface acetabular shell liner according to an embodiment of the invention.
[0021] [0021]FIG. 2B is a cross-sectional view of the liner of FIG. 2A.
[0022] [0022]FIG. 2C illustrates the rim angle variation of the liner of FIG. 2A.
[0023] [0023]FIGS. 3 and 4 are perspective views of a femoral component and acetabular shell liner of a hip prosthesis for a left hip according to an embodiment of the invention.
[0024] [0024]FIG. 5 is a partial view of the femoral component and acetabular shell liner of FIG. 4.
[0025] [0025]FIG. 6 is a perspective view of a femoral component and acetabular shell liner of a hip prosthesis for a left hip according to an embodiment of the invention.
[0026] [0026]FIG. 7 is a partial view of the femoral component and acetabular shell liner of FIG. 6.
[0027] [0027]FIGS. 8 and 9 are perspective views of an acetabular shell liner according to an embodiment of the invention.
[0028] [0028]FIG. 10 is a graph showing a range of motion envelope for a variable geometry rim surface acetabular shell liner according to this invention and a range of motion envelope of a non-variable geometry rim surface liner.
[0029] [0029]FIG. 11A is a cross-sectional view of an acetabular liner having a concave rim surface.
[0030] [0030]FIG. 11B is a cross-sectional view of an acetabular liner having a convex rim surface.
[0031] [0031]FIG. 11C is a cross-sectional view of an acetabular liner having a recessed internal diameter.
[0032] [0032]FIG. 11D is a cross-sectional view of an acetabular liner having a “cut out” or recessed rim segment.
[0033] [0033]FIG. 12 is a flow chart outlining the steps for making the variable geometry rim surface liner.
[0034] [0034]FIG. 13 is a functional block diagram of a system in which the method of FIG. 12 may be performed.
[0035] [0035]FIG. 14A is a diagram showing the arrangement of an acetabular shell, shell liner and femoral component within a human pelvis.
[0036] [0036]FIG. 14B is a diagram showing coronal, saggital and transverse planes of the body.
DETAILED DESCRIPTION
[0037] Methods and structures according to this invention seek to improve the range of motion of the femoral component of a hip prosthesis by varying the rim surface geometry of the rim of an acetabular shell liner in which the femoral component articulates. Varying the geometry of the rim surface relative to the internal concave surface opening or axis of the liner at different areas on the liner allows for optimization of the rim surface geometry, thus providing an increased range of motion. A variable geometry rim surface liner according to this invention has an overall range of motion generally at least comparable to a conventional constant geometry rim surface liner.
[0038] Optimization of the acetabular shell liner rim surface geometry requires consideration of many elements in the design of the liner, including, but not limited to, range of motion of the femoral component, mechanical integrity, locking strength between the liner and the shell, material thickness constraints, as well as other considerations. All of these factors must be balanced in designing an optimized acetabular liner, including the variable geometry rim surface. Thus, changing the geometry of a liner to obtain the best possible range of motion is impacted by other design constraints.
[0039] The rim, or impingement surface, is the surface of the liner that restricts the rotation of the femoral component. One example of a possible rim surface geometry is a chamfer. One reason a chamfer, curve, or other rim surface, is used is so that if subluxation occurs, the rim surface serves as a guide to aid in hip reduction, or proper relocation.
[0040] A liner according to the present invention has an internal concave surface adapted to receive the head of a femoral component, an external surface positioned on an opposing side of the liner from the internal concave surface, and a sculpted surface generally defining at least part of the rim of the liner and which varies around the rim of the liner.
[0041] As used herein the term “internal concave surface” refers to the internal concave surface of the liner which receives a femoral component head. The internal concave surface may be hemispherical, oval, elliptical, oblong, or any other generally concave geometric shape. The term “internal diameter” refers to the internal concave surface of a liner; it may be partially spherical, and it may be hemispherical or less than hemispherical. “External diameter” refers to an external surface opposing the internal concave surface which is adapted to be received in an acetabular shell or directly into the acetabulum of a patient. The term “articulation bearing surface” refers to the surface of the internal concave surface in which the head of the femoral component articulates or moves in a manner corresponding to motion of the femur relative to the acetabulum.
[0042] The term “rim” or “rim surface”, as used herein, refers to a surface of the liner located generally between the internal concave surface and an external surface of the liner, at least portions of which restrict the rotation of the femoral component within the internal concave surface of the liner. “Sculpted surface” means a surface which forms at least part of the rim of the liner and which varies around the rim of the liner according to the orientation of the femoral component in an impingement condition with the rim of the liner and according to other structural and mechanical variables.
[0043] One method according to this invention seeks to determine orientation of a femoral component in an impingement condition to the liner rim geometry in order to optimize the maximum range of motion. As an example, one method according to the invention, which may be performed manually or with the aid of a computer, is described below.
[0044] 1. Provide an acetabular shell liner and a femoral component comprising a head, neck and stem. Preferably, provide an acetabular shell, liner and femoral component. Alternatively, introduce data corresponding to a three dimensional model of a liner and femoral component into computer containing a processing functionality, storage functionality, and rendering functionality. More preferably, introduce information corresponding to the acetabular shell, liner, and femoral component.
[0045] 2. From an anatomic neutral position, rotate the femoral component within the internal concave surface of the liner to define a radial location on the rim of the liner where the femoral component contacts, i.e. impinges, the rim of the liner. If using a computer, the computer models and/or simulates the configuration of the shell, liner and femoral component and simulates the rotation of the femoral component until the femoral component impinges the rim of the liner at a defined radial location.
[0046] 3. With the femoral component in this position, note the radial location and define the impingement angle of the femoral component in that position at that radial location on the rim.
[0047] 4. Record the structure and orientation of this angle at this radial location. Define the location and desired shape of a cross-sectional rim segment at this impingement angle and radial location, based at least in part on the cross-sectional shape of the femoral component where it impinges the rim at this radial location, and note this desired shape.
[0048] 5. Rotate the femoral component within the liner to define a separate radial location on the rim of the liner where the femoral component impinges on the rim. In the computer example, the computer simulates the movement of the femoral component and may record the radial location.
[0049] 6. Repeat steps three through five for a desired number of radial locations around the rim. In the computer simulation, the computer may track the data corresponding to the impingement angles and cross-sectional shape of the femoral component in an impingement condition with the liner at each of a plurality of radial locations around the rim.
[0050] In one example rotate, or simulate the rotation of, the femoral component within the liner relative to a relevant anatomical axis of the body. Preferably, rotate the femoral component relative to anatomically relevant axes running through the center of rotation of a femoral component articulating within the internal concave surface of the liner, and oriented in a plane substantially parallel to transverse, coronal or saggital planes of the body. These planes are shown in FIG. 14B. More preferably, rotate or simulate the rotation of the femoral component about axes that are fifteen degrees apart in said planes.
[0051] 7. Repeat, if desired, steps 1-6, with different femoral component head offsets possible in the assembly of the stem and head to obtain a range of impingement angles and a cross-sectional envelope determined by the group of impingement angles and cross-sectional shapes corresponding to the plurality of femoral components used. Preferably, repeat steps 1-6 with any other structural variations in a set of stem, shell, and liner products or liners.
[0052] 8. Form the liner with the variable geometry rim surface using the data obtained in steps 1-6, or through step 7 if desired, and form the liner such that the shape of the liner rim varies at a plurality of radial locations in a manner corresponding to the cross-sectional shape of the femoral components in an impingement condition with the liner.
[0053] The geometry of the rim surface may be defined in part by using some or all of these data relating to the specified impingement angles and cross-sectional envelopes determined in steps 3-6. It may also, and in some cases additionally, be defined by specifying the rim surface geometry of the liner to be formed by doing necessary or desired extrapolation, interpolation, or estimation based on the impingement angles and locational data from steps 3-6. In the computer simulation example, the computer may define the geometry of the rim based at least in part on the impingement angles, cross-sectional envelope, and locational data obtained in the steps outlined above or on extrapolation, interpolation or estimation therefrom. The computer may produce a set of specifications based on the data obtained in the steps above for forming a liner with a variable geometry rim surface.
[0054] All of these steps are subject to the design goals of creating a rim surface optimized for range of motion of the femoral component relative to the liner. More preferably, all of these steps are subject to taking into account other anatomical, performance, durability and structural criteria.
[0055] [0055]FIG. 12 shows a functional block diagram illustrating the process described above for making the variable geometry rim surface liner of the present invention. The manual method is outlined on the left side of the flow chart, while the right side outlines the computer simulation example. FIG. 13 shows a functional block diagram which represents a hardware environment, or system, in which the simulation method of the present invention may be performed. The system illustrated comprises a processor capacity, a mass memory capacity, and an input/output capacity. Any or all functionalities represented in this diagram may be implemented or reside on one or more “computers,” processors, platforms, networks or other systems.
[0056] In a particular example, the liner shown in FIGS. 1 - 9 was made using Unigraphics® software, running on a Windows NT® operating system on a personal computer with a Pentium II® processor. Steps 1-6 outlined above were performed on Unigraphics® brand computer aided design package which used the data to produce an image of a three-dimensional solid model liner with a variable chamfer rim geometry. Any device design software or software which can be used to design objects, running on any desired platform using any operating system, whether or not network based, can be used in accordance with the present invention. Also produced was a code corresponding to the specification of this liner which was used to program a machine tool, such as a 5-axis CNC milling machine, to form the liner. The liners of the present invention may be formed of various materials, including but not limited to ceramic, polyethylene, ultra high molecular weight polyethylene, and highly cross-linked ultra high molecular weight polyethylene, more preferably ultra high molecular weight polyethylene.
[0057] The liners of the present invention are typically used in combination with a metallic shell. However, the liners may also be implanted directly into the acetabulum of a patient. When implanted directly into the acetabulum, the liners are generally secured into the acetabulum with bone cement. The liners also may be mechanically fixed within the acetabulum by bone screws or screw threads on the external surface of the liner. Another method of securing the liner in the acetabulum is by providing a bone in-growth surface which is integral to the external surface of the liner. This surface may be molded into or otherwise integral to the external surface of the liner. This integral bone in-growth surface may be made by creating a roughened area on the external surface of the liner. This integral bone in-growth surface may also comprise a textured matrix which is incorporated into the material of the external surface of the liner; such a matrix may include metal porous beads, fiber mesh, or other surfaces which provide a scaffold into which the patient's bone will grow, thereby physically securing the liner within the acetabulum.
[0058] The geometry of the rim surface specified according to the method of this invention is preferably a chamfered surface connecting at least part of the internal concave surface of the liner and an external surface of the liner. Structures according to this invention include a family of variable geometry rim surface acetabular liners having differing sizes, with each size having different rim surface geometries.
[0059] As one example of the present invention, consider generally hemispherically shaped liners whose internal diameters are 28 mm to fit a common size head of a femoral implant. These liners include a chamfer as the rim surface. Each of the outer diameters of the liners get progressively larger with each increasing size, corresponding to the size of the acetabulum. As the size increases, the rim surface angle, or chamfer angle, can widen, or become more obtuse as a general matter. In this particular example, the center axes of the internal diameters of the liners are oriented, or anteverted, at 20 degrees relative to the central axis of the shell, or other surface in which the liner is adapted to be received. In other words, the opening of the liner is at 20 degrees to the opening of the shell. The center axis of the liner internal diameter may be shifted relative to the center axis of the shell in any direction, in an anteverted liner, the axis is oriented toward the anterior of the body.
[0060] FIGS. 1 to 9 show an example of these types of liners. As shown in FIGS. 1 and 3 to 7 , acetabular shell liner 20 is adapted to receive head 22 of femoral component 24 . Liner 20 has variable angle chamfer 26 , which chamfer angle 27 (φ) varies in order to optimize the range of motion of femoral component 24 with respect to other structural variables. In these figures the chamfer angle, 27 is defined as the angle at any point on or near the periphery of the liner internal diameter at which the surface of the chamfer is positioned relative to the center axis of the opening of the internal diameter of the liner, about which the stem articulates. However, the angle may also be defined relative to any reference line or plane defined by the structure of the liner, such as the center axis or an axis of rotation of the inner diameter, the center axis or axis of rotation of the external, or outer, diameter, or some other reference entity. FIG. 2A shows a perspective view of a liner having variable chamfer, angle 27 . Variable angle 27 is shown in cross-section in FIG. 2B, and the mapping of the angle variation is depicted in FIG. 2C.
[0061] As shown in FIGS. 1 and 3 to 7 , head 22 and liner 20 act as a ball and socket joint. The contact during articulation of the femoral component neck 28 with liner 20 is minimized by varying the impingement angle 27 of chamfer 26 to allow neck 28 a broader range of motion prior to contact with liner 20 . In this example, neck 28 of stem 30 has a circulotrapezoidal (such as a rounded, generally rectangular) cross-section. As the femoral component 24 is rotated, the periphery of the neck 28 limits the rotation of the stem 30 relative to the liner 20 because contact of the neck 28 with the chamfer 26 stops rotation of the femoral component.
[0062] As follows from the method described above, at the points where the neck 28 is more likely to contact the outer edge of the chamfer 26 , the angle 27 is made more obtuse in order to produce a condition where the femoral neck contacts the inner and outer edges of the chamfer at the same time, thus allowing a broader range of motion. Where the neck 28 is likely to contact only the inner edge, the angle 27 is made more acute to produce a condition where the femoral neck contacts the inner and outer edges of the chamfer at the same time. According to the method described above, the condition of contact in which the neck will require the widest chamfer angle is isolated, resulting in a chamfer angle that is customized for the neck geometry of the femoral component.
[0063] In another embodiment, the variable angle 27 of liner 20 is made to correspond to any shaped stem neck so that the varying angle 27 is optimized for a neck with a particular geometry, such as cylindrical. Different liner rim surface geometries may be used depending upon the particular neck geometry.
[0064] As shown in FIGS. 1 and 3 to 7 , in this example, the center of rotation of the internal diameter in liner 20 is lateralized, or shifted laterally, by 4 mm. In another embodiment, a variable geometry rim surface is used with a nonlateralized liner, with a liner lateralized by up to 8 mm, or with a liner that is lateralized differently. As used herein and as understood by those of skill in the art, “lateralized” refers to a liner wherein the center of the internal concave surface, or internal diameter, has been shifted laterally, or laterally and somewhat inferiorly, with respect to how the liner is oriented in a patient. In another embodiment, a variable geometry rim surface is used with a liner wherein the center of the internal concave surface, or internal diameter has been shifted medially by up to 4 mm.
[0065] [0065]FIG. 10 graphically illustrates the comparison of range of motion of a variable angle chamfer acetabular shell liner according to this invention, the liner shown in FIGS. 1 - 9 , and range of motion of a prior art liner with a constant chamfer angle of 147°. Both liners have a 28 mm internal diameter, and in both liners the center of the internal diameter is lateralized by 4 mm and the opening of the internal diameter is anteverted by 20°. The femoral component used with both liners was a size 14 Smith & Nephew Synergy® Stem, measuring 160 mm in length and with a 28 mm diameter head.
[0066] The solid line curve shown in FIG. 10 illustrates an example of a range of motion envelope that was derived using the above described method for varying the rim surface geometry. This range of motion was characterized by components of flexion-extension and abduction-adduction. The dotted line is an example of a range of motion envelope provided by a non-variable, i.e. constant, geometry rim surface liner. On this graph the zero point, or anatomically neutral point, represents a liner oriented at 45° of abduction and 20° of anteversion and a femoral component oriented at 7° of adduction and 20° of anteversion. From this point the femoral component is rotated, as in a patient after implantation, about various anatomically relevant axes located, in this case, 15 degrees apart in a transverse plane of the body, to define the limit of range of motion, or impingement angle, about each axis.
[0067] This can be demonstrated by placing FIG. 10 face-up on the floor with the flexion axis pointed forward, i.e. anteriorly, and standing above it with the left foot positioned on top of the graph and aligned with the flexion/extension axis. Rotating the left leg forward, in flexion, the limit of motion to liner rim impingement is approximately 118° with the variable angle chamfer liner, but only about 113° with the prior art constant angle chamfer liner. Rotating the leg backwards about the same axis, in extension, the limit of motion to liner rim contact is about 38° with the variable chamfer angle liner and about 36° with the prior art constant angle chamfer liner. This procedure was repeated, rotating a femoral component about axes located 15 degrees apart, thereby generating a range of motion envelope for both the variable angle chamfer liner and prior art constant angle chamfer liner shown by the solid and dotted line curves, respectively. As can be seen, the range of motion provided by the liner according to the present invention is superior.
[0068] In the example shown in FIGS. 1 and 3 to 9 , liner 20 has a serrated edge 36 in order to interface with the acetabular shell. Each spline angle of serration is 15 degrees, thus, the liner can be oriented at 15 degrees all around and locked in place in an acetabular shell. Other types of interface with an acetabular shell may also be employed.
[0069] As described in the example above, the rim surface is a chamfer. Another example is a concave rim surface on a liner, as shown in FIG. 11A. In this embodiment, the liner fits with a stem that has a convex neck. A variable geometry rim surface according to this invention may be employed on this liner. In this example, the radius of curvature of the surface, or the center of curvature, varies relative to the internal diameter of the liner in order to optimize range of motion with respect to other structural variables, rather than varying the angle of the rim surface as with a chamfer. Other interface surfaces may also be optimized to obtain the maximum desired range of motion, such as a convex rim surface liner, shown in FIG. 11B.
[0070] A variable geometry rim surface according to this invention may be employed with many types of acetabular shell liners. For example, in one embodiment, a variable geometry rim surface is used with a 0 degree liner. The variable geometry rim surface may be applied to a liner which is anteverted, as shown in the figures, or with a liner that is not anteverted. In another embodiment, a variable geometry rim surface is applied to an acetabular shell liner with a less than 180 degree capture angle, i.e. a liner that provides less than 180 degrees of coverage of a femoral head adapted to be received in the internal concave surface of the liner. The invention can also be used with a liner that has a recessed radial segment, or lip, that dips below 180 degrees of coverage, as shown in FIG. 11D. The variable geometry rim surface can also be applied to a high-wall liner, which is a liner with a raised radial segment, also called a lip or shoulder, which extends above 180 degrees of coverage.
[0071] One alternative embodiment of this invention involves the use of a variable geometry rim surface in a constrained liner. A constrained liner is one that has greater than hemispherical coverage around the head such that the head is constrained within the internal diameter, thus preventing subluxation and dislocation. While use of a constrained liner is generally not desirable due to resulting decreased range of motion, it is necessary in some patients who are repetitive dislocators.
[0072] The variable geometry rim surface may also be employed in a liner with a sunken, or recessed, internal concave surface. A recessed internal concave surface liner is similar to a constrained liner in that it provides greater coverage of the femoral component head to reduce the risk of dislocation. In the recessed liners the center of the internal concave surface is recessed to sink the articulation bearing surface of the internal concave surface deeper into the liner, creating a surface between the articulation bearing surface of the internal concave surface and the rim of the liner, which serves to reduce dislocation. In recessed liners with a hemispherical internal concave surface, the hemispherical portion of the internal diameter is sunken into the liner, creating a recessed, cylindrical shaped, area near the opening of the internal diameter where the sides of the internal diameter extend substantially straight in the direction of the opening, rather than continuing to curve around the femoral component head. Such a liner is depicted in FIG. 11C.
[0073] Another embodiment of the invention is a divided rim surface in which the rim surface of the liner is divided into several constant angle sections so as to approximate a single varying angle rim surface. In another embodiment, the geometry of the rim surface varies around the rim of the liner and is symmetric about a plane, i.e. the reflection about the plane is a mirror image.
[0074] The foregoing description of the preferred embodiments of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to enable others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. | An acetabular shell liner having a variable rim surface geometry, which improves range of motion of the femoral component within the liner and decreases the incidence of dislocation and subluxation, and methods of making and using the acetabular shell liner. Prosthetic devices, more particularly hip joint prostheses, containing the acetabular shell liner having a variable rim surface geometry are also provided. | 0 |
This application is a national stage application of PCT/BR02/00104, filed on Jul. 26, 2002, which claims priority to Brazilian patent application number PI0104510-5, filed on Jul. 27, 2001.
FIELD OF INVENTION
This invention is related to anti-microbial peptides with activity against a broad range of Gram-negative and Gram-positive bacteria, fungi and protozoa. Pharmaceutical compositions containing the anti-microbial peptides here disclosed are useful to be used in prophylaxis and therapeutic treatment of human and animals under conditions which depress or compromise their immune system. Compositions based on the peptides of the invention are also useful in retarding plant pathogens growth.
BACKGROUND OF THE INVENTION
Bacteria and fungi as well as other organisms, including plant pathogens, coexist with all living organisms and besides this fact, pathogenic infections are not frequent because of the efficiency of self defense mechanisms. Microorganisms that invade the human or animal body and plants are challenged by several defense mechanisms.
When host defenses lacks an efficient barrier against pathogen invasion, antibiotics have been used to function as bactericides and, in general, anti-microbials. However, different antibiotics have been continuously sought due to the severe side-effects and the emergence of mutant microorganisms acquired resistance to the long-term used antibiotics. In this regard, attempts to develop novel antibiotics have been carried out by screening secondary metabolites of microorganisms, by synthesizing analogues of known antibiotics such as quinolones or by isolating proteins or peptides induced by intracellular defense mechanisms of plants and animals.
In fact, host defenses include mechanical and chemical factors. One of the chemical defense mechanisms of animals and plants against infection is the production of peptides that have anti-microbial activity. Naturally occurring amphipathic lytic peptides play an important if not critical role as immunological agents and have some defense functions in a range of animals. The function of these peptides is to destroy prokariotic and other non host cells by disrupting the cell membrane and promoting cell lysis. Common features of these naturally occurring peptides include an overall basic charge, a small size (23-39 amino acid residues) and the ability to form amphiphilic α-helices.
Many different families of anti-microbial peptides, classified by their amino acid sequence and secondary structure have been isolated from insects (Steiner, H.; Hltmark, D.; Engstrom, A.; Bennich, H. & Boman, H. G.,1991 . Nature .292, 246-248); plants (Cammue, B. P.; De Bolle, M. F.; Terras, F. R.; Proost, P.; Van Danrne, J.; Rees, S. B.; Vanderleyeden, J. and Broekaert, W. F. 1992 . J. Biol. Chem . 267. 2228-2233.), mammals (Nicolas, P. & Mor, A. .1995 . Annu. Rev. Imunol . 49: 277-304) and microorganisms (Boman, H. G.1995 . Annu. Rev. Imunol . 13: 61-92).
Cecropin, cysteine-containing defensin and sapecin, isolated from insects, are examples of antibacterial peptides whose target site is lipid membrane of Gram positive bacteria (Kuzuhara, T. et al. 1990. J. Biochem. 107: 514-518). Studies have demonstrated that Cecropin B isolated from Bombix mori have biological activity against bacterial species (Kadono-Okuda, K. Taniai, K., Kato, Y. Kotani, E. & Yamakawa, M. 1995 . J. Invertebr. Pathol . 65, 309-310). Further, it was reported that this peptide when translocated into the intercellular spaces in rice transgenic plants is protected from degradation by plant peptidases and confers enhanced resistance against Xanthomonas oryzae pv. oryzae infection (Sharma, A.;, Sharma, R.; Imamura, M.; Yamakawa, M. & Machii, H. 2000 . FEBS . 484: 7-11).
Attacin, sarcotoxin, deftericin, coleoptericin, apidaecin and abaecin are other antibacterial peptides whose target site are lipid membranes. These peptides conserve G and P domains, and have an influence on the cell differentiation of Gram negative bacteria. In particular, attacin has been also reported to break down outer membrane of the targeted bacteria by inhibiting the synthesis of outer membrane proteins.
Besides the above cited antibacterial peptides of insects, several antibiotic peptides have been also isolated from amphibia. Indeed, as other animals, amphibians are rich in anti-microbial peptides (Zasloff, M. 1987 . Proc. Natl. Acad. Sci . 89:5449-5453), and many of them belong to the group of amphipathic α-helical structure peptides such as magainins (Daba, H., Pandian, S., Gosselin, J. F. Simard, R. E., Huang, J. and Lacroix, C. 1991 . Appli. Environ. Microbiol . 57, 3450-3455), bombinins (Gibson, B. W., Tang, D., Mandrell, R., Kelly, M. and Spindel, E. R. 1991 . J. Biol. Chem . 266, 23103-23111), bufonins (Park, C. B., Kim, M. S. and Kim, S. C. (1996) Biochem. Biophys. Res. Comm . 218, 408-413.), dermaseptins (Batista, C. V. C., Silva, L. R., Sebben, A., Scaloni, A., Ferrara, L., Paiva, G. R., Olamendi-Portugal, T., Possani, L. D. and Bloch, C. Jr. 1999 . Peptides 20, 679-686) and defensins (Kagan, B. L. et al. 1990. “Anti-microbial defensin peptides form voltage-dependent ion-permeable channels in planar lipid bilayer membranes. Proc Natl Acad Sci. USA. 87(1):210-214). Most of these peptides have been isolated from glands and gastrointestinal tract.
All these molecules has been subject of intense research in order to clarify their biosynthesis, mechanism of action, activity towards microorganisms and potential clinical applications.
An important class of anti-microbial peptides are those known as Magainins. According to Zasloff (1987), at least five proteins may be isolated from the skin of the African clawed frog ( Xenopus laevis ). The natural proteins are active against a broad range of microorganisms including bacteria, fungi and protozoans. The broad spectrum anti-microbial activity is also present in synthetic peptides and in certain truncated analogs of the natural proteins. Such a class of broad spectrum bio-active polypeptides have been described in the U.S. Pat. No. 5,643,876. These peptides have a molecular weight of about 2500 Da or less, are highly water soluble, amphiphilic and non-hemolytic. They are also defined as a class of substantially pure, homogeneous peptide composed of about 25 amino acids.
The U.S. Pat. No. 5,424,395 discloses a synthetic peptide with 23 amino acid, derived from magainin II showing anti-microbial activity in plants. U.S. Pat. No. 5,912,231 presents a compound comprising a Magainin I or a Magainin II peptide with biological activity, wherein at least one substitution may be made for certain amino acid residues with other amino acids residues. The resulting peptides are known as substitution analogues. Preferred peptides are those obtained by deletion or substitution of at least one amino acid residue in the position 15 andor 23.
U.S. Pat. No. 5,424,395 also describes synthetic peptides derived from Magainin I and Magainin II having anti-microbial activity. The peptides contain 23 amino acid residues and are useful in retarding the growth of plant pathogens.
U.S. Pat. No. 5,912,230 discloses an invention based on substantially pure peptides which have anti-candidal or anti-bacterial activity which are equivalent to that of naturally occurring histatins but are smaller in size. These peptides represent defined portions of the amino acid sequences of naturally occurring human histidine-rich salivary proteins called histatins.
Defensins are relatively small polypeptides of about 3-4 kDa, rich in cysteine and arginine. As a class of anti-microbial peptides, defensins have activity against some bacteria fungi and viruses. The defensins are believed to have molecular conformations stabilized by cysteine bonds, which are essential for biological activity.
The documents U.S. Pat. No. 5,861,378 and U.S. Pat. No. 5,610,139 disclose peptides isolated from horseshoe crab hemocyte, having a similar amino acid sequence to those of defensin and showing strong anti-microbial activities in the fraction 5S, as well as compositions and pharmaceutical preparations using them. They also provide a DNA encoding one or more peptides which show significant physiological activity against Gram positive and Gram negative bacteria and fungi. U.S. Pat. No. 5,610,139 also presents antimicrobial compositions, containing the referred peptides combined with one or more β-lactol or chloramphenicol antibiotics, these compositions exihibing synergistic bactericidal effect against S. aureus infections.
In the U.S. Pat. No. 5,766,624 is proposed a method for treatment of microbe infection in mammals using defensins; U.S. Pat. No. 5,821,224 also presents a β-defensin of 38-42 amino acid, with anti-microbial activity, obtained from bovine neutrophil.
Cathepsin G is a granule protein with chymotripsin-like activity being also known as chymotripsin-like cationic protein. Some polypeptides mutually homologous to cathepsin G are called defensins. In the U.S. Pat. No. 5,798,336 various peptides with anti-microbial activity are provided, being the sequence of said peptides related to amino acid sequences within Cathepsin G. Despite of some of the peptides have showed specificity because of being more effective against determined microorganism, mostly they were effective against both, Gram-negative and Gram-positive bacteria. It is mentioned that pharmaceutical compositions containing these peptides are useful in prophylaxis treatment of infections.
Another type of anti-microbial peptides named buforin was isolated from the stomach tissue of the Asian toad Bufo bufo garugrizans . Two molecules derived from histone H2A were identified, Buforin I and Buforin II which contain 39-aa and 21-aa respectively. These molecules showed different mechanisms of action, having buforin II much stronger anti-microbial activity, killing bacteria without lysing cells and presenting high affinity for DNA and RNA. This suggests that the target of this peptide is the nucleic acids and not the cell membranes (see Park, C. B.; Yi, K.; Matsuzaki, K.; Kim, M. S.; Kim, S. C. 2000 . PNAS . 97:8245-8250).
U.S. Pat. No. 5,877,274 provides a novel class of cationic peptides referred to as bactolysins, which have anti-microbial activity and have the ability to significantly reduce the level of lipopolysaccharide (LPS)-induced tumor necrosis factor (TNF). In this document, it is also proposed a method of inhibiting either the growth of bacteria or an endotoxernia or sepsis associated disorder by administering a therapeutically effective amount of the peptide.
Each one of these different peptide types is distinguished by sequence and secondary structure characteristics. Based only on the sequence, it is difficult to predict either the activity of a peptide or the secondary structure that it will be formed (Hancock, R. E. W., and Chapple, D. S. 1999 . Anti-microbial Agents and Chemotherapy . 43, 1317-1323).
Most of the peptides without disulfide bridges have random structures in water, and when they bind to a membrane or other hydrophobic environment, or, self-aggregate, they form a structure (Bello, J., Bello, H. R., and Granados, E. 1982 . Biochemistry 21, 461-465; Falla, T. J., Karunaratne, D. N., and Hancock, R. E. W. 1996 . J. Biol. Chem . 271, 19298-19303). For example, cecropins and mellitin only acquire amphiphilic alpha-helices in membranous environments. It is known that the both dual cationic and hydrophobic nature of the peptides is important for the initial interaction between the peptide and that is the cationic character of the bacterial membrane what promotes interaction with bacterial outer and cytoplasmic membranes (Hancock, R. E. W., Falla, T., and Brown, M. H. 1995 . Adv. Microb. Physio . 37, 135-175).
Several hypotheses have been suggested for the mechanism of action of the lytic peptides, most of them related to membrane destruction. Whatever the mechanism of lytic peptide-induced membrane damage, an ordered secondary conformation such as an amphiphilic helix and positive charge density are supposed to participate in the peptide-promoted lysis reaction.
Membrane-binding is the first step of the peptide-membrane interaction V mechanism and the knowledge of its determinants and driving force are prerequisites for understanding the mechanism itself and the molecular reasons for the prokaryotic specificity (Saberwal, G., and Nagaraj, R. 1994 . Biochem. Biophys. Acta 1197, 109-131). The positively charged peptides were found to bind preferentially to negatively charged membranes what is a major reason for the prokaryotic specificity. The enhanced affinity is caused by an electrostatic attraction of the peptides to the negatively charged membrane surface rather than a specific-lipid interaction (Westerhoff, H. V., Juretic, D., Hendler, R. W., and Zasloff, M. (1989) Proc. Natl. Acad. Sci. USA . 86, 6597-6601).
The present invention discloses a novel class of anti-microbial peptide, isolated from skin of Phyllomedusa hypochondrialis , a kind of frog native to Amazonian, Brazil. It was termed Phylloseptins and its structure did not show any homology with another known peptides.
SUMMARY OF THE INVENTION
This invention is related to anti-microbial peptides having the same amino acid sequence and at least the same anti-microbial activity as those of Phylloseptins which are isolated from the skin of Phyllomedusa hypochondrialis . The peptides did not have any structural homology with another known peptide. The 19-residue anti-microbial peptides are cationic and based on their primary structure, all peptides can be fitted to an amphiphilic α-helix. The peptide masses analyzed by mass spectrometry were in the range of 1.9 to 2.0 kDa. Preferred peptides of the present invention include the peptides named Phylloseptin-I, Phylloseptin-II and Phylloseptin-III which are defined by their amino acid sequence SEQ ID No. 1, SEQ ID No. 2 and SEQ ID No. 3.
The amphiphilic nature of these peptides presumably underlines their biological activities which enables them to associate with lipid membranes and disrupt normal membrane function. However, no significant hemolytic activity was found for these peptides which suggests a selectivity for prokaryotic over eukaryotic membranes
A first embodiment of the present invention refers to an antibiotic peptide with broad spectrum anti-microbial activity having the same amino acid sequence and at least the same anti-microbial activity as the peptide defined in the formula:
Phe Leu Ser Leu Ile Pro His Ala Ile Asn Ala Val Ser Xaa 1 Xaa 2 Xaa 3 Xaa 4 His Xaa 5
(SEQ ID NO: 4) wherein Xaa 1 , Xaa 2 , Xaa 3 , Xaa 4 and Xaa 5 are each independently a hydrophobic amino acid, a hydrophilic basic amino acid or a hydrophilic neutral amino acid, with the provisos that (i) when Xaa 1 , Xaa 2 and Xaa 3 are hydrophobic amino acids, Xaa 4 is a hydrophilic basic amino acid and Xaa 5 is a hydrophilic neutral amino acid; (ii) when Xaa 2 , Xaa 3 and Xaa 5 are hydrophobic amino acids, Xaa 1 is hydrophobic amino acid or a hydrophilic neutral amino acid and Xaa 4 is a hydrophilic basic amino acid or a hydrophilic neutral amino acid.
A second embodiment is directed to a composition for inhibiting growth of a target cell e.g. fungus, bacteria, protozoa, comprising (a) at least one antibiotic peptide as defined in claim 1 and (b) an acceptable pharmaceutical carrier.
A third embodiment refers to a composition for retarding plant pathogens and for protecting plants from pathogens, comprising (a) at least one antibiotic peptide as defined in claim 1 and (b) an agriculturally acceptable carrier.
