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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to guides for sliding gates and more particularly to a modular guide frame that may be easily adapted for use with gates having different or slightly irregular thicknesses.
2. Description of the Related Art
Simple mechanical gates, such as slide gates, stop gates and weir gates have been used for countless years in fields such as agriculture, municipal water systems, wastewater systems, and the like. Such systems are typically comprised of a single, planar gate that slides between open and closed positions within an elongated guide or channel, which is shaped to conform to the shape and size of the gate. These gates and their guides have been previously fabricated from numerous different materials, including wood, steel, galvanized steel, extruded aluminum, reinforced polymers, and the like. Clearly, one of the most common methods of fabricating such a system is to prepare a gate, having a particular size and shape, and then fabricating a gate guide to fit the gate. The gate guide may be provided in the form of one or more elongated, one-piece channels that may be cut to size and reconfigured into a particular shape that will slidably receive the gate. The gate guide may then be mechanically secured in position or imbedded within concrete or other suitable material, depending upon the particular application.
However, a problem frequently encountered in the assembly and installation of a gate system occurs when a gate is selected that has an uncommon or slightly irregular thickness. In these instances, pre-fabricated gate guide materials may provide a channel width that is too broad to provide an adequate sealing engagement between the gate and the gate guide, or the channel may be too narrow, preventing the gate from being received within the gate guide. In either situation, the installer is forced to custom fabricate a gate guide to adequately receive the gate, if a new gate, having standard dimensions cannot be used. Unfortunately, custom fabricating gate guides can be costly and time consuming. This is especially true in large-scale settings that require a plurality of gates having one or more unique gate sizes or configurations.
Accordingly, what is needed is a modular gate guide frame that may be fabricated using efficient, extrusion methods while being quickly and easily adapted for use with one or more gates having unusual or slightly irregular dimensions.
SUMMARY OF THE INVENTION
The gate guide frame of the present invention is preferably provided in a modular configuration, having separate first and second side portions. Each side portion is provided with elongated first and second wing members that extend outwardly from the rearward portion of a hub. Each hub is shaped to have at least to side faces that extend forwardly from the backsides of each hub. At least two mating faces extend inwardly from the distal ends of the side faces, forming a forward end portion for each hub. The mating surfaces are shaped and positioned so that the mating faces from opposing side portions may be operatively coupled with one another. Side faces from each hub combined to define the width of the channel that is formed when the two side portions are coupled with one another. In a preferred embodiment, the side faces of each hub are provided with different widths. Accordingly, the hubs from the opposing side portions may be selectively joined with one another in different configurations to provide a gate guide with one of various different widths.
Each side portion of the gate guide is provided with at least two wing members that extend along the length of the gate guide. The wing members are positioned with respect to the hub so that, depending upon the manner in which the opposing hubs are coupled with one another, one wing member from each side portion will combine to form a pair of spaced-apart frame rails, while the remaining wing members provide anchors for stabilizing the gate guide.
In one preferred embodiment, elongated channels are formed within the wing members. Resilient sealing members may be secured to the wing members within the elongated channels inside the spaced-apart frame rails, to provide a smooth sliding motion and a snug, sealing fit for the gate in a closed position.
It is therefore a principle object of the present invention to provide a modular guide frame for gates that may be easily adapted for gates having various thicknesses and configurations.
A further object of the present invention is to provide a modular guide frame for gates of various thicknesses that may be fabricated from a single extrusion form.
Still another object of the present invention is to provide a modular guide frame for gates that may be formed using a single pair of frame halves to form a guide channel having one of at least three different, pre-selected, channel widths.
Yet another object of the present invention is to provide a modular guide frame for a gate that is formed from a single pair of identically shaped frame halves and an optional expansion plate to easily accommodate at least four different, pre-selected gate widths.
A further object of the present invention is to provide a modular guide frame for gates that is relatively simple and inexpensive to manufacture.
Still another object of the present invention is to provide a modular guide frame for gates that may be easily adapted in the field for use with gates having a wide range of thicknesses and further provide the option of using resiliently deformable sealing members to engage the opposing surfaces of the gate as it moves between open and closed positions.
These and other objects will be apparent to those having skill in the relevant art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of one preferred embodiment of the modular guide frame of the present invention as the same could be assembled for use with a gate having a narrow thickness;
FIG. 2 is a front elevation view of the guide frame depicted in FIG. 1 as the same could be assembled for use with a gate having a large thickness;
FIG. 3 is a front elevation view of the guide frame depicted in FIG. 1 as the same could be assembled for use with a gate having an intermediate thickness;
FIG. 4 is an isometric view of one manner in which the modular guide frame of the present invention could be assembled for use with a gate in a fluid passageway;
FIG. 5 is a sectional, side elevation view of one preferred embodiment of the modular guide frame of the present invention as the same could be configured to slidably receive a gate;
FIG. 6 is an exploded isometric view of still another embodiment of the modular guide frame of the present invention; and
FIG. 7 is a top, section view of the guide frame depicted in FIG. 6 as the same could be assembled for use with a relatively wide gate.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of exemplary embodiments, reference is made to accompanying FIGS. 1-7 , which form a part hereof and show, by way of illustration, exemplary embodiments of the present invention. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other embodiments may be utilized, however, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims.
The modular guide frame 10 of the present invention may be used with sliding gates of various shapes and sizes and in a wide array of different applications. In its preferred embodiment, the guide frame 10 is provided with a first side portion 12 and a second side portion 14 . While it is contemplated that the first and second side portions 12 and 14 could be provided with various structural differences to accommodate specific applications, it is preferred that they be nearly identical in size and shape. Accordingly, both first and second side portions 12 and 14 are provided with a first wing member 16 and a second wing member 18 that extend outwardly from the rearward portion of a hub 20 . The hubs 20 are each multi-facetted, being provided with at least a first side face 22 and a second side face 24 that extend forwardly from the rearward portions of each hub 20 . Each hub is further provided with at least a first mating face 26 and a second mating face 28 . As depicted in the accompanying figures, the first and second mating faces 26 and 28 should extend outwardly and inwardly from the distal end portions of the first and second side faces 22 and 24 . While only two side faces and two mating faces are shown for each hub, it is contemplated that certain applications may permit the hubs 22 to have a geometry that utilizes additional side faces and/or mating faces to accommodate the needs of the particular applications.
The first and second mating faces 26 and 28 on the hubs 20 are shaped and positioned so that they may be coupled with a first mating face 26 or second mating face 28 from an opposing hub 20 in various configurations, as depicted in FIGS. 1-3 . While the first and second mating faces 26 and 28 are depicted as being flat, it is contemplated that textured, curved, keyed, or other specifically shaped faces could be provided to the first and second mating faces 26 and 28 . Regardless of the shape selected, however, the shapes should be provided in a manner that is easily and securely matable with one another. The orientation of the first and second mating faces 26 and 28 should be such that one of the first and second side surfaces 22 and 24 on one hub 20 will align with either the first side surface 22 or the second side surface 24 of the opposing hub. While the side surfaces depicted in FIGS. 1-3 align with one another in a generally coplanar fashion, it is contemplated that the orientation may be angular with respect to one another, so long as the combining side faces form an operable base for the guide channel, which will slidably receive a gate 30 .
In a preferred embodiment, the first and second side faces 22 and 24 on each hub 20 have different widths, one being shorter than the other. In this manner, when the first and second side faces 22 and 24 are coupled adjacent one another, a gate guide frame 10 may be provided having one of two or more different gate channel widths when the first side portion 12 and second side portion 14 are coupled with one another. For example, FIG. 1 depicts an instance where the second side surfaces 24 from two opposing hubs 20 are coupled adjacent one another to form a narrow gate channel 32 . FIG. 2 depicts an arrangement where the first side portion 12 and second side portion 14 are coupled with one another in a manner that places the first side surfaces 22 of both hubs 20 adjacent one another. This arrangement produces a wide gate channel 34 . FIG. 3 , on the other hand, depicts an arrangement where the first side portion 12 and second side portion 14 are arranged with respect to one another so that a first side surface 22 and second side surface 24 are positioned adjacent one another, forming an intermediate width gate channel 36 .
FIG. 4 depicts one contemplated arrangement of the modular guide frame 10 , as the same could be provided to slidably receive a gate. This figure demonstrates the fact that a single section of modular guide frame can first be cut into a first side portion 12 and a second side portion 14 and then cut again into a plurality of pieces so that the first and second side portions 12 and 14 may be arranged in the desired configuration, such as the rectangular passageway depicted in FIG. 4 . While the guide frame 10 is depicted in FIG. 4 as being imbedded within a solid material, such as concrete, other known materials are contemplated into which the components of the guide frame 10 may be imbedded. Moreover, it is contemplated that certain applications may permit the guide frame 10 to be mounted to a surface using one or more mechanical fasteners. Irrespective of its final form, it may be advantageous to first join the first side portions 12 and second side portions 14 so that the side portions do not move with respect to one another when one or more sections are being installed. Depending upon the materials selected to fabricate the guide frame 10 , various adhesives, structural fasteners, and methods of welding, such as the spot welds 38 are contemplated. The guide frame 10 may be formed from nearly any material that will withstand the operating environment of the desired application. Examples of such materials may include, but will certainly not be limited to steel, galvanized steel, wood, reinforced polymers and the like. However, certain extrusion processes and materials, such as those used to manufacture extruded aluminum, may be highly desirable due to the strength and lightweight of the material and the ease in which it may be mass produced from a single form.
In one preferred embodiment, elongated channels 40 are formed along the lengths of at least one side of the first wing members 16 and second wing members 18 . The channels 40 should be sized and shaped to securably receive elongated sealing members 42 . The sealing members 42 should extend outwardly from the channels 40 so that, when the channels 40 are disposed along inner walls of generally parallel, spaced-apart frame rails formed by either the first wing members 16 or second wing members 18 , a portion of the sealing members 42 will slidably engage the outer surfaces of a gate 30 as it is moved between open and closed positions. In a preferred embodiment, the sealing members are formed to have a generally curved cross section, such that the portion that engages a surface of the gate 30 will present few, if any flat surfaces or corners that may be exposed to and snagged by edge portions of the gate 30 . However, it is contemplated that the sealing members 42 can be provided in a wide variety of shapes, having curved features, flat features, or a combination of the two. The deformably resilient nature of the material used in forming the sealing members 42 will further accommodate the fit of a gate 30 having a thickness that is slightly more or less than desirable for the channel width provided. Moreover, the sealing engagement between the sealing members 42 and the gate 30 will help to inhibit the passage of fluids between the guide frame 10 and the gate 30 . Although several natural and synthetic materials, such as rubber and certain closed cell foam products, an ultra high-molecular weight (UHMW) polymer will be preferred due to its ability to minimize friction between the gate 30 and the sealing members 42 , which will ultimately reduce the operating force required to move the gate 30 between open and closed positions.
Another preferred embodiment of the modular guide frame 10 is depicted in FIGS. 6 and 7 . These figures demonstrate the use of an extension plate 44 that has a width which extends between opposite side portions. The opposite side portions of the extension plate 44 are preferably sized and shaped to engage either of the first or second mating faces 26 and 28 on either of the first side portion 12 or second side portion 14 . An extension plate 44 may be provided with a specific width and used with the first and second side portions 12 and 14 to provide a guide frame 10 for use with gates having a substantial thickness. Accordingly, extension plates 44 may be provided in several different widths or cut to length and width in the field to accommodate gates of various dimensions. As with the previously described embodiments, one of the first and second side surfaces 22 and 24 from each of the first and second side portions 12 and 14 will align with a surface of the extension plate 44 to provide a channel base for the guide frame 10 . While the channel base depicted in the figures is generally coplanar, it is contemplated that curved or angled variations may be provided to accommodate particular applications.
In the drawings and in the specification, there have been set forth preferred embodiments of the invention and although specific items are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and proportion of parts, as well as a substitution of equivalents, are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
Thus it can be seen that the invention accomplishes at least all of its stated objectives.
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A modular guide frame for use with gates of various thicknesses is assembled from separate side portions. The side portions are provided with hubs, having facets of different widths. The hubs may be coupled with one another to align the facets and provide different gate guide configurations, having various channel widths. An extension plate may be coupled between the side portions to further expand the width of the channel. Elongated sealing members may be secured within the channel to further customize the fit between the guide frame and a gate. The symmetrical nature of the side portions allow them to be manufactured from a single extrusion form, while retaining the ability to be used with one or more differently sized gates.
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FIELD OF THE INVENTION
The present invention relates to a novel drug delivery technology. More particularly the invention relates to a method of delivering at least one therapeutic compound or a formulation comprising the at least one therapeutic compound to a patient; to a throwaway or reusable device for delivering at least one therapeutic compound or a formulation comprising the at least one therapeutic compound to a patient in a manner as set out by the method; to a pioneer projectile for use in said method; to formulations for use in said method and to an injectate comprising a pioneer projectile and formulation. It also relates to a disposable component containing either a pioneer projectile or an injectate.
BACKGROUND TO THE INVENTION
One route of administration for therapeutic compounds is through the skin. The skin is also one of the more efficient routes for delivery of a therapeutic compound when compared to other standard delivery routes such as oral or pulmonary delivery.
Administration to the skin is most commonly undertaken using a needle and syringe as a delivery system with the therapeutic compound in a liquid form.
Such a system has a number of associated problems including the pain and fear associated with needles, the fact they are really best suited to injecting liquids which are not necessarily the best way of delivering compounds to a patient and the fact that sharps are left which create a disposal problem.
Drug delivery systems that do not incorporate needles are also used for injecting liquids through the skin and this is achieved by the delivery system creating a very fine, high velocity liquid jet that creates its own hole through the skin. There are however a number of problems with such a method including splash back.
With both these forms of liquid delivery relatively large volumes of liquid are injected which, because they are incompressible, have to tear the tissue apart in order to be accommodated.
However, drug injection through the skin does not have to be achieved with the drug in a standard liquid form. Solid form drugs have been successfully administered with the PowderJect system, which uses a compressed gas source to accelerate powdered drugs to a velocity at which they can penetrate the outer layers of the skin. This system typically employs powdered drug particles of less than 100 microns in diameter, which require a velocity of several hundred meters per second in order to penetrate human tissue. However the system has its own inherent problems such as controlled delivery.
It has also been shown in the past that solid rods or splinters of a therapeutic compound can be pushed, at a relatively low velocity, into the skin without the requirement for a needle although more traditionally these are delivered as implants.
The current transdermal drug delivery techniques can thus be categorised into groups based on the drug form and the velocity of the injection as set out in table 1 below:
TABLE 1
Drug Form
Drug Injection Velocity
Liquid
Solid
High Velocity
Liquid Jet Injector
PowderJect Systems
Drug darts
Low Velocity
Needle and Syringe
Drug ‘Splinters’
Drug darts are disclosed in a number of publications. WO 96/40351 (American Cyanamid) discloses an implant dart with a head of a solid plastics material which takes the form of a blade and a tubular body that contains one or more sustained release drug delivery implant packages. Flexible stabilizing wings are provided on either side of the dart head which serve as a lock or barb to prevent the dart being pulled out after entry. The dart has on outside diameter of about 7 mm and a length of about 45 mm and is delivered with an injection gun which fires the dart into an animal, but not a human, when a trigger is released. The propulsion mechanism delivers a force sufficient to impart a high accelerating velocity of from 40-60 mph on the dart. To inject the dart at low speed it is necessary to make a small incision in the animal and operate the push bar manually.
U.S. Pat. Nos. 3,948,263 and 4,326,524 also disclose ballistic delivery devices. U.S. Pat. No. 3,948,263 discloses a ballistic implant which is fired from a 0.25 calibre rifle. The projectile exits at about 900 ft/sec and can travel 20-40 ft before implanting into muscle some 1-2 inches beneath the skin. U.S. Pat No. 4326 524 discloses a solid dose ballistic projectile formed entirely of a cohesive mixture comprising biologically active material, in the form of grindable solid particles and a binder which is capable of withstanding the stresses imparted on impact. The projectile has a body portion with a diameter of from 4.5 to 7.6 mm, with a conical nose portion with a base diameter smaller than the diameter of the body such that a slight shoulder region is formed between the body and the nose. The end remote from the nose is preferably concave to aid flight.
GB 2365100 is another example of a remote ballistic delivery device which is fired and attains velocities of greater than 500 m/s. In contrast to those described above the device is slowed on impact so that it does not enter the body but instead the device's nose is moved back such that a needle enters the body, and a drug is injected. Such a device is not needleless.
CA1019638 discloses a projectile which is launched by a conventional air gun or bow. It comprises a head piece and a shaft, the head piece pierces the animals flesh and the shaft breaks away. In one embodiment the head piece is made of a porous material which retains a liquid drug through capillary action through launch and impact and which releases it by diffusion when it is inserted into the animal. In a second embodiment the head piece takes the form of a hardened cake. To aid penetration a metal or plastics tip may be provided. The drug delivering element remaining in the skin is about 3 mm diameter by 13 mm in length.
U.S. Pat. No. 3,901,158 Ferb discloses a hypodermic projectile which is again fired from a rifle or pistol. It comprises a shatterable front end of plastic or glass which breaks on impact releasing the liquid contents.
None of the described high velocity devices bear any resemblance to the present invention in which the at least one therapeutic compound or a formulation comprising the at least one therapeutic compound is pushed at low velocity from a device which contacts the skin and in which the pioneer projectile is water soluble, lipid soluble or otherwise biodegradable in the human or animal and is furthermore significantly smaller having a width or diameter of less than 3 mm in width, more preferably still less than 2.5 mm through 2 mm and 1.5 mm to about 1 mm in width; a height of less than 10 mm in height, more preferably about 1.5 to 2 mm in height and an aspect ratio of less than 1:8, preferably less than 1:6, more preferably less than 1:4, more preferably still less than 1:3, and most preferably about 1:1.5.
High velocity liquid systems are exemplified by U.S. Pat. No. 116,313 Mc Gregor. Liquid is first ejected from a small orifice in a probe at a very high velocity and pressure which will penetrate the skin and then the main charge of liquid is ejected at a lower velocity into the channel formed by the initial penetration
EP0139286 (Sumitomo Chemical Co Limited) discloses sustained-release preparations in the form of needle like or bar like shapes, which comprise an active ingredient and a pharmaceutically acceptable biodegradable carrier. The sustained-release preparation can be administered to the body by injection by pushing it through a hollow needle or by implantation.
WO 94/22423 (Bukh Meditec A/S) discloses a drug administration system. The method of parenteral administration comprises administering a drug substance by penetrating the skin or the mucosa of a human or an animal by a body with an appropriately formed solid pharmaceutical composition. The body of the pharmaceutical composition may be needle shaped so as to avoid external penetration equipment. The solid pharmaceutical composition comprises at least one drug substance and has a shape and/or strength to enable penetration.
The composition is made by mixing a material, preferably a polymer and optionally a filler with an active drug substance; extruding the mixture to form an elongate body; drying it and forming a pointed end.
U.S. Pat. Nos. 5,542,920, 6,117,443 and 6,120,786 (Cherif Cheikh) all disclose needle-less parenteral introduction devices. A medicament is made in the form of a solid needle having a pointed end that has sufficient structural integrity to penetrate the skin. The needles are less than 2 mm, preferably 0.2 to 0.8 mm, in diameter and 10 to 30 mm in length.
U.S. Pat. No. 6,102,896 (Roser) is primarily directed to a disposable injector device for injecting controlled release water soluble glass needles. It however also recognises that these glass needles, which are about 1 mm in diameter by 10 mm in length and contain a medicament may also be used as pioneer projectiles to produce a low resistance pathway through the tissue along which a liquid suspension (exemplified as a drug in a suspension of PFC fluid) can flow. This document appears the first and only document to recognise that a dissolvable pioneer projectile may be used to enable the introduction of a medicament. It however fails to recognise that it may be used as a general technique for introducing medicaments in other forms. Indeed this is readily apparent from the document in which a dry powdered formulation is made into a non viscous liquid by suspending it in PFC.
SUMMARY OF THE INVENTION
The present invention takes the concept of using a pioneer projection (as disclosed in U.S. Pat. No. 6,102,896) further and follows from the applicants recognition that a pioneer projectile can be used as a means for introducing medicaments in forms other than a free flowing, non viscous liquid.
According to a first aspect of the present invention there is provided a method of delivering at least one therapeutic compound or a formulation containing the at least one therapeutic compound to a human or animal in the form of a needleless injection comprising:
i) Penetrating the skin with a water soluble, lipid soluble or otherwise biodegradable pioneer projectile having a diameter of less than 3 mm which is left in the human or animal; and ii) Introducing directly, or substantially directly, behind the pioneer projectile, the at least one therapeutic compound or the formulation containing the at least one therapeutic compound, which at least one therapeutic compound or the formulation containing the at least one therapeutic compound is provided and delivered in a contained state.
By contained state is meant either:
i) As a liquid contained by a membrane; ii) As a liquid with a viscosity of at least 5000 centipoises (the viscosity of honey), more particularly at least 50,000 (the consistency of mayonnaise) and most preferably still at least 100,000 (the consistency of peanut butter), such that the liquid has characteristics more akin to a solid than a liquid i.e. they have a definite shape as well as volume (and are not readily free flowing); iii) As a semi-solid (having a viscosity and rigidity intermediate that of a solid or a liquid); iv) As a paste (having a soft malleable consistency); v) As a gel (a liquid dispersed in a solid) which materials can all be considered to have a degree of stiffness; or vi) As a solid (a state in which the matter retains its own shape).
Introducing a medicament in such a contained state has advantages in that splash back and seepage can be avoided and more controlled dosages delivered when compared to a following non viscous liquid formulation. The viscous, semi solid or solid nature of the medicament ensures that the pioneer projectile is pushed to the requisite depth and is followed by the medicament rather than seeping around the sides of the projectile. The semi solid formulations, gels, pastes and solids are also generally more stable than liquid formulations and are more patient compliable.
Furthermore it will be appreciated that by introducing the medicament in a form other than as a non viscous liquid behind a pioneer projectile it is possible to tailor the characteristics of the medicament for optimum pharmacokinetic delivery rather than for penetration.
Similarly the pioneer projectile can be developed to have optimised penetrating capabilities independent of the medicament.
Preferably the pioneer projectile is independent of the at least one therapeutic compound or the formulation containing the at least one therapeutic compound.
Alternatively the pioneer projectile is independent of yet forms an integral part of the at least one therapeutic compound or the formulation containing the at least one therapeutic compound.
Most preferably the pioneer projectile forms a head to the at least one therapeutic compound or the formulation containing the at least one therapeutic compound.
The at least one therapeutic compound or the formulation containing the at least one therapeutic compound can take a number of forms.
In one embodiment the at least one therapeutic compound or the formulation containing the at least one therapeutic compound is a liquid contained in a water soluble, lipid soluble or otherwise biodegradable membrane.
In another embodiment the at least one therapeutic compound or the formulation containing the at least one therapeutic compound is provided in a solid form such as, for example, crystals, particles, granules, beads, rods, discs or a combination thereof.
In yet another embodiment the at least one therapeutic compound or the formulation containing the at least one therapeutic compound is provided as a viscous liquid, semi solid, gel or paste which may be further supported, if desirable, by a water soluble lipid soluble or otherwise biodegradable membrane.
In the method of the invention the skin is penetrated and the therapeutic compound administered at a low velocity. By low velocity is meant less than 100 m/s. Preferably the velocity is less than 10 m/s, more preferably still less than 5 m/s and most preferably in the order of a few m/s.
Since the injectate is pushed at a low velocity rather than fired at a high velocity it is possible to ensure that the dosage is always delivered to the correct (and same) depth under the skin. This means that the system can be used on different skin types and skin locations and the dosage will still be delivered to the same depth.
According to a second aspect of the invention there is provided a method of facilitating the delivery of at least one therapeutic compound or a formulation containing the at least one therapeutic compound to a human or animal as a needleless injection comprising:
i) Providing a water soluble, lipid soluble or otherwise biodegradable pioneer projectile having a diameter of less than 3 mm capable of penetrating the human or animals skin; and ii) Providing directly, or substantially directly, behind the pioneer projectile, the at least one therapeutic compound or the formulation containing the at least one therapeutic compound in a contained state.
The act of pushing the at least one therapeutic compound in the contained state causes the pioneer projectile to penetrate the human or animals skin and the therapeutic compound or the formulation containing the at least one therapeutic compound follows the pioneer projectile and is introduced into the human or animal in the contained state.
The invention also extends to novel pioneer projectiles.
According to a third aspect of the present invention there is provided a water soluble, lipid soluble or otherwise biodegradable pioneer projectile having a diameter of less than 3 mm, and which is capable of penetrating the skin of a human or animal to thereby facilitate the injection of at least one following therapeutic compound or therapeutic compound containing formulation in a contained state, comprising:
i) A first “penetrating” face which in use penetrates the human or animals skin and ii) Remote from the first face a second “driven” face which in the course of injection is the face upon which a driving force is exerted through the contained therapeutic compound or therapeutic compound containing formulation; characterised in that said pioneer projectile has an aspect ratio (width to height) of less than 1:10.
Because the pioneer projectile has been developed separately of the medication it has been possible to reduce its size from one of at least 10 mm in length to about a few millimeters. It has also been possible to optimise its shape such that it functions as a leading head or tip for a following contained formulation the two components forming an injectate.
Preferably the pioneer projectile has an aspect ratio of less than 1:8, preferably less than 1:6, more preferably less than 1:4, more preferably still less than 1:3, and most preferably about 1:1.5.
Preferably the pioneer projectile is less than 3 mm in width, more preferably still less than 2.5 mm through 2 mm and 1.5 mm to about 1 mm in width.
Preferably the pioneer is less than 10 mm in height, more preferably about 1.5 to 2 mm in height. By reducing the height to a minimum it is possible to maximise the amount of therapeutic compound being injected. In this regard it should be noted that if the combined pioneer projectile and following drug formulation is too long it might not be possible to deliver the drug to the optimum depth.
In one embodiment the pioneer projectile is free of any therapeutic compound. In another embodiment it comprises at least one therapeutic compound. Thus, for example it might be beneficial to include, for example, an antibiotic in the pioneer projectile or have it release a therapeutic compound at a different rate to the formulation in, for example, the case of insulin injections.
The skin penetrating face of the pioneer projectile preferably comprises a cutting element to facilitate entry. This may take the form of a sharp point or an oblique edge. Alternatively the skin penetrating face may be blunt or gently curved.
In one embodiment the face for contacting the therapeutic compound or therapeutic compound containing formulation in a contained state is flat. Alternatively it may be concave or otherwise hollowed to facilitate pushing and formulation containment.
The pioneer projectile may be made of any suitable material. Suitable materials are those hard and rigid enough to facilitate penetration at low velocities. Preferred materials include glassy materials e.g. the sugar glasses as noted in WO 98/41188 which materials are included herein by reference. The term “sugar” thus covers not only disaccharide sugars, such as, trehalose, but also monosaccharide sugars and their non reducing derivatives, such as, sugar alcohols including: mannitol, inositol, xylitol, ribitol and the like, which form a general class of stabilising glass-forming sugars and sugar derivatives. The term “sugar glass” is to be understood as covering not only glasses which are readily and rapidly dissolved in an aqueous environment, such as, trehalose but also sugar glasses in which the sugar molecule has been modified by the attachment of one or more hydrophobic side chains to make the glass more slowly soluble in bodily fluids than the native sugar in order to give controlled release characteristics.
In some circumstances the pioneer projectile may comprise a barrier material over at least the face that contacts the therapeutic compound in a contained state or vice versa such that the respective components will not react with one another.
The invention also extends to novel formulations.
According to a fourth aspect of the present invention there is provided a therapeutic compound or therapeutic compound containing formulation which is held in a contained state and adapted for introduction into a human or animal in the form of a needleless injection behind a water soluble, lipid soluble or otherwise biodegradable pioneer projectile having a diameter of less than 3 mm.
Preferably the formulation comprises less than 50 mg of therapeutic compound in a volume of less than 50 mm 3 , more preferably less than 10 mg of therapeutic compound in a volume of less than 10 mm 3 .
The therapeutic compound or therapeutic compound containing formulation may be provided as a liquid contained in water soluble, lipid soluble or otherwise biodegradable membrane.
In an alternative embodiment the therapeutic compound or therapeutic compound containing formulation is provided in a solid form comprising for example crystals, particles, granules, beads, rods, discs or a combination thereof which are generally likely to be more stable than traditional non-viscous liquid formulations with a viscosity similar to that of water e.g.1 Centipoise or glucose e.g. 500 Centipoises.
In a preferred embodiment the therapeutic compound or therapeutic compound containing formulation is provided as a semi solid, gel or paste. In this form it is particularly patient compliant and the therapeutic compound is generally likely to be more stable than if it were in a traditional non-viscous liquid formulation.
Where the therapeutic compound or therapeutic compound containing formulation is a viscous liquid, it preferably has a viscosity of at least 10,000 Centipoises more preferably at least 50,000 Centipoises and more preferably still at least 100,000 Centipoises.
The formulation may comprise an end piece beyond the therapeutic compound or therapeutic compound which is free of the “active” being injected thus ensuring that the entire therapeutic compound enters the patient in a unit dose rather than risk under or over dosing.
The therapeutic compound or therapeutic compound containing formulation may comprise a plurality of differently formulated elements.
The therapeutic compound or therapeutic compound containing formulation may be packaged in a cap, cartridge, carousel or cassette.
The invention also extends to an injectate comprising a pioneer projectile and a therapeutic compound or therapeutic compound containing formulation.
According to a fifth aspect of the present invention there is provided a needleless injectate for injection comprising:
a) A water soluble, lipid soluble or otherwise biodegradable pioneer projectile having a diameter of less than 3 mm; and b) A therapeutic compound or therapeutic compound containing formulation which is held in a contained state behind the pioneer projectile.
These components are as previously described.
The pioneer projectile and therapeutic compound or therapeutic compound containing formulation may both be water soluble, lipid soluble or otherwise biodegradable to differing degrees.
A barrier may be provided between the pioneer projectile and the therapeutic compound or therapeutic compound containing formulation.
The injectate may be contained/packaged in a cap, cartridge, carousel or cassette optionally together with a means, e.g. an ejector pin, for pushing the pioneer injectate out of its container.
Alternatively the pioneer projectile and the therapeutic compound or therapeutic compound containing formulation are contained/packaged in separate caps, cartridges, carousels or cassettes.
The invention also extends to a device for injecting a pioneer projectile and a therapeutic compound or therapeutic compound containing formulation.
According to a sixth aspect of the present invention there is provided a needleless device ( 60 ) for injecting a water soluble, lipid soluble or otherwise biodegradable pioneer projectile ( 10 ) having a diameter of less than 3 mm and at least one contained therapeutic compound or therapeutic compound containing formulation ( 42 ) into a human or animal body, said device comprises a housing ( 62 ) containing a mechanism ( 92 ) capable of generating a force which will cause a striker ( 84 ) to travel along a striker guide ( 86 ), said housing having an end face ( 100 ) which is in operative communication with a component ( 72 ) comprising a casing ( 74 ) having an aperture ( 76 ) in which is mounted an ejector pin ( 78 ) and, therebelow, an injectate ( 40 ) comprising a pioneer projectile ( 10 ) and a formulation ( 42 ) such that in use the striker will contact the ejector pin and the injectate will be pushed out of the casing as a single unit into the human or animal body.
The reference numerals given above are non-limiting but have been included solely for the purpose of assisting the reader.
The term ejector pin is intented to cover a pin, piston, rod or like member which functions to push the injectate from the aperture.
The power source for initiating or assisting the pushing may be a mechanical spring in the form of, for example, a coiled spring or a lever spring. Alternatively, a gas spring might be used or even an electrically powered system. A mechanical spring would allow reuse of the delivery system although this would mean the user has to recharge the spring between administrations. Alternatively, the spring (mechanical or gas) could be precharged during manufacture so that it can only be used once and then the whole system would be thrown away. In a reusable device there will be a throw away component containing the pioneer projectile or the pioneer projectile and the therapeutic compound or therapeutic compound containing formulation.
The device preferably incorporates a safety mechanism to avoid accidental actuation. Actuation might be triggered with a push button on the device but preferably would be undertaken by pushing the device against the skin thus ensuring good contact with the skin on actuation.
In a reusable device the reusable component and the throw away component comprise means by which they are connected to one another.
The device may be adapted to inject multiple doses either sequentially or simultaneously. In one embodiment the device comprises a cartridge, carousels or cassette containing a plurality of pioneer projectiles or a plurality of injectates comprising a pioneer projectile and a therapeutic compound or therapeutic compound containing formulation.
In another embodiment the device comprises a cap containing a single pioneer projectile and a single unit dose of the therapeutic compound or therapeutic compound containing formulation.
The various aspects described above give rise to a system having a number of advantages over the prior art delivery methods and some of these are noted in table 2 below:
TABLE 2
Benefit
Justification
1
Can use
Many drugs are more stable in solid form than in a
formulations with
liquid state. A viscous liquid formulation would be
Increased Product
more akin to a solid drug in terms of its stability
Stability.
characteristics because of the excipients that can be used
2
Improved Product
The increased stability with some compounds may
Storage
allow storage of the final delivery system at room
temperature rather than requiring refrigeration
3
Reduced Risk Of
Without the need for needles there is a reduced risk of
Cross Infection
blood borne diseases
4
Small Device Size
Spring, trigger, injectate and piston are the main
components required
5
Cheap Device
A spring is a cheap power source. Small overall
number of device components
6
Reusable Device
The design can allow for the spring to be primed for
reuse. Disposable components would be small in
terms of size and cost but would include the
component holding the injectate or pioneer projectile
7
Variable Power System
A spring-powered device could allow the tension on
the spring to be altered for different skin types and
skin positions on the body, if necessary.
8
Small Skin Response
As experienced with splinters
9
Quiet Device
Actuation of a spring powered delivery system will be
quiet
10
Easy to Understand
Easy to comprehend the forces involved in pushing a
Delivery System
foreign body into the skin to a known depth. Easy to
measure the physical characteristics required for a
‘dose’ of injectate of this size
11
Variable Dose
With a viscous injectate it will be possible to alter the
dose injected
12
Self Injection
With a simple system patients can inject themselves,
thus reducing healthcare costs
13
Controlled Depth Of
Pushing the injectate into the skin rather than firing it
Penetration Of The
enables a consistent and controlled depth of
Delivered Dose
penetration in the skin
14
Large Doses
Large doses of one or more drugs are achievable by
Achievable
having one or more doses of injectate administered in
the same injection
The concept behind the invention allows for a simple needleless drug delivery device that pushes a drug in a “contained” state.
A semi solid, paste or gel is the preferred form since unlike a non-viscous liquid it would follow the pioneer projectile. (A non-viscous liquid can “splash back” and more easily seep around the track formed by the pioneer projectile.) Its stiffness relative to a non-viscous liquid also means it is easier to push than a non-viscous liquid material. The more solid in nature the better this is. However from a comfort perspective a semi solid or paste or gel is more likely to be patient compliant and dissolve more readily in the body.
The delivery device for delivering such an injectate (pioneer projectile and formulation) could take a number of forms and one such device is described by way of example.
The device described is a spring-powered device with the spring, triggering the pushing of a pin. The pin then engages the injectate to push it into the skin with the pin being stopped by either an end stop within the device or by coming into contact with the skin, preferably over a relatively wide area (compared to the injectate) to reduce the force felt on the skin.
If the device is to be reusable then the component holding the injectate might be detached from the rest of the device and thrown away and a new disposable component attached before the next injection. The injection itself would occur in a matter of milliseconds after actuation and would seem instantaneous as far as the user is concerned. Alternatively the formulation might be injected from, for example, a tube and a new pioneer projectile would be required for a further injection.
The various aspects of the invention will now be described, by way of example only, with reference to the following drawings and Examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a - e are embodiments of pioneer projectiles of varying shapes and sizes;
FIGS. 2 a - c are embodiments of pioneer projectiles with hollow driven faces;
FIGS. 3 a - d are embodiments of pioneer projectiles with an oblique cutting edge;
FIGS. 4 a - c are embodiments of pioneer projectiles with an oblique cutting edge and hollow driven faces;
FIGS. 5 a - c are a plan view, side elevation and end elevation respectively of a pioneer projectile with an oblique cutting edge;
FIGS. 6 a - c are a plan view, side elevation and end elevation respectively of a pioneer projectile with a central piercing point and faceted sides;
FIGS. 7 a - c are a plan view, side elevation and end elevation respectively of a pioneer projectile with a central cutting edge;
FIGS. 8 a - c are a plan view, side elevation and end elevation respectively of a pioneer projectile with a central piercing point;
FIG. 9 is one embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 10 is another embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 11 is another embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 12 is another embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 13 is another embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 14 is another embodiment of an injectate of the invention shown housed in a support or device chamber;
FIG. 15 is another embodiment of an injectate of the invention shown housed in a support or device chamber; and
FIG. 16 is cross sectional view of a delivery device of the invention.
DETAILED DESCRIPTION
Referring to the drawings, FIG. 1 a is a side elevation of a pioneer projectile 10 according to one aspect of the present invention. It is made of a crystalline or amorphous material, preferably a glassy material, (e.g. a sugar glass such as trehalose, palatinit, glucopyranosyl sorbitol, glucopyranosyl mannitol, lactitol or monosaccharide alcohols such as mannitol or inositol) which is water-soluble and dissolves in the body. The material may include a hardening agent, such as, for example, povidone (pvp). The pioneer projectile comprises a penetrating face 12 comprising one of more facets, which has a central point, one or more guiding faces 16 for guiding the pioneer projectile within a central aperture or chamber of a needleless device for injecting an injectate (comprising the pioneer projectile and a formulation) thus ensuring the pioneer projectile meets the skin at a suitable angle to aid penetration, and a driven face 14 . The pioneer projectile has an aspect ratio (width W to height H) of about 1.25:1.
The pioneer projectile can however take a number of forms and some further embodiments are illustrated in FIGS. 1 b - d , FIGS. 2 a - 2 c , FIGS. 3 a - d , FIGS. 4 a - c , FIGS. 5 a - c , FIGS. 6 a - c ; FIGS. 7 a - c and FIGS. 8 a - c.
Briefly: FIG. 1 b illustrates a pioneer projectile with a very small aspect ratio of about 1:0.5; FIG. 1 c illustrates a pioneer projectile with an aspect ratio of about 1:2; FIG. 1 d illustrates a pioneer projectile with a blunt and planar penetrating face 12 , and an aspect ratio of about 1:0.2; and FIG. 1 e illustrates a pioneer projectile which does not have a guiding face 16 but consists of a penetrating face 12 and a driven face 14 .
FIGS. 2 a to 2 c illustrate variations in the driven face 14 . Thus in FIG. 2 a the driven face is completely hollowed forming a void 18 which can hold, at least in part, at least one therapeutic compound or compound containing formulation. In FIG. 2 b the hollow 18 has a flat bottom 20 and in FIG. 2 c it has a concave bottom 22 .
Of course, the penetrating face 12 need not have a central point and FIGS. 3 a - d , and 4 a - c illustrate embodiments in which the pioneer projectiles have an oblique cutting edge 24 .
The shape of the penetrating face can, as noted above, take a number of forms as exemplified with reference to FIGS. 5-8 . In each of these FIGS. a) is a plan view; b) is a side elevation and c) is an end elevation. Thus:
In FIG. 5 the pioneer projectile is circular in x-section ( FIG. 5 a ), has an oblique cutting edge 24 ( FIG. 5 b ), and a planar penetrating face 12 ( FIG. 5 c ).
In FIG. 6 the pioneer projectile is circular in x-section ( FIG. 6 a ), has a central point 26 ( FIG. 6 b ), and four facets 28 making up the penetrating face 12 ( FIG. 6 c ).
In FIG. 7 the pioneer projectile is circular in x-section ( FIG. 7 a ), has a central cutting edge 30 ( FIG. 7 b ), and two facets 28 making up the penetrating face 12 ( FIG. 7 c ).
In FIG. 8 the pioneer projectile is circular in x-section ( FIG. 8 a ), has a conical penetrating face ( FIG. 8 b ), culminating in a point 30 and a penetrating face 12 ( FIG. 8 c ).
Of course the pioneer projectile need not be circular in cross section but could be, for example, three sided (triangular), four sided (square) or indeed any other suitable shape.
A pioneer projectile might be manufactured in a number of ways such as by moulding, extrusion or sectioning a rod of the material.
Preferably the pioneer projectile will dissolve in the tissue in a matter of minutes or hours depending on the material used.
The pioneer projectile together with at least one therapeutic compound or formulation forms an injectate.
The physical characteristics of the formulation are very important to ensure that the injectate can be administered to the skin in a reliable and repeatable manner
The formulation could take a number of forms:
In one embodiment it might take the form of a paste. This can be achieved by mixing the active drug with the appropriate excipients to end up with consistency, say, like toothpaste. The excipients would obviously need to maintain the active ingredient in a condition such that it was still active during manufacture, storage and administration.
In other embodiments the formulation will be a semi solid, gel, solid or contained liquid.
The therapeutic component of the formulation might be present in one or more of the following formats:
1. Pure drug; 2. With excipients to alter the physical characteristic of the material; 3. With excipients to bulk out the active ingredient; 4. With excipients to buffer the active ingredient; 5. With excipients to change the release profile of the active ingredient; and 6. As a mixture of more than one therapeutic compound.
The formulation can be designed to give the desired release profile for the application. This might involve either a sustained release formulation or a quick dissolving formulation for immediate release into the body. In some cases, such as for the administration of insulin, a formulation might be required that provides an immediate release of some of the therapeutic compound and then a sustained release of another component in the formulation. This might for example be achieved by having the formulation in a plurality of parts or by incorporating a medicament into the pioneer projectile.
Alternatively the therapeutic compound might be formulated as small beads. A number of the beads could be lined up in the device behind a pioneer projectile. On actuation of the device the pioneer projectile pierces the skin and the beads are pushed into the skin behind the pioneer projectile.
The therapeutic component of the formulation must of course not react with the material used for the pioneer projectile or the materials used in the delivery system.
FIGS. 9 to 15 are some embodiments illustrating injectates and formulations of the invention.
In FIG. 9 an injectate 40 comprises a pioneer projectile 10 and a formulation 42 . The formulation is in a contained state supported by its own viscosity or a membrane 44 . The formulation is thus a contained liquid or a solid. The injectate may be self-supporting or contained in an optional support 46 which may be a chamber 76 of a device or a throwaway component.
In FIG. 10 the formulation is a high viscosity liquid, gel, paste or semi-solid.
FIG. 11 illustrates an injectate comprising a plurality of different formulations 42 a , 42 b and 42 c . These could be formulations with different release profiles or different active ingredients, for example combination therapies. Though not illustrated there could be membranes between the components e.g. lipid soluble membranes between water-soluble formulations and or an end piece.
FIGS. 12 , 13 and 14 illustrate injectates with different solid formulations. In FIG. 12 the solid formulation takes the form of beads 46 . In FIG. 13 and 14 they are granules, particles or crystals 48 .
In FIG. 15 a barrier 50 is shown between the formulation 42 and the pioneer projectile 10 .
The skilled man will of course realise that the features illustrated with reference to one embodiment could easily be applied to other embodiments.
An injectate will be introduced into a human or animal using a device that injects the injectate in a needleless manner.
One such device is illustrated by way of example only in FIG. 16 .
The needleless injection device 60 is shown in the primed position. It comprises an outer housing or holder 62 the lowermost end 64 of which is slidably mounted over the uppermost end 66 of an innermost casing 68 .
At the lowermost end 70 of innermost casing 68 is fitted a disposable component 72 such as, for example, a drug cassette. The disposable component comprises a casing 74 having a central aperture or chamber 76 in which is mounted the injectate 40 comprising the pioneer projectile 10 and the formulate 42 . A large headed ejector pin 78 comprising a flat head 80 and an elongate body 82 is positioned over the injectate 40 so that when the ejector pin is contacted, in use, by a striker 84 it is pushed along the aperture or chamber 76 and out into the patient. A resilient member 87 , such as a rubber block urges the ejector pin back a little after injection.
The disposable component 72 is loaded into the needleless injection device, by for example, screwing it into the lowermost end 70 of the inner housing 68 . Mounted within the innermost housing 68 is a striker guide 86 having a surface 88 which maintains a detent 90 in the loaded position (shown) and houses an actuating mechanism or spring 92 and spring follower 94 .
The disposable component 72 is shaped such that when it is in contact with the skin it pre-tensions it prior to actuation. This ensures that the dosage will penetrate the skin rather than just stretch the skin.
The injector pin 78 is designed to push the injectate beyond the end of the device by up to (say) 2.5 mm. This means that the end of the injector pin (which preferably has the same profile and diameter as the end of the pioneer projectile) might just penetrate the skin but it would ensure that the injectate has been fully administered into the skin.
Prior to actuation, the tip of the injectate might be in contact with the skin. However, it is preferred that the tip is a few millimeters away from the skin prior to actuation. This ensures that the injectate is moving when it impacts the skin and also ensures that the tip of the injectate does not start to dissolve, and therefore soften the tip, with any moisture from the skin surface when the device is placed on the skin.
To use the device 60 the outer most casing is retracted (pulled in the direction of arrow A) so that it slides against the innermost housing 68 . This action causes the spring 92 to be compressed, and the detent to be moved from a vertical position to the position shown where it is held stable against surface 88 . In the process a quill spring 96 stabilises the detent by abutting against a surface 98 . Once loaded the disposable component, is screwed into the end 70 of the innermost housing 68 of the device 60 .
The injector pin 78 that pushes the injectate into the skin is preferably, (but not necessarily) in contact with the injectate prior to actuation.
To actuate the device a user, for example, grips the device around the outer housing 62 with their thumb over the end cap 102 . The end face 100 of the disposable component 72 is positioned against a patient's skin, which should be held taught, and the outer housing 62 is pushed in a direction away from arrow A. This action causes the outermost casing to slide over the inner housing 68 . As it does so the detent is caused to rotate about it's axle 104 as a result of the detent riding up inclined wall 106 . This forces the quill spring 96 out (as shown by the broken line). When the detent reaches a vertical position the coil spring releases its stored energy and assists in ensuring the striker 84 travels along the striker guide 86 until it contacts the head 80 of the ejector pin 78 with a force that causes the injectate 40 to pierce the skin. The ejector pin 78 continues to push the formulation 42 into the patient to the required depth, which is determined by the length of the injectate and the extent to which it is pushed by the ejector pin 78 . The rubber stop 87 is squashed by the ejector pin head 80 during delivery of the injectate but the elastic properties of the rubber stop 87 enable the tip of the ejector pin to be withdrawn into the disposable component 72 of the device.
Injection Sites
The injectate could potentially be injected in a wide number of sites across the human or animal body. The easiest direction to administer the injectate is perpendicular to the skin and so with most skin sites this would mean penetrating the epidermis into the dermis and, depending on the skin thickness, into the subcutaneous layers or muscle. The ‘best’ injection sites might therefore be those where there is the smallest density of nerve endings to avoid any pain that might be associated with the injection. This might include injections to the back or to the lobe of the ear.
Alternatively, injection sites might include those with a thicker epidermis so that the injectate does not penetrate into the dermis where the nerve endings are located. The injectate might be injected obliquely into the skin so that it is located totally in the epidermis. The same result might be achieved by injection into a fold of skin that has been pinched.
The elastic properties of the skin can be employed to seal the skin after the injectate has been administered, as is often the case with splinters. This ensures the drug does not leak from the skin as it dissolves.
The most likely area of the body for drug administration with this technology is the stomach because of the high fat content and easy accessibility for self-administration. An alternative might be the thigh although this is often less accessible if the recipient is wearing trousers.
Product Applications
There are many possible product applications for this technology because of the doses that are achievable including therapeutic, prophylactic and diagnostic applications. Illustrative examples include, but are not limited to:
Conventional Vaccines—first and third world applications or veterinary applications; Insulin; Migraine Treatments; and Hormones.
The term “at least one therapeutic compound or a formulation containing at least one therapeutic compound” as used in this application is intended to cover prophylactic and diagnostic applications as well as therapeutic applications.
The maximum dose that could be delivered using the technique will depend upon a number of factors. However, an injectate with an overall length of approximately 4.0 mm and a diameter of approximately 1.0 mm (similar to a 19 G venflon) would be sufficient to allow a dose of approximately 2 mg of a standard therapeutic in one administration. This magnitude of dose would be suitable for each of the applications exemplified above. If several doses of injectate are delivered simultaneously then there is the potential for an even larger number of applications.
Delivery of the injectate will be very quick and any pain associated with the delivery technique should not be any worse than a needle of similar dimensions. If the delivery technique were painful then it would be possible to anaesthetise the tissue prior to the injection. To avoid needles then this anaesthetic might be given with a patch, a spray or a cream.
EXAMPLE 1
Drug Splinters.
A rod of 0.9 mm diameter pencil lead was broken to lengths of approximately 6 mm and a point was sanded on one end of each length and a flat on the other to create solid splinters. The splinters were placed in a drug package and successfully administered to pig skin using a prototype delivery system.
EXAMPLE 2
Pioneer Projectile Followed by a Solid Rod.
The same pencil lead detailed in example 1 above was cut into short lengths of approximately 3 mm in length. These had a point sanded on one end and a flat on the other end to create pioneer projectiles. Further rods of the same pencil lead were cut at approximately 4 mm in length and had both ends sanded flat. When a pioneer projectile and a solid rod were placed in a drug package they were successfully administered to pig skin using a prototype delivery system.
EXAMPLE 3
Pioneer Projectile Followed by a Soft Rod.
A soft rod of wax was extruded through a die and rods of approximately 4 mm in length were cut with a flat at each end. Further sections were cut with a point at one end and a flat at the other end. When a pointed section (identical in shape and size to the splinter used in example 1) was administered to pig skin using a drug package the wax did not pierce the skin but was flattened on the skin surface. When a rod of the same waxy material was placed behind a pioneer projectile used in example 2 and administered to pig skin using a drug package then both the pioneer projectile and the waxy material were successfully delivered into the tissue. The wax material used for this experiment could easily be squashed between a finger and a thumb.
EXAMPLE 4
Pioneer Projectile Followed by Solid Beads.
Beads of diameters 0.5-0.75 mm were placed in a drug package behind a pioneer projectile as detailed in example 2. The pioneer projectile and all the beads were successfully administered to pig skin using a prototype delivery system.
The experiments outlined above demonstrated that a range of different materials could be delivered behind a solid pioneer projectile. Ideally it is preferred that the pioneer projectile is manufactured from pharmaceutical grade compounds that will dissolve in the target tissue. Two processes have been used to produce such pioneer projectiles as outlined below:
EXAMPLE 5
A hot melt of sugars is produced which can then be moulded into the correct form for a pioneer projectile or extruded to produce long rod. If an extrusion process is used then the pioneer projectiles can be cut to shape from the soft extrudate or the sharp ends of the pioneer projectile can be formed when the extrudate has solidified. This process produces a material similar to a boiled sweet which can be very hard and incorporate a sharp point on one end.
EXAMPLE 6
A mix of powders is produced using pharmaceutical grade sugars together with a hardening agent such as polyvinylpyrolidone (PVP). The powder blend is extruded through a die to produce a long rod of the compound. Some blends require a lubricant to facilitate the extrusion and binding process such as water or ethanol. The pioneer projectiles are formed by cutting the long rod into short sections. This process can be facilitated by using a hot knife. If necessary, the point or flat end of the pioneer projectile can be created by sanding or filing a short rod of the extrudate.
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The invention relates to a novel drug delivery technology. More particularly the invention relates to a method of delivering at least one therapeutic compound or a formulation comprising the at least one therapeutic compound to a patient: to a throwaway or reusable device for delivering at least one therapeutic compound or a formulation comprising the at least one therapeutic compound to a patient in a manner as set out by the method; to a pioneer projectile form use in said method; to formulations for use in said method and to an injectate comprising a pioneer projectile and formulation. It also relates to a disposable component containing either a pioneer projectile or an injectate.
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This is a division of application Ser. No. 09/310,873 filed May 12, 1999, now U.S. Pat. No. 6,354,000.
BACKGROUND OF THE INVENTION
The present invention relates to a method for making a planar array of independently connected electrical contact pads connected through multiple layers of conductive paths. There are many applications for this type of device. For example, such a device may be used to provide a rectilinear array of pads for testing of ball grid array (BGA) modules or circuit boards with BGA interconnect patterns that are too small to be tested by conventional pin probe testers. Another application is to provide for interconnection to a similarly patterned array of independently connectable electrical contact pads in an electrically stimulated array. The requirement that the electrical contact pads be independently connectable creates a conductive path routing and cross-talk suppression challenge.
One use for a planar array of independently connectable electrical contact pads is for electrical stimulation of, and electrical reception from, an ultrasound array. For a more complete description of the requirements for a connector to an ultrasound array, please see U.S. Pat. No. 5,855,049, issued Jan. 5, 1999, which is hereby incorporated by reference as if fully set forth herein. As noted in this reference, it is typical to use a flex circuit electrical contact pad array for the purpose of electrically connecting an ultrasound array to take advantage of the acoustical and mechanical characteristics of a flex circuit. A flex circuit has enough flexibility to permit a full set of connections without suffering the effects of the gaps that can be created by slight nonuniformities between two rigid surfaces. In addition, the flex circuit can be flexibly routed to connect the array to external circuit boards or cabling.
Another use for an array of independently connectable electrical contact pads is for attachment to the terminals of an integrated circuit (IC) die. IC dies are typically produced having a set of terminals along the periphery of the die and with the terminals mutually spaced apart by 50 to 100 microns. The die is typically placed in a package to form an outside interconnect pitch of 1.27 mm or smaller, for connection to a PCB. The IC die terminals are typically connected to an intermediate chip scale package circuit by means of wire bonding or by flip chip mounting to a flex circuit that expands outwardly from the die perimeter to a larger rectilinear array. The principle reason why the IC die terminals are arranged solely along the perimeter of the IC die is because of the limitations of wire bonding and flex circuit manufacturing technology. If a flex circuit having a partial or full rectilinear array of interconnect pads with a pitch on the order of tens of microns could be efficiently produced, this would permit IC dies to be produced having terminals in a matching array, thereby permitting more terminals into and out of the IC, a highly desirable goal.
Yet another application for planar array of independently connectable electrical contact pads, is in the testing of PCBs. It is highly desirable to test a PCB after production but prior to connecting circuitry to the PCB. If a flaw in the PCB is discovered after circuitry has been connected to the PCB, the entire circuit must typically be discarded. For a PCB having a tightly pitched array of terminals for connecting to a ball grid array, however, it may be extremely difficult to form a test connector that independently contacts each one of these terminals. It would, therefore, be highly desirable to have a tightly packed planar array of independently connectable electrical contact pads for the purpose of forming a test connector for a PCB bearing tightly packed arrays of electrical contact pad contacts or to convert the tightly pitched array of terminals to a less tightly packed array which can be tested by conventional means. In addition, a tightly packed planar array of electrical contact pads can also be used to test the ball grid array IC circuit itself.
One method used to construct planar arrays of independently connectable electrical contact pads is known as the “thin film\wet chemistry” process of building up a flex circuit layer by layer. Each dielectric layer is spin coated on to the top of the previously created laminate structure, then drilled or etched, plated and patterned. For via interconnects, a pad is first formed on a deposited layer for connection to the prospective next layer to be deposited. After the next layer is deposited a blind via is drilled to the underlying pad, followed by platting and patterning of a pad directly over the via, forming an electrical connection to the pad below. The disadvantages of this method are that it is expensive and a mistake on any layer can ruin the entire flex circuit.
Another traditional method to construct planar arrays of independently connectable electrical contact pads has been to join together conductively patterned dielectric layers each having mutually co-located connective pads. Individual patterned dielectric layers are first bonded together, typically through an intermediate dielectric, followed by via drilling and plating through the mutually co-located electrical contact pad pads to connect one layer to the next. Typically the connective paths are patterned to allow through hole drilling to connect layers. As additional layers are added they are drilled and plated to form connections. There are two principle problems associated with this method. First, many process steps are involved to drill and plate the various layers. Second, the accuracy required to align the various layers and successfully drill and plate to connect them severely limits the array density. If through hole drilling instead of blind vias are used to connect layers, the traces must be routed so as to avoid drilling through traces running above or below the layer to be connected, further limiting the array density.
Yet an additional method of constructing an array of contact pads interconnected through a multi-layer structure involves laminating patterned circuits together using anisotropic or z-axis adhesives which connect conductive portions of the individual layers together without forming a conductive short to neighboring traces. A disadvantage of this approach is the additional complexity involved in laying out the conductive circuit patterns as well as the higher cost and uncertain reliability of the anisotropic connective approach.
Although it theoretically might be desirable to adhere together a stack of layers bearing conductive paths to a top layer bearing an array of electrical contact pads and then drill and plate vias to connect each electrical contact pad to a target conductive path on an inner layer, a number of problems are presented in any attempt to implement such a method of construction. First, it is a challenge to drill through several layers without drilling through a conductor on a layer interposed between the drilling surface and the target conductive path. Second, some target conductive paths may be by necessity very thin, on the order of microns, presenting a challenge to one attempting to accurately drill a via to the target conductive path. Our invention addresses these limitations as described below.
SUMMARY OF THE INVENTION
The present invention is a method of constructing an electric apparatus, comprising the following steps. First, a set of dielectric layers is provided. Next, a set of conductive features and at least one fiducial marking are formed on a first one of the dielectric layers, in mutual reference to each other so that their relative positions are known to a first tolerance. Then, a set of pin holes is formed in each dielectric layer, each pin hole formed in relation to the fiducial marking for its dielectric layer and all of the sets of pin holes having a mutually identical placement. Finally the dielectric layers are arranged onto a pin fixture having a set of pins that match the mutually identical placement of the pin holes.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a greatly expanded plan view of a planar array of electrical contact pads born on the top surface of an electrical interconnecting device produced according to the present invention.
FIG. 2 is a greatly expanded plan view of a set of traces etched onto the bottom surface of the dielectric layer of FIG. 1 .
FIG. 3 is an expanded plan view of a copper plating pattern on the top of the second, third and forth dielectric layers of the planar array of electrical contact pads apparatus of FIG. 1 .
FIG. 4 is a greatly expanded plan view of the traces on the bottom of the second dielectric layer of the interconnecting device of FIG. 1 .
FIG. 5 is a greatly expanded plan view of the traces on the bottom of the third dielectric layer of the interconnecting device of FIG. 1 .
FIG. 6 is a greatly expanded plan view of the traces on the bottom of the forth dielectric layer of the interconnecting device of FIG. 1 .
FIG. 7 is a greatly expanded cross-sectional view of the device of FIG. 1, taken along line 7 — 7 of FIG. 1 .
FIG. 8 shows a pair of layers being positioned on a fixture, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, in a preferred embodiment, the method of the present invention produces an interconnecting device 8 , such as a flex-circuit, having an array of active interconnect pads at electrical contact pad sites 12 and ground interconnect pads at sites 14 . As noted in the Brief Description of the Drawings Section, FIG. 1 is greatly enlarged, with the actual total size of array 10 being on the order of a square centimeter and each active interconnect pad site 12 being on the order of 300 microns square. Each active interconnect pad must be individually and uniquely conductively connected to a pin on the outer edge of device 8 (not shown). The ground electrical contact pads should be all conductively connected together and also connected (with a maximum conductivity) to a pin or set of pins at the exterior of device 8 . Noting the array dimensions, it is apparent that the problems involved in connecting all of the active interconnect pad sites 12 to pins at the exterior of device 8 without permitting appreciable cross-talk are considerable.
The preferred method begins with the etching, by photolithography, of a set of conductive features (when the term “conductive” is used in the detailed description portion of this application, the preferred material to be used is either copper or gold) on a set of dielectric (preferably polyimide) layers 110 , 112 , 114 and 116 each having two opposed surfaces of which top surface 110 a and bottom surfaces, 110 b , 112 b , 114 b , and 116 b are shown in the drawings. Each layer surface 110 a through 116 b is etched to combine with the other layer surfaces 110 a through 116 b in a prospective stack 118 in a predetermined order according to preplanned distance from top surface 110 a , which is to be etched as shown in FIG. 1 .
Referring to FIGS. 2 and 4 - 6 , the bottom surface 110 b is etched with a set of first conductive traces 120 which are arranged to connect some of the active electrical contact pad sites 12 to pins at the exterior of device 8 (not shown). These traces 120 define a first interior perimeter inside of which none of the traces 120 on surface 110 b extend. A set of second conductive traces 122 are etched onto the bottom of surface 112 b of the second layer 112 as shown in FIG. 4 . These traces 122 all terminate inside the first interior perimeter defined by first traces 120 and, in turn, define a second interior perimeter inside of which none of the second traces 122 extend. In turn, a set of third conductive traces 124 are etched on surface 114 b and extend beyond the second interior perimeter and define a third interior perimeter. Finally, a set of forth conductive traces 126 are etched onto surface 116 b and extend beyond the third interior perimeter.
A set of ground traces 130 are etched onto surface 110 b for attachment to ground 14 . There is no need to keep the traces 14 separate and traces 14 are, indeed, all connected together as shown. In an alternative preferred embodiment, these traces are not needed and are not present. For example, in the case where device 8 is used for PCB testing, only active interconnect pads are needed, eliminating the need for ground traces 130 .
Each of the interposed top surfaces of 112 , 114 and 116 is etched with the pattern of conductive material shown in FIG. 3 (drawn to a much smaller scale than FIGS. 1, 2 , 4 , 5 and 6 ). A central region 146 that is bare of conductive material corresponds to the area shown in FIGS. 1, 2 , 4 , 5 and 6 for either the bottom surface of layers 112 , 114 and 116 (FIGS. 4, 5 and 6 ) or the corresponding area on the top or bottom of the top layer 110 (FIG. 1 ). Conductive material plated onto this area on top surfaces of 112 , 114 , or 116 would interfere with subsequent drilling and interconnection of top surface pads 12 to bottom surfaces 112 b , 114 b and 116 b , as will be described. The outlined areas represent conductive material plating that is preferably grounded, with a pair of main wings 210 extending outwardly to be interposed between the conductive traces 120 , 122 , 124 and 126 of different layers 110 , 112 , 114 and 116 as traces 120 extend from the central region 146 to the exterior pins of device 8 . A pair of transverse wings 212 extend outwardly to shield ground traces 130 as they likewise extend from central region 146 to the exterior ground pins of device 8 . In an alternative preferred embodiment, the layers represented by FIG. 3 are omitted.
During the etching process, at least one uniquely located fiducial marking 150 , 152 , 154 and 156 is produced by photolithography on each layer 110 , 112 , 114 and 116 respectively. Each marking 150 , 152 , 154 and 156 is produced using the same optical mask that produces the traces 120 , 122 , 124 and 126 respectively on layers 110 , 112 , 114 and 116 respectively, contemporaneously with the formation of the traces 120 , 122 , 124 and 126 .
In each layer, 110 , 112 , 114 and 116 , a set of pin holes 160 (FIG. 3) not shown for the top layer 110 , but placed identically to pin holes 160 of layers 112 , 114 and 116 (FIG. 3) are preferably laser drilled with reference to the fiducial markings 150 , 152 , 154 and 156 for the layer 110 , 112 , 114 and 116 , respectively. Referencing with respect to fiducial markings 150 , 152 , 154 and 156 permits accuracy on the order of about 5 microns in the placement of the pin holes 160 . After the etching of traces 120 , 122 , 124 , 126 and 130 is complete, layers 110 , 112 , 114 and 116 are aligned by placing pin holes 160 in each layer 110 , 112 , 114 and 116 through a matching set of pins (not shown) on a fixture. Layers 110 , 112 , 114 and 116 are then adhered together by way of standard techniques into the aforementioned stack 118 , having adhesive layers 136 . Unfortunately, the alignment afforded by this method has an accuracy of about 10-15 microns due to a certain amount of excess clearance in placing pins through the pin holes 160 , and from compression of dielectric layers 110 , 112 , 114 and 116 in the lamination process. This is a higher level of accuracy than was heretofore possible in this type of layer stacking, but not accurate enough to subsequently connect all layers without additional alignment means as will be described.
As is visible in the drawings, each trace 120 ends in a slightly expanded-in-width trace terminus 142 . To attach active interconnect pads 12 to traces 120 , 122 , 124 and 126 a via must be drilled through each active electrical contact pad site 12 to an underlying trace terminus 142 . As is shown in FIG. 7, because of the arrangement of traces 120 , there are no traces interposed between each trace terminus 142 and the overlying prospective electrical contact pad 12 .
The figures are greatly expanded. In reality, trace termini 142 are each on the order 50 μm wide and a set of ground electrical contact pad targets 144 located at the intersections of traces 130 are no larger. Therefore, very precise drilling is required from each electrical contact pad site 12 of top surface 110 a down to the corresponding target trace terminus 142 or ground target 144 for a plated via to be able to connect an electrical contact pad site 12 or 14 to the correct terminus 142 or target 144 , respectively.
Because the fiducial markings 150 , 152 , 154 and 156 are offset from one another in the x-y dimensions of layers 110 , 112 , 114 and 116 , and because layers 110 - 116 are transparent, each fiducial marking 150 is observable from the exterior of stack 118 , enabling an operator to drill a set of vias 138 (see FIG. 7) in fixed relation to the fiducial markings for each layer 110 , 112 , 114 or 116 upon which the target trace terminus 142 exists. This represents an advancement over the prior art in which fiducial markings on different layers were typically not separately observable from a location outside of the device being constructed. If layers 110 , 112 , 114 and 116 were made of an opaque material an x-ray device could be used to render fiducial markings 150 , 152 , 154 and 156 observable. A nd:YAG frequency multiplied laser used with an accurate x-y laser/work piece positioning system is an excellent tool for use in drilling a via to a specific depth at a specific location. As the laser and the stack may be moved very accurately with respect to each other, and because the fiducial markings are produced from the same optical mask as the traces, the laser drilling may be positioned accurately enough in relation to the target trace terminus 142 so that terminus 142 is reached and so that no other traces are connected to the via 138 . Because of the comparatively large size of the active electrical contact pad sites 12 and ground electrical contact pad sites 14 , it is practically a certainty that the electrical contact pad site 12 or 14 being connected to terminus 142 will completely overlay the target trace terminus 142 even allowing for up to 10-15 microns of inaccuracy in layer placement. The via 138 that contacts a trace terminus 142 will therefore also contact the desired corresponding electrical contact pad site 12 .
After the drilling of vias 138 , vias 138 are plated with a conductive material such as copper or gold. Additionally electrical contact pads at sites 12 and 14 are then constructed by standard photo lithographic and plating techniques. There is typically some overlap between the via 138 plating steps and the plating for producing electrical contact pads at sites 12 and 14 .
By practicing the method of the present invention it is possible to quickly and efficiently build up a multi-layer electronic apparatus without drilling vias separately on each layer. Moreover, it is possible to build a connective device having a grid of closely spaced electrical contact pads that are separately routed to pins on the exterior of the connective device for translating from a pitch on the order of tens of microns to a pitch on the order of hundreds of microns or millimeters.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claim which follows.
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A method of constructing an electric apparatus, comprising the following steps. First, a set of dielectric layers is provided. Next, a set of conductive features and at least one fiducial marking are formed on a first one of the dielectric layers, in mutual reference to each other so that their relative positions are known to a first tolerance. Then, a set of pin holes is formed in each dielectric layer, each pin hole formed in relation to the fiducial marking for its dielectric layer and all of the sets of pin holes having a mutually identical placement. Finally the dielectric layers are arranged onto a pin fixture having a set of pins that match the mutually identical placement of the pin holes.
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BACKGROUND OF THE INVENTION
a. Field of the Invention
The invention relates to a SQUID magnetometer made by using a thin-film technology and particularly useful for a device for measuring weak magnetic fields, wherein the magnetometer is of the kind having a d-c SQUID with a SQUID loop and a super conducting flux transformer for the inductive coupling of a measuring signal into the SQUID.
b. Description of the Prior Art
A measuring device with a SQUID can be found in the publication "IEEE Transactions on Magnetics," Vol., MAG-17, No. 1, January 1981, pages 400 to 403.
Superconducting quantum interferometers which are generally known in the art as SQUID's (Superconducting QUantum Interference Devices), are used for the measurement of very weak magnetic fields as described in "J. Phys. E.: Sci. Instrum.," Vol. 13, 1980, pages 801 to 813; and "IEEE Transactions on Electron Devices," Vol. ED-27, No. 10, October 1980, pages 1896 to 1908. These interferometers are particularly preferred in the field of medical technology, and in particular, magnetocardiology and magnetoencephalography, since the field intensities produced by magnetic heart and brain waves are in the order of about 50 pT and 0.1 pT, respectively. (See e.g. "Biomagnetism - Proceedings of the Third International Workshop on Biomagnetism, Berlin 1980," Berlin/New York 1981, pages 3 to 31).
For measuring such biomagnetic fields, measuring devices are known which can be designed with one or more channels (see, for instance, DE-OS No. 32 47 543). Depending on the number of channels, these devices contain at least one SQUID magnetometer.
Such a magnetometer can be made with thin-film technology, as described in the "IEEE Trans. Magn." reference mentioned above. It has a relatively wide ring-shaped SQUID loop of superconducting material which forms a quasi-square or rectangular frame about a corresponding shaped central coupling hole. On one side, this loop is interrupted by a narrow transversal slot which leads to the outside and is almost completely overlapped by a strip-shaped conductor run. In the free region of the slot (i.e., the region not covered by the conductor), the SQUID loop is closed with two Josephson tunnel elements characteristic for a d-c SQUID. The magnetometer also includes a frame-shaped coupling coil formed of superconductive turns surrounding the coupling hole. In this-known embodiment, the SQUID loop also serves as the supporting base plane for the coupling coil. This coupling coil, together with at least one superconducting gradiometer coil connected thereto forms a flux transformer, by which a measuring signal to be detected can be coupled into the SQUID via the SQUID loop. The coupling losses are here proportional to the self-inductance of the strip line which is formed by the coupling coil and the SQUID loop. The self-inductance is given by the following relationship:
L=u.sub.o ·1·d.sub.iso /WK
where 1 is the length of the coupling coil, d iso the distance between the SQUID loop and the coupling coil, W the track width of the coupling coil and K the so-called fringe factor which depends on d iso /W. The self-inductance L is therefore a function of 1 and d iso /W. More particularly, L is proportional to d iso /W.