A further embodiment of the invention is to provide therapeutic compositions suitable for human, veterinary, or pharmaceutical use, comprising one or more of the peptides released in this invention and an adequate pharmacological carrier.
Preferred peptides of the present invention include the peptides named Phylloseptin-I (PSI), Phylloseptin-II (PSI) and Phylloseptin-III (PSIII) which are defined by their amino acid sequence SEQ ID No. 1, SEQ ID No. 2 and SEQ ID No. 3, respectively.
SEQ ID No. 1:
Phe Leu Ser Leu Ile Pro His Ala Ile Asn Ala Val Ser Ala Ile Ala Lys His Asn
SEQ ID No. 2:
Phe Leu Ser Leu Ile Pro His Ala Ile Asn Ala Val Ser Thr Leu Val His His Phe
SEQ ID No. 3:
Phe Leu Ser Ueu Ile Pro His Ala Ile Asn Ala Val Ser Ala Leu Ala Asn His Gly
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 : shows the chromatographic display of the crude extract of skin secretion of Phyllomedusa hypochondrialis (A) and the peptides Phylloseptin I (PS1), Phylloseptin II (PS2) after the rechromatographic procedure (B).
FIG. 2 : shows the helical wheel, plots of the Phylloseptins and their amphiphilic structure.
FIG. 3 : shows an AFM image of intact morphological structure of Pseudomonas aeruginosa.
FIG. 4 : shows one cell of P. aeruginosa with membrane alterations due to treatment with the peptide PS I.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of clarity and a complete understanding of the invention, the following terms are defined
“Anti-microbial” refers to peptides that inhibit, prevent, or destroy the growth or proliferation of microbes such as bacteria, fungi, protozoa, or the like.
“Anti-bacterial” is used to mean the peptides which produce effects adverse to the normal biological functions of bacteria, including death or destruction and prevention of the growth or proliferation of the bacteria when contacted with the peptides of the present invention.
“Antibiotic” means the peptides which are unfavorable to the normal biological functions of the non-host cell, tissue, or organism when contacted with the peptides of the present invention.
“Anti-fungal” means the peptides which inhibit, prevent, or destroy the growth or proliferation of fungi.
“Anti-parasitic” refers to peptides which inhibit, prevent, or destroy the growth or proliferation of parasites.
“Anti-infection effective amount” of a pharmaceutical composition means any amount of a pharmaceutical composition which is effective to inhibit or prevent the establishment, growth or spread of an infection sensitive to the peptides of the invention.
“Plant pathogen” encompasses those organisms that can cause damage and/or disease to plants, and includes fungi, prokaryotes (bacteria and mycoplasma), nematodes, protozoa, and the like.
The skins of the South American Phyllomedusa frogs are an excellent source of peptide molecules (see Bevins, C. L., Zasloff M. 1990 . Annu. Rev. Biochem . 59, 295-414; Batista et al. 1999). Phyllomedusa hypochondrialis (Anura, Hylidae ) is an arboreal. frog native to Amazonian, Brazil.
The present invention relates to a novel class of biologically active peptides named Phylloseptins. More particularly, this invention provide three new peptides named Phylloseptin-I (PSI), Phylloseptin-II (PSII) and Phylloseptin-III (PSIII), isolated from the skin of adults of Phyllomedusa hypochondrialis.
In order to identify and characterize PSI, PSII and PSIII peptides were isolated by fractionation of the total skin secretion of the lyophilized crude extract from P. hypochondrialis . The techniques used to isolate the components of such extracts are well known to the skilled artisans and is not a critical feature of the present invention. To illustrate, the isolation of PSI, PSII and PSIII was performed by application (5-mg aliquots each time) of the crude extract to a semi-preparative Vydac reverse-phase chromatographic column, C 18 , 10μ (10×250 mm) in system HPLC. Peptides were purified by using a double linear gradient, initially 0% to 80% acetonitrile containing 0.1% TFA (trifluoacetic Acid) for 70 min, followed by 80% to 100% of same solvent for 20 min. The experiment was monitored 216 nm and fractions were collected manually and lyophilized. The isolated fractions were re-chromatographed by using a Vydac 218 TP 54, C 18 , 5μ (0.46×25 cm), with optimized gradients of acetonitrile in 0.1% TFA over 60 min and their purity was monitored by mas spectrometry (MALDI/TOF).
FIG. 1 shows the chromatographic display of the crude extract (A) and the peptides Phylloseptin II (PSII), Phylloseptin III (PSIIUI) after the rechromatographic procedure (B).
The helical wheel plots of the Phylloseptins showing their amphiphilic structure is illustrated in the FIG. 2 . In this conformation, periodic variation in the hydrophobicity value of the residues along the peptide backbone with a 3.6 residues/cycle period characterize an α-helix (Schiffer, M. and Edmunson, A. B. 1967. “Use of helical wheels to represent the structures of proteins and to identify segments with helical potential”. Biophys J . 7(2): 121-35).
The cationic molecules of this invention are unstructured in solution and they could be initially attracted to bacterial surface by electrostatic interactions with negatively charged species (phospholipid heads) on their surface. Then they assume an amphipathic α-helical structure at the membrane surface by inserting the hydrophobic sector into the membrane, in contact with the lipids chains, while polar or, charged residues on the hydrophilic sector remain in contact with the anionic head groups of phospholipids and the outside environment. They thus accumulate on the outer leaflet of membrane with their axis parallel to its surface, causing deformation and thinning.
The antibiotic peptide sequences of the present invention can be composed by either α-D- and/or α-L-amino acid residues in the complete polypeptide chain or specific parts of it (e.g. N-terminal, C-terminal or internal helical regions).
The 19-residue anti-microbial peptides are cationic and based on their primary structure, all three peptides can be fitted to an amphiphilic α-helix. The peptide masses analyzed by mass spectrometry were in the range of 1.9 to 2.0 kDa.
These peptides showed effective activity against a broad range of Gram-negative and Gram-positive bacteria and fungi, However, no significant hemolytic activity was found for these peptides which suggests a selectivity for prokaryotic over eukaryotic membranes.
The term isolated as used herein refers to a peptide substantially free of proteins, lipids, nucleic acid, for examples. Those of skill in the art can make similar substitutions to achieve peptides with the same anti-microbial activity as the peptides of the invention.
The peptides of this invention may be produced by known techniques and obtained in substantially pure form. For example, the peptides may be synthesized manually or on an automatic peptide synthesizer. It is also possible to produce the peptides by genetic engineering techniques. The codons encoding specific amino acids are known to those skilled in the art, and therefore DNA encoding the peptides may be constructed by appropriate techniques, and one may clone such DNA into an appropriate expression vehicle (e.g., a plasmid or a phage) which is transfected into a suitable system for expression of the peptides.
As mentioned before, the peptides of the present invention have a broad range of potent antibiotic activity against a plurality of microorganisms including Gram positive and Gram negative bacteria, fungi, protozoa and other parasites that are harmful to animals, including human, and plants.
Concerning animal prophylaxis and therapeutic treatment, the peptides of the present invention may be employed in promoting or stimulating healing of a wound in a host. The wound healing involves several aspects which include, but are not limited to, increased contraction of the wound, increased deposition of connective tissue, as evidenced by, for example, increased deposition of collagen in the wound, and increased tensile strength of the wound. In short, the peptides of the present invention work as to reverse the inhibition of wound healing caused by conditions which depress or compromise the immune system. Their wound healing activity includes the treatment of external burns and to treat and/or prevent skin and burn infections. In particular, the peptides may be used to treat skin infections caused by Gram positive and/or Gram negative bacteria, such as P. aeruginosa and S. aureus.
The peptides of the invention also have prophylactic and therapeutic properties concerning eye infections which may be caused by bacteria such as P. aeruginosa, S. aureus and N. gonorrhoeae , by fungi such as P. braziliensis, C. albicans and A. fumigatus , by parasites such as A. casreliani , or by protozoa.
The peptides of the present invention or analogues thereof may be administered in combination with a non-toxic pharmaceutical carrier or vehicle such as filler, non-toxic buffer, or physiological saline solution. Such pharmaceutical compositions may be used topically or systemically and may be in any suitable form such as liquid, solid, semi-solid, injectable solution, tablet, ointment, lotion, paste, capsule, or the like. The peptide compositions of the present invention may also be used in combination with adjuvants, protease inhibitors, or compatible drugs where such a combination is seen to be desirable or advantageous in controlling infection caused by pathogenic microorganisms including protozoa, and the like, as well as by parasites.
Depending on the use, a composition in accordance with the invention will contain an effective anti-microbial amount and/or an effective antifungal amount and/or an effective anti-parasitic amount and/or an effective antibiotic amount of one or more of the peptides of the present invention.
The peptides disclosed in the present invention may be used in compositions containing other peptides having anti-microbial activity. Examples of these peptides are mentioned in Park, C. B. et al. “Structure-activity analysis of buforin II, a histone H2A-derived antimicrobial peptide: The proline hinge is responsible for the cell-penetrating ability of buforin II” PNAS . 97(15), pp. 8245-8250. 2000 and those described the patents U.S. Pat. No. 5,424,395, U.S. Pat. No. 5,912,230, U.S. Pat. No. 5,861,378, U.S. Pat. No. 5,610,139, U.S. Pat. No. 5,821,224 and U.S. Pat. No. 5,877,274.
Referring to the administration form, the peptide compositions of the present invention may be administered by direct application of the peptides to the target cell, or indirectly applied through systemic administration.
Methods of administering pharmaceutical compositions to animals include intravenous, intra-arterial, intra-ocular, intra-peritoneal, intramuscular, intra-nasal, intra-vaginal, subcutaneous, rectal and topical administration. The mode of administration chosen for a particular pharmaceutical composition will depend upon a number of factors well known to the ordinarily skilled artisan or well within his purview to determine without undue experimentation. These include, but are not limited to the treatment subject and its age, size and general condition; the active agent being administered; and the disease, disorder or condition being treated.
Typically, the anti-infection effective of the pharmaceutical compositions provided herein is an amount containing between about 0,1 mg to about 1000,0 mg of one or more of the peptides of the invention per kg of the body weight of the animal to which the composition is administered. Within this range, the amount or dose of the pharmaceutical composition given a particular animal will depend upon a number of factors well known to the skilled person in the art. The particular amount of the pharmaceutical composition administered for the particular disease, disorder or condition indicated may be determined by methods well known to the skilled artisan, e.g., by dose ranging trials.
The peptides, when used in topical compositions, are generally present in an amount of at least 0.1%, by weight. In such pharmaceutical preparations, amounts greater than 2.0%, by weight are common.
In employing systemically administered compositions, such as intramuscular, intravenous, intraperitoneal, the peptide or peptides of the invention are present in an amount to achieve a serum level of peptide(s) of at least about 5 μg/ml. In most cases, the serum level need not exceed 500 μg/ml. Such serum levels, may be achieved by incorporating the peptide in a composition to be administered systemically at a dose of from 1 to about 100 mg/kg.
In another embodiment, the peptides of the present invention are useful for retarding plant pathogens, and for protecting plants from plant pathogens. In external application, the peptides may, be diluted in liquid solutions or suspensions, or mixed with a solid diluter to be applied as a dust to give a composition containing an amount of between about 1 to abort 100 μg of one or more peptides of the invention. Detailed methods for adapting general methods of application to specific crops and pathogens were disclosed in Methods for evaluating pesticides for control of plant pathogens . Hickey, K. D., Ed., The American Phytopathological Society (St. Paul, Minn.), 1986. Methods of application that are expected to be particularly useful in accordance with this aspect of the present invention include intermittent aqueous and non-aqueous sprays of the entire plant or parts thereof, seed coatings, and inclusion in irrigation systems (e.g., green-house mist-benches). Adjuncts that could be added to the formulation would include agents to aid solubilization, wetting agents and stabilizers, or agents that would produce microencapsulated product.
The present invention will be further described with respect to the examples as follows, but the scope of the invention is not to be limited thereby.
EXAMPLES
Example 1
Peptide Purification
Frog skin secretion (crude extract) was obtained from adult specimens of Phyllomedusa hypochondralis captured in Brasilia, Brazil. Frog secretion was obtained by moderate electric estimulation of the skin granular glands of P. hypochondrialis and freshly collected in distilled water as a crude extract. The extract was filtered by gravity through filter paper, frozen and lyophilized (Centrivap Concentrador LABCONCO). Peptides separation was performed by application (5-mg aliquots each time) of the crude extract to a semi-preparative Vydac reverse-phase chromatographic column, C 18 , 10μ (10×250 mm) in system HPLC. Peptides were purified by using a double linear gradient, initially 0% to 80% acetonitrile containing 0.1% TFA (trifluoacetic Acid) for 70 min, followed by 80% to 100% of same solvent for 20 min. The experiment was monitored 216 nm and fractions were collected manually and lyophilized. The isolated fractions were re-chromatographed by using a Vydac 218 TP 54, C 18 , 5μ (0.46×25 cm), with optimized gradients of acetonitrile in 0.1% TFA over 60 min and their purity was monitored by mass spectrometry (MALDI/TOF).
The chromatrographic profile correspondent to the total skin secretion of P. hypochondrialis after RP-HLPC purification is showed in the FIG. 1A . Peaks 1 to 7 correspond to other bioactive molecules which are not included in the present invention. PSI (Phyloseptin I) is assigned directly on the profile and the component marked with the asterisk (*) corresponds to the mixture of PSII and PSIII; which were individually separated as shown on the insert 1 B.
Example 2
Molecular Weight Determination and N-terminal Amino Acid Sequencing
The molecular mass of the anti-microbial peptides was determined by MALDI-TOF (Matrix-Assisted Laser Desorption/Ionization—Time Of Flight) mass spectrometry. Individual peptides were mass analyzed in a Voyager DE-STR MALDI-TOF mass spectrometer (PerSeptive Biosystems). Approximately 5 pmol of lyophilized peptide dissolved in distilled water was mixed with a saturated solution of α-cyano-4-hydroxycinnarnic acid. The experiment was carried out under reflector mode for monoisotopic resolution. Data were processed using, GRAMS V. 4.30 (Galactic Software). All spectra were obtained with close internal calibration using Sequazyme PerSeptive Biosystems molecular mass standards.
Amino acid sequencing was performed by the automated Edman degradation method on an PPSQ-23 Protein Peptide Sequencer SHIMADZU and the pairwise and multiple sequence alignment among sequences, were determined by using CLUSTAL V multiple sequence alignment software.
TABLE 1
Maximized pairwise and multiple sequence
alignments of Phylloseptins I, II and III.
(SEQ ID NOS 1, 2, 1, 3, 2, 3, 1, 2 and 3,
respectively in order of appearance)
PEPTIDE
SIMILARITY
PS I
FLSLIPHAINAVSAIAKHN
74%
PS II
FLSLIPHAINAVSTLVHHF
************* *
PS I
FLSLIPHAINAVSAIAKHN
84%
PS III
FLSLIPHAINAVSALANHG
************** * *
PS II
FLSLIPHAINAVSTLVHHF
79%
PS III
FLSLIPHAINAVSALANHG
************* * *
PS I
FLSLIPHAINAVSAIAKHN
74%
PS II
FLSLIPHAINAVSTLVHHF
PS III
FLSLIPHAINAVSALANHG
************* *
Example 3
Hemolysis Assay
Human erythrocytes (blood type O − ) from a 25-year-old healthy male were freshly prepared prior to each experiment. Hemolytic activity was assayed as described by Aboudy etal (Aboudy, Y., Mendelson, E., Shalit, I., Bessalle, R., Fridikin, M. 1994 . Int. J. Peptide Protein Res . 43, 573-582.) with minor modifications. Three milliliters of freshly prepared erythrocytes (for methodology see Gibson, B. W., Tang, D., Mandrell, R., Kelly, M. and Spindel, E. R. 1991 . J. Biol. Chem . 266, 23103-23111.21) was washed with isotonic phosphate-buffered saline (PBS), pH 7.4, until the color of the supernatant turned clear. The washed erythrocytes were then diluted to a final volume of 20 ml in the same buffer. Aliquots of cell suspentions (190 μl) containing samples (10 μl) were serially diluted in PBS, incubated at 37° C. for 30 min and then centrifuged at 4000×g for 5 min; 100 μl of supernatant was taken, diluted to 1.0 ml with PBS, and monitored at 567 nm. The relative optical density, as compared with that of the cell suspension treated with 0.2% Triton X-100, was defined as % hemolysis.
The hemolytic activity of Phylloseptin I and II was tested at different concentrations. The results are showed in Table 2.
TABLE 2
Hemolytic activities of Phylloseptin I (PS I)
and Phylloseptin II (PS II).
% Hemolysis of
Concentrations
human red blood cells
μg/mL
μM
PS I
PS II
1
0.496
0.00
0.00
2
0.990
0.00
0.00
4
1.980
0.00
0.10
8
3.968
0.30
0.28
16
7.937
0.57
0.70
32
15.873
0.60
0.80
64
31.746
0.98
1.05
128
63.492
1.98
2.05
Example 4
Anti-microbial Assay
The microorganisms Escherichia coli ATTC 25922 , Pseudomonas aeroginosa ATTC 27853 , Staphylococcus aureus ATTC 25923 and Enterococcus faecalis ATTC 29212 and a Brazilian strain of P. aeroginosa were used for the anti-microbial assay
The microorganisms were cultured in stationary culture at 37° C. Bacteria were grown in Tryptic Soy Broth (TSB). The bioassays were performed by liquid growth inhibition assay lawn as described by Bulet et al (Bulet, P., Dimarcq, J. L., Hetru, C., Lagueux, M., Charlet, M., Hegy, G., VanDorsselaer, A. and Hoffmann, J. A. 1993 . J. Biol. Chem . 268, 14893-14897). Molecules of Phylloseptin I were dissolved in sterile distilled and deionized water and diluted 8-fold in TSB (OXIOD England) broth. Various concentrations of PSI solution were tested, being the highest 128 μg/ml. The initial inoculum was approximately 1×10 5 colony forming units (CFU)/ml and limit of detection was 10 2 CFU/ml. The final volume was 250 μl (25 μl of the peptide test in water, 25 μl of the inoculum in TSB, and 200 μl of TSB broth). The minimal inhibitory concentration (MIC) was measured for turbidity (OD at 595 nm) 20 h after all microorganisms were grown in stationary culture at 37° C. The lowest concentration of the peptide in which no growth occurred was defined as the MIC.
The minimal inhibitory concentrations (MICs) of the isolated Phylloseptin I against several Gram-positive and Gram-negative bacteria were determined as described by Park et al (Park, C. B., Kim, M. S., and Kim, S. C. 1996. 218 Biochem. Biophys. Res. Commun . 408-413.). The lowest concentration of anti-microbial peptide which showed visible suppression of growth was defined as the MIC. That is, the minimal inhibitory concentration was defined as the peptide concentration which produces 100% of microorganism growth inhibition after 20 h incubation in culture media. The results are showed in Table 3.
TABLE 3
Antibacterial activity of PS I defined by criteria of minimal inhibitory concentration.
Minimal Inhibitory concentration
Bacteria
PS I
Chloranfenicol
Gentamicyn
Amplicilyn
Polimixyn B
μg/mL
Pseudomonas aeruginosa wt
6
—
64
—
16
Staphilococcus aureus ATTC
16
32
—
—
—
Pseudomonas aeruginosa ATTC
8
—
64
—
16
Escherichia coli ATTC
16
32
64
64
64
Enterococcus faecalis ATTC
8
32
—
128
—
(—) there was no inhibition of bacteria proliferation on these concentrations.
Example 5
Determination of Peptide-induced Membrane Alterations by Atomic Force Microscopy
Atomic force microscopy (AFM) used in this experiment was a TopoMetrix 2000 Explorer (TopoMetrix, Santa Clara, Calif., U.S.A) operating in the contact mode and at ambient air. A piezoelectric hybrid tube scanner with a maximum scanning area of 50 microns square was used. Standard 200 microns V-shaped Si 3 N 4 cantilevers with integrated pyramidal tips was used. The nominal spring constant for the contact force of the tip on the specimen surface was set to 0.00 nA. The line scan speed was set to 20 μm/s. Pseudomonas aeruginosa ATTC 27853 was used in this experiment. The strain was cultured in nutrient broth at 37° C. for about 12 hours. The bacterial was collected and suspended in 150 mM KCl/20 mM MgCl 2 /10 mM Tris-HCl, pH 7.8. The concentration of the bacteria in the suspension was adjusted to approximately 4×10 8 bacteria/ml according to its turbidity. The bacterial suspension was placed on freshly cleaved mica and air dried. The mica was fixed on the specimen holder with a two-sided adhesive tape and was then installed on the top of the scanner for AFM observation.
AFM has been used extensively to study materials (Lacava, B. M., Azevedo, R. B., Silva, L. P., Lacava, Z. G. M., Skeff Neto, K., Buske, N., Bakuzis, A. F., and Morais, P. C. 2000 . Applied Physics Letter 77 (12):1876-1878.) and biological samples being considered to be a useful tool for identifying bacterial surface characteristics. AFM has also been used to detect topographic surfaces while operating under determined physiological conditions (Braga, P. C., and Ricci, D. 1998 . Anti-microbial Agents and Chemotherapy 42 (1):18-22).
The effect of peptide on the cell membrane of P. aeuruginosa was examined under AFM. FIGS. 4 shows image of a intact bacteria and in FIG. 5 one cell of P aeruginosa treated by peptides. Peptide was added to bacteria and incubated for 4 hour under the same conditions as in the anti-microbial assay. At the MIC, grooves were developed on the surface of P. aeuruginosa indicating that the inhibition of bacterial growth should be associated with the destruction of the bacterial membrane. | The present invention relates to a class of anti-microbial peptides, called Phyllosepti ns, isolated from Phyllomedusa hypochondrialis . The invention also relates to therapeutic and agricultural compositions comprising one or more Phylloseptins. Methods of treating infections of various mammalian organs such as the skin and methods of treating plant infections are also included in the invention. | 2 |
FIELD OF THE INVENTION
[0001] The invention relates to a spinning preparation machine with a drafting device for drafting at least one fiber sliver band, in particular a carding, drafting or combing machine, with at least one microwave sensor at the inlet and/or at the outlet of the drafting device for measuring the sliver thickness of the at least one sliver, which microwave sensor comprises at least one cavity resonator through which the at least one sliver is to be guided during the measurements. The invention also comprises such a cavity resonator.
BACKGROUND
[0002] In the spinning industry at first an evened-out fiber structure is produced from, e.g., cotton, in several process steps and finally a twisted yarn is produced as the end product. The spinning preparation machines such as carding, drafting and combing machines arranged upstream from the manufacture of yarn have the particular task of leveling out fluctuations of sliver mass of one or several slivers. To this end, sliver sensors are arranged, e.g., on drafting frames that measure the sliver thickness, also called sliver mass, and their fluctuations and transmit this information to a regulating unit that appropriately regulates at least one of the drafting members of the drafting device. Even in non-regulated drafting frames, information about the fluctuations of sliver thicknesses is desired in many instances. An appropriate sensor at the output of a drafting device emits, e.g., a corresponding cut-out signal for the machine and/or a warning signal if a threshold value of the sliver thickness is exceeded or dropped below.
[0003] The known measuring methods for determining fluctuations of sliver thickness are primarily based on mechanical scans. However, the dynamics of these mechanical sensors are no longer sufficient in the case of delivery speeds at the output of the drafting device of in particular more than 1000 m/min. In addition, the necessary strong mechanical compression in front of a mechanical sensor makes itself noticeable in a negative manner on the drafting capacity.
[0004] WO 00/12974 teaches a microwave resonator for the continuous detection of fluctuations of sliver thicknesses of moved textile strands at the inlet of the drafting device. Alternatively or additionally, a microwave sensor is arranged at the outlet of the drafting device that can be used in particular for monitoring the quality of the evened-out fiber material.
[0005] The device according to WO 00/12974 comprises a temperature sensor in order to compensate temperature influences by means of a processor. However, the cited design has the disadvantage that this temperature compensation for taking into account influences of temperature on the measured results is not an optimal solution since it is cost-intensive on the one hand and on the other hand is based on necessarily empirical calculating algorithms.
SUMMARY
[0006] The present invention has the problem of improving the precision of measurements of sliver thicknesses relative to the conditions prevailing in spinning mills. Additional objects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0007] This problem is solved in the spinning preparation machine of the initially cited type by means for preventing temperature-conditioned deformations of the resonator walls of the microwave sensor during the measurements. The problem is likewise solved by a cavity resonator with resonator walls that are manufactured at least in sections from a material with a low coefficient of thermal expansion.
[0008] The advantages of the invention reside in particular in the fact that temperature variations that have an influence on the measuring precision when microwaves are used can be eliminated to a great extent. Expensive calculating compensation solutions can possibly be completely eliminated.
[0009] During the production start, the temperatures in and on the machine are relatively low but rise with the time. In particular the development of heat due to the machine motors and other moved components, as well as the sliver friction on the input and output of the cavity resonator, cause a rise in temperature that results in deformations of the cavity resonator walls. Such changes of the resonator geometry cause a shifting of the resonator frequency (given an unchanged cross section of the sliver) and therewith a falsification of the measured values and/or result in inaccuracies of measurement. The measuring accuracy can be significantly raised by the means in accordance with the invention for preventing these temperature-conditioned deformations of the resonator walls. Thus, it is in particular immaterial whether the machine has just started or has been in operation for some time. If, on the other hand, a single calculating compensation regarding temperature influences were to be performed, at first the temperature would have to be measured and the appropriate point in the correction curve found that represents the correction value for a certain temperature.
[0010] In the cavity resonator in accordance with the invention that is used in an advantageous embodiment of the machine, the resonator walls are manufactured at least in sections from a material with a low coefficient of thermal expansion. Such a selection creates the advantage that temperature variations and therewith expansions and shrinkings of the resonator walls can occur only to a very slight extent. A preferred material in this connection is steel with a low thermal expansion, which steel has a thermal expansion at customary operating temperatures of approximately ⅕ and preferably approximately 1/10 of the thermal expansion of steel customarily used in textile machines. Such a steel is, e.g., an Ni36 steel, that is, a steel with a nickel component of approximately 35-37% as well as lesser amounts of other metals as well as carbon or a steel comparable to it. Ni36 steel has an almost negligible thermal expansion, that is, the coefficient of thermal expansion at 20° C. is approximately zero for such a steel. Such a steel is known, and referred to as “Invar” steel. Other comparable steels have other trade names. Furthermore, Ni36 steels are distinguished in addition to an almost negligible thermal expansion in that they are relatively elastic in comparison to ceramic material, that is, they do not have its brittleness and therewith its susceptibility.
[0011] If materials are used for the resonator walls that oppose the formation of a resonance and/or the ability to measure the resonance frequency and the damping at this frequency in the cavity of the sensor, its inner walls can be provided with a conductive layer. Such a layer can be, e.g., 5 μm thick.
[0012] It is alternatively or additionally advantageous to largely decouple the sensor from the rest of the machine in a thermal sense with thermal insulating material. Such a thermally screened island prevents waste heat from motors or other moving machine elements from reaching the sensor and causing changes of volume there and therewith a shifting of the resonance frequency of the resonator.
[0013] In the case of such a thermal decoupling, e.g., insulating foils can be arranged around rather large sections of the resonator. Alternatively or additionally, the sensor can be at least partially surrounded by a thermally screening housing. In another alternative or in an additional design the connecting elements with which the sensor is attached to a machine part are fastened with a material with low thermal conductivity so that the thermal conduction at this location is substantially interrupted.
[0014] Alternatively or additionally to the previously cited passive means for preventing temperature-conditioned deformations of the resonator walls, active temperature adjustment means are preferred. This achieves great flexibility in the adjusting of the temperature of these walls. An undesired heating or cooling off of the resonator walls can be counteracted in this instance in that the temperature is adjusted to the desired extent. To this end it is especially preferable if the temperature adjustment means can be regulated.
[0015] In order to realize such a regulation it is advantageous to provide one or several temperature measuring elements for measuring the temperature of the inner chamber of the resonator and/or the temperature of the resonator walls. To this end a conclusion can be made about the temperature of the resonator walls and/or of the ambient, e.g., by a resistance measurement. Such a known temperature measuring device, that is economical in addition, is, e.g., a so-called PT100, that is fastened, e.g., to an outer wall of the resonator. Alternatively, an inductive coil or some other suitable measuring method can be used.
[0016] The at least one temperature element is advantageously attached to a location that is representative for the temperature behavior of the entire resonator. Alternatively, several temperature sensors arranged at different locations can be used whose signal is preferably preprocessed. It is advantageous in this connection, e.g., to use an average value or some other evaluation for estimating a representative temperature value that is used for regulating the temperature.
[0017] An inhomogeneous temperature distribution in the resonator chamber with a undesired consequence of imprecise temperature measurements can be largely prevented if air with a constant temperature is conducted through the resonator and/or past the resonator. Such an airflow can also be used to clean the resonator chamber, especially to eliminate fibers that became loose from the fiber structure.
[0018] The regulation of the active temperature adjustment means can take place in various ways. For example, a separate control unit is provided in one embodiment. Alternatively or additionally, an evaluation unit associated with the at least one microwave sensor can be used to regulate the temperature. However, even the central machine control can assume the regulation of the temperature adjustment means.
[0019] It is especially advantageous that the temperature adjustment means comprises a heating means and that the end temperature of the resonator walls is advantageously above the temperature produced by the influences of the machines, the ambient and friction. A heating means that can be used with advantage is, e.g., a heating foil that can be attached in particular around rather large-area sections on the outside of the resonator.
[0020] Alternatively or additionally, at least one resonator wall is directly heated in that a heating voltage is preferably applied to it.
[0021] Instead of heating the resonator walls, cooling agents can be provided that adjust the resonator walls below the temperature produced by the influences of the machines, the ambient and friction.
[0022] Alternatively or additionally, cooling agents are designed to produce a cooling airflow. Such an airflow can also be used to clean the resonator chamber and/or bordering machine sections. The above-mentioned homogeneous temperature distribution, that is desired in a few instances, can likewise be achieved in the inner chamber of the resonator by such an airflow if this airflow is conducted at least partially through the inner chamber of the resonator.
[0023] Independently of whether the active temperature adjustment means bring about a heating or a cooling of at least one resonator wall, the corresponding electrical circuit of the heating or cooling agent can be interrupted, e.g., upon reaching the desired temperature or shortly before it. If the desired temperature is exceeded or drop below, the current is closed again in order to heat or cool. It is likewise advantageous to regulate the heating or cooling agents when the machine is engaged in order to rapidly achieve the desired temperature.
[0024] The temperature adjustment means are advantageously designed as a Peltier element in order to heat or cool at least one resonator wall. The at least one Peltier element removes, e.g., the heat from the resonator wall to be cooled when used as cooling agent and the temperature of the at least one resonator wall can be maintained distinctly below the temperature that would be achieved using conventional cooling.
[0025] It is also possible to regulate different elements of the resonator differently. E.g, the resonator side facing the inner chamber of the resonator can be cooled and the side facing away from it can be heated and the corresponding resonator sections do not necessarily have to have the same end temperature, but rather the goal is to maintain the resonator geometry constant during the measurements.
[0026] The various means for preventing deformations of the resonator walls during the measurements can be combined in various ways.
[0027] An independent aspect of the invention provides keeping the resonator chamber clean or cleaning it by an airflow. The strength and/or the flow path of the airflow can be advantageously adjusted by an airflow control means, e.g., by at least one throttle flap on an air baffle element of these means. The opening width of the at least one throttle flap can be adjusted in particular manually or electrically. In particular, an automatic actuation of the at least one throttle flap can be realized. The degree of contamination of the resonator can be taken as a control value, that can be determined with at least one appropriate sensor in an advantageous exemplary embodiment. Such a sensor can be, e.g., an optical sensor whose received signals become weaker with increasing contamination and finally fall below a threshold value. Other embodiments can be based, e.g., on the measuring of contamination-dependent resistance values that are a function, e.g., of a thickness of a contaminant film or grease film on the resonator walls. A conclusion about a contamination of the inner chamber can optionally also be made from the resonance signal itself, advantageously when a boundary value of the resonator characteristics (resonator quality) is exceeded when the resonator is empty. In this case the evaluation unit of the sensor advantageously emits an appropriate signal for controlling the at least one throttle flap of another airflow control means.
[0028] The airflow can be used as a suction flow or as a blowing flow. In addition, a continuous or an interrupted airflow can be used. The time intervals can be, e.g., periodic or made dependent on an exceeding of threshold or boundary values, e.g., on the degree of contamination or on the quality of the resonator.
[0029] The sequence of the successive suction or blowing impulses can advantageously be adjusted in their duration and/or their interval in time, e.g., on an operator desk (so-called panel) and/or from a central control device in the spinning mill. In correspondence with the above, the duration, interval, strength, flow path, etc. of the airflow can be adjusted manually and/or automatically.
[0030] In an advantageous variant the airflow is actuated during a can change since, if no so-called flying can change is being realized during continuous sliver production, no measurements are being carried out on the stationary sliver or slivers at this time.
[0031] It proved to be advantageous if the airflow is directed along the fiber material and it is especially preferred if the air is conducted on sides opposite the fiber material so that an effective removal of individual fibers and other contaminating particles is assured.
[0032] The airflows for cleaning and/or temperature adjustment can be directed differently. E.g., suction can be applied to the sensor from below. Likewise, a vacuum can be generated by airflow in a housing surrounding the sensor and insulating it thermally.
[0033] Advantageous further developments are characterized by the features of the subclaims.
[0034] The invention is explained in detail in the following with reference made to the figures.
BRIEF DESCRIPTION OF THE FIGURES
[0035] FIG. 1 shows a drafting frame with a regulation schematically shown as a block diagram.
[0036] FIGS. 2 a , 2 b , 2 c schematically show a microwave sensor with funnel in front and downstream calendar rollers in a top view, lateral view and rear view.
[0037] FIG. 3 schematically shows a microwave sensor in a housing.
DESCRIPTION
[0038] Reference is now made to one or more embodiments of the invention, examples of which are illustrated in the drawings. The embodiments are provided by way of explanation of the invention, and are not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with a different embodiment to yield still a further embodiment.
[0039] A regulating principle for drafting frame 1 is explained by way of example in the following using FIG. 1 . The sliver thickness of entering slivers 2 , in this instance six slivers 2 , is detected at the inlet of drafting frame 1 by microwave sensor 3 , that works in accordance with the resonator principle (microwave generator not shown). Funnel 18 designed as a compression means for compressing slivers 2 is connected in front of the sensor 3 . After passing microwave sensor 3 , slivers 2 are spread out to a fleece (shows as a triangle widening out toward drafting device 1 a ) that runs into drafting device 1 a . Drafting device 1 a is formed in this instance by an entrance roller pair, middle roller pair and a supply roller pair (only the lower roller 20 , 21 and 22 of the roller pairs is shown). A draft of slivers 2 is realized by clamping the slivers or fleece 2 between the rollers of the various roller pairs, that rotate with increasing circumferential speeds, viewed in the direction of sliver travel.
[0040] The measured values of sensor 3 are converted by evaluation unit 4 into electric voltage values that represent the fluctuations of sliver thickness and are supplied to memory 5 . This memory 5 is designed as a FIFO memory (first-in-first-out) and forwards the voltage with a defined delay in time to theoretical value stage 7 . To this end memory 5 receives a number of impulses from impulse generator 6 that is a measure for the speed of slivers 2 running through sensor 3 . The slivers are transported here from the pair of entrance rollers so that it is appropriate to couple impulse generator 6 to this roller pair. Using the impulses from impulse generator 6 , the voltage values of sensor 3 are retained in memory 5 in accordance with the path traversed by slivers 2 between sensor 3 and drafting device la. When the slivers or fleece 2 with the sliver piece to be regulated reach the fictitious draft location in the draft field of drafting device 1 a , the corresponding measured value is released by memory 5 and an appropriate placing handling is performed, which will be discussed in detail in the following. The interval between the measuring location a sensor 1 and the drafting location is called the regulation start point.
[0041] Alternatively, impulse generator 6 can be coupled to another roller pair, e.g., to a transport roller pair directly behind sensor 3 (viewed in the direction of sliver travel). In this instance the entrance roller pair does not transport the slivers through sensor 3 but rather the transport roller pair does.
[0042] Moreover, theoretical value stage 7 receives a pilot voltage from pilot tachometer 9 that is a measure for the speed of lower roller 22 of the supply roller pair, which roller 22 is driven by main motor 8 . Subsequently, a theoretical voltage is calculated in theoretical value stage 7 and forwarded to control unit 10 . A theoretical-average value comparison takes place in control unit 10 and the actual values of regulating motor 11 are transmitted to actual value tachometer 12 that then forwards the corresponding actual value to control unit 10 . The theoretical-actual value comparison in control unit 10 is used to impart a quite determined speed corresponding to the desired draft change to regulating motor 11 . Regulating motor 1 1 drives planetary transmission 13 so that the speeds of lower roller 20 of the entrance roller pair and of lower roller 21 of the middle roller pair is changed in accordance with the desired evening-out of the slivers. The sliver thickness in drafting device la is regulated at the so-called regulating start point, that is, at the draft location by the proportional superpositioning of the speeds of main motor 8 and of regulating motor 11 taking account of the cited dead [idle] time.
[0043] Other drive concepts, e.g., individual drives can be realized in other variants (not shown).
[0044] Microwave sensor 30 is arranged at the discharge of drafting device la and is connected in downstream from fleece nozzle 19 designed as a compression device in the exemplary embodiment shown. The sliver or sliver fleece 2 ′ leaving the drafting device is drawn off by calender roller pair 35 connected in downstream from sensor 30 . The signals of sensor 30 are supplied to evaluation unit 31 that supplies the electrical voltage signals in accordance with the sliver thickness of drafted sliver 2 ′ and forwards them to control unit 10 . For example, long-wave periodic fluctuations of slivers 2 presented to drafting device 1 a can be regulated by the signals from sensor 30 . Alternatively or additionally, the signals of sensor 30 are used for quality control during which the machine is advantageously turned off if a threshold value is exceeded or dropped below.
[0045] FIG. 1 schematically shows that a temperature element 40 , 41 is arranged on sensors 3 , 30 for measuring the temperature in the inner chamber of the resonator or on a resonator wall. Several temperature measuring elements can also be used in order to order to obtain, e.g., an average temperature value. Since it was found that the measuring accuracy of sensors 3 , 30 suffers on account of temperature fluctuations due to turning the machine on and off as well as on account of the machine environment and associated heating and cooling of the resonator walls, an appropriate temperature control is desirable.
[0046] Temperature elements 40 , 41 forward the measured temperature values to evaluation units 4 , 31 . In the exemplary embodiment shown evaluation units 4 , 31 likewise serve for temperature control in order to control correspondingly designed temperature adjustment means 14 , 15 . In the case of sensor 3 arranged in front of drafting device la evaluation unit 4 regulates heating circuit 14 that assumes the heating of at least one resonator wall of sensor 3 . Alternatively, at least one heating foil can be tied into heating circuit 14 that is arranged at least sectionally around the resonator, advantageously making contact, (not shown). Care is to be taken that these heating means do not cause any disturbance of the microwave resonance signals.
[0047] Heating circuit 14 can be actuated immediately after the machine has been turned on after it has been standing still for a rather long time in order to rapidly achieve the desired heating temperature. The goal is to bring the resonator walls to a largely constant temperature that is independent from the temperature in the interior of the machine but also from the ambient temperature of the machine and, if applicable, from temperature effects produced by sliver friction on resonator elements. Then, no temperature-conditioned deformations can occur at such a constant temperature, so that the accuracy of the measured values is increased.
[0048] During normal operation temperature measuring element 40 determines the current temperature, whereupon evaluation unit 4 regulates heating circuit 14 if a given threshold value is dropped below. If a given temperature registered by measuring element 40 is exceeded, evaluation unit 40 furnishes a corresponding command to heating circuit 14 for interrupting the heating process.
[0049] A corresponding design with an analogous heating method is provided at the discharge of drafting device 1 a for sensor 30 . Evaluation unit 31 likewise assumes the control of heating circuit 15 , that is designed to adjust the temperature of at least one resonator wall of resonator 30 .
[0050] The control of heating circuits 14 , 15 can also be realized by control unit 10 in an embodiment that is not shown. Even specific [individual] control units can be provided in another alternative.
[0051] Instead of a heating of the resonator walls and/or of the resonator chamber a cooling can be realized. It is important that the resonator walls are adjusted to a substantially constant temperature in order to suppress volumetric fluctuations of the resonator chamber as well as distortions of the resonance field.
[0052] In alternative or additional designs, the resonator walls are manufactured at least partially from a material with a low thermal expansion, e.g., Ni36 steel (e.g., Invar steel). Other possibilities that can be used alternatively or additionally include the thermal insulation of the sensor with the aid of fastening elements that suppress the conduction of heat that are attached to the machine and/or include thermal insulation housings and the like.
[0053] FIGS. 2 a (top view), 2 b (side view) and 2 c (rear view) show microwave sensor 300 , shown without a microwave generator, with funnel 118 in front and calender roller pair 135 that draws the at least one sliver 2 through funnel 118 and sensor 300 . In FIGS. 2 a , 2 b the at least one sliver 2 is indicated solely by a dotted arrow; in FIG. 2 c sliver 2 is shown in cross section as a composite of many individual fibers. Furthermore, funnel 118 and calender rollers 135 are not shown in FIG. 2 c.
[0054] Instead of funnel 118 other sliver guide elements can also be used, e.g., horizontally and/or vertically arranged deflection rods that can, e.g., also have concave guide surfaces in order to allow the at least one sliver 2 to run into sensor 300 in a centered manner. Furthermore, calender rollers 135 can be arranged rotated through 90° or any other angle.
[0055] Sensor 300 comprises resonator 300 a with two semicylinders 301 , 305 separated by slot 310 . Outer walls 302 , 306 of semicylinders 301 , 305 are manufactured from metal and inner walls 303 , 307 oriented toward sliver 2 are manufactured from ceramic material. The resonance develops in the inner resonator chamber between walls 302 , 306 .
[0056] An airflow is conducted through slot 310 in the direction of sliver travel on both sides of sliver 2 . This airflow is shown in FIGS. 2 a , 2 b in dotted lines and in FIG. 2 c as a circle with crossed lines sketched in it (direction of airflow is directed away from the observer). The air flow or airflows 50 can assume several functions. On the one hand they assure a largely homogeneous distribution of temperature in slot 310 and on the other hand they prevent a depositing of, in particular, fibers on inner walls 303 , 307 of semicylinders 301 , 305 as well as on the discharge of resonator 300 a and at the transition to calender rollers 135 . Such deposits of contaminants would detune resonator 300 a and result in inaccurate measurements.
[0057] Furthermore, airflow 50 can be used for a purposeful adjustment of temperature, in particular of resonator walls 302 , 306 . In particular, it is possible to use cooling air in order to cool off resonator walls 302 , 306 to the most constant temperature possible, that is lower in comparison to that of normal operation.
[0058] FIG. 3 shows another embodiment of a microwave sensor 3000 in which, in contrast to the embodiment of FIG. 2 , a housing 45 is additionally provided around cavity resonator 3000 a . Housing 45 , whose front wall facing the observer is shown removed, is thermally insulated in order to keep heat coming from the machine room and the environment from resonator 3000 a . In addition, two slots 312 , 314 are provided between the outer walls of resonator 3000 a and the inner walls of the housing through which slots airflow 51 is conducted. Even these airflows 51 can be used to clean slots 312 , 314 and/or to adjust the temperature of the resonator walls.
[0059] In FIG. 3 , the airflows guided to sensor 3000 branch off into two partial flows, on the one hand into airflow 51 already described and on the other hand into airflow 50 running through slot 310 . As an alternative, no airflow 50 through slot 311 or an airflow 50 provided specifically for slot 310 is provided.
[0060] Airflow 50 , 51 in FIGS. 2, 3 can be blowing or suction flows, which latter produce a vacuum in slots 310 , 312 , 314 .
[0061] It should be appreciated by those skilled in the art that modifications and variations can be made to the embodiments described above without departing from the scope and spirit of the invention as set forth in the appended claims and their equivalents. | A spinning preparation machine includes a drafting device for drafting at least one fiber sliver. The machine includes a microwave sliver thickness sensor through which the fiber sliver is guided, the sensor disposed at the inlet or outlet, or both, of the drafting device and includes at least one cavity resonator defined by a resonator wall. A device or system is incorporated with the sensor for minimizing temperature-conditioned deformations of the resonator during measurement of sliver thickness. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/CN2007/070261 filed Jul. 10, 2007, which claims the priority of Chinese Application No. 200610088895.4, filed on Jul. 24, 2006. The contents of both applications are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to the field of telecommunications, and particularly to a method and device for power control in High Speed Downlink Packet Access (HSDPA).
BACKGROUND OF THE INVENTION
Currently, the deployment of HSDPA technologies in Time-Division Synchronization Code Division Multiple Access (TD-SCDMA) and Wideband Code Division Multiple Access (WCDMA) systems has provided a higher data rate, a shorter service response time and improved service reliability.
A transmission channel introduced in the TD-SCDMA and WCDMA HSDPAs is a High Speed Downlink Shared Channel (HS-DSCH), which is used as a bearer of higher layer data from a User Equipment (UE) and corresponds to a physical channel of High Speed Physical Downlink Shared Channel (HS-PDSCH).
The Adaptive Modulation and Coding (AMC) technology deployed in the HSDPA is mainly applied to the HS-DSCH, so that a UE in an advantageous position may be provided with a higher data rate with the combination of the AMC and the Hybrid Automatic Repeat reQuest (HARQ), thereby improving an average throughput of a cell.
Furthermore, with the AMC modulation scheme without changing the transmission power, the transmission power of a Base Station is sufficiently utilized. When a channel for a UE is of a relatively high quality, higher order modulation and a higher coding rate are used at a network side and the UE is assigned with a higher data rate; and when the channel for the UE is degraded, lower order modulation and a lower coding rate are used at the network side and the UE is assigned with a lower data rate.
However, no power control is performed in the HS-DSCH of the prior art. When the transmission power of the Base Station is excessively high and exceeds a dynamic range of a receiver in the UE, the receiver in the UE may be saturated, so that the receiving performance is degraded. Furthermore, when the channel for the UE has a high quality and the transmission in the HS-DSCH is at the predetermined power, the Signal-to-Noise Ratio (SNR) may be higher than that required for the highest transmission rate of the UE, thus, system interference is increased, throughput of the cell is decreased and the power is wasted.
SUMMARY OF THE INVENTION
An aspect of the present invention is to provide a method and device for power control in HSDPA, thereby improving performance of a receiver, decreasing intra-cell and inter-cell interference, improving throughput in a cell and reducing power waste.
Another aspect of the present invention is to provide a method for power control in HSDPA, thereby efficiently assigning excessive power in the case of a plurality of UEs under scheduling, to improve power utilization, lower system interference and improve system throughput.
The solutions in the present invention include the following.
A method for power control in HSDPA is provided, including:
determining whether environment of a channel for a UE is favorable, and if the environment of the channel is favorable, decreasing transmission power; otherwise, monitoring a Channel Quality Indicator (CQI) returned by the UE, increasing the transmission power if the Channel Quality Indicator is lower than the highest rate level supported by the UE or data for retransmission is sent, and maintaining the transmission power unchanged if the Channel Quality Indicator is equal to the highest rate level supported by the UE and new data is sent.
Preferably, it is determined that the environment of the channel for the UE is favorable if one or more of the following cases is met:
a case where the Channel Quality Indicator returned uplink is received by a Base Station, and is always maintained at the highest rate level supported by the UE within a statistic period;
a case where a Transmit Power Control (TPC) command word sent by the UE through an uplink Dedicated Physical Channel (DPCH) is detected by the Base Station, and the TPC command word always instructs the Base Station to decrease the transmission power within a statistic period; and
a case where the uplink Dedicated Physical Channel or control channel is measured, and the SNR of the uplink channel is always higher than a target SNR of the channel within a statistic period.
Preferably, the transmission power is adjusted step by step by a predefined power control step.
Preferably, the transmission power is increased without exceeding the predefined maximum transmission power.
A method for power control in HSDPA is provided, including:
A: selecting a UE with the highest priority which desires to transmit data according to a scheduling algorithm, assigning a code channel to the UE and setting an initial transmission power value;
B: determining whether environment of the channel for the UE is favorable; if the environment of the channel is favorable, decreasing transmission power; otherwise, monitoring a Channel Quality Indicator returned by the UE, and then increasing the transmission power if the Channel Quality Indicator is lower than the highest rate level supported by the UE or data for retransmission is sent, and maintaining the transmission power unchanged if the Channel Quality Indicator is equal to the highest rate level supported by the UE and new data is sent; and
C: determining whether an available code channel remains and a UE with the second highest priority exists, and if the available code channel remains and the UE with the second highest priority exists, assigning a code channel for the UE with the second highest priority, using previous transmission power of the code channel as the initial transmission power value and returning to step B; otherwise, ending.
Preferably, it is determined that the environment of the channel for the UE is favorable if one or more of the following cases is met:
a case where the Channel Quality Indicator returned uplink is received by a Base Station, and is always maintained at the highest rate level supported by the UE within a statistic period;
a case where a TPC command word sent by the UE through an uplink Dedicated Physical Channel is detected by the Base Station, and the TPC command word always instructs the Base Station to decrease the transmission power within a statistic period; and
a case where the uplink Dedicated Physical Channel or control channel is measured, and the SNR of the uplink channel is always higher than a target SNR of the channel within a statistic period.
Preferably, the transmission power is adjusted step by step by a predefined power control step.
Preferably, the transmission power is increased without exceeding the predefined maximum transmission power.
The present invention further provides a device for power control in HSDPA, including:
a signal receiving and demodulating unit, adapted to detect and demodulate an uplink signal on a basis of a UE and a code channel, send the demodulated HS-DSCH data to a channel decoding unit, measure the uplink channel and send a measured SNR and a transmission TPC command word extracted from a downlink shared channel to a modulating and sending unit as the measured information;
the channel decoding unit, adapted to decode the HS-DSCH data to extract a Channel Quality Indicator and response information returned from the UE, and send the extracted Channel Quality Indicator and response information to a data scheduling unit;
the data scheduling unit, adapted to manage priority of the UE and schedule the UE, assign a code channel to the UE, determine transmission power of the code channel, and send the HS-DSCH data and the related control information to a channel coding unit;
the channel coding unit, adapted to code and map the HS-DSCH data to a physical channel, code the control information related to the HS-DSCH data, and send the coded and mapped data to the modulating and sending unit; and
the modulating and sending unit, adapted to modulate the data coded and mapped by the channel coding unit, perform power control with the measured information from the signal receiving and demodulating unit, and send out the power corresponding to each code channel, that is sent by the data scheduling unit, for further processing.
The signal receiving and demodulating unit is further adapted to measure the SNR of the uplink channel, and send the measured SNR and the transmission TPC command word extracted from the downlink shared channel to the data scheduling unit as the measured information. The data scheduling unit is further adapted to assist the scheduling and the HS-DSCH power control according to the received measured information.
In comparison with the prior art, the solutions provided in the present invention have the following technical benefits.
In the data communication of the UE using the HSDPA, the HS-DSCH power is controlled in real time with the technical solutions provided in the present invention, and the downlink data is always sent at appropriate power by monitoring and feeding back the conditions of the channel environment of the UE, so that the power waste and the interference in the cell is reduced.
Furthermore, the present invention discloses that the power in the channel environment of the UE may be decreased in the case where the Channel Quality Indicator returned uplink and received by the Base Station is always maintained at the highest rate level supported by the UE, in the case where a TPC command word sent by the UE through an uplink Dedicated Physical Channel and detected by the Base Station always instructs the Base Station to decrease the transmission power, or in the case where the measured SNR of the uplink Dedicated Physical Channel or control channel is always higher than a target SNR of the channel. In one or more of the cases above, the power in the channel environment can be decreased. With the invention, the transmission power can be adjusted in time according to the conditions of the channel environment.
In addition, the technical solutions in the present invention may be applied to the case of a plurality of UEs under scheduling. After power adjustment is performed for the UE with the highest priority in a scheduling queue, the power adjustment may be performed for the UE with the second highest priority selected from the scheduling queue if available power remains, so that the remained power may be utilized more efficiently, system interference may be reduced, and system throughput may be improved.
The invention is further described below in connection with the drawings and embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart illustrating control and adjustment on transmission power in an HS-DSCH according to an embodiment of the present invention;
FIG. 2 is a flow chart illustrating control and adjustment on transmission power in an HS-DSCH of one UE according to an embodiment of the present invention;
FIG. 3 is a flow chart illustrating transmission power control and adjustment for a plurality of UEs according to an embodiment of the present invention;
FIG. 4 is a flow chart illustrating control and adjustment on transmission power in HS-DSCHs of a plurality of UEs according to an embodiment of the present invention; and
FIG. 5 is a block diagram of the device for transmission power control in an HS-DSCH according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With the present invention, the HS-DSCH power is controlled dynamically so that downlink data is always sent at appropriate power, thereby reducing the power waste and the interference in the cell, and improving the throughput of the cell. The invention is described in detail below in connection with the drawings and embodiments.
A procedure of control and adjustment performed on transmission power of an HS-DSCH for one UE under scheduling is shown in FIG. 1 , and the procedure includes the following.
Step 101 : It is determined whether channel environment of the UE is favorable, and step 102 is carried out if the channel environment is favorable; otherwise, step 103 is carried out.
Step 102 : The transmission power is decreased.
Step 103 : A CQI returned by the UE is monitored, step 105 is carried out if the CQI is lower than the highest rate level supported by the UE or data for retransmission is sent, and step 104 is carried out if the CQI is equal to the highest rate level supported by the UE and new data is sent.
Step 104 : The transmission power is maintained unchanged.
Step 105 : It is determined whether available power remains in the system, and step 106 is carried out if the available power remains; otherwise, step 104 is carried out.
Step 106 : The transmission power is increased.
At step 101 , the channel environment of the UE is determined as favorable in one or more of the following cases.
Case 1: The CQI and an ACK/NACK that are returned uplink by the UE are received by a Base Station. If the CQI is always maintained at the highest rate level supported by the UE and ACKs are returned by the UE within a statistic period, the channel environment has a high quality and the transmission power may be decreased.
According to definition in the existing protocols in HSDPA, UEs are categorized based on their capabilities. In a TD-SCDMA system, fifteen categories of UEs are defined according to the highest rates supported by the UEs and sizes of internal buffers in the UEs. Various transmission block sizes corresponding to the respective transmission rate levels are defined in each category of UEs. The highest rate level of a UE means the highest service rate supported by the UE.
When accessing a network and applying for an HSDPA service, the UE reports its capability level to the network. An appropriate data volume for transmission may be selected in the scheduling at the network side according to the capability level of the UE. In the scheduling at a Base Station side in HSDPA, a primary reference is a CQI returned by the UE, which is obtained by the UE through measurement of the downlink channel. Generally, the SNR of the downlink channel for receiving downlink data may be measured directly. A mapping relationship between the reported CQI value and the transmission rate may be obtained through algorithmic conversion, because each SNR corresponds to a different transmission rate and a modulating mode. After the reported CQI value returned by the UE is received at the network side, a corresponding transmission rate (i.e. the size of a transmission block) recommended by the UE may be obtained.
Within a certain statistic period, a statistic threshold is denoted as an integer T larger than 0, and the power in an HS-DSCH for a UE is decreased only if the HS-DSCH meets the power decreasing conditions for T times. Further, the times for which the HS-DSCH for the UE meets the power decreasing conditions is denoted as a variable m, which has an initial value of 0 and is added by 1 each time the power decreasing conditions are met. However, m is reset as 0 once the power decreasing conditions are not met. When m is equal to T, the transmission power of the HS-DSCH for the UE is decreased once.
Case 2: The Base Station continuously detects a TPC command word from an uplink DPCH that is sent by the UE. If the TPC command word continuously instructs the Base Station to decrease the transmission power within a statistic period, it is meant that the channel environment for the UE has a high quality and the UE may be approaching the Base Station, and the transmission power of the HS-DSCH may be lowered according to the power control on the DPCH.
During the communication between the UE and the network, downlink power control and uplink power control may be performed in the system to ensure air interface communication quality and ensure that receiving SNRs of the uplink and downlink links are close to the target SNRs. In the downlink power control, the UE receives downlink data and measures the downlink link, compares a measured result with the target SNR, and then generates a downlink TPC command word to control the Base Station to increase or decrease the downlink transmission power. Particularly, when the SNR of the receiving signal measured by the UE is higher than the target SNR, the UE generates a TPC command word of decreasing the transmission power to instruct the Base Station to decrease the transmission power by the predefined power control step; and when the SNR of the receiving signal measured by the UE is lower than the target SNR, the UE generates a TPC command word of increasing the transmission power to instruct the Base Station to increase the transmission power by the predefined power control step. Accordingly in the invention, it is indicated that the environment of the downlink channel has a sufficiently high quality if all the TPC command words received by the Base Station instruct the Base Station to decrease the transmission power, and the SNR required for the service can be achieved with a lower transmission power.
Similar to case 1, within a certain statistic period, a statistic threshold is denoted as an integer T larger than 0, and the power in an HS-DSCH for a UE is decreased only if the HS-DSCH meets the power decreasing conditions for T times. Further, the times for which the HS-DSCH for the UE meets the power decreasing conditions is denoted as a variable m, which has an initial value of 0 and is added by 1 each time the power decreasing conditions are met. However, m is reset as 0 once the power decreasing conditions are not met. When m is equal to T, the transmission power of the HS-DSCH for the UE is decreased once.
Case 3: The uplink DPCH or control channel for the UE is measured. Within a certain statistic period, it is indicated that the environment of the channel for the UE has a high quality if the SNRs of the channel are higher than target SNR of the channel, and the transmission power of the HS-DSCH may be lowered. The SNR comparison and the statistic period are same as those in case 2 and are not described.
Further, the statistic period in the invention, which is not a constant value, is determined based on simulations and measurements, taking algorithm performance into consideration. In practice, the power control is performed in each sub-frame. The power control result according to a TPC command word based on only one sub-frame may be inaccurate due to frequent changes in the channel environment, and therefore a regressive average method is generally used in the power control algorithm. In other words, the next power control operation of increasing or decreasing the transmission power is determined from a TPC command word based on a plurality of sub-frames. For example, given that the statistic period is eight sub-frames, when a TPC command word to decrease the transmission power is received from the UE for successive eight sub-frames, it is indicated that the environment of the channel for the UE has a very high quality and transmission power of the corresponding HS-DSCH may be decreased.
At step 102 or 106 above, when it is determined to decrease or increase the transmission power of the HS-DSCH for the UE, the transmission power may be decreased or increased by the predefined power control step. The transmission power is not increased if the remaining power is not sufficient to increase the transmission power by one power control step. That is, the increased transmission power cannot exceed the predefined maximum transmission power of the HS-DSCH in the system.
The method above is described in detail below through an embodiment of the present invention. FIG. 2 shows a procedure of determining whether the HS-DSCH transmission power for a UE meets adjustment conditions during scheduling of the UE, and the procedure includes the following.
Step 201 : Information of CQI and NACK/ACK returned from the kth UE is obtained at the beginning of the nth scheduling period.
Step 202 : According to the CQI returned by the kth UE and the capability level of the UE, a rate level corresponding to the CQI is obtained from a lookup table. Further, it is determined whether the CQI corresponds to the highest rate level supported by the kth UE and whether NACK or ACK is returned by the UE, and if the CQI corresponds to the highest rate level supported by the kth UE and ACK is returned by the kth UE, step 203 is carried out subsequently; otherwise, step 209 is carried out subsequently.
Step 203 : It is determined whether a TPC command word sent by the kth UE via an uplink DPCH instructs the Base Station to decrease transmission power. If the TPC command word instructs the Base Station to decrease the transmission power of the downlink DPCH, step 204 is carried out subsequently; otherwise, step 209 is carried out subsequently.
Step 204 : It is determined whether an SNR of the uplink DPCH for the kth UE that is measured by the Base Station is higher than or equal to a target SNR. If the measured receiving SNR of the uplink DPCH for the kth UE is higher than or equal to the target SNR, step 205 is carried out subsequently; otherwise, step 209 is carried out subsequently.
Step 205 : HS-DSCH power decreasing conditions are met, and the times m for which the UE successively meets the HS-DSCH power decreasing conditions is added by 1.
Step 206 : It is determined whether m is equal to T (which is an integer larger than 0 and denotes a threshold, and the power in an HS-DSCH for a UE is decreased only if the HS-DSCH meets the power decreasing conditions for T times). If m is equal to T, step 207 is carried out subsequently; otherwise, step 208 is carried out subsequently.
Step 207 : The transmission power of the HS-DSCH is decreased by one power control step, and m is decreased by 1.
Step 208 : The predefined transmission power of the HS-DSCH is not changed.
Step 209 : The transmission power of the HS-DSCH is not decreased and m is reset as 0.
It is noted that once the UE receives data previously sent by the Base Station, the UE decodes the received data and returns an NACK or ACK to the network side depending whether the data is decoded correctly or not. If the data is decoded correctly, an ACK is returned, otherwise an NACK is returned. If an ACK is returned by the UE, it is indicated that the channel environment in which the data is previously sent has a high quality or the UE decoded correctly the data by combining retransmitted data, consequently, the Base Station may schedule new data to be sent subsequently. If an NACK is returned by the UE, it is indicated that the channel environment in which the data is previously sent has a low quality and the data is not decoded correctly by the UE, in this case, the Base Station determined whether the maximum retransmission times is reached, and retransmits the data continuously if the maximum retransmission times is not been reached. Therefore, the determination of whether the NACK or ACK is returned by the UE is to assist in determining whether the channel environment has a high quality or not. If the UE always returns an NACK, it is indicated that the channel has a low quality and a low SNR, thus the transmission power needs to be increased, instead of being decreased.
In the case of a plurality of UEs under scheduling, the power control and assignation procedure in which remaining power is assigned to UEs other than the UE on which the power adjustment has been performed using the method according to the present invention is shown in FIG. 3 , and the procedure includes the following.
Step 301 : It is determined whether a UE exists in a scheduling queue, and if the UE exists in the scheduling queue, step 302 is carried out subsequently; otherwise, the procedure is ended.
Step 302 : A UE with the highest priority is selected from the scheduling queue according to a scheduling algorithm.
Step 303 : It is determined whether the selected UE is to send data. If the selected UE is to send data, step 304 is carried out subsequently; otherwise the scheduling queue is updated to remove the selected UE from the scheduling queue. Subsequently, it is determined whether any more UE exists in the scheduling queue, and if no more UE exists in the scheduling queue, the procedure is ended; otherwise, step 302 is carried out.
Step 304 : If the UE with the highest priority is to send data, the related code channel is assigned to the UE. The power of the code channel is set as the previous transmission power of the code channel.
Step 305 : It is determined whether to adjust the transmission power according to the CQI and NACK/ACK returned by the UE. Step 308 is carried out subsequently if the transmission power needs no adjustment, step 306 is carried out subsequently if the transmission power needs to be decreased, and step 307 is carried out subsequently if the transmission power needs to be increased.
Step 306 : The transmission power is decreased. That is, the power of the code channel is decreased by a predefined step, and step 308 is carried out subsequently.
Step 307 : The transmission power is increased. That is, the power of the code channel is increase by the predefined step, without exceeding the maximum power of the code channel. Furthermore, if a plurality of code channels are occupied by the UE, all of the plurality of code channels are adjusted in the same way, and step 308 is carried out subsequently.
Step 308 : The scheduling queue is updated to remove the scheduled UE from the scheduling queue, and it is determined whether any code channel remains in the scheduling queue. If a code channel remains, step 301 is carried out subsequently; otherwise, the procedure is ended.
At step 305 above, the determination of whether power decreasing conditions are met is similar to the above determination of whether the channel environment for the UE meets conditions and therefore is not described hereinafter.
The above method is described in detail below through an embodiment of the present invention. FIG. 4 shows a procedure of adjusting HS-DSCH transmission power for a plurality of UEs during scheduling of the UEs according to an embodiment of the present invention, and the procedure includes the following.
Step 401 : A plurality of UEs are arranged in order based on their priorities according to a scheduling algorithm at the beginning of the nth scheduling period.
Step 402 : A UE with the highest priority is selected from the scheduling queue.
Step 403 : It is determined whether the selected UE is to send data. If the selected UE is to send data, step 404 is carried out subsequently; otherwise, step 409 is carried out subsequently.
Step 404 : A code channel is assigned to the UE, and the previous transmission power of the code channel is used as the initial transmission power of the code channel.
Step 405 : It is determined whether the transmission power of the HS-DCSH for the UE meets power decreasing conditions. If the transmission power of the HS-DCSH for the UE meets the power decreasing conditions, step 406 is carried out subsequently; otherwise, step 407 is carried out.
Step 406 : The current HS-DSCH transmission power for the UE is decreased by a power control step, and step 408 is carried out subsequently.
Step 407 : The current HS-DSCH transmission power for the UE is not changed, and step 408 is carried out subsequently.
Step 408 : It is determined whether any code channel remains. If a code channel remains, step 409 is carried out subsequently; otherwise, the procedure is ended.
Step 409 : It is determined whether any UE to be scheduled exists in the scheduling queue. If the UE to be scheduled exists in the scheduling queue, step 410 is carried out subsequently; otherwise, the procedure is ended.
Step 410 : A UE with the next highest priority is selected.
Step 411 : It is determined whether the HS-DCSH transmission power for the UE meets the power decreasing conditions. If the HS-DCSH transmission power for the UE meets the power decreasing conditions, step 412 is carried out subsequently; otherwise, step 415 is carried out.
Step 412 : It is determined whether the remaining code channel meets requirement of the highest rate level of the UE. If the remaining code channel meets the requirement of the highest rate level of the UE, step 413 is carried out subsequently; otherwise, step 414 is carried out.
Step 413 : A code channel is assigned to the UE, the HS-DSCH transmission power for the UE is decreased by the power control step, and step 408 is carried out subsequently.
Step 414 : A code channel is assigned to the UE, the HS-DSCH transmission power for the UE is not changed, and step 408 is carried out subsequently.
Step 415 : It is determined whether an NACK is returned by the UE. If an NACK is returned by the UE, step 416 is carried out subsequently; otherwise, step 414 is carried out.
Step 416 : It is determined whether any available power remains. If available power remains, step 417 is carried out subsequently; otherwise, step 414 is carried out subsequently.
Step 417 : A code channel is assigned to the UE, the HS-DSCH transmission power for the UE is increased by the power control step, and step 408 is carried out subsequently.
With reference to FIG. 5 , the device for controlling HS-DSCH transmission power according to an embodiment of the present invention is described in detail below. The device includes a data receiving and sending unit 501 , a data scheduling unit 502 , a channel decoding unit 503 , a channel coding unit 504 , a signal receiving and demodulating unit 505 , a modulating and sending unit 506 and a radio frequency receiving and sending unit 507 .
The data receiving and sending unit 501 receives and sends data frames and control frames in Iub FP protocol. In the downlink direction, the data receiving and sending unit 501 receives Forward Access Channel (FACH), Paging Channel (PCH), Dedicated Channel (DCH) and HS-DSCH data frames which are sent by a Radio Network Controller (RNC) via an Iub interface, sends the FACH, PCH and DCH data frames to the channel coding unit 504 , and sends the HS-DSCH data frame to the data scheduling unit 502 . In the uplink direction, the data receiving and sending unit 501 sends the RACH and DCH data frames received in the uplink direction to the RNC via the Iub interface.
Further, the data receiving and sending unit 501 functions to synchronize the Iub interface transmission channel and the node, receive and send control frames related to the HSDPA and assist the data scheduling unit 502 in traffic control at the HSDPA Iub interface.