It has now been found that such magnetometers, especially for multichannel measuring devices, can be realized with satisfactory properties only with great difficulty. For example, the dimensions of the SQUID loop, for one, must be chosen at least large enough so that the turns of the relatively extensive coupling coil can be put on this loop. However, wide loop strips effect the properties of the SQUID adversely. Thus, undesirable resonances are observed between the straight conductor sections of the turns of the coupling coil and the SQUIDS located below. In addition, the parasitic inductance at the slot of the SQUID loop is relatively large. Because of this parasitic inductance, the coupling of the magnetic flux from the coupling coil into the SQUID is impeded correspondingly.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to improve the SQUID magnetometer of the type mentioned at the outset in such a manner that the mentioned unfavorable effects are substantially eliminated and in a simple manner.
According to the invention, this problem is solved by providing a special superconducting surface with the coupling hole with which the coupling coil and/or the SQUID loop are associated, and by disposing the coupling coil surrounding the SQUID loop at a preselected distance.
Overlap regions between the coupling coil and the SQUID loop are therefore substantially avoided. In addition, the undesirable determination of the minimum extent of the SQUID loop as a function of the coupling coil is advantageously eliminated. Also relatively small SQUID loops can now be made with the fine lithography required for making SQUIDS, independently of the relatively coarse lithography for forming the coupling coils. The inductance of the SQUID is determined mainly by the inductance of the coupling hole in the special superconducting surface and not by the dimensions of the coupling coil. An exact positioning of the SQUID loop around this coupling hole is consequently no longer necessary. This leads to a substantial facilitation in the design of the magnetometer.
The SQUID loop can surround the coupling hole while maintaining a certain spacing. The effective area of the coupling hole is then equal to the actual coupling hole area. However, it is also possible that a SQUID loop arranged in the edge zone of the coupling hole protrudes in its inner rim zone a distance into the coupling hole, i.e., it covers up an edge of the coupling hole. In this case, the effective area of the coupling hole is smaller that its actual area, and the inductance is determined not by the coupling hole but by the inside dimensions of the SQUID loop.
BRIEF DESCRIPTION OF THE DRAWINGS
For the further explanation of the invention, reference is made to the following in the drawings, wherein:
FIG. 1 shows a plan view of a preferred embodiment of magnetometer constructed in accordance with the invention;
FIG. 1a shows an enlarged view of a portion of FIG. 1;
FIG. 2 shows a side sectional view of FIG. 1 taken along axis II--II;
FIG. 3 shows an orthogonal view of another embodiment of the invention; and
FIG. 4 shows a side view of the embodiment of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1, 1a and 2 show a magnetometer generally designated with 2, made by using thin-film technology as described for instance, in the "IEE Trans. Magn." reference mentioned above. The magnetometer serves particularly for the construction of single- or multiple-channel measuring devices, preferably in the area of medical technology. However, as opposed to earlier devices, the magnetometer 2 contains a separate area 3a of a base element 3. This area 3a, which in the present case is to be considered as the base area, is applied to a substrate 3b which consists, for instance, of silicon. It is formed by a ring-shaped loop of superconductive material such as niobium and has an approximately square circumference so that the shape of an approximately squareshaped frame results. The loop surrounds a central, likewise approximately square coupling hole 4. Area 3a is interrupted completely on one side by a narrow transversal gap or slot 5 which leads from the coupling hole to the outside. The base area 3a is coated in a manner known per se by a galvanically (electrically) separating layer 3c. On this layer 3c, which consists, for instance, of SiO or SiO 2 , the turns 7 which enclose the coupling hole 4 at a relatively large distance a are arranged, of a coupling coil 8 known per se. The number of turns forming, for instance, rectangular and in particular, approximately square loops is generally substantially larger than is detailed in FIG. 1. The coupling coil 8 is terminated in ends 9 which are brought out of the vicinity of the base area 3a. At least one loop of a known gradiometer, the coupling coil 8 forms a so-called superconducting flux transformer. Through this flux transformer and the special superconducting area 3a, a magnetic signal which can be detected by the gradiometer loop, can be coupled inductively into a d-c SQUID 11. The superconducting area 3a can therefore also be called a coupling plane. The SQUID 11 can advantageously be designed so that its selfinductance is small. To this end, it is composed substantially of an approximately square-shaped SQUID loop 12 which surrounds the coupling hole 4 at a relatively small distance d, and of two Josephson contacts or elements 13 and 14. SQUID loop 12 is likewise slotted in the area of the slot 5 of the base area 3a. The corresponding separating zone between the spaced opposite loop ends 16 and 17 of the SQUID loop 12 is designated with 18 as shown in FIG. 1a. Through the area of the slot 5 of the base area 3a further extends a SQUID connecting lead 19 which is wide enough so that it partially overlaps the two opposite ends 16 and 17 of the SQUID loop 12. The two Josephson contacts 13 and 14 are formed in the corresponding overlap areas. On the side of the SQUID loop 12 opposite the connecting lead 19 or the slot area 5, a second connecting lead 20 is provided which leads from the region of the base area 3a to the outside. Connecting leads 19 and 20 can be disposed either over or under the turns 7 of the coupling coil 8. A graphic presentation of further layers covering the SQUID 11 and the coupling coil 8 has been omitted in FIG. 2 for reasons of clarity.
Advantageously, the positioning of the SQUID loop 12 with respect to the coupling hole 4 is not particularly critical since the coupling of the coupling coil 8 to the SQUID 11 is accomplished via the base or coupling plane 3a galvanically (electrically) insulated therefrom. While the coupling coil 8 is magnetically strongly coupled to the SQUID 11 in this manner, direct coupling of the coil 8 and SQUID loop 12 can advantageously be avoided substantially, by the provision that these parts do not overlap as in the device described in reference "IEE Trans. Magn."
Instead, in the present invention loops 8 and 12 are spatially sufficiently separated from each other to eliminate direct coupling. The inside dimensions 1 1 of the coupling coil 8 are therefore larger than the outside dimensions 1 2 of the SQUID loop 12, a sufficient distance e being maintained between the turns 7 of the coupling coil and the SQUID loop.
According to the embodiment example shown in FIGS. 1 and 2, a rectangular and in particular, an approximately square-shaped coupling hole 4 was assumed, the shape of which results in a corresponding shape of the superconducting base area 3a, the SQUID loop 12 and the coupling coil 8. Parts 3a, 4, 12 and 8, can have other shapes and their shape need not correspond. Thus, for instance, an approximately circular coupling hole in an approximately annular base area can be enclosed by an approximately square-shaped SQUID loop and/or an approximately square-shaped coupling coil.
In addition, the SQUID loop 12 need not be made so large that between its inside edge facing the coupling hole 4 and the respective coupling hole edge, the small distance b exists. Also smaller inside dimensions of the SQUID loop are also possible. Thus, SQUID loops can also be provided, the inside dimensions of which are so small that they cover an edge region of the coupling hole 4.
As can clearly be seen from FIG. 2., the d-c SQUID 11 as well the turns of the coupling coil 8 are arranged directly on the separating layer 3c covering up the base area 3a.
However, it is also possible to place on layer 3c only the coupling coil or only the SQUID loop, while another support element is provided for the remaining coil or loop. Since these parts (i.e. coupling coil 8 and loop 12) must first be prefabricated separately they must be joined mechanically, for instance, by cementing or clamping in such a manner that an arrangement is obtained which approximately corresponds to the arrangement of the coupling coil and the SQUID loop shown in FIG. 1.
An alternative embodiment therefor is indicated in FIGS. 3 and 4. FIG. 3 represents here a partial orthogonal view of a magnetometer generally designated by 22. A cross section through this device can be seen from FIG. 4. According to this embodiment, there are located on the outer cylinder surface 23a of a cylindrical base element 23, a correspondingly curved approximately circular coupling coil 24 with several turns. This coupling coil is covered-up by a particular superconducting area 25 with a central circular coupling hole 26 and a radial slot 27, a galvanic (electric) separation between the coupling coil 24 and the cover or coupling surface 25 being assured. Optionally, the coupling area 25 and the coupling coil 24 can be applied to the cylinder surface 23a. A d-c SQUID not visible in the figures with a SQUID loop, the dimensions of which are matched to the size of the coupling hole 26 is located on a plane support element of its own, for instance, a silicon substrate. The corresponding SQUID chip is generally designated with 30 in the figures. According to the invention, it is therefore advantageously possible to couple a planar SQUID directly to a coupling coil which is located on a curved surface and thereby, a coupling coil with intrinsic curvature.
In the embodiment of FIGS. 3 and 4, it was assumed that the superconducting coupling surface 25 is assigned to the coupling coil 24. This is particularly advantageous in case of a curved coupling coil. If non-curved substrate supports are used, it is also possible to associate the superconducting coupling surface with the SQUID loop.
Obviously numerous modifications may be made to the invention without departing from its scope as defined in the appended claims.
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A SQUID magnetometer is disclosed which can be fabricated by thin-film technology and used for apparatus for measuring weak magnetic fields. It contains a d-c SQUID with a SQUID loop surrounding the effective area of a coupling hole as well as a superconducting flux transformer with a gradiometer coil and a coupling coil surrounding the coupling hole thereby to achieve an effective inductive coupling of a measuring signal into the SQUID. To this end, the invention provides a separate superconducting surface (3a) with the coupling hole (4), to which the coupling coil (8) and or the SQUID loop (12) is/are assigned. The coupling coil (8) surrounds the SQUID loop (12) while maintaining a sufficient distance (e) for d-c decoupling.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-098855, filed Mar. 30, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a semiconductor device manufacturing method. More particularly, the present invention relates to a CMP (chemical mechanical polishing) technique.
[0004] 2. Description of the Related Art
[0005] Known CMP methods are normally used to planarize the surfaces of thin films such as insulating films and metal films formed on semiconductor wafers by means of CVD (chemical vapor deposition) or some other technique.
[0006] Thus, the CMP method is used to planarize the thin films formed on the surface of a semiconductor wafer by making an abrasive agent containing abrasive grains fit to the surface of abrasive cloth and polishing the semiconductor wafer on a rotating abrasive disk. CMP apparatus that play an important role in manufacturing semiconductor devices comprise a CMP section for polishing the films on the surface of a semiconductor wafer and a cleaning section for cleaning the polished semiconductor wafer.
[0007] More accurately, the CMP apparatus comprises a chamber, a CMP section arranged in the inside of the chamber and a cleaning section. A wafer loading/unloading section is also arranged in the chamber and the CMP section includes a dressing unit and a CMP unit.
[0008] With CMP, an abrasive agent referred to as slurry and containing abrasive grains is fitted to the surface of abrasive cloth and the cloth is used to polish a semiconductor wafer arranged on a rotating abrasive disk in order to planarize the surface of the thin films formed on the surface of a substrate to be treated. However, as the abrasive cloth is used continuously for CMP, the surface of the abrasive cloth becomes clogged by slurry to degrade its polishing performance. A surface treatment technique referred to as conditioning (dressing) is used to get rid of the clogging due to slurry.
[0009] Various materials may be used for abrasive cloth that is by turn used with the CMP technique. Of these, polyurethane foam pads are popular. A polyurethane foam pad has densely arranged micro-pores on the surface, and the micro-pores hold slurry during the polishing operation. When a polyurethane foam pad is used for a polishing operation, an initial treatment referred to as conditioning that is an operation of making the surface slightly coarse before the use of the pad is required. Without such a treatment for making the surface coarse, the pad cannot provide a stabilized polishing rate and a uniform polishing effect.
[0010] Generally, as the CMP process progress, solid substances including ground-off particles and abrasive particles deposit on the abrasive cloth and the polishing rate is reduced as the deposit increases. Then, in such a case, the abrasive cloth needs to be subjected to a conditioning operation. However, the surface of the abrasive cloth can become undesirably coarse as a result of the conditioning operation. Then, it will become difficult to carry out a CMP operation in order to polish the films to be treated that are formed on the surface of a semiconductor substrate and make them satisfactorily planar.
[0011] Therefore, there is a strong demand for a CMP method and a semiconductor manufacturing method with which the abrasive cloth can be effectively subjected to a conditioning process by using a dresser that operate effectively relative to the abrasive cloth.
BRIEF SUMMARY OF THE INVENTION
[0012] According to a first aspect of the present invention, there is provided a chemical mechanical polishing method comprising:
[0013] preparing a workpiece to be treated; and
[0014] chemically and mechanically polishing the workpiece to be treated by pressing the workpiece to be treated against a rotating disk carrying a piece of abrasive cloth bonded to a surface thereof at a first position on the disk, while dropping abrasive solution on the abrasive cloth, and, in parallel with the polishing, dressing the abrasive cloth by pressing a dresser carrying diamond grains sticked thereto against the abrasive cloth at a second position on the disk.
[0015] According to a second aspect of the invention, there is provided a semiconductor device manufacturing method comprising:
[0016] forming a film to be treated above a semiconductor substrate; and
[0017] chemically and mechanically polishing the film to be treated by pressing the film to be treated of the substrate against a rotating disk carrying a piece of abrasive cloth bonded to a surface thereof at a first position on the disk, while dropping abrasive solution on the abrasive cloth, and, in parallel with the polishing, dressing the abrasive cloth by pressing a dresser carrying diamond grains sticked thereto against the abrasive cloth at a second position on the disk.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0018] [0018]FIG. 1 is a schematic illustration of a CMP system that can be used with the first embodiment, showing the arrangement of system components;
[0019] [0019]FIG. 2 is a schematic perspective view of the CMP section of FIG. 1, illustrating its operation;
[0020] [0020]FIG. 3A is a schematic plan view of a dresser to be used with the first embodiment, illustrating its surface condition;
[0021] [0021]FIG. 3B is a schematic cross sectional view of the dresser of FIG. 3A;
[0022] [0022]FIG. 4A is a schematic plan view of a conventional dresser, illustrating its surface condition;
[0023] [0023]FIG. 4B is a schematic cross sectional view of the dresser of FIG. 4A;
[0024] [0024]FIG. 5 is a graph illustrating the distribution of diamond grains of the dresser of the first embodiment (A) in comparison with that of a known dresser (B);
[0025] [0025]FIGS. 6 and 7 are schematic cross sectional views of semiconductor devices used as objects of CMP for the second embodiment;
[0026] [0026]FIG. 8 is a graph illustrating the change with time of the extent of abrasion of a Cu film obtained by using the second embodiment;
[0027] [0027]FIG. 9 is a graph illustrating the planarizing performance of the second embodiment after a CMP process;
[0028] [0028]FIGS. 10A through 10C are schematic cross sectional views of a semiconductor device used as object of CMP for the third embodiment, illustrating different manufacturing steps; and
[0029] [0029]FIG. 11 is a schematic cross sectional view of a semiconductor device used as object of CMP for the third embodiment, illustrating a damascene wiring arrangement.
DETAILED DESCRIPTION OF THE INVENTION
[0030] With a CMP method according to the embodiments of the invention, the abrasive cloth is subjected to conditioning during the CMP process being conducted on a wafer, using a dresser carrying diamond grains arranged substantially at regular intervals and having a uniform grain size, under a load lower than that of any conventional method. As a result, the problem of the reduction of the polishing rate that arises during the CMP process is suppressed to improve the effect of planarization and the dresser can be controlled quantitatively.
[0031] During a CMP process, debris of metal films and oxide films, abrasive grains contained in slurry and chemicals such as solvent may adhere to the abrasive cloth and the amount of such substances adhering to the abrasive cloth may increase as the polishing operation proceeds to by turn reduce the polishing rate. However, possible deposition of debris and abrasive grains on the abrasive cloth can be avoided to alleviate the problem of reduction of the polishing rate by conducting a conditioning operation during the process of polishing a silicon semiconductor substrate. A conditioning operation is an operation of pressing a disk (dresser), on which diamond grains with a grain size of 150 μm are electrodeposited at regular intervals of 0.7 μm, against a silicon semiconductor substrate that carries on the surface metal films, oxide films and so on and hence shows surface undulations.
[0032] Furthermore, the rate at which diamond grains bite the abrasive cloth can be reduced by selecting a load of 1.0 kgf/cm 2 to 20.0 kgf/cm 2 for pressing the disk carrying electrodeposited diamond grains against the semiconductor substrate. The polishing time will be prolonged if the load is smaller than 1.0 kgf/cm 2 whereas diamond grains will bite the abrasive cloth too deep if the load is greater than 20.0 kgf/cm 2 . If diamond grains bite the abrasive cloth less, the surface of the abrasive cloth will become less coarse. Then, as a result, the adverse effect of the abrasive cloth touching recesses of the surface undulations of the semiconductor substrate, which carries metal films and oxide films formed thereon, can be reduced and the projections of the surface undulations can be abraded preferentially to satisfactorily planarize the surface.
[0033] Now, the present invention will be described in greater detail by referring to the accompanying drawings that illustrate preferred embodiments of the invention.
[0034] (1st Embodiment)
[0035] [0035]FIG. 1 is a schematic illustration of a CMP system that can be used with the first embodiment, showing the arrangement of system components. The components of the CMP system are arranged within a chamber 1 and include a CMP section 2 arranged for actual CMP operations, a cleaning section 3 for cleaning wafers that have been subjected to a CMP operation and a wafer loading/unloading section 4 for feeding workpieces to be treated that may typically be silicon semiconductor wafers. The wafer 10 fed from wafer cassette 5 in the loading/unloading section 4 is moved to the CMP section 2 by means of transfer robot 6 a or 6 b.
[0036] The CMP section 2 mainly comprises CMP units 22 and dressing units 23 arranged on respective turn tables 21 .
[0037] [0037]FIG. 2 is a schematic perspective view of a principal area of the CMP section containing a CMP unit 22 and a dressing unit 23 . Referring to FIG. 2, abrasive cloth 221 is fitted onto the turn table 21 and is driven to rotate at a predetermined number of revolutions per unit time. As shown, a top ring 223 is fitted to a drive shaft 222 that is driven to rotate. A wafer is rigidly fitted to the top ring 223 and pressed against the abrasive cloth 221 , while dropping slurry 225 fed from a slurry tank (not shown) by way of a slurry supply pipe 224 onto the polishing spot.
[0038] During the CMP process, a conditioning operation is conducted by bringing dresser 233 supported by another drive shaft 232 into contact with the abrasive cloth 221 .
[0039] In the CMP process, the abrasive cloth is soaked with an abrasive agent referred to as slurry and containing abrasive grains and the wafer is chemically and mechanically polished on the rotating turn table to planarize the surface of the thin films arranged on the wafer. If the wafer is continuously polished in the CMP process, a problem of a clogged surface may arise to the abrasive cloth caused by debris of the abrasive agent. A surface treatment operation referred to as conditioning or dressing is conducted to recover the surface from clogging.
[0040] Each of the dressing units 23 in FIG. 1 is designed to perform a dressing operation on the abrasive cloth. The abrasive cloth that is typically made of polyurethane foam can be degraded during and after a CMP process using slurry due to the substances adhering thereto such as high molecular surfactant and polysaccharide as well as abrasive grains contained in the slurry.
[0041] The degraded abrasive cloth is a large factor that reduces the yield of manufacturing semiconductor devices in the CMP process of polishing wafers carrying semiconductor devices densely formed thereon to show micro-patterns. A dressing operation is conducted by means of a dressing unit to remove the foreign object clogging the surface of the abrasive cloth and scraping the surface of the latter. A dressing operation is normally conducted after chemically and mechanically polishing a wafer.
[0042] On the other hand, with this embodiment, a dressing operation is conducted on the abrasive cloth 221 arranged on the rotating turn table (disk) 21 during a CMP process. Additionally, as will be described hereinafter, the dresser 233 for dressing the abrasive cloth 221 is provided with diamond grains having substantially a same size and arranged substantially at regular intervals.
[0043] The wafer 10 that is treated by the CMP section 2 is then transferred to the cleaning section 3 . The cleaning section 3 contains therein a pair of transfer robots 6 a, 6 b for transferring a wafer at a time, reversers 9 for reversing a wafer, double side roll cleaners 7 and pencil cleaners 8 .
[0044] The wafer transferred from the CMP section 2 by the transfer robot 6 b is washed and cleaned by the corresponding double side roll cleaner 7 and then transferred further to the pencil cleaner 8 by way of the transfer robot 6 b, the reverser 9 and the transfer robot 6 a. After drying, the wafer 10 is transferred to the loading/unloading section 4 by means of the transfer robot 6 a and stored back in the wafer cassette 5 . Thereafter, it is delivered to the outside and then to another station for the next manufacturing step.
[0045] [0045]FIG. 3A is a schematic plan view of the dresser 233 to be used for the CMP process of the first embodiment, illustrating its surface condition. FIG. 3B is a schematic cross sectional view of the dresser 233 .
[0046] Referring to FIGS. 3A and 3B, the substrate 236 of the dresser 233 is typically made of stainless steel such as SUS. A Ni plating layer 234 is typically formed on the substrate 236 . Diamond grains 235 of about a same size, which is typically about 150 μm, are sticked to the Ni plating layer 234 substantially at regular intervals. The size of the diamond grains is preferably greater than 100 μm and smaller than 200 μm, more preferably not smaller than 120 μm and not greater than 180 μm.
[0047] The diamond grains 235 are buried into the Ni plating layer 234 by a predetermined depth so that they may hardly come off from the substrate 236 . The diamond grains 235 will practically never come off from the dresser 233 if they are exposed from the Ni plating layer 234 by less than 50% of their grain size (2R), or a height (t) of the diamond grains 235 projecting from the Ni plating layer 234 satisfies the requirement of (t/2R)<0.5. Any two adjacent diamond grains 235 are preferably separated by a distance (d), not smaller than 0.1 mm and not greater than 1.0 mm. An inter grain distance (d) of 0.7 mm will be appropriate for the purpose of the embodiment (see FIG. 3B).
[0048] On the other hand, the substrate 246 of a known dresser as shown in FIGS. 4A and 4B is also typically made of stainless steel such as SUS. Again, a Ni plating layer 244 is typically formed on the substrate 246 and diamond grains 245 are buried in the Ni plating layer 234 . While the average size of the diamond grains 245 is about 100 μm, they are not uniform and do not show a predetermined profile nor their arrangement is well controlled. Thus, the diamond grains 245 are apt to come off from the substrate 246 .
[0049] [0049]FIG. 5 illustrates the dispersion of the grain sizes of the diamond grains 235 of the dresser 233 of FIGS. 3A and 3B to be used with this embodiment in comparison with that of the diamond grains 245 of the known dresser of FIGS. 4A and 4B. In the graph of FIG. 5, the abscissa represents the grain size (μm) of diamond grain, while the ordinate represents the frequency of appearance. As seen from FIG. 5, the size distribution (A) of the diamond grains of the dresser to be used with this embodiment is found within a narrow range of about 40 μm because the grain size is limited to a predetermined value (centered at 160 μm in the case of the illustrated dresser), whereas the size distribution (B) of the diamond grains of the known dresser extends over a wider range.
[0050] As described above, the dresser to be used with this embodiment is so arranged as to efficiently condition the abrasive cloth and the abrasive cloth is conditioned during a CMP process of treating a wafer. As a result, any possible reduction of the polishing rate in a CMP process is effectively suppressed so that the effect of planarization is improved and it is possible to control the dresser quantitatively.
[0051] (2nd Embodiment)
[0052] Now, an embodiment of the present invention will be described in terms of application of the CMP method to the manufacture of semiconductor devices.
[0053] [0053]FIGS. 6 and 7 are schematic cross sectional views of a semiconductor substrate used as object of CMP for the second embodiment.
[0054] Referring firstly to FIG. 6, a specimen prepared by sequentially laying a 200 nm thick TEOS film 252 of silicon oxide, a 25 nm thick TaN film 253 , a 2,000 nm thick Cu film 254 on a silicon substrate 251 is brought in. Beside, as shown in FIG. 7, a specimen prepared by forming a 700 nm deep groove 262 in a silicon substrate 261 and laying a 1,400 nm thick TEOS film 263 on the substrate 261 including the inside of the groove 262 is also brought in.
[0055] Each of the specimens of wafers is fitted to the top ring 223 of FIG. 2 and subjected to a CMP process, paralleling the dressing process with the dresser 233 of the first embodiment. The Cu film 254 of the specimen of FIG. 6 is polished. On the other hand, the TEOS film 263 on the silicon substrate 261 is abraded and removed and a buried insulating film to be used as element isolating region is formed there.
[0056] [0056]FIG. 8 illustrates the extent of abrasion of the Cu film 254 of the specimen of FIG. 6 in a CMP process. In the graph of FIG. 8, the ordinate represents the extent of abrasion (nm) (average abrasion amount per two minutes) and the abscissa represent the polishing time (nm). In the CMP process (in-situ conditioning) using this embodiment, four different loads of 4.3 kgf/cm 2 , 7.2 kgf/cm 2 , 14.4 kgf/cm 2 and 28.8 kgf/cm 2 are used for pressing the dresser. For the purpose of comparison, the data obtained as a result of a conditioning operation (ex-situ conditioning) using a known method with a load of 28.8 kgf/cm 2 for pressing the dresser is also shown.
[0057] As seen from FIG. 8, the extent of abrasion per unit time is extremely reduced with the known method as the polishing time increases. On the other hand, with this embodiment, the extent of abrasion per unit time does not practically fall at all if the polishing time is extended. The extent of abrasion per unit time increases when a large load is used.
[0058] Thus, while the polishing rate falls if the dresser is not subjected to conditioning during the polishing process, it is maintained to a desired level if the dresser is conditioned during the CMP process.
[0059] [0059]FIG. 9 is a graph illustrating the planarizing performance of the second embodiment after a CMP process conducted on the TEOS film 263 of the specimen of FIG. 7. In the graph of FIG. 9, the abscissa represents the polishing rate and the ordinate represents the local step height after the polishing process (@300 μm/300 μm). Note that @300 μm/300 μm indicates that the specimen had 300 μm wide projections and 300 μm wide grooves.
[0060] In FIG. 9, the curve indicated by # 100 indicates the result obtained by using a known dresser provided with diamond grains of a size of about 100 μm and the curve indicated by # 80 indicates the result obtained by using the dresser of this embodiment provided with diamond grains of a size of about 160 μm that are arranged at a pitch of 0.7 mm for conditioning.
[0061] From FIG. 9, it will be seen that the dresser of this embodiment performs best in terms of planarization when a load of 4.3 kgf/cm 2 is applied to it for dressing. The performance of the dresser is excellent in terms of planarization when the load is within a range between 1.0 kgf/cm 2 and 20.0 kgf/cm 2 . Additionally, it will be seen that the embodiment can greatly increase the polishing rate if compared with the prior art, and therefore the use of the embodiment is very effective and efficient, even if the load for dressing is reduced to 1.0 kgf/cm 2 or more and 20.0 kgf/cm 2 or less.
[0062] Furthermore, while no numerical difference may appear if this embodiment is compared with the prior art in terms of local step height, the prior art dresser is always accompanied by the risk of falling diamond grains and hence the embodiment is by far superior in terms of quality.
[0063] Further, as shown in FIG. 9, the polishing method of this embodiment can obtain a sufficient polishing rate at a load for dressing lower than that of the prior art. Therefore, according to this embodiment, the load for dressing within a range from 1.0 kgf/cm 2 to 20.0 kgf/cm 2 can satisfy the requirements for the polishing rate and the planarization at the same time.
[0064] (3rd Embodiment)
[0065] Now, the third embodiment of CMP method will be described in terms of applying it to the damascene wiring of a semiconductor device.
[0066] [0066]FIGS. 10A through 10C are schematic cross sectional views of a semiconductor device used as object of CMP for the third embodiment, illustrating different manufacturing steps. The A1 damascene wiring method realized by applying a CMP method aforementioned will be described below. For the purpose of simplification, some semiconductor elements are omitted from FIGS. 10A through 10C. However, assume that a transistor comprising a gate electrode 310 and source/drain 311 , 312 is formed on a semiconductor substrate 300 and damascene wires 302 / 303 are formed on the surface of an interlayer insulating film 310 at a position located above the drain 312 with a contact hole 313 interposed between them.
[0067] Now, referring back to FIGS. 10A through 10C, an insulating film 301 that may typically be a silicon oxide film is formed on the semiconductor substrate 300 in which semiconductor elements (not shown) are formed. Then, a 400 nm thick wiring groove 304 is formed in the insulating film 301 by patterning. Subsequently, an about 30 nm thick Nb liner 302 is formed by deposition on the insulating film 301 and in the wiring groove 304 . Thereafter, an about 600 nm thick Al film 303 is formed on the Nb liner 302 by deposition (FIG. 10A).
[0068] Then, The Al film 303 and the Nb liner 302 on the semiconductor substrate 300 are removed except the parts in the groove 304 by means of the first embodiment of CMP method, using the CMP system described above by referring to the first embodiment (see FIGS. 1 and 2). In this process, to begin with, a first step polishing operation is conducted to remove the A 1 film 303 (FIG. 10B). Thereafter, a second polishing operation is conducted to remove the Nb liner 302 (FIG. 10C). This process is referred to as two-step polishing.
[0069] As a result of the CMP process, the Al film 303 that operates as wire and the Nb liner 302 that is a barrier metal layer are buried in the wiring groove 304 . The remaining part of the Al film 303 and that of the Nb liner 302 are removed by the CMP process (see FIG. 10C).
[0070] Thus, with the third embodiment, a conditioning operation is conducted during the CMP process and hence a uniform polishing rate can be maintained. Therefore, buried wires can be formed accurately and reliably.
[0071] As described above in detail, according to the embodiments, a conditioning operation is conducted during a process of polishing a silicon semiconductor substrate having undulations on the surface as a result of forming metal films and oxide films on the surface. In the conditioning process, a dresser is pressed against the surface of the abrasive cloth. Diamond grains having a preferable size are sticked to the dresser. With this arrangement, debris produced as a result of polishing operation and abrasive grains can be prevented from depositing on the abrasive cloth as they are eliminated from the abrasive cloth and hence any possible fall of the polishing rate can be effectively suppressed. Additionally, the surface of the abrasive cloth can be prevented from becoming coarse by reducing a load for dressing to lessen the extent to which diamond grains are buried in the abrasive cloth. Then, as a result, the adverse effect of the abrasive cloth touching recesses of the surface undulations of the semiconductor substrate carrying metal films and oxide films can be reduced and the projections of the surface undulations can be abraded exclusively to satisfactorily planarize the surface.
[0072] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A chemical mechanical polishing method comprises preparing a workpiece to be treated and chemically and mechanically polishing the workpiece to be treated by pressing the workpiece to be treated against a rotating disk carrying a piece of abrasive cloth bonded to the surface thereof at a first position on the disk, while dropping abrasive solution on the abrasive cloth, and, in parallel with the polishing, dressing the abrasive cloth by pressing a dresser carrying diamond grains sticked thereto against the abrasive cloth at a second position on the disk.
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(a) TECHNICAL FIELD OF THE INVENTION
The present invention generally relates to a design of connection structure for connecting a light-emitting element received in a receptacle of a light string to electrical wires.
(b) DESCRIPTION OF THE PRIOR ART
Light strings that are similar to that will be described herein are readily available in large number in the market. Such light strings often include light-emitting diodes to serve as the elements for emitting light. The connection between the light-emitting diodes and electrical wires is often realized through “piercing”, where contactors having sharp ends are set up in the receptacle and are in contact engagement with the pins of a light-emitting diode and the electrical wires are laid flat on a top of a bottom lid. When the bottom lid and the receptacle are coupled to each other, the sharp ends of the contacts of the receptacle are caused to pierce through the insulation jackets of the electrical wires and thus electrically connect metal cores of the wires. However, this way of connection with electrical wires through piercing may easily cause undesired breaking and separation of the electrical wires, leading potential risk of shorting of the entire light string. Apparently, such an arrangement is not perfect and further improvement may be desired.
SUMMARY OF THE INVENTION
To overcome the above discussed drawbacks of the conventional way of connection between a light-emitting element received in a receptacle of a light string and electrical wires, the present invention proposes to put away such a known way of connection by piercing sharp ends of contacts through electrical wire and instead, direct contact established between pins of a light-emitting diode and exposed portions of metal cores of partially-stripped electrical wires is adopted for the purposes of avoiding the occurrence of wire breaking.
To achieve the above object, the present invention provides a light of a light string that comprises a receptacle body comprising upper and lower sections. The upper section comprises a support plate mounted therein at a center to receive a light-emitting diode (LED) to straddle thereon. A cover is fit to the upper section. The lower section comprises a separation board mounted therein at a center and two stop boards that are spaced from each other at a fixed interval and are of a wedge configuration that is expanded at top and reduced at bottom to define a slant surface facing inwardly. The light-emitting diode has four pins extending into she lower section and positioned on the separation board. The electrical wires are partially stripped off to expose metal cores that are respectively received between the separation board and the stop boards of the lower section to be in contact engagement with the pins of the light-emitting diode. A bottom lid that comprises left and right holding boards mounted thereto is coupled to the lower section, whereby the left and right holding boards push the four electrical wires upwards, so that the slant surfaces of the stop boards provides a camming effect to have the metal cores of the electrical wires and the pins of the light-emitting diode tightly fixed between the separation board and the stop boards. As such, electrical connection between the electrical wires and the light-emitting diode can be accomplished without terminal piercing, so that the problem of damage and breaking of the electrical wires caused by piercing can be completely avoided.
The present invention provides a lower section that comprises two wire retention plates projecting from opposite sides of a circumferential wall and further extending downward, wherein the wire retention plates each form, in an inner surface thereof, four semi-circular juxtaposing wire grooves, and a bottom lid having a circumferential wall forming openings, at opposite sides thereof, to correspond to the wire retention plates of the lower section, wherein four semi-circular notches are formed in a bottom wall of the bottom lid within each of the openings to correspond to the wire grooves of the corresponding wire retention plate, whereby the wire notches of the bottom lid and the wire grooves of the wire retention plates collaboratively and tightly clamp bent portions of the electrical wires therebetween to protect metal cores of the wires from breaking resulting from undue stretching caused by external forces.
In the disclosure, an embodiment is described with reference to a light-emitting diode having four pins and four electrical wires. However, it is contemplated that the present invention can be embodied in a light string that includes a light adopting a light-emitting diode having two, three or more than four pins and two, three, or more than four electrical wires, which are considered within the scope of the present invention.
The foregoing objectives and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a first embodiment of the present invention.
FIG. 2 is a perspective view, taken from the bottom side, of a receptacle body of the first embodiment of the present invention.
FIG. 3 is a bottom view of the receptacle body of the first embodiment of the present invention.
FIG. 4 is a perspective view showing the first embodiment of the present invention in an assembled form.
FIG. 5 is a cross-sectional view of the first embodiment of the present invention.
FIG. 6 is another cross-sectional view of the first embodiment of the present invention.
FIG. 7 is a top plan view showing electrical wires coupled to a bottom lid of the first embodiment of the present invention.
FIG. 8 is an exploded view of a second embodiment of the present invention.
FIG. 9 is a perspective view, taken from the bottom side, of a receptacle body of the second embodiment of the present invention.
FIG. 10 is a bottom view of the receptacle body of the second embodiment of the present invention.
FIG. 11 is a perspective view showing the second embodiment of the present invention in an assembled form.
FIG. 12 is a cross-sectional view of the second embodiment of the present invention.
FIG. 13 is another cross-sectional view of the second embodiment of the present invention.
FIG. 14 is a top plan view showing electrical wires coupled to a bottom lid of the second embodiment of the present invention.
FIG. 15 is an exploded view of a third embodiment of the present invention.
FIG. 16 is a perspective view, taken from the bottom side, of a receptacle body of the third embodiment of the present invention.
FIG. 17 is a bottom view of the receptacle body of the third embodiment of the present invention.
FIG. 18 is a perspective view showing the third embodiment of the present invention in an assembled form.
FIG. 19 is a cross-sectional view of the third embodiment of the present invention.
FIG. 20 is another cross-sectional view of the third embodiment of the present invention.
FIG. 21 is a top plan view showing electrical wires coupled to a bottom lid of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following descriptions are exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes to the described embodiments may be made in the function and arrangement of the elements described without departing from the scope of the invention as set forth in the appended claims.
Referring to FIGS. 1-7 , a first embodiment of connection device of light receptacle of light string according to the present invention is illustrated, comprising a receptacle body ( 10 ), a light-emitting diode ( 20 ), a cover ( 30 ), a bottom lid ( 40 ), and electrical wires ( 50 ). The receptacle body ( 10 ) comprises an upper section ( 11 ) and a lower section ( 12 ) that are hollow and are spaced from each other by a partition board 110 . The upper section ( 11 ) comprises a support plate ( 13 ) mounted therein at the center thereof. The upper section ( 11 ) has an inner circumferential wall on which coupling projections ( 14 ) are formed. The lower section ( 12 ) comprises a separation board ( 15 ) mounted therein at the center thereof and two stop boards ( 16 ) mounted at each side of the separation board ( 15 ) and spaced at a fixed interval and having a wedge configuration that is top expanded and bottom reduced by comprising a slant surface that faces inwardly. The partition board 110 comprises a through hole ( 101 ) formed therein between the separation board ( 15 ) and each of the stop boards ( 16 ) adjacent thereto and between adjacent ones of the stop boards ( 16 ) so that the through hole extends between the upper section ( 11 ) and the lower section ( 12 ). Two wire retention plates ( 17 ) are provided on opposite sides of a circumferential wall of the lower section ( 12 ) and each comprises a first portion extending radially from the circumferential wall of the lower section ( 12 ) and a second portion extending downward from the first portion. Four wire grooves ( 171 ), which are preferably semi-circular in cross-section, are formed in an inside surface of the second portion of each wire retention plate ( 17 ) to juxtapose each other. Coupling lugs ( 18 ) are provided on another two opposite sides of the circumferential wall of the lower section ( 12 ) and are generally located at a lower end of the circumferential wall. The light-emitting diode ( 20 ) comprises four pins ( 21 ), of which two central pins are arranged to straddle on the support plate ( 13 ) of the upper section ( 11 ). The cover ( 30 ) is fit to the upper section ( 11 ) to house the light-emitting diode ( 20 ) and has an outer surface in which a coupling recess ( 31 ) is formed for engagement and coupling with the coupling projections ( 14 ) formed on the inner circumferential wall of the upper section ( 11 ). The bottom lid ( 40 ) has a circumferential wall in which openings ( 42 ) are formed at locations respectively corresponding to the wire retention plates ( 17 ) of the lower section ( 12 ) and also comprises four wire notches ( 421 ), preferably semi-circular in shape, formed in a bottom wall thereof within each opening ( 42 ) at locations corresponding to the wire grooves ( 171 ) of the corresponding wire retention plate ( 17 ). The bottom lid further comprises left and right holding boards ( 41 ) formed on the bottom wall at locations close to and facing the two openings ( 42 ). The circumferential wall of the bottom lid ( 40 ) has a top forming inwardly projecting coupling flanges ( 43 ). The electrical wires ( 50 ), which in the embodiment are of a number of four, are each partially stripped off an insulation jacket thereof to expose a portion of a metal core ( 51 ). The four pins ( 21 ) of the light-emitting diode ( 20 ) are respectively received through the through holes ( 101 ). The electrical wires ( 50 ) are bent at locations at opposite sides of the stripped portion and the bent portions are received in the wire grooves ( 171 ) of the wire retention plates ( 17 ) of the lower section ( 12 ) so that the metal cores ( 51 ) of the four wires are respectively positioned between the separation board ( 15 ) and the stop boards ( 16 ) and between adjacent stop boards ( 16 ) to respectively engage the four pins ( 21 ) of the light-emitting diode ( 20 ). The bottom lid ( 40 ) is coupled to the lower section ( 12 ) by having the coupling lugs ( 18 ) of the lower section ( 12 ) and the coupling flange ( 43 ) of the bottom lid ( 40 ) engaging each other so that the left and right holding boards ( 41 ) of the bottom lid ( 40 ) push the electrical wires ( 50 ) upward and forcibly move the metal cores ( 51 ) to induce tight clamping engagement between the metal cores ( 51 ) of the four electrical wire and the four pins ( 21 ) of the light-emitting diode ( 20 ) by means of the slant surface and the wedge configuration of the stop boards ( 16 ). The wire notches ( 421 ) of the bottom lid ( 40 ) and the wire grooves ( 171 ) of the wire retention plates ( 17 ) collaboratively and tightly clamp the bent portions of the electrical wires ( 50 ) therebetween to protect the metal cores of the electrical wires from breaking caused by undue stretching of the wires by external forces.
Referring to FIGS. 8-14 , a second embodiment of connection device of light receptacle of light string according to the present invention is illustrated, which has a structure that is substantially identical to that of the first embodiment. The difference resides in that the separation board ( 15 ) and the stop boards ( 16 ) of the lower section ( 12 ) are arranged in a different way, in which four separation boards ( 15 ) are arranged in the lower section ( 12 ) to alternate the through holes ( 101 ) and thus at least some of the separation boards ( 15 ) are each between adjacent ones of the four through holes ( 101 ) of the partition board 110 and each of the separation boards has a distal end face on which a stop board ( 16 ) is formed at one edge thereof so as to form a step-like configuration. The four pins ( 21 ) of the light-emitting diode ( 20 ), after set through the through holes ( 101 ), are bent at distal ends thereof in a substantially perpendicular manner to be positioned on the end faces of the separation boards ( 15 ). The electrical wires ( 50 ) are bent and the bent portions are received in the wire grooves ( 171 ) of the wire retention plates ( 17 ) of the lower section ( 12 ) so that the metal cores ( 51 ) are respectively positioned on the separation boards ( 15 ) to engage the bent ends of the pins ( 21 ) of the light-emitting diode ( 20 ) that are located on the end faces of the separation boards and the stop boards ( 16 ) isolate the metal cores ( 51 ) from each other. The bottom lid ( 40 ) is coupled to the lower section ( 12 ) by having the coupling lugs ( 18 ) of the lower section ( 12 ) and the coupling flange ( 43 ) of the bottom lid ( 40 ) engaging each other. The left and right holding boards ( 41 ) of the bottom lid ( 40 ) push the electrical wires ( 50 ) upward and forcibly move the metal cores ( 51 ) to have the metal cores ( 51 ) of the electrical wires in tight engagement with the bent ends of the pins ( 21 ) of the light-emitting diode ( 20 ).
Referring to FIGS. 15-21 , a third embodiment of connection device of light receptacle of light string according to the present invention is illustrated, which has a structure that is substantially identical to that of the first embodiment. The difference resides in that the separation board ( 15 ) and the stop boards ( 16 ) of the lower section ( 12 ) are arranged in a different way, in which single separation board ( 15 ) is provided in the lower section ( 12 ) at one side of the four through holes ( 101 ) to be substantially parallel with a straight line extending through the four through holes ( 101 ). The separation board ( 15 ) has an end face that is provided with four stop boards ( 16 ) respectively at locations alternating the four through holes ( 101 ) so that at least some of stop boards ( 16 ) are each at a location corresponding the spacing between every two adjacent ones of the four through holes ( 101 ). The four pins ( 21 ) of the light-emitting diode ( 20 ) are respectively received through the through holes ( 101 ) and each has a distal end that is bent to be substantially parallel to the electrical wires ( 50 ) and positioned on the end face of the separation board ( 15 ). The electrical wires ( 50 ) are bent and positioned in the wire grooves ( 171 ) of the wire retention plates ( 17 ) of the lower section ( 12 ) to have the four metal cores ( 51 ) set on the end face of the separation board ( 15 ). The four metal cores ( 51 ) are arranged to be isolated from each other by the stop boards ( 16 ) and the four metal cores ( 51 ) are in contact engagement with the bent ends of the pins ( 21 ) of the light-emitting diode ( 20 ). The bottom lid ( 40 ) is coupled to the lower section ( 12 ) by having the coupling lugs ( 18 ) of the lower section ( 12 ) and the coupling flange ( 43 ) of the bottom lid ( 40 ) engaging each other. The left and right holding boards ( 41 ) of the bottom lid ( 40 ) push the electrical wires ( 50 ) upward and forcibly move the metal cores ( 51 ) to have the metal cores ( 51 ) of the electrical wires in tight engagement with the bent ends of the pins ( 21 ) of the light-emitting diode ( 20 ).
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
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A light of a light string includes a receptacle having upper and lower sections. The upper section includes a support plate on which an LED straddles. The lower section includes therein a separation board and two stop boards having a wedge-like shape arranged at each side of the separation board. The pins of the LED extend into the lower section and each positioned against an upright face of the separation board and the stop boards. Metal cores of electrical wires that are partially stripped are received between the stop boards to contact the pins of the LED. A bottom lid having holding board provided thereon is coupled to the lower section, so that the holding boards force the metal cores of the electrical wires into tight engagement with the pins of the LED by being fixed between the separation board and the stop boards.
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This application takes priority from German Patent Application DE 10 2006 041 940.5 filed 7 Sep. 2006, the specification of which is hereby incorporated herein by reference
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrical feedthrough to be inserted into an opening of an implantable electrical treatment device. Such electrical treatment devices are, for example, implantable cardiac pacemakers, implantable cardioverters/defibrillators, or cochlear implants
2. Description of the Related Art
The electrical feedthrough has an electrically insulating insulation body, through which at least one electrically conductive terminal pin passes, which is connected to the insulation body hermetically sealed using a solder.
Electrical feedthroughs of this type are used for the purpose of producing an electrical connection between a hermetically sealed interior of a treatment device and the exterior of the treatment device. In known electrotherapy devices, such as cardiac pacemakers or cardioverters/defibrillators, a hermetically sealed metal housing is typically provided, which has a terminal body, also called a header, on one side, which carries terminal sockets for connecting electrode lines. The terminal sockets have electrical contacts which are used for the purpose of electrically connecting electrode lines to the control electronics in the interior of the housing of the cardiac pacemaker. A feedthrough, which is inserted hermetically sealed into a corresponding housing opening, is typically provided where the electrical connection enters the housing of the cardiac pacemaker.
Electrical feedthroughs of this type are frequently implemented as filter feedthroughs. In this case, the apparatuses carry an electrical filter, which is used for the purpose of short-circuiting external high-frequency electric interference, so that corresponding signals are fed, if at all, only strongly damped to the control electronics in the interior of the housing and the control electronics first experience interference at significantly greater signal strengths of the electrical interference than would be the case without the electrical filter. A filter of this type is typically formed by a filter body which is connected like a capacitor between a device ground and a particular electrical line passing through the feedthrough.
Such an electrical line passing through the feedthrough is typically formed by an electrically conductive terminal pin, which passes through a through opening in an electrically insulating insulation body. The electrically conductive terminal pin projects on both sides beyond the particular face of the insulation body, so that on both sides of the insulation body—and thus on both sides of the electrical feedthrough—continuing electrical lines may be connected to the terminal pin in each case—by soldering or welding, for example. A possible gap between a through opening in the insulation body, through which a particular terminal pin passes, and the terminal pin itself, is typically closed hermetically sealed using a solder, normally gold solder.
Manifold electrical feedthroughs of this type are known from the prior art. Examples may be found in U.S. Pat. No. 6,934,582, U.S. Pat. No. 6,822,845, U.S. Pat. No. 6,765,780, U.S. Pat. No. 6,643,903, U.S. Pat. No. 6,567,259, U.S. Pat. No. 6,768,629, U.S. Pat. No. 6,765,779, U.S. Pat. No. 6,566,978, and U.S. Pat. No. 6,529,103.
In spite of the manifold known feedthroughs, there is still the demand for improving them in regard to producibility and properties.
BRIEF DESCRIPTION OF THE INVENTION
This object is achieved according to the present invention in that glass or glass ceramic is provided as the material of the solder between insulation body and terminal pin. In particular if ceramic insulation bodies are used, a reduction of the production costs and an improvement of the reliability result simultaneously in that a solder may be connected directly to both the insulation body and also to the terminal pin and possibly the flange, without complex preparation work being necessary for this purpose, for example, in the ceramic production or a coating of the insulation body.
This provides the advantage that the number of components and process steps during production is reduced.
A further important advantage is that the glass or glass-ceramic solder material is electrically insulating and may thus be connected simultaneously to the flange and the pin. In contrast, with a conductive solder such as gold, pin and flange require at least two separate solder reservoirs, because otherwise an electrical short-circuit would occur between pin and flange. Therefore, an electrically insulating solder such as glass or glass ceramic allows simpler and more compact constructions of electrical feedthroughs.
A biocompatible surface of the insulation body on its exterior (in regard to the installed state) may also be achieved in this way without further measures.
The latter advantage is particularly provided if the insulation body comprises a ceramic material, which preferably contains Al 2 O 3 .
The degree of biocompatibility is also increased if the glass or glass-ceramic solder material is implemented as biocompatible and/or the ceramic insulation body and/or the flange are molded in such a way that a potential access of bodily fluid to the solder is additionally made more difficult via one or more tightly guided edges.
The soldering course of the glass or the glass ceramic becomes more controllable if, in addition to the insulation body facing toward the body, a further insulation body is also soldered onto the other side of the glass or glass-ceramic solder, so that the glass or glass-ceramic solder is enclosed in the flange hole from both sides by insulation bodies and both insulation bodies are soldered together with the flange and the pin.
The feedthrough is especially suitable for high voltage applications, such as defibrillators, if the insulation ceramic is shaped in such a way that long insulation distances arise on the surface and in the volume. Suitable shapes are, for example, bulges and edges. Such shapes are preferably implemented on the side of the feedthrough facing toward the body.
Accordingly, it is a separate idea, to be implemented independently of the other features of a feedthrough described here, to mold the insulation body in such a way that it offers long insulation distances on the surface and in the volume, i.e., for example, has a surface having corresponding depressions or protrusions which are used to lengthen the insulation distances.
Moreover, shapes of this type offer stable anchoring possibilities for the header, so that its attachment to the housing of the implant becomes more secure.
The terminal pin preferably comprises metal, which preferably contains platinum and is especially preferably a platinum-iridium alloy. Niobium, tantalum, and titanium, and their suitable alloys come into consideration as further, especially biocompatible and corrosion-resistant metals for the pin. Terminal pins of this type have the desired biocompatibility, are corrosion-resistant, and may be processed reliably.
In a preferred embodiment variation, the terminal pin or the terminal pins are each inserted into a through hole in the insulation body and connected mechanically solidly and hermetically sealed thereto by the solder formed by glass and/or glass ceramic. The flange either has a separate through hole for each pin or multiple pins share a joint through hole.
In a further embodiment variation, each pin has its separate insulation body, with the advantage that the insulation bodies may be implemented rotationally symmetric, e.g., cylindrical, and are simply producible.
To improve the soldered connection between terminal pin and insulation body, a corresponding through opening for the terminal pin may have an expansion on at least one longitudinal end, so that a space arises between terminal pin and expanded through opening, which is filled with glass or glass-ceramic solder. The space described may preferably be implemented as an annular space and is referred to for the sake of simplicity as a cavity in the following; it is expressly noted that the cavity may also assume any other shape. For example, the spaces may overlap and form a shared space which is filled with glass or glass-ceramic solder.
To be suitable for treatment devices whose electrical components in the interior of the housing are to be connected via multiple electrical lines, for example, to one or more electrode lines, the feedthrough is preferably implemented as multipolar and has multiple terminal pins, preferably running parallel to one another, and a corresponding number of through holes. These through holes preferably each only have a diameter on one longitudinal end which is significantly greater than the external diameter of the terminal pin, so that a cavity arises between terminal pin and hole. These cavities are preferably all situated on the same front face of the insulation body.
The attachment of electrical lines of a header is made easier if the terminal pins have different lengths on the exterior of the feedthrough (in relation to the installed state). The attachment of the electrical lines is also made easier in many cases if the pins are flattened, bent, or brought into the shape of nail heads or other suitable shapes on their ends.
To achieve the greatest possible distance of the terminal pins from one another in an insulation body which is as small as possible, the terminal pins are situated uniformly distributed on a circular arc concentric to the insulation body, preferably running parallel to one another. Alternatively, however, the terminal pins may also be situated linearly in one plane in the insulation body. This may make further manufacturing steps in the pacemaker production easier. A linear configuration in which two or more rows of terminal pins are each situated offset to one another in the insulation body also comes into consideration.
In particular in the first of the three last-mentioned embodiment variants, it is advantageous if the circular body has a cross-sectional area running transversely to the longitudinal direction of the terminal pin or terminal pins, which is round and preferably circular.
The insulation body is preferably enclosed transversely to the longitudinal direction of the pins by a sleeve-like metallic flange. The flange preferably comprises a material which is identical in its composition to the metallic housing of the treatment device as much as possible. The flange is either worked out of a solid material by turning or milling, for example, or produced by a suitable sintering process. In the latter case, the flange body may be penetrated by small pores, which do not impair the hermetic seal of the flange, however. A flange of this type may, for example, be connected hermetically sealed to a metallic housing of the treatment device by welding. Flange and insulation body are connected hermetically sealed to one another.
The feedthrough is preferably implemented as a filter feedthrough having a filter body. The filter body has disk-shaped capacitor electrodes running parallel to one another, which are alternately electrically connected to the flange and to a terminal pin.
In connection with the latter embodiment variant, the flange preferably extends far enough beyond the inner face of the insulation body that the flange also encloses the filter body over at least the majority of its length and in this way is easy to connect electrically to the capacitor electrodes of the filter body.
If the pins comprise iridium, niobium, tantalum, titanium, or similar materials which may not be soft-soldered directly, the electrically conductive connection of the pins to the capacitor electrodes of the filter body via electrically conductive adhesive or by soft soldering is made significantly easier if the pins are gilded using gold solder. The gilding may be restricted to the areas of the pins which are decisive for the electrical connection of the pins to the capacitor electrodes of the filter body.
In an idea which is independent of the present invention and is protectable separately, the capacitor electrodes of the filter body are soldered to the pins and the flange directly using gold solder, for example. A particularly heat-resistant filter body is required for this purpose. A filter feedthrough may be manufactured cost-effectively in a single soldering step in this way. In this case, the application of further, sealing gold or glass-ceramic solder may be dispensed with, instead, the insulation body is coated with iridium, niobium, titanium, tantalum, or their suitable alloys at suitable points, for example.
To judge the hermetic seal of the implant interior to the environment formed by the feedthrough, it is advantageous if the areas of the sintered connections or soldered connections (using glass, glass-ceramic, or gold solder) are accessible for a helium leak test and are not concealed by a filter body and its electrically conductive connections to the pins and the flange.
The ability to test the hermetic seal of the feedthrough may be ensured in multiple ways:
A through opening in the electrical filter body. A through opening in one of the electrically conductive connections between the filter body and the pins and/or the flange. The filter body is integrated in a socket which is connected via spot welds to the flange; the helium gas passage is ensured between the spot welds. The electrical connection of the filter to the flange or to the pins is produced by a (spring) terminal, either the flange being shaped in such a way that the springs are a component of the flange, or a separate spring body producing the electrical connection between the flange and the filter. The desired helium gas passage occurs in this case between the terminal points.
In one variant, the capacitor electrodes of the filter are already integrated in the insulation body, so that a separate filter body is dispensed with. A possible embodiment is that the same ceramic insulation material (Al 2 O 3 ) is used as the dielectric material between the capacitor electrodes as on the surface. In a further embodiment variant, a material adapted for the electrical filter function (e.g., BaTiO 3 or a similar ceramic material of high permittivity) is located between the capacitor electrodes, while a biocompatible insulating material is located on the surface (e.g., Al 2 O 3 ).
Finally, to ensure good mounting ability and a good seal between flange and insulation body, the insulation body preferably has a peripheral shoulder in the exterior peripheral surface, which works together with a corresponding shoulder in the inner wall of the flange when the two shoulders on the peripheral surface of the insulation body and in the inner wall of the flange run diagonally in relation to the longitudinal direction of the feedthrough, so that conical surfaces working together with one another result, and the shoulder also makes centering the insulation body in relation to the flange easier.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be explained in greater detail on the basis of exemplary embodiments with reference to the drawings. In the figures:
FIGS. 1 a through 1 h : show various embodiment variations of a unipolar feedthrough without a filter body longitudinal section, and/or a linear, multipolar feedthrough in cross-section;
FIGS. 1 i through 1 o : show different unipolar feedthroughs as filter feedthroughs in longitudinal section, and/or various linear, multipolar filter feedthroughs in cross-section;
FIG. 1 p : shows a filtered, unipolar feedthrough having two variants of the gas access to check the hermetic seal in a top view;
FIGS. 2 a through 2 i : show various variants of multipolar feedthroughs in longitudinal section;
FIGS. 2 j through 2 o : show various variants of multipolar feedthroughs as filter feedthroughs in longitudinal section;
FIG. 3 : shows an embodiment of a unipolar filter feedthrough in longitudinal section having integrated capacitor electrodes in the insulation body;
FIGS. 4 a and 4 b : show a front view ( FIG. 4 a ) and a side view ( FIG. 4 b ) of a multipolar filter feedthrough according to the present invention;
FIG. 4 c : show a longitudinal section through the filter feedthrough according to FIGS. 4 a and 4 b ; and
FIG. 5 : shows a cardiac pacemaker having a feedthrough according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
All of the feedthroughs illustrated in the exemplary embodiments according to FIGS. 1 a through 4 c have a flange 1 and at least one terminal pin 3 . The terminal pin 3 is electrically insulated in relation to the flange 1 with the aid of at least one insulation body 4 made of ceramic and with the aid of glass and/or glass-ceramic solder 2 , which connects the pin 3 to the insulation body 4 and to the flange 1 .
The structure of the particular feedthrough shown results from the following nomenclature:
The flange is identified in all embodiment variations by reference numeral 1 .
The glass and/or glass-ceramic solder is identified in all embodiment variations by reference numeral 2 .
The terminal pins are identified in all embodiment variations by reference numeral 3 .
Insulation bodies made of ceramic, in particular made of Al 2 O 3 , are identified in all embodiment variations by reference numeral 4 .
In the embodiment variations which show a filter feedthrough, the particular filter body is identified by reference numeral 5 . In these embodiment variations ( FIGS. 1 i - 1 p and 2 j - 2 o ) the reference numerals 6 and 7 identify an electrically conductive connecting material, such as an electrically conductive thermoplastic or an electrically conductive (metal) solder.
FIG. 1 a shows a hybrid glass/ceramic feedthrough which is unipolar and/or linearly multipolar in cross-section. The glass and/or glass-ceramic solder 2 simultaneously hermetically connects the pin or the pins 3 to the flange 1 and to the (ceramic) insulation body 4 . In the unipolar case, the insulation body 4 has a simple, cylindrical shape. The insulation body 4 is seated on the front face of the flange 1 . The advantage results that the glass and/or glass ceramic 2 is prevented from flowing out downward during the soldering, the surface of the insulation body 4 is biocompatible on the exterior (in the figure: on top), no coating of the insulation body 4 is necessary, visual checking of the component from the interior is possible (in the figure: from top to bottom), the insulation body 4 is to be produced simply and cost-effectively, and a good mechanical hold for the header on the projecting insulation body 4 is provided.
The embodiment variation according to FIG. 1 b is similar to that from FIG. 1 a , but the insulation body 4 projects into the hole of the flange 1 . In this way, automatic centering of the pin 3 in relation to the hole of the flange and a smaller insulation body 4 having smaller possible pitch dimension (distance from pin to pin) result as additional advantages.
The embodiment variation according to FIG. 1 c is similar to that from FIG. 1 b , but the insulation body 4 is implemented as a double cylinder: one cylinder projects into the hole of the flange 1 , the other abuts the front face of the flange 1 externally. In addition, the insulation body 4 has a slot (depression) on the front face of the large cylinder as a variant, which extends the insulation distances and increases the high-voltage resistance. An additional edge between the flange 1 and the insulation body 4 to reduce the interaction between the external area and the glass surface (keyword: dendritic growth) as well as automatic centering of the insulation body 4 and the pin 2 in the hole of the flange 1 result as advantages. The insulation body is molded in a more complicated way for this purpose.
The embodiment variation according to FIG. 1 d is similar to FIG. 1 a , but the insulation body 4 projects into a shoulder in the flange 1 . Automatic centering of the insulation body 4 and the pin 2 in the hole of the flange 1 , a geometrically simpler and more cost-effective insulation body 4 , as well as an additional edge between the flange 1 and the insulation body 4 to reduce the interaction between the external area and the glass surface (keyword: dendritic growth) result as advantages.
The embodiment variation according to FIG. 1 d is similar to FIG. 1 b , but the insulation body 4 terminates flush with the front face of the flange 1 . A more compact construction results as an advantage.
The embodiment variation according to FIG. 1 f is similar to that from FIG. 1 e , but the front face of the insulation body 4 is inside the hole of the flange 1 . The advantage results from this that the header is mechanically geared in the pocket hole up to the insulation body 4 .
The embodiment variation according to FIG. 1 g is similar to that from FIG. 1 a , but the glass solder 2 in the flange hole is delimited on top (interior of the implant) by a further insulation body 4 . A limitation of the solder volume to a defined area, improved control of the soldering process (no flowing away of the glass or glass-ceramic solder 2 ), and thus higher yields in the manufacturing process, centering of the pin 2 in relation to the hole of the flange 1 at two points instead of one, so that required geometries are maintained more securely, result as advantages here. However, a higher equipment outlay due to a further component also results.
The embodiment variation according to FIG. 1 h is similar to that from FIG. 1 g , but the second insulation body 4 projects out of the hole of the flange 1 . This makes it easier to handle the second insulation body 4 because of its size.
The embodiment variation according to FIG. 1 i is similar to that from FIG. 1 a , but having an attached filter body 5 via an electrically conductive point 6 on the pin 3 and an electrically conductive point 7 on the flange 1 . The points 6 and 7 do not have to be produced from the same material. Optional through openings 25 through the filter body 5 and/or the solder points 6 and/or 7 for checking the hermetic seal are not shown. A filter feedthrough having greater freedom in the variability of the filter size advantageously results in this way.
The embodiment variation according to FIG. 1 j is similar to that from FIG. 1 i , but the filter body 5 is located in a cavity of the flange 1 and the pin 3 is fixed by two insulation bodies 4 and the glass and/or glass-ceramic solder 2 is delimited in its course. A more compact construction thus results.
The embodiment variation according to FIG. 1 k is similar to that from FIG. 1 j , but the insulation body 4 and the flange 1 have bevels 18 and 19 which are tailored to one another and cause especially good centering of the insulation body 4 in relation to the flange 1 . In addition, the insulation body 4 is shaped in its further course outside the flange 1 in such a way that it is designed for higher operating voltages, as occur in defibrillators, for example, because it insures longer current paths between the flange 1 and the pin 3 . In addition, the special shaping of the insulation body 4 causes improved retention of the header. A free space 20 between the filter body 7 and the flange 1 , which allows a gas access to the glass and/or glass-ceramic soldered point to check the hermetic seal, is also indicated.
The embodiment variation according to FIG. 1 l is similar to that from FIG. 1 k , but the filter body 5 is soldered into a socket 21 , which is in turn connected via soldered points 23 to the flange 1 . In this way, a gas access between the soldered points 23 is ensured for checking the hermetic seal.
The embodiment variation according to FIG. 1 m is similar to that from FIG. 1 l , but the socket 21 comprises the flange 1 .
The embodiment variation according to FIG. 1 n is similar to that from FIG. 1 m , but does not represent an embodiment variation of the claimed invention, because instead of an electrically insulating glass and/or glass-ceramic solder 2 , a metallic solder 24 is provided for connecting the insulation body 4 to the pin 3 and the flange 1 . For this purpose, a suitable metallic coating of the insulation body 4 is required on at least two different points which do not overlap, so that the metallic solder 24 may produce a solidly adhering, hermetically sealed connection to the insulation body 4 .
The embodiment variation according to FIG. 1 o is similar to that from FIG. 1 n , but the filter body 5 is connected directly in a cavity of the flange 1 to the flange 1 via the electrically conductive connection 7 and to the pin 3 via the electrically conductive connection 6 .
FIG. 1 p shows the same feedthrough as in FIG. 1 o , but in a top view of the filter body 5 . Through openings 25 for checking the hermetic seal in the filter body 5 and/or in the electrically conductive connection 7 are indicated.
It results as a shared feature from the embodiment variations 1 a through 2 o that the particular glass solder 2 fills up a cavity which is defined by at least one particular insulation body 4 made of ceramic as well as at least one terminal pin 3 and possibly additionally by a flange 1 .
In addition, it is to be noted that the feedthroughs as shown in FIG. 1 are all unipolar feedthroughs. In addition, the cross-sections according to FIGS. 1 a - 1 o may also be understood as cross-sections through linear, multipolar feedthroughs, which are more or less produced by arraying a series of unipolar feedthroughs.
FIGS. 1 j through 1 p show for exemplary purposes that the feedthroughs shown may also be implemented as filter feedthroughs. It is to be noted that the filter feedthrough according to FIG. 1 i , except for the filter body 5 and the electrically conductive connections 6 and 7 , corresponds to the feedthrough from FIG. 1 a.
FIG. 2 a shows an unfiltered, hybrid glass/ceramic feedthrough which is bipolar or multipolar and/or double linearly multipolar in cross-section. The glass and/or glass-ceramic solder 2 connects the pins 3 and the flange 1 hermetically to the (ceramic) insulation body 4 . The insulation body 4 may have a simple, cylindrical shape, but may also be oval or elongate. The insulation body 4 is located in a cavity of the flange 1 and is seated on a shoulder in the flange. All pins 3 are located in a shared insulation body 4 , but at least two pins 3 are located in each insulation body 4 . The pins 3 may—as indicated here—be implemented having different lengths. The top side of the feedthrough is located in the external area of the implant in this image. During the soldering in the production of the feedthrough, the orientation is reversed, so that the glass and/or glass-ceramic solder 2 rests on the flange 1 and the insulation body 4 , for example. An advantage is that the glass and/or glass-ceramic solder 2 is prevented from flowing out upward during the soldering. In addition, the insulation body 4 has a biocompatible surface on its exterior side (in the figure: top). Coating the insulation body 4 is not necessary. Moreover, it is possible to check the component visually from the interior (in the figure: direction downward).
The feedthrough illustrated in FIG. 2 b is similar to that illustrated in FIG. 2 a , but at least two pins 3 each have a separate insulation body 4 in separate holes of the flange 1 . The insulation body 4 terminates flush with a front face of the flange 1 . Higher mechanical stability due to the cell-like structure of the (metallic) flange 1 results as an advantage from this. In addition, the insulation body 4 may be shaped cylindrically in a mechanically simple way and therefore universally and cost-effectively.
The feedthrough illustrated in FIG. 2 c is similar to that illustrated in FIG. 2 b , but the insulation body 4 extends beyond the front face of the flange 1 . A larger insulation distance and an improved mechanical hold for the header of the implant result as advantages.
The feedthrough illustrated in FIG. 2 d is similar to that illustrated in FIG. 2 a , but the glass and/or glass-ceramic solder 2 is delimited by further insulation bodies 4 on both sides. Improved control of the solder course and centering of the pin 3 at two points results from this.
The feedthrough illustrated in FIG. 2 e is similar to that illustrated in FIG. 2 b , but the glass and/or glass-ceramic solders 2 are delimited by further insulation bodies 4 on both sides. Improved control of the solder course and centering of the pin 3 at two points also results here.
The feedthrough illustrated in FIG. 2 f is similar to that illustrated in FIG. 2 e , but at least two outwardly (upwardly in the drawing) directed insulation bodies 4 are countersunk in the holes of the flange 1 .
The feedthrough illustrated in FIG. 2 g is similar to that illustrated in FIG. 2 a , but the insulation body 4 projects out of the hole of the flange 1 . In addition, the insulation body 4 has a bevel 19 , which corresponds to a bevel 18 of the flange 1 and causes especially good centering of the insulation body 4 in relation to the flange 1 . Moreover, the insulation body 4 has a so-called “slot” 29 , which extends the insulation distance between the pins 3 and offers a better hold for the header of the implant. A shared glass and/or glass-ceramic solder 2 connects at least two pins 3 hermetically sealed to the flange 1 and the insulation body 4 . Optionally, a ground pin 26 is attached to the flange 1 via a connection 23 . The connection 23 is preferably implemented by welding.
The feedthrough illustrated in FIG. 2 h is similar to that illustrated in FIG. 2 c , but the insulation body 4 and the flange 1 have bevels 19 and 18 corresponding to one another, which cause the centering of the insulation body 4 in relation to the flange.
The feedthrough illustrated in FIG. 2 i is similar to that illustrated in FIG. 2 c , but insulation bodies 4 are replaced by filter bodies 5 . The filter bodies 5 have electrode plates 22 and 27 , which are alternately in contact with the pin 3 via electrically conductive connections 6 and with the flange 1 via electrically conductive connections 7 . The electrically conductive connections 6 and 7 may comprise the same material. A glass and/or glass-ceramic solder 2 ensures the hermetically sealed connection of the filter body 5 to the pin 3 and the flange 1 . The dielectric material of the filter body 5 preferably comprises a biocompatible, preferably ceramic material or the filter body 5 is provided with a biocompatible coating.
FIG. 2 j shows a filter, hybrid glass/ceramic feedthrough, preferably linearly multipolar and/or double or multiple linearly multipolar in cross-section. The glass and/or glass-ceramic solder 2 connects the pins 3 and the flange 1 hermetically sealed to the preferably ceramic insulation body 4 . The insulation body 4 preferably has a simple, cylindrical shape, but may also be oval or elongate perpendicular to the cross-sectional view shown. The insulation bodies 4 are located in holes of the flange 1 . All pins 3 each have a separate insulation body 4 , but two or more pins 3 may also be located in each insulation body 4 perpendicularly to the cross-sectional view. The pins 3 may—as not indicated here—be implemented having different lengths and/or be shaped suitably for better attachment on their ends, e.g., flattened, nail-shaped, bent, etc. In this image, the upper side of the feedthrough is located in the exterior area of the implant. During the soldering while the feedthrough is produced, the orientation is reversed, so that the glass and/or glass-ceramic solder 2 rests on the insulation body 4 , for example. In this image, electrical filter bodies 5 are attached to some of the pins 3 , if necessary also to all pins 3 or—in an unfiltered version—to none of the pins 3 . The electrically conductive connection of the filter bodies 5 to the pins 3 is produced here via a metallic solder and/or an electrically conductive compound 6 . The electrically conductive connection of the filter body 5 to the flange 1 is also executed via the material 7 , the materials 6 and 7 being able to comprise the same substance. Through openings 25 which lead through the connections 6 or 7 , through the filter bodies 5 , or through the walls of the flange 1 to free spaces 20 are not shown, so that the hermetic seal of the finished component may be checked. Alternatively, the electrically conductive connections 6 and/or 7 may be implemented by terminals or by spring force, so that the through openings 25 described may be dispensed with. Optionally, a ground pin 26 is connected to the flange 1 via an electrically conductive material 24 , preferably a metallic solder. The advantage also results here that the glass and/or glass-ceramic solder 2 is prevented from flowing out upward during the soldering. A further advantage is a biocompatible surface of the insulation body 4 on its exterior side (in the figure: direction upward). No coating of the insulation body 4 is necessary. In addition, a visual check of the component from the inside (in the figure: direction downward) before the attachment of the filter bodies 5 is possible. A relatively small pitch dimension (distance from pin to pin) is possible due to the shared flange 1 and especially mechanically stable together with separate holes.