The data scheduling unit 502 , which plays a role of a MAC-hs entity in HSDPA, functions to manage a UE priority queue, schedule a plurality of UEs and perform an HARQ function. Scheduling of a plurality of UEs includes selecting a UE under scheduling and the UE priority queue, assigning a code channel, determining amount of data under scheduling, a modulating mode and a code rate, and determining transmission power of the code channel. After scheduling the UE, the data scheduling unit 502 may determine whether the data sent is for retransmission or new, determine the number of the assigned HS-PDSCH code channels, and a power value, a modulation mode and a code rate of each code channel, send the data to be sent and control information related to the data, such as the code rate, the modulation mode and HS-PDSCH code channel information, to the channel coding unit 504 , and send parameter of transmission power of each code channel to the modulating and sending unit 506 .
Further, the data scheduling unit 502 receives HS-DSCH data from the common channel and dedicated channel Iub FP data receiving and sending unit 501 , and performs traffic control at Iub through the related control frames. The data scheduling unit 502 receives the CQI and NACK/ACK returned by the UE from the channel decoding unit 503 , receives a measurement report on the signal quality in uplink DPCH from the signal receiving and demodulating unit 505 and TPC command word statistic information from the UE, and assists in the scheduling and the HS-DSCH power control.
The channel decoding unit 503 receives uplink high speed shared control channel or high speed dedicated control channel data in the uplink RACH, DPCH and HSDPA from the signal receiving and demodulating unit 505 , decodes the RACH and DPCH data, and sends the decoded RACH and DPCH data to the common channel and dedicated channel Iub FP data receiving and sending unit 501 . The channel decoding unit 503 further decodes the uplink high speed shared control channel or high speed dedicated control channel to extract and send the CQI and NACK/ACK returned by the UE to the data scheduling unit 502 .
The channel coding unit 504 receives the FACH, PCH and DCH data from the common channel and dedicated channel Iub FP data receiving and sending unit 501 , and performs processing such as channel coding, interleaving and physical channel mapping on the received FACH, PCH and DCH data. Further, the channel coding unit 504 receives the HS-DSCH data and the related control information from the data scheduling unit 502 , performs processing such as coding, interleaving and physical channel mapping on the HS-DSCH data, and multiplexing, coding and mapping the control information related to the HS-DSCH data to the High Speed Downlink Shared Control Channel (HS-SCCH). Subsequently, the channel coding unit 504 sends the coded and mapped data to the modulating and sending unit 506 .
The signal receiving and demodulating unit 505 receives data from the radio frequency receiving and sending unit 507 , detects and demodulates uplink signals on a basis of UEs and code channels, and sends the demodulated signals to the channel decoding unit 503 .
The signal receiving and demodulating unit 505 further measures the uplink channel. For example, the signal receiving and demodulating unit 505 measures an SNR of the uplink channel, and sends the measured SNR and a TPC command word obtained from the DPCH to the data scheduling unit 502 . In addition, the measured SNR and the TPC command word are sent to the modulating and sending unit 506 , to complete DPCH power control and uplink synchronization control (for a TDD system).
The modulating and sending unit 506 receives, modulates and scrambles data subjected to processing such as coding and physical channel mapping from the channel coding unit 504 , receives the measured information from the signal receiving and demodulating unit 505 to perform power control (and uplink synchronization control in the case of a TD-SCDMA), and performs weighting of the data according to the transmission power that is set at a higher level or obtained through the power control in the modulating and sending unit 506 . In the case of a TD-SCDMA system, the modulating and sending unit 506 may further perform beamforming of the DPCH data, and the HS-DSCH and HS-SCCH data, and send the resultant data to the radio frequency receiving and sending unit 507 .
The radio frequency receiving and sending unit 507 receives a signal in the uplink direction, performs processing such as low-noise amplifying, AD converting and digital down-converting on the received signal, and converts a radio frequency into a baseband signal. In the downlink direction, the radio frequency receiving and sending unit 507 performs processing such as digital up-converting, DA converting and power amplifying on a downlink signal and transmits the processed signal.
The invention is described with, but is not limited to, the preferred embodiments of the invention described above. Various modifications, alternatives and improvements made to the invention without departing from the scope of the invention are indented to be within the scope of the invention defined by the appending claims. | The method for power control in HSDPA includes Step A, the UE with the highest priority and having data to be transmitted is selected according to the algorithm, the channel resource is distributed to the UE, and the original power level is set. Step B, the transmission power is deduced when the channel quality meets the condition; Otherwise the CQI is checked, if the value of CQI is under the highest rate level, or the data is the re-transmitting data, the transmission power is increased, or the power is kept the same level. Step C, channel resource and the UE with the highest priority are checked, if there exist, then go to step B, otherwise the method is ended. So the redundant power can be used when several UEs are controlled at the same time, the efficiency and the throughput performance are improved, and the interface is reduced. The device for power controlling is given at the same time. | 7 |
BACKGROUND OF THE INVENTION
The present invention is directed to a hole machine, more specifically to a sewing machine for forming buttonholes or the like with lock stitches and chain stitches.
In general, a hole sewing machine is comprised of a sewing machine head, a support stand upon which the head is mounted, an electric motor for driving the head and transmission means between the motor and the head. The various mechanisms for forming the stitches are associated with the sewing machine head and include a needle bar mechanism, a feed mechanism, a looper-spreader mechanism, a cloth clamping mechanism, a cloth cutting mechanism, a sector mechanism, a looper stand mechanism, and a clutch mechanism. The feed mechanism includes cam means for controlling the movement of the needle along a button-hole shaped path and for operating the button hole cutting means.
In the operation of such a conventional buttonhole sewing machine, the sewing machine is started and upon operation of the suitable clutch mechanism the feed mechanism is energized to perform a sewing operation along the configuration of an eyelet hole which is determined by the cam means. In order to prevent irregular stitching during the sewing of the eyelet hole, the needle bar and looper stand are turned in synchronism with the stitches by the action of the cam means. When the desired number of stitches have been completed, the cloth cutting means is operated to complete a single cycle of operation and the sewing machine is automatically stopped. Depending upon the specifications of the sewing operation, the cloth cutting means may be operated prior to the sewing operation.
In the conventional buttonhole sewing machine the shape of the buttonhole is uniformly determined by the configuration of the sewing machine head and the associated cam means. Thus, while it is often desired to produce buttonholes in various patterns, the conventional buttonhole sewing machine cannot produce the various patterns. More specifically, in order to change the buttonhole sewing pattern, it is necessary to change a large number of components in the sewing machine, including the cam means for the feed mechanism. The adjustment of the length of the line portion of the buttonhole and pitch of the buttonhole sewing stitches requires specialized tools and a considerable amount of delicate adjustment work. In addition, it is impossible to separately adjust the pitch of the stitches for the straight part of the buttonhole and the round part of the buttonhole.
SUMMARY OF THE INVENTION
The present invention provides a new and improved buttonhole sewing machine in which a number of buttonhole sewing patterns having a variable pitch for buttonhole stitches can be obtained by selecting programmed data by suitable switching means.
The present invention provides a new and improved buttonhole sewing machine including a work support member upon which cloth retaining means are provided which is coupled to a sliding plate which is driven by an X-axis motor and an Y-axis motor. A rotating mechanism for sychronously rotating the needle bar and looper stand and a device for supplying drive signals to the rotating mechanism according to a predetermined hole sewing program are also provided so that a buttonhole is stitched in the desired pattern in accordance with the selection of a specific buttonhole sewing program.
The foregoing and other features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a buttonhole sewing machine in accordance with the present invention.
FIG. 2 is a schematic view of the essential components of the buttonhole sewing machine according to the present invention.
FIGS. 3a-3e are explanatory diagrams for the buttonhole sewing pattern according to the present invention.
FIG. 4 is a schematic view showing the central components of the cloth cutting device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The buttonhole sewing machine according to the present invention as shown in FIG. 1 is comprised of a sewing machine head 10, a table stand 12, a motor 14 for driving the head 10 and a transmitter 16 provided for transmitting rotation from the motor 14 to the head 10. The sewing machine head 10 includes a support base 18, a bed 20 and an arm 22. All the mechanisms for forming the stitches are carried by the support with the details of the feed mechanism being shown in FIG. 2.
In FIG. 2 the work support member 50, upon which suitable cloth retaining means (not shown) are installed, is coupled to sliding plate 52 which is moveable in the direction of the arrows X and Y. More specifically, the plate 52 is mounted for movement in opposite directions along the Y axis on the guide means 54Y which in turn is mounted for movement in opposite directions along the X axis on the guide means 54X. An X-axis stepping motor 56X drives a timing belt 58X in opposite directions which in turn is operatively connected to the guide means 54Y for moving the same along the X axis guide means 54X. Likewise, the Y axis stepping motor 56Y rotates the timing belt 58Y in opposite directions with the timing belt 58Y being operatively connected to the plate 52 through the rod 93 for moving the same along the Y axis guide means 54Y. The foregoing components which constitute the X-Y movement system are located below the bed 20 of the sewing machine.
A needle bar 60 and a looper stand 62 are rotatably mounted in the sewing machine and are sychronously rotated under the control of the stepping motor 64 which operates the timing belt 66 in opposite directions for rotating the shaft 67. A pair of gear segments 69 are secured to the shaft 67 for rotation therewith and are operatively meshed with complementary gears on the needle bar 60 and the looper stand 62.
The stepping motors 56X and 56Y for driving the sliding plate 52 and the stepping motor 64 for rotating the needle bar 60 and the looper stand 62 are controlled by a stored program system control device 68. Control data in the system is selectively set for the motors by operating a buttonhole configuration selecting switch, a buttonhole pattern contracting and enlarging dial, a buttonhole link dial, a seam length dial, and a sewing speed dial. More specifically, when the setting inputs 100 are applied to the control device 68, the stepping motor is operated in synchronism with the vertical movement mechanism for the needle bar 60 so that the needle bar 60 coupled to the sewing needle 71 and the looper stand 62 are turned in a range from 0° to 360° during a buttonhole sewing operation. Control programs for a variety of buttonhole configurations, as for example the eyelet hole shown in FIG. 3, are stored in the control device 68 so that buttonholes of different configurations can be selected and stitched as required.
A typical example of a buttonhole will be described with reference to FIGS. 3a-3e wherein the buttonhole is comprised of a line portion 44 and a round portion 46. Several patterns are provided for the round portion 46 and the buttonhole is stitched as follows. The cloth is first cut according to the sewing pattern with the cloth cutting device 23 described hereinafter. The needlebar 60 is operated along the length of the hole in a zigzag pattern to form a seam 48 as shown in 3e. Three different zigzag patterns 70, 72, and 74, as shown in FIGS. 3b, 3c, and 3d, respectively, can be obtained by selecting a specific timing feed for the X-Y sliding plate. The pattern of the round portion 46 may be contracted or enlarged in the X or Y direction. In a single cycle buttonhole sewing operation from the point P to the point U in FIG. 3a, the length PQ and QR in the line portion 44 can be adjusted as required and the size of the round portion 46 can also be selected as required.
A cloth cutting device 23 as shown FIG. 4 is provided for cutting a piece of cloth along the length of the buttonhole before or after the buttonhole is stitched. The device 23 is carried by a support adjacent the bed 20 of the sewing machine and the support stand 18. A movable cutting anvil is detachably secured to the end of a support lever 42 which is rotatably mounted on a fulcrum (not shown) which extends through the opening 24. The moveable cutting anvil is operatively opposed to a knife 26 so that the cutting of the buttonhole is accomplished by the two cutting elements upon pivotable movement of the lever 42.
A link mechanism 27 is provided to drive the moveable anvil with respect to the knife 26. The link mechanism 27 is comprised of a drive lever 29 adapted to be rotatably mounted on a shaft (not shown) extending through the opening 28. One end of the drive lever 29 and one end of the lever 42 are pivotably coupled to each other by means of a rod 30. An air drive device 31 for driving the moveable anvil 25 is comprised of an air cylinder 32 having a piston shaft 33 pivotally connected to the drive lever 29 by means of the rod 34. An air compressor (not shown) supplies air to a solenoid control valve 37 through a pipe 39 having a pressure regulator 40 associated therewith. Air is supplied to and from the cylinder 32 by means of an air supply pipe 35 and an air discharge pipe 36, both of which are connected to the solenoid control valve. Upon energization of the solenoid valve 37, the air which is supplied through the pipe 39 from the compressor is delivered through the air supply pipe 35 into the air cylinder 32. Upon de-energization of the solenoid 37, the air in the air cylinder 32 is discharged through the air discharge pipe 36. The energization of the solenoid valve 37 is programmed by a control means 43 so that the solenoid valve 37 is energized and de-energized at the desired times. The control means 43 has an anvil operation selecting switch 38 associated therewith so that the operation and non-operation of the hammer 42 are selected as required.
In order to adjust the operating speed of the moveable anvil 25, speed controllers 46 and 48 are provided in the air supply pipe 35 and the air discharge pipe 36, respectively. The speed controllers 46 and 48 may be needle valves which are adjustably controlled by the knobs 46a and 48a which are operatively associated with the speed controllers 46 and 48 respectively.
In order to control the operating pressure of the cutting anvil 25, the pressure control 40, which also may be a needle valve, can be adjusted under the control of the knob 40a.
Upon receiving a pre-set signal from the control means 43, the solenoid valve 37 is energized so that air is supplied from the air compressor through the pipe 39 and the air supply pipe 35 into the air cylinder 32. As a result, the piston shaft 33 is moved in the direction of the arrow A in FIG. 4 to pivot the drive lever arm 29 in the clockwise direction, thereby pivoting lever 42 in the counter-clockwise direction. The cutting anvil 25 is moved into cooperative relation with the knife 26 to cut a buttonhole having a desired configuration in the cloth. Upon completion of the cutting of the buttonhole, the solenoid valve 37 is de-energized so that the air in the air cylinder 32 is discharged through the air discharge pipe 36. As a result, the shaft 33 is moved in the direction of the arrow B under the influence of a spring (not shown) in cylinder 32 and the cutting anvil 25 is returned its original position. The stroke of the anvil 25 can be controlled by changing the period of excitation of the solenoid valve 37. Thus, depending upon the thickness of the piece of cloth, the stroke can be set to the most suitable length.
Furthermore, the operating speed of the cutting anvil 25 can be controlled by the adjusting valves 46a and 48a of the speed controllers 46 and 48. Therefore, the cloth cutting can be carried out at any desired speed. In addition, the operating pressure of the cutting anvil 25 can be controlled by turning the adjusting valve 40a of the pressure control 40. Therefore, depending on the thickness of the piece of cloth being subjected to the buttonhole cutting operation, the cloth cutting pressure can be set to the most suitable valve within the range which is allowed by the mechanical strength of the various components including the cutting anvil 25 and the stationary knife 26.
Thus, by using only a single buttonhole sewing machine according to the present invention various buttonholes having different configurations can be stitched. In a buttonhole sewing machine according to the present invention, unlike conventional buttonhole sewing machines, intricate cam mechanisms and coupled link mechanisms are substantially excluded. Accordingly, the buttonhole sewing machine of the present invention is very high in mechanical reliability, low in manufacturing cost and high in application and flexibility.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | In a hole sewing machine of the type adapted to stitch a buttonhole or the like, an X-Y table member is operatively connected to a work support member upon which the material to be stitched is placed, motors are provided for driving the table along orthogonal X-Y axes and a further motor is provided for synchronously rotating the needle bar and looper stand of the sewing machine about the axis of the needle bar. A control device is provided for supply drive signals to the various motors in accordance with the predetermined buttonhole sewing program so that the buttonhole is stitched in accordance with the desired pattern by merely selecting a specific buttonhole sewing program. | 3 |
This application is a division of application Ser. No. 765,840, filed Aug. 15, 1985, now U.S. Pat. No. 4,616,991.
FIELD OF THE INVENTION
The present invention relates to a process and apparatus for the manufacture of a corrugated wafer board panel.
BACKGROUND OF THE INVENTION
Typically, a wafer board panel comprises layers of wood flakes or wafers formed into a composite structure using a resinous binder. The preparation of wafer board panels is complex, but broadly consists of two principal stages. The first stage comprises the preparation of the wafers and the admixing thereof with the binder to form a loose layer or mat; the second stage involves subsequent compression and heating of the mat to cure the resin and form the consolidated panel.
At present, wafer board is manufactured in the form of planar or flat sheets. The cost of production of such wafer board panels is economically attractive, because a low grade timber may be utilized as the raw feedstock. Wafer board is a recognized structural panel, finding wide application in the construction industry, particularly as a plywood substitute in residential construction.
Inherent disadvantages of wafer board panels, of planar configuration, reside in the low structural stiffness and strength thereof, which fall much below that of the more costly plywood.
Improvement in the performance characteristics of flat wafer board panels has been attained by optimization of such parameters as wafer orientation, wafer geometry, resin selection and content, and the like. However, existing technology would appear to have exhausted these possibilities of increasing structural strength.
In an attempt to improve the flexural strength characteristics of wafer board panels, applicants contemplated the provision of a wafer board panel having a corrugated configuration. The fundamental concept of corrugating materials to thereby improve the structural properties is not a novel one.
A method which readily comes to mind, for providing a corrugated wafer board panel involves placing a flat resin-coated wood flake mat between corrugated platens and heating and compressing the mat therebetween. However, this approach has not been successful because the mat must elongate to assume the form of the corrugated platens. Due to the unlocked state of the wafers, they tend to shift in certain portions of the mat during the compression-elongation operation and the compressed product is characterized by density variations.
Thus, to form the mat by compression and heating of a planar mat between corrugated platens results in a panel of non-uniform density because of the freely displaceable characteristics of the flakes. Alteration of the mat from the planar to the corrugated configuration entails `stretching` or increasing the length thereof, with resulting uneveness in the density thereof occurring.
SUMMARY OF THE INVENTION
In a contrasting approach, applicants provide spaced apart upper and lower platens, each of which is convertible between substantially planar and corrugated configurations. The platens each supply a steel or like working surface which is of sufficient size to form a panel, is substantially non-porous, and is convertible between the two configurations. (By `non-porous` is meant that the wood wafers are retained by the platen surface.)
Having developed the platens, it then became possible to practise the following novel combination of fabrication steps, namely:
(a) distributing a mat of loose wood wafers between upper and lower platen surfaces maintained in the planar configuration;
(b) biasing the platens together to pre-compress the mat, to thereby substantially fix the wafers together and limit their further relative movement;
(c) then converting the two platen surfaces, still in pressing association with the mat, from the planar to the corrugated configuration; and
(d) then applying additional pressure and heat for a sufficient time to cure the binder and produce a corrugated wafer board.
The main advantage of the process is that the panel product is found to have generally constant density.
Broadly stated, the invention in an apparatus aspect comprises a platen assembly, for use in forming corrugated wafer board panels, comprising: support means forming a planar support surface; parallel, spaced apart, elongate end members forming inner working faces that are generally perpendicular to the support surface, at least one of said end members being movable toward the other along the support surface while remaining parallel thereto; a plurality of elongate bracing elements positioned on the support surface in spaced relationship, between the end members, said bracing elements being slidable along the surface in parallel relationship; link means, pivotally interconnecting each pair of adjacent bracing elements, for providing in conjunction with said bracing elements a broad substantially non-porous platen surface whose configuration can be mechanically converted between a substantially planar form and a corrugated form; and means for moving the end members together and apart to convert the link means between the corrugated and planar forms.
In a process aspect, the invention comprises distributing a mat of loose binder-coated wood wafers between a pair of spaced apart, substantially horizontally disposed platens having substantially non-porous and planar platen surfaces, said platens being adapted to be mechanically actuated to move the surfaces together and, when further required, to be converted from the planar configuration to a corrugated configuration by application of a side force; biasing the platens together vertically to pre-compress the mat between the planar surfaces, to substantially fix the wafers together to limit their further relative movement; then converting the two platens and their platen surfaces, still in pressing association with the mat, from the planar to the corrugated configuration; and applying heat and additional pressure with the platen surfaces to the mat for sufficient time to cure the binder and produce a corrugated wafer board panel.
DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b and 1c are schematic side views showing top and bottom platen assemblies in the three stages of the process for production of a corrugated wafer board panel in accordance with this invention;
FIG. 2 is a perspective view of the platen assembly showing the links in the corrugated position;
FIG. 3 is a perspective view showing a link unit in the planar position;
FIG. 4 is a top plan view showing the base plate, bracing members, key-ways, biasing and stop members, and the cylinders;
FIG. 5 is a perspective view showing the base plate, biasing and stop members, and the cylinders;
FIG. 6 is a perspective view showing the inverted T-type bracing member;
FIG. 7 is a perspective view showing the T-type link; and
FIG. 8 is a perspective exploded view showing a bracing member, two links, and connecting rods.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Having reference to the drawing, there is shown a platen assembly 1 which includes a base plate 2. The base plate 2 illustrated is a flat, rectangular, solid steel block having longitudinal edges 3 and end edges 4.
Four elongate key-ways 5 are cut in the surface of the base plate 2. The key-ways 5 are parallel and extend longitudinally the length of the base plate 2 at spaced points across its width.
An elongate, bar-like stop member 6 is affixed to the base plate 2 along one end edge thereof, to extend transversely thereacross.
An elongate, bar-like biasing member 7 is positioned on the base plate 2 along its other end edge, in opposed relation to the stop member 6. The biasing member 7 has keys (not shown), protruding downwardly from its base, for engaging the key-ways 5. Thus the transversely extending biasing member 7 is arranged to be slidable along the base plate 2 toward the stop member 6, the walls of the key-ways 5 being operative to maintain the biasing member 7 parallel to the stop member.
The stop member 6 and biasing member 7 form end members for a convertible platen to be described.
A pair of double-acting hydraulic cylinders 8 are secured to the base plate 2 at one end thereof in spaced apart relationship. Said cylinders 8 extend longitudinally parallel to the main plane of the base plate 2. The pistons 8a of the cylinders are connected to the biasing member 7. Extension or contraction of the cylinders 8 serves to advance or retract the biasing member 7, along the key-ways 5, toward or away from the stop member 6 and parallel thereto.
Spaced apart rows 9 of abutting bracing members 10 extend transversely across the base plate 2 parallel to the stop and biasing members 6, 7.
As can be seen in FIGS. 2 and 3, each bracing element or row 9 is comprised of "entire" bracing members (as illustrated in FIG. 6), or sections thereof. More particularly, a first row 9a comprises a linear array of entire bracing members 10; at each end of the array, there is positioned an end bracing member 12. Said end bracing member 12 is a longitudinal half section of an entire bracing member. The adjacent second row 9b is formed only of entire bracing members 11.
Rows 9a and 9b are repeated sequentially, as required to form the bulk of a platen 13 of a desired length. However, at the biasing member end of the platen 13, an end row 9c is provided. Row 9c is formed of an array of bracing members 14 having an end bracing member 15 positioned at each end thereof. The bracing members 14 are each a transverse half section of an entire bracing member 11; the end bracing members 15 are each a transverse and longitudinal half section of an entire bracing member 11.
The bracing members which together make up each of the rows 9a, 9b, 9c are held together by rods 16 which extend through suitable transverse bores formed in said members.
The individual bracing members positioned over the key-ways 5 are provided with downwardly projecting keys (not shown), which engage said key-ways.
Thus, each row of bracing members extends transversely across the base plate 2 in parallel relationship to the biasing member 7 and the stop member 6. The bracing members in each row abut one another in closely positioned, consolidated formation. Each row is slidable as a unit along the length of the base plate 2. And the walls of the key-ways 5 cooperate with the bracing member keys to maintain the parallel disposition of the rows as they are biased along the base plate 2.
An elongate, flat spacer 17 is positioned between each pair of adjacent rows of bracing members. When the platen 13 is in the extended position, the spacers 17 extend across only part of the gaps existing between adjacent rows. Thus the rows of bracing members may each be moved through a limited pre-determined distance or travel as the biasing member 7 pushes the rows and spacers into abutting relationship against the stop member 6. Given that the spacer and gap between each pair of rows are of common widths, the distance through which the various rows can be shifted is the same.
In broad summary, therefore, there is provided:
(a) a planar support surface;
(b) parallel, spaced apart, elongate members (the stop and biasing members) forming inner working faces which are generally perpendicular to the support surface and which are movable together while remaining parallel;
(c) a plurality of equally spaced apart, elongate bracing member rows slidably positioned on the support surface in parallel relationship between said working faces, said bracing member rows being movable together, by the closing action of the working faces, through equal and limited travel distances; and
(d) means for biasing or closing the working faces together.
In an alternative version of the previously described embodiment, one could substitute a movable member for the fixed stop member and connect such movable member with means, such as a cylinder, for controllably advancing said substitute member toward the previously described biasing member. The end result would be two biasing members simultaneously pushing the bracing member rows together through equal travel distances in parallel formation.
An assembly 18 of links 19 is pivotally interconnected with each pair of adjacent rows of bracing members and extends therebetween.
Each link assembly 18 comprises two rows 18a, 18b formed of entire links 19 or sections thereof. An "entire" link 19 is illustrated in FIG. 7.
Each link row 18a is formed end-to-end of entire links 19. The links of each said row 18a dovetail at one end thereof with the bracing members of a bracing member row 9a.
Each link row 18b is formed of an array of entire links 19 having an end link 20 at each end thereof. The end links 20 are each a longitudinal half section of an entire link 19.
The links of each row 18b dovetail at one end with the links of a row 18a and are pivotally interconnected therewith by a rod 21 which extends through transverse bores formed through the link ends. At their opposite end, the links of each row 18b dovetail with the bracing members of a row 9b and are pivotally interconnected therewith by a rod 22.
At the stop member end of the platen 13, there is provided a link row 18b whose links at one end abut the stop member 6. This link row 18b is provided with rollers 23 to permit the row to ride up and down on the vertical working face 24 of said stop member 6.
This mechanical assemblage is characterized by the following:
(1) the bracing member rows are fixed to the base plate by the key and key-way interconnections--they can shift along the length of the base plate toward each other in parallel formation, but they remain at a constant elevation;
(2) the pivoting link means are functional to pivot upwardly into a V-like position when the bracing member rows are forced together.
Thus the dovetailing pivoting link means and slidable bracing member means combine to provide a broad, substantially non-porous platen whose surface configuration can be mechanically converted, between a substantially planar form and a corrugated form, by the sideways pincer action of the biasing and stop members.
It is intended that the platen assembly be used to form wafer board from a mat of binder-coated wafers. Heat is needed in such process. Therefore, heating means are required to heat the platen 13. In the embodiment shown, electrical heating rods 25 are provided to extend through transverse bores 26 formed through the links.
FIGS. 1a, 1b, 1c show two horizontal assemblies 1 arranged in spaced, opposed top and bottom arrangement. Conventional press members (not shown) may be connected to the platen assemblies 1, for biasing the latter together in a vertical direction and applying pressure thereto.
To produce corrugated wafer board, a loose mat 27 of thermosetting resin binder-coated wafers is positioned between the fully extended, planar top and bottom platen assemblies 1, as shown in FIG. 1a. The press members are actuated to force the flat platen assemblies 1 toward each other and pre-compress the mat to substantially fix the wafers together, to prevent their relative movement. Typically, a 4" thick mat would be compressed to about a 1 inch thickness. The so pre-compressed mat is substantially free of density variations. The cylinders 8 are then expanded to cause the biasing members 7 of the two platen assemblies 1 to move toward the stop members 6, thereby simultaneously applying a horizontal force at the same rate to the link rows 18a, 18b, to pivot them into the corrugated configuration, while the pre-compressed mat is held between the opposed surfaces of the platens 13. Heat and final pressure is then applied by the platen assemblies 1 to the corrugated mat, via the electrical heating rods 25, to cure the binder and produce a cohesive corrugated wafer board of desired final thickness, typically 1/2 inch. | A platen assembly is provided having a working surface which can be mechanically converted between planar and corrugated configurations. A mat of wood wafers coated with thermosetting resin binder is deposited between upper and lower, spaced apart platen assemblies of this type. The platen assemblies, in the planar configuration, are then pressed together to a limited extent to pre-compress the mat to fix the wafers. Horizontal force is then applied to the platen assemblies to convert them to the corrugated configuration, with the pre-compressed mat retained therebetween. The mat is therefore forced to adopt a corrugated form. The platen assemblies are then further pressed together and heated, to cure the resin and produce a corrugated wafer board panel. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a means and method for stabilizing shorelines. More specifically, the invention relates to an offshore barrier module and its use for stabilizing an adjacent shoreline.
Waves impinging on a beach dislodge soil particles, i.e. sand, which are then swept seawrd where they can form an underwater ridge of sand parallel to the shoreline. This is known as a long shore bar. In times of heavy wave action, the beach tends to decrete, i.e. lose sand, and the bar tends to accrete. In times of light wave action, however, the movement of sand particles is reversed and the beach tends to accrete at the expense of the bar. This is a natural phenomenon and on most beaches there is a constant exchange of sand between these two features with the direction of transport being dependent on the character of the waves. When the waves are large and follow close upon each other, as they do under storm conditions, the beach is eroded and the bar builds up. When calm conditions return, the small waves rebuild the beach at the expense of the bar.
However, this natural beach stabilizing phenonmenon is not always present because of littoral currents, predominating wind directions, man-made objects which are interposed on the beach or other natural and artificial causes. Various structures have therefore been utilized in an attempt to stabilize beaches.
It has long been known that beaches and shorelines of rivers, lakes, and oceans may be protected or stabilized by placing structures along the shoreline or at some distance offshore under water. The structures can serve to obstruct the flow of sediment carrying water and cause the deposition of at least part of the sediment in the immediate vicinity of the stabilizing structure. Examples of such structures are impermeable groins, permeable groins, artificial seaweed and the like.
Impermeable groins are constructed of sheet piling of steel, concrete, or wood driven in a continuous row generally perpendicular to the shoreline. Sediment will be deposited from water moving transverse to the row of piling in a direction upstream from the structure. Such groins may also be constructed from mounds of stones, concrete blocks, and the like.
Permeable groins are similarly constructed except that the sheet piles are driven at some distance apart permitting sediment carrying water to pass through the structure between the sheets but so reducing the velocity of the water which passes through that heavier particles of sediment will be deposited downstream from the structure. Such structures are constructed by securing vertical boards at some distance apart on a frame and positioning the frame transverse to the flow of sediment carrying water where it is secured by piles driven into the ground.
Another type of stabilizing structure is artificial seaweed. It has been discovered that naturally growing seaweed tends to trap water-borne sediments by reducing the water velocity to the point that sediment deposition occurs. This effect is duplicated by artificially assembling clusters of low density synthetic tapes or filaments and securing the clusters to the seabottom by a weighting means such as sandbags to form an array of some area in extent similar to a large bed of naturally growing seaweed. Such arrays have been used to protect the legs of offshore oil drilling platforms from erosion of the surrounding soil. Synthetic filaments have been produced from air blown polypropylene to produce filaments of maximum buoyancy.
However, all of the aforementioned types of barrier structures have their problems. Impermeable groins are extremely expensive to construct and obstruct the full utilization of the water adjacent the shore by small boat traffic and individuals. Also, for construction purposes, access to the site is required by heavy equipment. Soil decretion downstream or downdrift of such groins is pronounced and is detrimental to the owners of adjacent property.
Permeable groins present all of the problems mentioned with regard to impermeable groins except that they cause a downdrift accretion of sediment and so may actually benefit the owners of downdrift property. However, permeable groins are ineffectual in preventing a littoral movement of soil particles dislodged by wave action unless they extend so far seaward from the shoreline as to be impossibly expensive. Thus, permeable groins are used effectively only to control the movement of soil parallel to the shoreline caused by longshore currents as in a river or along a shoreline where there is a pronounced littoral sediment carrying current.
Artificial seaweed has been successfully used at substantial depths of water to trap current borne sediment. However, it has not been effective in preventing the movement of sediment along shorelines. This is so because the high velocity and turbulence of water near a shore due to the breaking of waves causes the synthetic filaments to assume a position nearly parallel to the flow of water and so the water-borne sediments easily pass over the filaments with a minimal reduction in water velocity. Also, the plastic from which the filaments are constructed apparently suffers a loss of buoyancy with the passage of time which then renders the filaments ineffective to trap sediment.
Another known apparatus for prevention of shore erosion involves the use of modules including a plurality of spaced wooden boards secured to belts which are anchored to a concrete base. This assembly is said to cause sand to be deposited from de-energized waves. However, the modules are not commercially acceptable because the floating wooden boards are objectionable to bathers and others who wish to use the adjacent shoreline. Since the wooden boards are rigid, bathers can be struck and injured by them as the boards are moved by the action of waves in the body of water.
Accordingly, it has been considered desirable to develop a new and improved means and method for stabilizing shorelines which would overcome the foregoing difficulties and others while providing better and more advantageous overall results.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, an offshore barrier module adapted to retard the wave induced erosion of an adjacent shoreline is provided.
The prior art barrier structures are attempting to protect beaches from the damage caused not only by normal wave action but also by major storms. It is doubtful that this can be done economically. Such storms tear up a beach and carry the soil or sand out to sea far beyond the normal offshore sandbars thereby permanently eroding the beach.
While it is doubtful that barrier structures can prevent storms from tearing up a beach in the first place, the barrier module of the present invention is so designed that it can catch some of the beach soil before it is washed out to sea. The soil or sand so caught can be caused to accumulate in an artifically created offshore sandbar. Subsequently, during mild weather low water waves will wash this sand back up onto the beach where it can again be sacrificed to the next major storm.
More particularly in accordance with the invention, the barrier module includes a porous barrier means for retarding the flow of water therepast to reduce the velocity thereof and to thereby promote the deposition of particulate matter at and adjacent to the barrier means. The barrier means comprises an elongated hollow substantially cylindrical body which includes horizontal and vertical elements that extend around the body and are secured to each other. A ballast means is provided for weighing down the barrier means.
According to another aspect of the invention, the horizontal elements comprise a plurality of spaced apart elongated slats and the vertical elements comprise at least two spaced apart hooplike straps to which the slats are secured.
According to still another aspect of the invention, the slats are unevenly spaced on the periphery of the cylinder such that approximately 75% of the periphery near the top of the cylinder, above the center line thereof, is open area but only approximately 25% of the periphery near the base of the cylinder, below the center line thereof, is open area.
According to yet another aspect of the invention, the slats and straps are fabricated from a plastic material having a relatively high modulus of elasticity.
According to still another aspect of the invention, the cylindrical body is comprised of a three dimensional mesh material.
According to yet still another aspect of the invention, the barrier module further comprises a barrier member located within the porous barrier means. Preferably, the barrier member comprises a diaphragm extending along a longitudinal centerline of the bore of the porous barrier means.
In accordance with a further aspect of the invention, the barrier module further comprises a cylindrical body located within the barrier means. The body is comprised of a three dimensional mesh material and has a smaller diameter than the barrier means to allow the body to reciprocate within the barrier means as waves and currents dictate.
In accordance with a still further aspect of the invention, the ballast means includes at least one anchor member secured to the barrier means.
In accordance with a yet further aspect of the invention, the barrier means comprises an elongated hollow substantially cylindrical body which is flexible so that the force of waves transverse to the axis of the body can deform the body.
In accordance with still yet another aspect of the invention, an offshore barrier array is provided. The barrier array is adapted to retard the wave induced erosion of an adjacent shoreline and comprises a plurality of barrier modules.
One advantage of the present invention is the provision of a means for beach stabilization which does not try to protect the beach from the damage caused by a severe storm but rather catches some of the soil or sand that would normally be washed out to sea by such a storm. This sand is caused to accumulate in an artifically created sandbar offshore. The sand from this sandbar can then be washed back to shore during milder weather by normal wave action.
Another advantage of the present invention is the provision of a means for stabilizing beaches which presents no obstruction to shoreline utilization and enjoyment and will benefit rather than damage the owners of adjacent property.
Still another advantage of the present invention is the provision of a means for stabilizing beaches which is very economical to construct and does not require the access of heavy equipment to a shoreline to construct or deploy the structure, and is equally effective in controlling wave dislodged sediment and current formed sediment.
Yet another advantage of the present invention is the provision of a means for stabilizing beaches which can be as easily and economically installed at great distances from the shoreline as along the shoreline itself and can be used either in shallow water or at great depths of water.
A further advantage of the present invention is the provision of a means for stabilizing beaches which is comprised of an elongated hollow substantially cylindrical body made of a flexible material so that the force of waves transverse to the axis of the body can deform the body and so that an object striking the body can also deform the body thereby preventing damage to objects striking the body.
Yet still another advantage of the present invention is the provision of a means for stabilizing beaches which does not depend upon the buoyancy of a barrier structure for entrapment of water-borne sediment and is capable of functioning at both low wave speeds and high wave speeds and in the presence of turbulent water to trap water-borne sediment.
Still other benefits and advantages of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
FIG. 1 is a perspective view of a first preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 2 is an end elevational view of the stabilizing means of FIG. 1 together with a ballast means for securing the stabilizing means in relation to a sea bottom;
FIG. 3 is a side elevational view of a second preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 4 is a perspective view of a third preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 5 is a perspective view of a fourth preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 6 is a perspective view of a fifth preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 7 is a perspective view of a sixth preferred embodiment of a means for stabilizing shorelines according to the present invention;
FIG. 8 is an end elevational view in reduced size of a process of sand accumulation and positioning of a plurality of stabilizing means according to the present invention over a period of time;
FIG. 9 is a reduced top plan view of a plurality of stabilizing means according to the present invention positioned in a staggered row generally parallel to a shoreline; and,
FIG. 10 is a reduced top plan view of a plurality of stabilizing means according to the present invention arrayed in a staggered overlapping pattern generally transverse to the shoreline.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein the showings are for the purpose of illustrating the preferred embodiments of the invention only and not for purposes of limiting same, FIG. 1 shows the subject new means for stabilizing beaches in the form of a module A. The module includes a cylindrical body 10 that is comprised of a plurality of axially spaced apart hoop members 12 and a plurality of radially spaced apart slat members 14.
The hoops and slats are so connected at their points of intersection as to resist rotation of the assembly in a direction parallel to the axis of the module. The points of intersection of the hoops 12 and slats 14 can be secured by sonic welding, or the like, at respective weld joints 16.
The material of which the hoops and slats are constructed may be a plastic material with a relatively high modulus of elasticity such as polyester or polypropylene. Such material is often used in package strapping and one commercial producer of such strapping material is the Signode Corporation of Chicago, Illinois. One material contemplated for this application is a strapping material which is on the order of approximately two inches wide and which has a thickness of approximately 0.030 inches. The modulus of elasticity of the material can be on the order of 1 million psi and the tensile strength can be on the order of 60,000 psi.
The plastic material from which the module is constructed can be carbon loaded to reduce it's structural degradation due to its exposure to water, ozone, ultraviolet radiation, and other strength degrading substances and conditions. The plastic material is preferably flexible and not buoyant. It should, however, be appreciated that the body can be made from any other suitable type of material, which does not necessarily have to be plastic, and may be buoyant if desired. However, the material is advantageously flexible or resilient since this will prevent in jury to bathers who might strike the body 10 while swimming or wading.
The body 10 can be anywhere from 12-18 inches in diameter and can be approximately six feet long.
With reference now also to FIG. 2, preferably the module A is held in a predetermined position at a sea bottom 19 by a ballast means 20. The ballast means can comprise a block 22 and a cable 24 which is secured at one end to the cylinder body 10 and at the other end in the block 22. Over the course of time, the block 22 may become embedded in the sand 26 at the sea bottom 19 or it may originally be embedded in the sand if desired.
As an onshore wave 30 strikes the module A, it will be deflected toward the shore as at 32 since the module is made of a flexible material. As an offshore wave 34 strikes the module, it will deflect as at 36 in response thereto. When the wave action is dissipated, the module will preferably return to its original substantially cylindrical upright position as illustrated in solid lines in FIG. 2 due to the tensile stresses induced in the preferably resilient hoops 12 thereof when they are bent into a circle.
In FIGS. 1 and 2, the slats attached to the circular hoops are uniformly spaced around the circumference of the hoops. Alternatively, it would also be conceivable to have a non-uniformly spaced series of slats as is illustrated in FIG. 3. For ease of illustration and appreciation of this modified construction, like components are identified by like numerals with a primed suffix (') and new components are identified by new numerals.
In FIG. 3, a module B is shown as having a body 10' comprising plurality of hoop members 12', only one of which can be seen in the end elevational view of FIG. 3, as well as a plurality of spaced slats 14'. In this embodiment, however, the slats are more closely spaced toward each other near the bottom of the module and spaced further apart near the top of the module. One desirable such spacing can provide approximatey 75% open area near the top of the module, approximately 50% open area near the longitudinal centerline of the module, and approximately 25% open area near the bottom of the module. A 50% open area can be achieved, approximately, by spacing a two inch wide slat 14' on a four inch center assuming that the circular hoops 12' present a small face toward the movement of water. The hoops can, in this embodiment, be approximately 2 inch wide bands that are spaced apart on 18 inch centers.
Such variable spacing of the slats around the hoops might be desirable when the volume of sediment transported is much heavier near the sea bottom than it is at some short distance thereabove. This condition is typical of sand washed offshore by impinging waves. In this type of an application, uniformly spaced slats on a barrier module would simply present an unnecessary obstruction to the movement of water without materially improving sediment entrapment. Also in this embodiment, a different ballast means 40 for the module B is disclosed. More specifically, the ballast means 40 includes a bag 42 which can be filled with a suitable particulate material such as sand or the like. The ballast means can be placed inside the body 10' to weigh it down and prevent movement thereof by waves. Of course, a plurality of ballast means can be provided if desired.
A third type of module C is shown in FIG. 4. For ease of illustration and appreciation of this embodiment, like components are identified by like numerals with a double primed (") suffix, and new components are identified by new numerals.
In this embodiment, the hoop and slat construction disclosed in FIGS. 1-3 is replaced by a U-shaped body 50 made of a flexible or resilient material. A substantial number of apertures 52 are provided in the body to allow water to flow therethrough as urged by waves or currents. A base 54 is provided for the U-shaped body and a plurality of fasteners 56 secure the lateral ends 58, 59 of the body to the base. The base 54 can also serve as the anchor means for holding the body 50 in place on the sea bottom if desired by being made from a heavy material such as concrete, as illustrated. Alternatively, a separate anchor means could be provided for the body 50.
The body 50 can be made of suitable elastically deformable conventional plastic sheet material which has been provided with apertures 52 in suitable number to allow an appropriate percentage of open area as required by the site at which the barrier module will be used.
In order to give the body some rigidity, it can be provided with longitudinally extending ribs 60 separated by grooves 62. Alternatively, the sheet of plastic does not have to be corrugated if that is not required.
The corrugations are, however, advantageous in order to allow the sheet of barrier material to flex more easily in response to wave or current action. The amount of flexure required is a function of site conditions and can be controlled by the varying the heighth and width of the U-shaped body as well as the thickness and elasticity of the sheet material and the depth of the corrugations.
A yet fourth type of barrier module D is illustrated in FIG. 5. For ease of appreciation of this alternate embodiment, like components are identified by like numerals with a triple primed suffix ("') and new components are identified by new numerals.
In this embodiment, the barrier module D is comprised of a cylindrical body 70 which is made out of a mesh material. One suitable such material is formed of randomly oriented monofilaments of carbon loaded nylon and is produced under the tradename of "Enkamat" by the BASF Corporation. This material is a three dimensional non-woven fabric-like material with a thickness of approximately 3/8 to 3/4 inches. The material is elastically deformable and can be rolled into a cylinder and secured in this configuration by conventional means.
In general, the barrier module according to the present invention need not be constructed of hoops and slats or of sheet material but can be formed of any material with requisite structural properties and porosity. For example, one embodiment which can be visualized would be a barrier module constructed of several layers of plastic gridwork laced together to provide the requisite structural and hydraulic properties. All such materials are to be encompassed hereunder and are defined by the generic term "mesh".
In this embodiment, the ballast means comprises concrete blocks 22"' which are secured by cables 24"' to the cylindrical body 70. The concrete blocks 22"' can rest in the sand 26"' on the sea bottom.
The cable 24"' can be a non-corroding tension resisting member such as revetment cable constructed of parallel strands of polyester fiber or the like within a woven or extruded sheath.
Yet another type of barrier module E is illustrated in FIG. 6. For ease of appreciation of this embodiment, like components are identified by like numerals with a quadruple primed suffix ("").
In this FIGURE, the barrier module E comprises a cylindrical body 10"" which encloses a cylindrical body 74 of mesh material of a smaller diameter than the body 10"". The body 74 can be called a "valve" or a "filter member." The advantage of positioning a so-called filter member within the body 10"" is that the filter member can be useful in enhancing the performance of the device by further attenuating the velocity of water moving therethrough. The smaller barrier member 74 can be free to move about within the larger cylindrical body 10"" as dictated by waves and currents. However, the smaller diameter body 74 could also be tethered by any conventional means within the larger body 10"" to limit the extent of its movement if that were considered desirable.
To secure the body 10"" in place on a sea bottom 19"", a ballast means comprising block members 22"" and cable members 24"" is provided.
With reference now to FIG. 7, yet another barrier module F is illustrated therein. For ease of appreciation and understanding of this embodiment, like components are identified by like numerals with a quintuple primed suffix (""') and new components are identified by new numerals.
This module configuration F includes a body 80 comprising a plurality of spaced hoops 82 and spaced slats 84. A planar barrier member 86 is positioned within the body 80 and is secured therein by a suitable conventional securing means 88 such as welding. A plurality of suitably configured spaced apart apertures 90 is provided in the barrier 86 to allow water to flow therethrough. The advantage of positioning such a barrier within the module is to enhance the performance of the module as a sand trap by interposing additional velocity attenuating material within the area of moving water. Additionally, the barrier 86 can also deform the module to some extent by modifying a resilient otherwise substantially cylindrical shape. The diaphragm or barrier 86 is placed under a light tension by the tendency of the hoops 82 to maintain a substantially circular configuration.
Although only one barrier or diaphragm 86 is illustrated in FIG. 7, it should be appreciated that more than one diaphragm can be placed within the module to enhance its performance. A ballast means comprising block members 22"" and cable members 24"" secures the module F in place on a sea bottom 19"".
With reference now FIG. 8, a sea bottom adjacent a shoreline is there illustrated in schematic form. When beach stabilizing soil movement does not take place naturally or when protection from severe storms is desired, beach stabilizing soil movement can be encouraged and stimulated by the placement of the barrier modules described hereinabove, some distance offshore, in a relatively shallow depth of water. The distance from the shoreline and the water depth will depend on site conditions in each case. The depth can be on the order of approximately 3 feet, if desired. In one particular embodiment, it could be imagined that the modules would be placed approximately 1000 feet offshore, parallel to the shoreline in a three foot depth of water.
As the offshore currents in water 100 wash sand away from a beach (not visible in FIG. 8), some of the sand accumulates on a sea bottom 102 inside and behind a first module 104. In such a configuration, there would be a two foot depth of water above the preferably twelve inch diameter first barrier module. This would permit waves up to two feet in height to pass over the module 104 without breaking. Such waves would then break on the shoreline, dislodging soil particles which would be swept away from the beach by the returning wave and which would be deposited in the vicinity of the barrier module 104. At least some of this deposited soil would remain in place between the seasons. Therefore, additional modules 106, 108 could be placed in successive seasons behind and somewhat above the first module as is illustrated to further accumulate a supply of offshore soil and thereby promote beach stability.
With reference now to FIG. 9, a means for stabilizing shorelines can be positioned adjacent a beach 120 in water 122 as shown. In this embodiment, modules 124, 126 are placed in a staggered row substantially parallel to the shoreline as is illustrated. This placement would constitute an impermeable groin-type placement. But since the modules of the present invention are permeable, the resultant means for stabilizing would be permeable.
Alternatively, the modules can be arranged in a staggered overlapping pattern generally transverse to a beach 130 in water 132 as is illustrated in FIG. 10. In this FIGURE, the water 132 adjacent the beach 130 holds a plurality of staggered modules 134, 136 in several rows. In this embodiment, while each row of the modules is positioned in a permeable groin-type arrangement, the overall configuration again corresponds to an impermeable groin-type structure. However, since the modules are themselves permeable, the resultant means is also permeable.
One advantage of placing modules in spaced rows is that further attenuation of water velocity takes place at the second row of modules thereby trapping more sand or soil particles thereat.
Although the invention has been shown and described with respect to several preferred embodiments, modifications and alterations thereof will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | An offshore barrier module which is adapted to retard the wave induced erosion of an adjacent shoreline includes a porous barrier member for retarding the flow of water therepast, to reduce the velocity thereof and to thereby promote the deposition of particulate matter at and adjacent to the barrier member. The barrier member includes an elongated hollow, substantially cylindrical body which has horizontal and vertical elements that extend around the body and are secured to each other. A ballast member is also provided for weighing down the barrier member. | 4 |
This application is a continuation-in-part of U.S. application Ser. No. 09/961,775 filed 18 Sep. 2001, now abandoned.
BACKGROUND OF THE INVENTION
Police officers have seen great changes in their equipment in recent years, with but one constant problem. They struggle most times with the removal of the equipment from the belts and placing them into action in a quick and easy fashion. This invention relates generally to an easy and quick access to the items held on a police officer's belt, more particularly to the non-lethal weapons and ammunition clips, but not limited to these in anyway. Hereinafter the term officer refers to a police officer.
BACKGROUND AND PRIOR ART
The modern police officer carries a variety of implements that reflect new technologies and new policing philosophies. The police officer of a generation ago wore a belt having a holster for a 0.38 caliber revolver, a ring to carry his hand-carved espontoon and a loop to carry handcuffs. Today the belt is used to carry a variety of devices, including a semiautomatic pistol, an additional ammunition magazine, an expandable “ASP®” tactical baton (an extendable baton, usually in three sections, available in various lengths and made by Armament Systems and Procedures, Appleton, Wis.), a flashlight and a pepper spray canister in addition to handcuffs and a radio. The magazine, baton, flashlight and pepper spray must be readily accessible with one hand when needed, but otherwise securely mounted.
Since police departments converted from the traditional espontoon to the ASP® baton, numerous designs have been put forward for holstering the baton.
U.S. Pat. No. 5,104,076 is directed to a reconfigurable article holder formed from strips of hook and loop material (Velcro™).
U.S. Pat. No. 5,217,151 discloses a belt mountable scabbard having a “front pocket” having an open top and a closed bottom for holding a baton in the closed position and a “back pocket” for holding a baton in the extended position.
U.S. Pat. No. 5,263,619 is directed to a tubular holder for a telescoping baton characterized by a shoulder ring into which the outer baton section seats in either the folded or open positions.
U.S. Pat. No. 5,551,610 is directed to a holster for a truncheon having a handle grip and a cross guard characterized by a clamshell shape swivally mounted on a belt so that the elongated staff of the truncheon may be worn upwardly or downwardly depending whether the police office is seated or standing.
U.S. Pat. No. 5,647,591 describes a pin and socket bayonet-type connection mechanism for connecting police accessories to an ASP® baton but does not disclose use of the connection mechanism for attaching the accessories to a belt.
U.S. Pat. No. 5,699,943 discloses a belt-mounted flashlight holder using a flexible moveable jaw and cradle which can be rotated to several detented positions and allows for a breakaway when jerked strongly.
U.S. Pat. No. 5,839,630 discloses a holster for a “side-handled” baton which has a cradle for the side handle and a shaft cradle. Snap and hook and loop fasteners secure holding tabs projecting vertically above the side handle.
U.S. Pat. No. 5,906,303 is addressed to a ring-type baton holder having a resilient coating to hold the baton in place.
U.S. Pat. No. 5,947,352 describes a baton holder of the scabbard type which attaches to belt and suspenders and allows the wearer to release the baton with a single upward hand motion.
U.S. Pat. No. 6,267,279 describes a holster for elongated hand weapons using a standardized track structure in the holster and complimentary slides on opposite faces of the device to be holstered.
Armament System and Procedures Inc. also sells a snap out flexible holster for their baton which is a slotted tapered tubular carrier sold under the name ASP Sidebreak Holster.
BRIEF SUMMARY OF INVENTION
Rapid Access Technology (R.A.T.), as it relates to weapons and items carried on the belt of an officer or into a combat situation, enhances the need and ability to quickly and easily bring weapons, such as ASP® baton or pepper spray containers into action, or the ability to insert an ammunition clip into an automatic pistol using only (if need be) one hand with no loss of speed or control of the weapon. Other commonly used items such as flashlight and handcuffs can also be carried using this system.
R.A.T. works on the need to keep these items secure until the weapon or ammunition clip is needed. When the officer unlatches the holder, the R.A.T. activates the carrier allowing gravity or spring assist to swing down pulling a locking hinge into position where it rests at an angle of 20–600. The item inside is held in place by a slip fitting, a dovetail, or any other locking device to allow easy retrieval of the needed item. A different holder may be used for each item.
Using R.A.T. for the reloading of the automatic pistol, the office unlatches the ammunition clip holder latch and the drop bottom swings down (this can also be pushed outward with a spring), pulling the locking hinge into place at an angle just away from the body. After expelling the used clip the officer aligns his weapon over the fresh ammunition clip and slams it into his weapon, pushing forward or backward to release the clip without the need to first remove the ammunition clip from his belt or turn over the new clip. The ammunition clip is held in a base down position. The access attachment holds the ammunition clip securely while allowing for the handle of the weapon to slide over the ammunition clip until it locks into place. This arrangement can be used by both left or right handed officers. When used for the other items, ASP® baton and the pepper spray container, the R.A.T. carrier holds the items securely and when engaged, the items are held at an angle where the officer can grasp, hold the item and place it into action in a fraction of the time from case holders used today and/or described in the prior art described supra.
Profile of R.A.T. carrier, which can be made of many materials and shapes depending on what holder is being used, will have a metal or plastic backing plate with an angled lock on the hinge where the back will stop the hinged floor at an angled position. The hinged floor, also made of metal or plastic, with a connection means attached to the floor, holds the item in the carrier until the officer removes it. A latch strap or cover is wrapped around the item holding it in a secure position in a normal manner. When the latch is released the weight of the held item uses gravity or a spring assist to fall and pulls the floor down until its stop hits the backing plate which will hold it at the angle needed to allow access to the items.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the carrier in perspective view in the partially opened position.
FIG. 2 shows the carrier in cross-section in the closed position holding an ammunition clip.
FIG. 3 shows the carrier in cross-section in the opened position.
FIG. 4 shows details of the clip holder attached to the carrier.
FIG. 5 shows the clip holder removed from the carrier.
FIG. 6 shows a holder for a circular item attached to the carrier in the closed position.
FIG. 7A shows the carrier with a holder for handcuffs.
FIGS. 7B and 7C show an alternative carrier with a holder for handcuffs.
FIG. 8 shows an ammunition clip holder in exploded view according to a second embodiment of this invention.
FIG. 9 shows a flashlight holder in exploded view according to a second embodiment of this invention.
FIG. 10 shows a closed ASP® baton holder in exploded view according to a second embodiment of this invention.
FIG. 11 shows a pepper spray canister carrier in exploded view according to a second embodiment of this invention.
FIG. 12 shows the use of the attachment method from the second embodiment of this invention as a means for attachment of an implement on another piece of police equipment, in this case a hat.
DETAILED DESCRIPTION OF THE INVENTION
The invention is directed to systems which secure weapons and other accessory items to an officer's belt and which allow rapid, singe-handed access to those weapons and accessory items. The rapid access technology, R.A.T., uses systems for attaching items to the belt which allows for interchangeability of items in the same holder and which are adaptable to both left and right-handed persons.
As it relates to the weapons and items carried on the belt of an officer or into a combat situation where the need and ability to quickly and easily bring weapons, such as but not limited to ASP® baton or pepper spray canister, into action, or the ability to insert an ammunition clip into an automatic pistol using only one hand with no loss of speed or control of the weapon.
When closed, the system keeps these items secure until the weapon or ammunition clip is needed. When the officer unlatches the holder, R.A.T. activates. The carrier allows gravity or spring assist to cause the holder to swing down pulling a locking hinge into position where it rests at an angle between 20–60 degrees to the vertical. The item inside is held in place by a quick release attachment means to allow easy retrieval of the item the officer needs. A different holder is used for each item based on its shape.
FIG. 1 illustrates the basic components of the R.A.T. system. The carrier 1 consists of a substantially flat, stiff rectangular plate 3 with a belt loop 5 for attachment to a standard service belt. A rectangular floor 7 is attached to plate 3 using a hinge 9 . A stop 11 limits the free rotation of floor 7 . Attached to the floor 7 at the end away from hinge 9 is strap 13 which is formed from a semi-rigid material. At the end of strap 13 is an attachment means 14 which co-operates with latch 15 to hold the strap 13 securely to the plate 3 until released. In the embodiment shown, a plurality of slots 17 are present in floor 7 as one means for providing attaching means or holders for securing accessories to the floor of the device.
FIG. 2 illustrates the carrier in the closed position with the latch opened. In this illustration, an ammunition clip 21 is inserted into a holder 22 . The holder has a base 23 which is attached to floor 7 using prongs 25 inserted into slots 17 . A plurality of spring loaded clasps holds the clip 21 in place. Element 27 represents clasps for the broader side of the clip; element 29 represents the clasps for the front and rear of the clip which has a rectangular plan view.
FIG. 3 is a side elevation of the carrier of FIG. 2 in the open position. FIG. 4 is a perspective view of the carrier of FIG. 2 in the closed position showing the attachment of base 23 to floor 7 using prongs 25 inserted through slots 17 .
FIG. 5 shows the holder 22 as a separate element. The clasps 27 , 29 and prong 25 must be resilient and preferably formed from spring steel or a very resilient engineering plastic.
FIG. 6 illustrates the use of the R.A.T. system with a cylindrical accessory such as an ASP® baton, pepper spray canister or flashlight. The cylindrical item 31 is retained in attaching means such as a base 23 having multiple clasps 33 which may be shorter than clasps 27 , 29 used with a rectangular ammunition clip. Unlike the circumstance with a rectangular item such as an ammunition clip, the number of clasps needed for a cylindrical object is variable and may be from 2 to less than a complete cylinder.
FIG. 7A illustrates the use of the R.A.T. with an ubiquitous law enforcement item, handcuffs. A base 43 similar to holder base 23 of FIG. 5 is attached to floor 7 as in the previous drawings. Base 43 supports two cups, 45 , which have a closed forward position 47 and an open rearward aspect 49 . As shown in this embodiment, the base 43 is attached to floor 7 using fasteners such as screws 41 or rivets. The bottom is extended at 51 to hold handcuffs 53 in position when strap 13 is secured.
An alternative embodiment of a holder for handcuffs as shown in FIG. 7A , is shown in FIGS. 7B and 7C . Unlike the embodiment of FIG. 7A , this embodiment holds the handcuffs in linear arrangement. A flat plate 203 having belt loops 205 has a floor 207 attached mounted rigidly at an angle to serve as a stop. A base 241 is attached to flat plate 203 through a hinge pin 209 inserted through bore hole 242 and bore hole 210 . Spring 206 may be used to preload base 241 away from flat plate 203 . Post 243 , which carries cup 245 , is secured to the base 241 using screws 252 passing through untapped holes 256 . Handcuffs 53 are cradled in cup 245 and held in place by strap 214 held in place on plate 203 by rivets 213 and having fastener means 215 attaching to fastener means 250 .
FIG. 8 shows an alternative embodiment of the invention. In this embodiment, a dovetail connector is employed in the attaching means in lieu of clasps. The dovetail socket or dovetail pin 104 may be mounted on the implement 121 and corresponding socket or pin mounted on the holder. As shown in FIG. 8 , a flat plate 103 having a belt holder 105 has a stop 107 mounted rigidly at an angle. Optionally, a spring 106 may urge the dove tail socket 102 floor to the open position. As in the previous embodiment, the stop 107 is a stop to limit the downward movement. A latch 115 and cover 113 and attachment means 114 operate as do items 13 , 14 , and 15 of the first embodiment.
The floor containing the dovetail socket 102 is attached to flat plate 103 through a hinge pin 109 inserted through bore hole 110 and the bore hole 210 of 102 as in the previous embodiments. As shown in FIG. 8 , a dovetail pin 104 is attached to or formed into the implement such as ammunition clip 121 .
FIG. 9 illustrates an adaptation to the dovetail attachment system with particular utility for a flashlight. A backing plate 163 carries a dovetail pin 104 which mates to a dovetail socket 102 which may by securely mounted to flashlight 131 . A swivel pin 165 secures the dovetail pin to the backing plate 163 using socket 166 . A plurality of magnets 167 may be inserted into the dovetail pin. A spring washer 164 maintains tension between pin 104 and backing plate 163 so that the flashlight may be rotated and holds in the rotated position. When the backing plate 163 is metal and/or the dovetail socket is metal, the magnets eliminate any looseness in the connection while allowing quick removal of the flashlight or rotation of the flashlights to allow no-hands lighting of an area. A strap 169 secures the backing plate 163 , preferably passing through and secured to slot 120 and snapping into place.
FIGS. 10 and 11 illustrate an alternative use of the dovetail connection in which the dovetail pin is molded into the floor. The flat plate 103 carries a hinged floor 171 articulated at pin 109 is formed to serve as a dovetail pin. A latch 115 secures a cover 179 . A dovetail socket 173 having screws 175 , rivets, or made a part thereof, is secured to the implement, such as ASP® baton 169 . In the case of a pepper spray canister 183 , the dovetail socket may be molded into a ring mount 181 .
Finally, the dovetail connection may be used with other types of police equipment. As shown in FIG. 12 , a dovetail pin 205 may be mounted on a hat 201 or helmet and the dovetail socket 203 attached to flashlight 131 becomes a moveable spotlight similar to a miner's lantern. Alternatively, the socket 203 may be slid onto dovetail pin 104 at the base of an ammunition clip 121 to illuminate where a firearm is pointed.
In a further utility, the ASP® baton may be used to steady the weapon by sliding the socket 173 of the baton onto dovetail pin 104 . Such an arrangement reduces fatigue in standoff situations.
In each embodiment, the implement can be accessed with one hand with a minimum of motions and quickly re-secured when no longer needed.
The flat plate 3 , 103 and floor 7 , 107 may be formed from a metal or an engineering plastic such as polyethylene, polypropylene, polyurethane, polyvinyl chloride and polycarbonate. The attaching means or holder should be engineering plastic. Strap 13 , cover 113 and latch 15 , 115 may be a flexible plastic such as polyethylene or polypropylene.
The invention has been described in terms of preferred embodiments which illustrate in a non-limiting way, the concept of the invention. Additions and modifications of the invention will be obvious to those skilled in the art and are included within the scope and spirit of the invention. | A system for carrying and rapidly accessing implements carried on a belt, especially implements used by law enforcement officers. The system uses a hinged floor carried on a flatplate having a belt loop. The hinged floor is held perpendicular to the flat plate by a strap or cover having a quick-release latch at the top. When the strap or cover is released the floor drops to form an angle with the flat plate, allowing the user to quickly remove the implement using one hand. | 8 |
RELATED APPLICATION DATA
[0001] This application claims benefit of and priority to U.S. Application Ser. No. 60/241,664 filed Oct. 19, 2000, entitled “Frequency Domain Supplemental Training of the Time Domain Equalizer for DMT,” which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] In general, the systems and methods of this invention relate to time domain equalizer training. In particular, this invention relates to systems and methods for supplemental frequency domain training of the time domain equalizer in a discrete multi-tone system.
[0004] 2. Description of Related Art
[0005] In Discrete Multi-tone Modulation (DMT) systems, the time domain equalizer (TDQ) is a finite impulse response (FIR) filter located at the receiver side of a DSL modem. The TDQ is used to reduce the intersymbol interference (ISI). If the channel is shortened in time to have a length no greater than the length of the cyclic prefix, the intersymbol interference can be eliminated. Thus, a common method for training the TDQ in a DMT system is to jointly optimize the numerator and denominator of the autoregressive (AR) model for the channel where the order of the numerator is equal to the cyclic prefix length and the denominator is used as the TDQ setting. The training is based on transmission and reception of a known reference signal, such as the reverb signal in ADSL systems, using a least squares fit of the AR channel model.
SUMMARY OF THE INVENTION
[0006] The supplemental training according to the exemplary systems and methods of this invention starts with the least squares solution of the time domain equalizer coefficients outlined above as its starting point, and iteratively improves on it.
[0007] Specifically, the medley-based supplemental training which is the subject of this application takes as input the output of a reverb-based TDQ training algorithm. Examples of reverb-based training algorithms are described in Stuart Sandberg and Michael Tzannes, “Overlapped Discrete Multitone Modulation for High Speed Copper Wire Communications,” IEEE JSAC, vol 13, no. 9, December 1995, pg 1571-1585, incorporated herein by reference in its entirety, and include channel shortening schemes based on an AR fit to the transmission channel.
[0008] The improvement is geared towards maximizing the number of bits per frame loaded over the TDQ choice. In particular, capacity is maximized directly rather than setting a goal to shorten the channel and hoping that the capacity would be maximized as a result. The supplemental training operates in medley transmission mode, and requires a number of pseudo-random data frames.
[0009] Medley operation is selected in that the reverb data transmission, which is the repetitive transmission of the same reference frame, would not produce ISI in the received signal, and the SINR (Signal-to-Interference and Noise) determined in this way would not take into account the very component of error that the TDQ is intended to reduce. From the medley data, the SINR can be estimated over the bins used in the actual data transmission mode, and therefore, the number of bits per frame loaded.
[0010] The systems and methods of this invention use a directed search method on the capacity function to obtain an improved TDQ. The function in question is highly non-linear, and after linearization, e.g., using the first two terms in a Taylor series expansion around the starting TDQ point, a local extremum is sought. Since this does not guarantee the best solution, the same supplemental training can be repeated one or more times, each time starting with the TDQ solution resulting from the previous run.
[0011] In accordance with an exemplary embodiment of the invention, an aspect of the invention relates to performing frequency domain supplemental training of a time domain equalizer.
[0012] Additionally, aspects of the invention also relate to performing frequency domain supplemental training of a time domain equalizer in a discrete multi-tone environment.
[0013] Additional aspects of the invention also relate to performing the supplemental training numerous times, with each instance of the supplemental training using the last determined time domain equalizer coefficients to improve the quality of the results.
[0014] These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The embodiments of the invention will be described in detail, with reference to the following figures wherein:
[0016] FIG. 1 is a functional block diagram illustrating a DMT DSL modem according to this invention;
[0017] FIG. 2 illustrates how supplemental training fits into a sequence of ADSL receiver initialization/training tasks; and
[0018] FIG. 3 is a flowchart detailing the perform supplemental training step of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] The exemplary embodiments of this invention will be described in relation to the application and the invention to an ADSL transceiver environment. However, it should be appreciated that in general, the systems and methods of this invention will work equally well for any multi-carrier communication system including, but not limited to, DSL, VDSL, SDSL, HDSL, HDSL2, or any other discrete multi-tone, discrete wavelet multi-tone DSL or wireless OFDM system.
[0020] As discussed above, the supplemental training according to an exemplary embodiment of this invention commences with a Least Squares solution for the TDQ and improves on the accuracy. Specifically, the number of bits per frame loaded is maximized over the TDQ choice. The function to maximize is the sum of the number of bits that can be loaded in the bins that are used for transmission, and the maximization is over the TDQ setting:
[0000] Max (a) (SUM (k) (log 10 (SINR k ))),
[0000] where:
[0021] a is the TDQ vector of size L×1,
[0022] k is the bin index (out of N used bins, while N<M where M is the size of the receiver Fourier Transform), and
[0023] SINR k is the signal to noise and interference ratio in bin k, expressed as a function of TDQ coefficients, a.
[0000] The above is the equivalent of minimizing the following:
[0000] min (a) (SUM (k) (lnE[|e k | 2 ]−lnE[|s k | 2 ])),
[0000] where:
[0024] E[|e k | 2 ] is the mean square error in bin k,
[0025] E[|s k | 2 ] is the mean square signal in bin k, and
[0026] s k =u k H k A k a,
[0027] where:
u k is the medley 4-QAM reference symbol in bin k, H k is an estimated (during reverb training) complex channel frequency response at bin k, A k is a Fourier basis row vector of length L, having frequency 2πk/M, and e k =s k −F k B a,
where:
F k is a Fourier basis row vector of length M, having frequency 2πk/M, B is the received data matrix of size M×L, and each column of which is the received data frame (before the TDQ block), shifted by one sample as to represent the time passing operation. In the following, the dependence of B, u k and s k on frame will sometimes be shown explicitly as B(n), u k , (n), and s k (n), where n is the frame index.