The embodiment variation according to FIG. 2 k largely corresponds to that from FIG. 2 j , but the insulation bodies 4 have bevels 19 , which correspond to bevel 18 of the flange 1 , so that the insulation body 4 obtains improved centering in the holes of the flange 1 . The filter body 5 filters signals to other pins 3 in relation to FIG. 2 j.
The embodiment variation according to FIG. 2 l largely corresponds to that from FIG. 2 k , but the pins 3 are guided through a shared insulation body 4 . All pins 3 are provided with separate filter bodies in this embodiment variation.
The embodiment variation according to FIG. 2 m largely corresponds to that from FIG. 2 k , but the insulation bodies 4 and the pins 3 are connected hermetically sealed to the flange 1 via a shared glass and/or glass-ceramic solder 2 . A shared filter body 5 is also used for the pins 3 in this embodiment.
The embodiment variation according to FIG. 2 n does not show an embodiment variation of the present invention, because according to the embodiment variation from FIG. 2 n —which is otherwise similar to that from FIG. 2 m —the insulation body 4 is connected hermetically sealed to the pins 3 and the flange 1 with the aid of a preferably metallic solder 24 , so that the glass and/or glass-ceramic solder 2 may be dispensed with. The insulation body 4 must have a suitable coating for this purpose, so that it may be wetted with the solder 24 .
The embodiment variation according to FIG. 2 o is similar to that from FIG. 2 k , but the pins 3 are filtered via a shared filter body 5 , which is electrically connected to a socket 21 via a material 7 . The socket 21 is electrically and mechanically connected solidly to the flange 1 at suitable points 23 , preferably by welded bonds. A gas access into the free space 20 between the glass and/or glass-ceramic solder 2 and the filter body 5 and/or the feedthrough 21 is possible between the points 23 , so that additional through openings 25 on the filter body 5 or the connections 6 and 7 may be dispensed with and it is possible to check the hermetic seal on the component in the finished state.
Finally, FIG. 3 shows a variant of a filter feedthrough in which the filter body 5 simultaneously assumes the function of the insulation body, i.e., on one hand it is used as a hold for the terminal pin 3 and on the other hand delimits the cavity which is filled with glass solder 2 together with the flange 1 and the terminal pin 3 . FIG. 3 shows how a filter body 5 may also act as an insulation body in the meaning of the present invention. In this meaning, the ceramic bodies 4 according to the embodiment variations 1 a through 1 f or 2 b , 2 c , 2 e , 2 f , 2 h , and 2 i may also be implemented as filter bodies.
As may be inferred from FIG. 3 , a filter body 5 differs from a purely ceramic body in that the filter body 5 has electrically conductive capacitor electrode disks 22 and 27 , which are alternately each electrically connected to the terminal pin 3 and to the flange 1 . An insulating material, such as ceramic, which is preferably biocompatible, is located between the capacitor electrode disks.
Finally, a quadropolar filter feedthrough is shown in FIG. 4 . FIGS. 4 a and 4 b show the filter feedthrough in a top view and a side view. FIG. 4 c is a longitudinal section AA through the filter feedthrough (see FIG. 4 a ).
The filter feedthrough from FIG. 4 has four terminal pins 3 , which project through corresponding through openings in an insulation body, which is implemented as a ceramic body 4 .
The ceramic body 4 preferably comprises Al 2 O 3 . The terminal pins 3 preferably comprise a platinum-iridium alloy PtIr 90/10. The through openings in the ceramic body 4 , through which the terminal pins 3 project, are each expanded at a longitudinal end in such a way that a cavity in the form of an annular space 10 arises between the particular terminal pin 3 and the ceramic body 4 . These annular spaces 10 are situated on an internal front face 14 of the ceramic body 4 . The annular spaces 10 are filled with glass or glass-ceramic solder in the finished, mounted feedthrough, which is not shown in FIG. 4 .
The ceramic body 4 is enclosed by a flange 1 , which preferably comprises titanium. Furthermore, it is to be noted in regard to the design of the ceramic body 4 according to the exemplary embodiment variation shown in FIG. 4 that the ceramic body 4 has a cross-section, running perpendicularly to the longitudinal direction of the terminal pin 3 , having a circular circumference. The four terminal pins 3 are parallel to one another and are distributed uniformly on a circular arc, which is concentric to the remaining ceramic body 4 , in relation to the cross-section of the ceramic body 4 .
Two of the terminal pins 3 are shorter than the two other terminal pins 3 , to make contacting corresponding terminals in a header of an implant easier.
It may be seen in the longitudinal section through the ceramic body 4 shown in FIG. 4 c that the ceramic body 4 has a shoulder 18 in its external peripheral surface 16 , so that a conical mantle surface results, which corresponds to a corresponding shoulder 19 in the flange 1 .
The flange 1 extends beyond the inner front face 14 of the ceramic body 4 in the longitudinal direction of the filter feedthrough, so that the flange 1 encloses a free space 20 on the interior of the filter feedthrough in which a filter body 5 is inserted. The filter body 5 is optional and may also be left out in the case in which a simple feedthrough and not a filter feedthrough is required.
A typical filter body 5 has multiple electrodes running parallel to one another and transversely to the longitudinal direction of the terminal pin 3 , of which each second electrode 22 extends up into an external peripheral surface of the filter body 5 , while the electrodes 24 lying between them extend up to a particular through hole for a particular terminal pin 3 ; see FIG. 3 .
A ground pin 26 is situated on the exterior of the flange 1 , which provides a possibility of electrically contacting the implant housing with the control electronics securely.
Finally, FIG. 5 shows an example of a cardiac pacemaker 20 whose metallic housing has already been closed using a filter feedthrough of the type shown in FIGS. 4 a - c . For the sake of simplicity, the typical heading of a cardiac pacemaker is not shown in FIG. 5 , in which the terminal sockets for the electrode lines are located. The electrical contacts of these terminal sockets are electrically connected to the pins 3 of the filter feedthrough in the finished cardiac pacemaker. The filter feedthrough—more precisely its flange 1 —is connected hermetically sealed to the housing 22 of the cardiac pacemaker 20 , preferably by welding. Therefore, it is advantageous if the flange 1 of the filter feedthrough comprises the same metal as the housing 28 of the cardiac pacemaker 20 .
It is to be noted that the variations shown in FIGS. 1 a through 2 o may also occur in further combinations, which are not shown here.
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The present invention relates to an electrical feedthrough for insertion into an opening of an implantable electrical treatment device having an electrically insulating insulation body through which at least one electrically conductive terminal pin passes, which is connected hermetically sealed to the insulation body using a solder, the solder material being glass or glass ceramic.
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BACKGROUND OF THE INVENTION
This invention relates to the field of waste disposal and, more specifically, to an apparatus (comprising a frame and a bag) and to a preferred bag for packaging waste for disposal.
Under the so-called "pooper scooper" laws, those responsible for a dog (usually, the owner) must promptly remove any solid or semi-solid waste material left by the dog on sidewalks, etc. Thus, a person wishing to obey such a law has the problems of removing the offending material and then of its disposal.
There have been various attempts to deal with those problems. For example, those who can reason with their dogs often ask the dogs to consider using a circumscribed area on the ground upon which a substrate such as newspaper has been placed. If there are no mishaps, the newspaper may be folded to wrap the waste and the entire package thereafter disposed of. Those who cannot reason with their dogs as to the location but have quick reflexes sometimes attempt to place the substrate/wrapping material into position on the ground before the waste hits the ground.
For those with slower reflexes who still wish to comply with the law, a shovel may be employed to remove the waste material from the ground after the fact. The waste can then be put into a bag or placed on a substrate for wrapping and disposal. Some individuals have been known to place one of their hands inside a bag made of flexible material as if it were a glove, pick up the waste material using the "gloved" hand, and pull the end of the bag off the hand in a manner so as to invert the bag and package the waste material inside the bag for later disposal.
One device that has been used for attempting to scoop up waste after it is on the ground consists of a framework having a rectangular opening at its front end and a bag that is attached to the framework with the opening of the bag congruent with the rectangular front opening of the framework. The framework with the bag attached is placed on the ground with one side of the rectangular opening touching the ground. The device is pushed forward towards the waste material on the ground to scoop up the waste and have it pass through the rectangular opening into the rest of the attached bag. The bag is removed from the framework for disposal.
Each of those methods and devices has drawbacks. One problem with the apparatus just described is that the opening of the bag and the frame become contaminated with waste material. That is because the opening of the bag is at the leading edge of the framework and contacts the waste on the ground during the scooping maneuver. This makes closing the bag and disposal somewhat tricky. Other drawbacks of the various apparatus and methods used are obvious. Shovels become contaminated; the "gloved hand" method is aesthetically unpleasing, not to mention the problems encountered if the "glove" (i.e., bag) breaks at an inopportune moment.
SUMMARY OF THE INVENTION
A new apparatus that avoids the above-noted problems and has numerous other advantages has now been developed. Broadly, the device facilitates the disposal of the waste by packaging it in a rapid and reliable manner and with a minimum of handling and comprises:
(a) a bag having an open end, a periphery, a central portion, an inner surface, and an outer surface; and
(b) a frame having sides and having an inversion point, the frame being at least partially within the bag thereby to support it and having an open area located near the central portion of the bag; the bag being larger than the frame to provide sufficient slack so that after waste is placed on the outer surface of the central portion of the bag, the waste and that portion of the bag nearest the waste are pulled down by gravity at least partially into the open area of the frame and sections of the bag are drawn snug towards the frame, the frame and bag thereafter cooperating so that as a portion of the open end of the bag is moved towards the inversion point to remove the bag from the frame, the portion of the bag lying near the inversion point becomes inverted and further movement of the end of the bag in a direction to remove the bag from the frame results in inverting the rest of the bag, thereby placing the outer surface of the bag on the inside and packaging the waste inside the bag.
In other aspects of the invention, the frame comprises at least two members (and preferably three in the approximate shape of a triangle), and/or the bag carries closure or locking means so that it may be tied shut after the waste material is inside, and/or a plurality of bags may be stacked or nested one inside the other on the frame, and/or a handle portion is attached to the frame and the handle has grippers or other securing means for preventing the bag or bags from sliding off or otherwise being removed from the frame until such removal is required. Sticks or other disposable members may be carried within the handle and the sticks employed to help position the waste material on the device.
Another aspect of the invention concerns a preferred bag having integral flaps for tying the bag closed. The two major faces of the bag are attached directly or indirectly (i.e., through an intervening edge panel) to each other at their corresponding edges.
The frame itself need not be rigid and may be comprised of pieces that can rotate with respect to one another. Accordingly, in one embodiment the frame is collapsible and may be collapsed and retracted into or around or about the handle of the device to provide a small readily portable device. In another embodiment, the frame members may be rotated with respect to one another to form a "V" shape to provide an inversion point at what becomes the lowest vertical point of the "V" frame rather than at the lateral sides of the flat (unrotated) frame.
Devices of this invention may be used to efficiently and effectively scoop waste material off a variety of substrates (for example, concrete, carpeting, sand, grass, snow, leaves) or the device may be used to catch the waste in mid-air, before it hits the ground. The frame of the device remains clean because it is covered by the bag, and the open end of the bag is not contaminated with waste either during the scooping procedure or later. The leading edge of the bag, which does become contaminated during the scooping procedure, is placed inside by the inversion procedure. Thus, what becomes the outer surface of the bag after packaging is complete and the open end of the bag remain free of waste. Other advantages, aspects, and embodiments of the invention will be described below.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate further description of the invention, the following drawings are provided in which:
FIG. 1 is a perspective view of the device being held in a position to scoop up waste material on the ground;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a side elevational view of the device of FIG. 1 before waste material is on the device;
FIG. 4 is a detail view of FIG. 3 after the waste material has been placed on the device;
FIG. 5 is a perspective view showing the first stage in removing the bag from the frame of the device of FIG. 4 to package the waste material;
FIG. 6 is a perspective view of the device showing a further stage in the removal of the bag from the device;
FIG. 7 is a cross-sectional view of the device of FIG. 6 taken along line 7--7 of FIG. 6;
FIG. 8 is a perspective view showing a later stage in the removal of the bag from the frame of the device;
FIGS. 9 and 10 are detail views showing subsequent steps in the removal of the bag from the frame;
FIG. 11 shows the waste material in the bag after the bag has been completely inverted and is no longer supported by the frame;
FIG. 12 is a view showing the two integral strips on the bag tied together to securely close the bag;
FIG. 13 is a plan view of the preferred bag of the invention;
FIG. 14 is a plan schematic view of the preferred frame and handle of the invention;
FIG. 15 is a perspective view of another embodiment of the invention in which the two frame members are rotatably connected to one another;
FIG. 16 is a view of the device of FIG. 15 after the two frame members have been rotated up towards one another;
FIG. 17 is a view of a third embodiment of the device in which the frame members are rotatably connected to one another to permit the frame to be collapsed for storage and portability;
FIG. 18 is a view of the device of FIG. 17 showing the frame being collapsed for storage within the handle of the device; and
FIG. 19 is a view of the device of FIGS. 17 and 18 in which the frame has been collapsed and is being retracted into the handle of the device.
These drawings are provided for illustrative purposes only and should not be construed to limit the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, handle 40 of device 20 is being held in left hand 22. The device comprises frame 24 and bag 26 having periphery 28 and two integral flaps 38 at open end 168 (or rear extent) of the bag. Frame 24 comprises side 32, side 34, and side 36, which is located at the leading or front edge of the device. The three sides lie substantially in the same plane and in substantially the shape of a triangle. Optional securing means 44 prevents bag 26 from sliding down and off the frame while the device is downwardly disposed towards waste 30, which is on the ground. The device need not have securing means 44. In that case, left hand 22 could hold the rear portion of the bag against handle 40 to prevent the bag from sliding off the frame. Central portion 42 of bag 26 is located in gap (or space or void) 84 between frame members (or sides) 32, 34, and 36.
In the cross-sectional view of FIG. 2, central portion 42 of bag 26 lies below the plane of frame members 32 and 34. Bag 26 has two major faces, upper face 50 and lower face 52, each of which has an inner surface 54 and an outer surface 56. Bag 26 may be thought of as having one continuous inner surface (or inside) 54 and one continuous outer surface (or outside) 56. Pressure pad 64, which is attached to front end 72 of securing means 44 (as more clearly shown in FIG. 3), temporarily secures bag 26 in place. The pad may be of any material that provides the required friction, such as rubber or flexible foam.
In FIG. 3, the device has been positioned with its leading edge on ground 74 so that it can be moved in the direction indicated by arrow 70 to scoop up waste material 30, which is also on the ground. Handle 40 has front end 46 and rear end 48. The frame is attached to the front end of the handle, and cylindrical cavity 66 terminates at rear end 48. Elongate sticks 68 (for example, ice cream sticks or tongue depressors) are stored within cavity 66. A stick 68 may be removed from cavity 66 and used to help push and position waste 30 on central portion 42 of the bag (see FIGS. 1 and 2).
Each of the two securing means 44 is rotatably connected to the handle, here by a pivot pin 62 in ears 60. The two securing means 44 are biased (spring biasing means not shown) so that pressure pads 64 connected to front ends 72 frictionally retain reinforced areas 88 of bag 26 against the outer portion of front end 46 of handle 40. (Reinforced areas 88 on bag 26 are better seen in FIG. 13.)
In FIG. 4, waste 30 is positioned adjacent central portion 42, both of which have been pulled down by gravity so that much of waste material 30 lies below the plane defined by the frame members. Arrow 78 indicates the direction of travel of the front end of the device for subsequent use.
As best seen by comparing FIGS. 1 and 2 with FIGS. 4 and 5, before waste 30 is positioned on central portion 42 of bag 26, the bag fits somewhat loosely on the frame because the bag is larger than the frame, that is, there is some slack. In FIG. 2 periphery 28 is seen to extend beyond frame members 32 and 34. In contrast, in FIGS. 4 and 5, the weight of waste 30 has pulled central portion 42 of the bag downward so as to take up the slack by pulling various portions of periphery 28 of the bag against the frame. For example, a portion of the front or leading edge of the bag has been drawn snug against a corresponding portion of leading side 36 of the frame and sections of the periphery of the bag have been drawn snug against corners (or shoulders) 80, which are located at the approximate places where lateral side members 32 and 34 meet front side member 36. In FIG. 5, left hand 22 is holding the device and right hand 76 is commencing the bag-removal and wrapping (or packaging) procedure.
During the removal procedure, the bag is inverted so that the outside of the bag becomes the inside and the waste material thereby becomes packaged inside the bag. Inversion of the bag may be facilitated by the frame increasing in transverse size from the rear of the frame to the front. For example, the device of FIG. 5 increases in lateral width from near handle 40 to a maximum at the imaginary line connecting the two corners 80. Inversion is also made possible in the embodiments shown by the periphery of the bag or at least certain sections of the periphery of the bag being pulled or drawn snug towards the inversion point and at least one other point on the frame. Usually, the weight of the waste material will pull the central portion of the bag down sufficiently to take up the slack in the bag provided the bag is sufficiently flexible and is not too big.
In FIG. 5, right hand 76 is grasping a portion of the open end of the bag towards the rear of the device. Right hand 76 then moves in a direction towards the front side 36 of the frame. The bag is usually manipulated at or near the beginning of this procedure to partially invert the small section of the opening of the bag between the thumb and forefinger of hand 76. That part of the bag is then drawn forward (i.e., towards front side 36 of the frame). Whether or not such preliminary inversion is carried out, at some point along the frame at or before corner 80, the bag will not be able to slide off the frame (because the bag lies so tightly against the frame) and the outer surface of the bag immediately adjacent to that point will be forced to fold over on itself as the open end of the bag continues to be pulled forward. Alternatively, gripping means (for example, adhesive) may be placed on a small section of the side portion of the frame to prevent the bag from sliding off the frame and thereby to cause inversion to occur at that point as the opening of the bag is being pulled forward. In that case, the lateral sides of the frame need not be diverging and may be parallel or converging.
In FIG. 6, arrow 82 indicates the direction in which the end of bag 26 is pulled to continue the removal procedure. Left hand 22 is holding the device by handle 40 and at the same time it is pushing release mechanism handles 58 towards main handle 40 to move pressure pads 64 away from the bag, thereby to release the bag and allow the inversion and removal procedure to continue. In many cases it will not be necessary to push release handles 58 because the act of pulling inverted portion 170 of the bag forward will pull the temporarily secured portions of the bag out from under pressure pads 64.
At some point during the inversion/removal procedure, the part of the opening of the bag lying at the bottom of the bag-frame combination must pass below the lowest point of central portion 42. If that does not occur, the edge of the already inverted portion of the opening of the bag will not clear the waste material and central portion of he bag that are located below the plane of the frame, and the inversion and removal procedure will not be able to continue. Thus, FIG. 7 shows a section of inverted portion 170 of the bag positioned below the bottom most part of central portion 42 and waste material 30 to enable the opening of the bag to clear (pass below) them at their lowest point. The top section of inverted portion 170 must pass above waste 30, and FIG. 7 shows this too. Finally, FIG. 7 shows that the weight of waste material 30 on central portion 42 has drawn part of periphery 28 of the bag against frame sides 32 and 34.
In FIG. 8 the bag has cleared corner 80 between frame members 34 and 36 and the inversion process is essentially complete: outer surface 56 is now the inside of the bag in contact with waste material 30. Void (or space or gap) 84 between the three frame members is no longer completely covered by the bag. The full completion of the inversion/removal procedure is then accomplished as leading edge 168 of the inverting bag clears the remaining shoulder between frame members 32 and 36. This occurs with continued travel along the direction of arrow 166.
FIGS. 9 and 10 show further stages of removing the bag from the frame. Arrow 86 indicates the direction of travel of the bag to complete removal.
FIG. 11 shows the completely inverted bag containing the waste material situated freely within void 84 of the frame at the conclusion of the removal/inversion procedure. Inner edge 164 of integral flaps 38 define U-shaped cutout 90. Two reinforced areas 88 (only one of which is shown) are located at the bottom of the U-shaped cutout. It is those two portions of the bag that securing means 44 contacts to temporarily secure the bag to the frame. Reinforced areas 88 are optional; any non-reinforced area of the bag may serve as the contact area of the bag for the gripping means.
FIG. 12 shows integral flaps 38 tied together so as to close and secure the opening of the bag to prevent waste material from leaving the bag.
FIG. 13 is a plan view of the preferred bag. The dimensions of the bag will depend principally on the dimensions of the frame: the bag must be larger than the frame so that the bag can fit onto the frame but should not be so large that too much slack is provided. FIG. 14 is a schematic diagram of a preferred frame and handle of the invention in which the frame is generally triangular in shape. Various combinations of bag and frame shapes and sizes may be used. For the shapes shown in FIGS. 13 and 14, three preferred size combinations are shown below.
______________________________________Dimension Approximate Size In InchesLine Set I Set II Set III______________________________________A 20 16 12B 12.5 10.5 8.5C 12.5 10.5 8.5D 10.5 8.5 5.5E 8.25 6.5 5F 10.5 8.5 6.5G 9.5 7.5 5.5______________________________________
The bag may be made of any material that has the required physical properties. Important physical properties include abrasion resistance, drapability, deformability, resilience, and strength. Preferred bags are of thin (about 0.5-2.5 mils in thickness) plastic film. Any size and shape bag and any bag material may be used so long as the bag in combination with the frame and rest of the device is capable of performing the desired function. Shapes and features other than that shown in FIG. 13 may be used, for example, the bag may be square or rectangular or have no U-shaped cutout or have no reinforced areas.
Similarly, the frame and handle may be made of any materials that have the required properties such as strength and resilience. Usually, the frame and handle will be made of metal and/or plastic. The particular size and shape of the frame are not important so long as the frame can interact with the bag to perform the desired function. Thus, the frame will generally have one or more frame members that provide a point along the frame at which inversion of the bag can take place (usually because of the bag being pulled taut in a transverse direction by a transverse frame size that increases towards the front of the device). Desirably, the frame will have a leading side to facilitate scooping up waste material that is on the ground and the leading member will be thin and not easily bent or deformed. The leading side may be straight or concave in, concave out (as shown in FIG. 14) being preferred. The bag must be sufficiently abrasion resistant so that the integrity of the bag is not compromised by the bag's being pushed along the ground (see FIGS. 3 and 4).
The location of the inversion point for a given bag/frame combination will vary depending on what means are used to retard the forward motion of the bag and hinder its sliding on the frame, e.g., adhesive on a lateral side of the frame, the bag's being pulled taut against the frame by the weight of the waste, etc. If the bag is pulled taut by the frame (as in the embodiments of FIGS. 1-19), the location of the inversion point will depend on the sizes of the bag and the frame, the physical characteristics of the bag employed (for example, the resistance of the bag to stretching, its tensile strength, and its flexibility and resilience), and on how tightly the bag's periphery is pulled against the frame and where. The increase in the lateral size of the frame of FIG. 14 towards the front of the frame and use of a bag not too much larger than the frame insures that inversion will occur at or before corner 80. If the bag is too large, inversion will not occur, regardless of the weight of waste material 30.
Two or more bags may be nested within one another and the frame placed within the innermost bag of the nested stack. In that case, the user would employ only the outermost bag, thereby leaving the rest of the stack of bags on the frame for subsequent use.
Other shapes may be employed for the frame. For example, the frame may be a polygon of more than three sides or the frame may be circular. The particular shape is not important so long as the device is able to perform the desired function. A frame with parallel or even converging sides may be used if adhesive or other such means is located on one section of a side for causing the inversion.
The frame need not lie in only one plane. For example, the front or leading edge of the frame and the forward sections of the two side frame members of the device of FIG. 1 may be bent upwards. Even if the frame members lie in a single plane at the start of the scooping and disposal operation, the frame need not remain in that one plane. For example, FIGS. 15 and 16 illustrate frame members that can rotate with respect to one another. The frame comprises side pieces 92 and 96, front piece 94 (which itself is comprised of segments 94a and 94b) and pivot 100. Corners 98 are located between the side pieces and the front pieces. Side pieces 92 and 96 are connected to straight portions 102 and 104, which are rotatably mounted in block 132. Extensions 102 and 104 terminate in bent portions 106 and 108, which prevent the frame from being pulled out of block 132.
FIG. 16 shows the two halves of the frame rotated up out of the plane they define when they are in their normal (or down) position. In FIG. 16, corners 98 have been rotated up out of the plane and towards one another.
To use this device, waste material is again positioned on the central portion of the bag (not shown), which is within gap (or void) 84 between the frame members. The two frame members are then rotated u into the position shown in FIG. 16 either manually or by spring-loaded or other means (not shown). At this point, most or all of the waste material hangs down below the two corners 98. To remove and invert the bag of this device, the bottom portion of the bag near its opening, which is pointed towards the rear of the handle, is grasped and pulled forward. That portion of the bag must be low enough to clear the bottom of the waste material and the central portion of the bag adjacent to it at their lowest point while they are hanging from the frame. Pivot point 100, which as shown in FIG. 16 is a low point for the frame, may help invert the bag. However, inversion may start before the lower open end of the bag is brought forward enough to meet pivot point 100. The top of the open end of the bag must also pass over the high points of the frame, corners 98 in FIG. 16.
FIGS. 17, 18, and 19 illustrate another embodiment of the invention, namely, a collapsible device. This device may be used in the same manner as the devices previously described except that it has the advantage that the frame can be collapsed. All of the frame or a substantial portion of it can be stored inside or around or about the handle so that the device may be carried in, for example, a pocket or pocketbook.
The frame comprises side piece 110, front piece 112 (which comprises portions 112a and 112b), side piece 114, corners 116, straight extension portions 124 and 126 (which are slidably mounted within block 134), and bent portions 128 and 130 (which prevent the frame from being pulled forward out of slidable block 136). The frame pieces are rotatably connected to one another at pivot points 120, 118, and 158. Extension or tab 122 on frame member 112b prevents sections 112a and 112b from rotating with respect to one another to move pivot point 120 forward beyond its forwardmost location shown in FIG. 17. Sliding block 136 is slidably mounted in path 138 of handle 40. Block 136 is biased towards the rear of the handle by spring 140, which is attached at its forward end to block 136 and at its rear end to fixed point 142.
Release mechanism 144 is rotatably mounted to handle 40 on ears 150. The forward end of release mechanism 144 carries pin 146, which passes through the outer surface of handle 40 into hole 148 located at the top of sliding block 136. As long as pin 146 lies within hole 148, block 136 is prevented from moving back under the force of spring 140. When trigger 152 of release 144 is pushed down in the direction shown by arrow 160, pin 146 is withdrawn from hole 148 and spring 140 pulls block 136 back in the direction shown by arrow 162. Prior to depressing trigger 152, pivot 120 is moved towards the rear of the device in the direction shown by arrow 154. That in turn causes rotation of the frame members with respect to one another and movement of side pieces 110 and 114 towards one another in the directions shown by arrows 156. When trigger 152 is depressed, the collapsed frame will be drawn into the front hollow storage section of handle 40. (A similar type of spring-powered mechanism may be used to rotate the two frame halves of the device of FIG. 15 when a trigger is depressed.)
To use this device, the front end of the collapsed frame is pulled forward and pivot 120 is moved to its forwardmost position (FIG. 17). A spring (not shown) biases trigger 152 up, thereby pushing pin 146 down into hole 148 when the hole is brought into registration with the pin. That prevents the frame from collapsing and being moved inward by spring 140. A bag may be stored in a rear hollow section of handle 40. Regardless of where the bag is stored, it is placed on the frame and the device is used in the same manner the device of FIG. 1 is used. After disposal of the waste, the device may be collapsed and stored again in a pocket or pocketbook.
The collapsible frame and bag may have any shapes and be of any materials that allow them to perform the desired function. The frame may be circular, oval, rectangular, etc. so long as it can be collapsed or folded into or around or about the handle. Means may be present to push out or unfold or erect the collapsed frame. For example, spring-biased means similar to those in FIGS. 17-19 may be used to push the collapsed frame out of the handle when a trigger is depressed. Other means dissimilar to those of FIGS. 17-19 may also be used. The frame need not fold only but could also have telescoping members.
Other variations and modifications may be made in this and all other embodiments shown herein, and the claims are intended to cover all variations and modifications that fall within the true spirit and scope of the invention.
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Apparatus (including a frame and a bag), a preferred bag, and a method for packaging waste for disposal are disclosed. The frame fits into the bag at the open end of the bag. The frame has a central open area, and when waste material is placed on the outside of the bag corresponding to the open area of the frame, the waste material and the adjacent portion of the bag are pulled by gravity down through the open area of the frame. That pulls the bag tightly around the frame, which in turn facilitates the inversion of the bag as the bag is removed from the frame. Inversion of the bag results in the waste being trapped inside the bag, which may then be securely closed for disposal of the waste. The sizes and shapes of the frame and bag are not critical. The device finds particular use as a so-called "pooper scooper" for dogs.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/EP01/01539, filed Feb. 12, 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 a rotor seal, in particular for turbomachines, for sealing a sealing gap which is present between a stationary housing and a rotor that rotates relative to the housing. The rotor seal has sealing elements disposed one behind the other in the circumferential direction of the rotor.
[0004] A rotor seal of this type is known, for example, from International Patent Disclosure WO 00 03 164 A1, Published, European Patent Application EP 09 33 567 A2 or German Patent DE 44 03 605 C2. In the case of the lamellar seal described in DE 44 03 605 C2, the lamellae are folded from a strip material in such a way that folded edges are located at the beginning and end of the prospective lamellae. After folding, the strip material, which has been folded in concertina form, is brought into the desired shape and the strip material is cut at the folded edges, so that individual lamellae that seal the sealing gap between the housing and rotor are formed.
[0005] A drawback of the lamellar seal, and also of all other lamellar seals, is that there must inevitably be a space between the individual lamellae, in order to ensure sufficient elasticity of the lamellae in the radial direction. If this elasticity is not ensured, the lamellar seal becomes worn very quickly when the rotor, for example as a result of thermal expansion, moves out of its central position with respect to the lamellar seal. Moreover, fluid can flow through the gaps that are present between the lamellae, which reduces the sealing effect of the lamellar seal.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a rotor seal with a folding strap that overcomes the above mentioned disadvantages of the prior art devices of this general type, which has a sealing performance that is improved compared to lamellar seals and which withstands higher compressive loads. Moreover, it should be possible for the compressive force, elasticity and sealing action of the rotor seal according to the invention to be adapted in a simple manner to a very wide range of requirements.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a rotor seal for sealing a sealing gap present between a stationary housing and a rotor that rotates relative to the stationary housing. The rotor seal contains a folding strip being folded into a plurality of sealing elements disposed one behind another other in a circumferential direction of the rotor. The folding produces folded edges and the folded edges, in an installed state of the folding strip, run in a plane lying perpendicular to a rotor axis.
[0008] Possible application areas of the rotor seal according to the invention are turbomachines, such as steam turbines, gas turbines and compressors. However, the application of the rotor seal according to the invention is not restricted to the above-mentioned application areas.
[0009] In the case of turbomachines, it is important to provide a seal at the compensation piston, at the rotor outlets and at the blading, such that very small sealing gaps are possible despite non-steady-state thermal expansions or rotor displacements. The use of the rotor seal according to the invention is highly beneficial in turbomachines, since their efficiency increases if, despite the large radial thermal expansions that occur there, it is possible to have smaller sealing gaps.
[0010] The fact that a plurality of lamellae are folded from one folding strip results in that there is no longer any gap between the sealing elements, and consequently the sealing action of the rotor seal according to the invention is increased considerably compared to known lamellar seals. The rotor seal according to the invention can be used even for very high-pressure differences if the width, number of folds, setting angle and material thickness of the folding strip are selected accordingly. Moreover, the rotor seal according to the invention with a folding strip can be produced more easily and fitted more easily than a conventional lamellar seal.
[0011] In the rotor seal according to the invention, the sealing gap is very small under all operating conditions. After a brief spell of stripping, for example as a result of rotor oscillations or thermal expansions, the rotor seal according to the invention springs back into the starting position without being damaged. The elasticity of the rotor seal according to the invention is great in the radial direction.
[0012] In a further configuration of the invention, it is provided for the strip material to be folded along parallel folded edges and for the folding to take place in the opposite direction at two adjacent folded edges, so that any desired number of sealing elements can be produced integrally by folding a folding strip. In this way, the production of different sizes of rotor seals from an endless folding strip can easily be effected by varying the number of sealing elements that are folded onto one another.
[0013] In a variant of the invention, it is provided for the two parallel longitudinal edges of the folding strip and the parallel folded edges to include a production angle of <90°. The production angle is dependent on a pitch and width of the rotor seal. In this embodiment of the invention, the folded edges, in the installed state, do not run radially with respect to the axis of rotation of the rotor, but rather are inclined to a greater or lesser extent with respect to the surface of the rotor.
[0014] In an advantageous variant of the invention, there is provision for the folded edges, in the installed state, to include a setting angle γ of between 10° and 70°, particularly preferably between 20° and 45°, with a radius which originates from the rotor axis, so that the rotor seal according to the invention is on the one hand sufficiently elastic to be able to compensate for relative movements in the radial direction between the rotor and the housing and on the other hand has sufficient dimensional stability to provide a reliable seal under all operating conditions. Consequently, the sealing elements can easily be deflected in the radial direction of the axis of rotation of the rotor and can therefore easily compensate for relative movements in the radial direction between the rotor and the housing. The rigidity of the rotor seal according to the invention can easily be varied within wide limits according to the choice of the setting angle.
[0015] In this embodiment of the rotor seal according to the invention, the contact line between the sealing elements and the rotor does not, as in conventional lamellar seals, run parallel to the rotor axis, but rather runs as a zigzag line in the circumferential direction of the rotor.
[0016] In another configuration of the invention, a slit is provided in the region of the folded edges. A depth of the slit is less than the width of the folding strip, so that it is ensured that the sealing elements are held together even after slitting of the folding strip.
[0017] The operating performance of the rotor seal according to the invention changes according to which folded edges of the folding strip are slit. In the installed state, the folded edges lie in two parallel planes, one plane lying closer to the interior of the housing, which is at an increased pressure compared to ambient pressure, and the other plane-lying closer to the outer side of the housing.
[0018] If the folded edges that lie in the plane that lies closer to the interior of the housing are slit, a pressure increase in the interior of the housing causes the slits to close up, so that the sealing action is improved. If the folded edges that lie in the other plane are slit, a pressure increase in the interior of the housing causes the slits to open, so that there is protection against unacceptably high pressures.
[0019] In a further addition to the invention, the rotor seal, at its end that is remote from the sealing gap, has a carrier ring, so that the rotor seal can easily be connected to the housing or, if the rotor seal is to rotate with the rotor, to the rotor.
[0020] In a further configuration of the invention, the carrier ring has a sealing lip, so that a secondary leakage between the carrier ring and the housing or the rotor is reduced or eliminated. The sealing lip may also be configured as a latching element, so that the rotor seal according to the invention can be latched into a correspondingly shaped mating part of the housing or of the rotor.
[0021] In a further addition to the invention, there is provision for the strip material to be formed of a metallic material and/or for the strip material to be plastically deformable in the region of the folded edges and for the strip material otherwise to be resilient, so that the rotor seal can be used over a wide temperature range, has a high ability to withstand temperature and pressure, and moreover has a long service life.
[0022] To facilitate folding, the folding strip can be soft-annealed in the region of the folded edges.
[0023] In the folded state, the folding strip can be connected to a seal carrier in a force-locking or form-locking manner or by material-to-material bonding. In turn, the seal carrier can easily be connected to the housing or, if the rotor seal is to rotate, to the rotor. Therefore, an optimum connection between the folding strip and the seal carrier can be achieved according to the requirements imposed on the rotor seal.
[0024] In a particularly advantageous configuration of the invention, a recess is provided in the region of the folded edges, it being possible for the recess to be connected in a form-locking manner to a suitably shaped annular groove in a seal carrier, so that the sealing elements can be pushed into the annular groove in the longitudinal direction thereof and the form-lock prevents radial movement of the sealing elements relative to the seal carrier.
[0025] To further simplify the installation of the sealing elements, the seal carrier may be of a multipart configuration.
[0026] To further simplify installation, it is also possible for the parting plane of the seal carrier to run substantially parallel to the folded edges in the region of the parting plane.
[0027] In an advantageous embodiment of the invention, the seal carrier is secured to the housing, so that the rotor seal is only exposed to compressive loads.
[0028] In another configuration of the invention, the seal carrier is secured to the rotor, so that the sealing elements are also exposed to centrifugal forces. This effect can be used to make the distance between the sealing elements and the sealing surface on the housing dependent on the rotational speed. This is advantageous in particular if the distance, when the critical speed is passed through, is still sufficiently great to prevent excessive wear to the sealing elements and, when the operating speed is reached, the distance has reduced sufficiently to achieve an optimum sealing action.
[0029] A variant of the invention that is particularly suitable in terms of installation is characterized in that the rotor seal contains a plurality of segments, and in that each segment is folded from a folding strip. This embodiment makes it possible to produce even very large rotor seals.
[0030] A form-locking connection is one that connects two elements together due to the shape of the elements themselves, as opposed to a force-locking connection, which locks the elements together by force external to the elements.
[0031] A force-locking connection is one that connects two elements together by force external to the elements, as opposed to a form-locking connection, which is provided by the shapes of the elements themselves.
[0032] In accordance with another feature of the invention, the folding strip is soldered, welded or connected in a form-locking manner to the carrier ring.
[0033] In a concomitant feature of the invention, the rotor seal is a radial seal or an axial seal.
[0034] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0035] Although the invention is illustrated and described herein as embodied in a rotor seal with a folding strip, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0036] 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
[0037] [0037]FIG. 1 is a diagrammatic, cross-sectional view through a turbine housing according to the invention;
[0038] [0038]FIG. 2 is a perspective view of a detail II shown in FIG. 1 on an enlarged scale;
[0039] [0039]FIG. 3 is a perspective view of an illustration of a folding operation during installation of a folding strip;
[0040] [0040]FIG. 4 is a plan view of a first embodiment of a folding strip;
[0041] [0041]FIG. 5 is a plan view of a second embodiment of the folding strip;
[0042] FIGS. 6 A- 6 G are cross-sectional views of various lamellae;
[0043] [0043]FIG. 7 is an illustration of a partial region of a split seal carrier;
[0044] [0044]FIG. 8 is an illustration of a configuration of lamellae as seen in an axial direction of a seal carrier;
[0045] [0045]FIG. 8A is a sectional view taken along the line VIIIA-VIIIA shown in FIG. 8;
[0046] [0046]FIG. 9 is a sectional view of a configuration of the lamellae which differs from that shown in FIG. 8A; and
[0047] [0047]FIG. 10 is a perspective view of a further exemplary embodiment of a rotor seal according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a cross-sectional view through a turbine housing 1 , illustrating various seals 3 and 4 which act with respect to a rotor 2 . In the context of the present invention, the term “rotor” is to be understood as meaning all components that rotate relative to a housing or a bearing. An internal pressure p 1 prevails in an interior of the housing 1 , and an ambient pressure p 2 prevails outside the turbine housing 1 . The pressure difference p 1 −p 2 causes leaks between the interior of the housing 1 and the environment.
[0049] In FIG. 2, which shows a detail II from FIG. 1 on an enlarged scale and in perspective, an annular groove is introduced into the turbine housing 1 and is used as a seal carrier 5 . The groove has, on each of its opposite walls, a contoured projection 6 . A multiplicity of individual lamellae 7 , which contain metal sheets with a thickness of 0.04 to 0.1 mm, are stacked on top of one another in the annular groove in the seal carrier 5 . The lamellae 7 are connected to the seal carrier 5 in a form-locking manner via notches 8 that interact with the projections 6 .
[0050] The lamellae 7 are inclined at a setting angle γ of approximately 45° with respect to the normal to the longitudinal axis of the annular groove. Other forms of the cross sections of the seal carriers 5 are illustrated in FIGS. 6A to 6 D.
[0051] In principle, a folding strip 9 according to the invention can be secured to the turbine housing 1 in any desired way. The securing should be as elastic and pressure-tight as possible. The radial securing, with a rectangular annular groove as shown in FIG. 6A, is affected by compression, or is produced by the shape of a conical groove as shown in FIG. 6B or a contoured groove as shown in FIGS. 6C and 6D.
[0052] In a second embodiment, as shown in FIG. 6E, the folding strip 9 is soldered or welded to a carrier ring 23 or is connected to the latter in a form-locking manner. The carrier ring 23 can now very easily be anchored in an annular groove 24 in the turbine housing 1 .
[0053] Favorable solutions are achieved if the carrier ring 23 is configured, as shown in FIG. 6F, as a seal with a sealing lip 25 . The sealing lip 25 may be configured in such a way that it widens out under the pressure pi that is present, thus improving the sealing action. In a variant of this type, which is particularly suitable for high-pressure differences, the folding strip 9 can be supported by a supporting web 16 . This makes it possible in particular to ensure that the stresses at the location where the folding strap 9 is secured to the carrier ring 23 are minimized. In a further variant, as shown in FIG. 6G, deformation of the carrier ring 23 in operation is prevented.
[0054] The folding strip 9 with the carrier ring 23 can also be introduced radially into the annular groove 24 , and it can there latch in a shoulder. For this purpose, in particular the exemplary embodiment shown in FIG. 6F or 6 G with an integrated sealing lip 25 is recommended, since the sealing lip 25 can act as a latching lug and the carrier ring 23 can be latched to the annular groove 24 .
[0055] To ensure that it is not necessary for each lamella 7 to be manufactured individually and to simplify operations during installation, in accordance with FIG. 3, a plurality of lamellae 7 a are produced from the folding strip 9 .
[0056] The structure of the folding strip 9 is described below with reference to the exemplary embodiments illustrated in FIGS. 4 and 5. The folding strip 9 has two longitudinal edges 13 a and 13 b parallel to one another. A plurality of folding edges 11 run over the folding strip at a non-illustrated angle that is designated below as a production angle β. An angle α represents the additional angle between the non-illustrated production angle β and a normal 12 to the longitudinal edges 13 a and 13 b . The choice of the optimum production angle β is dependent, inter alia, on the pitch of the folding strip 9 . The choice of the production angle β makes it easy to adjust the operating performance of the rotor seal 7 a.
[0057] A bore 14 is introduced at each folded edge 11 , at a predeterminable distance from the longitudinal edge 13 b of the folding strip 9 . As an alternative to the round bore 14 that is illustrated, it is also possible to select other cutouts of any desired contour.
[0058] The folding strip 9 is folded directly into the annular groove in the seal carrier 5 (see FIG. 3) along the folded edges 11 , in each case in opposite directions, using a calking tool, which is denoted by 15 . After the folding, the bores 14 form a virtually semicircular cutout 8 a that engages in the correspondingly shaped projection 6 of the seal carrier 5 . The folding may also take place outside the seal carrier 5 , and the rotor seal 7 a formed from the folding strip 9 can then be introduced into the annular groove in the seal carrier 5 in the folded state. However, it is preferable for the folding to be carried out directly during installation using the calking tool 15 .
[0059] After the rotor seal 7 a has been installed, there can be no secondary leaks in the region of the folded edges 11 , and consequently a supporting web 16 indicated in FIG. 6D is not required.
[0060] In the exemplary embodiment shown in FIG. 4, the folding strip 9 is provided with slits 10 in the region of the folded edges 11 . Longitudinal axes of the slits 10 and of the folded edges 11 run parallel to one another. If, as illustrated in FIG. 4, a slit 10 is provided in the region of each folded edge 11 , the operating performance of the rotor seal 7 a according to the invention (see FIG. 2) substantially corresponds to that of a conventional lamellar seal. If the slit 10 is not provided at each folded edge 11 , the operating performance of the rotor seal according to the invention can be influenced further.
[0061] For example, if the slit 10 is only provided at every second folded edge 11 , by installing the rotor seal 7 a in the turbine housing 1 it is possible to further influence the operating performance. Specifically, if the rotor seal 7 a is installed in such a way that the slits 10 face in the direction of the higher pressure, the compressive forces, as the pressure difference p 1 −p 2 increases, cause the width of the slits 10 to close up. Otherwise, if the rotor seal 7 a is installed in such a way that the slits 10 face in the direction of the lower pressure, the compressive forces, as the pressure difference p 1 −p 2 increases, cause the slits 10 to open up, so that the seal cannot be destroyed by excess pressures.
[0062] A further advantage of the folding is that, depending on a depth T of the slits 10 (see FIG. 4) in the folding strip 9 and the thickness of the material of the strip, it is possible to have an influence on the rigidity. Furthermore, the folding ensures a certain minimum gap is present between the individual metal sheets. During installation of the folding strip 9 in the annular groove in the seal carrier 5 , fanning out in the radial direction is brought about automatically.
[0063] [0063]FIG. 5 illustrates a further exemplary embodiment of the folding strip 9 according to the invention. The depth T of the slits 10 is selected in such a way that the bore 14 as in the exemplary embodiment shown in FIG. 4 is not required. In the present exemplary embodiment, the folding strip 9 is locked to the base of the slit 10 at the projection 6 of the angular groove in the seal carrier 5 . In this exemplary embodiment, the supporting web 16 as shown in FIG. 6D may be necessary, in order to avoid secondary leakage. FIG. 5 indicates a soft material zone 19 , which is produced by heat treatment, in the region of the folded edges 11 , making it easier to fold the folding strip 9 .
[0064] In order for the folding strip 9 to be installed in an annular groove, the latter is provided with a non-illustrated local widening. As indicated in FIG. 7, in the case of installation in a split seal carrier 5 a , a parting surface 17 is inclined at an angle γ T with respect to a normal to the longitudinal axis of the annular groove. The angle γ T approximately corresponds to the setting angle γ indicated in FIG. 2. In the region of the parting surface 17 , the folded folding strip 9 can be prevented from dropping out by a lamella with a protuberance N engaged in the circumferential direction, the protuberance N being secured by a rivet 18 that is introduced into the parting surface 17 . Securing by a welded spot, local compression of the groove region, a notched pin or a screw is also possible.
[0065] [0065]FIG. 8 shows the fan-shaped configuration of the folded edges 11 in the split seal carrier 5 with a setting angle γ of 45°. The angle γ T of the parting surface 17 in this exemplary embodiment corresponds to the setting angle γ of the folded edges 11 .
[0066] As can be seen from FIG. 8A, end sides 20 of the lamellae, facing the rotor, run parallel to a rotor axis 21 .
[0067] A further improvement to the sealing performance is achieved by the slightly inclined installation of the lamellae shown in FIG. 9. The inclination is described by an angle of inclination δ between the rotor axis 21 and the end sides 20 of the rotor seal 7 a . In the exemplary embodiment shown in FIG. 9, the angle of inclination δ is approximately 10° to 20°. However, the angle of inclination δ is not restricted to this angle range.
[0068] The inclination of the end sides 20 makes it possible to achieve the effect which is known from brush seals, according to which the lamellae 7 bear against one another as a result of the pressure difference p 1 −p 2 and as a result of momentum forces. This can also be promoted by a transverse slit 22 in the lamellae 7 .
[0069] [0069]FIG. 10 provides a perspective illustration of a further exemplary embodiment of a rotor seal according to the invention. This illustration clearly indicates that folded edges 11 a lie in a plane that runs perpendicular to the rotor axis 21 . The folded edges 11 b likewise lie in a plane that runs perpendicular to the rotor axis 21 . The two planes run parallel to and at a distance from one another, the distance corresponding to a width b of the folding strip 9 .
[0070] If the folding strip 9 is fitted to the turbine housing 1 , it is not additionally subjected to loads and deformation by centrifugal forces. At the internal diameter d i , the folding strip 9 is elastic in the radial direction. At its external diameter d a , the folding strip 9 is connected in a sealed manner to a turbine housing. The setting angle γ, which cannot be shown in FIG. 10 on account of the perspective illustration, is partially responsible for determining the rigidity of the folding strip 9 in the radial direction.
[0071] It may be advantageous if the width b is slightly greater than the pitch t measured at the internal diameter d i . The free height of the folding strip is determined by the radial elasticity required.
[0072] Finally, it should also be mentioned that the folding strip 9 can also be applied so as to act axially in the same way. Moreover, for some situations, on account of a low centrifugal force action, it is acceptable for the folding strip 9 to be secured to the rotor 2 . This may even be desirable, if it is necessary for the centrifugal force acting on the folding strip 9 to be utilized in such a manner that the definitive gap width is only established when the full rotational speed is reached. This would provide the option of having greater gap widths when a turbomachine is being started up and when passing through the critical speed, which in turn significantly increases the operational reliability.
[0073] All the features which have been disclosed in the description, the drawing and the patent claims may be pertinent to the invention both individually and in any desired combination with one another.
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A rotor seal, especially for turbo engines, is described. The sealing elements are folded from a pleated band and are connected to each other even when the rotor seal is in the assembled state. The barrier effect of the inventive rotor seal is thus increased in relation to lamella seals that always require a gap between the individual lamella.
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FIELD OF INVENTION
This invention relates to the synthesis of heteroarylamine compounds which are useful in the production of heteroaryl ureas a key component in pharmaceutically active compounds possessing a heteroaryl urea group.
BACKGROUND OF THE INVENTION
Aryl- and heteroaryl-substituted ureas have been described as inhibitors of cytokine production. These inhibitors are described as effective therapeutics in cytokine-mediated diseases, including inflammatory and autoimmune diseases. Examples of such compounds are reported in WO 99/23091 and in WO 98/52558.
A key step in the synthesis of these compounds is the formation of the urea bond. Various methods have been reported to accomplish this. For example, as reported in the above references, an aromatic or heteroaromatic amine, Ar 1 NH 2 , may be reacted with an aromatic or heteroaromatic isocyanate, Ar 2 NCO, to generate the urea Ar 1 HC(O)NHAr 2 .
If not commercially available, one may prepare the isocyanate by reaction of an aryl or heteroaryl amine Ar 2 —NH 2 with phosgene or a phosgene equivalent, such as bis(trichloromethyl) carbonate (triphosgene) (P. Majer and R. S. Randad, J. Org. Chem. 1994, 59, 1937) or trichloromethyl chloroformate (diphosgene) (K. Kurita, T. Matsumura and Y. Iwakura, J. Org. Chem. 1976, 41, 2070) to form the isocyanate Ar 2 —NCO, followed by reaction with Ar 1 NH 2 to provide the urea. Other approaches to forming the urea reported in the chemical literature include reaction of a carbamate with an aryl or heteroaryl amine, (see for example B. Thavonekham, Synthesis, 1997, 1189 and T. Patonay et al., Synthetic Communications, 1996, 26, 4253) as shown in Scheme II. U.S. Provisional Application No. 60/143,094 also discloses a process of making heteroaryl ureas by reacting particular carbamate intermediates with the desired arylamine.
U.S. application Ser. No. 09/505,582 and PCT/US00/03865 describe cytokine inhibiting ureas of the following formula:
An intermediate required to prepare preferred compounds described therein has a 1,4-disubstituted naphthalene as Ar 2 and is illustrated in the formula below.
The preparation of these intermediates require the coupling of the naphthyl ring with X. Preferred X include aryl and heteroaryl groups. Previously described methods, including U.S. application Ser. No. 09/505,582 and PCT/US00/03865 achieve the coupling of these aromatic residues by using a coupling reaction catalyzed by a transition metal, such as palladium, in the presence of a ligand, such as triphenyl phosphine. Coupling methods include Stille coupling, requiring the preparation of a tributylstannyl intermediate, or a Suzuki coupling, requiring the preparation of a boronic acid intermediate (Scheme III).
Some steps in these methods require cooling to extreme temperatures (−78° C.). Others require reaction under high pressure, require chromatography to purify the product, or use expensive reagents. For these reasons, these methods are not suitable for large-scale or industrial-scale production.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a novel method of producing heteroaryl amines of the formula(I):
wherein X, Y and Z are described below, the heteroarylamines are useful in the production of heteroaryl ureas as mentioned above.
DETAILED DESCRIPTION OF THE INVENTION
Disclosed herein is a novel process for preparing preferred heteroarylamine intermediates including those heteroarylamine intermediates described in U.S. application Ser. No. 09/505,582, and PCT/US00/03865. The processes described herein have several advantages. They use inexpensive starting materials and reagents, the reactions are run at moderate temperatures, there are no high-pressure reactions and chromatography is not required.
The novel feature of the invention is the construction of naphthalene ring, as exemplified in Scheme I below, from the appropriately substituted carboxylic acid 5, which in turn was synthesized beginning from a novel ester of the formula (II) and a diester such as diethyl succinate. Any of the compounds of the formula (II) as described herein can be synthesized from readily available and cost efficient starting materials such as example 1 below.
This invention provides a novel strategy for the synthesis of heteroarylamine compounds of the formula (I):
wherein:
the naphthyl ring is further optionally substituted by one or more R 1 or R 2 ;
X is chosen from
a C 5-8 cycloalkyl and cycloalkenyl optionally substituted with one to two oxo groups or one to three C 1-4 alkyl, C 1-4 alkoxy or C 1-4 alkylamino chains each being branched or unbranched;
aryl, furanyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, pyridinyl, pyrimidinyl, pyridinonyl, dihydropyridinonyl, maleimidyl, dihydromaleimidyl, piperdinyl, benzimidazole, 3H-imidazo[4,5-b]pyridine, piperazinyl, pyridazinyl and pyrazinyl; each being optionally independently substituted with one to three C 1-4 alkyl, C 1-4 alkoxy, hydroxy, nitro, nitrile, amino, mono- or di-(C 1-3 alkyl)amino, mono- or di-(C 1-3 alkylamino)carbonyl, NH 2 C(O), C 1-6 alkyl-S(O) m or halogen;
Y is chosen from
a bond and a C 1-4 saturated or unsaturated branched or unbranched carbon chain optionally partially or fully halogenated, wherein one or more methylene groups are optionally replaced by O, N, or S(O) m and wherein Y is optionally independently substituted with one to two oxo groups, phenyl or one or more C 1-4 alkyl optionally substituted by one or more halogen atoms;
Z is chosen from
phenyl, pyridinyl, pyrimidinyl, pyridazinyl, pyrazinyl, imidazolyl, pyrazolyl, triazolyl, tetrazolyl, furanyl, thienyl, pyranyl, each being optionally substituted with one to three halogen, C 1-6 alkyl, C 1-6 alkoxy, hydroxy, amino, mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) m , CN, CONH 2 , COOH or phenylamino wherein the phenyl ring is optionally substituted with one to two halogen, C 1-6 alkyl or C 1-6 alkoxy;
tetrahydropyranyl, tetrahydrofuranyl, 1,3-dioxolanonyl, 1,3-dioxanonyl, 1,4-dioxanyl, morpholinyl, thiomorpholinyl, thiomorpholinyl sulfoxidyl, thiomorpholinyl sulfonyl, piperidinyl, piperidinonyl, piperazinyl, tetrahydropyrimidonyl, cyclohexanonyl, cyclohexanolyl, pentamethylene sulfidyl, pentamethylene sulfoxidyl, pentamethylene sulfonyl, tetramethylene sulfide, tetramethylene sulfoxidyl or tetramethylene sulfonyl each being optionally substituted with one to three nitrile, C 1-6 alkyl, C 1-6 alkoxy, hydroxy, amino, mono- or di-(C 1-3 alkyl)amino-C 1-3 alkyl, CONH 2 , phenylamino-C 1-3 alkyl or C 1-3 alkoxy-C 1-3 alkyl;
halogen, C 1-4 alkyl, nitrile, amino, hydroxy, C 1-6 alkoxy, NH 2 C(O), mono- or di(C 1-3 alkyl) aminocarbonyl, mono- or di(C 1-3 alkyl)amino, secondary or tertiary amine wherein the amino nitrogen is covalently bonded to C 1-3 alkyl or C 1-5 alkoxyalkyl, pyridinyl-C 1-3 alkyl, imidazolyl-C 1-3 alkyl, tetrahydrofuranyl-C 1-3 alkyl, nitrile-C 1-3 alkyl, carboxamide-C 1-3 alkyl, phenyl, wherein the phenyl ring is optionally substituted with one to two halogen, C 1-6 alkoxy, hydroxy or mono- or di-(C 1-3 alkyl)amino, C 1-6 alkyl-S(O) m , or phenyl-S(O) m , wherein the phenyl ring is optionally substituted with one to two halogen, C 1-6 alkoxy, hydroxy, halogen or mono- or di-(C 1-3 alkyl)amino;
C 1-6 alkyl-S(O) m , and phenyl-S(O) m , wherein the phenyl ring is optionally substituted with one to two halogen, C 1-6 alkoxy, hydroxy or mono- or di-(C 1-3 alkyl)amino;
R 1 and R 2 are independently chosen from:
a C 1-6 branched or unbranched alkyl optionally partially or fully halogenated, C 1-4 branched or unbranched alkoxy, each being optionally partially or fully halogenated, halogen, C 1-3 alkyl-S(O) m optionally partially or fully halogenated and phenylsulfonyl;
and
m is 0, 1 or 2.
The process of the invention in its broadest generic aspect is provided below and exemplified in a non-limiting embodiment shown in Scheme 1:
said process comprising:
a) reacting a Z—Y—X—COO—R x ester (II) wherein R x is C 1-5 alkyl or aryl with a di-alkyl or diaryl ester (III) in a suitable solvent protic or aprotic, polar or nonpolar, preferably aprotic such as THF, DME, DMSO, ether, dioxane, CH 2 Cl 2 , CHCl 3 , toluene, pyridine or DMF, or suitable alcohols, preferably the solvent is chosen from THF and DMSO, more preferably THF, and a suitable base such as organic or inorganic bases such as NaH, NaNH 2 , sodium alkoxides such as Na-t-butoxide, Na-ethoxide, NaOH, pyridine, TEA, DBU or BuLi, preferably NaH or Na t-butoxide, and optionally where appropriate as in Example 3, in the presence of an additive such as DMPU and HMPA, preferably DMPU, under the temperature of about 0 to 200° C. for a reaction time of about 5 min to 24 h, preferably when using the preferred solvent THF at 60-70° C. for about 8 h and isolating the compound intermediate (IV). Examples 1 & 2 are representative methods for preparation of compounds of the formula(II), methods of preparing other compounds of the formula(II) is within the skill in the art.
b) subjecting the product of step a) to acidic or basic hydrolysis, preferably acidic hydrolysis, and decarboxylation under suitable acid conditions apparent to those skilled in the art, such as conc. H 2 SO 4 in HOAc at a temperature of about 50 to 200° C. and for about 5 min to 24 hours, preferably about 100° C. for about 7 h; followed by esterification under appropriate conditions with a C 1-5 alcohol, preferably EtOH; subsequent phenyl nucleophilic addition via for example a phenyl Grignard reagent PhMgBr, phenylLi, phenylZnCl, preferably phenyl Grignard, the phenyl being optionally substituted by R 1 and/or R 2 ; reductive cleavage under appropriate conditions such as HCOONH 4 /Pd/C/EtOH to form a carboxylic acid compound which on treatment with a strong mineral acid such as H 2 SO 4 , HCl, MeSO 3 H, CF 3 SO 3 H, PPA or Lewis acid such as SnCl 4 , AlCl 3 , BF 3 —OEt 2 and Yb(OTf) 2 , preferably PPA, optionally in a suitable solvent at RT to 200° C., preferably about 110° C., to form a product intermediate of the formula(V), and isolating the product:
c) reacting the product from step b) with HNR y R z or it's respective salt thereof, to form an enamine or imine, preferably an oxime, compound of the formula(VI) under suitable conditions.
wherein R y is C 1-5 alkyl or hydrogen, R z is C 1-5 alkyl, hydrogen or OH with the proviso that when formula (VI) is an enamine tautomer then R y and R z are both C 1-5 alkyl, or when formula (VI) is an imine tautomer then R z is OH, C 1-5 alkyl or hydrogen and R y is not present:
In a preferred but nonlimiting embodiment, forming an oxime by adding NH 2 OH.HCl (where R y is H and R z is OH) in a suitable solvent such as EtOH with a suitable base such as NaOH at about RT for about 1 to 24 h, preferably 18 h;
c) 1) where the product of step c) is an imine, preferably an oxime (R y ═H, R z ═OH), preferably in a one pot reaction acylating and reducing the product of step c) under conditions known in the art, a preferred but non-limiting example is acetylating/reducing conditions, such as treating compound (VI) with acetic anhydride, acetic acid and a suitable reducing agent such as Fe, SnCl 2 and Zn, preferably Fe, at about 55° C. for about 5 hours; then treating the unsaturated amide product (8) under oxidizing conditions capable of forming the naphthalene ring of the formula(I) above, for example, treating the amide product(8) with an oxidizing reagant such as DDQ, O 2 , CrO 3 and KMnO 4 , preferably DDQ, in a nonpolar solvent such as methylene chloride, at about 0 to 50° C., preferably RT for about 0.5 to 10 h, preferably 5 h; followed by deprotection by methods known in the art to provide the formation of formula (I):
or
2) where the product of step c) is an enamine, oxidizing the enamine under suitable oxidizing conditions to form the naphthalene ring, then deprotecting the nitrogen to form the amine of the formula (I). In a non-limiting example, R y and R z are benzyl, oxidation to the naphthalene ring may be accomplished as described above, and debenzylation may be accomplished by methods known to those skilled in the art, for example H 2 /palladium/C.
Compounds of the formula (I) possessing a particularly desired Ar—X—Y—Z combination can be synthesized without undue experimentation by variations apparent to those of ordinary skill in the art in view of the teachings in this specification and the state of the art. More specific examples of possible X—Y—Z combinations are to be found in PCT application no. PCT/US00/03865 and U.S. application Ser. No. 09/505,582 each of which is incorporated herein by reference in their entirety.
In another embodiment of the invention there is provided a novel process of making compounds of the formula(I) as described above and wherein:
X is chosen from
a C 5-8 cycloalkyl and cycloalkenyl optionally substituted with one to two oxo groups or one to three C 1-4 alkyl, C 1-4 alkoxy or C 1-4 alkylamino chains each being branched or unbranched;
aryl, pyridinyl, pyrimidinyl, pyridinonyl, dihydropyridinonyl, maleimidyl, dihydromaleimidyl, piperdinyl, benzimidazole, 3H-imidazo[4,5-b]pyridine, piperazinyl, pyridazinyl and pyrazinyl; each being optionally independently substituted with one to three C 1-4 alkyl, nitro, nitrile, mono- or di-(C 1-3 alkyl)amino, mono- or di-(C 1-3 alkylamino)carbonyl, NH 2 C(O), C 1-6 alkyl-S(O) m or halogen;
Y is chosen from
a bond and
a C 1-4 saturated or unsaturated carbon chain wherein one of the carbon atoms is optionally replaced by O, N, or S(O) m and wherein Y is optionally independently substituted with one to two oxo groups, phenyl or one or more C 1-4 alkyl optionally substituted by one or more halogen atoms;
Z is chosen from:
phenyl, pyridinyl, pyrimidinyl, pyridazinyl, pyrazinyl, imidazolyl, furanyl, thienyl, dihydrothiazolyl, dihydrothiazolyl sulfoxidyl, pyranyl, pyrrolidinyl which are optionally substituted with one to three nitrile, C 1-3 alkyl, C 1-3 alkoxy, hydroxy, amino, mono- or di-(C 1-3 alkyl)amino or CONH 2 ;
tetrahydropyranyl, tetrahydrofuranyl, 1,3-dioxolanonyl, 1,3-dioxanonyl, 1,4-dioxanyl, morpholinyl, thiomorpholinyl, thiomorpholinyl sulfoxidyl, piperidinyl, piperidinonyl, piperazinyl, tetrahydropyrimidonyl, pentamethylene sulfidyl, pentamethylene sulfoxidyl, pentamethylene sulfonyl, tetramethylene sulfidyl, tetramethylene sulfoxidyl or tetramethylene sulfonyl which are optionally substituted with one to three nitrile, C 1-3 alkyl, C 1-3 alkoxy, hydroxy, amino, mono- or di-(C 1-3 alkyl)amino or CONH 2 ;
nitrile, C 1-6 alkyl-S(O) m , halogen, hydroxy, C 1-4 alkoxy, amino, mono- or di-(C 1-6 alkyl)amino, mono- or di-(C 1-3 alkyl)aminocarbonyl and NH 2 C(O).
In yet another embodiment of the invention there is provided a novel process of making compounds of the formula(I) as described immediately above and wherein:
X is chosen from
aryl, pyridinyl, pyrimidinyl, benzimidazole, 3H-imidazo[4,5-b]pyridine, piperazinyl, pyridazinyl and pyrazinyl; each being optionally independently substituted with one to three C 1-4 alkyl, nitro, nitrile, mono- or di-(C 1-3 alkyl)amino, mono- or di-(C 1-3 alkylamino)carbonyl, NH 2 C(O), C 1-6 alkyl-S(O) m or halogen;
Y is chosen from
a bond and
a C 1-4 saturated carbon chain wherein one of the carbon atoms is optionally replaced by O, N or S and wherein Y is optionally independently substituted with an oxo group;
Z is chosen from
phenyl, pyridinyl, pyrimidinyl, pyridazinyl, pyrazinyl, imidazolyl, dihydrothiazolyl, dihydrothiazolyl sulfoxide, pyranyl and pyrrolidinyl which are optionally substituted with one to two C 1-2 alkyl or C 1-2 alkoxy;
tetrahydropyranyl, morpholinyl, thiomorpholinyl, thiomorpholinyl sulfoxidyl, piperidinyl, piperidinonyl, piperazinyl and tetrahydropyrimidonyl which are optionally substituted with one to two C 1-2 alkyl or C 1-2 alkoxy; and C 1-3 alkoxy.
In yet still another embodiment of the invention there is provided a novel process of making compounds of the formula(I) as described immediately above and wherein:
X is chosen from
pyridinyl and pyrimidinyl, each being optionally independently substituted with one to three C 1-4 alkyl, nitro, nitrile, mono- or di-(C 1-3 alkyl)amino, mono- or di-(C 1-3 alkylamino)carbonyl, NH 2 C(O), C 1-6 alkyl-S(O) m or halogen;
Y is chosen from
a bond,
—CH 2 —, —CH 2 CH 2 —, —C(O)—, —O—, —S—, —NH—CH 2 CH 2 CH 2 —, —N(CH 3 )— and —NH—;
In yet a further embodiment of the invention there is provided a novel process of making compounds of the formula(I) as described immediately above and wherein:
Y is chosen from
—CH 2 —, —NH—CH 2 CH 2 CH 2 — and —NH— and
Z is morpholinyl.
All terms as used herein in this specification, unless otherwise stated, shall be understood in their ordinary meaning as known in the art. For example, “C 1-6 alkoxy” is a C 1-6 alkyl with a terminal oxygen, such as methoxy, ethoxy, propoxy, pentoxy and hexoxy. All alkyl, alkenyl and alkynyl groups shall be understood as being branched or unbranched where structurally possible and unless otherwise specified. Other more specific definitions are as follows:
The term “aroyl” as used in the present specification shall be understood to mean “benzoyl” or “naphthoyl”.
The term “aryl” as used herein shall be understood to mean aromatic carbocycle or heteroaryl as defined herein.
The term “carbocycle” shall be understood to mean an aliphatic hydrocarbon radical containing from three to twelve carbon atoms. Carbocycles include hydrocarbon rings containing from three to ten carbon atoms. These carbocycles may be either aromatic and non-aromatic ring systems. The non-aromatic ring systems may be mono- or polyunsaturated. Preferred carbocycles include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptanyl, cycloheptenyl, phenyl, indanyl, indenyl, benzocyclobutanyl, dihydronaphthyl, tetrahydronaphthyl, naphthyl, decahydronaphthyl, benzocycloheptanyl and benzocycloheptenyl. Certain terms for cycloalkyl such as cyclobutanyl and cyclobutyl shall be used interchangeably.
The term “heterocycle”, unless otherwise noted, refers to a stable nonaromatic 4-8 membered (but preferably, 5 or 6 membered) monocyclic or nonaromatic 8-11 membered bicyclic heterocycle radical which may be either saturated or unsaturated. Each heterocycle consists of carbon atoms and one or more, preferably from 1 to 4 heteroatoms selected from nitrogen, oxygen and sulfur. The heterocycle may be attached by any atom of the cycle, which results in the creation of a stable structure. Unless otherwise stated, heterocycles include but are not limited to, for example oxetanyl, pyrrolidinyl, tetrahydrofuranyl, tetrahydrothiophenyl, piperidinyl, piperazinyl, morpholinyl, tetrahydropyranyl, dioxanyl, tetramethylene sulfonyl, tetramethylene sulfoxidyl, oxazolinyl, thiazolinyl, imidazolinyl, tertrahydropyridinyl, homopiperidinyl, pyrrolinyl, tetrahydropyrimidinyl, decahydroquinolinyl, decahydroisoquinolinyl, thiomorpholinyl, thiazolidinyl, dihydrooxazinyl, dihydropyranyl, oxocanyl, heptacanyl, thioxanyl, dithianyl or 2-oxa- or 2-thia-5-aza-bicyclo[2.2.1]heptanyl.