[0034] This function is highly nonlinear, and only the portion around the TDQ starting point is modeled by taking the first two terms of the Taylor series expansion. As a result, the function to minimize (over TDQ setting a) is:
[0000] SUM (k) (w k e E[|e k | 2 ]−w k s E[|s k | 2 ]),
[0000] where the weights are:
[0035] w k e =1/E[|e k,0 | 2 ],
[0036] w k s =1/E[|s k,0 | 2 ], and
[0037] e k,0 and s k,0 are e k and s k , evaluated for the initial TDQ setting.
[0038] E[.] is evaluated as an average, over medley frames.
[0000] After some manipulation, the function to be optimized can be rewritten as:
[0000] min (a) ( E[a′G e a−a′G s a ])=min (a) {a′E[G e ]a−a′E[G s ]a}
[0000] where:
[0039] G e =G e — mat + W e G e — mat , is a matrix of size L×L and where + is the conjugate transpose,
[0040] G s =G s — mat + W s G s — mat , is a matrix of size L×L,
[0041] G s — mat =D u D H A, is a matrix of size N×L,
[0042] D u =diagonal (u) and D H =diagonal(H), are both matrices of size N×N,
[0043] A is a Fourier basis matrix of size N×L, consisting of previously described vectors A k ,
[0044] G e — mat =G s — mat −FB, is a matrix of size N×L,
[0045] F is a Fourier basis matrix of size N×M, consisting of previously described vectors F k ,
[0046] W e =diagonal(w k e ), W s =diagonal(w k s ), are both matrices of size N×N, and
[0047] B is a received data matrix of size M×L, as discussed above.
[0000] The directed search for the minimum starts with the initial TDQ vector, a 0 , and for each iteration the TDQ is updated:
[0000] a i =min eigenvector { E[G e ]−E[G s ]}
[0000] where E[G e ]−E[G s ] has been linearized/localized about a 1−1 as described above.
[0048] In practice, as discussed hereinafter, the iterations of the supplemental training are continued until arriving at a TDQ with satisfactory performance, or for some other predetermined number of iterations. Note that to obtain the TDQ for a new iteration, the TDQ from the previous iteration is used to estimate the signal, the error, and to obtain the updated matrix E[G e ]−E[G s ].
[0049] FIG. 1 illustrates an exemplary DSL modem 5 according to this invention. In particular, the DSL modem 5 comprises a bit loading module 10 , an encoder 20 , an Inverse Fast Fourier Transform module 30 , a cyclic prefix module 40 , an echo canceller 50 , a digital-to-analog converter 60 , an analog-to-digital converter 70 , a time domain equalizer 80 , a training module 90 , a cyclic prefix module 100 , a Fast Fourier Transform module 110 , a frequency domain equalizer 120 , a decoder 130 and a bit loading module 140 . As will be appreciated by one of ordinary skill in the art, various other components may be present in a DSL modem, however have been omitted for the sake of clarity.
[0050] While the exemplary embodiment illustrated in the FIG. 1 shows the modem 5 and various components collocated, it is to be appreciated that the various components of the modem can be combined or located at distant portions of a distributed network, such as a local area network, a wide area network, an intranet and/or the Internet, or within a modem. Thus, it should be appreciated, that the components of the modem 10 can be combined into one device or collocated on a particular node of a distributed network or combined into one or more of a CO or CPE modem. Thus, it will be appreciated from the following description, and for reasons of computational efficiency, that the components of the modem 10 can be arranged any location, such as in a general purpose computer or within a distributed network or dedicated modem without affecting the operation of the system. Furthermore, the term module as used herein is to be understood to include, but is not limited to, one or more of hardware components and/or associated software for performing a given function.
[0051] In operation, the encoder, in cooperation with the bit loading module 10 , receives the input data bit stream and encodes it into M QAM constellation points. This encoding is accomplished in accordance with a bit loading table that is stored in the bit loading module 10 . The bit loading table defines the number of bits carried by each tone.
[0052] The IFFT module 30 receives the encoded data and determines a sum of N carriers each modulated by a predetermined phase and amplitude. Specifically, the input to the IFFT module 30 is a vector of QAM constellation points—N complex numbers, defining the amplitude and phase of each carrier.
[0053] The cyclic prefix module 40 receives the output of the IFFT module 30 and separates the received symbols in time in order to decrease the intersymbol interference (ISI). As is well known, the signal passing through the line is linearally convolved with the impulse response of the line. If the impulse response is shorter than the duration of the cyclic prefix as discussed above, each symbol can be processed separately, thereby eliminating the intersymbol interference.
[0054] The echo canceller 50 generates a replica of the transmitted signal that leaks back into the receiver. Upon subtraction of the near-end echo-replica, the received far-end signal can be processed as if its only impairment has been the channel induced noise sources. In general, the echo cancellation in DSL systems considers the asymmetric upstream/downstream nature that results in different sampling rates for upstream and downstream communications. However, many variations and methods for reducing echo are well known to one of ordinary skill in the communications arts and will not be discussed herein.
[0055] The time domain equalizer module 80 is a filter designed to minimize the intersymbol interference and interchannel interference (ICI). This is done by reducing the total impulse response of the line to the length of the cyclic prefix, as discussed above, such that one symbol does not interfere with the next symbol and accordingly intersymbol interference can be reduced or eliminated.
[0056] The cyclic prefix module 100 complements the cyclic prefix module 40 and forwards its output to the FFT module 110 . The FFT module 110 complements the operation of the IFFT module 30 by transforming the received N carriers back into amplitude and phase information, which is then decoded back into bits in cooperation with the decoder 130 and the bit loading module 140 .
[0057] The training module 90 manages a number of training features that are present in the ADSL modem system 5 . However, for the sake of clarity, only the training related to the application of this invention will be described. Clearly, one of ordinary skill in the art will appreciate that additional training will be present during the training and/or operating condition of a typical DSL modem.
[0058] In particular, during a portion of initial training, the DSL modem 5 enters into reverb. During this reverb training, and in conjunction with the training module 90 , an estimate of the channel frequency response (H k ) is determined. For example, as discussed in the Sandberg article referenced above, the channel frequency response can be estimated.
[0059] Next, a reverb based TDQ training algorithm, such as the one discussed the Sandberg article referenced above, is used to determine the initial TDQ coefficients. Upon determination of these coefficients, which are stored in a memory (not shown) in the training module 90 , medley is commenced. During medley, the training module 90 , operating on data received from the echo canceller 50 , performs one or more supplemental TDQ training sessions according to the systems and methods of this invention. Then, the updated time domain equalizer coefficients are provided from the training module 90 to the time domain equalizer 80 .
[0060] Based on the determined TDQ, additional medley training is performed such as, but not limited to, FDQ training and SNR measurements for bit loading. At this point, the DSL modem 5 is ready to enter showtime.
[0061] FIG. 2 outlines an exemplary method of performing supplemental training to determine updated time domain equalizer coefficients according to an exemplary embodiment of this invention. In particular, control begins in step S 100 and continues to step S 110 . In step S 110 , reverb is commenced. Next, in step S 120 , the channel frequency response (H k ) is estimated. Then, in step S 130 , a reverb based TDQ training algorithm is used to determine the initial TDQ coefficients. Control then continues to step S 140 .
[0062] In step S 140 , medley is commenced. Next, in step S 150 , the supplemental TDQ training in accordance with this invention determines the improved time domain equalizer coefficients by maximizing the number of bits per frame. Then, in step S 160 , the updated time domain equalizer coefficients are provided to the time domain equalizer for use during showtime. Control then continues to step S 170 .
[0063] In step S 170 , based on the determined TDQ, additional medley training such as frequency domain equalizer training and signal-to-noise ratio measurements for the determined time domain equalizer coefficients that are used for the bit loading is completed. Then, in step S 190 , the modem enters the showtime. Control then continues to step S 200 , where the control sequence ends.
[0064] FIG. 3 outlines in greater detail the perform supplemental training block S 150 in FIG. 2 . In particular, control begins in step S 500 and continues to S 510 . In step S 510 , the time domain equalizer coefficients are initialized. Next, in step S 520 , m is set to zero. Then, in step S 530 , the mean squared signal value is determined for each bin, for the given time domain equalizer coefficients. Note that the s k is equal to the medley 4-QAM reference symbol in bin k multiplied by the estimated complex channel frequency response at bin k, obtained during reverb training, multiplied by a Fourier basis row vector of length L having frequency 2πk/m, multiplied by the time domain equalizer coefficients (a). Control then continues to step S 540 .
[0065] In step S 540 , n is set equal to zero and the mean square error is also set to zero. Next, in steps S 550 through S 570 , the average error squared value is evaluated, over N 1 frames, for each bin. Thus, the signal s k (n) and the received data B(n) are frame dependent. Then, in step S 580 , W s and W e will be established as diagonal matrices with elements W k s and W k e . This allows localization of linearized metrics about the current time domain equalizer coefficients. Control then continues to step S 590 .
[0066] In step S 590 , n is set equal to zero, and the matrices G e and G s are initialized to all-zeros matrices. Next, in steps S 590 through S 650 , G s and G e , which are functions of the reference signal u k (n) and the received data B(n) for each frame, are averaged over N 2 frames. Note that a + {E[G e ]−E[G s ]} a is a linearized/localized approximation for
[0000] Σlog 10 (1/SNR k )
[0067] which is the metric to be minimized. Then, for the next TDQ vector, the minimum Eigen vector solution is determined and the process is repeated using the updated determined localization. Control then continues to step S 690 where the control sequence ends.
[0068] As illustrated in FIG. 1 , the time domain equalizer coefficient determination system can be implemented either on a single program general purpose computer, or a separate program general purpose computer. However, the time domain equalizer coefficient determination system can also be implemented on a special purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element, an ASIC or other integrated circuit, a digital signal processor, a hard-wired electronic or logic circuit such as a discrete element circuit, a programmable logic device such as a PLD, PLA, FPGA, PAL, a modem, or the like. In general, any device capable of implementing a finite state machine that is in turn capable of implementing the flowcharts can be used to implement the time domain equalizer coefficient determination system according to this invention.
[0069] Furthermore, the disclosed method may be readily implemented in software using object or object-oriented software development environments that provide source code that can be used on a variety of computer or workstation hardware platforms. Alternatively, the disclosed line time domain equalizer coefficient determination system may be implemented partially or fully in hardware using standard logic circuits or VLSI design. Whether software or hardware is used to implement the systems in accordance with this invention is dependent on the speed and/or efficiency requirements of the system, the particular function, and the particular software and/or hardware systems or microprocessor or microcomputer systems being utilized. The time domain equalizer coefficient determination system and methods illustrated herein, however, can be readily implemented in hardware and/or software using any known or later-developed systems or structures, devices and/or software by those of ordinary skill in the applicable art from the functional description provided herein and a general basic knowledge of the computer and communications arts.
[0070] Moreover, the disclosed methods may be readily implemented as software executed on a programmed general purpose computer, a special purpose computer, a microprocessor, or the like. In these instances, the methods and systems of this invention can be implemented as a program embedded on a personal computer such as a Java® or CGI script, as a resource residing on a server or graphics workstation, as a routine embedded in a dedicated line characterization system, a modem, a dedicated time domain equalizer coefficient determination system, or the like. The time domain equalizer coefficient determination system can also be implemented by physically incorporating the system and method into a software and/or hardware system, such as the hardware and software systems of a time domain equalizer coefficient determination system or modem, such as a DSL modem.
[0071] It is, therefore, apparent that there has been provided, in accordance with the present invention, systems and methods for determining time domain equalizer coefficients. While this invention has been described in conjunction with a number of exemplary embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, the invention is intended to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention. | Using a known or later developed time domain equalizer coefficient training algorithm, a least square solution for the time domain equalizer coefficients is taken at a starting point and iteratively improved on. In particular, the improvement is directed towards maximizing number of bits per frame loaded over the time domain equalizer coefficient choice. This can be accomplished by maximizing capacity directly rather than setting a goal to shorten the channel and hoping that the capacity will be maximized as a result. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to sleep monitors, used e.g., in therapy, diagnosis, or research, which differentiate various sleep and wakeful states.
Normal individuals experience distinct sleep states. One important sleep state, REM sleep, is characterized by rapid eye movements, small muscle twitches, and the absence of other body movements. The other sleep state, non-REM (NREM) sleep is subdivided into four grades or states (I-IV), stage I being the most shallow (least restful or refreshing) and stage IV being the deepest.
Monitoring and individual's sleep state is important for diagnosising sleep disorders. It is also important for diagnosising and following response to treatment of depression (affective disorder) in which REM latency is significantly reduced.
It is estimated that 8-15% of the adult U.S. population have frequent complaints about sleep quality and quantity, and 3-11% use sedative hypnotic drugs for these complaints. Sleep disorders can be debilitating. They are expensive and difficult to diagnose and treat. For diagnosis, the patient's sleep state may be monitored to determine the pattern and duration of various sleep states. Sleep is qualitatively and quantitatively evaluated by measuring the electrical signals produced by brain and muscle activity, using electrophysiological techniques and instruments. A widely used technique for this purpose (described in Rechtshaffen and Kales, eds., A Manual of Standardized Terminology, Techniques, and Scoring System For Sleep Stages of Human Subjects, Wash. D.C. U.S. Gov't. Print Off. Public Health Service) involves simultaneously and continuously measuring electroencephalographic (EEG) data--signals derived primarily from the cortex of the brain and sometimes referred to as an electrocortigram (ECoG)--along with an electromyogram (EMG) signal which monitors muscle activity, generally from one of the muscles of the lower jaw, together with left- and right-eye electrooculogram (EOG) signals produced by eye movement. These EEG, EMG, and EOG signals are conventionally recorded on a multi-channel physiological recorder (sometimes referred to as a polysomnograph). A skilled technician, using standardized criteria for evaluating such recordings, grades each period of the recording as awake, NREM state I to IV sleep, or REM sleep, to produce a sleep profile of the type of sleep as a function of time. The technician will then determine the proportion of the total sleep period spent in each of the grades of NREM sleep and in REM sleep.
The above method, which is the "standard" in sleep research, usually involves the use of a large number of (e.g. ten) electrodes pasted and taped to the subject's body. These electrodes and the wires connecting them to the polygraph recorder cause discomfort and restricted movement. It can be difficult to obtain a time series study on a subject because of the discomfort involved from the associated measurement apparatus.
The above method also requires costly equipment and skilled labor. A standard sleep investigation can cost in the neighborhood of $1000 per night, and it can last for several nights. There may be long waiting lists for sleep evaluation labs.
In view of the difficulties with existing sleep evaluation techniques, many patients who present with sleep disorders are not tested with those techniques, and are treated with sedative-hypnotic drugs without detailed evaluation.
Photographic techniques also have been used to evaluate sleep state. Hobson et al. (1978) Science 201: 1251-1255 measured the mobility of sleeping subjects photographically and predicted transitions between NREM and REM on the premise that major body posture shifts occur immediately preceeding and following REM sleep. Hobson et al. suggest that " . . . [P]ostural immobility, easily detectable in time lapse photographic data, could by itself provide a simple quantitative read-out of the state of the brain oscillator controlling the REM-NREM sleep cycle." Time lapse photography is suggested as a means of conducting field studies of sleep behavior.
Aaronson et al. (1982) Arch. Gen. Psychiatry 39: 330-335 report the use of time-lapse video recording to monitor sleep state, based on the knowledge that major body movements are known to occur predominantly before and after recurrent episodes of REM sleep, and the longest periods of immobility are associated with non-REM episodes. Sleep latency and REM onset were predicted from such major movements. Evidence of small body movement specific to REM sleep was also observed.
Kayed et al. (1979) Sleep 2 (2): 253-260 disclose an antioculographic sleep monitor (AOGM) system for recording eye movement, body movements and electromyogram (EMG) signals to monitor muscle activity. In addition to the EMG signal, the system includes a piezo-ceramic transducer attached to the eyelid to sense eye movements and a second transducer attached to an index finger joint to sense body movement. Analog signals from each of the sensors are recorded on tape, and the tapes are analyzed and scored by standard criteria. At p. 260, Kayed et al. say,
"The introduction of miniature transducers that can be applied directly on the eyelid provides an easy method for recording eye and body movements and makes simultaneous eye and body movement monitoring possible. The various combinations of these two parameters await further attention, and the study of their temporal relationships may provide interesting information to sleep phenomenology. The use of submental EMG helps to confirm the transition from non-REM to REM; however, further experience may prove that its use is not mandatory."
SUMMARY OF THE INVENTION
We have obtained satisfactory information for automatically (e.g., computer generated without technician intervention) reporting the sleep state of an individual subject of applying an electronic filter to analog signals representative of eye movement. The filter receives the analog signal and produces a binary output signal having two values, one representing substantial movement, and the other representing the absence of substantial movement. Additional filtering of this output signal permits designation of time periods of predetermined duration as eye-movement periods or non-eye-movement periods. In this way, a simple eye movement detector can be combined with the above described electronic filters to provide reliable discrimination between REM and NREM sleep.
Accordingly, the invention generally features apparatus for reporting an individual's sleep state comprising: (a) means responsive to an individual's eye movement generating an analog signal; (b) means responsive to the analog signal to generate an output signal having a first value during substantial eye movement and a second value during the absence of substantial eye movement; and (c) means responsive to the output signal for designating a time period of predetermined duration as an eye-movement period of a non-eye-movement period.
Preferably, to avoid designating wake periods as REM, the apparatus includes means responsive to the individual's body movements for generating a second analog signal, and means responsive to the second analog signal to designate periods of substantial body movement as non-eye-movement periods.
For more sophisticated sleep state reports that differentiate between wake, REM and NREM, the body-movement detector is connected to means responsive to the second analog signal for generating a second output signal having a first value during substantial body movement and a second value during the absence of substantial body movement. The apparatus also includes means to designate predetermined periods as body-movement or non-body-movement periods, responsive to the second output signal. An electronic signal representative of sleep state (wake, REM or NREM) is produced responsive to both the first and the second output signals using electronic storage means for providing reference signals representative of criteria for designating sleep state, and means for comparing those reference signals to the first output signal value and to the second output signal value. Preferably the first and second output signals are filtered by means for counting the number of times each of the output signals switches from its first value to its second value, and comparing that number to threshold eye-movement and head-movement frequencies, respectively.
The above apparatus is particularly well suited for simple, inexpensively produced, non-invasive head gear, which contains at least some of the electronic circuitry described above, and which has the body-movement sensor mounted on it. The eye-movement sensor is attached to the head gear circuitry, so there is no need for any additional equipment or electrical attachments to the subject. One headgear design includes a sweat band extending circumferentially around the head and a crossband on which the head-movement sensor is mounted.
A second aspect of the invention features automatically determining the sleep state of an individual by generating a first analog electrical signal responsive to the individual's eye movement and, responsive to that signal, producing a first output electrical signal having a first value during substantial eye movement and a second value in the absence of substantial eye movement. Responsive to the output signal, time periods of predetermined duration are successively designated as eye-movement periods or non-eye-movement periods.
In preferred embodiments of the method, a second analog signal representative of body movement is generated as described above and used to designate predetermined time periods as body-movement or non-body-movement periods. Specifically, the analog signals may be filtered as described above to determine whether they exceed predetermined threshold values a predetermined number of times in the time period.
The invention thus enables an effective lightweight, unobtrusive, automatic sleep state indicator, that does not require subjective operator evaluation and does not involve EMG measurement.
Other features and advantages of the invention will be apparent from the following description of preferred embodiments and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
We first briefly describe the figures of a preferred embodiment of the invention.
Figures
FIG. 1 is a highly diagrammatic view of a headband for reporting an individual's sleep state.
FIG. 2 is a diagram of electronic circuitry used in the headgear of FIG. 1.
APPARATUS
In FIG. 1, the sleep state reporting apparatus 10 is fixed in place by headband 12 consisting of circumferential elastic band 14, such as an athletic sweatband, and transverse elastic band 16.
Apparatus 10 includes two movement sensors 18 and 20: Eye-movement sensor 18, e.g. a semiconductor strain gauge or a piezo-electric film gauge such as those available from Penwalt Co., Valley Forge, PA, is attached to the eyelid with adhesive tape. Head-movement sensor 20 is positioned on the middle of transverse band 16. Sensor 20 is a piezo-ceramic phonograph crystal fixed between layers of headgear band 16.
Some or all of the electronic circuitry 30 and 32 shown in FIG. 2 may be positioned within head band 10. As shown in FIG. 2, sensors 18 and 20 produce two distinct analog electric signals representative of eye movement and head movement respectively. The signals are filtered by low pass filters 21 and 23 to remove extraneous signals having frequencies above 5 Hz. The signals are then amplified by standard operational amplifiers 22 and 24, respectively, yielding signals 25 and 27, respectively which are then filtered by filters 26 and 28, respectively.
Filter 26 consists of a transistor which converts analog signals above a certain threshold (e.g. 0.3 volts) to a digital signal 34 ignoring analog values below that threshold; filter 28 consists of a transistor which also converts along signals above a certain threshold (e.g. 0.2 volts) to a second digital signal 36, ignoring analog values below that threshold.
Digital signals 34 and 36 are input to noise filters 37 and 39 and then to an electric comparison filter 38 (also called a sleep state predictor) which compares digital movement reports to predetermined criteria indicative of sleep states. Comparison filter 38 can be a computer (e.g. a personal computer) with a suitable software program to perform operations, described below or it can be an electronic circuit containing a ROM, committed to make those operations. In designing filters 37, 38, and 39:
(a) a sample period is selected to determine the existence of movement;
(b) a filter is established to determine the number of digital signals required in the sampling period to designate the period as positive for movement;
(c) a sleep-state predictor is established to determine sleep state based on the movement pattern represented by the digital signals.
Filters 37 and 39 are designed so that a minimum of between 0 and 5 signals per period (30-90 seconds, preferably 60 seconds) are required to designate the period as a period of movement. The value selected for this filter varies from subject to subject, for example for light sleepers versus heavy sleepers, but that value remains relatively constant for a given subject from night to night. Comparison filter 38 is designed to recognize the following general principles: head movement of prolonged duration (greater than three minutes) indicates wakefulness; lack of head and eye movement indicate NREM sleep; and eye movement alone indicates REM sleep. Specifically, the comparison filter is set so that:
(a) if subject is in a wake state, if a certain number (3-8) of consecutive periods substantially lacking in both eye and head movement, an output signal indicating change to NREM is generated;
(b) if subject is in NREM, an output signal indicating change to REM is generated if a certain number (2-4) of consecutive periods of substantial eye movement which are substantially lacking in head movement;
(c) if subject is in NREM or REM, an output signal indicating wake is generated if a certain number (2-5) of consecutive periods of substantial head movement;
(d) if subject is in REM, an output signal indicating NREM is generated if a certain number (4-7) of consecutive period substantially lacking in eye movement.
As diagrammed in FIG. 2, there is a hard-wire connection to transmit signals to filter 38. Other systems such as radio transmission or storage/read out systems can also be used.
The output 40 from filter 38 is a signal indicating sleep state, e.g., a light panel or a chart recorder, or storage in electronic memory.
The above-described filters and sleep-state predictor are highly accurate, and they avoid the need for costly, time-consuming and subjective scoring by individual researchers. It is convenient to use head movement as a measure of body movement, so that the entire apparatus can be contained in a single headgear, without remote sensing of outer body movements. There is no need to use EMG signals.
It is particularly significant and surprising that, predictions based on both eye and head movement, filtered as described above, provide satisfactory information as to sleep state. It is also significant and surprising that EOG recorded eye movement is unnecessary; the eye transducer responds to eyelid stretching from corneal movement or from blinking. The eye transducer is sensitive to small movements and clearly differentiates REM eye movements showing a much higher intensity of movement peaks during REM as opposed to NREM sleep.
Operation
In operation, the first sleep session may be used to calibrate the filters. Specifically, to calibrate noise filter 37, the number of digital signals 34 and 36 in a selected time period is plotted as a histogram, to determine the mode of signal frequency. Noise filter 37 is calibrated to treat period with fewer signals than the mode as non-movement periods. Alternatively, after the first session, the modes of signal frequency can be electronically determined, and the sleep state can be reported automatically as described above, using electronically determined mode values.
Such calibration is successful because surprisingly, while there is some variation from subject to subject (some people are more active sleepers than others), variations from night to night for a given subject are not severe.
After calibration, the subject is fitted comfortably with the headgear, e.g. using velcro tabs for adjustability, and sleep state is monitored as described above.
Other Embodiments
Other embodiments are within the following claims. For example, the physical location of noise filter 37 and comparison filter 38 can vary, as can the timing of performance of those functions. For example, digital signals can be stored in a storage microchip, that is fixed on the headband. When the sleep session ends, the stored information is transmitted to a remote location having (optically) filters and a computer programmed with appropriate software to perform the desired functions. The signals can be transmitted by a micro transmitter.
Particularly for sound sleepers, it has been found that the middle of a REM period occasionally may be scored as NREM; to avoid this problem, when two shifts to REM are indicated within a given short period (e.g. 10 minutes or less), the intervening period may be scored as REM, by retrospectively canceling the intervening indication of a change out of REM. | Electronic filters are applied to analog signals representative of eye movement and head movement, obtained from detectors attached to a simple headgear, to provide satisfactory information for automatically reporting an individual's sleep state. The filters determine whether there has been substantial eye and head movement in a given period. Each filter then generates binary output signals representing movement (or the absence of it). Noise filters and a comparison filter are then applied to the binary output signals to predict sleep state; REM sleep; NREM sleep; or wakefulness. | 0 |
BACKGROUND OF THE INVENTION
The present invention is a system, method, and computer readable medium for providing audio/video/data conferencing to an enterprise that has both internal and external entities joining a conference.
Currently, many service providers offer conferencing services to enterprises that support callers both internal and external to the enterprise. Typically, these services are provided by conferencing servers located at centralized data centers which are often co-resident with Public Switched Telephone Network (PSTN) ingress/egress points.
When a conference is setup, individual calls from the enterprise are backhauled to the data center through either a public or private, voice or data network. The problem with this approach is that backhauling all of the individual call legs takes a significant amount of bandwidth, and thus adds cost to the service provider which is often, in turn, passed onto the enterprise customer.
Therefore, what is needed to overcome the aforementioned limitation, is a system in which the enterprise legs of a conference can be combined before being backhauled to the conference service and a method for managing a conference in such a system. What is also required is the ability to maintain enterprise originated conference calls at the enterprise premise and bridge external participants as needed to the enterprise from other conference service providers.
SUMMARY OF THE INVENTION
The present invention, accordingly, eliminates the need for each leg of a conference to require its own, individual backhaul entity to the conferencing data center. This is accomplished by establishing equipment at the enterprise entity that allows each conferencing leg exiting the Public Branch Exchange (PBX) or similar entity at the enterprise to be mixed and converted to a consolidated, Integrated Protocol (IP) stream for processing over an IP Network. Certain entities of the Conferencing Service Provider's network are repeated at the enterprise premise to perform this consolidation. A Media Gateway and/or a Media Server is used at the enterprise site to:
mix all conferencing legs leaving the enterprise; convert PBX multi-media conference signaling formats to a consolidated IP stream for communication with the Conferencing Service Provider; serve as proxy server for interfacing with Conferencing Service Provider Application Server and local Media Servers.
Media Servers would reside at the enterprise premise for the hosting of enterprise conferences locally to the enterprise location. These units would also serve as Voice over IP (VoIP) interfaces with the Media Servers located at the Conferencing Service Provider's site as conference participants external to the enterprise join the conference.
By having a Media Gateway and Media Servers at the enterprise premise, it allows conferences established from the enterprise to be served at the enterprise with no backhaul connectivity required to the Conferencing Service Provider. As external conference participants join the conference, a single IP connection over the Wide Area Network (WAN) and interfaced with the Conferencing Service Provider for both signaling and bearer traffic would be used to join these external conference participants to the local enterprise conference. As additional conference calls are required to be established and served from the enterprise, the same IP connection can be used, therefore eliminating the need for multiple connections to be established back to the Conferencing Data Center for processing and thus eliminating the additional cost associated with providing and maintaining these connections.
In one embodiment of the present disclosure, a method for establishing a conference call comprises sending a first SIP INVITE message from a Media Gateway to an Application Server, associating a request with Media Server resources at the Application Server, sending a second SIP INVITE message to a first Media Server based on the associating, establishing a Real Time Transport Protocol (RTP) session between the Media Gateway and the first Media Server, gathering entered data at the first Media Server, sending the gathered data to the Application Server, sending a third SIP INVITE message from the Application Server to a Conference Controller based on the gathered data, allocating resources related to the conference call by the Conference Controller on a second Media Server, requesting by the Conference Controller for the Application Server to move data related to establishing the conference call from the first Media Server to the second Media Server, sending a fourth SIP INVITE message by the Application Server to the second Media Server and sending a SIP RE-INVITE message by the Application Server to the Media Gateway, receiving an acknowledgement by the Application Sever that the second Media Server and the Media Gateway are ready to establish the conference call; and establishing an RTP session between the Media Gateway and the second Media Server thereby establishing the conference call.
In one embodiment of the present disclosure, a system for establishing a conference call comprises a Media Gateway at a data center that sends a first SIP INVITE message initiated by a PSTN caller to an Application Server at the data center, a first Media Server at the data center that receives a second SIP INVITE message from the Application Server and establishes a Real Time Transport Protocol (RTP) session between the Media Gateway and the first Media Server, wherein the Application Server sends a first message to the first Media Server to gather data entered by the Caller at the Media Gateway for establishing the conference, wherein the first Media Server sends the entered data to the Application Server, a second Media Server at the data center, a third Media Server at an enterprise, and a Conference Controller at the data center that: receives a third SIP INVITE message from the Application Server based on the entered data, allocates resources related to the conference call on the second Media Server, requests the Application Server to move data related to establishing the conference call from the first Media Server to the second Media Server, sends a first message to the second Media Server and creates a conference at the at the second Media Server, sends a second message to the third Media Server and bridges the third Media Server with the conference at the at the second Media Server, and sends a third message to the Application Server to move the call from the first Media Server to the second Media Server, wherein the Application Server sends a second message to the Media Gateway and sends a third message to the second Media Server which establishes an RTP session between the Media Gateway and the second Media Server resulting in the PSTN Caller in a conference on the second Media Server bridged with an Enterprise Caller on the third Media Sever.
In one embodiment of the present disclosure a computer readable medium comprises instructions for sending a first message from a Media Gateway to an Application Server, sending a second message to a first Media Server based on the first message, establishing a session between the Media Gateway and the first Media Server, gathering entered data at the first Media Server, sending the gathered data to the Application Server, sending a third message from the Application Server to a Conference Controller based on the gathered data, moving data by the Application Server to move data related to establishing the conference call from the first Media Server to the second Media Server, sending a fourth message by the Application Server to the second Media Server and sending a SIP RE-INVITE message by the Application Server to the Media Gateway, and establishing an RTP session between the Media Gateway and the second Media Server thereby establishing the conference call.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a typical configuration of how users on an Enterprise System currently interface back to a Conferencing Service Provider via the PSTN Network for establishing or joining a pre-existing conference call in accordance with a preferred embodiment of the present invention;
FIG. 2 depicts the addition of Conferencing Media Gateway and Media Servers at the Enterprise site and the required physical connectivity to the WAN in accordance with a preferred embodiment of the present invention;
FIG. 3 depicts a further refinement of FIG. 2 by showing the logical connectivity of the embodiment and software protocols used to establish and maintain conference calls in accordance with a preferred embodiment of the present invention;
FIG. 4 depicts actual Session Initiated Protocol (SIP)/Real Time Transport Protocol (RTP) message flows required for both the Enterprise caller to establish or join a conference call in accordance with a preferred embodiment of the present invention; and
FIG. 5 depicts actual Session Initiated Protocol (SIP)/RTP message flows required for the external PSTN caller to join a conference call at the enterprise premise in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the principles of the invention, Enterprise Systems looking to reduce the cost of maintaining expensive PSTN connectivity for conference call activity, establish premise equipment (Media Gateway and Media Servers) to allow connectivity directly to the Conferencing Service Provider via the Wide Area Network (WAN). This allows the Enterprise System to bypass PSTN connectivity for all conference call activity and ultimately reduce the cost of maintaining multiple PSTN connections for this use.
With reference now to the figures and in particular with reference to FIG. 1 , a diagram of a Enterprise Telephony System interfaced to a Conferencing Service Provider is depicted in accordance with a preferred embodiment of the present invention. It should be noted that each device represented can have multiple instances within the architecture. FIG. 1 depicts only one instance of each entity for simplification purposes. Enterprise 185 represents any size business or organization requiring conferencing services from an external conferencing service provider. Enterprise 185 is represented herein as containing multiple Callers 100 connected to a Public Branch Exchange 105 or similar entity known in the art for serving business telecommunication needs. Callers 100 can be any multitude of entities within the Enterprise 185 and is beyond the scope of this invention. FIG. 1 represents multiple Caller 100 entities to clearly depict the problem of PSTN connectivity required as multiple callers exist in an Enterprise. “Caller”, as referenced in this embodiment, will represent either a conference host or conference participant. Conference host is defined as a user who is establishing and hosting a conference call. Conference participant is one of possible many participants that will join a conference that another “Caller” is hosting. “Callers” can reside at the enterprise or at the PSTN and can be either conference hosts or conference participants.
Connectivity between the Caller 100 and PBX 105 can be in any format or medium supported by the PBX. For clarity purposes, this invention assumes that this connectivity is a typical Time Division Multiplexed (TDM) circuit-switched connection. The PBX serves as the switching entity and telecommunications application server within the Enterprise 185 . It routes calls as required between internal callers within the enterprise and also routes internal callers to external interfaces outside of the Enterprise 185 via the PSTN 175 .
The PBX 105 interfaces with the PSTN 175 via multiple Circuit-Switched Connections 110 . These connections are typical DS1/E1 interfaces that are well known in the art. These connections are usually leased from the PSTN service provider. The amount of connections required is defined by the number of users being hosted on the PBX and the capability of the PBX to share these connections amongst multiple users.
Continuing to refer to FIG. 1 , Callers 170 represent conference host or conference participants external to the Enterprise 185 . For the purpose of this embodiment, Caller 170 represents any caller needing to host or join a conference call via the PSTN 175 hosted by the Conferencing Service Provider 190 . As is illustrated in the diagram, connectivity between the PSTN 175 and the entry point into the Conferencing Service Provider's network is supplied by Circuit-Switched Connections 130 . These connections can be of many varieties and are only limited by the interface connectivity method supported by the Conferencing Service Provider's Media Gateway 135 and the PSTN 175 . For the purpose of this invention, it should be assumed that this connectivity is DS1/DS3 (North American) or E1/E3 (International) based. It should also be assumed that PSTN 175 does not need to reside in the same geographical region as the Conferencing Service Provider. The Enterprise 185 and PSTN 175 could reside internationally with the Conferencing Service Provider residing locally.
The Conferencing Service Provider 190 is an entity that provides conferencing services to enterprises or other business entities. For the purposes of this embodiment, it is made up of multiple components all networked together to perform the service. The entities of this platform include the Media Gateway 135 , Media Servers 140 and 145 , an Application Server 155 , a Conference Controller 160 , and a networking backbone 180 that links all components together.
Media Gateway 135 is the device that interfaces directly with the PSTN and supplies the conversion of the circuit-switched conference call to an Internet Protocol (IP) stream and vice versa for processing within the conferencing system. The Media Gateway uses the Session Initiated Protocol (SIP) or similar IP control-plane protocol for session establishment and maintenance with the other components in the system. It uses the Real Time Transport Protocol (RTP) or similar bearer-plane protocol for establishing bearer-plane Voice over IP (VoIP) connections in the system. Media Servers 140 / 145 in the Conferencing System 190 are used to host the conference calls and supply all features associate with conferencing. These systems are well know in the art and can be comprised of common forms of processing medium capable of running commercially available software suites providing SIP conferencing or similar IP telephony based software packages.
The Media Servers 140 / 145 are assigned to specific conferences by the combination of the Application Server 155 and the Conference Controller 160 . The Application Server 155 is the heart of the conferencing system and provides all resource management within the system and works in conjunction with the Conference Controller in assigning media server resources within the conferencing system. It receives SIP calls from the Media Gateway 135 and establishes conference sessions via RTP between the Media Gateway 135 and Media Servers 140 / 145 . The Conferencing Controller serves to setup the conferences within the system and then maintain and control the call flow and conference business logic by communicating with the Media Servers 140 / 145 and Application Server 155 .
FIG. 1 represents the current connectivity that exists between the Enterprise System 185 and the Conferencing Service Provider 190 . Circuit-switched connectivity 110 can be costly for an Enterprise System to maintain and drives the need for alternative methods for multiple conference call traffic to the external Conferencing Service Provider.
With reference now to FIG. 2 , a recommended conference call routing mechanism is depicted in accordance with a preferred embodiment of the present invention. FIG. 2 shows the addition of a Media Gateway 210 , IP Backbone Network 280 , Media Server- 1 215 , Media Server- 2 220 , and Router 225 . These devices are added at the Enterprise System 285 premise for maintaining local conference call establishment and Internet Protocol routing of conference calls over the Wide Area Network 230 to the Conferencing Service Provider 290 . These devices allow the “bridging” or mixing of conference callers external to the enterprise with conference callers within the enterprise.
In the depicted figure and with particular reference to Enterprise System 285 , Callers 200 are interfaced to PBX 205 and are either conference hosts or conference participants with respect to the current invention. PBX 205 hosts these callers and performs telephony routing and call maintenance. Multiple circuit-switched connections leaving PBX 205 interface with a Media Gateway 210 . The Media Gateway 210 converts the circuit switched connections into IP based sessions and communicates directly with the Application Server 255 at the Conferencing Service Provider 290 via Routers 225 and 250 and the Wide Area Network (WAN) 230 . The Application Server 255 is the main interface server in the Conferencing Service Provider 290 network. It serves as a proxy server to all of the other SIP entities in the network and maintains location based data of all Media Server entities both internal and external to the network. It also performs the associated routing necessary to establish and maintain the conferences. Conferencing Controller 260 is the resource manager within the network. It maintains information on available Media Server resources and allocates these resources as requested. It communicates via the Application Server amongst all hosted Media Servers at the Conferencing Service Provider 290 , other Conferencing Service Providers—as required, and external Media Servers to the Conferencing Service Provider.
With reference now to FIG. 3 , a logical connectivity diagram is depicted in accordance with a preferred embodiment of the present invention. As discussed in FIG. 2 , Callers 300 communicate with the PBX in a format that is supported by that PBX. These Interfaces 373 are beyond the scope of this invention. For simplification purposes, it will be assumed that these Interfaces 373 are circuit-switched TDM interfaces. It is also assumed that Interface 373 exists between the PBX 305 and the Media Gateway 310 . This interface is driven by the supported media interface cards supported by the Media Gateway 310 and is beyond the scope of this invention. As Callers 300 either establish or attempt to join conferences, Media Server 310 communicates with Application Server 355 . At this point in the invention, all communication is based on IP Telephony protocols. These protocols can be any IP Telephony protocols that support session establishment/management as well as Real-Time Voice over IP. For the purposes of this invention, it will be assumed that all session based IP telephony is SIP based and all Voice over IP is RTP.
Continuing to reference FIG. 3 along with referencing FIG. 4 as a message flow reference, and assuming a conference call is being attempted to be setup by one of Callers 300 , a SIP INVITE 400 message would be exchanged between the Media Gateway 310 and the Application Server 355 for request for this conference host to establish a conference call. Application Server 355 associates request with Media Server resources at enterprise premise and sends a SIP INVITE 405 to Media Server 1 315 for establishment of RTP session with Media Gateway 310 . SIP acknowledgments are returned to both Media Gateway 310 and Media Server 1 315 requesting RTP negotiation between the two. RTP Session 420 is established between Media Gateway 310 and Media Server 1 315 . Once RTP linkage is established, a PROMPT AND COLLECT 425 is sent to Media Server 1 315 to gather entered data by Caller 300 for establishing the conference. Media Server 1 315 returns this data to Application Server 355 via a DTMF COLLECTED 425 message.
After the Application Server 355 has this data, it sends a SIP INVITE 430 to Conference Controller 360 to determine if the conference is already established. Since Caller 300 is establishing a new conference, Conference Controller confirms this based on information received from Caller 300 and allocates resources on Media Server 2 320 via a SIP INFO (Create Conference) 435 message for creating the new conference. Media Server 2 responds with a SIP 200 OK to acknowledge and confirm receipt. Conference Controller 360 then sends a SIP 302 MOVED TEMPORARILY 440 to Application Server 355 to inform Application Sever to move call from Media Server 1 to Media Server 2 . Application Server 355 acknowledges receipt of this with a SIP ACK. Application Server 355 Then sends SIP RE-INVITE 440 and SIP INVITE 445 to Media Gateway 310 and Media Server 2 320 respectively.
Both of these entities respond with SIP 200 OK messages to let Application Sever know that transaction was completed appropriately. After Application Sever has acknowledgement that both Media Server 2 and Media Gateway are ready to establish call, a SIP ACK 455 message is returned to Media Server 2 to complete the SIP transaction. At this point, an RTP session is established between Media Gateway 310 and media Server 2 320 . Finally, a SIP BYE Message 465 is sent from Application Server to Media Sever 1 315 to release resources originally reserved for this call. Media Sever 1 responds to Application Server with SIP OK to confirm cleanup. At this point, Enterprise Caller 300 is in a conference on Media Server 2 320 at the Enterprise 385 .
Continuing to reference FIG. 3 and now referring to FIG. 5 as message flow reference, PSTN Caller 370 is attempting to join a conference hosted at the Enterprise 385 . PSTN Caller 370 enters the appropriate numbers to access the conference call. The PSTN 375 , once receiving this dial string, routes the call to the Media Gateway 335 at the Conferencing Service Provider 390 . The Media Gateway performs the appropriate circuit to packet translation on the incoming data and sends a SIP INVITE 500 message to the Application Server 355 . Application Server 355 associates request with Media Server resources at Conferencing Service Provider premise and sends a SIP INVITE 405 to Media Server 1 340 for establishment of RTP session with Media Gateway 335 . SIP acknowledgments are returned to both Media Gateway 335 and Media Server 1 340 requesting RTP negotiation between the two. RTP Session 520 is established between Media Gateway 335 and Media Server 1 340 . Once RTP linkage is established, a PROMPT AND COLLECT 525 is sent to Media Server 1 340 to gather entered data by Caller 370 for establishing the conference. Media Server 1 340 returns this data to Application Server 355 via a DTMF COLLECTED 525 message.
After the Application Server 355 has this data, it sends a SIP INVITE 530 to Conference Controller 360 to determine if the conference is already established. Conference Controller determines that this conference is already established and is being hosted on an enterprise server. Conference Controller sends a SIP INFO (Create Conference) 535 to Media Server 2 345 for establishing Conference Service Provider leg of call. Media Server 2 responds with SIP 200 OK message confirming setup. At this point in the session, the Conference Controller 360 sends a SIP INFO (Bridge Mixers) 540 message to Media Server 2 345 and a SIP INFO (Bridge Mixers) 545 to Media Server 2 320 at enterprise site. At this point, Conference Controller 360 creates a conference at the Media Sever located at the Conferencing Service Provider Site and bridges it with the conference on the Media Server at the Enterprise location. Conference Controller 360 then sends a SIP 302 MOVED TEMPORARILY 555 to Application Server 355 to inform Application Sever to move call from Media Server 1 to Media Server 2 . Application Server 355 acknowledges receipt of this with a SIP ACK. Application Server 355 Then sends SIP RE-INVITE 565 and SIP INVITE 560 to Media Gateway 335 and Media Server 2 345 respectively. Both of these entities respond with SIP 200 OK messages to let Application Sever know that transaction was completed appropriately.
After Application Sever has acknowledgement that both Media Server 2 and Media Gateway are ready to establish call, a SIP ACK 570 message is returned to Media Server 2 to complete the SIP transaction. At this point, an RTP session is established between Media Gateway 335 and Media Server 2 345 . Finally, a SIP BYE Message 575 is sent from Application Server to Media Sever 1 340 to release resources originally reserved for this call. Media Sever 1 responds to Application Server with SIP OK to confirm cleanup. At this point, PSTN Caller 370 is in a conference on Media Server 2 345 at Conferencing Service Provider 390 bridged with the Enterprise Caller on Media Sever 2 320 at Enterprise 385 .
The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing form the scope of the present invention. For example, although the processes and apparatus of present invention are illustrated with voice conferencing and SIP/RTP IP Telephony messaging, the processes and apparatus of the present invention may be implemented in other types of networks and protocols. For example, the present invention may be illustrated in various application-level protocols such as SIP/RTP protocols or network-level protocols such as MPLS (Multi Protocol Label Switching)/RSVP (Resource Reservation Protocol) protocols. Further, although the Application Server and Conference Controller are depicted as separate components using SIP as the communication protocol between them, in one embodiment, the Application Server has functionality for both IVR and conference control operations. Also, although SIP INFO messages, such as SIP INFO ( 540 ), are used to bridge the conferences on the media servers at the enterprise and primary data center, in one embodiment at least one SIP INVITE message can be used to setup a call between the two conferences on the two media servers. | A system, method, and computer readable medium comprising instructions for establishing a conference call comprising sending a first SIP INVITE message from a Media Gateway to an Application Server, sending a second SIP INVITE message to a first Media Server, establishing a session between the Media Gateway and the first Media Server, sending a third SIP INVITE message from the Application Server to a Conference Controller, allocating resources related to the conference call by the Conference Controller on a second Media Server, requesting by the Conference Controller for the Application Server to move data related to establishing the conference call from the first Media Server to the second Media Server, sending a fourth SIP INVITE message by the Application Server to the second Media Server and sending a SIP RE-INVITE message by the Application Server to the Media Gateway, and establishing an RTP session between the Media Gateway and the second Media Server thereby establishing the conference call. | 7 |
CROSS-REFERENCE TO RELATED CASES
This application is related to my copending U.S. application Ser. No. 140,248, filed Apr. 14, 1980, and the therein mentioned copending applications.
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a self-monitoring warning or alarm installation containing a monitoring circuit and an alarm or warning circuit.
Alarm installations are used in those environments where there is monitored a variable magnitude or parameter and when there should be indicated that such variable magnitude has fallen below or exceeded a predetermined threshold. Typical examples are installations for monitoring the terminal position of displaceable machine components, the temperature or the concentration of combustion gases in rooms, the degree of filling of vessels or containers, the subjecting to jarring or damage of building openings or the deformation or displacement of terrain formations and structural walls.
A first group of heretofore known warning or alarm installations contains passive feelers which are affected by the magnitude or parameter which is to be monitored. These feelers are connected by means of an electrical signal line with an electronic monitoring circuit. This monitoring circuit periodically interrogates the state of the feeler and produces an alarm signal when this state or condition no longer is within a predetermined region or range.
A second group of prior art installations contain active feelers which are equipped with a related energy source or are connected with a central energy source. These feelers generate a signal as soon as the monitored magnitude has fallen below or exceeded a predetermined threshold. This signal again is transmitted by means of an electrical signal line to a central monitoring circuit. With a number of design constructions of such installations there is used the same electrical line or conductor for the infeed of the electrical energy to the feeler and for the return of the monitoring signal to the monitoring circuit. Alarm or warning installations are preferably structured as self-monitoring installations, generating a display or indicator signal when parts of the installation no longer are functional.
The heretofore known installations possess, independently of the special constructional embodiments and fields of applications, a number of basic defects. The cause of such defects or flaws are the use of feelers or sensors which are electrically interrogated or themselves generate electrical signals and the electrical signal lines needed for the interrogation and further transmission of the signals. Spurious signals can be induced in such feelers and the lines due to external electrical or magnetic fields. These spurious signals impair the proper functioning of the installation or can trip false alarms. In order to eliminate these defects it is necessary to electrostatically screen the feelers and lines. The procedure is expensive and not possible for many feelers without impairing their function. Moreover, electrical feelers or sensors and signal lines are not permissible in an explosion-endangered environment, although it is exactly at such locations that there is particularly needed the monitoring of different operating magnitudes.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide a new and improved construction of alarm or warning installation which is not associated with the aforementioned drawbacks and limitations of the prior art proposals.
Another and more specific object of the present invention aims at providing a new and improved construction of a self-monitoring warning or alarm installation whose feelers do not require any electrical supply voltage and whose signal line is suitable for transmission of non-electrical signals.
A still further significant object of the present invention aims at providing a new and improved construction of self-monitoring warning or alarm installation which is relatively simple in construction and design, extremely reliable in operation, not readily subject to breakdown or malfunction, and requires a minimum of maintenance and servicing.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the warning or alarm installation of the present development is manifested by the features that the monitoring circuit is structured as a free-running opto-electronic oscillator containing a light-emitting diode as the transmitter, a flexible optical conductor or guide as the transmission line or conductor and a photodiode as the receiver for the oscillating monitoring signal. The warning or alarm circuit contains at least one monoflop, whose signal input is connected with the monitoring circuit and which is switched by the monitoring signal into an unstable switching state. The oscillation frequency of the monitoring signal is greater than the flop frequency of the monoflop or monostable multivibrator, which thus remains in its unstable switching state as long as its signal input has infed thereto an oscillating monitoring signal and moves or flops into the stable switching state as soon as the monitoring signal has been interrupted.
The novel warning installation of the present development does not contain any electrical power or supply lines, which particularly constitute a potential source of danger in explosion-endangered environments, and at the optical conductor there practically cannot be introduced any spurious signals. The new and improved alarm installtion of the invention therefore enables attaining a heretofore unattainable operational reliability. Moreover, with the novel installation the optical conductor is employed for the self-monitoring signal and, at the same time, for the indicator or display signal of the feeler or feelers, rendering possible an extremely simple and economical construction of the entire installation. In fact it is even possible to operate the installation without any special feelers and to use the optical conductor or line as a feeler, which then interrupts the further transmission of the monitoring signals or attenuates the same to such a degree that there is triggered the alarm signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a principle circuit diagram of a monitoring circuit and alarm circuit suitable in particular for use in the novel self-monitoring alarm installation of the invention;
FIG. 2 schematically illustrates a signal line having an optical transducer;
FIG. 3 schematically illustrates a signal line used for monitoring a break or fissure at a wall or structure;
FIG. 4 is a sectional view through a first simple constructional embodiment of a feeler used for temperature monitoring;
FIG. 5 is a sectional view through a second simple embodiment of a feeler used for temperature monitoring; and
FIG. 6 is a sectional view through a simple constructional embodiment of a feeler utilized for level monitoring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, in FIG. 1 there is illustrated the principle circuit diagram of a preferred exemplary embodiment of monitoring circuit 10 and alarm or warning circuit 11, which are extremely well suited for the novel self-monitoring alarm installation. Both of the circuits 10 and 11 are connected with a common power supply, here shown as the supply voltage lines 12, 13. The monitoring circuit 10 contains a light-emitting diode 15, whose one terminal or connection 15' is directly coupled with the power supply line 13 and whose other terminal or connection 15" is connected by means of a switching transistor 16 with the power supply line 12. This monitoring circuit 10 further contains a photodiode 17, whose one terminal 17' is directly connected with the power supply line 13 and whose other terminal 17" is connected by means of a series resistance 18 with the power supply line 12. This monitoring circuit 10 additionally contains a comparator 19, whose non-inverting input 19' is connected with a reference voltage source 20 and whose inverting input 19" is connected by means of a resistance or resistor 22 with the node or connection point 23 between the photodiode 17 and the related series resistance 18. The inverting input 19" of the comparator 19 is connected by means of a capacitor 24 with the line 13 of the power supply system 12, 13. Leading from the output side 19'" of the comparator 19 is a line 26 to a control electrode 16' of a transistor 16 connected in series with the light-emitting diode 15. Finally, also belonging to the monitoring circuit 10 is an optical conductor or guide 27 which extends from the light-emitting diode 15 to the photodiode 17 and which is preferably constructed as a flexible glass fiber or fibers.
In order to describe the function of this monitoring or monitor circuit 10, it is assumed that the reference voltage source 20 is set at a value which is between that of both supply voltage lines 12, 13 and that upon turning-on the supply voltage the switching transistor 16 conducts current, so that the light-emitting diode 15 is excited and light is irradiated into the optical conductor 27. The light effluxing out of the optical conductor 27 then illuminates the photodiode 17, whose internal resistance is thus reduced. As a result, the voltage at the connection point or node 23 and thus also at the inverting input 19" of the comparator 19 drops to a value which is smaller than the reference voltage or potential, so that at the output 19'" of the comparator 19 there appears a positive signal. This positive signal is conducted by means of the line 26 to the control electrode 16' of the switching transistor 16, which is therefore blocked. Due to blocking of the switching transistor 16 the light-emitting diode 15 is now without current and the emission of light is interrupted. Hence, also the illumination of the photodiode 17 is interrupted, which, in turn, results that its internal resistance, and therefore, also the potential at the connection point or node 23 increases. As soon as the potential at the connection point 23, and thus, also at the inverting input 19" of the comparator 19 exceeds the reference potential or voltage, there appears at the output side or output 19'" of the comparator 19 a negative signal, which again places the transistor 16 into its conductive state.
In this way the light-emitting diode 15 is periodically excited or energized and again turned-off, so that the frequency of this periodic turning-off and turning-on operation as concerns the light-emitting diode 15 is essentially governed by the time constant of the RC-element 22, 24 arranged in circuit with the inverting input 19" of the comparator 19.
Continuing, the alarm or warning circuit 11 contains two monostable multivibrators or monoflops 30 and 31, whose respective signal inputs 30' and 31' are connected with the output 19'" of the comparator 19 of the monitoring circuit 10. Both of the multivibrators 30 and 31 are in a stable switching state when the signal at the control signal input is null or negative and are switched into an instable state by a positive control signal. The output 30" and 31" of each related multivibrator 30 and 31 is connected with the control input 32' and 33' of the respective related switching transistors 32 and 33. The one switching transistor 32 is a pnp-transistor, whose emitter 32" is connected with the positive bus of the power supply line 12, and the other switching transistor 33 is a npn-transistor, whose emitter 33" is connected with the negative bus of the power supply line 13. In the connection line between the collector 32'" of the one transistor 32 and the collector 33'" of the other transistor 33 there is arranged an excitation coil or winding 34 of a relay 35. The contacts 35' of this relay are used for switching a not particularly illustrated but conventional optical or acoustical warning device.
Now for the coaction of this warning or alarm circuit 11 with the above-described monitoring circuit 10 the flop time of both multivibrators 30 and 31 is adjusted such that this flop time is longer by a factor of about ten than the period of the monitoring circuit 10. With a practically tested exemplary embodiment the frequency of the oscillations of the monitoring circuit 10 amounted to about 20 to 100 Hz, the flop time of the multivibrators to about 0.1 to 0.5 seconds. In the non-energized stable state there appears at the output 30" of the one multivibrator 30 connected with the pnp-transistor 32 a positive output signal and at the output 31" of the other multivibrator 31 connected with the npn-transistor 33 a negative output signal.
As long as the monitoring circuit 10 oscillates in the above-described manner, then there appears at the output 19'" of the comparator 19 an uninterrupted pulse train which is infed to the control signal inputs 30' and 31' of both monostable multivibrators or monoflops 30 and 31, respectively, and switches such into their unstable state. Then there appears at the output 30" of the one multivibrator 30 a negative signal and at the output 31" of the other multivibrator 31 a positive signal, these signals switching the related pnp-transistor 32 and npn-transistor 33 into their conductive states, so that current flows through the relay winding 34 and there is made contact at one or the other of the relay contacts 35'. Because the flop time of the multivibrators 30 and 31 is greater than the pulse train frequency of the pulse signal train, the multivibrators 30 and 31 remain in their energized unstable condition or state for such length of time as there are infed to their inputs 30' and 31' the pulse signal train. As soon as there has been interrupted the oscillation of the monitoring circuit 10 and independently of whether such interruption arises due to failure of the power supply voltage or one of the electrical components, or due to an interruption or breaking of the optical conductor 27 or an interruption in the transmission of the optical signals by a feeler arranged in the signal line, both of the multivibrators 30 and 31 fall back into their stable switching state. Then there appears at the output 30" of the one multivibrator 30 a positive output signal, which blocks the related pnp-transistor 32, and at the output 31" of the other multivibrator 31 there appears a negative output signal which blocks the related npn-transistor 33. Both of the transistors 32 and 33 then interrupt the current flow through the winding 34 of the relay 35, so that the contact or contacts 35a thereof are interrupted and there is turned-on the excitation circuit for the alarm device.
FIG. 2 schematically illustrates a bipartite or two-part signal line 40, 41 containing a first optical partial line 40 and a second optical partial line 41. The first optical partial line 40 leads from a light-emitting diode 115' to a light transducer 42, while the second optical partial line 41 leads from the light transducer 42 to a photodiode 117'. Between the end of the second optical partial line 41 and the photodiode 117' there is arranged an optical filter 43.
During operation of this signal line 40, 41 the light emitted by the light-emitting diode 115' is converted by the light transducer 42 into light of a different wavelength, and there is used a photodiode 117' which is energized by the light of the light transducer or converter 42, but not by the light of the light-emitting diode 115'. Light transducers or converters suitable for this purpose are commercially available and well known and, for instance, can be purchased under the designation IR-converter screen Type IRW 2525. The use of a light transducer or converter 42 in the single line 40, 41 prevents interruption of the line by an unintentional or intentional optical shunt connection between the light-emitting diode and the photodiode, thereby appreciably increasing the reliability and operational integrity of the alarm installation.
It should be understood that between the light-emitting diode 115' and the neighboring end surface of the first optical partial line 40, just as between both surfaces of the light converter or transducer 42 and the outlet end of the second partial line 41 and the photodiode 117' there are advantageously arranged optical imaging systems insuring for an optimum optical coupling between these components. Such systems are well known to those skilled in the art and therefore need not here be further described.
With the novel warning or alarm installation the alarm signal is triggered as soon as the optical coupling between the light-emitting diode and the photodiode is markedly weakened or interrupted. This condition can be reached in that the signal line is directly interrupted or by means of a feeler which is incorporated into such line and which feeler, if desired, can be reset, or the transmission quality of the optical line varies at least throughout a limited length region.
FIG. 3 schematically illustrates the signal line 52 of an alarm installation which is used for monitoring the change of a wall fissure 51 and which generates an alarm or warning signal when the enlargement of such wall fissure or break exceeds the elongation of the signal line 52 and tears the same. To this end, the signal line 52 is spanned over the fissure in the wall 50 and secured by suitable attachment elements 53 and 54 at the wall. As soon as through enlargement of the wall fissure or break the signal line 52 is ruptured, then, as described above in detail, there is interrupted the oscillation of the free-wheeling optoelectronic oscillator and the alarm signal is triggered.
It should be understood that the same principle can be applied to other fields of application, for instance for monitoring the bending through or hang of highly loaded bridges, the shifting of earth dams, slide-endangered slopes and excavations, fillings and so forth.
The described inventive principles can be utilized to particular advantage for security installations for monitoring closed rooms or areas or containers. With such security installations the signal line is laid in a wall or the door of the room which is to be monitored or the container or the like, as the case may be, such that upon forceful breaking through the wall or opening the door the signal line will be torn or broken. As already previously explained, there are already known appropriate alarm installations utilizing an electrical line as the signal line. In contrast to the state-of-the-art installations, with the herein disclosed novel alarm installation, it is not possible to induce in the signal line spurious signals or to short-circuit the line loop or circuit, particularly if it contains a light transducer or converter according to the embodiment discussed above with reference to FIG. 2.
FIG. 4 shows in sectional view an extremely simplified construction of a resettable temperature feeler which is installed in the signal line. The temperature feeler, upon exceeding a predetermined temperature, interrupts the further transmission of a monitoring signal. The housing 60' of this feeler or sensor comprises a substantially cylindrical housing wall 60 at which there is formed a floor portion 61 and a fitted stopper or plug 62. At the inner surface of the housing wall 60 there are secured two bearing blocks 63 and 64 or equivalent structure, upon which there is movably retained a bimetallic strip 66. This bimetallic strip 66 is cut from a spherical-shaped bimetallic snap disk and therefore has a defined jump temperature. At the base or bottom portion 61 of the housing 60' there is retained the free end of a first glass fiber 67 and at the stopper or plug 62 the free end of a second glass fiber 68. The end surfaces of both of the glass fibers 67 and 68 are quite close to and in alignment with one another, so that the light effluxing out of the one glass fiber enters for the most part the other glass fiber. The glass fibers 67, 68 constitute a light conductor or light conductor means.
The housing wall 60 comprises a good thermally conductive material or has a multiplicity of perforations, so that the temperature in the internal space of the housing 60' practically corresponds to the ambient temperature. When this temperature increases and the predetermined surge or jump temperature of the bimetallic strip 66 is exceeded, then the latter assumes the phantom line position and thus deflects the free end of the thereat bearing glass fiber 68, so as to assume the position shown in broken lines at FIG. 4. In this position there is interrupted the further conductance of light between both of the glass fibers 67, 68 of the light conductor.
FIG. 5 illustrates a feeler or sensor which is suitable for use with the novel alarm installation of the present invention, this feeler being constructed as part of the optical conductor and serving to change the transmission quality of such conductor. The feeler contains a substantially cylindrical housing 70 having a base or bottom portion 71 formed thereat and a closure cap 72. The housing inner wall 70' is provided with a black lining or covering 73. The optical signal line is constructed as a glass fiber 74, and the housing 70 is placed over a region 76 of this glass fiber 74 where the fiber sheath has been removed and there is freely exposed the fiber core 77. The not particularly referenced internal space of the housing 70 is filled with a fine crystaline wax 78 having a white appearance in its solidified state, this wax having a predetermined solidification point.
As long as the temperature of the feeler is below the solidification temperature of the wax, then the signal light emanating from the core 77 of the glass fiber 74 is reflected for the most part back to the core 77. In this way the signal light is only gradually attenuated, and the sensitivity of the signal receiver of the monitoring circuit can be set without any particular measures such that the loss in signal intensity of the free-wheeling oscillator is not impaired. As soon as the ambient temperature of the feeler ascends beyond the solidification temperature of the wax 78 and the latter melts and becomes transparent, then the light effluxing out of the fiber core 77 arrives at the black lining or covering 73 where such light is absorbed. In this way the signal light is attenuated to such a degree that the function of the oscillator at the monitoring circuit is interrupted and there is triggered the alarm signal.
FIG. 6 illustrates a further embodiment of a feeler, by means of which there can be altered the transmission quality of the signal line or conductor. This feeler contains a housing 80 having a base or floor portion 81 formed thereat and a closure cap 82. The cylindrical housing wall 80' contains a number of relatively large perforations 83, 84. Extending through the housing base portion 81 and the closure cap or cover 82 is an optical line or conductor constructed as a glass fiber 86. The fiber sheath or jacket has been detached within the internal space of the housing 80 along a region 88, so that there is freely exposed the fiber core 87.
This construction of feeler is contemplated to be used as a level indicator for liquids. Through suitable selection of the material of the fiber core, as is well known to any one skilled in the art, it is possible to attain the result that the signal light remains predominantly within the fiber core 87 as long as the inner chamber or space of the feeler is filled with air and predominantly escapes out of the fiber core 87 as soon as such internal space or chamber is filled with the liquid which is to be monitored.
It is also possible to use such signal lines whose transmission quality can be directly altered by a magnitude or parameter which is to be monitored, without there being required for this purpose a special feeler or sensor. An example of such signal line is an optical fiber where at least the fiber sheath of jacket consists of an organic polymer which decomposes at a predetermined temperature, and thus, forms a black layer which absorbs the signal light. Such fiber is an optimum temperature alarm which is temperature sensitive throughout its entire length, and thus, is independent of locally distributed temperature feelers or sensors.
It should be understood that the novel installation can be accommodated to different special operating conditions and can be appropriately modified. For instance, it is possible to use instead of a light-emitting diode also a metallic filament lamp or a laser light source and instead of a single optical fiber there can be used a bundle of fibers, wherein the material of the fiber or fibers is appropriately selected in accordance with the wavelength of the light to be transmitted. Between the light source and the light receiver and the associated ends of the optical conductor there can be used optical systems which optimumly couple and decouple the light into and from the conductor. Finally, it is also possible to construct the alarm circuit with only one multivibrator and a subsequently connected transistor, without thereby impairing its function.
The described exemplary embodiments of novel alarm installations can be constructed of commercially available electronic and optical elements, and thus, these need not be here further described.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly, | Conventional warning installations possess electrically interrogated feelers or sensors or generate electrical signals, particularly if they are used for remote monitoring purposes. At the feelers and even more so at the signal lines it is possible for there to be produced spurious signals due to electrostatic charges or electrical or magnetic induction. These spurious signals trip unwarranted warning or alarm signals. The novel warning or alarm installation therefore contains an optical conductor or guide as a signal line, and the feelers are interrogated by means of optical signals. The optical conductor together with an electronic monitoring circuit forms a free-running opto-electronic oscillator which comes to standstill when there is interrupted the oscillating optical signal which is irradiated into the optical conductor and radiated back out of the conductor into the circuit. An alarm or warning circuit associated with the monitoring circuit generates an alarm signal when the opto-electronic oscillator comes to standstill. | 6 |
RELATED APPLICATION
This application is a Continuation-In-Part of U.S. Pat. application Ser. No. 08/390,017 filed Feb. 17, 1995 by the same inventor, now abandoned.
FIELD OF THE INVENTION
This invention is in the field of processes for synthesizing tetrafluoroethylene.
BACKGROUND OF THE INVENTION
Tetrafluoroethylene (TFE) is widely used as a monomer in the manufacture of plastic and elastomeric fluoropolymers. The general process for synthesizing TFE by pyrolysis of chlorodifluoromethane (CF 2 HCl, HCFC-22) is well known in the art, as illustrated by Downing et al. in U.S. Pat. No. 2,551,573. In the idealized reaction, pyrolysis of two moles of CF 2 HCl would yield one mole of TFE and two moles of HCl, representing 100% yield to TFE based on carbon and fluorine. In practice, the yield to TFE from converted CF 2 HCl is less than 100% because various by-products are formed, some desirable, some not so desirable. One desirable by-product, for example, is hexafluoropropylene (HFP) which is also used as a monomer in fluoropolymers. Other by-products include perfluorocyclobutane (C 4 F 8 ) which is considered to be a useful product in the sense that it can be pyrolyzed to give TFE and HFP in good yield. However, it is disadvantageous to do so if TFE and HFP can be synthesized directly.
The effects of pressure and conversion on the yield to TFE from CF 2 HCl pyrolysis are discussed, for example, by Scherer, et al. in U.S. Pat. No. 2,994,723, by Halliwell in U.S. Pat. No. 3,306,940, and by Edwards, et al. in U.S. Pat. No. 3,308,174. Generally, yield loss to by-products such as C 4 F 8 increases with CF 2 HCl conversion and with CF 2 HCl partial pressure. Halliwell suggests that partial pressure of CF 2 HCl is the major factor, rather than total pressure, and hence that the effect of reduced pressure may be achieved by dilution with an inert gas such as nitrogen or helium or carbon dioxide, and shows reduced C 4 F 8 formation at reduced partial pressure of CF 2 HCl. Scherer, et al. and Edwards, et al. use steam as diluent in different proportions in pyrolysis of CF 2 HCl in order to increase conversion without increasing yield loss to C 4 F 8 and other high-boiling by-products. Thus, the art offers a wide range of practical conditions for pyrolysis of CF 2 HCl to TFE with modest yield loss to by-products such as C 4 F 8 , from low conversion of undiluted feed at atmospheric or higher pressure, to high conversion of diluted feed at low CF 2 HCl partial pressure.