The term “heteroaryl”, unless otherwise noted, shall be understood to mean an aromatic 5-8 membered monocyclic or 8-11 membered bicyclic ring containing 1-4 heteroatoms such as N, O and S. Unless otherwise stated, such heteroaryls include: pyridinyl, pyridonyl, quinolinyl, dihydroquinolinyl, tetrahydroquinoyl, isoquinolinyl, tetrahydroisoquinoyl, pyridazinyl, pyrimidinyl, pyrazinyl, benzimidazolyl, benzthiazolyl, benzoxazolyl, benzofuranyl, benzothiophenyl, benzpyrazolyl, dihydrobenzofuranyl, dihydrobenzothiophenyl, benzooxazolonyl, benzo[1,4]oxazin-3-onyl, benzodioxolyl, benzo[1,3]dioxol-2-onyl, tetrahydrobenzopyranyl, indolyl, indolinyl, indolonyl, indolinonyl, phthalimidyl.
Terms which are analogs of the above cyclic moieties such as aryloxy or heteroaryl amine shall be understood to mean an aryl, heteroaryl, heterocycle as defined above attached to it's respective functional group.
As used herein, “nitrogen” and “sulfur” include any oxidized form of nitrogen and sulfur and the quaternized form of any basic nitrogen.
The term “halogen” as used in the present specification shall be understood to mean bromine, chlorine, fluorine or iodine except as otherwise noted.
DDQ—2,3-Dichloro-5,6-dicyano-1,4-benzoquinone;
PPA—Polyphosphoric acid;
HOAc—acetic acid;
RT or rt—room temperature;
n-BuLi—n-Butyllithium
DME—1,2-Dimethoxyethane
DMSO—Methyl sulfoxide
DMF—N,N-Dimethylformamide
DBU—1,8-Diazabicyclo[5.4.0]undec-7-ene
DMPU—N,N′-Dimethylpropyleneurea
HMPA—Hexamethylphosphoramide
TEA—Triethylamine
THF—Tetrahydrofuran.
The compounds of the invention are only those which are contemplated to be ‘chemically stable’ as will be appreciated by those skilled in the art. For example, a compound which would have a ‘dangling valency’, or a ‘carbanion’ are not compounds contemplated by the invention.
In order that this invention be more fully understood, the following examples are set forth in the overall reaction scheme below. These examples are for the purpose of illustrating preferred embodiments of this invention, and are not to be construed as limiting the scope of the invention in any way. Sample methods and starting materials to make compound (1) in Scheme I are shown in Examples 1 and 2 below.
EXAMPLES
Example 1
Preparation of chloride: A solution of alcohol shown above (18.0 g, 100 mmol) in 200 mL of CH 2 Cl 2 was prepared and cooled in an ice-water bath. A solution of SOCl 2 (22 mL, 300 mmol) in 100 mL of CH 2 Cl 2 was added to the above solution at the rate to keep the internal temperature below 10° C. After the addition, the cooling bath was removed and the reaction mixture was warmed to room temperature over 2 h. The reaction mixture was evaporated to remove all volatile by rotavap. The residue was dissolved in 150 mL of CH 2 Cl 2 and saturated sodium bicarbonate solution was added until pH=9. The aqueous layer was extracted with CH 2 Cl 2 . The combined organic layers were dried (MgSO 4 ) and concentrated to give 20.0 g (100%) of the desired chloride. 1 H NMR (CDCL 3 ): δ9.15 (s, 1H), 8.33 (d, J=8 Hz, 1H), 7.58 (d, J=8 Hz), 4.73 (s, 2H), 4.42 (q, J=7 Hz, 2H), 1.42 (t, J=7 Hz, 3H).
Example 2
Preparation of morpholine moiety: A solution of chloride from Example 1 above (20 g, 100 mmol) and triethylamine (15.2 g, 150 mmol) in 125 mL of CH 2 Cl 2 was prepared. 11 g (126 mmol) of morpholine was added and the reaction mixture was stirred at room temperature overnight (18 h). 100 mL of saturated sodium bicarbonate solution was added. The aqueous layer was extracted with CH 2 Cl 2 (2×50 mL). The combined organic layers were dried (MgSO 4 ) and concentrated to give 24.3 g (97%) of desired product. 1 H NMR (CDCL 3 ): δ9.15 (s, 1H), 8.25 (d, J=8 Hz, 1H), 7.52 (d, J=8 Hz, 1H), 4.40 (q, J=7 Hz, 2H), 3.73 (m, 6H), 2.51 (t, J=4 Hz, 4H), 1.40 (t, J=7 Hz, 3H).
Example 3
Diester (2). To a mixture of ester 1 (10.0 g, 40 mmol), diethyl succinate (7.0 g, 40 mmol) and sodium hydride (60% dispersion in mineral oil, 3.20 g, 80 mmol) in dry THF (200 ml) was added DMPU (20 ml) and methanol (0.10 ml) and the mixture was refluxed for 2.5 h. Additional diethyl succinate (10.50 g, 60 mmol) and sodium hydride (4.80 g, 120 mmol) were added in five equal portions to the refluxing reaction mixture at 0.75 h intervals. Refluxing was continued for additional 1.5 h. The cooled reaction mixture was poured into a stirring mixture of 2N HCl (200 ml) and ethyl acetate (200 ml). The aqueous phase was separated, the pH was adjusted to 8.5 with saturated sodium bicarbonate and it was extracted with ethyl acetate. The organic layer was washed with water and dried over anhydrous sodium sulfate. Evaporation of ethyl acetate gave almost pure 2 as yellowish brown oil (10.65 g, 70.4%). 1 H NMR (CDCl 3 ) δ1.16 (t, J-=7.2 Hz, 3H), 1.22 (t, J=7.2 Hz, 3H), 2.51-2.53 (m, 4H), 3.02-3.20 (m, 2H), 3.72-3.75 (m, 6H), 4.10-4.15 (m, 4H), 4.78-4.80 (m, 1H), 7.58 (d, J=8.0 Hz, 1H), 8.27 (d, J=6.0 Hz, 1H), and 9.18 (d, J=2.1 Hz, 1H).
Example 4
Keto ester (3). Concentrated sulfuric acid (10 ml) was added carefully to the solution of the diester 2 (11.55 g, 30.5 mmol) in acetic acid (60 ml). The mixture was stirred at 100° C for 6.5 h. After removing 30-40 ml of acetic acid under reduced pressure, ethanol (125 ml) was added to the residue and the reaction mixture was refluxed for 3.5 h. It was concentrated on a rotary evaporator followed by quenching with water. The mixture was extracted with ethyl acetate. The aqueous layer was separated, treated with saturated NaHCO 3 and extracted with methylene chloride. After drying over anhydrous sodium sulfate, the solvent was evaporated to give 3 as red viscous oil in practically pure state (8.35 g, 89%). Analytically pure sample was obtained from a silica gel column using ethyl acetate/hexane (1:1) as solvent for elution. 1 H NMR (CDCl 3 ) δ1.27 (t, J=7.2 Hz, 3H), 2.50-2.53 (m, 4H), 2.76-2.79 (m, 2H), 3.28-3.31 (m, 2H), 3.72-3.75 (m, 6H), 4.15 (q, J=7.2 Hz, 2H), 7.56 (d, J=8.0 Hz, 1H), 8.21 (d, J=6.0 Hz, 1H) and 9.13 (d, J=2.0 Hz, 1H).
Example 5
Lactone (4). Phenylmagnesium bromide (1M/THF, 37.1 mmol, 37.1 ml) was added slowly to a stirring solution of the keto ester 3 (8.11 g, 26.5 mmol) in dry THF at −5° C. so that the reaction temperature stayed below 0° C. The reaction mixture was stirred at this temperature for additional 0.5 h. After quenching with 10% ammonium chloride solution, it was extracted with ethyl acetate, dried over anhydrous sodium sulfate and evaporated to give crude 4. An analytically pure sample was obtained from a silica gel column using ethyl acetate as solvent. 1 H NMR (CDCl 3 ) δ2.47-2.49 (m, 4H), 2.58-2.62 (m, 2H), 2.92 (m, 2H), 3.62 (s, 2H), 3.70-3.72 (m, 4H), 7.29-7.42 (m, 6H), 7.69-7.71 (m, 1H) and 8.62 (d, J=2.0 Hz, 1H).
Example 6
Acid (5). To the solution of crude lactone 4 (from above) in reagent alcohol (100 ml) was added ammonium formate (5.0 g) and 10% Pd/C (0.66 g) and the reaction mixture was refluxed for 2.5 h. The catalyst was filtered and the filtrate was concentrated. A saturated solution of NaHCO 3 was added until the pH was 8.5. It was extracted with ethyl acetate to remove non-acidic impurities. The pH of the aqueous phase was then lowered to 6.5-7 with 2N HCl and it was extracted with CH 2 Cl 2 , dried over anhydrous sodium sulfate and concentrated to give 5 as light brown viscous oil (3.7 g, 41% over two steps). 1 H NMR (CDCl 3 ) δ2.27-2.42 (m, 4H), 2.54-2.56 (m, 4H), 3.65 (s, 2H), 3.71-3.3.73 (m, 4H), 4.09-4.13 (m, 1H), 7.22-7.31 (m, 6H), 7.49-7.51 (m, 1H) and 8.51 (s, 1H).
Example 7
Tetralone (6). A mixture of acid 5 (3.6 g, 10.6 mmol) and polyphosphoric acid (85 g.) was stirred at 110° C. for 1.5 h. After cooling, the reaction mixture was quenched with cold water and treated with 2N NaOH to bring the pH up to −5. It was extracted with CH 2 Cl 2 , dried over anhydrous sodium sulfate and evaporated to give almost pure ketone 6 as brown viscous oil (3.1 g, 90%). An analytically pure sample was obtained from preparative TLC using ethyl acetate as a solvent. 1 H NMR (CDCl 3 ) δ2.23-2.35 (m, 1H), 2.45-2.78 (m, 7H), 3.68-3.77 (m, 6H), 4.32-4.36 (m, 1H), 6.94 (d, J=6.4 Hz, 1H), 7.34-7.7.47 (m, 4H), 8.13 (d, J=6.4 Hz, 1H) and 8.45 (d, J=2.0 Hz, 1H).
Example 8
Oxime (7). A solution of NaOH (1N, 17.6 ml, 17.6 mmol) was added to a stirring solution of hydroxylamine hydrochloride (1.19 g, 17.1 mmol) in water (10 ml) at 0° C. over five minutes followed by addition of the solution of ketone 6 (3.06 g, 9.5 mmol) in reagent alcohol (20 ml). After stirring the reaction mixture at room temperature for 18 h, it was diluted with water and extracted with methylene chloride. The organic layer was dried over anhydrous sodium sulfate and evaporated to give crude product. It was purified by silica gel chromatography using ethyl acetate as the solvent to give 7 as a colorless oil. It solidified on standing (2.00 g, 62%). 1 H NMR (CDCl 3 ) δ2.02-2.12 (m, 1H), 2.16-2.26 (m, 1H), 2.50-2.60 (m, 4H), 2.70-2.90 (m, 2H), 3.7 (s, 2H), 3.72-3.78 (m, 4H), 4.15-4.20 (m, 4H), 6.90-6.95 (m, 1H), 7.20-7.35 (m, 3H), 7.98-8.02 (m, 1H), 8.4 (s, 1H) and 9.05 (bs, 1H).
Example 9
Amide (8). A solution of oxime 7 (1.42 g, 4.2 mmol) in acetic anhydride (15 ml) and acetic acid (1 ml, 16.8 mmol) was stirred at room temperature for 0.5 h. Iron powder (0.63 g, 10 mgatom) was added and the mixture was stirred at 55° C. for 5 h. The reaction mixture was cooled, ethyl acetate was added and the resulting mixture was filtered. The filtrate was evaporated to dryness. Water was added, the pH was adjusted to ˜8 with 2N NaOH and again extracted with ethyl acetate. It was dried over anhydrous sodium sulfate and concentrated. The crude product was purified by silica gel chromatography eluting with 2.5% MeOH/CH 2 Cl 2 to give 8 as yellow viscous oil (1.08 g, 71%). 1 H NMR (CDCl 3 ) 2.18 (s, 3H), 2.50-2.51 (m, 4H), 2.63-2.66 (m, 2H), 3.62-3.73 (m, 6H), 6.30-6.31 (m, 1H), 6.87-6.97 (m, 2H), 7.14-7.33 (m, 5H), 7.51-7.53 (m, 1H) and 8.41 (bs, 1H).
Example 10
N-Acetyl naphthalene (9). A solution of amide 8 (0.36 g, 0.99 mmol) in methylene chloride (5 ml) was added fairly rapidly to a suspension of DDQ (0.34 g, 1.5 mmol) in methylene chloride (15 ml) at room temperature. After stirring the black reaction mixture for 0.25 h., it was quenched with NaOH (2N, 7 ml). The organic phase was separated, dried and evaporated to give yellow residue. It was passed through a plug of silica gel to give pure 9 (0.21 g, 59%). 1 H NMR (CDCl 3 ) δ2.37 (s, 3H), 2.59-2.62 (m, 4H), 3.70-3.79 (m, 6H), 7.35-7.55 (m, 5H), 7.75-7.96 (m, 4H) and 8.66 (bs, 1H).
Example 11
Naphthyl amine (10). An aqueous solution of NaOH (3N, 6 ml) was added to a stirring solution of 9 (0.195 g, 0.54 mmol) in reagent alcohol (4 ml) and the mixture was refluxed for 5 h. The reaction mixture was cooled, diluted with water and extracted with methylene chloride. The organic layer was dried over anhydrous sodium sulfate and evaporated to give 10 as yellow foam (014 g, 80%). 1 H NMR (CDCl 3 ) δ2.59-2.61 (m, 4H), 3.75-3.80 (m, 6H), 4.28 (bs, 2H), 6.85 (d, J=7.60 Hz, 1H), 7.23-7.26 (m, 1H), 7.44-7.51 (m, 3H), 7.75-7.77 (m, 1H), 7.82 (d, J=8.0 Hz, 1H), 7.89 (d, J=8.0 Hz, 1H) and 8.67 (d, J=2.0, 1H).
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Disclosed is a novel method of producing heteroaryl amines of the formula(I):
wherein X, Y and Z are described herein, the heteroarylamines are useful in the production of heteroaryl ureas which are key component in pharmaceutically active compounds possessing a heteroaryl urea group.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to the field of well monitoring. More specifically, the invention relates to equipment and methods for real time monitoring of wells during various processes.
2. Related Art
There is a continuing need to improve the efficiency of producing hydrocarbons and water from wells. One method to improve such efficiency is to provide monitoring of the well so that adjustments may be made to account for the measurements. Other reasons, such as safety, are also factors. Accordingly, there is a continuing need to provide such systems. Likewise, there is a continuing need to improve the placement of well treatments.
SUMMARY
In general, according to one embodiment, the present invention provides monitoring equipment and methods for use in connection with wells. Another aspect of the invention provides specialized equipment for use in a well.
Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
FIG. 1 illustrates a well having a perforating gun with a control line therein,
FIG. 2 illustrates a perforating gun in a well having a control line positioned in a passageway of the gun housing.
FIG. 3 illustrates a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
FIG. 4 is a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
FIG. 5 is a side elevational view of a perforating gun housing of the present invention.
FIG. 6 shows an alternative embodiment of the present invention.
FIG. 7 illustrates another embodiment of the present invention.
FIG. 8 is a partial cross sectional view of an alternative embodiment of the present invention.
FIGS. 9 through 16 illustrate various other alternative embodiments of the present invention.
FIG. 17 shows an intergun housing of the present invention.
FIG. 18 illustrates an embodiment of the present invention in which an instrumented perforating gun is provided with a completion.
FIG. 19 illustrates an embodiment of the present invention in which the well may be perforated and gravel packed in a single trip into the well.
FIG. 20 shows an embodiment of the present invention in which the perforating charges are provided in the casing.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
In this description, the terms “up” and “down”; “upward” and downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
One aspect of the present invention is the use of a sensor, such as a fiber optic distributed temperature sensor, in a well to monitor an operation performed in the well, such as a perforating job as well as production from the well. Other aspects comprise the routing of control lines and sensor placement in a perforating gun and associated completions. Yet another aspect of the present invention provides a perforating gun 20 which is instrumented (e.g., with a fiber optic line 24 or an intelligent completions device 26 ). Referring to the attached drawings, FIG. 1 illustrates a wellbore 10 that has penetrated a subterranean zone that includes a productive formation 14 . The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 formed therein that allow fluid communication between the wellbore 10 and the productive formation 14 . Firing a perforating gun 20 having shaped charges 22 at the desired position in the well forms the perforations. The perforating gun 20 embodiment of FIG. 1 is a wireline-conveyed perforating gun and is instrumented with a control line 24 extending the length of the gun 20 . FIG. 1 also illustrates one embodiment in a cased hole although the present invention may be utilized in both cased wells and open hole completions.
Although shown with the control line 24 outside the perforating gun 20 , other arrangements are possible as disclosed herein. Note that other embodiments discussed herein will also comprise intelligent completions devices 26 on the perforating gun 20 or the associated completion.
Examples of control lines 24 are electrical, hydraulic, fiber optic and combinations of thereof. Note that the communication provided by the control lines 24 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement (as in a distributed temperature system), pressure measurement, sand detection, seismic measurement, and the like. Additionally, the fiber optic line may be used to detect detonation of the guns.
In the case of a fiber optic control line, the control line 24 may be formed by any conventional method. In one embodiment of the present invention, a fiber optic control line 24 is formed by wrapping a flat plate around a fiber optic line in a similar manner as that shown in U.S. Pat. No. 5,122,209. In another embodiment, the fiber optic line is installed in the tube by pumping the fiber optic line into a tube (e.g., a hydraulic line) installed in the well. This technique is similar to that shown in U.S. reissue Pat. No. 37,283. Essentially, the fiber optic line 14 is dragged along the conduit 52 by the injection of a fluid at the surface, such as injection of fluid (gas or liquid) by pump 46 . The fluid and induced injection pressure work to drag the fiber optic line 14 along the conduit 52 .
Examples of intelligent completions devices 26 that may be used in the connection with the present invention are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, detonation detectors, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, locks, release mechanisms, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, locators, devices to determine the orientation, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as mentioned above. In one example, the fiber optic line provides a distributed temperature and/or pressure functionality so that the temperature and/or pressure along the length of the fiber optic line may be determined.
In an embodiment of FIG. 1 in which the control line 24 is a fiber optic line, the fiber optic line 24 is connected to a receiver 12 that may be located in the vehicle 13 . Receiver 12 receives the optical signals through the fiber optic line 14 . Receiver 12 , which would typically include a microprocessor and an opto-electronic unit, converts the optical signals back to electrical signals and then delivers the data (the electrical signals) to the user. Delivery to the user can be in the form of graphical display on a computer screen or a print out or the raw data. In another embodiment, receiver 12 is a computer unit, such as laptop computer, that plugs into the fiber optic line 24 . In each embodiment, the receiver 12 processes the optical signals or data to provide the chosen data output to the operator. The processing can include data filtering and analysis to facilitate viewing of the data.
FIG. 2 shows a wireline-conveyed perforating gun 20 having a hollow-carrier gun housing 28 and a plurality of shaped charges 22 . The housing 28 has a passageway 30 (control line passageway) formed in the wall thereof with a control line 24 extending through the passageway 30 . The passageway 30 provides protection for the control line 24 and reduces the overall size of the perforating gun 20 when compared to a perforating gun in which the control line 24 is provided on an outer surface of the housing 28 .
FIG. 3 is a cross sectional view of the housing 28 showing alternative positions for the passageway 30 , the control line 24 , and the intelligent completions device 26 . The housing 28 has a scallop 32 therein. A scallop 32 , or recess, is a thinned portion of the gun housing 28 . A shaped charge 22 within the housing 28 is aligned with the scallop 32 to minimize the energy loss required to penetrate the housing 28 . The passageway 30 , the control line 24 and the intelligent completions device 26 are spaced from the scallop 32 to prevent damage to the instrumentation (i.e., the control line 24 and intelligent completions device 26 ) when the shaped charges 22 are fired. However, in some applications it may be desirable to fire through a control line 24 or a component of an intelligent completions component 26 to, for example, detect detonation or for other purposes.
In one alterative embodiment shown in FIG. 3 , a control line 24 a is provided in a passageway 30 a formed in the outer surface 34 of the housing 28 . In another alternative embodiment shown in FIG. 3 , a passageway 30 b is formed in an inner surface 36 of the housing 28 . An intelligent completions device 26 and a control line 24 b are positioned in the passageway 30 b.
FIG. 4 illustrates one alternative embodiment in which a passageway 30 c formed in the housing outer surface 34 has a control line 24 c therein. A cover 38 is provided over at least a portion of the length of the passageway 30 c to maintain the control line 24 c in the passageway 30 c . The cover 38 may be removeably or fixedly attached to the housing 28 such as by welding, screws, rivets, by snapping into mating grooves in the housing 28 , or by similar means. Alternatively, the perforating gun 20 may comprise one or more cable protectors, restraining elements, clips, adhesive, epoxy, cement, or other materials to keep the control line 24 in the passageway 30 .
In one embodiment, shown in FIG. 3 , a material filler 40 is placed in the passageway 30 a to mold the control line 24 a in place. As an example, the material filler 40 may be an epoxy, a gel that sets up, or other similar material. In one embodiment, the control line 24 a is a fiber optic line that is molded to, or bonded to, the perforating gun 20 . In this way, the stress and/or strain applied to the perforating gun 20 may be detected and measured by the fiber optic line 24 a.
Another embodiment shown in FIG. 4 provides an internal passageway 30 d within the wall of the housing 28 . A control line 24 d extends through the internal passageway 30 d.
FIG. 4 also shows an embodiment for positioning of an intelligent completions device 26 (e.g., a sensor). As in the embodiment shown, the intelligent completions device 26 may be placed within the wall of the housing 28 .
FIG. 5 shows a perforating gun 20 having a housing 28 with a passageway 30 (e.g., a recess, or indentation) formed in the outer surface 34 thereof. Brackets 42 , or clips, secure the control line 24 within the passageway 30 . The passageway 30 and control line 24 are offset from the gun scallops 32 .
FIG. 6 illustrates a perforating gun 20 that comprises a housing 28 and a loading tube 44 . The loading tube 44 has a plurality of openings 46 for holding shaped charges 22 . A detonating cord 48 is routed along the back of the shaped charges to fire the shaped charges 22 . The loading tube is placed in the housing 28 with the shaped charges 22 aligned with the housing scallops 32 . One embodiment of the invention illustrated in FIG. 6 has a control line 24 extending the length of the loading tube 44 . As discussed above with respect to the housing 28 , the control line 24 may extend through a passageway 30 provided on the loading tube 44 (e.g., the interior surface, the exterior surface, or internal to the wall). Another embodiment of FIG. 6 shows a control line 24 provided on the housing 28 of the perforating gun 20 .
Note that, in each of the embodiments discussed herein, the control line 24 may extend the full length of the perforating gun 20 or a portion thereof. Additionally, the control line 24 may extend linearly along the perforating gun 20 or follow an arcuate, or nonlinear, path. FIG. 6 illustrates a perforating gun 20 having a control line 24 that is routed in a helical path along the perforating gun 20 (both the loading tube embodiment and the housing embodiment). In one embodiment, the control line 24 comprises a fiber optic line that is helically wound about the perforating gun 20 (internal or external to the perforating gun 20 ). In this embodiment, a fiber optic line 24 that comprises a distributed temperature system, or that provides other functionality (e.g., distributed pressure measurement), has an increased resolution. Other paths about the perforating gun 20 that increase the length of the fiber optic line 24 per longitudinal unit of length of perforating gun 20 will also serve to increase the resolution of the functionality provided by the fiber optic line 24 .
FIG. 7 discloses another embodiment of the present invention in which a control line 24 is provided adjacent a shaped charge 22 . In the embodiment shown, the shaped charge 22 has a case passageway 52 provided in the shaped charge case 50 . The control line 24 extends through the case passageway 52 . In one embodiment, the control line 24 is a fiber optic line used for shot detection. When the shot fires, the fiber optic line is broken at that point. Light reflected through the fiber optic line indicates the end of the fiber optic line and point at which the line was broken.
FIG. 8 shows a wireline-conveyed perforating gun 20 having a control line 24 in the housing 28 and extending the length thereof.
FIG. 9 shows an alternative embodiment in which the passageway 30 is routed in an arcuate path (e.g., helical) along the loading tube of a high shot density perforating gun 20 .
FIG. 10 is a cross sectional view of a loading tube 44 showing additional alternative embodiments for instrumenting a perforating gun 20 . One embodiment shows a passageway 30 extending along the loading tube 44 . A pair of control lines 24 are routed through the passageway 30 . Another embodiment illustrated in FIG. 10 provides an intelligent completions device 26 mounted in the wall of the loading tube 44 , such as in a recess provided in the wall, or inside the loading tube 44 . Yet another embodiment shown in FIG. 10 provides a control line 24 inside the loading tube.
Although the aforementioned perforating guns 20 have been described as wireline-conveyed, tubing could also convey the guns 20 .
FIGS. 11 through 16 illustrate embodiments of the present invention in which the perforating gun 20 comprises a plurality of shaped charges 22 mounted on a carrier 54 . FIG. 11 shows a semi-expendable perforating gun 20 having a linear carrier 54 . A control line 24 is mounted to the carrier 54 . Similarly, FIG. 12 shows a semi-expendable carrier 54 having a plurality of capsule shaped charges 22 mounted thereon and a control line 24 mounted to the carrier 54 . Expendable guns may also be used with the present invention.
As used herein, the housing 28 , loading tube 44 , and carrier 54 are generically referred to as a “carrier component” of the perforating gun 20 .
In the perforating gun 20 of FIG. 13 , the carrier 54 is a hollow tube. A control line 24 extends through the carrier 54 , hollow tube.
FIGS. 14 and 15 show an alternative embodiment of the present invention used in conjunction with a pivot perforating gun 20 . The pivot gun 20 has a carrier 54 and a pull rod 58 . The shaped charges 22 are mounted to the pull rod 58 in a first position in which the axis of the shaped charges 22 generally pointed along the axis of the perforating gun 20 . Once downhole, the pull rod 58 is caused to move relative to the carrier 54 . A retainer 56 connecting each of the shaped charges to the carrier cause the shaped charges 22 to rotate to a second firing position. The pivot gun 20 may use a variety of other schemes to achieve the pivoting of the shape charges 22 .
FIG. 14 illustrates alternative embodiments of the present invention. In one embodiment, the pull rod 58 is a hollow tube having a control line 24 extending therein. In another embodiment, the carrier 54 has a control line 24 mounted therein (see also FIG. 15 ).
FIG. 16 shows another embodiment in which the perforating gun 20 comprises a spiral strip carrier 54 in which the carrier 54 is formed into a helical shape. A control line 24 extends along the carrier strip 54 .
It should be noted from the above that the shaped charges may be oriented in a variety of phasing patterns as illustrated in the figures.
FIG. 17 shows another embodiment of the present invention in which adjacent perforating guns are interconnected by an intergun housing 60 . The intergun housing 60 may contain one or more intelligent completions devices 26 that may be used, for example, to measure reservoir parameters, production characteristics, gun orientation, and gun performance metrics. Additionally, the intelligent completions device 26 in the intergun housing 60 may comprise safety devices that prevent detonation until certain conditions are satisfied (e.g., certain downhole parameters, like pressure, temperature, location, or orientation). Further, the intergun housing may comprise a swivel, a motor, or other device that will facilitate orientation of the perforating gun 20 . Also, the intergun housing 60 may contain other devices that inflate to isolate sections of the wellbore, to shut off zones, or devices that choke back production from sections of the well.
FIG. 18 illustrates an alternative embodiment of the present invention in which the perforating guns 20 are run as part of a permanent completion 62 . A completion 62 may comprise a large variety of components and jewelry such as packers, safety valves, sand screens, flow control valves, pumps, intelligent completions devices, and the like. In some circumstances, it is desirable to run the perforating gun 20 with the completion 62 to reduce the number of trips into the well and for other reasons. FIG. 18 shows a permanent completion 62 having a perforating gun 20 and a control line extending along the completion 62 and the perforating gun 20 .
FIG. 19 shows another embodiment of the present invention in which the well is perforated and gravel packed in a single trip into the well. The completion 62 has a perforating gun 20 connected thereto and comprises packers 64 , a sand screen 66 , and a crossover port 68 . The assembly of the completion 62 and the perforating gun is run into the well on a service string 70 . A control line 24 extends along the completion 62 and the perforating gun 20 . Once the perforating gun 20 is aligned with the formation 14 , the perforating gun 20 is fired. Generally, the perforating gun 20 is dropped into the rathole. The completion 62 is then moved into place and the packers 64 are set to isolate the formation 14 . Next, the annulus between the sand screen 66 and the wellbore wall is gravel packed and the service string 70 is removed from the well and replaced with a production tubing. In alternative systems, the gravel pack operation is performed using a through-tubing service tool so that the run-in string may also serve as the production string.
However, if a through-tubing gravel pack operation is not used and the service string 70 is replaced with a production tubing, the control line 24 extending above the packer 64 may need to be replaced. Accordingly, in one embodiment, the present invention uses a connector 72 at or near the upper packer 64 that allows the control line 64 to separate so that the upper portion of the control line 24 (the portion above the packer 64 ) may be removed from the wellbore 10 . When the production tubing is placed in the well 10 , a control line attached to the production tubing has a connector 72 that completes the connection downhole of the control line below the upper packer 64 that was previously left in the well 10 with the control line 24 attached to the production tubing.
In the embodiment of FIG. 20 , the perforating gun 20 is a casing-conveyed perforating gun 20 . In this embodiment, the casing 16 has one or more shaped charges 22 mounted thereto. The shaped charges 22 may be mounted in the wall of the casing 16 , inside the casing 16 , or attached to the outside of the casing 16 . A control line 24 extends along the perforating gun 20 (the portion of the casing having the shaped charges 22 therein). In the disclosed embodiment, the control line 24 has a ‘U’ configuration and extends from the surface into the well and returns to the surface. Such a ‘U’ configuration is particularly useful when the control line 24 is a fiber optic line that is blown into the well as previously described. In such a case, the control line may provide redundancy.
In some embodiments, the perforating gun 20 uses alternative forms of initiators 74 (see FIG. 11 ) for activating the shaped charges 22 . As an example, the initiator 74 may be an exploding foil initiator (EFI) which is electrically activated. As used here, “exploding foil initiator” may be of various types, such as exploding foil “flying plate” initiators and exploding foil “bubble activated” initiators. In addition, in further embodiments, exploding bridgewire initiators may also be employed. Such initiators, including EFIs and EBW initiators, may be referred to generally as high-energy bridge-type initiators in which a relatively high current is dumped through a wire or a narrowed section of a foil (both referred to as a bridge) to cause the bridge to vaporize or “explode.” The vaporization or explosion creates energy to cause a flying plate (for the flying plate EFI), a bubble (for the bubble activated EFI), or a shock wave (for the EBW initiator) to detonate an explosive. Some electrical initiators are described in described in commonly assigned copending U.S. Pat. No. 6,385,031, issued May 7, 2002, entitled “Switches for Use in Tools” and U.S. Pat. No. 6,386,108, issued May 14, 2002, entitled “Initiation of Explosive Devices,” which are hereby incorporated by reference.
When using an EFI or other electrically activated initiator, it is possible to selectively fire a sequence of perforating strings or even a series of shaped charges. As an example, if a plurality of control devices including a microcontroller and detonator assembly are coupled on a wireline, switches within the perforating gun may be controlled to selectively activate control devices by addressing commands to the control devices in sequence. This allows firing of a sequence of perforating strings or shaped charges in a desired order. Selective activation of a sequence of tool strings is described in commonly assigned copending U.S. Pat. No. 6,283,227, issued Sep. 4, 2001, entitled “Downhole Activation System That Assigns and Retrieves Identifiers” and U.S. patent application Ser. No. 09/404,522, filed Sep. 23, 1999 and published as WO 00/20820 on Apr. 13, 2000, entitled “Detonators for Use with Explosive Devices,” which are hereby incorporated by reference.
Accordingly, a perforating gun 20 having electrically activated initiators 74 may be instrumented in the manner previously described. In such a system, the instrumentation (e.g., the fiber optic line 24 or the intelligent completions device 26 ) may provide data during the perforation job. For example, the instrumentation may provide information relating to shot confirmation, pressure, temperature, or flow, among other information, between individual gun 20 or shaped charge 22 detonations. Therefore, in one example, a perforating gun 20 having a plurality of shaped charges 22 and electrically activated initiators is run into a well 10 . The shaped charges 22 are fired in a particular sequence while providing the option of moving the perforating gun 20 between shots, skipping defective charges 22 , as well as other features. The instrumentation 24 , 26 provides feedback regarding shot confirmation. In another example, the instrumentation 24 , 26 measures the temperature and pressure in the well following each shot.
In another embodiment of the present invention, the instrumentation 24 , 26 of the perforating gun 20 is used to determine the placement of a fracturing treatment, chemical treatment, cement, or other well treatment by measuring the temperature or other well characteristic during the injection of the fluid into the well. The temperature may be measured during a strip rate test in like manner. In each case remedial action may be taken if the desired results are not achieved (e.g., injecting additional material into the well, performing an additional operation). It should be noted that in one embodiment, a surface pump communicates with a source of material to be placed in the well. The pump pumps the material from the source into the well. Further, the instrumentation 24 , 26 in the well may be connected to a controller that receives the data from the intelligent completions device and provides an indication of the placement position using that data. In one example, the indication may be a display of the temperature at various positions in the well. In another example, the remedial action comprises firing a perforating gun 20 . In this example, the remedial action may comprise perforating a particular zone again, perforating a longer interval of the wellbore, perforating another zone, or the like.
The instrumented perforating gun 20 of the present invention should not be confused with prior perforating guns which have sensors placed above or below the perforating gun. Accordingly, in the present invention the term “instrumented” and the like shall mean that the instrumentation is provided on the perforating gun 20 itself, such as attached to a housing 28 , loading tube 44 , or carrier 54 of the gun 20 , positioned below the uppermost shaped charge 22 of the perforating gun 20 and above the lowermost shaped charge 22 , between shaped charges 22 , or in the substantially the same cross sectional portion of the well 10 as the shaped charges 22 . Thus, the instrument 24 , 26 is provided on the same shaped charge region of the perforating gun 20 as the shaped charges 22 .
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
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An instrumented perforating gun and associated methods. One aspect provides a recess for placement of instruments on the perforating gun. Another aspect provides methods for perforating and completing a well in a single trip. The present invention also provides an instrumented intergun housing. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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BACKGROUND AND BRIEF DESCRIPTION OF THE INVENTION
This invention relates in general to internal combustion engines and, in particular, to an improved internal combustion engine of the rotary type.
In an effort to eliminate many of the engineering problems associated with reciprocating, piston-type internal combustion engines, a considerable amount of research and design work has recently been directed toward development of a rotary type of engine. This effort has led to the development of three different types of rotary engines, including: (1) rotary engines having a three-lobed rotor for movement around a three-lobed chamber; (2) rotary engines having special rotating abutments; and (3) rotary engines with special sliding abutments.
This invention deals primarily with a rotary engine of the rotating abutment type. This type of engine typically includes an outer housing which is comprised of a cylindrically-shaped outer wall and a pair of end walls. One end wall is attached to each end of the cylindrically-shaped outer wall to provide an annular chamber within the housing. In addition, the end walls are typically arranged to support a drive shaft which is positioned to extend through the axial center of the annular chamber defined within the outer housing. A conventional spark plug is normally mounted in the circular outer wall of the housing such that it communicates with the annular chamber. An inlet port is provided in the outer housing to introduce a mixture of air and fuel into the annular chamber, and an outlet port is provided to release exhaust products therefrom.
Engines of the above-mentioned type also include a pair of piston-forming pieces which are typically mounted onto the drive shaft adjacent to each other. Each of the piston-forming pieces is normally constructed to have a central hub and a pair of oppositely disposed pistons which extend radially outward from the central hub. The piston-forming pieces are positioned on the drive shaft such that the pistons of these pieces are alternately situated within the annular chamber and such that the pistons of each piece overlap the hub portion of the adjacent piece and extend from one end wall of the inner chamber to the other. In this way, the pistons cooperate with the cylindrically-shaped housing and opposing side walls to define four separate chambers.
In operation, the piston-forming pieces interact to simulate the characteristics of an otto cycle, i.e., intake, compression, combustion and exhaust. A detailed description of the operation of this type of rotary engine is given in U.S. Pat. No. 2,088,779, which was issued to C. C. English on Aug. 3, 1937, and in U.S. Pat. No. 3,136,030, which was issued to A. E. Ievins on June 9, 1964. Both of these patents are herein incorporated by reference.
A brief description of the operation of this type of engine, however, will be undertaken at this time to provide a better basis for understanding the significance of the present invention. The combustion cycle is started when an explosive mixture of air and gas is compressed between two adjacent pistons in proximity to the spark plug. At this time, one of the pistons is locked in a stationary position and is designated the abutting piston. The other piston is designated the driving piston and is in turn temporarily coupled with the drive shaft.
The spark plug is then fired, causing the mixture of air and gas which is compressed between the abutting and driving pistons to be ignited. The explosive force thus produced causes the driving piston to be driven away from the abutting piston in a forward direction. Since the driving piston is now coupled with the drive shaft, rotary movement of this piston is in turn imparted to the drive shaft. Movement of the drive piston also causes the exhaust products from a previous firing to be driven out of the annular chamber through the outlet port.
The piston-forming piece of which the driving piston is a component carries an opposing piston which extends radially outward from the central hub portion of this piece in a direction which is diametrically opposite to that of the drive piston. Accordingly, both of these pistons move through the annular chamber in unison. As the opposing piston moves through the chamber, it draws air and gas into the inner chamber of the engine through the inlet port. Movement of this piston toward the abutting piston also causes the mixtue of air and gas located between these two pistons to become compressed. Further movement of the opposing piston twoard the abutting piston causes the abutting piston to be moved into position to become the driving piston for the next power stroke. To properly position the abutting piston for use as the driving piston during the next power stroke, forward movement of this piston is restricted to a set distance until just prior to firing of the spark plug initiating the next power stroke.
During the latter part of the first power stroke when the opposing piston is moving the abutting piston in position to be the driving piston for the second power stroke, the piston-forming piece carrying the opposing piston becomes coupled with the drive shaft so as to receive rotary motion therefrom. Once the opposing piston assumes the position previously occupied by the abutting piston, the piston-forming piece associated with the opposing piston is disconnected from the drive shaft and the opposing piston is locked in a stationary position to form the abutting piston for the next power stroke. Thereafter, the forward restriction on the new driving piston is removed, the piston-forming piece carrying the new driving piston is coupled with the drive shaft, and the spark plug is fired to initiate the next power stroke.
Accordingly, every rotary engine of the rotating abutment type must be operable to perform several basic functions. In particular, the engine must be able to control the movement of the rotating pistons to periodically form a combustion chamber about the spark plug. In order to do this, the engine must be operable to hold the abutting piston of the chamber in a stationary position when the spark plug is fired and to restrict forward movement of the driving piston until just before firing of the spark plug. The engine must also be operable to couple the driving piston to the drive shaft upon firing of the spark plug to thereby transfer to the drive shaft the rotary motion imparted to the driving piston upon firing of the spark plug. Finally, the engine must be operable to couple the drive shaft to the piston-forming piece carrying the driving piston during the latter part of the power stroke to thereby transfer rotary motion to the piston-forming piece.
These basic functions are normally regulated by a pair of movement control mechanisms which are incorporated into the engine. An example of such a movement control mechanism is given and described in U.S. Pat. No. 2,088,779, which was issued to C. C. English on August 3, 1937. Another technique for controlling these functions is given and described in U.S. Pat. No. 3,136,303, which was issued to A. E. Ievins on June 9, 1964. As mentioned above, both of these patents are incorporated by reference herein.
These prior art control mechanisms, however, are fairly complex in design and operation. As a result, the presently known rotary engines are costly to manufacture and maintain and are unreliable at higher speeds.
It is therefore an object of the present invention to provide an improved rotary engine of the rotating abutment type which is simple in design and operation.
Another object of the present invention is to provide an improved rotary engine of the rotating abutment type which is simple and economical to construct and operate.
An additional object of the present invention is to provide an improved rotary engine of the rotating abutment type which operates in a reliable manner at both high and low speeds.
Another object of the present invention is to provide an improved rotary engine of the rotating abutment type which may be quickly and easily repaired.
It is a further object of the present invention to provide an improved rotary engine of the rotating abutment type which utilizes a unique movement control mechanism that greatly simplifies the design and operation of such an engine.
It is an additional object of the present invention to provide an improved rotary engine of the rotating abutment type which utilizes a unique movement control mechanism that reliably controls the movement of the engine's pistons at both high and low speeds.
Other and further objects of this invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.
DETAILED DESCRIPTION OF THE INVENTION
In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are employed to indicate like parts in the various views:
FIG. 1 is a front elevational view of a rotary engine constructed according to a preferred embodiment of the present invention, with portions broken away for the purposes of illustration;
FIG. 2 is a cross sectional view taken generally along line 2--2 of FIG. 1 in the direction of the arrows with portions broken away for the purposes of illustration;
FIG. 3 is a cross sectional view taken generally along line 3--3 of FIG. 1 in the direction of the arrows;
FIG. 4 is a cross sectional view taken generally along line 4--4 of FIG. 1 in the direction of the arrows;
FIG. 5 is a cross sectional view taken generally along 5--5 of FIG. 1 in the direction of the arrows; and
FIG. 6 is a cross sectional view taken generally along line 6--6 of FIG. 1 in the direction of the arrows.
Reference is now made to the drawings in detail and initially to FIGS. 1 and 2 wherein the numeral 10 is used to designate a rotary engine which is constructed in accordance with a preferred embodiment of the present invention. The engine illustrated in these figures includes an outer casing which is comprised of an outer circular wall 14 and end walls 16 and 18. Each of the outer end walls is mounted to its corresponding end of the circular outer wall 14 by means of a plurality of mounting screws 20. In this way, the circular outer casing and end plates cooperate to define an annular chamber which is generally designated by the numeral 22.
A spark plug opening 24 is provided in outer circular wall 14. The upper portion of spark plug opening 24 is threaded at 26 to receive and hold a conventional spark plug 28. Spark plug 28 fits within opening 24 such that the electrodes of the plug communicate with annular chamber 22. An inlet port 30 and an outlet port 32 are also defined in the outer circular wall 14 of the casing.
A central shaft 34 is provided to properly align the operable components of the engine. This shaft in turn carries a pair of coupling pieces 44 and 46. Each coupling piece is comprised of a tubular piece of metal having a cylindrical outer surface and a hollow inner channel. The diameter of the inner channel in each coupling piece is slightly larger than the outer diameter of the central shaft to thereby allow for free movement of each piece on the shaft.
Coupling pieces 44 and 46 are positioned adjacent to each other on central shaft 34 such that they abut against each other at the center of annular chamber 22. Coupling pieces 44 and 46 extend outward from the center of annular chamber 22 in opposite directions. Central shaft 34 and coupling pieces 44 and 46 are positioned to extend through the axial center of annular chamber 22 and are allowed to pass through a circular opening (not shown herein) in each of the end walls 16 and 18 of the chamber. In particular, central shaft 34 and coupling piece 44 pass through a circular opening in end wall 16 while central shaft 34 and coupling piece 46 pass through an opening in end wall 18. A pair of fly wheels 36 and 38 are in turn attached to each end of central shaft 34 by means of mounting bolts 40 and 42, respectively. The flywheels and coupling pieces are spaced apart from each other and, as a result, rotate independently of each other.
A pair of piston-forming pieces 48 and 50 are respectively carried by coupling pieces 44 and 46 within the annular chamber 22 of the engine. Piston-forming piece 48 is constructed to have a central hub 52 and a pair of oppositely disposed pistons 54 and 56 which extend radially outward from the central hub of this piece. Central hub 52 is constructed to have a hollow inner channel which allows this piece to fit over its associated coupling piece 44 such that piston-forming piece 48 is free to move relative to coupling piece 44. Movement of piston-forming piece 48 relative to coupling piece 44, however, is limited by means of a keyed coupling between the piston-forming and the coupling pieces. This keyed coupling is accomplished by means of a key element 58 which interacts with an opening 60 in coupling piece 44. Key element 58 is attached to and extends radially inward from the central hub 52 of piston-forming piece 48. The key element 58 fits within opening 60 and is capable of traversing this opening to provide limited rotational movement of piston-forming piece 48 relative to coupling piece 44. Opening 60 is comprised of a rectangular slot which is arranged to have a forward wall 61 and a back wall 63.
Piston-forming piece 50 is likewise comprised of a central hub 62 and a pair of oppositely disposed pistons 64 and 66 which extend radially outward from the central hub of this piece. The central hub 62 of piston-forming piece 50 is also constructed to have a hollow inner channel with a diameter slightly larger than the outer diameter of its associated coupling piece 46 to thereby allow for free movement of the piston-forming piece relative to the coupling piece. Movement of piston-forming piece 50 relative to coupling piece 46 is likewise restricted by means of a key element 68 which interacts with an opening 70 in coupling piece 46. Key element 68 is attached to central hub 62 of piston-fomring piece 50 such that it is capable of moving back and forth within opening 70 to thereby provide limited rotational movement of piston-forming piece 50 relative to coupling piece 46. Opening 70 is comprised of a rectangular shaped slot which is arranged to have a forward wall 71 and a back wall 73. When the engine is fully assembled, the hub 52 of piston-forming piece 48 is positioned within inner chamber 22 adjacent to hub 62 of piston-forming piece 50. In this position, pistons 54 and 56 of piston-forming piece 48 protrude toward and overlap hub 62 of piston-forming piece 50 so as to extend from the inner surface of end wall 16 to the inner surface of end wall 18. Pistons 64 and 66 of piston-forming piece 50 likewise protrude toward and overlap hub portion 52 of piston-forming piece 48 so as to extend from the inner surface of end wall 18 to the inner surface of end wall 16. In this way, the pistons of both piston-forming pieces are alternately situated within the annular chamber and cooperate with the circular outer wall 12 and end walls 16 and 18 to form four separate chambers.
The movement of each piston-forming piece is regulated by a movement control mechanism. The movement control mechanism associated with piston-forming piece 48 is generally designated by the numeral 72, while the movement control mechanism associated with piston-forming piece 50 is designated by the numeral 74. Both of these movement control mechanisms are of the same basic construction. Since both of these mechanisms are similar in design and operation either mechanism can be used as the basis of a detailed explanation. As a result, only movement control mechanism 72 will be described in detail herein.
Movement control mechanism 72 is basically comprised of a plurality of latching mechanisms which are generally designated by the numerals 76, 78, 80 and 82. Latching mechanisms 76, 78, 80 and 82 cooperate with each other to control the operation of piston-forming piece 48. In particular, these mechanisms cooperate to couple piston-forming piece 48 with central shaft 34 at regular and timed intervals and to hold this piece in a stationary position at regular and timed intervals to thereby ensure the proper operation of the engine.
Reference is now made to FIGS. 1 and 3 for a more detailed description of latching mechanism 76. This latching mechanism is comprised of a ratchet piece 84 which is keyed by means of a key element 86 to coupling piece 44 for movement in combination therewith. Ratchet piece 84 is constructed to have a pair of abutting teeth 88 which are positioned at diametrically opposite points of the rachet piece. The outer contour of ratchet piece 84 is arranged to provide a smooth transition from the inner edge of one tooth to the outer edge of the other tooth.
Ratchet piece 84 is encircled by a stationary support ring 90. Support ring 90 is mounted to the outer surface of side wall 16 by means of mounting screws 92. The stationary support ring 90 is provided with a pair of recesses 94 which communicate with the interior area of the ring at diametrically opposite points thereof. Each recess 94 is arranged to receive a pawl 96 which is mounted within its associated recess by means of a pivot pin 98 such that the pawl is capable of pivoting between a first position wherein it is contained completely within its corresponding recess and a second position wherein it projects outward of its recesses into engagement with the abutting teeth 88 of ratchet piece 84. A pair of springs 100 are provided to releasably maintain pawls 96 in the second position.
Referring now to FIGS. 1 and 4, latching mechanism 78 is basically comprised of a circular ratchet piece 102 having a pair of abutting teeth 104 defined therein at diametrically opposite points thereof. Ratchet piece 102 is keyed to coupling piece 44 by means of a key element 106. In this way, ratchet piece 102 and coupling piece 44 are locked together to move in unison. Ratchet piece 102 is constructed to have an outer contour which provides a smooth transition from the outer edge of one tooth to the inner edge of the other tooth.
Latching mechanism 78 is also comprised of a stationary support ring which is designated by the numeral 108. Support ring 108 is mounted to end wall 16 adjacent to support ring 90 by means of mounting screws 92. The support ring is arranged to carry a pair of pawls 110 within a pair of recesses 112. Recesses 112 are arranged to open into the inner periphery of ring 108 at diametrically opposite points thereof. Each pawl 110 is mounted within its associated recess 112 by means of a pivot pin 114. In this way, each pawl is capable of pivotally moving between a first position wherein it is contained within its associated recess and a second position wherein it projects outward of its recess into the path of movement of the abutting teeth 104 on ratchet piece 114. Each pawl is also provided with an associated spring such as 116 which is arranged to urge its corresponding pawl into its associated recess.
Support ring 108 is in turn encircled by a camming ring 118 which is attached to fly wheel 38 by means of a plurality of mounting screws 120. As shown in FIG. 4, camming ring 118 is constructed to have a pair of inclined camming surfaces 122 each of which extends along one quarter of the inner circumference of the ring and terminate in steps 124.
A pair of positioning pins 126 are provided to regulate the position of the pawls 110 carried by support ring 108 in response to the profile of camming ring 118. The positioning pins 126 are carried by the stationary support ring 108 within an associated mounting channel such as 128. Each pin is positioned within its associated channel for free movement therein. One end of each pin rides along the inner surface of the camming ring while the other end of the pin rests against the back surface of its corresponding pawl.
Reference is now made to FIGS. 1 and 5 for a more detailed description of latching mechanism 80. Latching mechanism 80 is basically comprised of a circular ratchet piece 130 which is constructed to have two tapered inclined profiles 132 which terminate in abutting teeth 134. Ratchet piece 130 is keyed to coupling piece 44 by means of a key element 136.
Latching mechanism 80 also includes a rotating support ring 138 which is coupled with fly wheel 38 by means of a plurality of mounting screws 140. Support ring 138 is also provided with a pair of recesses 142 which are arranged to open into the inner periphery of the ring at diametrically opposite points thereof. A pawl 144 is in turn pivotally mounted within each recess 142 by means of a pivot pin 146. Each pawl is mounted within its associated recess such that it is capable of being pivotally moved between a first position wherein it is contained within its associated recess and a second position wherein it is projecting out of its recess into the path of the abutting teeth 134 of ratchet piece 130. Each pawl is biased into its associated recess by means of a coil spring such as 148.
Support ring 138 is encircled by camming ring 118 and by a second camming ring 150. Camming ring 150 is fixedly secured to end wall 16 of the outer housing and remains in a stationary position at all times. As shown in FIG. 5, the thickness of camming ring 150 is varied to provide a pair of inclined camming surfaces 152, each of which extends along one quarter of the inner circumference of the ring and terminates in steps 154. The position of each of the pawls 144 carried by support ring 138 is regulated by means of a control pin 156 in accordance with the inner profile of camming ring 150. Each of these pins sits within a corresponding channel 158 in support ring 118. Each of the positioning pins 156 is positioned within its associated channel for free movement therein. As shown in this figure, one end of each positioning pin 156 rests against the back surface of its corresponding pawl while the other end of the pin rides along the inner surface of camming ring 150. Camming ring 118 is equipped with a pair of openings such as 160 which allow the positioning pins 156 to pass through this ring unimpeded.
Referring now to FIGS. 1 and 6, latching mechanism 82 includes a ratchet piece 162, a movable support ring 164 and a pair of pawls 166. Ratchet piece 162 is carried by coupling piece 44 and is keyed to this piece by means of a key element 168. The ratchet piece 162 is constructed to have a pair of tapered inclined profiles which are generally designated by the numeral 170. These profiles terminate in abutting teeth 172. Ratchet piece 162 is constructed to have an outer contour which provides a smooth transition from the inner edge of one abutting tooth to the outer edge of the other abutting tooth.
The movable support ring 164 is mounted onto the fly wheel for movement in combination therewith by means of mounting screws 140. The support ring 164 is also provided with a pair of recesses which are generally designated by the numeral 174. Each of the recesses 174 opens into the interior area of support ring 164 and is arranged to receive one of the pawls 166 carried by the support ring. Each of the pawls 166 is mounted within its associated recess by means of a pivot pin 176. Both of the pawls are capable of pivotally moving between a first position wherein they are contained within their associated recesses and a second position wherein they project outward from their recesses into the path of the abutting teeth 172 of ratchet piece 162. These pawls are biased into the latter position by means of a pair of coil springs 178.
In operation, each piston-forming piece is aternately coupled with the central shaft to provide impulses thereto. To accomplish this drive action, each piston-forming piece is periodically coupled to the central shaft for a predetermined time interval which is regulated by its associated movement control mechanism. As described above, both of the movement control mechanisms are identical in design and operation.
FIGS. 1-6 show the operable components of the engine in their respective positions just prior to ignition of spark plug 28. As shown in FIG. 2, pistons 56 and 64 are positioned adjacent to each other to form a combustion chamber about spark plug 28. At this time, piston-forming piece 50 is securely locked in a stationary position by means of its control mechanism 74. As a result, piston 64 of this piece constitutes the abutting wall of the combustion chamber.
Forward or clockwise movement of piston 56 is also restricted at this time by means of latching mechanism 78 which is particularly shown in FIG. 4. As shown in this figure, the positioning pins 126 carried by support ring 108 are being forced inward at this time by means of the camming surfaces 112 of camming ring 118. With the positioning pins in this position, pawls 110 are brought into engagement with the abutting teeth 104 of ratchet piece 102 to thereby prevent clockwise movement of the ratchet piece. Since ratchet piece 102 is keyed to coupling piece 44, clockwise rotation of the coupling piece is likewise prohibited. In addition, piston-forming piece 48 has now moved as far in a clockwise direction relative to coupling piece 44 as key element 58 and opening 60 will allow. As shown in FIGS. 1 and 2, key element 58 is now resting against the forward wall 61 of opening 60 to thereby prevent the piston-forming piece from any further clockwise movement relative to the coupling piece. Since clockwise movement of coupling piece 44 is inhibited by latching mechanism 78 and since further forward movement of piston-forming piece 48 relative to coupling piece 44 is prohibited by key element 58, clockwise movement of piston-forming piece 48 is inhibited and the forward position of piston 56 is thereby maintained.
As camming ring 118 continues to rotate in combination with fly wheel 38, the terminating steps 124 of the camming surfaces 112 move past the positioning pins 126. Once terminating steps 124 pass positioning pins 126, the biasing force imparted to pawls 110 by means of their associated coil springs causes the pawls and their associated pins to move radially outward from the interior of support ring 108. When this occurs, the pawls 110 carried by support ring 108 move out of engagement with the abutting teeth 104 of ratchet piece 102 thereby permitting rachet piece 102 to move in a clockwise direction.
Thereafter, the power stroke is initiated by causing spark plug 28 to be fired. Firing of the spark plug in turn causes the mixture of air and gas which is compressed between pistons 56 and 64 to be exploded. The explosive force thus produced causes piston 56 to be driven in a clockwise or forward direction. This rotary movement of piston 56 is in turn imparted to central shaft 34 via coupling piece 44 and latching mechanism 82. In particular, key element 58 of piston-forming piece 48 pushes against the forward wall 61 of opening 60 to thereby cause coupling piece 44 to move in combination with the piston-forming piece. The rotary motion thus imparted to coupling piece 44 is in turn transferred to ratchet piece 162 because of the keyed connection between the coupling and ratchet pieces. As shown in FIG. 6, clockwise rotation of ratchet piece 162 causes its abutting teeth 172 to come in contact with the pawls 166 carried by support ring 164 to thereby transfer rotational motion from the ratchet piece to the support ring. Support ring 164 is in turn coupled with fly wheel 36 so that the rotational motion imparted to the piece is also transferred to the fly wheel.
As piston 56 rotates in a clockwise direction, it causes the exhaust products from the previous power stroke to be driven out of the inner chamber through outlet port 32. In addition, the other piston 54 of piston-forming piece 48 moves in a clockwise direction in combination with piston 56 causing a mixture of fuel and air to be sucked into the inner chamber behind it through inlet port 30. Clockwise movement of piston 54 also causes the mixture of gas and air which is located between pistons 54 and 64 to be compressed to prepare it for the next power stroke.
As piston 54 approaches piston 64, piston 54 is at the end of the power stroke, and as a result, the driving force behind piston-forming piece 48 is relatively small. In addition, the compressive force of the air and gas mixture between pistons 54 and 64 becomes relatively large, producing a force which tends to resist further clockwise movement of piston 54. To ensure that piston 54 will move the required distance to form a combustion chamber about spark plug 28 for the next power stroke, piston-forming piece 48 is coupled with fly wheel 36 through latching mechanism 80 during the latter part of the power stroke. As shown in FIG. 5, the camming surfaces 152 of camming ring 150 engage positioning pins 156 during the latter part of the power stroke to thereby cause these pins to move their respective pawls 144 into engagement with the abutting teeth 134 of rachet piece 130. Upon engagement of the pawls and abutting teeth, the rotary movement of support ring 138 is imparted to rachet piece 130 to thereby cause this piece to rotate in a clockwise direction in unison with the support ring. Since rachet piece 130 is keyed to coupling piece 44, the rotary motion imparted to the rachet piece is simultaneously transferred to the coupling piece causing it also to rotate in a clockwise direction.
As coupling piece 44 begins to rotate in response to the rotary motion imparted to it from fly wheel 36, coupling piece 44 moves independently of piston-forming piece 48 causing key element 58 to traverse opening 60 in coupling piece 44. Once key element 58 reaches the back wall 63 of opening 60, further movement of coupling piece 44 causes piston-forming piece 48 to move in combination therewith.
As piston 54 approaches piston 64, the air and gas mixture which is contained between these two pistons becomes compressed, thereby producing a force which acts on piston 64 to move it in a clockwise direction. The extent of this clockwise movement is regulated by movement control mechanism 74. This mechanism operates to restrict the distance that piston 64 is allowed to move to thereby properly position this piston about spark plug 28.
Returning now to FIG. 5, the camming surface 152 of camming ring 150 is arranged to keep the pawls 144 carried by support ring 138 in contact with the abutting teeth 134 of ratchet piece 130 long enough to cause piston-forming piece 48 to move a distance sufficient to locate piston 54 in the position previously occupied by piston 64. As piston 54 reaches this position, positioning pins 156 move past the terminating steps 154 of camming surfaces 152, thereby allowing pawls 144 to pivot out of engagement with the abutting teeth 134 of ratchet piece 156. Upon disengagement of these pawls and abutting teeth, piston-forming piece 48 no longer moves in a clockwise direction.
Once piston 54 reaches the position previously occupied by piston 64, latching mechanism 76 acts to preclude counterclockwise movement of piston 54. As shown in FIG. 3, ratchet piece 84 is keyed to coupling piece 44 and moves in combination therewith. As piston 54 reaches the position previously occupied by piston 64, the abutting teeth 88 of ratchet piece 84 move past the pawls 96 carried by support ring 90, thereby allowing these pawls to drop in place behind the abutting teeth to prevent counterclockwise movement of the ratchet piece. Since ratchet piece 84 is keyed to coupling piece 44, coupling piece 44 is also prevented from moving in a counterclockwise direction. Counterclockwise movement of piston-forming piece 48 is also prevented because key element 58 is resting against the back wall 63 of opening 60 at this time. In this way, latching mechanism 76 operates to prevent piston 54 from moving in a counterclockwise or rearward direction to thereby provide the abutting wall of the combustion chamber for the next power stroke.
Once piston-forming piece 48 has been locked so as to preclude rearward movement thereof, spark plug 28 is fired a second time causing piston 64 to be driven in a forward or clockwise direction. This piston is coupled with the central shaft 34 through its control mechanism 74 to thereby provide an impulse to this shaft. As piston 64 moves in a clockwise direction, its opposing piston 66 moves in a clockwise direction toward piston 54. Movement of piston 66 toward piston 54 causes the air and gas mixture which is contained between these two pistons to become compressed. Further movement of piston 66 toward piston 54 causes piston 54 to begin moving in a clockwise direction. Just before piston 54 begins moving in a clockwise direction, however, latching mechanism 78 (shown in FIG. 4) is placed in condition to prevent forward movement of ratchet piece 102. In particular, the camming surfaces 122 of camming ring 118 act through positioning pins 126 to move pawls 110 into engagement with the abutting teeth 104 of ratchet piece 102. Engagement between pawls 110 and the abutting teeth 104 of ratchet piece 102 prevents ratchet piece 102 from moving in a clockwise direction. Since the ratchet piece 102 is keyed to coupling piece 44, coupling piece 44 is also prevented from moving in a clockwise direction. Even though coupling piece 44 is now precluded from moving in a clockwise direction by control mechanism 78, piston-forming piece 48 is capable of limited clockwise or forward movement due to the type of connection between the piston-forming piece and coupling piece 44. In particular, the piston-forming piece 48 is capable of moving in a forward or clockwise direction relative to coupling piece 44 until the key element 58 carried by the piston-forming piece comes in contact with the front wall 61 of the opening 60 in the coupling piece 44. The distance that piston 54 is capable of moving is determined by the length dimension of opening 60. Opening 60 in turn is constructed to have a length sufficent to allow piston 54 to be moved into position to become the driving piston for the next combustion stroke. Just before spark plug 28 is fired to initiate the next power stroke, latching mechanism 78 releases ratchet piece 102 as described above, thereby allowing piston 54 to move in a forward or clockwise direction upon firing of spark plug 28. In this way, latching mechanism 78 operates in combination with coupling piece 44 to properly position the drive piston and to hold this piston in place until just before spark plug 28 is fired.
The above-described cycle of operation is then repeated using piston 56 as the drive element. The rotary engine of the present invention continues to operate in this manner with control mechanisms 72 and 74 operating to alternately couple their corresponding piston-forming pieces to the central shaft at regular and controlled intervals to prevent rearward movement of their corresponding piston-forming pieces at regular and controlled intervals and to restrict forward movement of their corresponding piston-forming pieces at regular and controlled intervals. In particular, latching mechanism 76 operates to prevent rearward movement of its associated piston-forming piece when one of the pistons carried by its associated piston-forming piece is to be used as the abutting piston of the combustion chamber. Latching mechanism 78, on the other hand, operates to restrict forward movement of its associated piston-forming piece just prior to ignition of the spark plug to ensure that one of the pistons carried by its associated piston-forming piece will be properly positioned to act as the drive piston during the power stroke. Latching mechanism 80 functions to transfer rotary motion from the fly wheel to its associated piston-forming piece during the latter part of every other power stroke. Finally, latching mechanism 82 is operable to transfer rotary motion from its associated piston-forming piece to the fly wheel when one of the pistons carried by this piece is acting as the drive piston.
From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects herein set forth together with other advantages which are obvious and which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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This invention deals with an improved rotary engine of the rotating abutment type and, more particularly, with a unique movement control mechanism which is suitable for use with such an engine. An engine of this type is equipped with two of these movement control mechanisms, each of which is arranged to control the operation of two of the engine's four pistons. In particular, each movement control mechanism is operable to periodically prevent rearward movement of its associated pistons for a predetermined interval and to limit forward movement of these pistons to a set distance during said predetermined interval. Each movement control mechanism is also operable to periodically couple its associated pistons to the engine's central shaft to thereby transfer rotary motion to and receive rotary motion from the central shaft at regular and predetermined intervals.
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CROSS REFERENCE
This application claims priority from a provisional patent application entitled “Apparatuses, Methods, and Systems Using Integrated Circuits” filed on Apr. 19, 2013 and having an Application No. 61/814,153. Said application is incorporated herein by reference.
FIELD OF INVENTION
The present invention generally relates to receiver detection on a computer bus and, in particular, to methods and systems for detecting a receiver on a Peripheral Component Interconnect Express bus.
BACKGROUND
The Peripheral Component Interconnect Express (“PCI-Express”) standard defines how one or more peripheral devices can communicate with a computing device over a serial bus link. The serial bus link can be within a single computing device or can link one or more computing devices and peripheral devices. PCI-Express uses discrete logical layers to process inbound and outbound information. For instance, PCI-Express devices receive serial data, align the serial data and then convert the serial data into parallel data. PCI-Express devices use PCI-Express core logic for interfacing with host systems. The PCI-Express core logic includes a control status module (“PCS module”) that has a serial/de-serializer (“SERDES”) and other components. The SERDES in the PCS module communicates with a SERDES in a host system. However, before the SERDES in the PCS module can communicate with a SERDES in the host system, the PCS module detects if a receiver (i.e. the SERDES in the host system) is present and/or available to receive data.
In conventional systems, a SERDES vendor provides the mechanism to detect if a receiver is present. Often, the mechanism provided indicates that a receiver is present by using specific receiver detection protocol incorporating a set frequency, for example, 3 to 15 kilohertz if a receiver is present or above 30 kilohertz is a receiver is not present. Such proprietary conventional techniques have shortcomings. For example, detecting a receiver at a frequency of 3 kilohertz may cause delay and may take too long.
In addition, another prior art method and apparatus for detecting a receiver over a PCI-Express bus is to adjust a common mode voltage by current injection using a charge pump into one or more transmitter output nodes and detecting whether a receiver is present based on a voltage change rate. The current is injected by a charge pump under control of an amplitude control circuit. The charge pump consumes large amounts of power, and thus this prior art method is not appropriate for low power applications. Therefore, there is a need for a low power method and system to perform the receiver detection efficiently.
SUMMARY OF INVENTION
An object of this invention is to provide low power methods and systems for receiver detection on a computer bus.
Another object of this invention is to provide methods and systems for receiver detection on a PCI-Express bus using a voltage mode driver.
Yet another object of this invention is to provide methods and systems for receiver detection that have safeguards to prevent a voltage on a computer bus from exceeding a protocol dictated maximum common mode voltage.
Briefly, the present invention discloses methods and systems for detecting a receiver on a computer bus, comprising the steps of: applying a low voltage state on transmission lines of the computer bus using a voltage mode driver; applying a high voltage state on the transmission lines using the voltage mode driver; determining a voltage rate change for transmission voltages on the transmission lines; and determining the presence of the receiver on the computer bus as a function of the voltage rate change.
An advantage of this invention is that low power methods and systems for receiver detection on a computer bus are provided.
Another advantage of this invention is that methods and systems for receiver detection on a PCI-Express bus using a voltage mode driver are provided.
Yet another advantage of this invention is that methods and systems for receiver detection that have safeguards to prevent a voltage on a computer bus from exceeding a protocol dictated maximum common mode voltage are provided.
DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects, and advantages of the invention can be better understood from the following detailed description of the preferred embodiment of the invention when taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a diagram of a voltage mode driver of the present invention for detecting a receiver on a computer bus.
FIG. 2 illustrates a diagram for a receiver detection system of the present invention.
FIG. 3 illustrates a diagram for an equivalent circuit of a computer bus when a receiver is present.
FIG. 4 illustrates a diagram for an equivalent circuit of a computer bus when a receiver is not present.
FIG. 5 illustrates a waveform of various signals for a receiver detection system of the present invention when a receiver is not present on a computer bus.
FIG. 6 illustrates a waveform of various signals for a receiver detection system of the present invention when a receiver is not present on a computer bus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description of the embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration of specific embodiments in which the present invention may be practiced.
Generally, methods and systems are provided for detecting a receiver over a PCI-Express link (or any other computer bus standard or protocol). A receiver can be detected on a PCI-Express link by bringing the common mode voltage of a voltage mode driver for the PCI-Express link to a low voltage state, e.g., by pulling the differential outputs of the voltage mode driver low. Once the low voltage state is detected on both differential outputs, a pulse signal can be applied via the voltage mode driver to bring the common mode voltage to a high voltage state. The differential outputs of the voltage mode driver can be compared to one or more predefined reference voltages. The time between applying the pulse signal and the time the differential outputs reach the one or more predefined reference voltages can be used to determine whether there is a receiver on the PCI-Express link.
FIG. 1 illustrates a diagram of a voltage mode driver of the present invention for detecting a receiver on a computer bus. A voltage mode driver of the present invention 40 comprises multiplexers 10 and 12 , NAND gates 16 and 20 , NOR gates 14 , 18 , and 22 , inverter 24 , control input signals, and driver cells 26 and 28 . The driver cell 26 comprises a PMOS transistor, two resistors, and an NMOS transistor serially connected to generate a positive output T xp for the transmission lines of the PCI-Express link. The driver cell 28 comprises a PMOS transistor, two resistors, and an NMOS transistor serially connected to generate a negative output T xn for the transmission lines of the PCI-Express link. The positive output T xp and the negative output T xn can also be referred to as the transmission voltages for the transmission lines of the PCI-Express link.
The controls signals RcvDetectEn, RcvDetectClr, and DisDrv are inputted to the voltage mode driver 40 via the multiplexers 10 and 12 , NAND gates 16 and 20 , NOR gates 14 , 18 , and 22 , inverter 24 to control the output of the voltage mode driver 40 . A positive input voltage in_T xp and the RcvDetectEn signal are inputted to the multiplexer 10 , which is controlled by the output of the NOR gate 14 . The not output of the multiplexer 10 is inputted to the NAND gate 16 and the NOR gate 18 . A negative input voltage in_T xn and the RcvDetectEn signal are inputted to the multiplexer 12 , which is controlled by the output of the NOR gate 14 . The not output of the multiplexer 12 is inputted to the NAND gate 20 and the NOR gate 22 . The RcvDetectEn signal and the RcvDetectClr signal is inputted to the NOR gate 14 .
The DisDrv signal is inputted to the inverter 24 and the NOR gates 18 and 22 . The inverter 24 output is inputted to the NAND gates 16 and 20 . The NAND gate 16 drives the gate of the PMOS transistor of the driver cell 26 . The NOR gate 18 drives the gate of the NMOS transistor of the driver cell 26 . The NAND gate 20 drives the gate of the PMOS transistor of the driver cell 28 . The NOR gate 22 drives the gate of the NMOS transistor of the driver cell 28 .
When the RcvDetectEn signal is low and the RcvDetectClr signal is high, the transmission voltages T xp and T xn are both driven low. When the RcvDetectEn signal is high and the RcvDetectClr signal is high, then the transmission voltages T xp and T xn are both driven high. When the DisDrv signal is high, then the voltage mode driver 40 is tri-stated, and effectively disabled.
In normal operation (e.g., when the RcvDetectClr, RcvDetectEn, and DisDrv signals are low), the multiplexer 10 is enabled so that the input signal in_T xp for the differential transmission line is directed to the output T xp of the voltage mode driver 40 . The multiplexer 12 is also enabled so that the input signal in_T xn for the differential transmission line is directed to the output T xn of the voltage mode driver 40 .
FIG. 2 illustrates a diagram for a receiver detection system of the present invention. The receiver detection system of the present invention comprises the voltage mode driver 40 , a signal generation and control unit 42 , a low detect logic 44 , a high detect logic 46 , a disable drive logic 48 , and a reference voltage generator 50 . The low detect logic 44 , the high detect logic 46 , and the disable drive logic 48 monitor the transmission voltages T xp and T xn . The signal generation and control unit 42 transmits the control signals RcvDetectEn, RcvDetectClr, and DisDrv to the voltage mode driver 40 based upon the results of the monitored transmission voltages T xp and T xn .
A host controller (not shown) can assert the control signal RcvDetEn to the signal generation and control unit 42 to start the receiver detection system. Upon receiving the RcvDetEn signal, the signal generation and control unit 42 drives the RcvDetectClr signal high and the RcvDetectEn signal low, which is inputted to the voltage mode driver 40 . The voltage mode driver 40 then brings down the transmission voltages T xp and T xn low.
The low detect logic 44 comprises a summing circuit and comparators that compare the transmission voltages T xp and T xn to a reference voltage A (e.g., 100 mV). The reference voltage A is generated by the reference voltage generator 50 and can be adjusted as desired. When the low detect logic 44 detects that the transmission voltages T xp and T xn are both below the reference voltage A, the low detect logic 44 signals this occurrence to the signal generation and control unit 42 via a LowDetect signal. The signal generation and control unit 42 then drives the transmission voltages T xp and T xn to high by outputting a high signal for the control signal RcvDetectEn.
The high detect logic 46 comprises a summing circuit and comparators that compare the transmission voltages T xp and T xn with a reference voltage B (e.g., 600 mV). The reference voltage B is generated by the reference voltage generator 50 and can be adjusted as desired. As the transmission voltages T xp and T xn are driven high, the high detect logic 46 detects when the signals T xp and T xn both exceed the reference voltage B. This occurrence is reported to the signal generation and control unit 42 to estimate the amount of time (which can be measured in clock cycles or in nanoseconds) it takes to raise the transmission voltages T xp and T xn from the reference voltage A to the reference voltage B.
The disable drive logic 48 comprises a summing circuit and comparators that compare the transmission voltages T xp and T xn with a reference voltage C (e.g., 700 mV). The reference voltage C is generated by the reference voltage generator 50 and can be adjusted as desired. Due to specific protocols and standards for the computer bus, the computer bus may have a stated maximum common mode voltage. The disable drive logic 48 detects whether or not the transmission voltages T xp and T xn exceed the reference voltage C, which can be set to this stated maximum common mode voltage or below the maximum common mode voltage to allow for some margin of error. If so, then the voltage mode driver 40 is disabled.
Operationally, the receiver detection system can begin by asserting a high signal for the control signal RcvDetEn. Upon receiving the control signal RcvDetEn, the signal generation and control unit 42 asserts the RcvDetectClr signal to the voltage mode driver 40 . The voltage mode driver 40 then pulls the transmission voltages T xp and T xn low. The low detect logic 44 determines whether the transmission voltages T xp and T xn is below the predefined reference voltage A. If the transmission voltages T xp and T xn are below the reference voltage A, the low detect logic 44 asserts a LowDetect signal to the signal generation and control unit 42 . The signal generation and control unit 42 then asserts the RcvDetectEn signal to the voltage mode driver 40 . The RcvDetectEn signal is inputted to the voltage mode driver 40 to drive the transmission voltages T xp and T xn high. The high detect logic 46 monitors whether the transmission voltages T xp and T xn have reached or exceeded the predefined reference voltage B, which is programmable. If the transmission voltages T xp and T xn are above the reference voltage B, then a HighDetect signal is asserted to the signal generation and control unit 42 .
The signal generation and control unit 42 checks the delay between the RcvDetectEn and HighDetect signal assertions. If the delay is less than or equal to a programmable value, T1, then the receiver is not present. Else, the receiver is present. The disable driver logic 48 determines whether the transmission voltages T xp and T xn have reached the predefined reference voltage C, which is programmable. If the transmission voltages T xp and T xn both exceed the reference voltage C, then a signal DisableDrv is asserted to the signal generation and control unit 42 . The signal generation and control unit 42 in turn disables the voltage mode driver 40 by enabling the DisDrv signal. This is to make sure the transmission voltages T xp and T xn are always less than the protocol dictated maximum common mode voltage. If the signal generation and control unit 42 determines that there is a receiver on the transmission line, then the signal RcvStatus is reported to the controller.
FIG. 3 illustrates a diagram for an equivalent circuit for a computer bus when a receiver is present. A voltage mode driver 60 of the present invention and a receiver 62 communicate over a differential transmission line 64 , e.g., a PCI-Express link. AC coupling between the voltage mode driver 60 and the receiver 62 is characterized through the coupling capacitors 66 . The transmission line 64 can be inputted to the voltage mode driver 60 from a transmitter that communicates over the differential transmission line 64 . The voltage mode driver 60 can adjust the voltage signals T xp and T xn on the differential transmission line 64 for output to the receiver 62 .
If the receiver 62 is present and connected to the differential transmission line 64 , then the resistors 68 can terminate the differential transmission line 64 by being serially connected across the differential transmission line 64 .
If the present invention recognizes that when the receiver 64 is present and connected to the transmission line 64 , large AC coupling capacitors 66 will act as a load to the voltage mode driver 60 . If the voltage mode driver 60 applies a high signal on the differential transmission line 64 , the transmission voltages T xp and T xn at the differential transmission line 64 will slowly rise due to the receiver 62 being connected to the differential transmission line 64 .
FIG. 4 illustrates a diagram for an equivalent circuit for a computer bus when a receiver is not present. A voltage mode driver 70 of the present invention and a possible receiver 72 communicate over a differential transmission line 74 , e.g., a PCI-Express link. AC coupling between the voltage mode driver 70 and the receiver 72 is characterized through coupling capacitors 76 . The differential transmission line 74 can be inputted to the voltage mode driver 70 from a transmitter that communicates over the differential transmission line 74 . The voltage mode driver 70 can adjust the transmission voltages T xp and T xn on the differential transmission line 74 for output to the receiver 72 .
If the receiver 72 is not present and/or not connected to the differential transmission line 74 , then the differential transmission line 74 does not have a terminating resistor at the receiver 72 .
When the receiver 72 is not present and/or not connected to the transmission line 74 , large AC coupling capacitors 76 will act as a load to the voltage mode driver 70 . If the voltage mode driver 70 applies a high signal on the differential transmission line 74 , the transmission voltages T xp and T xn at the differential transmission line 74 will quickly rise on the differential transmission line 64 when the receiver is not present and/or not connected to the transmission line 74 .
FIG. 5 illustrates a waveform of various signals of a receiver detection system of the present invention when a receiver is not present on a computer bus. When the receiver is not present, the transmission voltages T xp and T xn quickly exceed a predefined voltage, e.g., 700 mV, within a short time frame. The receiver detection system can determine the amount of time T1 for the transmission voltages T xp and T xn to reach the predefined voltage. If the time T1 is within a predefined amount of time, then the receiver detection system can signal that a receiver is not present.
FIG. 6 illustrates a waveform of various signals of a receiver detection system of the present invention when a receiver is not present on a computer bus. When the receiver is present, the transmission voltages T xp and T xn slowly rise to the predefined voltage, e.g., 700 mV, taking a relatively long amount of time to reach the predefined voltage. The receiver detection system can determine the amount of time T1 for the transmission voltages T xp and T xn to reach the predefined voltage or come close to the predefined voltage. If the time T1 exceeds a predefined time frame for detecting the receiver, then the receiver detection system can signal that a receiver is present.
While the present invention has been described with reference to certain preferred embodiments or methods, it is to be understood that the present invention is not limited to such specific embodiments or methods. Rather, it is the inventor's contention that the invention be understood and construed in its broadest meaning as reflected by the following claims. Thus, these claims are to be understood as incorporating not only the preferred methods described herein but all those other and further alterations and modifications as would be apparent to those of ordinary skilled in the art.
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A method for detecting a receiver on a computer bus, comprises the steps of: applying a low voltage state on transmission lines of the computer bus using a voltage mode driver; applying a high voltage state on the transmission lines using the voltage mode driver; determining a voltage rate change for transmission voltages on the transmission lines; and determining the presence of the receiver on the computer bus as a function of the voltage rate change.
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FIELD OF THE INVENTION
This invention relates to a currency security box which may be used in machines which accept bills, coins, tokens, chips, or similar type items to operate the machine.
BACKGROUND OF THE INVENTION
A currency security box is incorporated in a variety of devices where a user deposits bills or coins through a port in the device to actuate the device. Frequently, these currency security boxes accept bills, coins, tokens, or chips which have been first validated by an appropriate validator. In certain situations, these currency security boxes require a locking device to allow access to the deposited currency only by authorized personnel.
Since a person authorized to gain access to the internal structure of the device containing the locked security boxes may not have the additional authority to gain access to the currency inside the security box, it is desirable to provide a convenient means for allowing such a person to remove the locked security box from the device so that the locked box may be opened by an authorized person at a location remote from the device.
SUMMARY OF THE INVENTION
The invention is an improved currency security box which may be quickly and easily removed from a device containing the box and which is locked when removed from the device. The security box may then be later unlocked by an authorized person to gain access to currency or other items of value contained in the box.
In the preferred embodiment of the invention, a currency security box is releasably secured to a frame or support structure within a device, such as a vending machine, gaming machine, amusement machine, gaming table, arcade machine, or bank machine. The security box is automatically released from the frame by sliding a transportable security box cover over the security box.
At the time the security box cover releases the box from the frame, the security box cover has also effectively enclosed the security box and automatically latched onto the security box. The security box cover includes a locking device which must be activated to release the security box cover from the security box so as to gain access to the currency in the box.
After the security box cover has enclosed the box and released the box from the frame, the security box and the security box cover may now be removed from the machine and transported to a remote area where an authorized person would then disengage the security box cover from the security box by a key or combination to gain access to the currency within the security box.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the interaction of the security box cover, the security box, and the frame used in the preferred embodiment of the invention.
FIG. 2 illustrates the automatic latching of the security box to the frame when the security box is slid into position in the frame.
FIGS. 3a and 3b further illustrate the latching action of the frame.
FIG. 4 illustrates the means by which the security box cover is latched onto the security box for removing the security box from the frame.
FIGS. 5a through 5c show, in sequence, the operation of the latching means provided on the security box cover when latching onto the security box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows frame 3 which may be secured within any device in which currency or other items of value are inserted to operate the device. Such a device may be a vending machine, a gaming machine, a bill changer or any other machine.
Securing frame 3 within such a device is preferably done so as to prevent easy removal of frame 3 from the device by unauthorized personnel when currency security box 4 is latched onto frame 3. One such means of securing frame 3 within a device may be via bolts 6 and 7 which may only be unscrewed after security box 4 has been removed from the device. Other means of securing frame 3 within a device may be more applicable depending on the particular environment of the device, and such means for securing would be apparent to one of ordinary skill in the art.
All portions of frame 3 may be made of a suitable sheet metal.
Frame 3 includes a base 10 onto which security box 4 sits after being slid into position against back wall 12 of frame 3.
Spring-loaded latches 14 and 16 are shown protruding from slots 18 and 20, respectively, formed in left sidewall 22 of frame 3. An identical latch and slot structure is provided in right sidewall 24 of frame 3. Spring-loaded latches 14 and 16 each have an angled edge 26 to more easily enable security box 4 and security box cover 30, when slid in the direction of arrow 32, to push spring-loaded latches 14 and 16 further into slots 18 and 20 to accomplish the required latching and releasing operations to be described later.
Latches 14 and 16 have a rear blocking edge 34, approximately perpendicular to left sidewall 22, for securing security box 4 in place when properly slid into position in frame 3.
Latches 14 and 16 also have a front blocking edge 36, approximately perpendicular to left sidewall 22, which contacts a front edge of slots 18 and 20 for preventing forward movement of latches 14 and 16 in a direction opposite to arrow 32.
Left spring housing 38 and right spring housing 40 house the mechanisms which resiliently support the latches protruding from left sidewall 22 and right sidewall 24, as will be discussed in more detail with respect to FIGS. 3a and 3b.
As shown in FIG. 1, security box 4 is sized so as to be slid into place along base 10 of frame 3 against back wall 12 between left sidewall 22 and right sidewall 24. In the preferred embodiment shown in FIG. 1, currency security box 4 is essentially rectangular; however, security box 4 may be of any suitable shape to match the shape of any suitable frame, shown in one embodiment as frame 3. Currency security box 4, shown in FIG. 1, may be made of a durable metal of sufficient thickness to provide the desired mechanical strength.
As security box 4 is slid into place in frame 3 in the direction of arrow 32, latches 14 and 16 along left sidewall 22 are pushed within slots 18 and 20 of left sidewall 22 by being contacted by left sidewall 44 of security box 4. The same operation occurs with latches protruding from right sidewall 24 of frame 3 being contacted by right sidewall 50 of security box 4. This operation is illustrated in FIG. 3a, where a top view of latch 46, protruding from right sidewall 24 of frame 3, is shown prior to being contacted by right sidewall 50 of security box 4. When box 4 is slid in the direction of arrow 47, right sidewall 50 of box 4 pushes against latch 46, and spring-loaded latch 46 moves in a clockwise direction around axis 51.
FIG. 3b is a cutaway front view of right spring housing 40, which shows the spring loading of latches 46 and 60, whereby latches 46 and 60 may be formed of a single piece of metal. Latches 46 and 60 may be formed to rotate about axis 51 and are spring loaded by means of spring 62.
Both left sidewall 44 and right sidewall 50 of box 4 have slots formed therein such as slots 52 and 54 shown in FIG. 1. When security box 4 is slid into place against back wall 12 of frame 3, the slots, such as slots 52 and 54, align with the latches protruding from the respective sidewalls of frame 3 so that the spring-loaded latches enter the respective slots formed in the sidewalls of security box 4.
As shown in FIG. 2, once the spring-loaded latches enter the respective slots in security box 4, security box 4 is then latched in place. Security box 4 is now blocked from being slid out of frame 3 by rear edges 34 of latches 14 and 16 coming into contact with the edges of slots 56 and 58 formed in left sidewall 44 of security box 4.
Frame 3 and security box 4 are preferably located within a device such that, after a bill, coin, token, or chip is inserted into the device by a user, a validator deposits any inserted currency or other item into security box 4. This may be accomplished by positioning the validator so that any currency or other item will drop into security box 4 through top opening 70 or side opening 72 shown in FIGS. 1 and 2. Security box 4 may be designed to accept currency or other items from virtually any validator.
Preferably, frame 3 is positioned within a device such that, when security box 4 is in place and the device is opened to gain access to its internal structure, access cannot be gained to the currency within security box 4 by one who only has access to the internal structure of the device. This may be accomplished by providing a structure which would not allow a person to reach through openings 70 or 72 when box 4 is positioned in frame 3. For example, openings 70 or 72 may be blocked by a cover or by an overhanging portion of frame 3 itself when box 4 is secured to frame 3.
To now remove security box 4 from frame 3, security box cover 30, shown in FIGS. 1 and 4, is used. Security box cover 30, in the embodiment of FIGS. 1 and 4, provides essentially a four-sided enclosure having top surface 76, front surface 78, right side 80, and left side 82. The security box cover 30 of FIGS. 1 and 4 has no bottom surface or back surface so that security box cover 30 may be slid over the top of security box 4 and between the sides 44 and 50 of security box 4 and sides 22 and 24 of frame 3. Security box cover 30 may be made of a suitable sheet metal.
When security box cover 30 is slid over security box 4 and between the sides of security box 4 and frame 3 in the direction of arrow 32 in FIG. 1, left side 82 and right side 80 of security box cover 30 pushes the latches, such as latches 14 and 16, protruding from the sidewalls of frame 3 into their respective spring housings 38 and 40 so as to release security box 4 from these latches.
As shown in FIGS. 4 and 5, security box cover 30 contains a spring-loaded sliding latch 90, slidably mounted to its front surface 78. When security box cover 30 is sufficiently slid over security box 4 and pushed in the direction of arrow 92 in FIGS. 5a and 5b, sliding latch 90 is displaced in the direction of arrow 94 in FIG. 5b due to the interaction of angled edges 96 and vertical rods 98, rods 98 being connected to security box 4 as shown in FIGS. 1 and 2.
As security box cover 30 is further slid into place over security box 4, spring-loaded latch 90, after riding over rods 98, then automatically latches onto rods 98 in the direction of arrow 99 in FIG. 5c. It will be apparent that other latching or securing means may be used.
The position of FIG. 5c is shown in the cutaway view of FIG. 4, where security box cover 30 is now secured to the security box by means of latch 90 and rods 98. Thus, security box cover 30 is now secured to security box 4, and security box 4 is unlatched from frame 3 for removal from frame 3.
Security box 4 may then be removed from frame 3 by pulling security box cover handle 100 to enable easy carrying of security box 4 to a remote location where security box 4 may be unlatched from security box cover 30 to gain access to the currency in security box 4. Such unlatching may be accomplished by dialing the appropriate combination for lock 102, which when turned causes slidable latch 90 to disengage from rods 98.
As will be apparent, combination lock 102 may be replaced by a key lock or other locking mechanism. It will be apparent to those of ordinary skill in the art that many mechanisms may be used to cause latch 90 to be unlatched from rods 98 upon actuation of any locking device. One mechanism may include a well known type lever means or gear means connected to lock 102 which, when actuated by unlocking security box cover 30, would cause slidable latch 90 to slide in the direction of arrow 94 in FIG. 5b to release security box cover 30 from box 4.
Thus, a preferred embodiment of the invention has been disclosed. It will be apparent to those of ordinary skill in the art that the various latches discussed with respect to the preferred embodiment may be replaced by other latches for accomplishing a similar purpose. Further, the various latches may be incorporated on the security box itself rather than on the frame or cover. The various structures described may also have any suitable size or shape while still performing the functions described in this specification.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as followed in the true spirit and scope of this invention.
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In the preferred embodiment of the invention, a currency security box is releasably secured to a frame within a device, such as a vending machine, gaming machine, gaming table, amusement machine, bank machine or the like, and is automatically released from the frame by sliding a transportable security box cover over the security box. At the position where the security box cover releases the box from the frame, the security box cover also effectively encloses the security box and automatically latches onto the security box. The security box, along with the security box cover, may now be removed from the frame and the device. The security box cover includes a locking device which must be activated to release the security box cover from the security box so as to gain access to the currency in the box.
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SUMMARY OF INVENTION
The invention relates to a lifting apparatus for lifting and lowering a load, having
a) a lifting drum; b) a drive, by which the lifting drum can be set in rotation in both directions; c) at least two bands, serving as pulling means, which are secured by one end to the lifting drum and at the other end carry a holding device for the load; d) the bands being able to be wound up on the lifting drum, by rotation of the latter, in such a way that one turn lies above the other.
A wide variety of configurations of lifting apparatuses employing a lifting drum and at least one flexible pulling means which can be wound up on this drum are known. Ropes, chains or bands, in particular, are used as the pulling means. Bands have the advantage that they can be wound up on the lifting drum in a particularly well-defined manner and have a relatively high carrying capacity, while nevertheless remaining sufficiently flexible. For this reason, lifting apparatuses which employ bands as the pulling means, with which the present invention is also concerned, are enjoying increasing popularity.
A plurality of load-carrying bands are generally employed in cases where the carrying capacity of the lifting apparatus is to be increased or loads with large dimensions are to be lifted and lowered. In such lifting apparatuses known from the market, the different bands were wound up on the lifting drum one beside the other, i.e. in different axial regions. However, this gives rise to geometrical problems with the band guidance, in particular where there are a large number of bands or the space is confined.
The object of the present invention is to configure a lifting apparatus of the type mentioned at the outset in such a way that, while maintaining precise guidance of the bands, a large number of bands, suited to the requirements, can be employed without much space being required for their guidance.
This object is achieved according to the invention in that
e) at least two bands can be wound up on the lifting drum with accurate tracking and so as to lie one above the other.
According to the invention, the plurality of bands are thus no longer wound up one beside the other in axially different regions, but one above the other in the same axial region of the lifting drum. It is now no longer turns of one and the same band that lie directly one above the other, but turns of different bands. The winding-up behaviour of these bands lying one above the other can be controlled very well. Moreover, they can be guided in a relatively confined space. Each of the bands lying one above the other can be dimensioned in such a way that, in an emergency when another band breaks, it can take over the share of the load which has hitherto been carried by this other band and in this way emergency operation of the lifting apparatus is possible. This contributes to increased operating safety of the lifting apparatus.
Winding a plurality of bands on the lifting drum one above the other in the manner according to the invention gives rise to the problem that, on unwinding the bands from the lifting drum, at a certain angular rotation different lengths of the bands are unwound. This results from the fact that the turns of the bands, which are unwound simultaneously, lie on different radii. A configuration of the invention is therefore recommended in which the lower ends of the bands are connected to a holding device for the load, which is configured as a compensating device for the varying lengths, on winding up and unwinding, of the unwound parts of the bands lying one above the other on the lifting drum. This compensating device makes it possible for the lower ends of the bands lying one above the other to move at slightly different speeds on unwinding or winding up, without losing the uniform load distribution to the different bands.
By way of example, it is possible for two bands to be able to be wound up on the lifting drum with accurate tracking and so as to lie one above the other. In this case, the holding device can comprise a rocker element which connects the lower ends of the two bands to one another, the rocker element having, between the points at which the force is introduced by the bands, a fastening device for the load. The different vertical movements of the lower ends of the bands lying one above the other is offset by a pivoting of the rocker element.
In this case, the lower ends of the bands are expediently secured in clamping pieces articulated in opposite regions of the rocker element.
If three bands are to be able to be wound up on the lifting drum with accurate tracking and so as to lie one above the other, the following construction is possible: the lower ends of the two outer bands are connected to one another, the holding device comprising a deflection roller which is carried by the middle band and around which the connection between the two outer bands is guided. The vertical position of the holding device is in this case determined substantially by the middle band, while the vertical positions of the lower ends of the two outer bands are displaced, on unwinding and winding up, in opposite directions relative to the lower end of the middle band. As a result of the non-positive connection between the lower ends of the outer bands, the same stress is always present in these bands. The length of the middle band must be dimensioned in such a way that this band too carries substantially the same share of the load. This design presupposes, however, that at least the two outer bands have the same thickness.
The lower ends of the two outer bands can, in principle, be connected to one another in one piece, with the result that the two outer bands are formed by a single band laid around the deflection roller. A more favourable construction, however, is that in which the lower ends of the two outer bands are connected to one another by a piece of rope or chain which is guided around the deflection roller. It is thereby possible to use smaller-diameter and thus space-saving deflection rollers.
It is also possible for four bands to be able to be wound up on the lifting drum with accurate tracking and so as to lie one above the other. In this case, a design can be employed in which the lower ends of the first pair of adjacent bands and the lower ends of the second pair of adjacent bands are connected to one another, the holding device comprising:
a) a rocker element; b) a first deflection roller, around which the connection of the lower ends of the first pair of bands is guided and which is mounted in an end region of the rocker element; c) a second deflection roller, around which the connection of the lower ends of the second pair of bands is guided and which is mounted in the opposite end region of the rocker element; and d) the rocker element, at a point lying between the points at which the deflection rollers are mounted, having a fastening device for the load.
In this design, the two deflection rollers perform a vertical movement which corresponds to an average of the vertical movement of the two bands with which these deflection rollers are associated. Through the rocker element, in turn, a further averaging of the vertical positions of the two deflection rollers takes place.
In this latter design too, it is recommended for the reasons already mentioned above that the connections of the lower ends of the two pairs of bands are pieces of rope or chain.
The winding-up and unwinding of the bands lying one above the other involves a sliding movement of these bands relative to one another. It is therefore favourable if the bands are provided with a friction-reducing coating on at least one side, which coating may be a graphite or Teflon coating or the like.
As a result of the fact that the ends of the bands lying one above the other are fastened to the circumferential surface of the lifting drum, a step is formed which has to be overcome by the radially inner band after the first turn. In order to avoid bending of the band at this point, it is advantageous if at least one spacer element, on which the first turn of the radially innermost band can come to bear before reaching the step formed by the ends of the bands, is provided on the circumferential surface of the lifting drum.
Preferably, the bands consist of metal, in particular of steel.
BRIEF DESCRIPTION OF DRAWINGS
Exemplary embodiments of the invention are explained in more detail below with reference to the drawing, in which:
FIG. 1 shows a section through the lifting drum and two load-carrying bands of a lifting apparatus;
FIG. 2 shows a detail enlargement from FIG. 1 ;
FIG. 3 shows, in section, a holding device used in lifting apparatuses employing three bands; and
FIG. 4 shows, in section, a holding device used in lifting apparatuses employing four bands.
DETAILED DESCRIPTION
Reference is made first of all to FIG. 1 , which can be understood as a highly schematic illustration of a simple lifting apparatus. The lifting apparatus, identified as a whole by the reference symbol 1 , comprises as the main component a lifting drum 2 which is rotatably fitted in two bearing blocks 4 (only one indicated in the drawing) fixed on a mounting plate 3 . The lifting drum 2 can be rotated in both directions of rotation by a drive motor (not illustrated) which is likewise mounted on the mounting plate 3 .
The mounting plate 3 is placed at a certain height above the room floor, for example by means of a steel structure (not illustrated).
To lift and lower the load, two steel bands 5 a , 5 b are used as the pulling means, which bands can be wound up on the lifting drum 2 with accurate tracking and so as to lie one above the other in a plurality of turns likewise lying one above the other, as can be seen from FIGS. 1 and 2 . This means that following one another radially from the inside outwards on the lateral surface of the lifting drum 2 are first of all a turn of the steel band 5 a on the left in FIG. 1 , then a turn of the steel band 5 b on the right in FIG. 1 and then, in accordance with the position of the load to be lifted or lowered, further turns alternately of the steel band 5 a and of the steel band 5 b.
As can be seen in particular from FIG. 2 , the ends 6 a , 6 b of the two steel bands 5 a , 5 b are suitably secured to the lateral surface of the lifting drum 2 , for example by adhesive bonding, clamping, welding or else simply by the friction produced by turns of the two steel bands 5 a , 5 b lying thereabove. In the latter case, the steel bands 5 a , 5 b must of course not be unwound from the lifting drum 2 down to the last turn in normal operation.
The ends 6 a , 6 b of the two steel bands 5 a , 5 b form a step for the first turn of the steel band 5 a on the left in FIG. 1 , which step has to be overcome by the steel band 5 a and the height of which is equal to the sum of the thicknesses of the two steel bands 5 a and 5 b . This results in an empty space 7 between the first turn of the steel band 5 a and the lateral surface of the lifting drum 2 . In order to prevent the first turn of the steel band 5 a and hence, to a certain extent, also the further turns, lying thereabove, of both steel bands 5 a , 5 b from being pressed into the clearance 7 and thereby bent at the step formed by the ends 6 a , 6 b , a total of three spacer elements 8 a , 8 b and 8 c in the form of metal sheets 8 a , 8 b and 8 c curved in the shape of circular arcs are arranged in this empty space 7 . Each of these metal sheets 8 a , 8 b and 8 c has a constant thickness. The thickness of the metal sheets 8 a , 8 b , 8 c increases, however, in the clockwise direction towards the step formed by the ends 6 a , 6 b . Generally, the direction in which the thickness of the spacer elements 8 a , 8 b , 8 c is to increase, is opposite that direction in which the lifting drum 2 rotates on lifting the load.
The spacer elements 8 a , 8 b , 8 c thereby form bearing surfaces for the first turn of the steel band 5 a , preventing this turn from “caving in” too deeply, radially inwards. It is thus not absolutely necessary for the thickness of the spacer elements 8 a , 8 b , 8 c to increase continuously in the stated direction, so as to exactly fill up the empty space 7 formed geometrically. Nor do the spacer elements 8 a , 8 b , 8 c have to butt against one another. They can, seen in the circumferential direction, also be at a distance, which is bridged by the steel band 5 a . The number of spacer elements 8 a , 8 b , 8 c used can vary depending on the circumstances. The result, however, is that the first turn of the steel band 5 a and hence also the turns, lying thereabove, of both steel bands 5 a , 5 b undergo no bending or only insignificant bending at the step formed by the ends 6 a , 6 b , so that no appreciable alternating loading of the steel bands 5 a , 5 b occurs at this point.
Clamped to the lower ends of each of the steel bands 5 a , 5 b is a clamping piece 9 a , 9 b . The lower regions of the two clamping pieces 9 a , 9 b are each articulated with the aid of a bearing pin 10 a , 10 b at opposite end regions of a rocker element 11 . The rocker element 11 has in the central region a bore 12 , to which the load (not illustrated) can be attached. The rocker element 11 thereby forms with the clamping pieces 9 a , 9 b a holding device 50 for the load.
The operation of the lifting apparatus 1 described is as follows:
On lowering a load attached to the rocker element 11 , the lifting drum 2 is rotated in the clockwise direction in FIGS. 1 and 2 , whereby the two steel bands 5 a , 5 b unwind from the lifting drum 2 . Since the steel band 5 b has been wound up on the lifting drum 2 on a larger radius than the steel band 5 a , at a certain angular rotation of the lifting drum 2 a longer piece of the steel band 5 b is unwound therefrom than of the steel band 5 a . This difference in length of the two steel bands 5 a , 5 b is compensated for by a corresponding tilting of the rocker element 11 about the axis defined by the bore 12 . The stresses within the steel bands 5 a , 5 b remain substantially equal in this case, so that the load is uniformly distributed to the two steel bands 5 a , 5 b.
In order to reduce the mutual friction as they are wound up on and unwound from the lifting drum 2 , the two steel bands 5 a , 5 b are provided with a low-friction coating or intermediate layer, at least on a side which can come to bear on an adjacent steel band 5 a , 5 b on winding up. This may be a graphite coating or a Teflon band or the like.
In the exemplary embodiment described above with reference to FIGS. 1 and 2 , two steel bands 5 a , 5 b have been used to carry the load. If even greater loads are to be lifted and lowered, it may be necessary to increase the number of steel bands to be wound one above the other. Since it is obvious how the relationships on the lifting drum 2 would appear in such a case, a separate illustration of this has been dispensed with. What is interesting in these cases is how the respective lower ends of the steel bands are connected to one another.
An exemplary embodiment of a holding device 150 which can be employed with three steel bands 105 a , 105 b and 105 c is illustrated in FIG. 3 . The lower ends of these steel bands 105 a , 105 b , 105 c are again clamped in clamping pieces 109 a , 109 b , 109 c . In addition, the two ends of a piece of rope 120 , guided over a deflection roller 121 , are secured in the two outer clamping pieces 109 a , 109 c in the manner illustrated in FIG. 3 . The deflection roller 121 is rotatably mounted in the lower end region of the middle clamping piece 109 b by means of a bearing journal 122 . The load (not illustrated) is attached to the middle clamping piece 109 b or to the bearing journal 122 .
On lifting and lowering the load, its position is determined by the position of the clamping piece 109 b clamped to the lower end of the middle steel band 105 b . The differences in length which result on unwinding the two lateral steel bands 105 a , 105 c are compensated for by the clamping pieces 109 a , 109 c attached to their lower ends moving in opposite directions upwards and downwards, the stress present in them being transmitted via the rope 120 . A uniform distribution of the load to all three steel bands 105 a , 105 b , 105 c can thereby be achieved. However, this presupposes that at least the two outer steel bands 105 a , 105 c have the same thickness.
Finally, FIG. 4 shows how the lower ends of four load-carrying steel bands 205 a , 205 b , 205 c and 205 d can be connected to one another by a holding device 250 , in order to be able to compensate for the different movements of the lower ends of the steel bands 205 a to 205 d while uniformly distributing the load. The holding device 250 illustrated in FIG. 4 constitutes in a way a combination of the designs described above with reference to FIGS. 1 and 3 : The lower ends of the steel bands 205 a to 205 d are each again clamped in a clamping piece 209 a , 209 b , 209 c and 209 d . Once again, the opposite ends of a piece of rope 220 a , guided over a first deflection roller 221 a , are secured in the adjacent clamping pieces 209 a , 209 b associated with the steel bands 205 a , 205 b . In a corresponding manner, the opposite ends of a second piece of rope 220 b , guided over a second deflection roller 221 b , are clamped to the adjacent clamping pieces 209 c , 209 d associated with the steel bands 205 c , 205 d . The two deflection rollers 221 a , 221 b are each rotatably mounted with the aid of a bearing journal 222 a , 222 b in the opposite ends of a rocker element 211 .
In the middle between the two journals 222 a , 222 b , the rocker element 211 once again has a bore 212 , to which the load (not illustrated) can be attached and which forms the axis of rotation for the tilting of the rocker element 211 .
The difference in length which arises on unwinding or winding up the adjacent steel bands 205 a , 205 b can be compensated for with the aid of the deflection roller 221 a . Correspondingly, the difference in length which results between the steel bands 205 c , 205 d can be compensated for by the deflection roller 221 b , while each time ensuring the same stress in the steel bands 205 a , 205 b and 205 c , 205 d connected via the pieces of rope 220 a , 220 b , respectively. Differences between the average changes in length of the band pair 205 a , 205 b , on the one hand, and the band pair 205 c , 205 d , on the other hand, are compensated for by tilting the rocker element 211 about the axis defined by the bore 212 .
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A lifting apparatus for lifting and lowering a load comprises, in a known manner, a lifting drum and a drive, by which the lifting drum can be set in rotation in both directions. Serving as the pulling mechanisms are bands which are secured by one end to the lifting drum and at the other end carry a holding device for the load. At least two bands can be wound up on the lifting drum, by rotation of the latter, with accurate tracking and so as to lie one above the other, in such a way that all the turns of the bands lie one above the other. This lifting apparatus combines a high carrying capacity, high precision in the guidance of the bands and a high level of operating safety.
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BACKGROUND
[0001] A software system called TCM (Test Case Management) automatically executes test cases and manages test machines. In current implementations, TCM can manipulate test machines only if a TCM client is installed and run as a client application on each test machine.
[0002] Web applications also may be tested. However, customers using a web browser other than Internet Explorer running on a Windows® operating system are not supported. Existing TCM systems fail to support this case because no client applications are available, and/or because of difficulties in developing client application for non-Windows® operating systems. As a result test cases for non-Windows® operating systems have to be executed or launched manually, which increases the cost of software development.
SUMMARY
[0003] This Summary is provided to introduce a selection of representative concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in any way that would limit the scope of the claimed subject matter.
[0004] Briefly, various aspects of the subject matter described herein are directed towards a technology by which test case content in the form of a web application and its post-execution results are communicated between a client and a test case management system over a web server. This allows different web application test harnesses to be run on whatever Internet browser the client computing device is running. As one result, the test case management system and client computing device that runs the browser are independent of any particular operating system.
[0005] In one aspect, the client registers with the test case management system through a website. The test case management system returns an identifier for the browser for use in future communications between the browser and the test case management system. The client uses the identifier in heartbeats sent to the test case management system, including a heartbeat indicating when the client is available to run a test case.
[0006] In one aspect, when the client is available and the test case management system decides when to provide the client with a test case, a test case configured as a web application is provided to the client. The client runs the test case, and when complete, returns results to the test case management system, e.g., in a later heartbeat. In this manner, any client running any contemporary web browser and/or operating system may be supported by the test case management system.
[0007] Other advantages may become apparent from the following detailed description when taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
[0009] FIG. 1 is a block diagram showing an example test case management controller web access system.
[0010] FIGS. 2-4 are representations of communications and control flow between various components of the test case management controller web access system.
[0011] FIG. 5 shows an illustrative example of a computing environment into which various aspects of the present invention may be incorporated.
DETAILED DESCRIPTION
[0012] Various aspects of the technology described herein are generally directed towards delivering test case content and execution results over a web server, e.g., instead of via a test case management client application. While some of the examples described herein are directed towards protocols and interfaces to facilitate the delivery, along with interfaces to accommodate different test case management systems for test case management controller web access and interface to accommodate different web application test harnesses running on internet browsers, it is understood that these are only examples. Indeed, numerous other protocols and/or interfaces may be used to provide a similar benefit.
[0013] As such, the present invention is not limited to any particular embodiments, aspects, concepts, structures, functionalities or examples described herein. Rather, any of the embodiments, aspects, concepts, structures, functionalities or examples described herein are non-limiting, and the present invention may be used various ways that provide benefits and advantages in computing and test case management in general.
[0014] Turning to FIG. 1 , there is shown an example TCM controller web access implementation in which computing devices corresponding to test browser A and test browser B are being remotely test case managed via a web server 102 . Note that while test browser A and test browser B may be running on separate machines, it is understood that they may possibly share one test machine.
[0015] A virtual client manager (VCM) 104 acts as a bridge between a test controller web access (TCWA) subsystem 106 and the web server 102 , generally for handling test cases, execution results and task distribution. A job session service may be used to separate test case and web browser registration, e.g., to enable test case execution that may use multiple browsers and/or other execution units.
[0016] Note that as also shown in FIG. 1 , a virtual TCM (VTCM) 110 is an abstract of TCM with which the test controller web access (TCWA) subsystem communicates. The job Codec 112 provides a translation mechanism between a TCM system-specific job/result description and a test case running inside the virtual client manager 102 .
[0017] A virtual client 114 comprises a stateless website, which acts as HTTP channel with AJAX (asynchronous JavaScript and XML), and a web application running on a web browser, which manages the state of a web browser as an execution unit. Other components 131 - 134 of the product web server are shown for completeness.
[0018] Each text browser includes a JavaScript Test Arena (JTA) 120 A or 120 B): interface to test case running on the web browser. In each tested browser, a client Monitor (CM, 122 A or 122 B) comprises an application program running along with the web browser. One task of the client monitor is to restart the web browser for each test case, such as to compensate for any resource leaks and/or exception halts.
[0019] Turning to various communication scenarios, FIG. 2 represents a virtual client 120 registering with a test case management system. To this end, the virtual client manager 104 provides necessary information to the test case management system (e.g., adds the machine and gets back a browser identifier via the virtual test case manage 110 ), adds the browser identifier as a new execution unit and returns it to the client 120 .
[0020] FIG. 3 exemplifies a heartbeat sent from the virtual client 120 to the test case management system. More particularly, the virtual client 120 periodically sends a heartbeat request to announce its aliveness/availability, and to poll for whether there is a test case assigned to it. Note that the browser identifier received during the registration process of FIG. 2 is carried to the test case management system in the heartbeat request so that the system knows which client is reporting. Moreover, because the identifier is associated with the browser, multiple browsers running on the same machine may be differentiated via each one's identifier.
[0021] If a job is assigned, it is returned by the system 1 10 (via the manager 104 ) to the virtual client 120 ; the system waits for the job to finish with respect to that client. More particularly, when the test case management system decides to assign a test case as a job to one or more web browsers, it waits for the virtual client 120 to fetch the job; that is, the virtual client 120 will pass over a web browser's request. Given the fact that there may be many browsers being assigned a job at the same time, each job is buffered in the test case management system until it is fetched to the virtual client 120 .
[0022] FIG. 4 exemplifies result reporting from the virtual client 120 to the test case management system. As shown in FIG. 4 , when the test case as a job is finished in the virtual client 120 , the virtual client 120 sends a heartbeat with an attached execution result. The test case management system stops waiting (by the signal passed over from the virtual client 120 ) and reports the results.
[0023] In this manner, a web browser may be launched to navigate to a URL, whereby a test case from an existing text case management system is delivered to the browser, and executed, with the execution result sent back to the test case management system independent of the client application. This framework thus enables this process to work on any operating system. Note that the tested machine only needs a very simple client manager application ( 122 A or 122 b in FIG. 1 ) to handle exception and cleanup issues.
EXAMPLE INTERFACES
[0000]
Interface IWebTCM—implemented by VTCM as the interface between a VTCM and a VCM:
[0000]
Method
Parameter/Result
Description
Response Register(
assetName
VA name to help build
VCM wants to register a
string assetName,
unique ID
VA to VTCM
string assetInfo)
browserInfo
VA information
Return value
Asset ID returned if
succeeds
Response Unregister(
assetID
Specifying VA to
VCM wants to unregister
string assetID)
unregister
a VA from VTCM
Return value
Asset ID returned if
succeeds
Response Poll(
assetID
Specifying VA to query
VCM wants to query
string assetID,
assetStatus
Specifying current VA
whether a job is assigned
TcwaAssetStatus
status
to specific VA
assetStatus)
Return value
Job description text if
any, otherwise empty
string is returned
Response
assetID
Specifying VA to send
VCM wants to send back
SendResult(
result
the job result for specific
string assetID,
result
Job result
VA
string result)
Return value
ACK specifies feedback
Interface IJobCodec—implemented by Job codec:
[0000]
Method
Parameter/Result
Description
string EncodeJob(
job
Job description from
When IWebTCM.Poll is
string job)
VTCM
about to return the job
Return value
Encoded job
description he should call
description for test
this method to encode so
harness
that test harness gets a
TCM-independent format
string DecodeResult(
result
Result expression from
Before
string result)
test harness
IWebTCM.SendResult
Return value
Decoded result
really sends the result he
expression for VTCM
should call this method to
decode so that TCM gets
a test harness
independent format
UInt32 JobTimeout(
job
Job description from
Job timeout is required
string job)
VTCM
for plug-in and JTA to
Return value
Timeout value in
maintain reliability
milliseconds, zero if not
found
bool SendResult(
TCMReporter
Result sender
Send result in VTCM way
object TCMReporter,
job
Job description from
string job,
VTCM
string result)
result
Result to send for
VTCM
Return value
Succeeds or not
bool SendTimeout(
TCMReporter
Result sender
Send timeout result in
object TCMReporter,
job
Job description from
VTCM way
string job)
VTCM
Return value
Succeeds or not
Interface ITcwaService—implemented by VCM as the interface between a VC and a VCM:
[0000]
Method
Parameter/Result
Description
Response
browserName
Browser name to
VC wants to register a
RegisterBrowserInstance(
help build unique ID
browser to VCM
string browserName,
browserInfo
Browser information
string browserInfo)
Return value
Browser ID returned
if succeeds
Response
browserID
Specifying browser
VC wants to
UnregisterBrowserInstance(
to unregister
unregister a browser
string browserID)
Return value
Browser ID returned
from VCM
if succeeds
Response Heartbeat(
browserID
Specifying browser
VC wants to query
string browserID,
to query
whether a job is
string browserStatus,
browserStatus
Specifying current
assigned to specific
string browserData)
browser status
browser
browserData
Data to sent by VC
Return value
Job description text if
any, otherwise empty
string is returned
Interface JTAConfig is implemented by JTA. A JTAConfig.js file is used to provide information to VC:
JTAConfig.EntryPage—specify entry HTM file that hosts for test code.
JTAConfig.ReloadEntryPageBeforeEachTest—specify whether reloading entry page above, used in JSS scenario.
JTACOnfig.ResetDevPageBeforeEachTest—specify whether reset product code page to about:blank, used in JSS scenario.
JTAConfig.fn_IsLoaded—specify function to detect whether entry page above is loaded.
JTAConfig.fn_Initialize—specify function to initialize for given task, with task description and reference to the frame hosting product code.
JTAConfig.fn_Execute—specify function to start executing the task.
JTAConfig.fn_IsFinished—specify function to detect whether task is done, with null for not done and not null for task result.
JTAConfig.fn_IsLastTest—specify function to check whether this is the end of the whole test case, used in JSS scenario.
Exemplary Operating Environment
[0036] FIG. 5 illustrates an example of a suitable computing and networking environment 500 on which the examples of FIGS. 1-4 may be implemented. The computing system environment 500 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing environment 500 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 500 .
[0037] The invention is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to: personal computers, server computers, hand-held or laptop devices, tablet devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0038] The invention may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, and so forth, which perform particular tasks or implement particular abstract data types. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in local and/or remote computer storage media including memory storage devices.
[0039] With reference to FIG. 5 , an exemplary system for implementing various aspects of the invention may include a general purpose computing device in the form of a computer 510 . Components of the computer 510 may include, but are not limited to, a processing unit 520 , a system memory 530 , and a system bus 521 that couples various system components including the system memory to the processing unit 520 . The system bus 521 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus.
[0040] The computer 510 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer 510 and includes both volatile and nonvolatile media, and removable and non-removable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by the computer 510 . Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above may also be included within the scope of computer-readable media.
[0041] The system memory 530 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 531 and random access memory (RAM) 532 . A basic input/output system 533 (BIOS), containing the basic routines that help to transfer information between elements within computer 510 , such as during start-up, is typically stored in ROM 531 . RAM 532 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 520 . By way of example, and not limitation, FIG. 5 illustrates operating system 534 , application programs 535 , other program modules 536 and program data 537 .
[0042] The computer 510 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 5 illustrates a hard disk drive 541 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 551 that reads from or writes to a removable, nonvolatile magnetic disk 552 , and an optical disk drive 555 that reads from or writes to a removable, nonvolatile optical disk 556 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 541 is typically connected to the system bus 521 through a non-removable memory interface such as interface 540 , and magnetic disk drive 551 and optical disk drive 555 are typically connected to the system bus 521 by a removable memory interface, such as interface 550 .
[0043] The drives and their associated computer storage media, described above and illustrated in FIG. 5 , provide storage of computer-readable instructions, data structures, program modules and other data for the computer 510 . In FIG. 5 , for example, hard disk drive 541 is illustrated as storing operating system 544 , application programs 545 , other program modules 546 and program data 547 . Note that these components can either be the same as or different from operating system 534 , application programs 535 , other program modules 536 , and program data 537 . Operating system 544 , application programs 545 , other program modules 546 , and program data 547 are given different numbers herein to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 510 through input devices such as a tablet, or electronic digitizer, 564 , a microphone 563 , a keyboard 562 and pointing device 561 , commonly referred to as mouse, trackball or touch pad. Other input devices not shown in FIG. 5 may include a joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 520 through a user input interface 560 that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor 591 or other type of display device is also connected to the system bus 521 via an interface, such as a video interface 590 . The monitor 591 may also be integrated with a touch-screen panel or the like. Note that the monitor and/or touch screen panel can be physically coupled to a housing in which the computing device 510 is incorporated, such as in a tablet-type personal computer. In addition, computers such as the computing device 510 may also include other peripheral output devices such as speakers 595 and printer 596 , which may be connected through an output peripheral interface 594 or the like.
[0044] The computer 510 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 580 . The remote computer 580 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 510 , although only a memory storage device 581 has been illustrated in FIG. 5 . The logical connections depicted in FIG. 5 include one or more local area networks (LAN) 571 and one or more wide area networks (WAN) 573 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
[0045] When used in a LAN networking environment, the computer 510 is connected to the LAN 571 through a network interface or adapter 570 . When used in a WAN networking environment, the computer 510 typically includes a modem 572 or other means for establishing communications over the WAN 573 , such as the Internet. The modem 572 , which may be internal or external, may be connected to the system bus 521 via the user input interface 560 or other appropriate mechanism. A wireless networking component 574 such as comprising an interface and antenna may be coupled through a suitable device such as an access point or peer computer to a WAN or LAN. In a networked environment, program modules depicted relative to the computer 510 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 5 illustrates remote application programs 585 as residing on memory device 581 . It may be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
[0046] An auxiliary subsystem 599 (e.g., for auxiliary display of content) may be connected via the user interface 560 to allow data such as program content, system status and event notifications to be provided to the user, even if the main portions of the computer system are in a low power state. The auxiliary subsystem 599 may be connected to the modem 572 and/or network interface 570 to allow communication between these systems while the main processing unit 520 is in a low power state.
CONCLUSION
[0047] While the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention.
|
Described is a technology in which test case content in the form of a web application is provided to a client browser from a test case management system over a web server. Results of running the test case are similarly communicated back. This allows different web application test harnesses to be run on whatever Internet browser the client computing device is running, and is independent of any operating system. The client registers with the test case management system through the website, and receives a browser identifier for use in future communications. In one protocol, the client uses the identifier in heartbeats sent to the test case management system, including a heartbeat indicating when the client is available to run a test case, when the test case is complete, and the results of performing the test case. Also described are various interfaces that facilitate component communication.
| 6
|
FIELD OF THE INVENTION
[0001] The present invention generally relates to AC-to-DC power converters, and more particularly relates to single-phase full bridge boost converters and methods for charging a load coupled to a single-phase AC voltage source.
BACKGROUND OF THE INVENTION
[0002] In the vector control approach for multi-phase converters, variables that vary with time (e.g., AC voltage and AC current) are transferred to the synchronous rotating direct-quatrature (D-Q) reference frame to enable the converter system to work with constant values instead of time varying values. D-Q transformations have been defined for multi-phase converter systems (e.g., two-phase and three-phase systems), but have not been defined for a single-phase system.
[0003] Accordingly, it is desirable to provide single-phase full bridge boost converter systems. It is also desirable to provide methods for charging a load coupled to a single-phase AC voltage source. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY OF THE INVENTION
[0004] Systems are provided for issuing a switching to a single-phase full boost converter comprising a voltage sensor for detecting voltage in the DC side of the single-phase full bridge boost converter, a current sensor for detecting alternating current in the AC side of the single-phase full bridge boost converter, and a plurality of switches configured to control the alternating current. One exemplary system comprises a direct-quatrature (D-Q) control system configured to be coupled to the voltage sensor and the current sensor, and further configured to generate a control voltage (v con ) comprising a direct-phase voltage component and a quadrature-phase voltage component. The system also comprises a comparator coupled to the D-Q control system and configured to be coupled to the switch and to a waveform reference voltage (v tri ) source. In this embodiment, the comparator further configured to compare v con to v tri , generate the switching command based on the comparison of v con and v tri , and transmit the switching command to the switch.
[0005] Systems for charging a load are also provided. An exemplary system comprises a single-phase full bridge boost converter comprising a plurality of switches coupled to a load and an AC voltage source. The switches are configured to provide charging current to the load in response to receiving switching commands. The system also comprises a direct-quadrature (D-Q) control system coupled to the single-phase full bridge boost converter, wherein the D-Q control system is configured to receive a first AC current (i a ) value from the single-phase full bridge boost converter; delay the i a value to generate a second AC current (i b ) value; and issue the switching commands based on the i a and i b values.
[0006] Methods for charging a load in a single-phase full bridge boost converter comprising a plurality of switches coupled to the load, alternating current (i a ), and a voltage (v) are also provided. One exemplary method comprises the steps of performing a direct-quadrature conversion to the i a to generate a direct current including a direct-phase current (i d ) component and a quadrature-phase current (i q ) component, and issuing a switching command to the switch based on the i d component and the i q component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
[0008] FIG. 1 is a block diagram of a prior art single-phase full bridge boost converter;
[0009] FIG. 2 is a schematic diagram of a prior art two-phase full bridge boost converter connected to a direct-quadrature (D-Q) control system;
[0010] FIG. 3 is a diagram of one exemplary embodiment of a D-Q control system for use with the single-phase full bridge boost converter of FIG. 1 ;
[0011] FIG. 4 is a schematic diagram representing a “real” phase and an “imaginary” phase in a two-phase balance system;
[0012] FIG. 5 is a diagram representative of the transformation between a two-phase reference frame and a D-Q reference frame;
[0013] FIG. 6 is a diagram representative of the voltage and current vectors of the converter of FIG. 1 in the D-Q reference frame of FIG. 5 ; and
[0014] FIG. 7 is a block diagram of one exemplary embodiment of a system for charging a load comprising the single-phase full bridge boost converter of FIG. 1 and the D-Q control system of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
[0016] FIG. 1 is a schematic diagram of a prior art single-phase full bridge boost converter (hereinafter “converter”) 100 connected to an AC voltage source 110 . Converter 100 includes a node 122 connected to the negative terminal of AC voltage source 110 and an inductor 115 connected to the positive terminal of AC voltage source 110 and to a node 124 .
[0017] Converter 100 also includes diodes 140 , 145 , 150 , and 155 . Diode 140 includes an anode connected to node 124 and a cathode connected to a node 126 . Diode 145 includes a cathode connected to node 126 and an anode connected to a node 128 , which is also connected to node 122 . Diode 150 includes a cathode connected to node 128 and an anode connected to a node 130 , which is also connected to a node 132 and to ground. Diode 155 includes a cathode connected to a node 136 connected to node 124 , and an anode connected to node 132 , which is connected to a node 134 .
[0018] Also included in converter 100 are switches (e.g., semiconductor switches) 160 and 165 . Switch 160 is coupled to nodes 134 and 136 , which is antiparallel with diode 155 . Likewise, switch 165 is coupled to nodes 122 and 130 , which is antiparallel with diode 150 .
[0019] Converter 100 further includes a capacitor 170 coupled in parallel with a load (e.g., a battery) 175 . Specifically, the negative terminal of both capacitor 170 and load 175 are connected to a node 139 that is also connected to node 134 . The positive terminal of both capacitor 170 and load 175 are connected to a node 138 that is also connected to node 126 .
[0020] During operation, converter 100 uses four modes of operation to charge load 175 . That is, converter 100 provides current to load 175 from AC voltage source 110 or from capacitor 170 depending on the mode of operation. Specifically, mode 1 occurs when the AC voltage from AC voltage source 110 is positive and switches 160 , 165 are both OFF. When operating in mode 1 , current flows through inductor 115 , diode 140 , capacitor 170 , load 175 , and returns back through diode 150 .
[0021] Mode 2 occurs when the AC voltage is positive and switches 160 , 165 are both ON. When operating in mode 2 , current flows through switch 160 and back through diode 150 . At the same time, capacitor 170 discharges and supplies current to load 175 .
[0022] Mode 3 occurs when the input AC voltage is negative and switches 160 , 165 are both OFF. When operating in mode 3 , current flows through diode 145 , capacitor 170 , load 175 , and back through diode 155 and inductor 115 .
[0023] Mode 4 occurs when the input AC voltage is negative and switches 160 , 165 are both ON. When operating in mode 4 , current flows through switch 165 and back through diode 155 and inductor 115 . At the same time, capacitor 170 discharges and supplies current to load 175 .
[0024] FIG. 2 is a diagram of a prior art two-phase full bridge boost converter (hereinafter “converter”) 200 connected to a D-Q control system (hereinafter “system”) 300 . Converter 200 includes an A-phase and a B-phase that are each similar to converter 100 discussed above with reference to FIG. 1 .
[0025] System 300 is configured to issue switching commands to the plurality of switches in converter 200 . That is, system 300 is based on transforming a two-phase balance system from a time-varying frame to a synchronous frame.
[0026] As illustrated in FIG. 2 , system 300 includes a phase-locked loop (PLL) 103 coupled to a sine function 105 and a cosine function 107 . PLL 103 may be any hardware and/or device capable of maintaining a phase angle (θ). Sine function 105 is configured to determine the sine function value of θ (i.e., the sin θ value), and cosine function 107 is configured to determine the cosine function value of θ (i.e., the cos θ value).
[0027] System 300 also includes comparators (e.g., operational amplifiers) 112 , 114 , 116 , 118 , and 178 , controllers 143 , 146 , and 149 , multipliers 120 , 121 , 123 , 125 , 127 , 129 , 173 , and 175 , adders 131 and 133 , and subtractors 171 and 180 . Specifically, comparator 112 is coupled to controller 143 and to a voltage sensor 293 configured to detect a DC voltage (v dc ) in converter 200 , and to a DC reference voltage source (not shown) that is configured to supply a constant (or substantially constant) DC reference voltage (v dc-ref ). Comparator 112 is configured to compare the difference between v dc and v dc-ref to determine a voltage error in converter 200 and transmit the determined voltage error to controller 143 .
[0028] Controller 143 may be any hardware and/or device (e.g., a PI controller) capable of generating a signal representing a reference quadrature-phase current (i q-ref ) value from the determined voltage error. In one embodiment, controller 143 is configured to receive the voltage error from comparator 112 and determine an i q-ref value that, if applied to converter 200 , would cause v dc to equal v dc-ref . Controller 143 is coupled to comparator 114 and is configured to transmit determined i q-ref values to comparator 114 .
[0029] Comparator 114 is also coupled to subtractor 180 (discussed below), which supplies a quadrature-phase current (i q ) value to comparator 114 . Comparator 114 is configured to compare the i q value with the i q-ref value to determine a quadrature-phase current error. Comparator 114 is further coupled to controller 146 and is configured to transmit the determined quadrature-phase current error to controller 146 .
[0030] Controller 146 may be any hardware and/or device (e.g., a PI controller) capable of generating a quadrature-phase voltage (v q ) value based on the quadrature-phase current error. Controller 146 is also coupled to multipliers 120 and 173 , and is configured to transmit the generated v q value to multipliers 120 and 173 .
[0031] Multiplier 120 , in addition to being coupled to controller 146 , is coupled to sine function 105 and is configured to multiply the v q value supplied by controller 146 and the sin θ value supplied by sine function 105 to generate a v q sin θ value. Multiplier 120 is also coupled to adder 133 (discussed below) and is configured to transmit the v q sin θ value to adder 133 .
[0032] Multiplier 173 is also coupled to cosine function 107 and is configured to multiply the v q value supplied by controller 146 and the cos θ value supplied by cosine function 107 to generate a v q cos θ value. Multiplier 173 is also coupled to subtractor 171 (discussed below) and is configured to transmit the v q cos θ value to subtractor 171 .
[0033] Subtractor 180 is coupled to multipliers 121 , 123 and is configured to receive values from multipliers 121 , 123 and to subtract the value received from multiplier 123 from the value received from multiplier 121 to generate the i q value. Specifically, subtractor 180 is configured to subtract an i b cos θ value received from multiplier 123 from an i a sin θ value received from multiplier 121 to generate an (i a sin θ−i b cos θ) value, which is the i q value.
[0034] Multiplier 121 is coupled to sine function 105 and a current sensor 290 that detects AC current (i a ) in the a-phase of converter 200 . Multiplier 121 is further configured to receive the sin θ value from sine function 105 and an i a value from current sensor 290 , and multiply the sin θ value and the i a value to generate the i a sin θ value that is supplied to subtractor 180 .
[0035] Multiplier 123 is coupled to cosine function 107 and a current sensor 295 that detects AC current (i b ) in the b-phase of converter 200 . Multiplier 123 is configured to receive a cos 0 value from cosine function 107 and an i b value from current sensor 295 , and multiply the cos θ value and the i b value to generate the i b cos θ value that is supplied to subtractor 180 .
[0036] Multiplier 125 is coupled to sine function 105 and current sensor 295 , and is configured to receive the i b value from current sensor 295 and the sin θ value from sine function 105 . Multiplier 125 is further configured to multiply the i b value and the sin θ value to generate an i b sin θ component. Multiplier 125 is further coupled to adder 131 and is further configured to transmit the i b sin θ component to adder 131 .
[0037] Adder 131 is also coupled to multiplier 127 and is configured to receive an i a cos θ component from multiplier 127 and the i b sin θ component from multiplier 125 . Multiplier 127 is coupled to and configured to receive the cos θ value from cosine function 107 . Multiplier 127 is also coupled to current sensor 290 and is configured to receive the i a value from the current sensor and multiply the cos θ value and the i a value to generate an i a cos θ component.
[0038] Adder 131 is also configured to sum the i a cos θ component and the i b sin θ component to generate an (i a cos θ+i b sin θ) value, which is a direct-phase current (i d ) value. Adder 131 is further coupled to comparator 116 and is further configured to transmit the i d value to comparator 116 .
[0039] Comparator 116 is coupled to a direct-phase reference current source (not shown) and is configured to receive a direct-phase reference current (i d-ref ) value from the direct-phase reference current source. Comparator 116 is also configured to compare the i d value supplied from adder 131 to the i d-ref value to determine a direct-phase current error, and to transmit the determined direct-phase current error to controller 149 .
[0040] Controller 149 is coupled to comparator 116 and is configured to receive the direct-phase current error from comparator 116 . Controller 149 is also configured to generate a direct-phase voltage (v d ) value based on the direct-phase current error. Controller 149 is also coupled to multipliers 129 and 175 , and is configured to transmit the generated v d value to multipliers 129 and 175 .
[0041] Multiplier 129 is also coupled to cosine function 107 and adder 133 , and is configured to receive the v d value and the cos θ value from controller 149 and cosine function 107 , respectively. Multiplier 129 is further configured to multiply the v d value and the cos θ value to generate a v d cos θ value and transmit the v d cos θ value to adder 133 .
[0042] Adder 133 is coupled to multipliers 120 , 129 and is configured to receive the v q sin θ value and the v d cos θ value from multipliers 120 and 129 , respectively. Adder 133 is further configured to sum the v q sin θ value and the v d cos θ value (v q sin θ+v d cos θ) to generate an A-phase control voltage (v conA ), and to transmit v conA to comparator 118 .
[0043] Multiplier 175 is coupled to sine function 105 and subtractor 171 , and is configured to receive the v d value and the sin θ value from controller 149 and sine function 105 , respectively. Multiplier 175 is further configured to multiply the v d value and the sin θ value to generate a v d sin θ value and transmit the v d sin θ value to subtractor 171 .
[0044] Subtractor 171 is coupled to multipliers 175 and 173 , and is configured to receive the v d sin θ value and the v q cos θ value from multipliers 175 and 173 , respectively. Subtractor 171 is further configured to subtract the v d sin θ value from the v q cos θ value (v d sin θ−v q cos θ) to generate a B-phase control voltage (v conB ), and to transmit v conB to comparator 178 .
[0045] Comparator 118 is coupled to adder 133 , a triangular waveform reference voltage source (not shown), and to the plurality of switches in the A-phase of converter 200 . Comparator 118 is configured to receive v conA from adder 133 and a triangular waveform reference voltage (v tri ) value from the triangular waveform reference voltage source, and compare v conA and v tri to generate switching commands for the plurality of switches in the A-phase based on the comparison (e.g., v conA <v tri or v conA >v tri ).
[0046] Similarly, comparator 178 is coupled to subtractor 171 , the triangular waveform reference voltage source, and to the plurality of switches in the B-phase of converter 200 . Comparator 178 is configured to receive v conB from subtractor 171 and the v tri value from the triangular waveform reference voltage source, and compare v conB and v tri to generate switching commands for the plurality of B-phase switches based on the comparison (e.g., v conB <v tri or v conB >v tri ). The switching commands transmitted to the A-phase and B-phase switches are such that the switches in converter 200 turn ON/OFF such that i a and i b vary in a manner to properly charge a load (not shown) connected to converter 200 .
[0047] FIG. 3 is a diagram of one exemplary embodiment of a D-Q control system (hereinafter “system”) 400 for use with converter 100 (see FIG. 1 ). In the illustrated embodiment, system 400 comprises PLL 103 , sine function 105 , cosine function 107 , comparators 112 , 114 , 116 , and 118 , controllers 143 , 146 , and 149 , multipliers 120 , 121 , 127 , and 129 , adders 131 and 133 , and subtractor 180 configured similar to system 300 discussed above with reference to FIG. 2 .
[0048] System 400 also comprises a delay function 785 coupled to multipliers 123 and 125 that is capable of being coupled to a current sensor (see current sensor 591 in FIG. 7 ) in converter 100 . Delay function 785 may be any hardware and/or device capable of receiving a detected i a value from the current sensor and applying a phase delay to the i a value to generate the i b value. In one embodiment, delay function 785 is configured to apply a 90 degree delay to i a such that i b is substantially orthogonal to the i a detected by the current sensor. Delay function 785 is also configured to transmit the i b value to multipliers 123 and 125 such that system 400 operates to provide switching commands to switches 160 and 165 in a manner similar to system 300 discussed above.
[0049] FIG. 4 is a diagram representing a “real” phase and an “imaginary” phase in a two-phase balance system, wherein the imaginary phase is orthogonal to the real phase. Here, the imaginary phase includes reference numeral 785 similar to delay function 785 discussed above with reference to FIG. 3 . Though delay function 785 is not the equivalent of the imaginary phase, the i b value that delay function 785 generates (based in the i a value) and provides to system 400 is the equivalent of the i b value that system 300 receives from the b-phase of converter 200 via current sensor 295 . That is, because the two-phases in converter 200 are separated by 90 degrees, by delaying (via delay function 785 ) the i a value in converter 100 , a single-phase full bridge boost converter is capable of functioning similar to a two-phase full bridge boost converter. The following discussion presents a mathematical explanation of system 400 .
[0050] FIG. 5 represents the transformation between the two-phase and D-Q phase reference frames of converter 100 and system 400 , which reference frames are represented by the trigonometric relations given in equations (1) and (2). In addition, the voltage and current vectors of converter 100 in the D-Q reference frame are depicted in FIG. 6 .
[0000]
[
f
d
f
q
]
=
[
cos
θ
sin
θ
sin
θ
-
cos
θ
]
[
f
a
f
b
]
(
1
)
[
f
a
f
b
]
=
[
cos
θ
sin
θ
sin
θ
-
cos
θ
]
[
f
d
f
q
]
(
2
)
[0051] In equations (1) and (2), the variable “f′ can be defined as a set of voltages or currents in converter 100 . Based on FIG. 6 , active and reactive power equations in the synchronous frame can be written as follows:
[0000] P=v d i d +v q i q (3)
[0000] Q=v d i q −v q i d (4)
[0052] The q-axis is chosen to be aligned with the phase voltage vector of converter 100 or the “real” circuit, which means that the direct-phase voltage (v d ) is equal to zero (v d =0) and the quadrature-phase voltage (v q ) is equal to the magnitude of the grid voltage (v) in converter 100 (v q =|v|). With these v d and v q values, the equations for the active and reactive power can be simplified as:
[0000] P=|v|i q (5)
[0000] Q=−|v|i d (6)
[0053] Since the grid voltage, |v|, is a constant, active and reactive power can be controlled by controlling the quadrature-phase current (i q ) and the direct-phase current (i d ), respectively.
[0054] Using Kirchhoff's voltage law, the voltage equations in FIG. 5 can be written as:
[0000]
p
[
i
a
i
b
]
=
-
R
L
[
1
0
0
1
]
[
i
a
i
b
]
+
1
L
[
e
a
-
v
a
e
b
-
v
b
]
(
7
)
[0055] Transforming the voltage equations into the synchronous reference frame using equations (1) and (2), and considering that v d =0 and v q =|v|, equation (7) results in:
[0000]
p
[
i
d
i
q
]
=
[
-
R
/
L
-
ω
ω
-
R
/
L
]
[
i
d
i
q
]
+
1
L
[
e
d
e
q
-
v
]
(
8
)
[0056] To provide decoupled control of active power or i q , and reactive power or i d , based on equation (8), the output voltages of converter 100 in the synchronous reference frame should be chosen as:
[0000] e q =L ( x 1 −ωi d )+| v| (9)
[0000] e d =L ( x 2 +ωi q ) (10)
[0057] By substituting equations (9) and (10) into equation (8), the decoupled equations of system 400 can be rewritten as follows:
[0000]
p
[
i
d
i
q
]
=
-
R
L
[
1
0
0
1
]
[
i
d
i
q
]
+
[
x
1
x
2
]
(
11
)
[0058] As can be seen from equations (5) and (6), the active and reactive power may be controlled through i q and i d , respectively. Therefore, the control rules of equations (9) and (10) can be completed by defining the current feedback loops as follows:
[0000]
x
1
=
(
k
1
+
k
2
s
)
(
i
q
*
-
i
q
)
(
12
)
x
2
=
(
k
1
+
k
2
s
)
(
i
d
*
-
i
d
)
,
(
13
)
[0000] That is, system 400 is configured to issue switching commands to converter 100 consistent with equations (12) and (13).
[0059] FIG. 7 is a block diagram of one exemplary embodiment of a system 500 for charging a load 175 (e.g., a battery). The various embodiments of system 500 enable active and reactive power in system 500 to be independently controlled by a V-Q transformation.
[0060] As illustrated in FIG. 7 , system 500 , at least in this embodiment, comprises system 400 integrated with converter 100 . In doing such, system 500 comprises a current sensor 591 , a voltage sensor 593 , a DC reference voltage source 595 , a direct-phase reference current source 597 , and a triangular waveform reference voltage source 599 .
[0061] Current sensor 591 is coupled between AC voltage source 110 and inductor 115 of converter 100 , and is also coupled to multiplier 121 , multiplier 127 , and delay function 785 of system 400 . Current sensor 591 is configured to detect i a in converter 100 and transmit the detected i a value to each of delay function 785 , multiplier 121 , and multiplier 127 .
[0062] Voltage sensor 593 is coupled in parallel with capacitor 170 via nodes 521 and 523 , and is coupled to comparator 112 . Voltage sensor 593 is configured to detect v dc in converter 100 and transmit the detected v dc value to comparator 112 .
[0063] DC reference voltage source 595 is also coupled to comparator 112 . DC reference voltage source 595 is configured to provide the DC reference voltage (v dc-ref ) to comparator 112 , wherein v dc-ref is a predetermined or desired voltage value within converter 100 .
[0064] Direct-phase reference current source 597 is coupled to comparator 116 and is configured to transmit the direct-phase reference current (i d-ref ) value to comparator 116 . In one embodiment, i d-ref includes a value of zero amps for unity power factor operation, although other embodiments may include a different value for i d-ref .
[0065] Triangular waveform reference voltage source 599 is coupled to comparator 118 and is configured to provide the triangular waveform reference voltage (v tri ) to comparator 118 . The v tri is a threshold voltage that, when compared to v con , dictates whether the switching commands issued to switches 160 and 165 turn switches 160 and 165 ON or OFF.
[0066] It should be noted that when implementing system 400 with converter 100 , the reference currents (i d-ref and i q-ref ) in system 400 should be chosen as two times the desired values. The reference currents should be doubled because system 400 does not deliver any active or reactive power to, or absorb any active or reactive power from AC voltage source 110 .