Halliwell in U.S. Pat. No. 3,306,940 discloses a process for the co-synthesis of HFP and TFE by pyrolysis of CF 2 HCl at conversion in the range 86-94%. As noted by Halliwell, when CF 2 HCl is pyrolyzed at low conversion to obtain high yield of TFE, only a small amount of HFP is formed but about two parts of perfluorocyclobutane are formed for each part of HFP. Halliwell further discloses that C 4 F 8 formed in the pyrolysis reaction can be recycled to the CF 2 HCl feed stream for pyrolysis to HFP and TFE with very little yield loss on account of side reactions. Examples 18-21 show 15-45 wt % C 4 F 8 in CF 2 HCl feed to pyrolysis at about 90% CF 2 HCl conversion, with 78-100% conversion of the C 4 F 8 . I.e., there is substantial consumption of C 4 F 8 in these examples of Halliwell's process.
Ukihashi & Hisasue in U.S. Pat. No. 3,459,818 disclose a process for concurrently producing TFE and HFP in which CF 2 HCl is partially pyrolyzed, HCl is removed from the pyrolysis product to form a gas mixture consisting essentially of TFE and CF 2 HCl, and said mixture is then pyrolyzed in a second pyrolysis step. In Examples 1-7, both HFP and C 4 F 8 were formed in the first partial pyrolysis step, remained in the gas mixture consisting essentially of TFE and CF 2 HCl, and were present in increased concentration in the product of the second pyrolysis step. Excluding HCl but including CF 2 HCl, the concentration of C 4 F 8 was 0.5-2.1 mol % in the gas mixture formed by the first partial pyrolysis and 1.8-6.3 mol % in the product of the second pyrolysis, with C 4 F 8 concentration always increasing in the second pyrolysis step. Total conversions of CF 2 HCl in the examples of Ukihashi & Hisasue are high, in the range 71-97%.
Reduced formation of by-products in the pyrolysis of CF 2 HCl in a process aimed at TFE production is desired in order to increase the yield to TFE.
SUMMARY OF THE INVENTION
This invention provides a process comprising pyrolyzing CF 2 HCl to obtain tetrafluoroethylene (TFE) as desired reaction product and C 4 F 8 as undesired reaction product, and further comprising co-feeding C 4 F 8 along with said CF 2 HCl to the pyrolysis reaction in an amount effective to reduce the formation of C 4 F 8 as said undesired reaction product, essentially without consuming C 4 F 8 in the pyrolysis reaction, thereby increasing the yield of said TFE reaction product.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered that addition of C 4 F 8 to the feed stream for pyrolysis of CF 2 HCl to TFE reduces the amount of C 4 F 8 formed and increases yield to TFE. By adjusting and controlling the concentration of C 4 F 8 feed, formation of C 4 F 8 can be essentially eliminated.
As mentioned above, pyrolysis of essentially pure CF 2 HCl to form TFE in high yield can result in formation of by-product C 4 F 8 . If one adds C 4 F 8 in increasing proportions, starting at very low levels, to the CF 2 HCl feed stream under the same process conditons, the following effects occur. At low C 4 F 8 feed levels, the amount of C 4 F 8 formed is reduced slightly. The amount of C 4 F 8 formed is the difference between the amount of C 4 F 8 in the product stream and the amount of C 4 F 8 in the feed stream. Thus, while the amount of C 4 F 8 in the product stream will be greater than for the case with no C 4 F 8 in the feed stream, the difference between the amounts in product and feed streams will be smaller. As the amount of C 4 F 8 in the feed stream is increased from low levels, the amount of C 4 F 8 formed is further reduced. The amount of C 4 F 8 in the feed stream can be further increased, with further accompanying reduction in the amount of C 4 F 8 formed, until the amount of C 4 F 8 in the product stream is about equal to the amount of C 4 F 8 in the feed stream. Under this condition, the amount of C 4 F 8 formed is essentially zero, and the formation of C 4 F 8 in the pyrolysis reaction may be said to have been eliminated. This general behavior is illustrated by the examples below. If C 4 F 8 concentration in the feed stream is increased beyond that required to eliminate C 4F 8 formation, then the amount of C 4 F 8 in the product stream will be less than the amount in the feed stream. That is, C 4 F 8 will be consumed in the pyrolysis reaction. The process of this invention is intended to operate without consuming C 4 F 8 . As one skilled in the art will recognize, the condition for zero formation of C 4 F 8 may not be sharply defined, because the rate of change of C 4 F 8 formed with concentration of C 4 F 8 in the feed stream may be low at feed concentrations near the value for exactly zero C 4 F 8 formation.
The process of this invention is intended to synthesize TFE at high yield, such as 88% or more, from converted CF 2 HCl. Any process conditions that result in high yield can be used. One generally desires to operate at conversion as high as possible consistent with high yield. As discussed above, yield losses and, therefore, yield depend on conversion and partial pressure of CF 2 HCl. For example, conversions of 90% and higher can be employed to obtain high yield at low CF 2 HCl partial pressure of the order of 0.05 atm, as illustrated by Edwards, et al. for pyrolysis under steam dilution conditions. Vanishingly small partial pressures of CF 2 HCl have the obvious drawback of requiring larger equipment for given output. On the other hand, pyrolysis of undiluted CF 2 HCl at 4 atm pressure and 23% conversion may not deliver high yield, as illustrated by Downing's Example II. To achieve high yield in pyrolysis of undiluted CF 2 HCl at near-atmospheric pressure, conversion is typically in the range 10-50%, preferably 25-45%. To achieve high yield in pyrolysis of diluted CF 2 HCl, conversion can be as high as 30-90% depending on degree of dilution (CF 2 HCl partial pressure).
As is well known in the art, conversion can be controlled by adjusting temperature and/or residence time in the reactor. There are no particular constraints on temperature and residence time, except that the combination of residence time and the temperature of the gas exiting the furnace should be low enough to prevent overconversion of CF 2 HCl and to avoid transition into conditions that favor synthesis of higher proportions of HFP along with TFE. Reaction conditions that can be used in the process of this invention are generally the same as conditions employed in the absence of C 4 F 8 co-feed with CF 2 HCl for pyrolysis to TFE. Generally, reaction temperatures in the range 700°-1000° C. as indicated by reactor wall temperature, preferably 750°-850° C. can be used. For processes operating near atmospheric pressure and in the absence of diluent, mass velocities in the range 20-80 kg/m 2 . s, preferably 25-55 kg/m 2 . s, and gas exit velocities in the range 20-80 m/s, preferably 30-50 m/s, can be used. Under these conditions, flow is turbulent but not super-sonic. The choice of conditions, of course, will be influenced if not limited by the design of the reactor to be used. Since productivity is usually a practical concern, combinations of higher mass velocity and higher temperature are usually favored over combinations of lower mass velocity and lower temperature.
As discussed above, diluent substances such as steam (water vapor) or carbon dioxide can be present during the pyrolysis of CF 2 HCl. The use of diluents, especially steam, is within the scope of this invention. However, excessive dilution with steam, e.g., beyond 95% of total pressure, has the drawback of yield loss to hydrolysis and resultant formation of CO with its attendant separation difficulties. (See Edwards et al.) When steam dilution is employed, steam concentrations in the range of 25-95% of total pressure are ordinarily used.
The process of this invention can be carried out in any reactor equipment suitable for the pyrolysis of CF 2 HCl to make TFE. In particular, tube furnaces conventionally used for such pyrolysis can be used. In such furnaces, the tubes are usually made of corrosion-resistant alloy, such as Inconel®600 (The International Nickel Company). Heat for the endothermic reaction of this process can be supplied by any suitable means, such as by external heating, by induction heating, by injection of hot diluent (e.g., steam), by a combination of the foregoing, and the like.
CF 2 HCl is the principal reactive component of the feed stream for the process of this invention. Because CF 2 HCl and HFP form an azeotrope that has composition of about 0.15 mole of HFP for each mole of CF 2 HCl, and unconverted CF 2 HCl is typically recycled, it is convenient to include HFP in the feed along with CF 2 HCl. However, the presence of HFP in the feed is believed to have little influence on the reaction and is not required in the practice of this invention. Generally, the amount of HFP in the product stream is slightly greater than that in the feed stream, corresponding to the small amount of HFP formation noted by Halliwell. Other halocarbon compounds, for example, by-products of the process that are desirably recycled such as C 2 F 5 Cl, can be present in small concentration.
The amount of C 4 F 8 fed along with CF 2 HCl depends on the result desired. It may, for example, be desired to form a small amount of C 4 F 8 but less than the amount that would be formed with no C 4 F 8 in the feed. In general, formation of C 4 F 8 increases slightly with increasing conversion of CF 2 HCl, and the amount of C 4 F 8 required in the feed to eliminate C 4 F 8 formation increases accordingly. Roughly, the amount of C 4 F 8 in the feed required to eliminate C 4 F 8 formation is 15× the amount formed under the same conditions in the absence of C 4 F 8 feed. In the process of this invention, there is at least as much C 4 F 8 in the product stream from reaction as in the feed stream. The difference between the amounts of C 4 F 8 in the product and feed streams is a measure of C 4 F 8 formation. As shown by the examples to follow, as little as 1 wt % C 4 F 8 in the feed, based on combined weight of CF 2 HCl and C 4 F 8 , produces a discernible reduction in formation of C 4 F 8 . For high-yield pyrolysis at CF 2 HCl partial pressure of about 1 atm, concentrations of 5-10 wt % are preferred. Extrapolation of experimental data obtained under these conditions to zero formed C 4 F 8 indicates that formation is essentially eliminated at feed concentration in the range 8-10 wt %, which is most preferred. When C 4 F 8 concentration in the feed exceeds about 10-12 wt %, then, under these operating conditions C 4 F 8 will be consumed. That is, there will be less C 4 F 8 in the exit stream than in the feed stream. The process of this invention is intended to reduce or eliminate formation of C 4 F 8 without consuming C 4 F 8 in the pyrolysis of CF 2 HCl. The concentration of C 4 F 8 in the feed stream that eliminates formation of C 4 F 8 varies with the reaction conditions. For high-yield pyrolysis of CF 2 HCl diluted with steam, the amount of C 4 F 8 required in the feed to eliminate C 4 F 8 formation (essentially without consuming C 4 F 8 ) varies with the degree of dilution, but can range up to about 18 wt % based on combined weight of CF 2 HCl and C 4 F 8 for high dilution and total pressure near atmospheric pressure. Concentrations of C 4 F 8 in the range 6-16 wt % are especially effective under these conditions, preferably 8-16 wt %.
As one skilled in the art will recognize, attempts to operate so as to exactly eliminate C 4 F 8 formation may be handicapped by inexact process control. Thus, operation with this objective may be characterized by variation about the balance point, with periods of reduced C 4 F 8 formation, periods of exact balance, and periods of C 4 F 8 consumption averaging over time to give approximately zero C 4 F 8 formation. That is, formation of C 4 F 8 is essentially eliminated on a time-average basis. This is considered to be within the scope of the invention.
Any convenient pressure can be used for the process of this invention. Total pressures of about 0.4-1.5 atm are especially convenient. CF 2 HCl partial pressures of no more than about atmospheric pressure are preferred.
The feed stream can be cold when introduced into the pyrolysis furnace, or can be preheated. Thus, feed stream temperatures in the range 0°-500° C. can be used. Feed stream temperature in the range 300°-450° C. is preferred.
EXAMPLES
Experiments were carried out using a tube furnace under conditions characterized by temperature, mass velocity, and gas exit velocity given in the individual examples below. Pyrolysis stream flows were turbulent. All experiments were conducted at total pressure slightly in excess of atmospheric presssure. The feed stream was heated to about 350° C. for all examples. Reaction temperature (T) is reported as tube temperature measured by a thermocouple placed on the exterior surface at a position three-fourths of the length of the tube from the inlet end.
The base feed stream for the following examples was principally CF 2 HCl and HFP in the molar ratio of about 92/8. The stream also contained small amounts, less than 2 mol %, of other chlorofluorocarbon compounds, principally C 2 F 5 Cl. Perfluorocyclobutane was added to this base stream in different amounts to explore the effect of feed concentration on the amount of C 4 F 8 generated during pyrolysis. The amount of C 4 F 8 introduced was determined by an orifice flowmeter and its concentration in the feed stream was measured using a gas chromatograph (GC). The concentration of C 4 F 8 in the feed stream is given on the basis of C 4 F 8 and CF 2 HCl combined.
Product stream components were separated by distillation.
GC measurements were used to determine the conversion of CF 2 HCl and the yields to TFE and HFP based on converted CF 2 HCl. As is customary in the art, yield calculations were based on the CF 2 content of CF 2 HCl. Yields are presented as the sum of TFE and HFP yield. The yield to HFP, after deducting HFP in the feed, was essentially constant at about 1% throughout the tests reported in the examples. GC could not be used reliably to measure small changes in low concentrations of C 4 F 8 , so a mass balance approach was used. C 4 F 8 was isolated and accumulated in a weigh tank from which net production was determined. C 4 F 8 was simultaneously withdrawn from the same tank at the rate required for the feed to the reaction, so that at steady state the rate of C 4 F 8 accumulation was the rate of net C 4 F 8 formation (net generation). The net formation of C 4 F 8 is stated relative to the amount of TFE produced. TFE concentration in the product stream was determined by GC.
EXAMPLE 1
This example summarizes results for tests having CF 2 HCl conversion centered at about 37%, mass velocity in the range 29-46 kg/m 2 . s, and gas exit velocity in the range 37-43 m/s. Other conditions are shown in Table 1. As stated above, C 4 F 8 feed concentration (wt %) is based on combined weight of C 4 F 8 and CF 2 HCl, and C 4 F 8 formation is based on the amount of TFE formed (wt/100wt TFE). Analytical results also given in Table 1 show that C 4 F 8 produced decreased and yield to TFE and HFP increased as C 4 F 8 feed concentration was increased. From these data, it was estimated that C 4 F 8 feed concentration of about 9.9 wt % would result in zero production of C 4 F 8 .
TABLE 1______________________________________Conditions and Results for Example 1 Conversion C.sub.4 F.sub.8 Feed C.sub.4 F.sub.8 Produced YieldT (°C.) (% CF.sub.2 HCl) (wt %) (wt/100 wt TFE) (TFE + HFP, %)______________________________________780 37.2 0.13 1.60 91.7785 37.8 1.62 1.25 94.5782 36.5 2.53 1.31 95.8786 36.3 5.08 0.48 96.5______________________________________
EXAMPLE 2
This example summarizes results for tests having CF 2 HCl conversion centered at about 31%, mass velocity in the range 41-48 kg/m 2 . s, and gas exit velocity in the range 38-45 m/s. Other conditions are shown in Table 2. Analytical results also given in Table 2 show that C 4 F 8 produced decreased and yield to TFE and HFP increased as C 4 F 8 feed concentration was increased, with C 4 F 8 production decreasing to a very low value at feed concentration of 6.52 wt %. From these data, it was estimated that C 4 F 8 feed concentration of about 9.3 wt % would result in zero production of C 4 F 8 .
TABLE 2______________________________________Conditions and Results for Example 2 Conversion C.sub.4 F.sub.8 Feed C.sub.4 F.sub.8 Produced YieldT (°C.) (% CF.sub.2 HCl) (wt %) (wt/100 wt TFE) (TFE + HFP, %)______________________________________785 30.7 0.24 1.89 93.2779 30.3 1.69 1.61 94.0773 31.4 2.92 1.20 94.6774 32.4 6.52 0.27 96.1______________________________________
EXAMPLE 3
This example summarizes results for tests having CF 2 HCl conversion centered at about 28%, mass velocity in the range 40-44 kg/m 2 . s, and gas exit velocity in the range 37-41 m/s. Other conditions are shown in Table 3. Analytical results also given in Table 3 show that C 4 F 8 produced decreased and yield to TFE and HFP increased as C 4 F 8 feed concentration was increased, with C 4 F 8 production decreasing to a very low value at feed concentration of 7.65 wt %. From these data, it was estimated that C 4 F 8 feed concentration of about 9.0 wt % would result in zero production of C 4 F 8 .
TABLE 3______________________________________Conditions and Results for Example 3 Conversion C.sub.4 F.sub.8 Feed C.sub.4 F.sub.8 Produced YieldT (°C.) (% CF.sub.2 HCl) (wt %) (wt/100 wt TFE) (TFE + HFP, %)______________________________________775 29.0 0.25 1.82 94.5768 27.6 5.02 0.54 95.3775 28.9 6.69 0.27 95.6775 28.1 7.65 0.24 95.9______________________________________ | In the process of pyrolyzing chlorodifluoromethane to form tetrafluoroethylene, yield is improved by having a controlled concentration of perfluorocyclobutane in the feed to pyrolysis. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/EP01/14116, filed Dec. 3, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention relates to an apparatus for pressing shirts having a flexible inflatable body, a bottom part having a fan for inflating the inflatable body and on which the inflatable body is fastened by way of a bottom section, and a top part, which is disposed above the bottom part and on which the inflatable body is fastened by way of a top section and is connected to the bottom part by a load-bearing structure disposed within the inflatable body, the load-bearing structure being connected in a vertically displaceable manner to the bottom part.
[0004] Such an apparatus is known, for example, from German Published, Non-Prosecuted Patent Application DE 199 13 642 A1. This document describes an apparatus for drying and/or pressing damp laundry, in the case of which a collar-retaining device is firmly disposed above the inflatable body. Furthermore, a bottom part with further necessary components is disposed beneath the inflatable body, which has to be at least as high as the shirts that are to be pressed. This results in the appliance having a considerable overall height, which makes it difficult to accommodate.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide an apparatus for pressing shirts that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that achieves a more compact configuration to render the apparatus easier to accommodate.
[0006] With the foregoing and other objects in view, there is provided, in accordance with the invention, an apparatus for pressing shirts, including a flexible inflatable body having a bottom section and a top section, a bottom part having a fan communicating with the inflatable body for inflating the inflatable body, the inflatable body fastened to the bottom part at the bottom section, a load-bearing structure disposed within the inflatable body and connected in a vertically displaceable manner to the bottom part, a top part being disposed above the bottom part, the inflatable body fastened to the top part at the top section, the load-bearing structure connecting the top part to the bottom part, and the load-bearing structure being movably disposed to assume an extended position in which the load-bearing structure is extended out of the bottom part when the apparatus is in operation and a retracted position in which the load-bearing structure is retracted into the bottom part when the apparatus is not in operation.
[0007] By virtue of the inflatable body contributing largely to the overall height of the shirt-pressing apparatus, the invention makes it possible to achieve considerably more compact dimensions of the shirt-pressing apparatus outside the operating state. It is precisely in this state in which the apparatus has to be stowed away that small dimensions are necessary. In the operating state, in contrast, a large height does not prove disadvantageous because, in order to be used, the shirt-pressing apparatus has to be set up in unconfined conditions in any case. Within the inflatable body, it is possible to dispose further inner inflatable bodies, which are subjected, in particular, to relatively high pressure and can, likewise, be folded up when the top part is lowered. These inner inflatable bodies can be supported on the load-bearing structure to make possible for the inflatable-body enclosure to be forced specifically outward at certain locations. It is possible, here, for the connecting elements between the inner inflatable bodies and the load-bearing structure, for the purpose of absorbing the compressive forces, to be fastened in a displaceable manner on the load-bearing structure so that they can be pushed together when the load-bearing structure is lowered. The inner inflatable bodies may, thus, be provided with loops or rings that can be displaced along the load-bearing structure. Use may also be made, as load-bearing structure, of lowerable bars between which nettings or air-permeable fabric sections are tensioned, it being possible for the inner inflatable bodies to be supported against these and for their connections to the bars to be displaced along the latter. For example, the nettings or the air-permeable fabric sections may be fastened on the bars by straightforward loops or rings.
[0008] In accordance with another feature of the invention, there is provided a connecting device for transmitting at least one of tensile forces and compressive forces, the connecting device connecting the load-bearing structure to the inflatable body between regions in which the inflatable body is fastened to the bottom part and to the top part, the connecting device being displaceably connected along the load-bearing structure.
[0009] To insure that the operation of lowering a button-strip clamp is not obstructed, a connection between the load-bearing structure and the button-strip clamp is, advantageously, only disposed at the top end. As a result, the region of the inflatable body that is located therebetween can fold up during lowering of the load-bearing structure and/or of the button-strip clamp.
[0010] In accordance with a further feature of the invention, the inflatable body has an inside and the connecting device is pulling strips fastened on the inside and delimit inflation of the inflatable body.
[0011] In accordance with an added feature of the invention, the connecting device is inflatable air cushions disposed in the inflatable body and forcing the inflatable body outward at given locations.
[0012] It is the case with the button-strip clamp envisaged that the inflatable body, which is tensioned during operation, butts at the rear against the rear side of the button-strip clamp. This may result, on the two sides of the button-strip clamp, in producing a spacing between the inflatable body and a tensioned shirt because both the shirt and the inflatable body are pulled taut and located between the shirt and the inflatable body is a part of the button-strip clamp against which the button strip or buttonhole strip is clamped for fixing purposes. Such a spacing results in the inflatable bag not fitting closely against those regions of the shirt that are located in the vicinity of the button-strip clamp, and this may impair the pressing result in these regions.
[0013] To prevent this, the rear side of the button-strip clamp is substantially curved and, at the borders, moves at a shallow angle toward the plane in which the button strip or the buttonhole strip of a shirt that is to be pressed is clamped firmly. It is, thus, possible for the inflatable body in the inflated state, at a very small spacing from the borders of the button-strip clamp, to fit closely from the rear against the shirt that is to be pressed. The regions of the shirt in the vicinity of the button strip or of the buttonhole strip are, thus, not exposed to any abrupt transitions. As a result, it is possible to achieve pressing of the shirt without folds.
[0014] In accordance with an additional feature of the invention, there is provided a button-strip clamp for fixing one of the button strip of a shirt and a buttonhole strip of the shirt, the button-strip clamp being fastened in a vertically displaceable manner on the bottom part.
[0015] In accordance with yet another feature of the invention, the button-strip clamp and the load-bearing structure are coupled to one another with respect to vertical displacement.
[0016] In accordance with yet a further feature of the invention, the button-strip clamp and the load-bearing structure are vertical displaceably coupled to one another.
[0017] In accordance with yet an added feature of the invention, the button-strip clamp has a top connected to the top part.
[0018] In accordance with yet an additional feature of the invention, the button-strip clamp has a rear side, the inflatable body with the load-bearing structure pushes upward in an inflated state of the inflatable body and butts against the rear side of the button-strip clamp in the pushed upward state, the button-strip clamp has clamping surfaces against which one of the button strip or the buttonhole strip are to be pressed for fixing the button strip or the buttonhole strip, the clamping surfaces define a plane and have lateral borders, and the rear side of the button-strip clamp is located in a vicinity of the plane of the clamping surfaces at least at the lateral borders.
[0019] In accordance with again another feature of the invention, the clamping surfaces have outer borders, the rear side of the button-strip clamp has borders, and the borders of the rear side of the button-strip clamp are connected to the outer borders of the clamping surfaces and enclose an acute angle with the outer borders of the clamping surfaces.
[0020] In accordance with a concomitant feature of the invention, the load-bearing structure has a plurality of supporting rods connected to one another and disposed substantially parallel to one another, only one of the supporting rods is mounted axially in the bottom part and is secured against tilting, and a remainder of the supporting rods are guided axially in the bottom part and are not secured against tilting.
[0021] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0022] Although the invention is illustrated and described herein as embodied in an apparatus for pressing shirts, it is, nevertheless, not intended to be limited to the details shown because 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.
[0023] 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
[0024] [0024]FIG. 1 is a vertical cross-sectional view from the front of an apparatus for pressing shirts according to the invention in an extended, operating state;
[0025] [0025]FIG. 2 is a vertical cross-sectional view from the front of the shirt-pressing apparatus of FIG. 1 in the pushed-together state;
[0026] [0026]FIG. 3 is a perspective and partially cut away view of a number of interior components of the shirt-pressing apparatus of FIG. 1; and
[0027] [0027]FIG. 4 is a fragmentary, horizontal, cross-sectional view through a button-strip clamp of the shirt-pressing apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a shirt-pressing apparatus having a bottom part 3 with a shirt-form inflatable body 1 that is fastened thereon and serves for tensioning a shirt that is pulled thereover. Disposed for such a purpose in the bottom part 3 are a fan 6 , a heating device 7 , and an air channel 8 , by means of which a hot air stream can be produced. The air stream is divided up by the air channel 8 into two partial air streams, which are directed to a left-hand and a right-hand outlet opening of the bottom part 3 .
[0029] In each case one of the two supporting bodies 2 is connected to the two outlet openings, the supporting bodies being disposed in the interior of the inflatable body 1 and serving for forcing the trunk section of the inflatable body 1 outward at the sides in order, thus, to provide it with a flat cross-section. The supporting bodies 2 , like the inflatable body 1 , are produced from an air-permeable, flexible material, for example, synthetic-fiber fabric. The supporting bodies 2 extend substantially over the entire height of the trunk section of the inflatable body 1 .
[0030] Furthermore, a load-bearing framework 5 is fastened on the bottom part 3 such that it can be displaced vertically by bushings 9 . In the extended state, the load-bearing framework 5 extends beyond the height of the supporting bodies 2 in the inflated state.
[0031] Fastened on the load-bearing framework 5 is a top part 4 , on which the inflatable body 1 is fastened at the top and which serves for fixing and clamping the collar of a shirt fitted onto the inflatable body. Disposed for such a purpose on the top part 4 are two clamping flaps 10 , by which the two ends of a turned-up collar can be fixed. The top part 4 also has a not illustrated device that is disposed at the rear and is intended for tensioning in the circumferential direction a shirt collar that is fixed at its ends.
[0032] The interior structure for retaining and supporting the inflatable body 1 is illustrated in perspective, with further details, in FIG. 3. The load-bearing framework 5 includes four supporting tubes 11 , which are mounted in a vertically disposable manner within the bushings 9 in the bottom part. In each case, one supporting netting 12 is tensioned between the two supporting tubes 11 disposed on the left (with respect to FIG. 3) and the two supporting tubes 11 disposed on the right. The supporting nettings 12 are fastened on the supporting tubes 11 on the sides by loops, it being possible for the loops to slide along the supporting tubes 11 . The supporting nettings 12 serve for supporting the supporting bodies 2 so that the supporting bodies 2 , in the inflated state, can subject the sides of the trunk section of the inflatable body 1 to an outwardly directed pressure from the inside. The supporting bodies 2 have a bottom section fastened on the outlet openings of the bottom part 3 and a top section fastened at the top end of the load-bearing framework 5 . The supporting nettings 12 are fastened on the bottom part 3 at the bottom and at the top end of the load-bearing framework 5 at the top.
[0033] Furthermore, the bottom part 3 has a button-strip clamp 13 , which is mounted in a vertically adjustable manner substantially in the center of the front border of the bottom part 3 . The button-strip clamp 13 , which is illustrated in cross-section in FIG. 4, serves for fixing the button strip or the buttonhole strip of a shirt 19 fitted onto the inflatable body so that the shirt 19 can be tensioned by the inflatable body 1 . The button-strip clamp 13 has an oval supporting tube 18 and a supporting bar 17 , between which is disposed an air-permeable clamping body 14 , which may be produced, for example, from a perforated sheet. If the rest of the parts, in particular, the supporting bar 17 and the clamping body 14 , are sufficiently stable, it is possible to dispense with the oval supporting tube 18 . The clamping body 14 is in the form of a shallow trapezoid, of which the base surface is located on the side that is directed away from the inflatable body 1 and the side surfaces slope upward at a shallow angle.
[0034] Articulated on the borders of the supporting bar 17 in each case are flaps 15 , which are subdivided into a plurality of sections over the height of the button-strip clamp 13 . The flaps 15 each have fillings 16 made of a flexible and, if appropriate, air-permeable material. The fillings 16 may be provided with a non-slip coating on the surface on which the fabric of the shirt 19 ends up resting when the button strip or buttonhole strip is clamped firmly. This coating may have, for example, short bristles that are inclined inward, in the direction of the supporting bar 17 to make possible a retaining of the fabric of the shirt 19 counter to the outwardly directed pull when the inflatable body 1 is inflated. Each of the flaps 15 is assigned a respective spring element. The spring elements ensure that the flaps 15 are pressed against the clamping body 14 up to a certain point and, above the point, are retained in an open position, away from the clamping body. The individual spring elements may be individual links of a single spring plate. It is, thus, easily possible to use one part to create a plurality of spring elements that act independently of one another.
[0035] For pressing purposes, the shirt 19 is fitted, in particular, in a damp state, onto the inflatable body 1 , with the load-bearing framework 5 extended. In such a case, in the first instance, the flaps 15 of the button-strip clamp 13 and the correspondingly configured flaps 10 of the top part 4 are opened. The button strip or the buttonhole strip and the collar tips are positioned beneath the flaps 15 and 10 , respectively, and are fixed by virtue of the flaps 15 and 10 being closed. The shirt collar, for pressing purposes, is tensioned in the circumferential direction by actuation of the collar-tensioning and collar-clamping device in the top part 4 . The fan 6 is, then, set in operation, together with the heating device 7 , whereupon heated air is directed into the supporting body 2 . From the supporting bodies 2 , the air flows, through the air-permeable enclosures of the same, into the inflatable body 1 , inflates the latter, and, then, flows through the, likewise, air-permeable enclosure of the latter, to the shirt 19 that has been fitted thereon, and is pressed by the action of tensioning and heat. In the stationary state, the pressure prevailing in the supporting bodies 2 is higher than that in the inflatable body 1 , for example, a level of 6 mbar in the supporting bodies 2 in relation to a pressure of 3 mbar in the inflatable body 1 . The supporting bodies 2 are supported in the inward direction against the supporting nettings 12 and force the trunk section of the inflatable body 1 outward at the sides.
[0036] A shirt 19 fitted onto the inflatable body in a damp state is tensioned by the inflated inflatable body 1 , dried in the process, and, thus, pressed. In such a case, the inflatable body 1 positions itself against the button-strip clamp 13 from the rear, it being possible for the air to flow through the air-permeable clamping body 14 to the fixed button strip or buttonhole strip to dry the same. On account of the inclined side surfaces of the clamping body 14 , the inflatable body 1 , from a very small spacing from the clamping body 14 , butts against the shirt 19 from the rear. The regions of the shirt 19 in the vicinity of the button strip or of the buttonhole strip are, thus, retained without creases. As a result, no folds are produced by the fixing device during pressing.
[0037] Following operation, it is advantageous, for the purpose of accommodating the shirt-pressing apparatus, if the latter has small dimensions. For such a purpose, as is illustrated in FIG. 2, the load-bearing framework 5 is pushed downward, the supporting tubes 11 being pushed, through the bushings 9 , into the bottom part 3 . At the same time, the button-strip clamp 13 is also pushed into the bottom part 3 . Because both the inflatable body 1 and the supporting bodies 2 and supporting nettings 12 are only fastened at two points at the bottom and top, these are folded up above the bottom part 3 when the load-bearing structure 5 is lowered. In such a state, the inflatable body 1 , the supporting bodies 2 , and the supporting nettings 12 only take up a fraction of the space that they take up in the extended state.
[0038] In a development, it is possible for just one of the supporting rods 11 to be mounted axially in the bottom part 3 such that they are secured against tilting, and for the rest of the supporting rods 11 merely to be guided in the bottom part 3 . For such a purpose, for example, the one supporting rod 11 may be mounted in two pairs of rollers that are disposed one above the other and, in such a case, in each case at least one roller has a constriction or indent to make possible a securing of the supporting rod against tilting in all directions. The rest of the supporting rods 11 , in this configuration, may be guided in simple openings in the bottom part 3 . It is, thus, possible to achieve the situation where skewing of two or more supporting rods 11 does not result in the entire load-bearing structure 5 skewing during the extending and pushing-in operations. The guidance is, thus, improved to a considerable extent. In this configuration, provision may be made for the front supporting tubes, which are disposed on both sides of the button-strip clamp 13 , to be connected to one another by a cross member, beneath the axial mount or guide, within the bottom part 3 , in order to achieve additional stabilization. Above the guide or the mount, all the supporting rods 11 are connected to one another, in particular, at their top end. It is also possible for the button-strip clamp 13 to be fastened on this cross member and, thus, to be coupled to the load-bearing structure 5 in respect of vertical displacement.
[0039] It may be possible for the load-bearing structure 5 to be arrested in the extended state and/or in the pushed-in state. To make it easier for the load-bearing framework 5 to be extended, it is also possible to provide a spring element that forces the load-bearing framework 5 upward counter to its weight. For example, it is possible to provide a roller spring that, advantageously, has a largely linear force profile. To simplify handling, the arresting mechanism may be configured to lock the load-bearing framework 5 at the bottom when first lowered and to unlock it again when forced in again. In such a case, the spring is, advantageously, configured such that, without any external action, it can move the load-bearing structure 5 slowly upward.
[0040] In a development, it is also conceivable for the spring to be configured such that the load-bearing framework 5 descends slowly downward without any external force action and the operation of extending the load-bearing framework 5 is brought about by virtue of the fan 6 being switched on, the supporting bodies 2 producing the necessary upwardly directed force during the inflating operation. Once at the top, the load-bearing framework 5 can lock itself, with the result that an operator, following use of the shirt-pressing apparatus, need only unlock the load-bearing structure to allow the latter to descend slowly downward.
[0041] The load-bearing structure 5 may be connected to a damping device with speed-dependent damping. As a result, the extending and/or pushing-in operations are damped. The damping device used may be, for example, a negative-pressure braking cylinder.
[0042] Furthermore, possible measures for supporting and/or moving the load-bearing structure 5 are manual drives, for example, a crank, motor drives, damped springs, or pneumatic springs. Provision may further be made for the locking and/or unlocking to be brought about by a turning action. | A shirt-smoothing device includes a lower part and an inflatable body fixed thereon. Because the inflatable body must be at least the same size as the shirt to be smoothed, the device has considerable height, however, the rigid components in the area of the inflatable body are lowerable to handle the device more easily and, more particularly, to stow it away easily. An internally disposed supporting frame and a button strip tensioner disposed in front of the inflatable body can be lowered after use into the lower part, whereby the inflatable body, which is exclusively connected to the supporting frame at the top becomes folded. The same applies to flexible inflatable support bodied and support nets disposed between the inflatable body and the supporting frame. The storage space required for the shirt smoothing device can be substantially reduced by the invention and the handling and storage thereof simplified. | 3 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.