[0067] During operation of system 500 , comparator 112 receives v dc (i.e., the voltage value detected between node 521 and node 523 ) from voltage sensor 593 and v dc-ref from DC reference voltage source 595 . At substantially the same time, delay function 785 , multiplier 121 , and multiplier 127 receive i a (i.e., the current value detected between AC voltage source 110 and inductor 115 ) from current sensor 591 .
[0068] Comparator 112 compares v dc to v dc-ref to determine the voltage error in converter 100 and transmits the voltage error to controller 143 . Controller 143 determines the i q-ref value needed to offset the voltage error and transmits the determined i q-ref value to comparator 114 .
[0069] Comparator 114 also receives an i q value from subtractor 180 and compares the i q value to the i q-ref value to determine a quadrature-phase current error. Comparator 114 then transmits the quadrature-phase current error to controller 146 .
[0070] Controller 146 receives the quadrature-phase current error and determines a v q value that would properly control switches 160 , 165 based on the detected i a and v dc values in converter 100 . Controller 146 then transmits the determined v q value to multiplier 120 .
[0071] Multiplier 120 receives the v q value from controller 146 and a sin θ value from sine function 105 , wherein sine function 105 receives a phase angle (θ) from PLL 103 . Multiplier 120 multiplies the v q value and the sin θ value to generate a v q sin θ component of v con , and transmits the v q sin θ component to adder 133 (described below).
[0072] As noted above, the current value i a detected by current sensor 591 is supplied to delay function 785 , multiplier 121 , and multiplier 125 . Delay function 785 provides a 90 degree delay to i a to generate an i b value (that is the equivalent of an i b value generated by the b-phase of a two-phase full bridge boost converter). Delay function 785 then transmits the i b (i.e., the i a value+90°) value to multipliers 123 and 125 . Multiplier 123 multiplies the i b value and a cos θvalue received from cosine function 107 to generate an i b cos θ value, wherein cosine function 107 received the phase angle (θ) from PLL 103 . Multiplier 123 then transmits the i b cos θ value to subtractor 180 . Multiplier 125 multiplies the i b value and the sin θ value received from sine function 105 to generate an i b sin θ value. Multiplier 125 then transmits the i b sin θ value to adder 131 .
[0073] Multiplier 121 multiplies the i a value and the sin θ value received from sine function 105 to generate an i a sin θ value. Multiplier 121 then transmits the i a sin θ value to subtractor 180 so that subtractor 180 may subtract the i b cos θ value supplied from multiplier 123 from the i a sin θ value to generate an (i a sin θ−i b cos θ) value or the i q value.
[0074] Multiplier 127 multiplies the i a value and the cos θ value received from cosine function 107 to generate an i a cos θ value. Multiplier 127 then transmits the i a cos θ value to adder 131 . Adder 131 sums the i a cos θ value and the i b sin θ value supplied from multiplier 125 to generate an (i a cos θ+i b sin θ) value or i d value. Adder 131 then transmits the i d value to comparator 116 .
[0075] Comparator 116 receives the i d value from adder 131 and an i d-ref value from direct-phase reference current source 597 . Comparator 116 then compares i d to i d-ref and generates a direct-phase current error based on the comparison. The direct-phase current error is then transmitted to controller 149 .
[0076] Controller 149 receives the direct-phase current error and determines a v d value that would properly control switches 160 , 165 based on the detected i a and v dc values. Controller 149 then transmits the determined v d value to multiplier 129 .
[0077] Multiplier 129 receives the v d value from controller 149 and the cos θ value from cosine function 107 . Multiplier 129 then multiplies the v d value and the cos θ value to generate a v d cos θ component of v con , and transmits the v d cos θ component to adder 133 .
[0078] Adder 133 receives the v q sin θ component from multiplier 120 and the v d cos θ component from multiplier 129 and sums the v q sin θ component and the v d cos θ component to generate a (v q sin θ+v d cos θ) value or v con value. Adder 133 then transmits the v con value to comparator 118 .
[0079] Comparator 118 receives the v con value from adder 133 and a v tri value from waveform reference voltage source 599 and compares v con to v tri . Comparator 118 then transmits switching commands to switches 160 , 165 based on the comparison of v con and v tri . For example, if v con is greater than v tri (i.e., v con >v tri ), the switching commands turn switches 160 , 165 ON, whereas if v con is less than v tri (i.e., v con <v tri ), the switching commands turn switches 160 and 165 OFF so that converter 100 operates similar to the discussion above with reference to FIG. 1 .
[0080] Notably, setting i d -ref to zero volts yields unity power factor operation in system 500 . Furthermore, i d -ref set to zero volts yields a low total harmonic distortion and exceptional “zero crossing” characteristics.
[0081] As one skilled in the art will recognize, system 400 may be implemented using computing hardware (and software), a computing device, and/or a computing system. That is, various embodiments of the invention contemplate that system 400 may be implemented via a processor, and specifically, a digital signal processor.
[0082] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.
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Single-phase full bridge boost converter systems and methods are provided. One system includes a direct-quatrature (D-Q) control system configured to generate a control voltage (v con ) including direct-phase and quadrature-phase voltage components. The system also includes a comparator configured to compare v con to a carrier waveform voltage, generate switching commands based on the comparison, and transmit the switching commands to a current switch. Another system includes a boost converter including multiple switches coupled to a load and an AC voltage source. The switches are configured to provide charging current to the load in response to receiving switching commands. A D-Q control system configured to receive and delay an i a value, and issue switching commands based on the i a and delayed i a value is also included. A method includes performing a D-Q conversion to generate DC current including direct-phase and quadrature-phase current components, and issuing switching commands based on the current components.
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TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to perforating a subterranean wellbore using shaped charges and, in particular to, a detonation transfer subassembly that is installed within a work string between loaded perforating guns to provide an area through which the work string may be severed without the potential for detonating the shaped charges carried in the perforating guns.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background will be described with reference to perforating a subterranean formation using shaped charge perforating guns, as an example.
After drilling the section of a subterranean wellbore that traverses a formation, individual lengths of relatively large diameter metal tubulars are typically secured together to form a casing string that is positioned within the wellbore. This casing string increases the integrity of the wellbore and provides a path for producing fluids from the producing intervals to the surface. Conventionally, the casing string is cemented within the wellbore. To produce fluids into the casing string, hydraulic opening or perforation must be made through the casing string, the cement and a short distance into the formation.
Typically, these perforations are created by detonating a series of shaped charges located within the casing string that are positioned adjacent to the formation. Specifically, numerous charge carriers are loaded with shaped charges that are connected with a detonating device, such as detonating cord. The charge carriers are then connected within a tool string that is lowered into the cased wellbore at the end of a tubing string, wireline, slick line, coil tubing or the like. Once the charge carriers are properly positioned in the wellbore such that shaped charges are adjacent to the formation to be perforated, the shaped charges are detonated. Upon detonation, each shaped charge creates a jet that blasts through a scallop or recess in the carrier, creates a hydraulic opening through the casing and cement and then penetrates the formation forming a perforation therein.
It has been found, however, that it may sometimes be necessary to shut in a well due to an out of control well situation while the tool string, including the perforating guns, is disposed within the well. For example, during a snubbing operation or after the well has been perforated. If live shaped charges remain in the perforating guns, it is possible that closing a set of shear rams on a live shaped charge or other explosive components could result in a detonation. If such a detonation occurs, the live shaped charge may fire causing damage and injury to well equipment and personnel.
A need has therefore arisen for an apparatus that can be installed within the tool string between the loaded perforating guns to provide an area through which the tool string may be severed without the potential for detonating the shaped charges carried in the perforating guns. A need has also arisen for such an apparatus that can transfer detonation from one perforating gun to the next perforating gun such that the perforating guns may be fired in sequence.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a detonation transfer subassembly that can be installed within a tool string between two detonation activated tools, such as live perforating guns, that provide an area through which the tool string may be severed without the potential for detonating the detonation activated tools. The detonation transfer subassembly of the present invention also provides for the transfer of detonation from one detonation activated tool to another detonation activated tool such that the detonation activated tools may be detonated in sequence.
The detonation transfer subassembly for the present invention comprises a first explosive carrying member and a second explosive carrying member. Each of these explosive carrying members has an explosive disposed therein. For example, the first explosive carrying member may have an explosive train including one or more boosters, a detonation cord and an unlined shaped charge. Similarly, the second explosive carrying member may have an explosive train including an initiator, one or more boosters and a detonation cord.
Disposed between the first and second explosive carrying members is a detonation transfer member. The detonation transfer member has a longitudinal passageway. In one embodiment, the detonation transfer member may include a barrel disposed within a housing such that a vent chamber is defined therebetween. In this embodiment, the longitudinal passageway is disposed within the barrel. In addition, the barrel may include one or more vent ports that create a communication path between the longitudinal passageway and the vent chamber.
A firing pin is disposed within the longitudinal passageway. The firing pin has a first position proximate the first explosive carrying member and a second position proximate the second explosive carrying member. The firing pin may be propelled from the first position to the second position in response to, for example, gas pressure generated by detonating the explosive disposed within the first explosive carrying member. Alternatively, a solid rocket propellant or other suitable propellant may be used or wellbore fluid pressure may be routed to the fire pin. In such an event, the firing pin impacts the explosive disposed within the second explosive carrying member, thereby transferring detonation from the first explosive carrying member to the second explosive carrying member.
To assure that the firing pin impacts the explosive disposed within the second explosive carrying member with sufficient force to detonate this explosive, the first explosive carrying member may include an expansion chamber for the gas generated from the detonation of the explosive or ignition of a propellant in the first explosive carrying member. In addition, the firing pin may be initially fixed relative to the barrel by a shear pin that selective prevents movement of the firing pin relative to the barrel until the force is sufficient to shear the shear pin. Finally, as the firing pin travels from the first position to the second position, air in the longitudinal chamber vents to the vent chamber to avoid creating unnecessary resistance to the movement of the firing pin.
As such, the detonation transfer subassembly of the present invention provides a region through which a tool string may be severed between two detonation activated tools that without the potential for detonating the detonation activated tools. Also, the detonation transfer subassembly of the present invention provides for the transfer of detonation from one detonation activated tool to another detonation activated tool through the detonation transfer member.
The method of the present invention for operating the detonation transfer subassembly involves, disposing a detonation transfer member between first and second explosive carrying members, creating a detonation within the first explosive member, propelling a firing pin from a first position proximate the first explosive carrying member to a second position proximate the second explosive carrying member through a longitudinal passageway in the detonation transfer member and impacting an explosive disposed within the second explosive member with the firing pin, thereby transferring detonation from the first explosive carrying member to the second explosive carrying member.
The method of the present invention for severing a work string between two detonation activated tools involves disposing a detonation transfer subassembly between the two detonation activated tools, positioning the detonation transfer member of the detonation transfer subassembly adjacent to shear rams of a blowout preventer and closing the shear rams of the blowout preventer, thereby severing the work string between the two detonation activated tools.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas platform operating a pair of detonation transfer subassemblies of the present invention that are disposed between successive perforating guns in a work string;
FIG. 2 is a schematic illustration of an offshore oil and gas platform depicting a work string tripping into or out of a well such that a detonation transfer subassembly of the present invention is adjacent to a set of shear ram preventers;
FIG. 3 is a schematic illustration of an offshore oil and gas platform depicting a work string after being severed by the shear ram preventers through a detonation transfer subassembly of the present invention;
FIGS. 4A-4B are half sectional views of successive axial sections of a detonation transfer subassembly of the present invention prior to transferring detonation;
FIGS. 5A-5B are half sectional views of successive axial sections of a detonation transfer subassembly of the present invention after transferring detonation;
FIGS. 6A-6B are half sectional views of successive axial sections of a detonation transfer subassembly of the present invention prior to transferring detonation; and
FIGS. 7A-7B are half sectional views of successive axial sections of a detonation transfer subassembly of the present invention after transferring detonation.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
Referring initially to FIG. 1, a pair of detonation transfer subassemblies of the present invention operating from an offshore oil and gas platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 including subsea blow-out preventers 23 . Disposed on deck 20 is a surface installation 24 including shear ram preventers 25 . Platform 12 has a hoisting apparatus 26 and a derrick 28 for raising and lowering pipe strings such as work sting 30 .
A wellbore 32 extends through the various earth strata including formation 14 . A casing 34 is cemented within wellbore 32 by cement 36 . Work string 30 include various tools including shaped charge perforating guns 38 , 40 , 42 and detonation transfer subassemblies 44 , 46 . When it is desired to perforate formation 14 , work string 30 is lowered through casing 34 until shaped charge perforating guns 38 , 40 , 42 are positioned adjacent to formation 14 . Thereafter, shaped charge perforating guns 38 , 40 , 42 are sequentially fired such that the shaped charges are detonated. Upon detonation, the liners of the shaped charges form jets that create a spaced series of perforations extending outwardly through casing 34 , cement 36 and into formation 14 .
Even though FIG. 1 depicts a vertical well, it should be noted by one skilled in the art that the detonation transfer subassemblies of the present invention are equally well-suited for use in deviated wells, inclined wells or horizontal wells. Also, even though FIG. 1 depicts an offshore operation, it should be noted by one skilled in the art that the detonation transfer subassemblies of the present invention are equally well-suited for use in onshore operations.
In the event that the well traversing formation 14 become out of control while work string 30 include shaped charge perforating guns 38 , 40 , 42 and detonation transfer subassemblies 44 , 46 are in the well, it may become necessary to shut in the well. For example, if the running of work string 30 into the well is a snubbing operation wherein another formation below formation 14 is live or if work string 30 is being tripped out of the well following the perforation operation and an uncontrolled situation occurs well, this could require a well shut in using shear ram preventers 25 . If the portion of work string 30 having shaped charge perforating guns 38 , 40 , 42 is adjacent to shear ram preventers 25 when the out of control situation occurs and if live shaped charges remain in perforating guns 38 , 40 or 42 , closing shear ram preventers 25 could cause a detonation event. As illustrated in FIG. 2, using work string 30 having detonation transfer subassemblies 44 , 46 positioned respectively between perforating guns 38 , 40 and perforating guns 40 , 42 , one of the detonation transfer subassemblies such as detonation transfer subassembly 46 may be positioned adjacent to shear ram preventers 25 . Once in this position, shear ram preventers 25 may be operated to shear through detonation transfer subassembly 46 , as best seen in FIG. 3, to shut in the well without the potential for causing an unwanted detonation.
Referring now to FIGS. 4A-4B, therein is depicted a detonation transfer subassembly of the present invention prior to transferring detonation that is generally designated 50 . Detonation transfer subassembly 50 includes an upper explosive carrying member 52 that has an upper pin end 54 that threadedly and sealingly couples with the lower box end of, for example, a perforating gun. Upper explosive carrying member 52 is a substantially cylindrical tubular member having a longitudinal bore 56 formed therein. Longitudinal bore 56 houses a holder member 58 which may be made from a suitable material such as steel or aluminum. Confined within holder member 58 is an explosive train that includes a booster 60 , a detonation cord 62 such as RDX plastic cover Primacord, an initiator booster 64 and an unlined shaped charge 66 . The lower portion of longitudinal bore 56 serves as an expansion chamber 68 the purpose of which will be explained in more detail below.
It should be apparent to those skilled in the art that the use of directional terms such as top, bottom, above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. As such, it is to be understood that the downhole components described herein may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
Detonation transfer subassembly 50 also includes a detonation transfer member 70 that is threadedly and sealingly coupled to the lower end of upper explosive carrying member 52 . Detonation transfer member 70 is a substantially cylindrical tubular member having housing 72 . Housing 72 has a radially reduced exterior region 74 that is preferably aligned with the shear ram preventers if the well in which detonation transfer subassembly 50 is disposed must be shut in and the shear ram preventers must be used to shear detonation transfer member 70 . Housing 72 also has a longitudinal bore 76 formed therein. Disposed within longitudinal bore 76 , in a substantially annularly spaced apart relationship, is a barrel 78 . The annular space between longitudinal bore 76 and barrel 78 is a vent chamber 80 , the purpose of which will be explained in more detail below. Barrel 78 defines a longitudinal passageway 82 therein. Barrel 78 also defines a plurality of vent ports 84 that create a path for communication between vent chamber 80 and longitudinal passageway 82 . A firing pin 86 is disposed within longitudinal passageway 82 . Firing pin 86 is initially fixed relative to barrel 78 by shear pin 88 .
Detonation transfer subassembly 50 also includes a lower explosive carrying member 90 that has a lower box end 92 that threadedly and sealingly couples with the upper pin end of, for example, a perforating gun. At its upper end, lower explosive carrying member 90 is threadedly and sealingly coupled with the lower end of detonation transfer member 70 . Lower explosive carrying member 90 is a substantially cylindrical tubular member having a longitudinal bore 94 formed therein. Longitudinal bore 94 houses a holder member 96 which may be made from a suitable material such as steel. Longitudinal bore 94 also houses a holder member 98 which may be made from a suitable material such as steel, aluminum or polymer. Disposed within longitudinal bore 94 above holder member 96 is a sealed initiator 100 . Confined within holder member 96 is a booster 102 and confined within holder member 98 is a booster 104 . Extending between booster 102 and booster 104 is a detonation cord 106 . Together, initiator 100 , booster 102 , detonator cord 106 and booster 104 form an explosive train.
Under normal operation, detonation transfer subassembly 50 is used to transfer detonation from one detonation activated tool to another detonation activated tool such as from one shaped charge perforating gun to another as depicted in FIG. 1 . This is achieved by receiving a detonation from the detonation activated tool that is threadedly and sealingly coupled to pin end 54 of upper explosive carrying member 52 . This detonation then travels through the explosive train within upper explosive carrying member 52 . Specifically, the detonation travels through booster 60 , detonation cord 62 , initiator booster 64 and finally to unlined shaped charge 66 . Upon detonation of unlined shaped charge 66 , a large volume of gas is generated that accumulates and pressurizes in expansion chamber 68 .
When the gas pressure in expansion chamber 68 reaches a predetermined level, the force created by the gas pressure on firing pin 86 shears pin 88 . Once shear pin 88 has sheared, firing pin 86 is propelled from its position proximate upper explosive carrying member 52 through longitudinal passageway 82 until firing pin 86 impacts sealed initiator 100 in lower explosive carrying member 90 , as best seen in FIGS. 5A-5B. Upon impact with sealed initiator 100 , seal initiator 100 detonates which in turn sends a detonation down the explosive train in lower explosive carrying member 90 including booster 102 , detonation cord 106 and booster 104 . Booster 104 then transfers the detonation to the detonation activated tool that is threadedly and sealingly coupled to box end 92 of lower explosive carrying member 90 . As such, detonation transfer subassembly 50 transfers detonation from one detonation activated tool to another detonation activated tool by transferring detonation from upper explosive carrying member 52 to lower explosive carrying member 92 through detonation transfer member 70 .
Even though FIG. 4 has depicted the explosive train within upper explosive carrying member 52 as ending with unlined shaped charge 66 which generates the gas pressure in expansion chamber 68 , it should be noted by those skilled in the art that other techniques may be used to propel firing pin 86 from its position proximate upper explosive carrying member 52 to its position impacting sealed initiator 100 in lower explosive carrying member 90 . For example, the explosive train within upper explosive carrying member 52 could alternatively terminate in other types of propellants including, but not limited to, a solid rocket propellant. As another alternative, the explosive train within upper explosive carrying member 52 could terminate by opening a port to the exterior of detonation transfer subassembly 50 to allow high pressure fluid to enter expansion chamber 68 and provide the force to shear pin 88 and propel firing pin 88 .
Importantly, the design of detonation transfer subassembly 50 assures that firing pin 86 impacts sealed initiator 100 with sufficient velocity to create detonation. Specifically, this is achieved by allowing gas generated by the detonation of unlined shaped charge 66 to expand and pressurize in expansion chamber 68 . In addition, this is achieved by selectively preventing movement of firing pin 86 relative to barrel 78 until the force created by the gas pressure in expansion chamber 68 is sufficient to shear pin 88 . Finally, this is achieved by allowing air in longitudinal chamber 82 to vent through ports 84 into vent chamber 80 as firing pin 86 travels through longitudinal chamber 82 . As such, firing pin 86 strikes sealed initiator 100 with sufficient force to cause sealed initiator 100 to detonate.
Referring now to FIGS. 6A-6B, therein is depicted a detonation transfer subassembly of the present invention prior to transferring detonation that is generally designated 150 . Detonation transfer subassembly 150 includes an upper explosive carrying member 152 that has an upper pin end 154 that threadedly and sealingly couples with the lower box end of, for example, a perforating gun. Upper explosive carrying member 152 is a substantially cylindrical tubular member having a longitudinal bore 156 formed therein. Longitudinal bore 156 houses a holder member 158 which may be made from a suitable material such as steel or aluminum. Confined within holder member 158 is an explosive train that includes a booster 160 , a detonation cord 162 such as RDX plastic cover Primacord, an initiator booster 164 and an unlined shaped charge 166 . The lower portion of longitudinal bore 156 serves as an expansion chamber 168 .
Detonation transfer subassembly 150 also includes a detonation transfer member 170 that is threadedly and sealingly coupled to the lower end of upper explosive carrying member 152 . Detonation transfer member 170 is a substantially cylindrical tubular member having housing 172 . Housing 172 has a radially reduced exterior region 174 that is preferably aligned with the shear ram preventers if the well in which detonation transfer subassembly 150 is disposed must be shut in and the shear ram preventers must be used to shear detonation transfer member 170 . Housing 172 also has a longitudinal bore 176 formed therein. Disposed within longitudinal bore 176 , in a substantially annularly spaced apart relationship, is a barrel 178 . The annular space between longitudinal bore 176 and barrel 178 is a vent chamber 180 . Barrel 178 defines a longitudinal passageway 182 therein. Barrel 178 also defines a plurality of vent ports 184 that create a path for communication between vent chamber 180 and longitudinal passageway 182 . A firing pin 186 is disposed within longitudinal passageway 182 . Firing pin 186 is initially fixed relative to barrel 178 by shear pin 188 .
Detonation transfer subassembly 150 also includes a lower explosive carrying member 190 that has a lower box end 192 that threadedly and sealingly couples with the upper pin end of, for example, a perforating gun. In the illustrated embodiment, lower explosive carrying member 190 is integral with detonation transfer member 170 . Lower explosive carrying member 190 has a bore 194 formed therein. Bore 194 houses a holder member 196 which may be made from a suitable material such as steel. Bore 194 also houses an alignment member 198 which may be made from a suitable material such as steel. Alignment member 198 receives the lower end of barrel 178 therein. Alignment member 198 is threadably coupled to holder member 196 . Disposed within holder member 196 is a sealed initiator 200 .
Under normal operation, detonation transfer subassembly 150 is used to transfer detonation from one detonation activated tool to another detonation activated tool such as from one shaped charge perforating gun to another as depicted in FIG. 1 . This is achieved by receiving a detonation from the detonation activated tool that is threadedly and sealingly coupled to pin end 154 of upper explosive carrying member 152 . This detonation then travels through the explosive train within upper explosive carrying member 152 . Specifically, the detonation travels through booster 160 , detonation cord 162 , initiator booster 164 and finally to unlined shaped charge 166 . Upon detonation of unlined shaped charge 166 , a large volume of gas is generated that accumulates and pressurizes in expansion chamber 168 .
When the gas pressure in expansion chamber 168 reaches a predetermined level, the force created by the gas pressure on firing pin 186 shears pin 188 . Once shear pin 188 has sheared, firing pin 186 is propelled from its position proximate upper explosive carrying member 152 through longitudinal passageway 182 until firing pin 186 impacts sealed initiator 200 in lower explosive carrying member 190 , as best seen in FIGS. 7A-7B. Upon impact with sealed initiator 200 , seal initiator 200 detonates which transfers the detonation to the detonation activated tool that is threadedly and sealingly coupled to box end 192 of lower explosive carrying member 190 . As such, detonation transfer subassembly 150 transfers detonation from one detonation activated tool to another detonation activated tool by transferring detonation from upper explosive carrying member 152 to lower explosive carrying member 192 through detonation transfer member 170 .
Importantly, the design of detonation transfer subassembly 150 assures that firing pin 186 impacts sealed initiator 200 with sufficient velocity to create detonation. Specifically, this is achieved by allowing gas generated by the detonation of unlined shaped charge 166 to expand and pressurize in expansion chamber 168 . In addition, this is achieved by selectively preventing movement of firing pin 186 relative to barrel 178 until the force created by the gas pressure in expansion chamber 168 is sufficient to shear pin 188 . Finally, this is achieved by allowing air in longitudinal chamber 182 to vent through ports 184 into vent chamber 180 as firing pin 186 travels through longitudinal chamber 182 . As such, firing pin 186 strikes sealed initiator 200 with sufficient force to cause sealed initiator 200 to detonate.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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A detonation transfer subassembly for coupling two detonation activated tools in a work sting such that the work string may be severed between the two detonation activated tools without risk of a detonation. The detonation transfer subassembly comprises first and second explosive carrying members having a detonation transfer member disposed therebetween. The detonation transfer member defines a longitudinal passageway therein. A firing pin is disposed within the longitudinal passageway. The firing pin has a first position proximate the first explosive carrying member and a second position proximate the second explosive carrying member. The firing pin is propellable from the first position to the second position following a detonation within the first explosive carrying member such that the firing pin impacts an explosive disposed within the second explosive carrying member, thereby transferring detonation from the first explosive carrying member to the second explosive carrying member.
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BACKGROUND
[0001] The present disclosure relates to a vacuum cleaner.
[0002] In general, a vacuum cleaner is an apparatus that uses suctioning force generated by a suctioning motor installed within a main body to suction air including dust, and then filter the dust within the main body.
[0003] Vacuum cleaners can largely be categorized into canister vacuum cleaners that have a suctioning nozzle connected via a hose to a main body, and upright vacuum cleaners that have the suctioning nozzle and main body integrally formed.
[0004] In an upright vacuum cleaner, the main body is capable of rotating with respect to the suctioning nozzle. The suctioning nozzle is height adjustable with respect to a floor surface.
SUMMARY
[0005] Embodiments provide a vacuum cleaner.
[0006] In one embodiment, a vacuum cleaner includes: a suctioning nozzle suctioning air including dust; a height adjusting unit adjusting a height of the suctioning nozzle; a manipulating part manipulating the height adjusting unit; a position sensing part sensing the height adjusted by the height adjusting unit; and a display part displaying the height sensed by the position sensing part to an outside.
[0007] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a vacuum cleaner according to present embodiments.
[0009] FIG. 2 a schematic block diagram of suctioning nozzle controls on a vacuum cleaner.
[0010] FIG. 3 a cutaway view showing the structure of a suctioning nozzle.
[0011] FIG. 4 is an enlarged perspective view showing the height adjusting unit in FIG. 3 .
[0012] FIG. 5 is a detailed perspective view of a position sensing part.
[0013] FIG. 6 is perspective view showing the operation of a height adjusting unit.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings.
[0015] FIG. 1 is a perspective view of a vacuum cleaner according to present embodiments.
[0016] Referring to FIG. 1 , an upright vacuum cleaner is exemplarily described in the present embodiments. The vacuum cleaner includes a main body 2 with a built-in suctioning force generating member that generates suctioning force and a filtering member that removes impurities from suctioned air, and a suctioning nozzle 4 installed at the bottom of the main body 2 to suction impurities from a floor surface.
[0017] The main body 2 has a cover 3 coupled thereto, to enable the filtering member provided within the main body to be inserted and removed. A handle 6 is formed at the top of the main body 2 . A switch 8 is provided on a side of the main body 2 to control the operation of the main body 2 .
[0018] The main body 2 is coupled rotatably to the suctioning nozzle 4 . A lever 12 is provided at the rear of the suctioning nozzle 4 , to control the rotation of the main body 2 with respect to the suctioning nozzle 4 , with the main body 2 in an upright position. Also, a manipulating part (described below), for adjusting the height of the suctioning nozzle 4 , is provided at the rear of the suctioning nozzle 4 .
[0019] The operation of the above-configured vacuum cleaner will be briefly addressed below. When a user connects a cord 10 to an electrical socket, power may be supplied to the vacuum cleaner.
[0020] In this state, when a switch 8 installed on one side of the main body 2 is manipulated, the operation of the vacuum cleaner commences. When the operation of the vacuum cleaner begins, impurities on a floor are suctioned together with air through a suctioning port defined in the undersurface of the suctioning nozzle 4 . The user grasps the handle 6 and moves the suctioning nozzle 4 to perform cleaning.
[0021] In the above cleaning operation, the suctioned air including impurities is guided through a connecting hose 14 into the main body 2 . The air guided into the main body 2 is removed of impurities by means of a filtering member built in the main body 2 . When required, the connecting hose 14 may be removed from the suctioning nozzle 4 , so that a user may clean crevices using only the connecting hose 14 .
[0022] The air that is removed of impurities by the filtering member within the main body 2 passes the internal suctioning force generating member, and is then expelled to the outside of the vacuum cleaner.
[0023] FIG. 2 a schematic block diagram of suctioning nozzle controls on a vacuum cleaner.
[0024] Referring to FIG. 2 , the vacuum cleaner 1 includes a manipulating part 20 that can be pressed by a user's foot, a height adjusting unit 30 that adjusts the height of the suctioning nozzle according to manipulation of the manipulating part 20 , a position sensing part 40 with a rotating part connected to the height adjusting unit 30 , and a display part 50 that displays the height of the suctioning nozzle 4 in response to an electrical signal output from the position sensing part 40 .
[0025] In detail, the manipulating part 20 is rotatably coupled to the rear portion of the suctioning nozzle 4 . The optimum position of the manipulating part 20 may differ according to the configuration of the lower nozzle 4 .
[0026] The height adjusting unit 30 is rotated in one direction by the manipulation of the manipulating part 20 , to incrementally adjust the height of the suctioning nozzle 4 .
[0027] The position sensing part 40 is a potentiometer with a rotating part that rotates in engagement to the height adjusting unit 30 , and is model no. “N-15” manufactured by the company, PIPHER, according to the present embodiment.
[0028] The rotating part of the position sensing part 40 is engaged with the height adjusting unit 30 , so that the height of the suctioning nozzle 4 may be automatically determined by the position sensing part 40 according to the operation of the height adjusting unit 30 .
[0029] The display part 50 may be formed above the suctioning nozzle 4 to enable the height of the nozzle 4 to be easily checked by a user. To allow a user to easily check the height of the suctioning nozzle 4 while manipulating the manipulating part 20 , the display part 50 may be disposed proximately to the manipulating part 20 . However, there are no restrictions to the position of the display part 50 , which may be formed on the handle 6 , for example.
[0030] Information displayed by the display part 50 includes information on the height of the suctioning nozzle 4 sensed by the position sensing part 40 . The display part 50 may display the height of the suctioning nozzle 4 in increments.
[0031] The display part 50 may be formed of a display part including a plurality of light emitting diodes (LEDs), or a liquid crystal display (LCD). If a plurality of LEDs is used, the number of illuminated LEDs may differ according to height. That is, when the suctioning nozzle 4 is in its lowermost position, the LEDs may remain unlighted, and the number of LEDs that are illuminated may increase as the position of the suctioning nozzle 4 is raised.
[0032] When an LCD is employed on the other hand, the suctioning nozzle may, for example, be depicted at height increments through bars. The method of depicting increments in height of the suctioning nozzle is not limited with the use of an LCD.
[0033] In addition, when using LEDs to emit light to the outside, any configuration may be used to emit light.
[0034] FIG. 3 a cutaway view showing the structure of a suctioning nozzle, FIG. 4 is an enlarged perspective view showing the height adjusting unit in FIG. 3 , and FIG. 5 is a detailed perspective view of a position sensing part.
[0035] Referring to FIGS. 3 to 5 , when viewed from the top of the suctioning nozzle, the manipulating part 20 is formed on one side at the rear of the suctioning nozzle 4 , and the lever 12 is formed on the other side at the rear of the suctioning nozzle 4 .
[0036] The height adjusting unit 30 includes a rotating member 320 that rotates, a transferring part 310 that transfers manipulative force from the manipulating part 20 to the rotating member 320 , a cam 330 provided inside the rotating member 320 and coupled to the transferring part 310 to rotate the rotating member 320 , and a stopping guide 340 that stops the rotating member 320 after a certain amount of rotation in one direction.
[0037] In detail, the transferring part 310 is elongated in a front-to-rear direction, with one end rotatably coupled to a coupling part 332 formed on the cam 330 . The coupling part 332 is cylindrical, and the transferring part 310 defines a through-hole 312 through which the coupling part 332 passes.
[0038] A supporting part 21 is formed on the suctioning nozzle 4 to support the transferring part 310 and guide the movement of the transferring part 310 . The transferring part 310 passes through the supporting part 21 . An elastic member 360 is coupled to the supporting part 21 and the transferring part 310 .
[0039] A first coupling rib 311 formed on the transferring part 310 and is coupled to one end of the elastic member 360 , and a second coupling rib 22 is formed on the supporting part 21 and is coupled to the other end of the elastic member 360 . Accordingly, when a user removes force after applying manipulating force to the manipulating part 20 , the elastic member 360 restores the manipulating part 20 to its original position.
[0040] The rotating member 30 is rotated in only one direction by the transferring part. That is, the rotating member 30 may be a ratchet. The ratchet is configured as a serrated wheel that is rotated in only one direction through interaction with a pawl, and is prevented from rotating in the reverse direction. Here, the stopping guide 340 functions as the pawl.
[0041] The rotating member 320 is rotated in a counterclockwise direction in FIG. 4 (toward the manipulating part). A plurality of outer slots 321 is formed in the outer circumference of the rotating member 320 to define the starting points of the serrations. When the stopping guide 340 is disposed at an outer slot 321 , the rotating member 320 is prevented from rotating clockwise.
[0042] A height adjusting part 350 is integrally formed at one side of the rotating member 320 . The height adjusting part 350 is rotated in concert with the rotating member 320 to adjust the height of the suctioning nozzle 4 .
[0043] The cam 330 is rotatably coupled inside the rotating member 320 . The cam includes a plurality of rotating guides 331 formed around its outer circumference, and a plurality of inner slots 322 is defined in the inner circumference of the rotating member 320 .
[0044] When the cam is rotated with the rotating guide 331 disposed at an inner slot 322 , the rotating member 320 is rotated in the same direction as the cam 330 through the rotating guides 331 .
[0045] The rotation shaft 334 of the cam 330 is supported by a mounting part 24 formed on the suctioning nozzle 4 . The mounting part 24 defines a through-hole 25 through which the rotation shaft 334 passes.
[0046] The position sensing part 40 is fixed to the mounting part 24 . The rotation shaft 334 is passed through the through-hole 25 and coupled to the position sensing part 40 .
[0047] That is, the mounting part 24 not only fixes the position sensing part 40 , but also fixes and guides the rotation of the rotation shaft 334 extending from the cam 330 .
[0048] A rotating part 42 is provided at the center of the position sensing part 40 and rotates in engagement with the rotation shaft 334 , and the position sensing part 40 senses the rotation of the rotating part 42 to determine the height of the suctioning nozzle 4 .
[0049] In the present embodiment, model no. “N-15” used as the position sensing part 40 is an “endless rotation” type ratchet whose rotating part 42 at the center thereof can rotate infinitely. The position sensing part 40 is engaged with the rotation shaft 334 , and separates data on the height of the suctioning nozzle 4 (already separated into multiple levels) into a plurality of levels to relay to the display part 50 , for every one turn of the rotating part 42 . That is, the position sensing part 40 discerns by how much the rotating part 42 has rotated from a reference position, to sense the height of the suctioning nozzle 4 .
[0050] Below, a detailed description of the operating process of the vacuum cleaner will be given with reference to FIG. 6 .
[0051] FIG. 6 is perspective view showing the operation of a height adjusting unit.
[0052] Referring to FIG. 6 , the rotating member 320 is stopped by the stopping guide 340 positioned at an outer slot 321 from rotating clockwise.
[0053] In this state, when a user steps on the manipulating part 20 , the transferring part 310 moves to the left. Thus, the cam 330 is rotated counterclockwise by the transferring part 310 .
[0054] When the cam 330 rotates counterclockwise, the rotating guide 331 formed on the outer circumference of the cam 330 rotates the rotating member 320 counterclockwise.
[0055] The amount by which the rotating member 320 is rotated counterclockwise is an amount that allows the stopping part 340 to insert into the subsequent outer slot.
[0056] Accordingly, when a user releases the pressure on the manipulating part 20 , the transferring part 310 is moved to the right by means of the restoring force of the elastic member 360 . Then, the stopping guide 340 inserts into the next outer slot 321 , preventing reverse rotation (clockwise) of the rotating member 320 .
[0057] When the rotating member 320 is rotated counterclockwise, the height adjusting part 350 is rotated, thereby adjusting the height of the suctioning nozzle 4 through the rotation of the height adjusting part 350 . This is made possible due to the oblong shape of the rotating member 320 , as shown in the diagrams. Thus, the rotation of the rotating member 320 becomes the cause for the height variation of the height adjusting part 350 (that is engaged to the rotating member 320 .)
[0058] When the cam 330 is rotated counterclockwise, the rotating part 42 , fixed and coupled to the rotation shaft 334 , rotates by a predetermined angle. The position sensing part 40 senses the fixed state of the suctioning nozzle 4 according to the amount by which the rotating part 42 has rotated.
[0059] The information sensed by position sensing part 40 is relayed to the display part 50 , which displays the height of the suctioning nozzle 4 .
[0060] The present embodiment employs a method using an oblong rotating member 320 to adjust for optimally respective heights along the rotating member 320 according to the rotation of the rotating member 320 , thereby automatically adjusting the height of the height adjusting part 350 engaged to the rotating member 320 .
[0061] However, this method is limited to only one embodiment, and in other embodiments, the height adjusting part 350 may be directly engaged with the cam 330 to rotate therewith.
[0062] Any reference in this specification to “one embodiment,” “an embodiment,” “exemplary embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with others of the embodiments.
[0063] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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A vacuum cleaner is provided. The vacuum cleaner includes a suctioning nozzle, a height adjusting unit, a manipulating part, a position sensing part, and a display part. The suctioning nozzle suctions air including dust. The height adjusting unit adjusts the height of the suctioning nozzle. The manipulating part manipulates the height adjusting unit. The position sensing part senses the height adjusted by the height adjusting unit. The display part externally displays the height sensed by the position sensing part.
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BACKGROUND
This specification relates to digital data processing, and particularly to computer-implemented search services.
Query suggestion is a search service that helps users reformulate queries to better describe their information needs and reduce the time needed to find information that satisfies their needs. Search services provide search query suggestions as alternatives to search queries input by the users. For example, a search engine can provide a query input field that receives an input search query. In response to receiving search query terms input in the query input field, a search service can provide to the user search query suggestions for the input search query terms. A user can select a search query suggestion for use as a search query.
Conventional search services provide search query suggestions that are particular to a correlation measure used by the search service that generated the search query suggestions. For example, some correlation measures are based on search results returned by queries, others are based on temporal usage patterns. Some conventional search services provide query suggestions that are specifically directed at searching a particular type of resource, for example, images, videos, or web pages. Query suggestions provided based on one correlation measure usually differ from query suggestions provided based on another correlation measure.
SUMMARY
In general, one innovative aspect of the subject matter described in this specification can be embodied in methods that include the actions of receiving a first query and a plurality of second queries, each of the first and second queries including one or more terms, and for each second query and a linear model, receiving a plurality of correlation scores measuring the correlation between the first query and the respective second query, each correlation score received from a respective correlation process, and each respective correlation process being different from the other respective correlation processes, applying the linear model to the plurality of correlation scores to determine a combined correlation score that quantifies a combined correlation between the first query and the respective second query based on the plurality of correlation scores; and ranking the plurality of second queries in an order according to their respective combined correlations scores. Other embodiments of this aspect include corresponding systems, apparatus, and computer programs, configured to perform the actions of the methods, encoded on computer storage devices.
These and other embodiments can each optionally include one or more of the following features. The linear model is selected from a group consisting of a logistic regression model, a linear model, and a log-linear model. The methods can further include the action of training the linear model based on annotated queries using a machine learning process. The ranking is a Boolean classification indicative of a semantic relevance of the second query with respect to the first query.
In general, another aspect of the subject matter described in this specification, wherein the plurality of correlation scores measuring the correlation between the first query and the respective second query include a first correlation score, can be embodied in methods that include determining the first correlation score, including the actions of, for each respective query included in the first query and the respective second query, selecting, for each query term in the respective query, context terms from terms included in a corpus, wherein each context term is selected based on a distance metric between the query term included in the respective query and the terms included in the corpus, generating, for each query term in the respective query, a context vector associated with the query term, the context vector having a plurality of context vector elements, each context vector element corresponding to a term included in the corpus, and, for each context vector, determining, for each context vector element corresponding to a selected context term in the context vector, a frequency value based on a measure of occurrence of the selected context term in the context terms selected for the query term associated with the context vector, and generating a query vector for the respective query based on the context vectors for each query term in the respective query, the query vector having a plurality of query vector elements, each query vector element corresponding to a term in the corpus, and each query vector element having a value based on the values of the corresponding vector elements in the context vectors, and determining, from the query vectors for the first query and the respective second query, the first correlation score.
These and other embodiments can each optionally include one or more of the following features. The first correlation score is one of a cosine similarity, a dot-product, mutual information, Jensen Shannon divergence, or dice coefficient. The methods can further include the action of determining a conditional independence for each query based on the query vector generated for the query. The conditional independence is determined based on a statistical test selected from a group consisting of a test based on term-frequency/inverse-document-frequency (tf-idf), a test based on mutual information, a χ 2 test, a t-student test, a test based on pointwise mutual information (PMI), and a G-test. Each distance metric is based on a number of terms between the query term and the corpus terms. The number of terms between the query term and the corpus terms is 3 or less. The corpus comprises Internet resources. The Internet resources include one or more of a search query log, a collection of news articles, a collection of blog entries.
Particular embodiments of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages. The methods and systems described in this specification are not only applicable in the field of search query suggestion, but also in other fields, such as sponsored search. For example, when advertisers are required to provide keywords that should match user queries for their advertisements to be displayed, the methods and systems disclosed in this specification provide advertisers with alternative keywords that are related to, and more relevant than, the ones they have entered.
The combination of temporal correlation and corpus-based similarity metrics facilitates generating improved query suggestions. Further, also general-purpose textual corpora can be used to generate query suggestions; such corpora are more freely available and offer a greater diversity of potential suggestions when compared to search query logs alone. Textual corpora are also available for time periods preceding the widespread use of search engines (and, therefore, preceding the availability of query logs).
The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram of an example environment in which a search system provides search services.
FIG. 1B is a block diagram of an example query similarity system that can be used in the search system of FIG. 1A .
FIG. 2 is a flow chart of an example process for ranking multiple search queries based on a combined correlation score of each of the multiple search queries.
FIG. 3 is a flow chart of an example process for determining a correlation score for multiple search queries.
FIG. 4 is a flow chart of an example process for training a linear model for combining multiple correlation scores of a search query.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1A is a block diagram of an example environment 100 in which a search system provides search services. The example environment 100 includes a network 102 , for example, a local area network (LAN), a wide area network (WAN), the Internet, or a combination of them, that connects web sites 104 , user devices 106 , and the search system 110 . The environment 100 may include a large number of web sites 104 and user devices 106 .
A web site 104 is one or more resources 105 associated with a domain name and hosted by one or more servers. An example web site is a collection of web pages formatted in the hypertext markup language (HTML). Web pages can contain text, images, multimedia content, and programming elements (e.g., scripts). A web site 104 is generally maintained by a publisher, for example, an entity that manages and/or owns the web site.
A resource 105 is any data that can be provided over the network 102 and that is associated with a resource address. Resources 105 include, for example, HTML pages, word processing documents, portable document format (PDF) documents, images, video, and feed sources. The resources 105 may include content, for example, words, phrases, images and sounds and may include embedded information (e.g., meta information and hyperlinks) and/or embedded instructions (e.g., JavaScript programming code). A resource may, but need not, correspond to a file.
A user device 106 is an electronic device that, in operation, is under the control of a user and is capable of requesting and receiving resources 105 over the network 102 . Example user devices 106 include personal computers, mobile communication devices, and other devices that can send and receive data over the network 102 . A user device 106 typically includes a user application, for example, a web browser or WAP browser, to facilitate sending and receiving of data over the network 102 .
To facilitate searching of resources 105 , the search system 110 identifies resources 105 by crawling and indexing the resources 105 provided on web sites 104 . Data about the resources 105 can be indexed based on the resource to which the data corresponds. Indexed and cached copies of the resources 105 are stored in an indexed cache 112 .
The user devices 106 submit search queries 109 to the search system 110 . In response, the search system 110 identifies responsive resources 105 and generates search results 111 that identify the responsive resources 105 and returns the search results 111 to the user devices 106 . Each search result 111 identifies a resource 105 that is responsive to a query and includes a link to the resource 105 . A search result 111 can include a web page title, a snippet of text or a portion of an image (or thumbnail of the image) extracted from the web page, and the URL of the web page.
In response to receiving a search query 109 , the search system 110 accesses historical data 114 and correlation data 116 to identify alternative search queries that are similar to the search query 109 and provides query suggestions 113 to the user device 106 .
The user device 106 receives the query suggestions 113 , for example, in the form of a collection of one or more alternative search queries, and renders the query suggestions 113 as items contained in a drop-down list element, displayed in combination with an input box element located on a rendered web page or within a browser window. In other implementations, the query suggestions 113 can be presented with the search results 111 . For example, the query suggestions 113 can be presented as a list of suggestions rendered at the bottom of a page of search results 111 .
In response to a user selecting an alternative search query from among the query suggestions 113 , the user device 106 submits the alternative search query to the search system 110 over the network 102 . The search system 110 provides search results 111 and, optionally, one or more additional query suggestions 113 , in response to the alternative search query.
The user device 106 receives the search results 111 , for example, in the form of one or more web pages, and render the search results for presentation to users. In response to the user selecting a link in a search result at a user device 106 , the user device 106 may request the resource 105 identified by the link. The web site 104 hosting the resource 105 receives the request for the resource from the user device 106 and provides the resource 105 to the requesting user device 106 .
In some implementations, the search system 110 provides search results 111 and query suggestions 113 independent from each other. For example, the search system 110 receives, in addition to a partial query term, each character, number, or symbol of the partial query term or additional query terms of search query 109 as they are entered by the user. In another example, the search system 110 receives, in addition to at least one query term, each additional query term of search query 109 as they are entered by the user. In response to the partially entered search query 109 (e.g., the partial query term or terms), the search system provides query suggestions 113 to the user device 106 .
Data for the search queries 109 submitted during user sessions are stored in a data store, for example, the historical data store 114 . For example, for search queries that are in the form of text, the text of the query is stored in the historical data store 114 . Additionally, query suggestions 113 and the queries 109 for which the query suggestions 113 were provided can also be stored in the historical data store 114 .
Selection data specifying actions taken in response to search results provided in response to each search query are also stored in the historical data store 114 . These actions can include whether a search result 111 was selected, and for each selection, for which search query 109 the search result 111 was provided. These actions can also or alternatively include whether a query suggestion 113 was selected, and for each selection, for which search query 109 the query suggestion 113 was provided.
The search system 110 includes a query similarity subsystem 120 to determine similarity measures that quantify or indicate the similarities between two search queries. Although described as a subsystem, the query similarity subsystem 120 can be implemented as an entirely separate system in data communication with the search system 110 . The query similarity subsystem 120 can be used to offer multiple different features.
Users of a search engine need to come up with a suitable search query in order to fulfill their information needs. Sometimes ambiguous terms are used, which results in documents that relate to different subjects and information relating to the ambiguous terms. Consider, for example, the different meanings of the word “bank”. In one context, the term relates to a financial institution in the topic of finance; yet in another context, the term relates to a maneuver in the topic of aviation. Absent additional relevant terms being included in the query, the resources identified may relate to many different subjects. A related problem arises in other scenarios where short texts similar to search queries are required. For example, advertisers are required to provide keywords that should match user queries for their advertisements to be displayed. Query suggestion systems can also help advertisers by suggesting keywords that are related to the ones they have entered.
Further, when search engines determine that, with high probability, the results shown in response to a user's query could be greatly improved by extending or replacing the user query with a related query, such a replacement can be effected automatically, for example, invisible to the user. In such cases, the results corresponding to a suggested query, or corresponding to a combination of the original and the suggested queries, can be shown. Similarly, advertiser keywords can be automatically extended with synonyms, in order to increase the set of user queries that match an advertiser campaign. These processes are commonly known as query expansion and expanded broad match, respectively. Another application involves query categorization. Here, given a predefined set of categories, the search engine determines, for example, the top five categories to which a query can be assigned.
The system 110 , for example using the query similarity subsystem 120 , can provide correlation or similarity measures that can be used for query suggestion, query expansion, expanded broad match, and query categorization.
A query term can be a unigram or an n-gram, i.e., a query term can contain one or more terms. For example, a term can be a unigram (e.g., “burger”) or an n-gram (e.g., “New York”, a bigram, or “New York City”, a trigram). A query term containing multiple terms can also be referred to as a phrase.
FIG. 1B is a block diagram of an example query similarity system 120 that can be used in the search system of FIG. 1A . The operation of the query similarity system 120 is described with reference to FIG. 2 , which is a flow chart of an example process 200 for ranking multiple search queries based on a combined correlation score of each of the multiple search queries.
The system 120 receives a search query and multiple additional search queries ( 202 ). The search query and additional queries can be received, for example, from historical data 114 as shown in FIG. 1A . Each of the additional search queries includes one or more query terms (e.g., words or word combinations).
For each additional search query, the process 200 receives multiple correlation scores 122 that measure the correlation between the search query and the respective additional search query ( 204 ). Each correlation score is received from a respective correlation process, and each respective correlation process is different from the other respective correlation processes. The multiple correlation scores 122 can include, for example, a correlation score determined based on the temporal series of the appearance of terms in a textual corpus or of queries in a query log. Further, the multiple correlation scores 122 can include a correlation score determined based on distributional similarity, for example, term-occurrence in a textual corpus, syntactic dependencies in the corpus, or contextual windows in which terms appear. One example correlation process provides a correlation score based on a correlation of the temporal series of two search queries using normalized frequencies in a search query log during specific time intervals (e.g., time series similarity). Another correlation process provides a correlation score based on co-occurrence statistics determined using a corpus analysis (e.g., distributional similarity). Other correlation scores can be determined, for example, based on a cosine similarity, a dot-product, mutual information, Jensen Shannon divergence, or a dice coefficient. An implementation of a correlation process is described below, with respect to FIG. 4 .
The process 200 applies ( 206 ) the linear model to the multiple correlation scores to determine ( 208 ) a combined correlation score that measures the correlation between the search query and the additional search query based on the multiple correlation scores. The linear model 124 can be, for example, a logistic regression model or a log-linear model. Other models can be used.
The combination of different correlation scores, each of which are determined based on different processes, facilitates the training of the linear model 124 to calculate a combined correlation score that more closely matches quality control data, such as human evaluated query suggestions for queries. In particular, a combined correlation based on time series similarity and a distributional similarity improves the quality of the generated suggestions, relative to the quality of suggestions based on any one correlation process. The training of the linear model is described with respect to FIG. 3 below.
The process 200 ranks the multiple additional search queries in an order according to their respective combined correlations scores.
FIG. 3 is a flow chart of an example process 300 for training a linear model 124 for combining multiple correlation scores of a search query. The process 300 can be implemented in the query similarity subsystem 120 .
The process 300 receives multiple correlation scores between two search queries, each correlation score indicative of a similarity of the two search queries ( 302 ). Examples of different correlation scores are described below. The correlations scores can be generated by the various correlation processes described below, and stored in a data store that is later accessed by the query similarity subsystem 120 .
The process 300 trains the linear model using a machine learning process or algorithm based on human annotated data ( 304 ). For example, a machine learning process can provide a Boolean classification indicative of a semantic relevance of the additional search queries with respect to the search query, or provide a ranking of several suggestions for a search query. In one example, the human annotated data are generated based on a query suggestion data set containing a set of sample search queries and, for each query, a set of candidate query suggestions. Each query suggestion is rated by human raters using a 5-point Likert scale, ranging from irrelevant to highly relevant. The linear model 124 is trained to provide a ranking of the suggestions that most closely resembles the scores given by the human raters.
In some implementations, the evaluation is based on information retrieval (IR) metrics, for example, precision at 1, 3, and 5, and mean average precision. This means that not all retrieved documents are taken into account, but a specific cut-off rank (e.g., 1, 3, or 5) is chosen, so that only the topmost results returned by the system are considered. In order to compute the precision- and recall-based metrics, a binary distinction from the ratings is inferred (e.g., related or not related). In one implementation the system trains the linear model by combining two different correlation scores (e.g., time series similarity and distributional similarity), using 10-fold cross validation.
The process 300 determines a combined correlation score based on the trained linear model ( 306 ) and provides the combined correlation score of the two search queries ( 408 ).
A context vector (e.g., a vector holding context terms and/or term frequencies) for a query can be collected by identifying the contexts in which the query appears. Queries such as “buy a book” and “buy some books” appear close to similar context words in a bag-of-words model and have a high similarity. However, with increasing length of the queries, the probability of finding exact queries in the corpus decreases, so that meaningful statistics about the contexts of the queries cannot be collected. Also, many user queries are simply a concatenation of keywords with a weak underlying syntax, or none at all. Such concatenations may not appear as such in well-formed text found in, for example, web documents, even though the concatenations constitute popular queries. A context vector can also be determined for each term in a query by identifying context terms (e.g., terms appearing in the context of the respective query term).
FIG. 4 is a flow chart of an example process 400 for determining a correlation score for multiple search queries. The example process 400 can be implemented in the search system 110 , for example, in the query similarity subsystem 120 of FIGS. 1A and 1B . For convenience, the process 400 is described with respect to a system that performs process 400 . In this implementation, the process for determining the correlation score is based on co-occurrence statistics using a corpus analysis.
The process 400 receives multiple search queries, each search query including one or more query terms ( 402 ). For example, given a query as p=[w 1 , w 2 , . . . , w n ], n is the number of query terms w i in the query. Generally, a search query can be regarded as a number of terms that may or may not form a grammatically correct sentence. Examples for search queries include: “Sir Arthur Conan Doyle Books” and “hotel cheap New York fares”.
The process 400 then performs a number of steps ( 406 , 408 , 410 , 412 , 414 ) for each query ( 404 ). This includes performing ( 406 ) the steps of selecting ( 408 ) context terms and generating ( 410 ) context vectors for each query term included in each query.
For each query term w i in a query, the process 400 selects context terms from terms included in a corpus, where each context term is selected based on a distance metric between the respective query term and the terms included in the corpus ( 408 ). Therefore, for each query term w i , all terms that appear close to w i are collected. The distance metric can be a number of terms located between the query terms and the corpus terms. In one example, the number of terms located between the query terms and the corpus terms is 3 or less. Other values or other distance metrics can be used.
The corpus can be any suitable large and structured set of text (e.g., web documents, news articles, etc.). In one example, a corpus of hundreds of millions of documents crawled from the Internet is used to collect the contextual features for terms and phrases.
For each query term w i in the query, the process 400 generates a context vector {right arrow over (v)} i ( 410 ). Each context vector {right arrow over (v)} i has multiple context vector elements, each corresponding to a term included in the corpus.
The process 400 determines for each context vector element a frequency value f i1 , f i2 , . . . , f i|V| ( 412 ), where |V| is the size of the corpus used, based on a measure of occurrence of the selected context term in the context terms. Thus, the vector of frequencies for each term w i in the query is given as {right arrow over (v)} i =[f i1 , f i2 , . . . , f i|v| ].
The process 400 generates a query vector {right arrow over (qv)} for the query based on the context vectors {right arrow over (v)} i for each query term in the query ( 414 ). The query vector {right arrow over (qv)} has multiple query vector elements, each corresponding to a term in the corpus and each having a value based on the values of the corresponding vector elements in the context vectors. In some implementations, each query vector element has a value based on the geometric mean of corresponding vector elements in the context vectors, determined as
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Here, the geometric mean is used to approximate a Boolean “AND” operation between the vectors and to keep track of the magnitude of the product of the frequencies. Therefore, if two queries only differ on a very general word (e.g. “buy books” or “some books”), the vector associated to the general words (“buy” or “some” in the example) will have non-zero values for most of the contextual features, because they are not topically constrained. Further, the vectors for the queries will have similar sets of features with non-zero values. Additionally, terms that are related will appear in the proximity of a similar set of words and will have similar vectors. For example, if the two queries are “Sir Arthur Conan Doyle books” and “Sir Arthur Conan Doyle novels”, given that the vectors for books and novels are expected to have similar features, these two queries will receive a high similarity score. Also, this query vector reduces word ambiguity. For example, for the query “bank account”, the vector for bank will contain words related to the various contexts (e.g., account (finance), river (geographic), maneuver (aviation), etc. However, when combining the vector with the vector for “account”, the majority of non-zero frequencies that remain relate to terms that belong to the financial category and that are shared between the two vectors. Only these terms will be included in the final query vector.
In some implementations, the process 400 determines a conditional independence for each search query based on the query vector {right arrow over (qv)} generated for the query. Depending on, for example, a value indicative of the conditional independence of terms, the corresponding frequency values can be adjusted. The frequency values of terms having a high degree of dependence can be adjusted (e.g., for the corpus). For example, the terms “New” and “York” usually exhibit a high degree of dependence because of the frequent occurrence of the bigram “New York”. This concept applies to unigrams and n-grams, as the terms “New York” and “City” usually also exhibit a high degree of dependence (because of the frequent occurrence of the trigram “New York City”). The conditional independence can be determined, for example, based on a statistical test, for example, a test based on term-frequency/inverse-document-frequency (tf-idf), mutual information, χ 2 , t-student, or pointwise mutual information. The conditional independence can be tested for based on other tests.
The process 400 selects two different queries from the multiple search queries ( 416 ) and determines, from the query vectors for the two queries, a similarity measure that is a measurement of the similarity of the two queries ( 418 ). The similarity measure can be one of a cosine similarity, a dot-product, a mutual information, a Jensen Shannon divergence, a dice coefficient. Other similarity measures can be used.
In some implementations, the system 120 further selects multiple terms included in a query to form a combined query term and processes combined query terms (i.e., n-grams) in the same way as conventional query terms (i.e., single terms or unigrams). For example, in order to provide relevant results for the search query “hotel cheap New York fares”, the terms “New” and “York” are joined into a combined query term, and the constituent terms “New” and “York” are not processed as single terms. In some implementations, the system 120 can also process the constituent terms. This example illustrates the different meanings of terms based on the terms being considered one by one or in combination.
The system can select query terms for combination based on the occurrence of a combined query term within quotes in a search query log and/or as an entry in an encyclopedia or dictionary. Generally, a user can mark search query terms for combination by including some or all of the terms within quotes (e.g., “hotel cheap “New York” fares”). This way, candidates for query term combination can be extracted, for example, from search query logs. Another way to acquire potential candidates for query term combination are entries in an encyclopedia or a dictionary (e.g., an online encyclopedia such as Wikipedia). Generally, any number of query terms can be joined into a combined query term (e.g., “Free Democratic Party of Switzerland”). In some implementations, query terms are combined greedily. Therefore, longer n-grams are preferred and the number of terms in a combined query term is maximized. The system can select query terms for combination based on multiple metrics, for example, the occurrence of combined terms in a search query log and in an encyclopedia. Other metrics can be used exclusively or in combination.
Other correlation processes can include time-based similarity correlation that determines a correlation score by specifying a time interval, dividing the interval into equally spaced subintervals, and representing each phrase of interest as the sequence of frequencies with which the phrase was observed in the subintervals. The system uses as the correlation score the correlation coefficient between the two series, given two phrases and their associated time series.
A further example of a correlation process is based on processing temporal series of occurrence of terms in textual corpora having timestamps. Examples for textual corpora having time stamps are news articles or blog entries. Here, a similarity measure is based on the co-occurrence (i.e., terms occur within the same time period) of terms in different textual corpora.
Embodiments of the subject matter and the operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions, encoded on computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions can be encoded on an artificially-generated propagated signal, for example, a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. A computer storage medium can be, or be included in, a computer-readable storage device, a computer-readable storage substrate, a random or serial access memory array or device, or a combination of one or more of them. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium can be a source or destination of computer program instructions encoded in an artificially-generated propagated signal. The computer storage medium can also be, or be included in, one or more separate physical components or media (e.g., multiple CDs, disks, or other storage devices).
The operations described in this specification can be implemented as operations performed by a data processing apparatus on data stored on one or more computer-readable storage devices or received from other sources.
The term “data processing apparatus” encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, a system on a chip, or multiple ones, or combinations, of the foregoing. The apparatus can include special purpose logic circuitry, for example, an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). The apparatus can also include, in addition to hardware, code that creates an execution environment for the computer program in question, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system, a cross-platform runtime environment, a virtual machine, or a combination of one or more of them. The apparatus and execution environment can realize various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, object, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform actions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, for example, an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing actions in accordance with instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, for example, magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, for example, a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device (e.g., a universal serial bus (USB) flash drive), to name just a few. Devices suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, for example, EPROM, EEPROM, and flash memory devices; magnetic disks, for example, internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a computer having a display device, for example, a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, for example, a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, for example, visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.
Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, for example, as a data server, or that includes a middleware component, for example, an application server, or that includes a front-end component, for example, a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, for example, a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), an inter-network (e.g., the Internet), and peer-to-peer networks (e.g., ad hoc peer-to-peer networks).
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. In some embodiments, a server transmits data (e.g., an HTML page) to a client device (e.g., for purposes of displaying data to and receiving user input from a user interacting with the client device). Data generated at the client device (e.g., a result of the user interaction) can be received from the client device at the server.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous.
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Methods, systems, and apparatus, including computer programs encoded on a computer storage medium, for determining query suggestions from multiple correlation measures. In one aspect, a method includes receiving a first query and second queries, each of the first and second queries including one or more terms; for each second query and a linear model, receiving correlation scores measuring the correlation between the first query and the respective second query, each correlation score received from a respective correlation process, and each respective correlation process being different from the other respective correlation processes, and applying the linear model to the plurality of correlation scores to determine a combined correlation score that quantifies a combined correlation between the first query and the respective second query based on the plurality of correlation scores. The second queries are ranked in an order according to their respective combined correlations scores.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 191,255, filed May 6, 1988, abd which is a continuation of Ser. No. 692,300 filed Jan. 17, 1985, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a process for treating liquid electrolytes in electrochemical cells which are non-partitioned or partitioned by at least one separator and have at least one gas diffusion electrode.
The process is preferentially suitable for Faraday reactions or secondary reactions within the electrochemical cell which form gas and consume gas. However, the process is also suitable for electrochemical reactions in which no gases are involved.
It is known, particularly in reactions which consume gas, to use the gas diffusion electrode as a vertical vessel wall for the electrolyte and to supply, or to remove, the necessary gas to, or from, respectively, the rear side of the electrode. In order to assist the production from the electrolyte of any gas bubbles which are formed, the electrolyte flows upwards through the cell. The pressure difference between gas and electrolyte should really be the same at every point of the gas diffusion electrode. However, as a result of the difference in density between the gas and the liquid, a hydrostatic pressure which decreases as the height increases is set up. At great heights of construction such as are customary in industrial plants, it can therefore happen that, in the upper section, gas passes through the gas diffusion electrode into the electrolyte, while in the lower section electrolyte enters the gas space. Both effects interfere with the progress of the reaction and the operation of the plant.
In reactions in which gas is evolved, it is not absolutely necessary to keep the rear side of the gas diffusion electrode free from electrolyte. The gas diffusion electrodes can, therefore, dip vertically into the electrolyte, as known, for example, from expanded metal electrodes. The gas diffusion electrode can also be firmly attached to a separator. Gas bubbles which rise within the electrolyte are then formed on at least one side of the gas diffusion electrode. This two-phase flow causes pressure fluctuations and vibration. In addition, the electrodes and separators are subjected to varying loads along the height of construction as a result of the static pressure of the electrolyte. Although some effects can be moderated by low heights of construction and by enlarging the rearward electrolyte space behind the gas diffusion electrode, these effects cannot be eliminated.
French Patent Application 2,514,376 discloses an electrolysis process in electrolytic cells partitioned by separators, in which the electrolyte is passed as a film over the surface of an electrode under the influence of gravity. Any gas formed can escape through the openings in the expanded metal electrode located above. It is not mentioned how the process is to be carried out for industrial electrolysis processes which evolve or consume gas.
SUMMARY OF THE INVENTION
The object of the invention, therefore, consists in substantially eliminating the hydrostatic and hydrodynamic effects.
A process of the type initially described is, therefore, suggested, in which a gas space is located laterally to the direction of flow of the electrolyte, which comprises allowing the electrolyte to flow by means of gravity in a thin layer through the electrochemical cell in such a way that the gas diffusion electrode is at least partially wetted.
In accordance with a further embodiment of the process, the electrolyte can flow between the gas diffusion electrode and a counter-electrode, it being possible for the counter-electrode to have a solid, perforated or microporous structure.
The electrolyte can also flow between the gas diffusion electrode and a separator or between the separators. The electrolyte can also flow between a counter-electrode having a perforated or solid structure and a separator. Several different electrolytes can be employed in partitioned electrochemical cells. The electrolyte can flow at least partially within the separator or the gas diffusion electrode for a low consumption of electrolyte.
The electrolyte can flow at least partially on the rear side of the gas diffusion electrode or only at the lateral regions of a strip-shaped gas diffusion electrode. It is also possible to wet the gas diffusion electrode on all sides. The gas diffusion electrode can also be wetted by means of a special capillary system which ensures that the electrolyte is transported between the gas diffusion electrode and the downward flowing electrolyte at another cell structure or at the capillary system.
The electrolyte can also flow in channels created by the geometrical shape of the gas diffusion electrode, of the separator or of the distance pieces. The channels can also be arranged so that the electrolyte is forced to flow in a meandering pattern.
By setting up a pressure difference between the spaces upstream and downstream of the gas diffusion electrode, it is also possible to induce the electrolyte to flow at least partially transversely through the gas diffusion electrode. Similarly, the electrolyte can also flow transversely through an arrangement comprising one to two gas diffusion electrodes and a separator constructed in the form of a diaphragm, if a difference in pressure is set up on the two sides of such an arrangement.
In accordance with a further embodiment, the electrolyte can also flow transversely through a stack of cells comprising several diaphragms and several gas diffusion electrodes, if a difference in pressure is set up in the spaces upstream and downstream of this stack of cells. The principle of the mode of operation of such a stack of cells, known as the ELOFLUX cell, originates, for example, from DECHEMA monographs, volume 92, 1885 . . . 1913; pages 21 to 43, Verlag Chemie, Weinheim, N.Y., 1982. As a result of the application of the process according to the invention to the terminal gas diffusion electrodes, the electrolyte pressure in the pores is substantially independent of the height of construction, so that this type of cell too can be constructed in a very large form.
The pressure difference upstream and downstream of a gas diffusion electrode can also be modified hydrodynamically by changing the cross-section of flow of the electrolyte flowing upstream of the gas diffusion electrode one or more times. This modification can also be outside the gas diffusion electrode. It is thus possible to produce a pressure difference between the electrolyte and the gas even in cases where the electrolyte and the gas come into contact at the inlet and outlet. This modification can also be used to cause the electrolyte to flow in part transversely through a suitable gas diffusion electrode.
In a further embodiment of the invention, an electrode having a perforated structure can be used as the counter-electrode, and the electrolyte can be caused to flow downwards by means of gravity at the perforated electrode in such a way that a gas space is formed laterally to the direction of flow. This embodiment of the invention is particularly advantageous in the case of partitioned electrochemical cells. For example, in the electrolysis of alkali metal chlorides, an oxygen-consuming cathode and a chlorine-evolving perforated anode can be used together in a membrane cell. In spite of the development of bubbles in the anolyte, this cell is substantially free from static pressure phenomena, fluctuations in pressure and vibration.
In a further embodiment of the invention, it is possible to use a counter-electrode having a solid structure in a partitioned electrochemical cell and to arrange a gas space on the rear side of the counter-electrode and to cause the electrolyte to flow by means of gravity in a thin layer between the counter-electrode and the separator. In this way it is possible to avoid the influence of static pressure on the separator and the counter-electrode. Any desired pressure difference, independent of the height of construction, can be set up between this gas space and the electrolyte.
A separator is to be understood as meaning a sheet which separates the anolyte and the catholyte and/or the gases concerned from one another. It can be composed of a cation or anion exchange membrane or of porous material. The separator can also form one unit together with the gas diffusion electrode or a perforated electrode. As a result of its microporous structure, the gas diffusion electrode can assume the function of gas separation.
A gas diffusion electrode is to be understood as meaning an electrode having very small apertures or pores which offer a greater area of contact to the gas than the area corresponding to the projected macroscopic surface area. As is known per se, the gas diffusion electrode can be built up from several layers. These layers can also assume, wholly or partly, the function of a diaphragm. By a suitable choice of material, it is possible to influence the wetting property of the electrode surface. It is also possible to influence the depth of penetration of the electrolyte by suitable layer structure. A layer impervious to liquid can also be composed, for example, of finely porous PTFE sheeting which shuts off the rear side of the gas diffusion electrode. The depth of penetration of the electrolyte can, however, also be influenced by means of an appropriate pressure difference between the electrolyte space and the gas space.
With a view to simple technical construction, the electrodes and separators should be substantially vertical However, any angle of more than 0° and less than 180° to the horizontal is possible.
The electrodes and separators can be flat or curved, for example undulating or in the form of tubes. Arrangements composed of several electrodes and separators can have either bi-polar or mono-polar electrical interconnections.
If the electrolyte is to flow between two walls which can be regarded as hydraulically impervious, such as, for example, between the separators, the gas diffusion electrodes, a gas diffusion electrode and a separator or a solid electrode, care must be taken always to provide sufficient electrolyte so that gas bubbles are not sucked in, nor is an undesirable hydrostatic excess pressure formed. The pressure relationships will be illustrated by the example of an idealized case: the electrolyte should flow from a flat distribution channel which has pressure equalization on the gas side with the rearward gas space of a gas diffusion electrode, into the aperture between the gas diffusion electrode and the separator, and should flow out into the rearward gas space at the lower end of the electrode. It is also assumed that the properties of the materials, the volume of electrolyte and the width of the aperture do not alter with the height of construction. The resulting flow rate is then exactly that at which the potential energy of the electrolyte is dissipated by the frictional loss. The difference in pressure in relation to the rearward gas space is therefore constant and independent of the height of construction. Under the above assumptions, the pressure difference is virtually zero. In practice, of course, the volume of the electrolyte and the properties of the materials will alter. The effect on the pressure distribution can, however, generally be tolerated. It is also possible, however, to modify the flow cross-section for the electrolyte as a function of the height of construction for a particular design so that here too the potential energy of the electrolyte per unit of flow length is just dissipated by frictional losses.
The desirable invariance of the pressure difference with the height is thus achieved by imposing the same pressure at the inflow and outflow of the electrolyte. The electrolyte pressure can, of course, differ from the gas pressure in the rearward space downstream of the gas diffusion electrode. The measures necessary to ensure separate pressure chambers are known per se. The speed of the electrolyte in the aperture should be markedly less than 4 m/second, preferably not more than 1 m/second, so that the energy can be dissipated mainly by frictional losses and does not remain in the electrolyte as kinetic energy at the outflow. Typical aperture widths for low-viscosity electrolytes are between 0.1 and 1 mm. The aperture widths are larger in the case of meander-shaped deflections and if distance pieces having an increased resistance to flow are used. In general, the flow rate selected will be that which is desirable for the exchange of material or for the removal of heat. The speed of the electrolyte can be varied within very wide limits by means of the spacing of the aperture, the nature of the interposed distance pieces and the shape and nature of the electrodes and separators.
The process according to the invention is suitable for all electrochemical processes using liquid electrolytes which can be operated by means of gas diffusion electrodes. These can be processes which form gas or consume gas. Not only Faraday reactions are suitable, but also reactions in which gases take part in a secondary reaction. The process according to the invention can also be applied to processes in which no gases are involved. In these cases an inert gas is introduced. Instead of the customary electrodes having a solid structure, gas diffusion electrodes through which partial transverse flow can be arranged by the process according to the invention are then employed. This enables the large internal surface area to be utilized for reducing the overvoltage. In the case of reactions which are retarded by diffusion, the limiting current density is also increased.
In partitioned electrochemical cells, the suggested process can be applied to both halves of the cell or only to one. Both halves of the cell can be operated with gas diffusion electrodes, or an electrode having a perforated or solid structure can be used as a counter-electrode.
It is thus always possible to ensure that, even in the case of partitioned electrochemical cells, the unfavorable hydrostatic and hydrodynamic effects are eliminated. Vibrations and pressure fluctuations caused by the process do not occur. As a result of the early phase separation of electrolyte and gas in the electrode or in the near vicinity to the electrode, it is possible to make a great reduction, as a rule to a few millimeters, in the depth of the cell in electrolysis cells. Special apparatus for phase separation can often be dispensed with, since the phases have already been virtually separated on leaving the cells. The mechanical stress on electrodes, separators and other cell structures is extremely low when the process according to the invention is used. Electrodes and separators can therefore be thinner. This is an important contribution towards lowering the ohmic losses of potential and towards increasing operational safety. As a result of the disappearance of vibration and pressure fluctuations, chafing of electrodes and separators is also avoided. The sensitive layers on separators and electrodes are treated gently. Loosening of the structure of gas diffusion electrodes is also avoided. The electrodes and separators achieve a longer service life. The separation of the gas diffusion electrode from the counter-electrode or from the separator, is, as a rule, so small that one can virtually describe it as a zero separation. As a result of the suggested process, the gas diffusion electrode can be developed in an improved manner for its real task, since the finely porous barrier layer of gas which retards the mass transfer no longer needs to be designed for a wide range of pressures. A factor to be singled out is that the height of constuction of electrochemical cells is virtually no longer limited, which is particular importance for industrial use. The process according to the invention can also be employed in cases where the actual electrolyte between the anode and cathode is a solid, for example an ion exchange membrane (SPE process). The liquid electrolyte then only serves to supply or carry away the substances taking part, or is used for heat regulation.
The process according to the invention is also suitable for electrochemical cells having several separators between a pair of electrodes, such as, for example, cells for the electrodialysis of sea water.
In principle, the suggested process is suitable for all electrochemical processes for which it is possible to produce microporous electrodes having an adequate service life. The following may be mentioned as examples:
Electrolysis of alkali metal chlorides
Electrolysis of water
Fuel cells
Electrodialysis
Organic syntheses
Redox systems for the electrochemical production and storage of energy.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described using FIGS. 1 to 31 as examples. Only those elements which are important for understanding are shown, and in a highly diagrammatic form. The figures are in all cases sections unless the contrary is expressly mentioned in the text. The casing, the inlet and outlet lines and the apparatus for distributing and collecting electrolyte have not been shown pictorially, since they are known per se to anyone skilled in the art. The distance pieces, which are also known per se, between electrodes and separators are only shown where particular importance attaches to their shape. For the sake of simplicity, all the arrangements shown have been drawn in a vertical position. The gas space formed laterally to the main direction of flow is immediatley adjacent to the electrodes or to the electrolyte which is flowing in a thin layer. A description in greater detail is only given in special cases. It will be clear to anyone skilled in the art whether an arrangement is suitable for gas-producing reactions or for gas-consuming reactions, and greater detail is only given in special cases.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a gas diffusion electrode 3 and an electrode 4 having a solid structure. The electrolyte 1 flows in the aperture between the electrodes 3 and 4. The gas spaces 10 and 11 are located on the rear side of the electrodes 3 and 4.
FIG. 2 shows a gas diffusion electrode 3 and a perforated electrode 4. The electrolyte 1 preferably flows in the aperture between the electrodes 3 and 4. The electrolyte 1 can wet the perforated electrode 4 wholly or partly, and this is also possible from the rear side. The openings in the perforated electrode 4 should be larger than the gas bubbles formed in the electrolyte, so that the openings do not become blocked by individual bubbles. Examples of suitable materials are perforated plates, expanded metals, woven wire cloth, electrodes composed of individual bars or strips of sheet metal and electrodes having recessed indentations in which the gas can be drawn off.
FIG. 3 shows a horizontal section containing a perforated electrode 4, which is shown here as an electrode having recessed indentations. This electrode 4 can at the same time assume the function of a bi-polar separator. The gas space 11 is, therefore, located within the electrode 4. If the gas diffusion electrode 3 carries an insulating layer on its front side, the two electrodes 3 and 4 can lie immediately one on top of the other. The insulating distance can, of course, also be fixed by means of distance pieces. The electrolyte 1 runs downwards in channels. The position of the electrolyte can be affected by the wetting properties of the perforated electrode 4 or by tilting it slightly. The gas space 10 belonging to the gas diffusion electrode 3 is immediately adjacent to the gas diffusion electrode 3.
FIG. 4 shows two gas diffusion electrodes 3 and 4, which are located at a slight distance from one another. The electrolyte 1 flow through this aperture and wets both electrodes.
FIG. 5 shows an arrangement having a separator 6 and two gas diffusion electrodes 3 and 4. The electrolyte 1b flows in the aperture between the separator 6 and the gas diffusion electrode 3. The separator 6 can comprise a diaphragm. The electrode 4 is then wetted directly by the electrolyte 1b. The separator 6 can, however, comprise an ion exchange membrane. In the event that the ion exchange membrane transports ions which result in gaseous products, or if gaseous products are supplied to the electrode 4, the electrode 4 remains dry. Other products must, however, be brought up or removed by means of a further electrolyte, with at least partial wetting.
FIG. 6 shows an arrangement having a centrally located separator 6 and two gas diffusion electrodes 3 and 4 which are wetted by the two electrolytes 1a and 1b.
FIG. 7 shows an arrangement having two separators 6 and 7 and two gas diffusion electrodes 3 and 4. The electrolyte 1 flows between the separators. As already mentioned, however, the separators 6 and 7 can also be an integral constituent of the gas diffusion electrodes 3 and 4. This arrangement is suitable for fuel cells and for the electrolysis of water.
FIG. 8 shows an arrangement in which the electrolyte 1 flows within the separator 6. The separator 6 can have a homogeneous composition of a porous material or can be constructed in a heterogeneous manner from several layers having different structures. For example, this separator 6 can be conceived as having been formed from FIG. 7, if it is imagined that the separators 6 and 7 in that Figure, which are, if necessary, supported by distance pieces, are so close to one another that it is virtually possible to speak of one unit, particularly if a firm mechanical bond has been formed. The arrangement is preferentially suitable for a low throughput of electrolyte, for example in hydrogen/oxygen fuel cells operating with highly concentrated aqueous electrolytes or with melts as the electrolyte. The electrolyte 1 then flows only to maintain good conductivity through the separator 6. The water formed leaves the fuel cell chiefly in the form of gas.
FIG. 9 and FIG. 10 show two gas diffusion electrodes 3 and 4 which rest immediately on the separator 6 or are connected mechanically. FIG. 10 is an enlarged section of FIG. 9. The electrolytes 1a and 1b should in this case completely cover, for example, the rear sides of the gas diffusion electrodes 3 and 4. A gas-producing reaction should therefore take place at both electrodes. In the electrolyte flowing down in a thin layer, the gas formed in the gas diffusion electrodes produces gas bubbles 9 which burst at the phase boundary to the gas space. A diaphragm can be used without problems as the separator 6 for the electrolysis of water. In the electrolysis of alkali metal chlorides, it is preferable to use a cation exchange membrane.
FIG. 11 shows an arrangement similar to that already illustrated and described in FIG. 9. FIG. 11 is, however, intended to illustrate operation in an electrolysis of water using a proton-conducting ion exchange membrane as the separator 6. Only one electrolyte 1 is required, because the hydrogen formed leaves the gas diffusion electrode 4 in the form of gas.
FIG. 12 shows a horizontal section having a separator 6 and a gas diffusion electrode 3. The counter-electrode is not shown. The rear side of the gas diffusion electrode 3 has strips which are located close beside one another and have a readily wettable surface and a less readily wettable surface. The electrolyte 1b then flows in strands preferentially on the readily wettable parts of the surface. The flow of electrolyte does not have to be uniform. For example, waves can be formed or the electrolyte 1b can flow down in droplets in contact with the surface, it being possible for parts of the less readily wettable surface to be covered transiently. Other patterns can also be provided instead of the hydrophobic and hydrophilic strips. Part of the surface should at least transiently be available for mass transfer in the form of gas. The electrolyte 1b can also be prevented from flowing over the whole of the surface by forcing it away by means of porous, hydrophobic strips arranged on the rear side of the gas diffusion electrode 3. These strips can be so thick that the electrolyte 1b flows, as it were, in channels. The gas diffusion electrode 3 should be constructed in a bi-porous form. The gas can then be transported, for example, in a continuous system of coarse pores, and the electrolyte 1b can be transported in a continuous system of fine pores. The arrangement shown can be employed in conjunction with a counter-electrode either for gas-consuming reactions or for gas-producing reactions.
FIG. 13 shows a horizontal section. The mode of action and the construction are substantially the same as those of FIG. 12, but the runways for the electrolyte 1b are in this case cut into the gas diffusion electrode 3.
FIG. 14 shows a horizontal section having a gas diffusion electrode 3 and separator 6. The counter-electrode is not shown here. The electrolyte 1b flows down a wall 2 which can, for example, be a bi-polar separator. The gas diffusion electrode 3 is wetted via a capillary system 12 which can, for example, be made of a hydrophilic, porous or fibrous material. A slight inclination is helpful in ensuring that the electrolyte 1b remains in its illustrated position. The gas space 10 is located between the gas diffusion electrode 3 and the electrolyte 1b.
FIG. 15 shows a horizontal section without a counter-electrode. The electrolyte 1b runs in recessed channels in the gas diffusion electrode 3. In this case the channels are bounded by the separator 6. They can, however, also be completely recessed into the electrode.
FIG. 16 shows a horizontal section without a counter-electrode. In this case the electrolyte 1b flows in channels which are formed by the undulating shape of the gas diffusion electrode 3. The channels are bounded by the separator 6. A small distance piece can be provided in order to improve the mass transfer in the interstices.
FIG. 17 shows an arrangement without a counter-electrode, having a gas space 10 which is located within the gas diffusion electrode 3 and which is in this case bounded by the separator 6. The electrolyte 1b flows on the rear side of the gas diffusion electrode 3. Arrangements having an internal gas space can be put together to form a very compact stack of cells. The electrolyte 1b can then flow in a thin layer between two electrodes.
FIG. 18 shows a horizontal section without a counter-electrode, having a strip-shaped gas diffusion electrode 3 which is completely wetted by the electrolyte 1b. This arrangement is, of course, preferentially suitable for gas-producing reactions. The gas diffusion electrode 3 can release the gas 9 formed, preferably on the rear side, through a finely porous layer which does not take part in the reaction.
FIG. 19 shows an arrangement having a gas diffusion electrode 3 and a counter-electrode 4 which has a solid structure. The electrolyte 1a flows between the counter-electrode 4 and the separator 6. The electrolyte 1b flows between the gas diffusion electrode 3 and the separator 6. The gas space 10 is immediatley adjacent to the gas diffusion electrode 3. As already mentioned above, the components 3, 4 and 6 are not under the stress of the hydrostatic pressure of the two electrolytes--nor are they even if the electrolytes have different densities and the height of construction is very great. In order also to avoid hydrostatic loads coming from the rear side of the counter-electrode 4, a gas space 11 should also be located at the rear side of the electrode 4. This achieves a considerable saving of valuable materials and enables the design of the cells to be carried out in light-weight construction.
FIG. 20 shows an arrangement having a gas diffusion electrode 3, a separator 6 and a perforated electrode 4 as the counter-electrode. The electrolyte 1b flows between the separator 6 and the gas diffusion electrode 3. The electrolyte 1a flows partly on the rear side of the electrode 4 and partly between the electrode 4 and the separator 6. This arrangement is suitable for gas evolution at the perforated electrode 4. During operation an electrolyte film containing bubbles is formed. The gas bubbles reach the gas space 11, which is immediately adjacent, by a short path and release their gas content by bursting. At the current densities customary in industry, only a small proportion of gas will escape direct into this gas space 11 by diffusion at the phase boundary to the gas space 11.
FIG. 21 shows an arrangement having two gas diffusion electrodes 3 and 4 and a separator 6. A further separator 7 is located on the front side of the gas diffusion electrode 4. The separator 7 can, however, also be an integral constituent of the gas diffusion electrode 3. As is known per se, a finely porous layer of a material which does not take part in the reaction is to be preferred for this purpose. These materials can also be metals having an appropriately high overvoltage. The electrolyte 1a flows between the two separators 6 and 7. The electrolyte 1b flows between the separator 6 and the gas diffusion electrode 3. The gas spaces 10 and 11 are located on the rear sides of the gas diffusion electrodes 3 and 4. Either gas-producing or gas-consuming reactions can be carried out with this arrangement. It is also possible, for example, to carry out gas-consuming reactions at the gas diffusion electrode 3 and gas-producing reactions at the gas diffusion electrode 4.
FIG. 22 shows a diagram of a meander-shaped electrolyte flow. The meander-shaped formation of channels can be forced by means of distance pieces 5, but also by suitably shaping the electrodes or separators. In the event that the electrolyte 1 flows between hydraulically impervious walls, for example separators or gas diffusion electrodes, the channels should be completely filled with the electrolyte 1. Equalizing the pressure between individual channels and any gas spaces is not necessary, because here too, similar to the description given above for non-meander-shaped flow, the potential energy of the electrolyte 1 on its flowpath is always reduced as a result of fluid friction. If a small width is selected for the channels running transversely, it is possible to neglect the low static pressure differences between the upper region and the lower region of a channel. The flow rate, the dwell time and the distance between electrodes and separators can be varied within wide limits by suitable design of the channel cross-section.
FIG. 23 is intended to illustrate how the pressure difference between the electrolyte 1b and the gas space 10 can be influenced by hydrodynamic effects. As already explained, this pressure difference is independent of the height of construction, if the distance between the boundary walls of the downward-flowing electrolyte does not alter, and the flow properties and flow rate remain virtually constant. The boundary walls shown here are a gas diffusion electrode 3 and a separator 6. If, therefore, a restriction point is installed at the inflow of the electrolyte 1b, for example by means of a change in the cross-section of the distance piece 5, a subnormal pressure is formed immediately downstream of the restriction point. If the distance between the boundary walls 3 and 6 remains constant, the subnormal pressure will be reduced continuously until the electrolyte 1b emerges. It is assumed in this example that the electrolyte 1b is in direct contact with the gas space 10 at the inlet and outlet. If it is desired to maintain at a constant level, over the height, the subnormal pressure set up by restriction, the cross-section of flow in the lower region can be enlarged, for example by means of a fixed wall 14 adjoining the gas diffusion electrode 3. A subnormal pressure is formed because, as a result of the enlarged aperture, the potential energy of the electrolyte on its flow path is no longer completely removed in the form of fluid friction. The subnormal pressure caused by the restriction point and the enlargement in cross-section can be adjusted to the same value, thus giving a constant pressure difference in relation to the gas space 10 over the entire height of construction of the gas diffusion electrode 3. It is also possible to locate the restriction point below and the enlargement in cross-section above. An excess pressure, in relation to the gas space, which is independent of the height of construction is then set up. Cell design can be simplified by utilizing these effects. Even so, the most advantageous pressure difference can be selected for the gas diffusion electrode.
FIG. 24 shows an arrangement without a counter-electrode having a gas-producing gas diffusion electrode 3 and a separator 6. The electrolyte 1b flows through a continuously narrowing aperture. A hydrostatic excess pressure is formed as a result. This excess pressure can be used to cause the electrolyte to flow in part transversely through the gas diffusion electrode 3 and thus to ensure removal of the static pressure. The four short arrows are intended to indicate the flow through the gas diffusion electrode 3. This makes it possible to avoid concentration gradients within the gas diffusion electrode to a substantial extent. It is, therefore, possible to apply very high current densities. Since the constriction of the aperture between the gas diffusion electrode and the separator can be limited to fractions of a millimeter, the differential ohmic voltage drop can be neglected. Instead of the narrowing aperture it is also possible to employ distance pieces having a resistance to flow which increases in a downward direction. In gas-producing reactions the gas diffusion electrode 3 should be so designed that the gas emerges on the rear side. The gas bubbles 9 can then readily release their gas content to the adjacent gas space 10.
It is also possible to reverse the direction of flow of the electrolyte flowing transversely through the gas diffusion electrode, for example by means of an aperture which becomes wider.
If care is taken that the reverse side of the gas diffusion electrode--as described in FIG. 12 or 28--is only partially wetted, this arrangement can also be employed for gas-consuming reactions.
It should also be noted that it is not only reactions involving a gas which can be carried out by means of this arrangement. A porous electrode through which there is transverse flow and which is close to a separator or electrode is of interest for many processes in which restriction of diffusion and high overvoltages must be expected. An inert gas can then be introduced into the gas space.
FIG. 25 shows an arrangement without a counter-electrode, in which the electrolyte 1b flows several times, with a change of direction, transversely through the gas diffusion electrode 3. FIG. 25 is a variant of FIG. 24. Instead of continuous restriction, several restriction points produced by special distance pieces 5 are installed. A counter-electrode can also be employed instead of the separator 6.
FIG. 26 shows a plan view of a special embodiment of the distance pieces 5. An effect similar to that of the transversely placed, strip-shaped distance pieces of FIG. 25 is achieved by this means. The restriction point is achieved in FIG. 26 by continuously narrowing the cross-section of flow. The pressure relationships do not change as abruptly as in FIG. 25. There is, therefore, a more uniform transverse flow through the gas diffusion electrode 3.
FIG. 27 shows an arrangement of several individual cells employing the flow principle of FIG. 25. A non-partitioned cell is illustrated. It is also possible, however, to provide separators between the two gas diffusion electrodes 3 and 4. The arrangement can have monopolar or bi-polar electrical connections. Component 13 is an electron-conducting contact bridge. The flow pattern of the electrolyte 1, for example at a gas diffusion electrode 3, is indicated by arrows. The electrodes 3 and 4 have a common gas space 10. The electrolyte 1 is several times restricted in its flow by distance pieces 5. When it has bi-polar connections, the arrangement is particularly suitable for reactions in which only one gas is formed or no gas at all takes part in the reaction. In the latter case an inert gas is introduced. The gas space constitutes a good insulator. It is therefore possible, even with bi-polar connections, to employ electrolytes of good conductivity without producing a short circuit on the electrolyte side, as in the so-called bi-polar particle electrodes. Very high current densities can be achieved by making use of the large internal surface areas of diffusion electrodes, coupled with short flow paths.
FIG. 28 shows a horizontal section without a counter-electrode, having a separator 6 and a gas diffusion electrode 3. The electrolyte 1b flows in the aperture between the separator 6 and the gas diffusion electrode 3 and, in part, in strands on the reverse side of the gas diffusion electrode 3. If the pressure in the gas space 10 is adjusted to a value higher than that in the aperture between the separator 6 and the electrode 3, it is possible--as indicated by means of arrows--for part of the electrolyte 1b to flow transversely through the biporous gas diffusion electrode 3 and thus to ensure equalization of differences in concentration. Since the reverse side of the gas diffusion electrode 3 is partly free from electrolyte, it is also possible to carry out gas-consuming reactions.
FIG. 29 shows a horizontal section without a counter-electrode, having a separator 6 and a gas diffusion electrode 3. Channels, in which a gas can be fed in or removed, are sunk into the gas diffusion electrode 3 to form a gas space 10. Part of the electrolyte 1b flows between the separator 6 and the gas diffusion electrode 3, and another part wets a capillary system 12, for example a diaphragm. It is possible to ensure, by means of a pronounced pressure difference between the two part streams, that the electrolyte flows--as indicated by means of arrows--in one direction or the other. The electrolyte 1b which wets the capillary system 12 can have lateral contact with a further gas space 8 or can flow between the capillary system 12 and another partition, not illustrated here. It can be advantageous to modify the cross-sections of flow in accordance with the details relating to FIGS. 24, 25 and 26.
FIG. 30 shows an arrangement having two gas diffusion electrodes 3 and 4 and a separator 6. The electrolytes 1a and 1b flow on the reverse side of the gas diffusion electrodes 3 and 4 and cover the surface at least partially. If a pressure difference is set up between the gas spaces 10 and 11 and a diaphragm is used as the separator, the electrolyte 1a can--as indicated by means of the horizontal arrow--flow transversely through the gas diffusion electrodes 3 and 4 and the separator 6. Since, without transverse flow of electrolytes, concentration would take place on one side of the separator 6 and dilution would take place on the other side, for example in the alkaline electrolysis of water or in the hydrogen-oxygen fuel cell, the transversely flowing electrolyte 1a can result in an equalization of concentration. At the same time a concentration gradient within the gas diffusion electrodes is reduced thereby. Restriction of diffusion is, therefore, hardly to be expected. As a result of the large surface area which can now take an active part in the process, the overvoltage is low. Bubbles of gas formed are led by a very short path to the phase boundary at the gas spaces. In spite of high current loading, very compact cells can thus be constructed. The gas spaces 10 and 11 need to be only a few millimeters deep.
FIG. 31 shows the application of the suggestion according to the invention to a so-called ELOFLUX stack of cells. This makes it possible substantially to eliminate the hydrostatic pressure which also acts on the electrolyte-conveying pore system. A stack of this type comprises a plurality of gas diffusion electrodes 3 and 4 and separators 6 which are constructed as diaphragms. The reaction gases formed or required are transported within the gas diffusion electrodes 3 and 4 by means of the gas-conveying pore system. In order to assist the transport of gas, channels are, if necessary, sunk into the electrodes, for example in a manner similar to that in FIG. 29. The two terminal gas diffusion electrodes are covered by a capillary system 12, for example a diaphragm. If the electrodes are suitably constructed, the capillary system can also be omitted. The electrolytes 1a and 1b flow downwards as an open falling film with complete wetting of the two capillary systems 12.
If a pressure higher than that in the gas space 10 is set up in the gas space 11, part of the electrolyte 1a flows--as indicated by the horizontal arrow--transversely through the stack of cells. As already explained elsewhere, the electrolytes 1a and 1b can also flow in a narrow aperture between fixed walls, for example at electrodes, diaphragms or the cover plates of the stack of cells. The approximate equality of pressure between the inflow and outflow of the electrolytes 1a and 1b can be achieved easily in this case, for example by means of levelling vessels.
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A process for the manipulation of liquid electrolyte and gas during the operation of an electrochemical cell having at least one gas diffusion electrode and a counter electrode forming an electrolyte space for a flowing electrolyte which flows through the cell, from the upper end of the cell to its lower end, which electrolyte space is nonpartitioned or is partitioned by a separator, the gas diffusion electrode having a surface facing toward the electrolyte space and an opposite surface facing opposite from the electrolyte space, and the cell having a gas space located on the opposite surface, the process comprising:
feeding gas to or discharging gas from the gas space,
feeding electrolyte to the electrolyte space and permitting the electrolyte to flow through the space from its upper end to its lower end by gravity only, the hydrostatic pressure between the upper end of the electrolyte space and the lower end of the electrolyte space being compensated for by decreasing the hydrodynamic pressure to provide a constant pressure at all locations along the length of the electrolyte space, from the lower end to the upper end.
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TECHNICAL FIELD
[0001] The present invention relates to a dual clutch device.
BACKGROUND ART
[0002] Conventionally, there have been known dual clutch transmissions including a first input shaft connected to a first clutch that is configured to connect and disconnect the transmission of power from an engine and a second input shaft connected to a second clutch that is configured to connect and disconnect the transmission of power from the engine and configured to change a gear ratio by applying the first clutch and the second clutch alternately (for example, refer to Patent Literature 1).
[0003] In a general dual clutch transmission, one clutch corresponds to an odd-numbered gear train and the other clutch to an even-numbered gear train. Owing to this, for example, when effecting an upshift from the second to third gear, the third speed synchromesh mechanism is engaged with the clutch for the even-numbered gear train applied and the second speed synchromesh mechanism engaged. Then, the clutch for the odd-numbered gear train is applied while releasing the clutch for the even-numbered gear train, whereby the change of the gear ratio can be realized without the occurrence of torque loss.
CITATION LIST
Patent Literature
[0004] Patent Literature 1: JP-A-2010-531417
SUMMARY OF INVENTION
Technical Problem
[0005] In a general dual clutch device, when applying a clutch, a hydraulic pressure is supplied into a hydraulic pressure chamber, and a hydraulic pressure is released from a hydraulic pressure canceling chamber, causing a piston to move one stroke to bring clutch plates into press contact with one another, whereby the desired application of the clutch is realized. On the contrary, when releasing the clutch, the hydraulic pressure in the hydraulic pressure chamber is released, allowing a return spring in the hydraulic pressure canceling chamber to move the piston away from the clutch plates, whereby the desired release of the clutch is realized. Supplying the hydraulic pressure to the hydraulic pressure chamber or releasing the hydraulic pressure from the hydraulic pressure chamber is controlled by switching on or off solenoid valves provided for the hydraulic pressure chambers.
[0006] Owing to this, for example, in the event that at least one of the solenoid valves fails due to disconnection or sticking, the corresponding clutch is held applied, leading to a risk of triggering a double meshing of the transmission.
[0007] An object of the invention is to provide a dual clutch device which can prevent effectively the double meshing of a transmission.
Means for Solving the Problem
Solution to Problem
[0008] In order to achieve the above object, a dual clutch device comprises a first clutch comprising a first plate for connecting and disconnecting the transmission of power from an engine to a first transmission input shaft and a second clutch comprising a second plate for connecting and disconnecting the transmission of power from the engine to a second transmission input shaft, the dual clutch device characterized by comprising: a first piston configured to apply the first clutch by pressing the first plate by means of a hydraulic pressure supplied into a first hydraulic pressure chamber and release the first clutch by being moved away from the first plate by a first spring accommodated in a first hydraulic pressure canceling chamber; a second piston configured to apply the second clutch by pressing the second plate by means of a hydraulic pressure supplied into a second hydraulic pressure chamber and release the second clutch by being moved away from the second plate by a second spring accommodated in a second hydraulic pressure canceling chamber; a first supply line for supplying a hydraulic pressure into the first hydraulic pressure chamber and the second hydraulic pressure canceling chamber; a second supply line for supplying a hydraulic pressure into the second hydraulic pressure chamber and the first hydraulic pressure canceling chamber; a first opening-closing valve, which is provided on the first supply line, and which is configured to allow or cut off the supply of a hydraulic pressure into the first hydraulic pressure chamber and the second hydraulic pressure canceling chamber; and a second opening-closing valve, which is provided on the second supply line, and which is configured to allow or cut off the supply of a hydraulic pressure into the second hydraulic pressure chamber and the first hydraulic pressure canceling chamber.
[0009] It may be preferable that a biasing force of the first spring is set greater than a difference between a hydraulic pressure that is supplied into the first hydraulic pressure chamber via the first supply line to be applied on the first piston and a hydraulic pressure that is supplied into the first hydraulic pressure canceling chamber via the second supply line to be applied to the first piston.
[0010] It may be preferable that a biasing force of the second spring is set greater than a difference between a hydraulic pressure that is supplied into the second hydraulic pressure chamber via the second supply line to be applied on the second piston and a hydraulic pressure that is supplied into the second hydraulic pressure canceling chamber via the first supply line to be applied to the second piston.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a schematic vertical longitudinal sectional view showing an upper half of a dual clutch device according an embodiment of the invention.
[0012] FIG. 2 is a diagram illustrating a state in which a first wet type clutch is applied while a second wet type clutch is released in the dual clutch device according to the embodiment of the invention.
[0013] FIG. 3 is a diagram illustrating a state in which the first wet type clutch is released while the second wet type clutch is applied in the dual clutch device according to the embodiment of the invention.
[0014] FIG. 4 is a diagram illustrating hydraulic pressures applied to pistons and biasing forces of return springs in the dual clutch device according to the embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
[0015] Hereinafter, a dual clutch device according to an embodiment of the invention will be described based on the accompanying drawings. Like reference numerals are given to like component parts, and this will also be true with names and functions. Consequently, the detailed description of those constituent components will not be repeated in the description.
[0016] As shown in FIG. 1 , a dual clutch device 10 includes a first wet-type clutch C 1 and a second wet-type clutch C 2 . Reference numeral 11 denotes a clutch input shaft into which power of an engine E is transmitted. Reference numeral 12 A denotes a first transmission input shaft on which a speed change gear train which establishes, for example, odd-numbered gears of a transmission T is provided, and reference numeral 12 B denotes a second transmission input shaft on which a speed change gear train which establishes, for example, even-numbered gears is provided. The second input shaft 12 B is supported rotatably via bearings 13 within a hollow shaft of the first input shaft 12 A.
[0017] The first wet-type clutch C 1 includes a clutch hub 20 which rotates together with the clutch input shaft 11 , a plurality of first inner plates 21 A which are spline fitted in the clutch hub 20 , a first clutch drum 22 which rotates together with the first transmission input shaft 12 A, a plurality of first outer plates 21 B which are disposed alternately between the first inner plates 21 A and which are spline fitted in the first clutch drum 22 and a first cylindrical piston 23 which can press both the plates 21 A, 21 B together in an axial direction.
[0018] The first piston 23 is accommodated slidably within a first annular piston chamber 24 which is defined within the clutch hub 20 . In this first piston chamber 24 , a first hydraulic pressure chamber 25 A and a first centrifugal hydraulic pressure canceling chamber 25 B are defined by the first piston 23 . A first return spring 26 , which is configured to bias the first piston 23 in a direction in which the first piston 23 moves away from the plates 21 A, 21 B, is accommodated within the first centrifugal hydraulic pressure canceling chamber 25 B. Reference sign S denotes a seal member which seals up a gap between the first piston 23 and the first piston chamber 24 .
[0019] When a hydraulic pressure is supplied into the first hydraulic pressure chamber 25 A, the first piston 23 moves one stroke in the axial direction to thereby bring the plates 21 A, 21 B into press contact with one another (the first wet-type clutch C 1 : applied). On the other hand, when the hydraulic pressure within the first hydraulic pressure chamber 25 A decreases and a hydraulic pressure is supplied into the first centrifugal hydraulic pressure canceling chamber 25 B, the first piston 23 is caused to move away from the plates 21 A, 21 B by means of a biasing force of the first return spring 26 and a hydraulic pressure force within the first centrifugal hydraulic pressure canceling chamber 25 B to thereby release the plates 21 A, 21 B from the press contact state (the first wet-type clutch C 1 : released).
[0020] The second wet-type clutch C 2 includes a plurality of second outer plates 31 A which are spline fitted in the clutch hub 20 , a second clutch drum 32 which rotates together with the second transmission input shaft 12 B, a plurality of second inner plates 31 B which are disposed alternately between the second outer plates 31 A and which are spline fitted in the second clutch drum 32 , and a second cylindrical piston 33 which can press and contact both the plates 31 A, 31 B together in the axial direction.
[0021] The second piston 33 is accommodated slidably within a second annular piston chamber 34 which is defined within the clutch hub 20 , In this second piston chamber 34 , a second hydraulic pressure chamber 35 A and a second centrifugal hydraulic pressure canceling chamber 35 B are defined by the second piston 33 . A second return spring 36 , which is configured to bias the second piston 33 in a direction in which the second piston 33 moves away from the plates 31 A, 31 B, is accommodated within the second centrifugal hydraulic pressure canceling chamber 35 B. Reference sign S denotes a seal member which seals up a gap between the second piston 33 and the second piston chamber 34 .
[0022] When a hydraulic pressure is supplied into the second hydraulic pressure chamber 35 A, the second piston 33 moves one stroke in the axial direction to thereby bring the plates 31 A, 31 B into press contact with one another (the second wet-type clutch C 2 : applied). On the other hand, when the hydraulic pressure within the second hydraulic pressure chamber 35 A decreases and a hydraulic pressure is supplied into the second centrifugal hydraulic pressure canceling chamber 35 B, the second piston 33 is caused to move away from the plates 31 A, 31 B by means of a biasing force of the second return spring 36 and a hydraulic pressure within the second centrifugal hydraulic pressure canceling chamber 35 B to thereby release the plates 31 A, 31 B from the press contact state (the second wet-type clutch C 2 : released).
[0023] A hydraulic pressure circuit 40 has a first upstream supply line 43 which connects an oil pan 41 to a first solenoid valve 60 and a second upstream supply line 45 which branches off the first upstream supply line 43 to be connected to a second solenoid valve 65 . An oil pump OP, which is driven by the power of the engine E, is provided on a portion of the first upstream supply line 43 which lies upstream of the branch portion. A lubrication oil supply line 46 on which a throttle valve 47 is provided is connected to the second upstream supply line 45 .
[0024] A first downstream supply line 50 is connected to the first solenoid valve 60 . This first downstream supply line 50 branches into a first hydraulic pressure chamber line 50 A and a second canceling chamber line 50 B within the clutch hub 20 . A downstream end of the first hydraulic pressure chamber line 50 A is connected to the first hydraulic pressure chamber 25 A, and a downstream end of the second canceling chamber line 50 B is connected to the second centrifugal hydraulic pressure canceling chamber 35 B.
[0025] The first solenoid valve 60 is closed by means of a biasing force of a spring 61 when it is deenergized (OFF) and is energized (ON) to be opened by an electronic control unit, not shown. A hydraulic pressure is supplied into the first hydraulic pressure chamber 25 A and the second centrifugal hydraulic pressure canceling chamber 35 B when the first solenoid valve 60 is opened (ON). On the other hand, when the first solenoid valve 60 is closed (OFF), no hydraulic pressure is supplied into the first hydraulic pressure chamber 25 A and the second centrifugal hydraulic pressure canceling chamber 35 B, and the hydraulic pressures within the first hydraulic pressure chamber 25 A and the second centrifugal hydraulic pressure canceling chamber 35 B are returned to the oil pan 41 via a fluid return line 62 .
[0026] A second downstream supply line 51 is connected to a second solenoid valve 65 . This second downstream supply line 51 branches into a second hydraulic pressure chamber line 51 A and a first canceling chamber line 51 B within the clutch hub 20 . A downstream end of the second hydraulic pressure chamber line 51 A is connected to the second hydraulic pressure chamber 35 A, and a downstream end of the first canceling chamber line 51 B is connected to the first centrifugal hydraulic pressure canceling chamber 25 B.
[0027] The second solenoid valve 65 is closed by means of a biasing force of a spring 66 when the second solenoid valve 65 is deenergized (OFF) and is energized (ON) to be opened by the electronic control unit. When the second solenoid valve 65 is opened (ON), a hydraulic pressure is supplied into the second hydraulic pressure chamber 35 A and the first centrifugal hydraulic pressure canceling chamber 25 B. On the other hand, when the second solenoid valve 65 is closed (OFF), no hydraulic pressure is supplied into the second hydraulic pressure chamber 35 A and the first centrifugal hydraulic pressure canceling chamber 25 B, and the hydraulic pressures in the second hydraulic pressure chamber 35 A and the first centrifugal hydraulic pressure canceling chamber 25 B are returned to the oil pan 41 via a fluid return line 67 .
[0028] Next, the application and release of the dual clutch device 10 and the working effect thereof will be described based on FIGS. 2, 3 .
[0029] When transmitting power from the clutch input shaft 11 to the first transmission input shaft 12 A, as shown in FIG. 2 , the first wet-type clutch C 1 is applied (the first solenoid valve 60 : ON) and the second wet-type clutch C 2 is released (the second solenoid valve 65 : OFF).
[0030] When the first solenoid valve 60 is ON, since a hydraulic pressure is supplied not only to the first hydraulic pressure chamber 25 A but also to the second centrifugal hydraulic pressure canceling chamber 35 B, both the biasing force of the second return spring 36 and the hydraulic pressure within the second centrifugal hydraulic pressure canceling chamber 35 B are applied to the second piston 33 . As a result, for example, even though a failure such as disconnection or sticking is caused in the second solenoid valve 65 , the second piston 33 can be moved away from the plates 31 A, 31 B in an ensured manner, thereby making it possible to prevent a double meshing of the transmission in an ensured manner.
[0031] When transmitting power from the clutch input shaft 11 to the second transmission input shaft 12 B, as shown in FIG. 3 , the first wet-type clutch C 1 is released (the first solenoid valve 60 : OFF), and the second wet-type clutch C 2 is applied (the second solenoid valve 65 : ON).
[0032] When the second solenoid valve 65 is ON, since a hydraulic pressure is supplied not only to the second hydraulic pressure chamber 35 A but also to the first centrifugal hydraulic pressure canceling chamber 25 B, both the biasing force of the first return spring 26 and the hydraulic pressure within the first centrifugal hydraulic pressure canceling chamber 25 B are applied to the first piston 23 . As a result, for example, even though a failure such as disconnection or sticking is caused in the first solenoid valve 60 , the first piston 23 can be moved away from the plates 21 A, 21 B in an ensured manner, thereby making it possible to prevent a double meshing of the transmission in an ensured manner.
[0033] Next, how to set an optimal biasing force for the return springs 26 , 36 will be described based on FIG. 4 .
[0034] In FIG. 4 , R A1 denotes an outside diameter of the first piston 23 , R B1 an outside diameter of the first centrifugal hydraulic pressure canceling chamber 25 B, R A2 an outside diameter of the second piston 33 , R B2 an outside diameter of the second centrifugal hydraulic pressure canceling chamber 35 B, P a hydraulic pressure, F S1 a biasing force of the first return spring 26 , and F S2 a biasing force of the second return spring 36 . When these satisfy the following conditional expressions (1), (2), even though both the first and second solenoid valves 60 , 65 are switched ON at the same time, the first and second wet-type clutches C 1 , C 2 can be released in an ensured manner.
[0000] [Expression 1]
[0000] ( R A1 2 - R B1 2 )·π< F S1
[0000] [Expression 2]
[0000] ( R A2 2 - R B2 2 )·π< F S2
[0035] In this way, by setting the biasing force of the first return spring 26 greater than a difference in hydraulic pressure between the first hydraulic pressure chamber 25 A and the first centrifugal hydraulic pressure canceling chamber 25 B which is applied to the first piston 23 and setting the biasing force of the second return spring 36 greater than a difference in hydraulic pressure between the second hydraulic pressure chamber 35 A and the second centrifugal hydraulic pressure canceling chamber 35 B which is applied to the second piston 33 , the first and second wet-type clutches C 1 , C 2 are released in an ensured manner, thereby making it possible to prevent effectively the occurrence of a double meshing of the transmission.
[0036] The invention is not limited to the embodiment described heretofore but can be carried out by making modifications thereto as required without departing from the spirit and scope of the invention.
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A dual clutch device includes a first piston applying a first clutch by a hydraulic pressure supplied into a first hydraulic pressure chamber and releasing the first clutch by a first spring, a second piston applying a second clutch by a hydraulic pressure supplied into a second hydraulic pressure chamber and releasing the second clutch by a second spring, a first supply line supplying a hydraulic pressure into the first hydraulic pressure chamber and a second hydraulic pressure canceling chamber, a second supply line supplying a hydraulic pressure into the second hydraulic pressure chamber and a first hydraulic pressure canceling chamber, a first valve allowing or cutting the supply of hydraulic pressure into the first hydraulic pressure chamber and the second hydraulic pressure canceling chamber, and a second valve allowing or cutting the supply of hydraulic pressure into the second hydraulic pressure chamber and the first hydraulic pressure canceling chamber.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/878,792, filed Jun. 11, 2001, now issued as U.S. Pat. No. 6,770,628 B2, which is a continuation of U.S. patent application Ser. No. 09/304,199, filed May 3, 1999, now issued as U.S. Pat. No. 6,300,314 B1, which claims priority under 35 U.S.C. section 119(e) to U.S. Provisional Patent Application Ser. No. 60/084,128 filed May 4, 1998, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to methods and products for producing increased numbers of hematopoietic cells, of restoring to preselected normal levels numbers of hematopoietic cells, to therapies for treating deficiencies in hematopoietic cells and to in vitro methodologies for culturing hematopoietic cells.
PT-100 is a dipeptide consisting of valine-prolineboronic acid (ValboroPro) designed to interact with the cell surface receptor CD26. CD26, a type II transmembrane protein is expressed on the cell surface of a number of cell types, including lymphocytes (Marguet, D. et al., Advances in Neuroimmunol. 3:209–215 (1993)), hematopoietic cells (Vivier, I. et al., J. Immunol. 147:447–454 (1991); Bristol, et al., J. Immunol. 149:367 (1992)) thymocytes (Dang, N. H. et al., J. Immunol. 147:2825–2832 (1991), Tanaka, T. et al., J. Immunol. 149:481–486 (1992), Darmoul, D. et al., J. Biol. Chem. 267:4824–4833 (1992)), intestinal brush border membrane and endothelial cells. Cell surface associated CD26 is a sialoglycoprotein, with most of its mass on the outside of the cell.
CD26 has been best characterized on peripheral T cells where it functions as a potent costimulatory signal for T cell activation. Its surface expression is upregulated upon T cell activation (Dong, R. P. et al., Cell 9:153–162 (1996), Torimoto, Y. et al., J. Immunol. 147:2514 (1991), Mittrucker, H-W. et al., Eur. J. Immun. 25:295–297 (1995), Hafler, D. A. et al, J. Immunol. 142:2590–2596 (1989), Dang, N. H. et al., J. Immunol. 144:409 (1990)). CD26 has also been identified in rodents as an important regulatory surface receptor in hematopoiesis and lymphoid development (Vivier, I. et al., J. Immunol. 147:447–454 (1991)). The primary structure of CD26 is highly conserved between species (Ogata, S. et al., J. Biol. Chem. 264:3596–3601 (1998)). In humans CD26 seems to be involved in the regulation of thymocyte activation, differentiation and maturation (Dang, N. H. et al., J. Immunol. 147:2825–2832 (1991); Kameoka, J. et al., Blood 85:1132–1137 (1995)). We have evidence that CD26 is expressed within the human and murine hematopoietic systems.
CD26 is an ectoenzyme with activity identical to that of Dipeptidyl Peptidase IV (DPP-IV), a serine type exopeptidase with high substrate specificity. It cleaves N-terminal dipeptides from proteins if the penultimate amino acid is proline, or in some cases alanine (Fleischer, B. Immunol. Today 15:180 (1994)). PT-100 is a potent inhibitor of DPP-IV activity.
The prior art PCT published application WO94/03055 teaches methods of producing increased numbers of hematopoietic cells by administering inhibitors of DPP-IV. The teaching of this published application, however, is that dosages of at least 1 mg/kg body weight are necessary to achieve such hematopoietic cell increases. This published application also teaches that inhibitors are administered to mammals which have an established deficiency of hematopoietic cells. The teaching also suggests that cytokines be administered in conjunction with the inhibitors to increase the production of hematopoietic cells in a subject.
SUMMARY OF THE INVENTION
The invention is based upon a variety of surprising and unexpected findings. It has been discovered, unexpectedly, that the agents useful according to the invention stimulate growth factor production by stromal cells. It also has been discovered, unexpectedly, that the agents useful according to the invention stimulate proliferation of primitive hematopoietic progenitor cells, but do not stimulate directly the differentiation or proliferation of committed progenitor cells. It further has been discovered, unexpectedly, that the agents useful according to the invention can be administered at doses much lower than would have been expected according to the teachings of the prior art. Another unexpected finding is that the agents according to the invention can accelerate the time it takes to achieve hematopoietic cell recovery after treatment with an hematopoietic cell inhibitor. Another unexpected finding is that the agents useful according to the invention can at relatively low doses, restore normal levels of neutrophils at least as fast as the most successful commercially available product used worldwide for this purpose, except that the agents useful according to the invention can be used orally, whereas the commercially available product (which represents more than a billion dollar market) must be injected. These unexpected results have important therapeutic and experimental research implications.
According to one aspect of the invention, a method is provided for treating a subject to stimulate hematopoiesis in the subject. The invention involves administering to a subject in need of such treatment an amount of an agent effective to increase the number of hematopoietic cells or mature blood cells in the subject, wherein the amount is less than 1 mg/kg body weight per day and wherein the agent is a compound of Formula I.
The agents useful according to the invention are compounds of Formula I:
wherein m is an integer between 0 and 10, inclusive; A and A 1 are L-amino acid residues (for glycine there is no such distinction) such that the A in each repeating bracketed unit can be a different amino acid residue; the C bonded to B is in the L-configuration; the bonds between A and N, A 1 and C, and between A 1 and N are peptide bonds; and each X 1 and X 2 is, independently, a hydroxyl group or a group capable of being hydrolysed to a hydroxyl group in aqueous solution at physiological pH. By “the C bonded to B is in the L-configuration” is meant that the absolute configuration of the C is like that of an L-amino acid.
Thus, the
group has the same relationship to the C as the —COOH group of an L-amino acid has to its α carbon. In some embodiments, A and A 1 are independently proline or alanine residues; m is 0; X 1 and X 2 are hydroxyl groups; the inhibitor is L-Ala-L-boroPro; and the inhibitor is L-Pro-L-boroPro.
In one important aspect of the invention, the subject has an abnormally low level of hematopoietic cells or mature blood cells and the agent is administered in an amount effective to restore levels of a hematopoietic cell-type or mature blood cell-type to a preselected normal or protective level. The agent preferably is administered to the subject in at least 2 doses in an 18 hours period. The invention has particularly important applications in the restoration of normal or protective levels of neutrophils, erythrocytes and platelets. The most preferred agent is ValBoroPro.
According to another aspect of the invention, a method is provided for shortening or eliminating the time that a subject has an abnormally low level of hematopoietic or mature blood cells resulting from treatment with a hematopoietic cell inhibitor. An agent is administered to a subject in need of such treatment in an amount effective to increase the number of hematopoietic cells or mature blood cells in the subject, wherein the administration of the agent begins prior to or substantially simultaneous with administration of the hematopoietic cell inhibitor. The agents and the preferred agent are as described above. In one important embodiment, the hematopoietic cell inhibitor causes an abnormally low level of hematopoietic cells or mature blood cells in the subject and the agent is administered in an amount effective to restore levels of a hematopoietic cell type to a preselected normal or protective level. Preferably, the agent is administered to the subject in at least 2 doses in an 18 hour period. In important embodiments, the agent is used to restore in the subject normal or protective levels of neutrophils, erythrocytes or platelets. The preferred effective amount of agent is as described above.
According to another aspect of the invention, a method is provided for preparing a subject for treatment with a hematopoietic cell inhibitor. The method involves administering to the subject prior to the subject receiving the hematopoietic cell inhibitor an agent in an amount effective to stimulate in the subject production of growth factors. In one embodiment the agent stimulates stromal cell production of growth factor. The agents and the preferred agent are as described above. In one important embodiment, the growth factor is granulocyte colony stimulating factor. In other embodiments the growth factor is selected from the group consisting of IL-1, IL-2, IL-3, IL-4, IL-6, IL-11, IL-17, TPO, EPO, MCSF, GMCSF, FLT-3 Ligand and Stem Cell Factor. Preferably, the amount administered to the subject is less than 1 mg/kg body weight per day. It also is preferred that the administration of the agent be in at least 2 doses of the agent in an 18 hour period.
According to another aspect of the invention, a method is provided for treating a subject to increase the number of hematopoietic cells or mature blood cells in the subject. An agent is administered to a subject in need of such treatment in an amount effective to increase hematopoietic cells or mature blood cells in the subject, wherein the agent is administered in a first regimen consisting of 2 doses or 3 doses in an 18 hour period. The agents and the preferred agent are as described above. In one important embodiment, the agent is administered in a second regimen consisting of 2 doses or 3 doses in an 18 hours period, wherein the second regimen is separate in time from the first regimen. In another embodiment, the agent is administered in a third regimen consisting of 2 doses or 3 doses in an 18 hour period, wherein the third regimen is separate in time from the first and second regimens. In other embodiments, the agent is administered optionally in a fourth regimen, a fifth regimen, a sixth regimen, or a seventh regimen, wherein each of such regimens consists of 2 doses or 3 doses in an 18 hours period, and wherein the regimens are separate in time from one another and from the prior regimens. In one important embodiment, the subject has an abnormally low neutrophil count and the amount is effective to restore in the subject a preselected level of neutrophils. In other important embodiments the subject has abnormally low levels of erythrocytes and platelets. The preferred dosages, agents, and the like are as described above. In important embodiments, the dosage is no more than six regimens, no more than five regimens, no more than four regimens, no more than three regimens, and even no more than two regimens.
According to another aspect of the invention, a method is provided for preparing a subject's cells for reintroduction into the subject. The method involves treating the subject with an agent in an amount effective to stimulate in the subject the hematopoietic cells, then collecting the hematopoietic cells from the subject. The collected cells later are reintroduced into the subject. The collected cells optionally can be ex vivo cultured. The agents and preferred agent are as described above. In one embodiment, the ex vivo culturing is carried out in the presence of an amount of the agent effective to stimulate proliferation of the collected cells. In another embodiment, the concentration of the agent in medium surrounding the collected cells is less than 10 −8 moles per liter, and less than 10 −9 moles per liter and even less than 10 −10 moles per liter.
According to another aspect of the invention, a method is provided for stimulating growth factor production by stromal cells. The method involves contacting the stromal cells with an agent in an amount effective to stimulate growth factor production by the stromal cells. The agents and the preferred agent are as described above. In one embodiment, the stromal cells are in an in vitro layer of stromal cells for supporting early progenitor cell growth and further comprising culturing the stem cells in the presence of these stromal cells. In another embodiment, the stromal cells are in vivo in a subject. In another embodiment, the growth factor is granulocyte colony stimulating factor. In other embodiments the growth factor is selected from the group consisting of IL-1, IL-2, IL-3, IL-4, IL-6, IL-11, IL-17, TPO, EPO, MCSF, GMCSF, FLT-3 Ligand and Stem Cell Factor. In an in vivo embodiment, the agent is administered to a subject in an amount less than 1 mg/kg body weight per day. In still another embodiment, the stem cells are cultured in an environment free of exogenously added granulocyte colony stimulating factor. In important embodiments the stromal cells are bone marrow or thymic stromal cells.
According to another aspect of the invention, a kit is provided for treating a subject having an abnormally low level of hematopoietic cells resulting from treatment with a hematopoietic cell inhibitor or for treating prophylactically a subject being treated with a hematopoietic cell inhibitor to prevent decrease or loss of hematopoietic and/or mature blood cells. The kit is a package containing a first dosage and instructions for treating a subject substantially simultaneous with or prior to treatment with the hematopoietic cell inhibitor. The package also contains a second dosage and instructions for treating a subject only after treatment with the hematopoietic cell inhibitor. The dosages are in effective amounts and the agents and preferred agent are as described above. In one embodiment, the second dosage is between 2 and 5 regimens, each of the regimens consisting of 2 or 3 doses per day of the agent. In one embodiment, the combination of the doses is less than 1 mg/kg body weight per day. One preferred kit is for treatment of neutropenia. Other preferred kits are for treatment of an abnormally low level of erythrocytes or platelets.
According to still another aspect of the invention, a kit is provided for treating a subject having abnormally low level of hematopoietic cells. The kit is a package containing a complete dosage for restoring normal levels of a hematopoietic cell type. The package consists essentially of: (1) a first dosage in an effective amount for administration to the subject during a first day, (2) a second dosage in an effective amount for administration to the subject during a second day, (3) optionally, a third dosage in an effective amount for administration to the subject during a third day, (4) optionally, a fourth dosage in an effective amount for administration to the subject during a fourth day, (5) optionally, a fifth dosage in an effective amount for administration to the subject during a fifth day, (6) optionally, a sixth dosage in an effective amount for administration to the subject during a sixth day and (7) optionally, a seventh dosage in an effective amount for administration to the subject during a seventh day. The agents and preferred agent are as described above. In one important embodiment, each of the dosages consists of 2 or 3 doses of the agent for administration each day. Preferred doses and dosages are as described above. In important embodiments, the kit consists essentially of less than 5, less than 4, and less than 3 and even less than 2 dosages.
These and other aspects of the invention will be described in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a medicinal package for administering a 5 day medicinal course of treatment for treating myelosuppression or anemia resulting from cancer chemotherapy.
FIG. 2 is a graph depicting the regeneration of neutrophils in cyclophosphamide-treated mice. PT-100 at indicated doses or saline administered by gavage. Absolute neutrophil counts in mice not treated with cyclophosphamide are on the average 190×10 4 cells/ml as indicated by the dashed horizontal line.
FIG. 3 is a graph depicting the regeneration of neutrophils in cyclophosphamide-treated mice in response to subcutaneous administration of PT-100. Saline or PT-100 were administered b.i.d. for 5 consecutive days. The average absolute neutrophil count in mice not treated with cyclophosphamide was 185×10 4 cells/ml as indicated by the horizontal dashed line.
FIG. 4 is a graph depicting the regeneration of neutrophils in cyclophosphamide-treated mice in response to PT-100 and granulocyte colony stimulating factor. PT-100 in saline was administered by gavage, and GCSF by subcutaneous injections, for 5 days. Absolute neutrophil count in mice not treated with cyclophosphamide are on average 190×10 4 cells/ml as indicated by the dashed horizontal line.
FIG. 5 is a graph depicting the effect of PT-100 dose number on the regeneration of neutrophils in cyclophosphamide-treated mice. PT-100, at indicated concentrations, was administered either once or twice per day subcutaneously for 5 days. The average absolute neutrophil count for mice not treated with cyclophosphamide was 200×10 4 cells/ml as indicated by the dashed horizontal line.
FIG. 6 is a graph depicting the effect of duration of PT-100 administration on absolute neutrophil count and rate of neutrophil recovery in cyclophosphamide-treated mice. PT-100 (5 μg/b.i.d.) was administered to cyclophosphamide-treated mice by gavage for the indicated length of time. The dashed horizontal line indicates the average absolute neutrophil count for mice not treated with cyclophosphamide.
FIG. 7 is a graph showing the effect of duration of PT-100 treatment on the regeneration of neutrophils in cyclophosphamide-treated mice. PT-100 (2 μg/b.i.d.), or saline were administered by gavage for the indicated duration. The average absolute neutrophil count for mice not treated with cyclophosphamide was 0.1 94×10 4 cells/ml as shown by the dotted line.
FIG. 8 is a graph depicting the colony formation ability of cells in response to PT-100 in a long-term culture (LTC) assay. Human bone marrow cells were incubated in LTC for 4 weeks in the absence or presence of indicated amounts of PT-100, followed by a 2 week culture in semi-solid medium.
FIG. 9 is a graph showing that PT-100 stimulates hematopoiesis in the spleen of normal mice.
FIG. 10 is a graph showing that PT-100 stimulates production of G-CSF by human stromal cells.
DETAILED DESCRIPTION OF THE INVENTION
The invention involves the stimulation of proliferation, differentiation and mobilization of hematopoietic cells. The invention is useful whenever it is desirable to stimulate the proliferation or differentiation, of or to mobilize, hematopoietic cells. Mobilization of hematopoietic cells is characterized by the enrichment of early progenitor cells in the bone marrow and the recruitment of these cells to the periphery in response to a mobilization agent (e.g. G-CSF, GM-CSF, etc.). The agents useful according to the invention can be used to inhibit hematopoietic cell deficiencies or to restore hematopoietic and mature blood cell count in subjects with such deficiencies. Such agents also may be used in connection with hematopoietic cell transplants, such as bone marrow or peripheral blood transplants, when used to replenish or create an immune system in a subject. The agents further can be used as an immune booster. The agents also are useful in vitro in connection with the culturing of cells for therapeutic and research uses.
As used herein, subject means humans, nonhuman primates, dogs, cats, sheep, goats, horses, cows, pigs and rodents.
One important aspect of the invention involves restoring or preventing a deficiency in hematopoietic cell number in a subject. Such deficiencies can arise, for example, from genetic abnormalities, from disease, from stress, from chemotherapy (e.g. cytotoxic drug treatment, steroid drug treatment, immunosuppressive drug treatment, etc.) and from radiation treatment.
The invention is useful in general to restore deficiencies created by hematopoietic cell inhibitors. A hematopoietic cell inhibitor is an exogenously-applied agent (such as a drug or radiation treatment) which causes a decrease in the subject of hematopoietic cells and/or mature blood cells.
Hematopoietic cells as used herein refer to granulocytes (e.g. promyelocytes, neutrophils, eosinophils and basophils), erythrocytes, reticulocytes, thrombocytes (e.g. megakaryoblasts, platelet-producing megakaryocytes and platelets), lymphocytes, monocytes, dendritic cells and macrophages. Mature blood cells consist of mature lymphocytes, platelets, erythrocytes, reticulocytes, granulocytes and macrophages. In certain important aspects of the invention, the agents useful according to the invention increase the number of neutrophils, erythrocytes and platelets. In connection with neutrophils, the agents may be used to treat, inter alia, drug or radiation-induced neutropenia, chronic idiopathic neutropenia and cyclic neutropenia.
One important aspect of the invention is restoring in a subject “normal” or “protective” hematopoietic cell levels. A “normal” level as used herein can be a level in a control population, which preferably includes subjects having similar characteristics as the treated individual, such as age. The “normal” level can also be a range, for example, where a population is used to obtain a baseline range for a particular group into which the subject falls. The population can also be divided into groups, such as into quadrants, with the lowest quadrant being individuals with the lowest levels of hematopoietic cells and the highest quadrant being individuals having the highest levels of hematopoietic cells. Thus, the “normal” value can depend upon a particular population selected. Preferably, the normal levels are those of apparently healthy subjects which have no prior history of hematopoietic cell disorders. Such “normal” levels, then can be established as preselected values, taking into account the category in which an individual falls. Appropriate ranges and categories can be selected with no more than routine experimentation by those of ordinary skill in the art. Either the mean or another preselected number within the range can be established as the normal preselected value. Likewise, the level in a subject prior to treatment with a hematopoietic cell inhibitor can be used as the predetermined value.
In general, the normal range for neutrophils is about 1800–7250 per μl (mean −3650); for basophils 0–150 per μl (mean −30); for eosinophils 0–700 per μl (mean −150); for macrophages and monocytes 200–950 per μl (mean −430); for lymphocytes 1500–4000 per μl (mean −2500); for erythrocytes 4.2×10 6 –6.1×10 6 per μl; and for platelets 133×10 3 –333×10 3 per μl. The foregoing ranges are at the 95% confidence level.
In connection with certain conditions, the medical community has established certain preselected values. For example, mild neutropenia is characterized as having a count of between 1000 and 2000 per μl, moderate neutropenia at between 500 and 1000 per μl and severe neutropenia at below 500 per μl. Likewise, in adults, a lymphocyte count at less than 1500 is considered a medically undesirable condition. In children the value is less than 3000. Other preselected values will be readily known to those of ordinary skill in the art. The agents useful according to the invention can be used to establish or to re-establish such preselected values, including normal levels.
Protective levels of hematopoietic cells is the number of cells required to confer clinical benefit to the patient. The required levels can be equal to or less than the “normal levels”. Such levels are well known to those of ordinary skill in the art. For example, a protective level of neutrophils is above 1000, preferably, at least 1500.
According to another aspect of the invention, the agents useful herein can be applied at doses below those which were described in the prior art. In particular, it has been discovered unexpectedly that the agents of the invention can be administered in doses less than 1 mg/kg body weight per day. In particular, the agents of the invention have been used successfully at levels of 0.1 mg/kg body weight per day, which is one order of magnitude below the teachings of the prior art. As will be readily recognized by those of ordinary skill in the art, this has advantages in that less material is required for treatment, thereby lessening any risk of side effects. Likewise, this has advantages in connection with the cost of manufacture of the drug products of the invention.
According to another aspect of the invention, better therapeutic results can be achieved when the agents are applied in multiple doses per day. This finding is unexpected and, additionally, it has been found that there is no added medically useful effect when the agents useful according to the invention are administered for lengthy periods of time. Thus, it has been discovered, unexpectedly, that only very brief periods of treatment are needed to achieve established therapeutic goals.
As described in the examples below, subjects treated with the agents useful according to the invention in 2 doses per day versus 1 dose per day achieved recovery of hematopoietic cells almost 33% faster than subjects receiving only 1 dose per day. Surprisingly, this result did not depend upon the absolute amount of drug given to the subject, but instead related to the number of times the subject was administered the drug. In other words, as shown below, giving twice as much drug, but only once a day, did not speed the recovery of hematopoietic cell number. Thus, an aspect of the invention involves giving the agents useful according to the invention in 2 or 3 doses in an 18 hour period. As used herein, an 18 hour period refers in general to the time during which a subject is awake in any 24 hour period; it is intended to indicate 2 doses per day, 3 doses per day, and the like.
According to still another aspect of the invention, it has been discovered unexpectedly that the agents useful according to the invention need be administered for fewer days than expected according to the prior art. In particular, in the mouse models employed, there was very little difference in the speed of recovery of hematopoietic cell count and in the ability to reestablish normal levels of hematopoietic cells when treatment was 3 days, versus 4 days, versus 5 days. It is believed, therefore, that when applied to humans, a complete drug treatment will involve 7 days or less, more preferably 6 days or less, more preferably 5 days or less, more preferably 4 days or less, and even more preferably 3 days or less. As a result, the invention therefore provides kits which contain complete treatment packages for restoring hematopoietic cell count, which kits are described in greater detail below.
According to another aspect of the invention, the time that a subject has an abnormally low level of hematopoietic cells resulting from treatment with a hematopoietic cell inhibitor is shortened. It has been discovered, unexpectedly, that the agents used according to the invention stimulate growth factor production by stromal cells. For example, granulocyte colony stimulating factor (GCSF) production by stromal cells is stimulated. GCSF acts to drive specifically neutrophil-lineage differentiation. It does not affect the differentiation or proliferation of other committed hematopoietic cells, including other granulocytes, such as eosoniphils, basophils, mast cells and macrophages. (It is known to act synergistically, however, in vitro with other cytokines to affect proliferation of pluripotent stem cells, though the in vivo importance of this observation is not known). Because stromal cells are not rapidly dividing cells and are not generally adversely impacted by hematopoietic cell inhibitors, the agents useful according to the invention can be applied to subjects substantially simultaneously with or even prior to treatment with a hematopoietic cell inhibitor in order to stimulate stromal cells to produce growth factor which will be readily abundant and helpful in regenerating the hematopoietic cells after treatment by the hematopoietic cell inhibitor. In the prior art, such treatment has been delayed until substantially after treatment with the hematopoietic cell inhibitor. Substantially simultaneously with, as used herein, means within 24 hours of treatment with the hematopoietic cell inhibitor. Preferably, the agents useful according to the invention are administered within 2 hours of treatment with the hematopoietic cell inhibitor, if they are administered after treatment with the hematopoietic cell inhibitor. If they are administered before treatment with the hematopoietic cell inhibitor, then they are administered close enough in time to the treatment with the inhibitor so that stromal cell production of growth factor is enhanced in the days immediately following treatment with the hematopoietic cell inhibitor.
Another aspect of the invention involves treatment of a subject to prepare a subject for subsequent treatment with other agents. It has been discovered, unexpectedly, that the agents useful according to the invention stimulate the proliferation of primitive, noncommitted hematopoietic progenitor cells, but not directly the differentiation of committed progenitor cells. It is known in the art that such cells may or may not include CD34 + cells. CD34 + cells are immature cells present in blood products, express the CD34 cell surface marker, and are believed to include a subpopulation of cells with the capacity to self-renew and to differentiate into all of the mature blood cell types. Because the agents useful according to the invention stimulate the proliferation of such self-renewing cells, the invention is useful to prepare a subject for treatment with other exogenous growth factors and cytokines which in turn result in the differentiation of such uncommitted progenitor cells into committed progenitor cells. Likewise, the agents useful according to the invention can be administered to a subject to expand in the subject hematopoietic cells and to mobilize such cells, prior to extracting the cells from the subject for transplantation or re-infusion. Such cells may be used for research purposes or can be treated ex vivo or reintroduced into the subject with or without expansion in vitro.
The agents useful according to the invention can be administered in conjunction with exogenous growth factors and cytokines which are specifically selected to achieve a particular outcome. For example, if it is desired to stimulate a particular hematopoietic cell type, then growth factors and cytokines which stimulate proliferation and differentiation of such cell type are used. Thus, it is known that interleukins-1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 and 17 are involved in lymphocyte differentiation. Interleukins 3 and 4 are involved in mast cell differentiation. Granulocyte macrophage colony stimulating factor (GMCSF), interleukin-3 and interleukin-5 are involved in the eosinophil differentiation. GMCSF, macrophage colony stimulating factor (MCSF) and IL-3 are involved in macrophage differentiation. GMCSF, GCSF and IL-3 are involved in neutrophil differentiation. GMSCF, IL-3, IL-6, IL-11 and TPO are involved in platelet differentiation. Flt3 Ligand is involved in dendritic cell growth. GMCSF, IL-3, and erythropoietin are involved in erythrocycte differentiation. Finally, the self-renewal of primitive, pluripotent progenitor cells capable of sustaining hematopoiesis requires SCF, Flt3 Ligand, G-CSF, IL-3, IL-6 and IL-11. Various combinations for achieving a desired result will be apparent to those of ordinary skill in the art. Because the agents useful according to the invention stimulate primitive, non-committed hematopoietic progenitor cells, they can be used in connection with any of the foregoing categories of agents to stimulate specifically the proliferation of a particular hematopoietic cell type. The foregoing factors are well known to those of ordinary skill in the art, and most are commercially available.
The invention also lends itself to a variety of in vitro uses. Hematopoietic progenitor cells are preserved or expanded, or their colony forming unit potential increased, in vitro. One benefit that can be obtained according to the invention is the stimulation of hematopoietic progenitor cells by the agents useful according to the invention. Another benefit that can be obtained is the effect that the agent can have on stromal cells used in in vitro culturing of hematopoietic progenitor cells. In vitro culturing of hematopoietic cells is often carried out in the presence of stromal cells. Hematopoietic progenitor cells typically will not survive, proliferate or differentiate for very long periods of time in vitro without appropriate growth factor support.
Stromal cell layers are used to supply such growth agents to cultured hematopoietic cells, either by culturing the hematopoietic progenitor cells in vitro with such stromal cells or by supplying the hematopoietic progenitor cells with stromal cell-conditioned medium. The agents useful according to the present invention can be used to treat such stromal cells to cause the stromal cells to manufacture and release growth factors. The incubation of stromal cells with the agents useful according to the invention and in medium is for a period of time sufficient to allow the stromal cells to secrete factors into the medium. The medium then can be used to supplement the culture of hematopoietic progenitor cells and other hematopoietic cells.
The culture of hematopoietic cells is with media which is conventional for culturing cells. Examples include RPMI, DM, ISCOVES, etc. The conditions for such culturing also are known to those of ordinary skill in the art. The conditions typically refer to a combination of parameters (e.g. temperature, CO 2 and O 2 content, nutritive media, etc.). The time sufficient to increase the number of cells is a time that can be easily determined by a person skilled in the art, and can vary depending on the original number of cells seeded and the amount added of growth factors and agents useful according to the invention.
The colony forming potential of hematopoietic uncommitted progenitor cells can be increased by in vitro culturing of hematopoietic cells. The cells can be obtained from any blood product or organ containing cells of hematopoietic origin. Crude or unfractionated blood products can be enriched for cells having hematopoietic progenitor cell characteristics in ways well known to those of ordinary skill in the art, prior to or after culture with the agents useful according to the invention.
A particularly important aspect of the invention is in the use of the agents for treatment of neutropenia. A combination of unexpected results makes the invention particularly useful in the treatment of neutropenia. Firstly, the agents according to the invention can stimulate the proliferation of uncommitted progenitor cells. Secondly, the agents according to the invention also stimulate stromal cells to make GCSF, which is the growth factor critical in the differentiation and production of neutrophils per se. Thus, the patient has the dual benefit of stimulation of progenitor cells and differentiation of those cells into neutrophils using the agents useful according to the invention. Similar effects are shown with erythrocytes and platelets. Thus, treatment to restore neutrophils, erythrocytes and platelets form an independent and distinct aspect of the invention, based on the unexpected findings described above.
The invention also involves kits for housing an entire medicinal course of treatment for a hematopoietic cell deficiency such as neutropenia. As discussed above, it has been discovered surprisingly that the number of doses per day and the number of doses overall affect favorably the recovery of hematopoietic cells after treatment with a hematopoietic cell inhibitor. These unexpected findings lend themselves to the development of a medicinal dispenser which houses an entire medical course of treatment using the agents useful according to the invention. Patient compliance therefore will be enhanced, and an entire prescription can be contained in a single package. Ordinarily, a pharmacist individually fills a dispenser unit with a medicament once the pharmacist receives a doctor's prescription. Because the dispenser of the invention includes an entire medicinal course of treatment and can always include a specific number of solid oral dosage forms, the package can be pre-filled with the appropriate number of units of medicament for treatment for a particular medical purpose.
The medicinal dispenser is a package defining a plurality of medicinal storage compartments, each compartment for housing an individual unit of medicament. An entire medicinal course of treatment is housed in a plurality of medicinal storage compartments.
A package defining a plurality of medicinal storage compartments may be any type of disposable pharmaceutical package or card which holds medicaments in individual compartments. Preferably the package is a blister package constructed from a card, which may be made from stiff paper material, a blister sheet and backing sheet. Such cards are well known to those of ordinary skill in the art.
FIG. 1 shows a medicinal dispenser ( 1 ) for housing a preferred entire medicinal course of treatment for neutropenia. The day indicia ( 2 ) indicate which day the individual units of medicament are to be taken. These are marked along a first side of the medicinal package. The dose indicia ( 3 ) is marked along a second side of the medicinal package perpendicular to the first side of the medicinal package and indicates the time which the individual unit of medicament should be taken. The unit doses ( 4 ) are contained in the dispenser which is a blister pack. This particular package shows a 5 day course of treatment, with 2 doses per day.
The pharmaceutical preparations, as described above, are administered in effective amounts. The effective amount will depend upon the mode of administration, the particular condition being treated and the desired outcome. It will also depend upon, as discussed above, the stage of the condition, the age and physical condition of the subject, the nature of concurrent therapy, if any, and like factors well known to the medical practitioner. For therapeutic applications, it is that amount sufficient to achieve a medically desirable result. In some cases this is any increase in hematopoietic cell count or mature blood cell count. In other cases, it will be an increase to a preselected level.
The invention is useful in one aspect to ameliorate the effects of treatment with a hematopoietic cell inhibitor. If the agents are used prophylactically, they can decrease the amount of hematopoietic cells that would be lost in the subject versus the amount lost if the subject were treated with the inhibitor but not with the agent. If used prophylactically or acutely, the agents can shorten the time for recovery of a hematopoietic cell-type to at least protective levels, and preferably to normal levels, versus the length of time which would pass before protective or normal levels were achieved if the subject were treated with the inhibitor but not with the agent.
Generally, doses of active compounds of the present invention would be from about 0.01 mg/kg per day to less than 1 mg/kg per day. A variety of administration routes are available. The methods of the invention, generally speaking, may be practiced using any mode of administration that is medically acceptable, meaning any mode that produces effective levels of the active compounds without causing clinically unacceptable adverse effects. Such modes of administration include oral, rectal, topical, nasal, interdermal, or parenteral routes. The term “parenteral” includes subcutaneous, intravenous, intramuscular, or infusion. Intravenous or intramuscular routes are not particularly suitable for long-term therapy and prophylaxis. They could, however, be preferred in emergency situations. Oral administration is preferred for the convenience to the patient as well as the dosing schedule. See Remington's Pharmaceutical Sciences, 18th edition, 1990, pp 1694–1712; incorporated by reference). Those of skill in the art can readily determine the various parameters and conditions for producing dosages without resort to undue experimentation.
Compositions suitable for oral administration may be presented as discrete units, such as capsules, tablets, lozenges, each containing a predetermined amount of the active agent. Other compositions include suspensions in aqueous liquids or non-aqueous liquids such as a syrup, elixir or an emulsion.
Preparations for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers (such as those based on Ringer's dextrose), and the like. Preservatives and other additives may also be present such as, for example, antimicrobials, anti-oxidants, chelating agents, and inert gases and the like. Lower doses will result from other forms of administration, such as intravenous administration. In the event that a response in a subject is insufficient at the initial doses applied, higher doses (or effectively higher doses by a different, more localized delivery route) may be employed to the extent that patient tolerance permits. Multiple doses per day are contemplated.
The agents may be combined, optionally, with a pharmaceutically-acceptable carrier. The term “pharmaceutically-acceptable carrier” as used herein means one or more compatible solid or liquid filler, diluents or encapsulating substances which are suitable for administration into a human. The term “carrier” denotes an organic or inorganic ingredient, natural or synthetic, with which the active ingredient is combined to facilitate the application. The components of the pharmaceutical compositions also are capable of being co-mingled with the molecules of the present invention, and with each other, in a manner such that there is no interaction which would substantially impair the desired pharmaceutical efficacy.
When administered, the pharmaceutical preparations of the invention are applied in pharmaceutically-acceptable amounts and in pharmaceutically-acceptably compositions. Such preparations may routinely contain salt, buffering agents, preservatives, compatible carriers, and optionally other therapeutic agents. When used in medicine, the salts should be pharmaceutically acceptable, but non-pharmaceutically acceptable salts may conveniently be used to prepare pharmaceutically-acceptable salts thereof and are not excluded from the scope of the invention. Such pharmacologically and pharmaceutically-acceptable salts include, but are not limited to, those prepared from the following acids: hydrochloric, hydrobromic, sulfuric, nitric, phosphoric, maleic, acetic, salicylic, citric, formic, malonic, succinic, and the like. Also, pharmaceutically-acceptable salts can be prepared as alkaline metal or alkaline earth salts, such as sodium, potassium or calcium salts.
Other delivery systems can include time-release, delayed release or sustained release delivery systems. Such systems can avoid repeated administrations of the agent, increasing convenience to the subject and the physician. Many types of release delivery systems are available and known to those of ordinary skill in the art. They include polymer base systems such as poly(lactide-glycolide), copolyoxalates, polycaprolactones, polyesteramides, polyorthoesters, polyhydroxybutyric acid, and polyanhydrides. Microcapsules of the foregoing polymers containing drugs are described in, for example, U.S. Pat. No. 5,075,109. Delivery systems also include non-polymer systems that are: lipids including sterols such as cholesterol, cholesterol esters and fatty acids or neutral fats such as mono- di- and tri-glycerides; hydrogel release systems; sylastic systems; peptide based systems; wax coatings; compressed tablets using conventional binders and excipients; partially fused implants; and the like. Specific examples include, but are not limited to: (a) erosional systems in which the agent is contained in a form within a matrix such as those described in U.S. Pat. Nos. 4,452,775, 4,667,014, 4,748,034 and 5,239,660 and (b) difusional systems in which an active component permeates at a controlled rate from a polymer such as described in U.S. Pat. Nos. 3,832,253, and 3,854,480. In addition, pump-based hardware delivery systems can be used, some of which are adapted for implantation.
Use of a long-term sustained release implant may be particularly suitable for treatment of chronic conditions. Long-term release, are used herein, means that the implant is constructed and arranged to delivery therapeutic levels of the active ingredient for at least 30 days, and preferably 60 days. Long-term sustained release implants are well-known to those of ordinary skill in the art and include some of the release systems described above.
EXAMPLES
We have demonstrated in a series of in vivo studies that the agent ValboroPro (PT-100), has the ability to shorten myelosuppression caused by chemotherapy in mice. In these studies, mice were injected intraperitoneally with a sublethal dose of 220 mg/kg cyclophosphamide (Day 1). This treatment reproducibly induced a nadir in blood cell counts by Day 4. After 72 hours (Day 3) mice were divided into 3 groups. One group received PT-100, at the concentrations indicated, by gavage or by subcutaneous administration (s.c.), one group received G-CSF by s.c. injections and the third group received saline as a control, either by oral gavage or by s.c. injections. G-CSF was used at 0.04 ug/dose (4 μg/kg/day) which is the dose frequently used in published reports studying the G-CSF effects in mice and is also the equivalent dose used in cancer patients. All administrations were performed twice daily (b.i.d.) for 5 consecutive days or as indicated. Blood samples were taken from individual mice on Day 4–8, and in some experiments on Days 13 or 17. At each time pont four or five test animals were sampled. Total and differential white blood cell counts of Gimsa-stained blood smears were performed.
PT-100 Dose Response for Regeneration of Neutrophil
For data presented in FIG. 2 , cyclophosphamide treated mice received 0.1 μg, 2 μg or 5 μg/b.i.d. of PT-100 or saline by oral gavage twice daily for 5 consecutive days starting on Day 3 post cyclophosphamide treatment and continuing through Day 7. In mice that received 2 or 5 μg/b.i.d. PT-100 recovery of neutrophils reproducibly preceded recovery of saline treated mice by 1 or 2 days, while 0.1 μg/b.i.d. of PT-100 did not significantly enhance neutrophil recovery over saline. Normal levels of absolute neutrophil counts (ANC) were reached on Day 5 for mice receiving 2 μg or 5 μg/b.i.d. of PT-100, while saline treated mice did not reach normal levels until Day 7. On Day 5 mice had received a total of 4 doses of PT-100 (on Days 3 and 4). Additional administration of PT-100 on Days 5, 6 and 7 caused a further increase in ANC.
The effect of PT-100 on neutrophil recovery when administered by s.c. route was very similar to that seen when administered orally. For data shown in FIG. 3 mice were injected s.c. with doses of PT-100 ranging from 1 to 20 μg/b.i.d. for 5 days and blood cell counts determined on Days 4 through 8, and on Day 17. For mice receiving 5 μg, 10 μg, or 20 μg/b.i.d. PT-100, neutrophil recovery was accelerated over that observed in the saline treated mice. A dose of 1 μg/b.i.d. PT-100 did not show much effect. After termination of treatment with PT-100. In conclusion, PT-100 accelerates neutrophil regeneration in cyclophosphamide treated mice.
Comparison of PT-100 and G-SCF Effects on Neutrophil Regeneration
G-CSF is currently used to accelerate neutrophil recovery in cancer patients undergoing chemotherapy. The effects of G-CSF in mice are well established and can be used as a reference for elucidating the mechanism by which PT-100 stimulates hematopoiesis in mice. FIG. 4 shows data from an experiment in which the effects of PT-100 and G-CSF on neutrophil regeneration are compared. Cyclophosphamide treated mice were administered 2 μg/b.i.d. of PT-100 by gavage or 0.04 μg/b.i.d. of G-CSF (the dose equivalent used in patients and most commonly used in published reports for murine studies) by subcutaneous injections for 5 consecutive days starting on Day 3. Blood cell counts were performed on Days 4–8, and on Day 13.
PT-100 and G-CSF treated mice stimulated neutrophil regeneration to a similar level during the treatment period. After treatment was stopped, ANC decreased to normal counts by Day 13. Although PT-100 has a very similar effect on neutrophil reconstitution, the mechanism of action is different from that of G-CSF. Not only does PT-100 target a different cellular receptor (CD 26), it also has been shown to stimulate growth of early human hematopoietic progenitor cells which are not affected by G-CSF.
Dose Numbering of PT-100 Administration
To determine the dose numbering of administration for optimal recovery of neutrophils, PT-100, at indicated doses, was administered s.c. to cyclophosphamide treated mice, either once or twice per day over a five day period, starting on Day 3 post cyclophosphamide treatment. As shown in FIG. 5 , for both doses, a twice daily administration resulted in a faster rate of neutrophil recovery to higher neutrophil levels than once per day administration.
Duration of PT-100 Administration
In the experiments described above mice had been treated with PT-100 for 5 consecutive days. To determine whether a shorter period of treatment with PT-100 was sufficient for the recovery of neutrophils 5 μg, 2 μg, or 1 μg/b.i.d. (six hours apart) of PT-100 was administered to cyclophosphamide treated mice by gavage for 1, 2, 3, or 5 days starting on Day 3 post cyclophosphamide treatment. Blood counts were obtained on days 4 through 8.
Administration of PT-100 for one day was sufficient to cause an accelerated reconstitution of neutrophils over saline treated animals. However, additional administrations of PT-100 for 2 or 3 days increased the rate of recovery even further. Data for the 5 μg dose are shown in FIG. 6 .
Continued administration of PT-100 for a total of 4 or 5 days does not significantly increase the rate of neutrophil recovery or the ANC over that achieved with 3 day administrations (data for 2 μg/b.i.d. are shown in FIG. 7 ).
Results shown in FIGS. 6 and 7 indicate that the PT-100 effect on the regeneration of neutrophils occurs early during treatment and continues until ANC between 1000 and 1400 are achieved. Repeated administrations affect the kinetics of neutrophil restoration during the early period but does not significantly alter the ANC reached after 3 days of administration.
In conclusion, PT-100 accelerates neutrophil reconstitution over that seen with saline even after a one day of treatment. An accelerated reconstitution of neutrophils is obtained with each additional day of treatment for up to three days. A fourth or fifth day of treatment did not significantly increase ANC or the kinetics of reconstitution.
Human Hematopoietic Cell Responses In Vitro
Hematopoiesis is sustained by a pool of hematopoietic stem cells (HSCs) that can self-renew and differentiate into hematopoietic progenitor cells (HPCs). HPCs are committed to specific lineages which can be identified based on their colony morphology when grown in semi-solid media in vitro, typically over a 2 week period. The colonies grown in the semi-solid colony assay are functionally defined as colony- or burst-forming units and include BFU-E and CFU-E (cells committed to the erythroid lineage), CFU-GM (cells committed to the granulocytic/monocytic lineage), BFU-MK and CFU-MK (cells committed to the megakaryocyte lineage) and CFU-GEMM (multipotent progenitors). Although the semi-solid colony assay is a valuable tool to identify factors, such as G-C SF, which affect terminal differentiation, it does not assess the proliferative potential or self renewing properties of the primitive hematopoietic progenitor cells (PHPCs) (Dexter, T. A. et al., Acta Hemat. 62:299–305 (1979); Chen, B. P. et al., Immunological Reviews: 157:41–51 (1997)).
An assay to evaluate the effect of a compound or of growth factors on PHPCs was first described by Dexter (Dexter T. M. et al, J. Cell. Physiol. 91:335–344 (1977)), and combines the Long-Term Culture (LTC) with the semi-solid colony assay. LTC is initiated over a pre-formed stromal cell layer which provides the necessary hematopoietic growth factors. It has been used extensively for the in vitro examination of murine and human hematopoiesis and to evaluate the ability of test compounds to generate LTC-ICs.
The effect of PT-100 on growth of human hematopoietic cells was examined in the 2 week CFU and the 4 and 5 week LTC assays using human bone marrow, apheresed peripheral blood or umbilical cord blood cells. PT-100 did not stimulate the generation of CFUs in the 2 week semi-solid assay, indicating that PT-100 does not affect the differentiation of committed progenitor cells into mature blood cells. It also suggests, that the mechanism and the cellular targets for PT-100 for the stimulation of neutrophil regeneration in vivo is different from that of G-CSF which has been shown to stimulate CFU formation in this assay. In the LTC assays, which test for effects on early progenitor cells, PT-100 significantly increased the growth of very early progenitor cells from all three cell sources. Moreover, the data suggest that the effect of PT-100 is on PHPCs as increases in LTC-ICs were observed at 4 weeks ( FIG. 8 ) 5 weeks and 6 weeks (data not shown) in culture. At this time less primitive hematopoietic progenitor cells have undergone terminal differentiation and lost the ability to form colonies in semi-solid cultures.
For the LTC assays, CD34 + cells were isolated by positive selection from human bone marrow cells, apheresed peripheral blood or umbilical cord blood using a MAC separation system. To establish a stromal feeder layer, human bone marrow cells were cultured in Myelocult long term culture medium for 2 weeks. One day prior to use, the adherent stromal cells were cultured overnight with indicated concentrations of PT-100 in LTC medium and irradiated. Isolated CD34+cells were overlaid onto the stromal cell layer and incubated for 30 days in the absence or presence of indicated amounts of PT-100. Medium and PT-100 was exchanged every three days thereafter. At the end of the culture period the culture was assayed for progenitor cells by plating in semi-solid medium (methylcellulose) supplemented with growth factors (Stem Cell Factor, GM-CSF, IL-3 and Erythropoietin).
The total number of myeloid, erythroid, blast forming and multilineage clonogeneic progenitors (colonies CFU-GM, CFU-E, BFU-E and CFU-GEMM, respectively) were determined after 14 days in methylcellulose culture.
Data showing in FIG. 8 for a human bone marrow culture indicate that during a 4 week LTC assay, PT-100 increased, in a dose dependent manner, the number of clonogeneic progenitors which are able to form colonies in semi-solid medium. This suggests that PT-100 stimulates growth of primitive hematopoietic progenitor cells.
In similar fashion CD34 + cells purified from apheresed peripheral blood or umbilical cord blood were cultured on irradiated primary stromal cells for 30 days. As had been observed with bone marrow cells, PT-100 increased the number of 4 and 5 week LTC-ICs from peripheral and umbilical cord blood to very similar levels, indicating the PT-100 is able to stimulate primitive hematopoietic progenitor cell growth from these cell sources as well (data not shown).
PT-100 does not Stimulate Differentiation of Committed Progenitor Cells
Human bone marrow cells were enriched for CD34+ cells and 200 CD34+ cells per well were incubated in serum free x-vivo 15 medium (Biowhittaker) with or without the indicated concentrations of PT-100 for 4 hours at 37° C. The pre-incubated CD34+ cells were added to 0.9% methylcellulose in Iscove's MDM containing sub-optimal concentrations of recombinant human growth factors (5 ng/ml Stem Cell Factor, 1 ng/ml GM-CSF, 1 ng/ml IL-3, 0.3 units/ml Erythropoietin (Stem Cell Technologies Vancouver, BC). PT-100 was added to the medium at the same concentrations used for the pre-incubation. The methylcellulose mixture was plated in duplicate in 35 mm dishes and incubated for 14 days at 37° C. Progenitor colonies (CFU-E, CFU-GM, CFU-GEMM and BFU-E) were counted under an inverted microscope. PT-100 did not stimulate differentiation of these committed progenitor cells.
Stimulation of Hematopoiesis in the Spleen of Normal Mice
6–8 week old female BALB/c mice were administered either saline or PT-100 twice daily for 5 days at the indicated doses via either subcutaneous injection or oral gavage. On the sixth day the animals were sacrificed and their spleens were excised using sterile procedures. The spleens were disrupted to produce single cell suspensions which were subsequently treated with a solution of Tris ammonium chloride (pH 7.2) to lyse erythrocytes. The resulting splenocyte populations were in a hemocytometer and resuspended at 5×10 6 cells/mL in Iscove's Modified Eagles medium (IMDM) supplemented with 2% heat inactivated fetal calf serum. 0.3 mL of each splenocyte solution was added to 3 mL of Methocult™GF M3434 (Stem Cell Technologies, Vancouver, BC, Canada), a methylcellulose medium containing recombinant cytokines used for colony assays of murine progenitor cells. The medium was vigorously mixed and then 1.1 mL of the mixture was placed in duplicate onto sterile 35 mm diameter culture dishes, resulting in 5×10 5 splenocytes/plate. The plated cells were incubated at 37° C. under humidified conditions in 95% air/5% CO 2 for 7 days. CFU-E were enumerated as per the manufacturers specifications after 2 days, while BFU-E, CFU-GM and CFU-GEMM were enumerated after 7 days. For each mouse, the absolute CFU/spleen were calculated using the total splenocyte count determined in the hemocytometer. The data shown in FIG. 9 represents the mean±SD CFU/spleen from 3 mice in each dosing group. PT-100 stimulated hematopoiesis for all progenitor colony types tested.
PT-100 Induces Production of G-CSF from Human Bone Marrow Stromal Cells
Mononuclear cells were purified from bone marrow and cultured long-term culture medium, (Stem Cell Technologies, Inc., Vancouver, B.C.) for 2 weeks, with a single feeding of fresh medium after 1 week. The established stromal cells were removed by trypsin-EDTA digest and seeded into a 35 mm tissue culture plate at 10 6 cells per well in 1 ml of medium containing 10 −5 M PT-100 or medium alone as control. Culture media were collected on day 1. Supernatants were assayed for human G-CSF using a Quantikine high sensitivity immuno-assay kit (R+D Systems, Minneapolis, Minn.). FIG. 10 depicts the effect of PT-100 on the production of G-CSF by cultured human stomal cells. PT-100 stimulates production of G-CSF by such cells.
The manufacture of L-VAL-R-boroPro is described in a number of published procedures (Kelly, T. A., et al. J. Am. Chem. Soc. 1993. 115:12537–12638; Coutts, S. J., et al., J. Med. Chem. 1996. 39:2087–2094; Beak, P., et al., Tetrahedon Letters, 1989, 30:1197; Bean, F. R., et al., J. Amer. Chem. Soc. 1932. 54:4415). Pure isomers are preferred. See also U.S. Pat. Nos. 4,935,493 and 5,462,928, the disclosures of which are incorporated here by reference.
While the invention has been described with respect to certain embodiments, it should be appreciated that many modifications and changes may be made by those of ordinary skill in the art without departing from the spirit of the invention. It is intended that such modifications, changes, and equivalents fall within the scope of the following claims.
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Methods and products for stimulating hematopoiesis, preventing low levels of hematopoietic cells and producing increased numbers of hematopoietic and mature blood cells are provided. The methods and products can be used both in vivo and in vitro. The methods involve administering an agent of Formula I
wherein m is an integer between 0 and 10, inclusive; A and A 1 are L-amino acid residues such that the A in each repeating bracketed unit can be the same or a different amino acid residue; the C bonded to B is in the L-configuration; the bonds between A and N, A 1 and C, and between A 1 and N are peptide bonds; and each X 1 and X 2 is, independently, a hydroxyl group or a group capable of being hydrolyzed to a hydroxyl group in aqueous solution at physiological pH. The products include kits comprising the agent of Formula I.
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BACKGROUND OF THE INVENTION
The present invention relates to an actuator apparatus having a drive element which can tilt and/or pivot in a predetermined manner in response to electrical activation and which is formed such that it can be contacted by an output partner in order to transmit mechanical drive energy.
An apparatus of this type is generally known from the prior art and is used, for example, in connection with rotary actuation tasks.
Reference is made, by way of example, to WO 03/019582 A1 as the prior art which forms this generic type. Said document describes an electromagnetic rotary actuator which is used, in particular, in the automotive industry for moving a throttle valve for internal combustion engines. In this known prior art, a drive element in the form of a tilting or pivoting lever is held such that it can rotate about a bearing shaft, and, in response to a suitable supply of power to the coil system, the pivotable drive element is moved to a desired tilting position. In this case, the operating principle is based on a resonant switching principle using springs, for example helical springs, and, in the exemplary embodiment, renders possible rotary displacement of approximately 40° with a typical switching time in the range of between 2 and 3 ms.
The disadvantage of a known apparatus of this type is initially the high level of structural outlay; four coils have to be used in the abovementioned prior art in order to move a relatively large rotary armature as the drive element. High-frequency activation is also necessary for the known resonance principle, associated additional control-related expenditure and also a predetermined pivoting or end position of the drive element only have to be maintained when the coil system is acted on by a permanent holding current (also for overcoming the spring forces).
Accordingly, the object of the present invention is to simplify the design of an actuator apparatus which produces a tilting and/or pivoting movement of a drive element, in particular to reduce the mechanical and control-related expenditure while at the same time rendering possible a rapid switching (tilting and/or pivoting) process and providing the preconditions for a large number of actuator positions to be kept in the powerless state, that is to say the drive element remains at a predetermined tilting and/or pivoting angle as a rotary position, even if not electrically activated.
SUMMARY OF THE INVENTION
The object is achieved by actuator apparatus having a drive element which can tilt and/or pivot in a predetermined manner in response to electrical activation and which is formed such that it can be contacted by an output partner in order to transmit mechanical drive energy, characterized in that the drive element, as a connection element, is operatively connected to two expansion units, which are formed by means of magnetic shape-memory alloy material, such that the connection element executes a tilting and/or pivoting movement in response to an expansion or contraction movement of one of the expansion units, said expansion or contraction movement being produced by the electrical activation and also a magnetic field which is generated by said electrical activation.
According to the invention, the drive element is advantageously tilted and/or pivoted as desired (or moved to the associated tilting and/or pivoting position) by two expansion units, said expansion units each having a magnetic shape-memory alloy material which expands or contracts (typically longitudinally) in response to the electrical activation and a magnetic field which is generated by said electrical activation. According to the invention, this movement of the expansion units is then mechanically transmitted to the drive element such that the tilting and/or pivoting movement which is desired and intended according to the invention is realized.
According to the invention, this is mechanically and structurally drastically simplified compared, for example, to the procedure discussed above in relation to the prior art which forms this generic type, and furthermore the present invention can provide, as will be explained in detail further below, a bistable effect in a simple and elegant manner, this bistable effect making it possible for a large number of tilting and/or pivoting positions to be assumed without power being supplied (that is to say without the need for an electrically generated magnetic field having to keep an expansion unit and therefore the drive element in one position).
In this case, it is preferred, according to the invention, for the drive element to be designed as a tilting lever which can be pivoted about a rotary shaft and for the expansion units to be acted on at both ends of the rotary shaft such that the tilting and/or pivoting movement can be set and reset by in each case one of the pair of expansion units. Therefore, a hypothetical tilting and/or pivoting angle of up to 180° can be formed by suitably designing the (lifting) geometries, it being expedient here to set up a pivoting angle (angular travel) of between 45° and 90° within the scope of the invention and in order to realize the applications, which are advantageous according to the development, of the rotary actuator system, for example in the motor-vehicle or air-conditioning sector.
It is also preferred, according to the development, to realize a bistable effect of the present invention by, with the aid of a permanent unit, that is to say for example permanent magnets which can be associated with one or both of the expansion units and have a correspondingly fixed magnetic field, it being possible to set up or set positions, it then being possible for these positions to be suitably influenced by superimposition or neutralizing effects of an additional electromagnetic field which is generated by the electrical activation. Depending on the configuration, it is thus possible to either render possible bistable operation with regard to the respective end positions of the tilting and/or pivoting movement, or else to form predetermined intermediate positions in a stable manner without power, or to realize an actuation operation which is proportional to the activation.
In this case, it is expedient, within the scope of a first preferred embodiment, for each of the expansion units to have associated coil means as a magnetic field unit, so that, in particular from the point of view of modularization, suitable expansion units, which may possibly be simple to produce on a large scale, can be suitably selected, positioned and activated for actuation purposes.
As an alternative, it is possible to jointly provide a coil unit (that is to say, for example, a magnetic field coil pair) for a plurality of expansion units in order to further reduce the apparatus outlay in this respect. An analogous actuation and/or switching behavior can be achieved, in particular in conjunction with permanent magnet means which can be associated with at least one of the expansion units, as can virtually any desired configuration options depending on the respective intended dimensioning and use.
Whereas it is expedient and preferred, according to the invention, to use the present invention for rotary actuation tasks in the field of motor-vehicle and/or air-conditioning engineering, the range of application of the principle claimed by the present invention is, in principle, unlimited; instead, it can be assumed that both the apparatus and the method, according to the invention, which can be identified from the present document can be used for any desired rotary actuation purposes in which mechanically simple design with short switching times, high tolerance to environmental conditions and reliable operation have advantageous effects.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention can be found in the following description of preferred exemplary embodiments and with reference to the drawings, in which:
FIG. 1 shows a schematic view of an actuator apparatus according to a first exemplary embodiment of the present invention, with a pair of expansion units which are of symmetrical design and are symmetrically activated and, at both ends of a rotary shaft, act on a tilting lever, which is pivotably mounted on said rotary shaft, as a drive element;
FIG. 2 shows a schematic illustration for illustrating the movement geometry of the exemplary embodiment according to FIG. 1 ;
FIG. 3 shows a schematic illustration of an actuator apparatus according to a second exemplary embodiment of the invention, in which an electromagnetic coil unit is jointly provided for a pair of expansion units, said expansion units additionally having associated permanent magnets; and
FIG. 4 shows a magnetic field/movement graph for illustrating the manner of operation of the exemplary embodiment according to FIG. 3 .
DETAILED DESCRIPTION
FIG. 1 illustrates, in the schematic illustration through a longitudinal section, the manner of operation of a first exemplary embodiment. A pair of expansion units 10 , 12 is realized by means of a magnetic shape-memory alloy material (for example NiMnGa (as a mono-, multi- or polycrystal), magnetic field strength of approximately 1T). Materials of this type are known from the prior art and are distinguished in that they experience a change in length in response to an applied magnetic field; in practice, this change in length is typically approximately 4% to 6%, up to approximately 10%, of the elongation of such a material in relation to the extension direction.
As shown in FIG. 1 , the shape-memory alloy material 10 can be expanded by a magnetic field (group of arrows 14 ), this magnetic field being generated by a coil pair 16 in response to an electrical activation. Analogously, a second coil pair 18 generates a magnetic field (group of arrows 20 ) for the second expansion unit 12 .
As can additionally be seen in FIG. 1 , the (initially linear) actuating action of the expansion units is coupled to a tilting and/or pivoting lever 26 , which is mounted such that it can tilt and/or pivot about a stationary rotary shaft 28 and serves as a drive element for an output partner (that is to say, for example, an air-control valve for a vehicle interior), against the force of a respectively associated compression spring 22 (for setting a force or movement operating point) and in a manner mechanically coupled by means of a tappet unit 24 which extends in the expansion direction of the units 10 and 12 .
In response to, for example, power being supplied to the coil unit 16 , the shape-memory alloy material of the first expansion unit 10 would, during operation of the unit according to FIG. 1 , carry out a predetermined expansion movement in the direction of arrow 30 , with the result that, by force being applied to the lever 26 , said lever is moved into a pivoted position, indicated by the dashed line according to reference numeral 32 . In this operating state, the coil unit 18 is preferably not supplied with power, and therefore a magnetic field is not applied to the expansion unit 12 ; instead, said expansion unit is contracted by the mechanical action of force along arrow 34 by the lever 26 (in its position 32 ). A corresponding reversal in polarity or exchanged activation would then analogously cause a tilting and/or pivoting of the lever 26 in the opposite direction of rotation.
FIG. 2 illustrates the tilting or lever geometry of an arrangement of this type: said figure again shows how the pair of expansion units 10 , 12 mechanically interact with the tilting lever 26 (requisite magnetic field means are not shown in FIG. 2 ) and it can be seen that, in order to realize an effective tilting and/or pivoting movement a (of, for example, 60°, as shown in FIG. 2 ), this geometry is determined firstly by a magnetic field-induced change h in length of each of the expansion units, and secondly by a free limb length d of the pivoting lever 26 , measured from the pivoting shaft 28 up to the effective point of contact with one of the expansion units (the extension, illustrated in dashed lines, of the units 10 , 12 illustrates the expanded, stretched operating state).
In addition to the geometry shown in FIG. 2 , an expansion or stretching force of the units 10 , 12 , which (in a manner induced by the physical behavior of the shape-memory alloy material used) is approximately proportional to the material cross section of the respective expansion units perpendicular to the stretching direction, is important for dimensioning. The combination of the expansion force, which can be dimensioned in this way, in conjunction with the lever geometry d therefore permits a desired torque about the rotation shaft 28 to be measured and set up.
As illustrated in the above description of FIG. 1 , the use of compression or return springs 22 is not necessary in principle. However, an operating mode of an arrangement according to FIG. 1 , according to which both coils are supplied with power at the same time (but at different levels), and therefore proportional behavior of the rotary actuator can be achieved, that is to say any desired intermediate angle is achieved, by means of suitable power regulation (and therefore setting of the magnetic fields 14 , 20 ), is feasible. The above description also shows that the arrangement is bistable when power is not supplied, that is to say, the tilting lever 26 , as the drive element, remains in a respective end position (that is to say, for example, with a stretched first expansion element and contracted second expansion element, and vice versa), without a magnetic field needing to applied and therefore without power needing to be supplied to the coil units 16 and/or 18 in one of these end positions.
A second exemplary embodiment of the invention is described below with reference to FIGS. 3 and 4 .
A pair of expansion units 40 , 42 comprising a magnetic shape-memory alloy material again interacts with a drive element 26 , which is pivotably mounted as a tilting lever, with the interposition of tappet units 24 ; the respective (intermediate) positions are controlled in a stable manner without power being supplied or with reduced power.
However, in contrast to the exemplary embodiment of FIG. 1 , the pair of expansion units are jointly acted on by a coil pair 44 with an electrically induced magnetic field, indicated by the group of solid-line arrows 46 .
In addition, the permanent magnetic field of permanent magnets 48 and 50 acts on each of the expansion units, said permanent magnets being associated with the expansion unit 40 or 42 in the shown manner and each exerting a permanent magnetic field on the shape-memory alloy material, said permanent magnetic field being indicated by the arrows 52 (for the permanent magnet 48 ) and 54 (for the permanent magnet 50 ) which are illustrated in dashed lines.
The manner of operation of this arrangement is explained below with reference to the movement/magnetic field graph in FIG. 4 , where it is assumed that a permanent magnetic field of field strength B 0 is generated by the permanent magnets 48 and 50 . The polarity, which alternates due to current pulses, can now be achieved in that the expansion units alternately expand and contract again in the extension direction (arrow direction 56 for expansion, 58 for contraction), the springs 22 which are again indicated schematically generating an intentional mechanical prestress.
Therefore, under the permanent magnetic biasing fields +B 0 and −B 0 , the units 40 and 42 are in their starting position: the right-hand expansion unit 42 is extended (position 60 in FIG. 4 ), the left-hand expansion unit 40 is compressed (position 62 ). A power supply pulse for the coil pair 44 , which generates a coil field of field strength B SP ≈B 0 , leads to a field of strength −B 0 +B SP ≈0 being applied to the unit 42 , and, in contrast, a field of strength B 0 +B SP ≈2B 0 being applied to the unit 40 . Accordingly, unit 42 moves, in the direction of arrow pair 64 in FIG. 4 , from position 60 to position 66 , and unit 40 moves from position 60 to position 68 . This has the effect that the unit 40 (due to the action of the prestressing spring 22 ) is compressed, whereas unit 42 is extended at the same time, with the result that, after the end of the pulse, an inverse movement state 70 , 72 , which is pivoted in an opposite end state, is achieved compared to the initial state 60 , 62 .
Analogous behavior in the opposite direction is achieved, with the hysteresis pattern shown in FIG. 4 , by virtue of a current pulse to the coil unit 44 , this current pulse producing a coil field B SP =−B 0 .
The actuator is again stable in both end positions without any power being supplied at all, as long as, for example, material-specific force limits are not exceeded.
Further modifications, in particular the arrangement according to FIG. 3 , are possible within the scope of the present invention.
According to an additional development (not shown in the figures), it is feasible for the coil field which is to be produced by electrical activation to be realized with just one coil (which may then have to be larger). Equally, the permanent magnets 48 and 50 provided in FIG. 3 do not have to be equally strong and/or have the same dimensions, and in the same way the units 40 and 42 do not have to have the same actuation-related dimensions or symmetrical hysteresis behavior. Instead, it is possible, for example, to replace the shown pair of permanent magnets with a (common) permanent magnet which is suitably positioned centrally or asymmetrically between the pair of expansion units, in the same way that asymmetry of the permanent-magnetically or electromagnetically generated field can be deliberately planned.
According to the development, it is not necessary, for example, to set the permanent magnetic field strength (in the sense of biasing) such that it is central or symmetrical with respect to the hysteresis of FIG. 4 . If, for example, the permanent magnetic field strength is selected to be smaller (for example of the order of magnitude of the half of B 0 ), one of the expansion units can then advantageously be shortened during the current pulse as early as at a lower field strength and therefore take place earlier than the expansion of the other unit. Depending on the desired switching behavior, advance switching or gradation can be achieved: if, for example, a stable position of the actuator switches off the flow through a driven locking valve against a pressure, the reduction in the holding force can initiate the switching process by virtue of the excess pressure before the other expansion unit actively assists the switching process.
In addition, an application requirement that, in addition to the spring prestress, different torques and/or forces act on an extended expansion unit in both stable actuating positions can be effectively counteracted by selecting or setting up (permanent magnetic) fields (bias fields) of correspondingly different magnitudes; switching in the direction with greater loading is therefore simplified compared to the reverse process and the effect of an asymmetrically acting force is compensated for by the output partner.
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Actuator apparatus having a drive element ( 26 ) which can tilt and/or pivot in a predetermined manner in response to electrical activation and which is formed such that it can be contacted by an output partner in order to transmit mechanical drive energy, wherein the drive element, as a connection element, is operatively connected to two expansion units ( 10, 12; 40, 42 ), which are formed by means of magnetic shape-memory alloy material, such that the connection element executes a tilting and/or pivoting movement in response to an expansion or contraction movement of one of the expansion units, expansion or contraction movement being produced by the electrical activation and also a magnetic field which is generated by said electrical activation.
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BACKGROUND OF THE INVENTION
The present invention relates to maintenance of a sufficient supply of fibers for spinning machines having a plurality of processing locations, particularly for machines which operate periodically while unattended and which receive a band of fiber material, or roving, to be processed from supply containers. The invention is more particularly directed to open-end spinning machines containing apparatus for automatic replacement of bobbins and automatic correction of yarn breaks.
Textile machines, particularly open-end spinning machines, are presently automated by the provision of additional devices, for example, devices for correcting breaks in the yarn and for replacing bobbins, so that they can operate unattended during one or a plurality of shifts.
Their ability to operate unattended is assured only, however, if the supply of fiber material is controlled so that during the unattended shifts it will not be necessary to replace supply containers, i.e. the fill level of the supply containers must be checked at the beginning of an unattended work section and containers which do not contain a sufficient fill level must then be replaced, if necessary.
SUMMARY OF THE INVENTION
It is an object of the present invention to assure a sufficient supply of fiber material so that the maintaining of an adequate supply of fiber materials will be facilitated in more or less automatic textile machines and the need for attending personnel is reduced.
This and other objects of the invention are accomplished by an operating method in which the extent to which each supply container is filled is continuously determined by means of automatically operating monitoring devices and when a lower limit value is reached, an indication signal is produced.
The present invention is thus based on the concept of continuously monitoring, by means of suitable devices, the degree of fill of the supply containers holding the band-shaped fiber material to be processed. If the fill level in one of the supply containers falls below a certain value, this is indicated by the production of a signal so that the empty supply container can be replaced by a full supply container.
According to a particularly simple embodiment of the method according to the invention, the fill level is determined by measuring the length of the fiber material removed from each supply container. Preferably the fill level can also be monitored by measuring the reduction in gross weight which occurs during the removal of fiber material from a supply container.
According to a further suitable embodiment of the method, the fill level of each supply container is determined by measuring the top of the mass of fiber material in each container.
Apparatus according to the invention for use with textile machines, particularly open-end spinning machines having a plurality of processing locations and supply containers connected to each, includes at each location of a supply container, a monitoring device which is in communication, through the intermediary of an actual value/limit value comparison unit in which the limit value is adjustable, with an indicator device.
The monitoring device may be designed as a length measuring unit and be provided with a counter whose sensor is acted upon by the longitudinal movement of the fiber material into the spinning unit. With open-end spinning machines for example, the sensor of the counter may be coupled to the intake rollers associated with each spinning location. When the supply containers assigned to the individual spinning locations are exchanged, the counter is reset to the starting value "zero"; thus the counter indicates at any time the length of the fiber material already removed from the supply container.
According to another advantageous embodiment of the apparatus, the monitoring device is designed as a weighing unit provided with a variable height weighing platform on which its supply container is disposed.
The weighing platform preferably has associated with it a variable height controlled switch which is part of the indicator unit. The change in the weight of the supply container upon removal of fiber material results in a change of the height level of the weighing platform which, when a settable limit value is reached, actuates a switching pulse and thus causes the indicator unit to operate.
The apparatus may also be designed so that each supply container has associated to it an ultrasonic transmitting/receiving unit, which is placed above the surface of the material in the container. The ultrasonic unit evaluates the return signal reflected from the target object, i.e. the surface of the fiber material in the container, and when a maximum distance from the target object has been reached, which corresponds to a certain fill level in the supply container, it causes the indicator unit to operate.
Instead of an ultrasonic unit, the fill level in the supply container can also be monitored by monitoring devices which operate according to the magnetic-elastic principle, or by inductive sensors.
In certain cases, particularly when the fiber material is not very bulky, the device may be designed so that the fill level of the supply containers is determined directly, for example with the use of a sensor, which mechanically scans the surface of the contents of the container.
According to a further preferred embodiment of the present invention, a transmitting unit emitting radioactive radiation is disposed at one side of the contents of each supply container and on the side opposite thereto a receiver is disposed which feeds an indication of the radiation intensity, as it varies in dependence on the fill level, as an actual value signal to a comparison unit.
Apparatus according to the invention is advantageously designed so that each monitoring device has its own associated indicator unit. It is also possible, however, to combine the monitoring devices into groups, for example, with each group having a common indicator unit.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified pictorial, elevational view of an open-end spinning machine with supply containers arranged on a weighing unit and a switch associated with the weighing platform according to one embodiment of the invention.
FIG. 1a shows in an enlarged scale and more detailed the arrangement of the weighing unit and the associated switch.
FIG. 1b shows the principle structure of the switch associated to the weighing unit.
FIG. 2 is a view similar to that of FIG. 1 of an open-end spinning machine with ultrasonic transmitting/receiving units associated with the supply containers according to a second embodiment of the invention.
FIG. 3 is a view similar to that of FIG. 1 of an open-end spinning machine with transmitting units which emit radioactive radiation and receivers disposed opposite thereto with respect to the associated supply containers according to a third embodiment of the invention.
FIG. 4 shows in detail an intake roller and a break-up roller of an open-end spinning machine and a magnetic switch actuated by a magnet driven by the intake roller.
FIG. 5 shows an arrangement of a canister already shown in FIG. 1 but set on a platform pivoted on one axis and resting on a pressure force indicating switch box.
FIG. 6 shows a principal layout of a plurality of switches of monitoring devices combined in a group with a common indicator unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus shown in FIG. 1 includes an open-end spinning machine 1 whose basic components include a series of open-end spinning units 3 disposed side-by-side, perpendicular to the plane of the Figure, in a machine frame 2, each unit 3 having associated delivery rollers 4 arranged to supply the finished yarn 5 from its associated unit to a respective winding device or bobbin 6.
Fiber material 7 which is present in band form and is to be processed in the spinning machine is removed from canisters 8, each spinning location having its own canister. The fiber material 7 enters through an inlet opening 9 into the spinning machine, is there separated by means of one or a plurality of break-up rollers and then fed to a spinning rotor in whose fiber collecting trough the yarn 5 is formed.
The break-up roller or rollers, the spinning rotor and the feed roller moving the fiber material 7 are not shown in the general arrangement for reasons of clarity. Embodiments thereof are well-known in the art and any known arrangement can be used.
In the embodiment shown in FIG. 1 the canisters 8 which serve as the supply containers are arranged in two rows within a stand 10, each row extending perpendicular to the plan of the Figure. Each canister rests on a respective weighing platform 11 which is supported by spring devices 12 and a base surface 13. At the lower surface 110 of each weighing platform 11 there are fastened sleeves 111 slidable on sleeves 131 fastened to the base surface 13, so the weighing platforms 11 are movable in the vertical direction. Below each weighing platform 11, there is fastened a magnetic switch 15 to a holder 135 fixed to the base surface 13. The magnetic switch 15 being part of a switching circuit 16 for a signal light 17, is controlled by a permanent magnet 14. The permanent magnet 14 is fastened at the lower end of a holder 114 carried by the platform 11. Both the magnet 14 and the holder 114 are adjustable in height. The permanent magnet 14 is advantageously adjusted so, that when the fill level of a canister 8 has reached a lower limit value it is at the same height as the magnetic switch 15.
The removal of fiber material 7 from each canister 8 continuously reduces the weight acting on the associated weighing platform 11 and thus the height of the weighing platform is changed.
As soon as the fill level of a canister 8 has reached a lower limit value and the permanent magnet 14 and the magnetic switch 15 are at the same height, the magnet 14 attracts the core 151 of the switching element 150 against the force of a pressure spring 153 within the housing of the magnetic switch 15. So the contact bridge 152 of the switching element 150 is approached to the contacts 154 and 155 and the switching circuit 16, which until this time has been interrupted, is closed so that the associated signal light 17 lights up. The operator of the spinning machine can therefore determine at once at which point in time and at which location of the spinning machine it will be necessary to change canisters.
In the embodiment shown in FIG. 2, each canister has associated with it an ultrasonic transmitting/receiving unit 18. In the housing of the ultrasonic unit 18 there are arranged adjacently an ultrasonic transmitter and an ultrasonic receiver. The transmitter as well as the receiver are conventional items and are available commercially from, e.g. the Endress + Hauser GmbH + Co., D - 7867 Maulburg, F.R. of Germany, these elements being designated both as "Ecosonic U 3" by that corporation. The transmitter emits soundwaves 18' directed toward the contents of the canister. The reflected soundwaves are evaluated in the receiver of the ultrasonic unit 18. The evaluation method is conventional; see, e.g. Lubcke: "Akustische Tiefenmessung," published in Archiv fur technisches Messen, Munic (Germany) and Oldenburg, volume 1935, part V 1124. When a maximum distance has been reached between the top surface of the canister contents and the ultrasonic unit, the latter emits a switching pulse which lights up a signal light 17 assigned to the ultrasonic unit.
The ultrasonic units 18, as well as the guide rollers 19 associated with canisters 8 are held stationary in stand 10.
A particularly simple embodiment of the present invention can be provided if instead of the ultrasonic units 18, or even the weighing platforms 11, counters are used as the monitoring devices. These counters may be coupled, for example, with the guide rollers 19 or with the feed rollers for the spinning machine.
Advisably an indicator unit is again associated with the counters which is caused to light up by means of a switching pulse when a certain count value has been reached. In this case the length of the fiber material band indicated by means of the counter serves to determine the fill level of the canisters 8, it being assumed that every canister 8 initially holds fiber material of the same length.
In an advantageous embodiment shown in FIG. 4 the feed roller 31 is forwarding the fiber material 7 to the break-up roller 32. A permanent magnet 14' is fastened to the shaft of the feed roller 31. Each revolution of the feed roller a magnetic switch 15' is actuated by the magnet 14' whereby the respective switching circuit of a comparison unit 22' is closed and an pulse is given to a counter within the comparison unit. The pulses are counted and compared with a predetermined number of pulses. When the predetermined number is reached the signal is lightened.
In another embodiment of the apparatus, shown in FIG. 3, above each canister 8 there is disposed a stationary transmitting unit 20 which emits radioactive radiation in the direction towards the open top of its associated canister 8. The transmitting unit has associated to it on the side opposite thereto with respect to the contents of the canister, i.e., in the present case below canister 8, a stationary receiver 21 which converts the received radioactive radiation into an analog measuring value. The principle of the respective measuring method is described by H. Maschner in "Automation und Rationalisierung in der Textilindustrie durch kernstrahlung" (1st part of the closing conference of the textile action of the bureau EURISOTOP at Evian-les-Bains, France, from May 8th to 10th, 1967), published by the "Information and Documentation" group of the bureau EURISOTOP.
On the way through the canister contents, the radioactive radiation is partially absorbed, i.e., the radiation intensity is reduced. The greater the mass of the fiber material 7 filling the canister, or the greater the fill level, the higher the radiation absorption. The measuring value formed in receiver 21 is fed to a comparison unit 22 shich compares it with an adjustable limit value. As soon as this limit value has been reached, a signal lamp 17 assigned to the canister and connected to the comparison unit lights up.
The bottom of canisters 8 advisably is made of a material which absorbs as little as possible of the radioactive radiation.
According to a modification of the embodiment shown in FIG. 3, the apparatus may also be designed so that the transmitting unit 20 is disposed below the associated canister 8 and the receiver 21 is consequently disposed above the canister.
In FIG. 5 is shown another modified embodiment of the invention. The platform 116 is pivoted on an axis 24 at one side. At the other side the platform is resting on a pin 25' of a switch 25 which may operate according to the magnetic-elastic principle, controlling the signal light 17 via the comparing unit 22. The signal lamp 17 may be controlled by inductive sensors or by strain gages, too. All these measuring principles are described by H. Nelting and G. Thiele in "Elektronisches Messen nichtelektrischer Grossen. Grundlagen und Praxis", published by Philips Technische Bibliothek (Hamburg, F. R. of Germany), 1966, pages 323-326.
The prescribed monitoring devices may be combined into groups, with each group having a common indicator unit. For instance the different switching circuits 16 of the respective switches 15 of the embodiment shown in FIGS. 1, 1a and 1b may be combined to one common circuit path 161, as shown in FIG. 6. If only one switch 15 is closed the signal lamp 17 lights up.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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In the processing of a band of fiber material at a plurality of processing locations in a textile machine which operates while periodically being unattended and receives the fiber material band to be processed from supply containers, a sufficient supply of fiber material to the machine is assured by automatically monitoring the quantity of fiber material in each container, and producing an output signal when the monitoring indicates that the quantity of fiber material in a container has reached a lower limit value.
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BACKGROUND
1. The Field of the Invention
This invention relates to supporting structures for use during construction, and more particularly to novel systems and methods for supporting decking for workmen above ground level in residential or other construction projects similar in nature.
2. The Background Art
Scaffolding has long been of both utility and concern in construction. In many state as well as in federal regulations, detailed specifications of requirements apply to "riggers" and their craft. Scaffolding may be thought of as decking for supporting materiel, workman, tools, and the like, above or below a common surface.
For example, a workman may stand on the ground while laying brick, working on certain woodwork, while wiring, and so forth. In construction of large, multi-storied buildings, special decking may be laid specifically for use during construction. Many feet above ground level, scaffolding built from the ground up becomes impractical. However, scaffolding may be used within a few stories' distance of the ground.
Scaffolding presents several problems. To provide proper structural strength, scaffolding is typically quite heavy. Moreover, special riggers' licensing may be required for use of scaffolding. In residential construction, the commitment of time and manpower for setting up and taking down scaffolding support may represent a substantial fraction of the task for which such scaffolding is set up in the first place.
Ladders are limited in their utility. Ladders must be moved frequently. Ladders may not be positionable readily both inside and outside the envelope of a building at all stages of construction where scaffolding may be useful or required. The weight, bulk, manpower, lack of flexibility in application, awkwardness in working indoors or in semi-finished areas, and the like add to the difficulty and expense of using conventional scaffolding.
What is needed is a simplified system for supporting workmen, tools, and materials, a distance above ground level suitable to facilitate several common tasks. For example, decking suitable for working near a top plate of a residential construction wall is necessary. A support for decking positionable to support a workman installing soffits, fascia, installing trusses, and working on other projects that cannot readily be reached from the ground, is needed.
A support system is needed that is easily portable. A system that can be set up and taken down in a minimum amount of time, while occupying a minimum of space during storage and transport is needed. Such a system capable of extending over a substantial working area upon deployment is needed. Likewise needed is a system that can be set up by a single workman. Adjustability in height, length, distance from a bearing wall and the like are preferable.
Preferably, such a system can hang from a top plate. It should adjust to a variety of widths of top plates. Simple removal from the top plate after closure of soffits, sheathing, and the like about walls and ceilings would be very useful.
A system is needed that does not require significant penetrations into a structure, and which can be used both interior and exterior to a bearing wall of a house. A system that could be used even when a building in initial stages of framing, and yet during stages of semi-finished condition inside or outside a wall, would be beneficial. A system is needed that is easily operable (e.g. adjustable, carriable, deployable, etc.) with a single hand, or by a single user.
What is needed is a deck or scaffold support that can be climbed readily by some support mechanism in order to quickly adjust the height of a deck. A system that is fail safe, such as being non-separable during adjustment, does not require multiple hands or adjustment, does not require precision alignments by a user, does not require eyes of a user to be located in a difficult position for adjustment, and does not require dismantling or removal in order to be adjusted, would be extremely efficient.
A system that provides for plank positioning close to and distanced from a wall, selectively at the choice of a user is needed. A system that can be collapsible or ready-storage and transport with a minimum of fitting and assembly for use would be extremely handy and efficient in use of manpower.
A deck or scaffold support is needed that provides simple adjustment of deck positions vertically and operational adjustment horizontally. The ability to work on open walls comprised merely of studs, or to work on closed walls, and even perhaps to work on partially bricked walls, would be preferred.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to provide a method and apparatus for creating, maintaining, and adjusting a scaffold or deck above ground level for supporting workmen, tools and materials.
It is an object of the invention to provide simple, portable support systems that can be easily set up by an individual.
It is an object of the invention to provide a support system that will hang from a top plate of a residential construction project, such as a bearing wall.
It is an object of the invention to provide a scaffolding support system that will adjust to multiple top plates and be removable therefrom after construction has been substantially closed in either interior or exterior to a wall from which the support mechanism is suspended.
It is an object of the invention to provide a system that may be supported substantially without penetrations to the structure.
It is an object of the invention to provide a climber mechanism for simple adjustment of height without intervention by the eyes of a user for removal of fittings, or installation of pins and similar mechanisms in precise locations requiring alignment, and without generally allowing free separation of mating parts.
It is an object of the invention to provide a fail safe supporting system for eliminating slippage, multiple hands, multiple workmen, or structural separation of parts during adjustment.
It is an object of the invention to provide non-separating parts, automatic adjustment and catching of a deck support at multiple locations along a supporting upright leg, all with one handed operation by a single user.
It is an object of the invention to provide a supporting mechanism for plank positioning horizontally, selectively closer or farther from a subject wall.
It is an object of the invention to provide a deck support mechanism that is collapsible and easily and simply dismantled with a minimum of motion, for convenient storage and transport occupying a minimal envelope in bulk, with a minimum of weight, while yet providing adequate safety, simplicity, and stability in deployment and operation.
Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, an apparatus and method are disclosed, for certain embodiments of an invention including a leg extending in a more-or-less vertical or upright direction and provided with a lateral foot extendable therefrom. The lateral foot may be connected to the leg by a climber mechanism that supports the foot in operation, while simply and safely disengaging and readjusting the height of the foot along the leg.
In one embodiment, an apparatus and method in accordance with the invention may provide a railing support secured, opposite the leg, to the foot in order to prevent falls by workmen from the deck extending across the foot. Multiple units may be deployed to support each end of decking materials. Likewise, decking materials of substantial lengths may be supported at their respective end and middle portions by multiple units of the apparatus. Decking may be extended beyond the standard length of a particular decking material by interleaving or overlapping decking across multiple pairs of apparatus deployed along a wall.
The support system may include railing supports that are removable or collapsible for storage, after a railing itself is removed. Railing may be provided from simple construction materials readily available at any work site. Thus, the system may be completely collapsible into a comparatively small envelope containing the leg and foot, and optionally the leg, foot, and railing support, in a single package, completely interconnected and not disconnected at any point.
In one embodiment, no pieces of the apparatus may be completely separated from other pieces without full intent, application of appropriate tools, and the like. Thus, the system may be fully adjustable with single-hand operation by a single user, while remaining failsafe.
In certain preferred embodiments, no pins, precision adjustments, alignments, or the like are required for height adjustments by a user. Instead, all the parts involved are self-aligning. The foot may comprise a climber that is both self-aligning, self-capturing, and rigidly locked against failure in a loaded direction. By contrast, the same system may be readily collapsible into a unit of three elongated pieces, including a leg, foot, and railing support positioned substantially in parallel and fully connected, pivotably, in a dismantled (with respect to decking and railing) mode.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is a rear quarter perspective view of one embodiment of an apparatus implementing various features of the invention;
FIG. 2 is a rear quarter, perspective view of the apparatus of FIG. 1 illustrating certain particular alternative embodiments of selected features such as a collapsible support for a railing post, and laterally extended hangers for the climber;
FIGS. 3 and 4 are rear quarter, perspective views of a collapsible support mechanism for a railing post in a deployed, and collapsed position, respectively, illustrating alternative mechanism for pivoting, stopping, locking, and the like;
FIG. 5 is a schematic, side elevation view of the envelope of various optional elements of a pedestal or post mount for the apparatus of FIGS. 1-4;
FIG. 6 is a perspective view of one embodiment of a lock, relying on an eccentric or cam;
FIG. 7, is a rear quarter, perspective, cut-away view of a portion of an alternative embodiment of an apparatus in accordance with the invention, relying on certain alternative structural members for various functions, as compared the apparatus of FIGS. 1-2;
FIG. 8 is a rear quarter, perspective view of an adjustment head for extending across a top plate from the leg of an apparatus of FIGS. 1-7;
FIGS. 9 and 10 are side elevation views of alternative embodiments for a climber of FIGS. 1-2 securing a leg to a foot in accordance with the invention;
FIG. 11 is a rear quarter perspective view of an apparatus in accordance with the invention, collapsed and retained for storage and transport.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, is not intended to limit the scope of the invention. The scope of the invention is as broad as claimed herein. The illustrations are merely representative of certain, presently preferred embodiments of the invention. Presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
Referring to FIG. 1, and apparatus 10 or support system 10 may be formed to have a leg 12 or an upright 12. The leg 12 provides vertical extension for positioning a deck 13 which may be comprised of wooden planks such as 2×12 boards, specialized decking materials, or the like.
The leg 12 may be formed of an I-beam member or a channel, and may even be tubular, whether circular in cross-section or rectangular in cross-section. Moreover, the leg 12 need not have a uniform cross-section, but may be designed to support loadings in different directions differently.
A foot 14 may extend from the 12, being secured thereto as a lateral member 14 extending away from a wall of interest supporting the leg 12. The foot 14 may be secured to the leg 12 to be easily adjustable, preferably by a single hand of a single user. Moreover, the foot 14 may be configured to be easily adjustable without requiring alignment, and to automatically secure to the leg 12 at the first available opportunity if dropped by a user during adjustment. The foot 14 may be adjustable by more than a single step in one motion. Thus, adjustability may be extremely rapid, and adjustability may extend over substantial distances in a single movement.
A riser 16 may be provided as a post 16 for supporting a rail 18 or a railing. The rail 18 may be formed of regular construction materials or may be provided from a specialty material. In general, construction materials may be used temporarily for a railing 18, and be removed for use in construction later. Thus, standard studs or planks may be used as rails 18 supported by the riser 16 or post 16 and secured thereto. Alternatively, specialty materials may be created of metals or other materials to be attachable and removable from securement to the riser 16.
In one presently preferred embodiment, a connector 20 may be provided as a connection mechanism 20 for securing the foot 14 to the leg 12 at a desired position. Thus, the connector 20 may be designed as an independent mechanism attachable to the foot 14 or the leg 12. In one presently preferred embodiment, the connector 20 may be welded or otherwise fixedly attached to the foot 14, thus preventing any failures of fastening mechanisms that may loosen with time, or be improperly installed.
Referring to FIG. 2, and continuing to refer to FIG. 1, a hanger 22 may be secured to one end of the leg 12. The hanger 22 may be adjustable for different sizes of top plates in a construction project. Similarly, a base 24 may be secured or securable to the foot 14, and may be thought of as forming a portion of the entire foot 14 assembly. The base 24 may support the riser 16 in a manner to render adjustable the riser 16 to a desired position, with respect to the leg 12, along the foot 14.
A bracket 26 may be provided for securing the rail 18 to the post 16 or riser 16. The bracket 26 may be fastened by any suitable means to the post 16. Nevertheless, welding may be used in certain preferred embodiments to assure that assembly, installation, security, and reliability remain high.
Inasmuch as the apparatus 10 is designed as a safety mechanism for operating above ground level, minimization of maintenance may be important. Accordingly, the bracket 26 may be bolted to the post 16, welded, or secured by other fasteners including slots, locks, pins, and the like, deemed suitable for proper support of a railing 18 and securement thereof to the post 16. The post 16 may be removed from the base 24 and nested between the flanges 30, 32 or the flanges 70, 72 for storage. An appropriate fastener may secure the post 16 there, for storage or for working in situations for which the railing 18 is inappropriate. For example, work in close quarters, near foundation holes close to outside walls, or indoors, in hallways, etc., may not be appropriate for use of a railing 18.
The leg 12 may include a web 28 and flanges 30, 32. In the embodiment illustrated in FIGS. 1-2, an I-beam construction is contemplated. Nevertheless, webs 28, and flanges 30 may be configured in a variety of shapes, including a common channel, boxed tube, or circular tubing. Nevertheless, in one embodiment, the web 28 is equivalent to a wall 28, while each flange 30, 32 is equivalent to a wall. Accordingly, an I-beam construction requires only three walls covering the same space that four walls would cover in a rectangular tubular configuration. Thus, virtually equivalent strength at the outermost fiber of each of the flanges 30, 32 is available, without the additional weight of a tubular construction.
The leg 12 may be provided with stops 34 or blocks 34 secured thereto. The stops 34 may be positioned at regular or irregular intervals. For example, in certain construction projects, the foot 14 may be profitably positionable at specific locations. Accordingly, stops 34 may not need to be installed at every position. For example, operation of a workman on decking 13 on the foot 14 at a maximum distance from the hanger 22 may be important.
Alternatively, positioning the decking 13 at a location as close to the hanger 22 as possible may provide access to the top plate by a workman. Intermediate thereto, the stops 34 may be positioned for standard tasks readily required at particular heights. Examples may include attachment of fascia and soffits. Likewise, a particular height may be suitable for installing trusses extending over top plates. Thus, stops 34 may be provided for those particular positions. Nevertheless, in one embodiment, the stops 34 may be distributed at uniform distances, such as two inches apart, four inches apart, six inches apart, or the like.
A security stop 36 may be provided at the bottom end of the leg 12. The security stop 36 may be thought of as an end plate. Nevertheless, the security stop 36 need not be a plate. In certain embodiments, the end stop 36 or security stop 36 may be a rod, a bar, or the like. In general, the security stop 36 may prevent passage of the connector 20 and the foot 14 beyond the end of the leg 12. Whether the security stop 36 is welded, bolted, riveted, fastened removably or fastened permanently may be determined as a design selection balancing strength, safety, manufacturing, and other considerations.
A mounting plate 38 may be secured to the leg 12. In certain embodiments, some may consider the leg 12 to include all parts pertaining thereto and not secured directly to the connector 20 or the foot 14. The mounting plate 38 may structurally stiffen the end of the leg 12 in order to receiver the hanger 22.
Opposite the hanger 22 may be positioned a stabilizer 40. The stabilizer 40 may be formed as a plate secured to the security stop 36 of the leg 12 or the flange 30. A stabilizer 40 may protect against transverse motion by the foot 14. In certain embodiments, the stabilizer 40 may be securable to the wall from which the apparatus 10 hangs.
For example, a nail through the stabilizer 40 or spur 40 may provide great stability with minimum effort and minimum effect on the structure of the wall to which secured. In one embodiment, the stabilizer 40 may be flared. A flare 41 may angle under the leg to point away from the wall sufficiently to be engaged by a hammer claw, pry bar, or other lever. Levers for which the flare 41 may be designed may include a wood scrap of common dimension, or other tool likely to be available at a construction site.
The foot 14 is connected to the leg 12, which hangs from the hanger 22. Decking 13 positioned on the foot 14 need not be secured thereto. Thus, although the leg 12 itself may stabilize the apparatus 10 against a wall from which it hangs, the stabilizer 40 may secure the leg 12 against movement along the wall. Thus, the stabilizer 40 may be nailed to a wall, or may have other mechanisms such as spikes, plates, bumpers, grippers, and the like for minimizing motion of the leg 12 with respect to a wall. For example, geometry and position of the stabilizer 40 may be such that even when a nail is used, the connector 20 may still operate behind the leg 12. The connector 20 may be designed to so operate. In another embodiment, the connector 20 may be positioned in contact against the wall, requiring movement away from the wall for adjustment of height. In each embodiment forces are shared between the leg 12 and connector 20 differently.
Returning to the hanger 22, a housing 42 may be secured directly to the leg 12 or fastened to a mounting plate 38. A housing 42 may be provided with a slide 44 fitted thereto. The slide 44 is movable with respect to the housing 42 for adjusting the hanger 22 according to a width of a top plate from which the apparatus 10 is to hang. A finger 45 may be secured at an end of the slide 44. Accordingly, the finger 45 and the leg 12 will capture between them the top plate or other surface. The surface may be on top of a structure such as a wall, foundation, fence, rafter, or the like, all referred to herein as the "wall."
The top surface may be horizontal, typically, but need only be substantially horizontal. That is, the hanger should not slide along transversely 64 with respect to the wall or surface unintentionally. Two copies of the apparatus 10 may be set at two separate heights of blocks 34 along their respective legs, with nails through the slide 44 into the surface to preclude transverse sliding along a surface that is tilted from horizontal. Thus, stability and safety must be accommodated, but substantially horizontal may be thought of as providing the majority of support longitudinally 60 directly from the wall (e.g. structure) to the hanger 22, with sufficient transverse 64 support to safely prevent slipping.
In one embodiment, the slide 44 may be secured to the housing 42 by a lock 46. The lock 46 may be a pin 46, provided with a keeper 48 such as a lynch pin 48. The lynch pin 48 may be tethered for safekeeping. For additional security, the finger 45 may be bent toward the leg 12 to fit under a top plate. Thus, in one embodiment, the finger 45 may even be bent to return parallel to the slide 44.
Nevertheless, gravity is typically sufficient to maintain the leg 12 in position, supported by the hanger 22 with a straight finger 45. The finger 45 may support a substantial couple created by a load on the deck 13 and foot 14, in conjunction with the support to the hanger 22. The couple is transferred to the finger 45 and connector 20 or other member touching the wall.
A climber 50 may be provided as part of, or the entire, connector 20. The climber 50 is designed to be secure under the load presented by the foot 14. For example, a balance of forces, even with the weight of the foot 14 alone is sufficient to position the climber 50 securely against the first available block 34. In certain embodiments binding may occur with a minimal block 34, and even with none at all. However, to prevent free-falling from an unloaded position (e.g. such as from a bouncing load), block 34 may be relied upon.
The climber 50 will provide simple adjustability of the foot 14 upward or downward. A simple tilting of the foot 14 counter to the load applied to or by the deck 13 will free the climber 50 from a block 34, so the leg 14 may be lifted higher to another block 34. The specific geometry of the climber 50 provides both secure attachment, positioning, and adjustability of the foot 14 with respect to the leg 12.
The climber 50 may contain multiple hangers 52, 54 such as the plates 52, 54. In addition, a catch 56 may extend between the hangers 52, 54. The catch 56 may be a bolt 56 secured by a nut 58. In one currently preferred embodiment, the nut 58 be a lock nut, such as a crown nut 58 provided with a nylon, friction-producing member to eliminate vibration or accidental removal of the nut 58. Other locking mechanisms may be available. In one embodiment, the catch 56 may be a rod welded permanently to the hangers 52, 54 to form the climber 50.
The climber 50 may move in a longitudinal direction 60 with respect to the leg 12. The climber 50, and particularly the hangers 52, 54 support the weight and moment of the deck 13, through the foot 14, in a longitudinal direction 60. The climber 50 also supports the foot 14 in a lateral direction, the foot 14 thus extending away from a wall supporting the leg 12.
Likewise, the hangers 52, 54, or plates 52, 54, in conjunction with the catch 56 may be slidably positioned along the leg 12 to resist motions (e.g. translation, rotation) in a transverse 64 direction. Thus, longitudinal 60, lateral 62, and transverse 64 directions may be referred to in describing the functionality, forces, and operation of the apparatus 10, and of the foot 14 and riser 16 with respect to the leg 12.
In addition, a circumferential direction 65 may be described with respect to any pivot point. For example, a circumferential direction 65 may be described with respect to the contact point (e.g. 205, see FIGS. 9-10) between the foot 14 and the leg 12 or with respect to the catch 56. Similarly, a circumferential direction 65 may be described with respect to any rotation of a component of the apparatus 10.
Regarding the deck 13, a positioner 66 or slide 66 may be provided to position decking materials 13 along the foot 14. For example, a user may desire space for working between the decking 13 and a wall supporting the leg 12. Accordingly, the positioner 66 may restrain decking 13 toward a distal end of the foot 14 away from the climber 50. The positioner 66 may be provided with a lock 68. The lock 68 may be designed to operate in a variety of manners. For example, a thumb screw, latch, pin, cam lock, or the like may be used for rapid or slow, distinct or continuous, convenient or inconvenient adjustment, for a variety of reasons.
In general, the flanges 70, 72 of the foot 14 may be connected by a single web 74. Alternatively, as discussed with respect to the leg 12, a different cross-section may be selected for the foot 14. As a practical matter, the outermost fibers of the flanges 70, 72 support the bending moment applied to the foot 14 by loads to the decking 13. Unless buckling failure becomes a significant design concern, the web 74 is sufficient for maintaining both position, load, and tolerating loading deflection.
Nevertheless, a tubular cross-section, whether rectangular, square, circular, or the like may be provided for the foot 14. In one presently preferred embodiment, reduced weight may be provided by a single web 74 extending between a pair of flanges 70, 74. Due to the nature of the bending loads on the foot 14 when personnel and material are positioned on the decking 13, double flanges 70,72 may be recommended.
A retainer 76 may form an end stop 76 on the foot 14. Accordingly, the retainer 76 may prevent movement of the base 24 beyond the end of the foot 14. In one embodiment, the retainer 76 or plate 76 may be welded or otherwise permanently secured to the flanges 70, 72 and web 74 of the foot 14. In other embodiments, the retainer 76 may be secured to be removable, such as by use of a clamp, set screw, bolt, rivet, or the like.
The base 24 may also contain a positioner 78 for positioning the base 24 along the foot 14. In one embodiment, the positioner 78 may also provide other functional features. For example, the retainer 66 or positioner 66 need not be particularly robust. On the other hand, protection and support of a user against a railing 18 may preclude use of a small positioner 78. Thus, the positioner 78 may be effectively designed to have sufficient bearing length in a lateral direction 62 for providing stability and structural integrity for all functions thereof
The positioner 78 may be secured movably, fixedly, pivotably, rotatably, or the like, with respect to a receiver 80. The receiver 80 may be adapted to receive the riser 16 supporting the railing 18. In one embodiment, the receiver 80 may be welded to the positioner 78. A lock 82 may secure the positioner 78 at a position longitudinally 62 (laterally 62 with respect to the leg 12) along the foot 14.
The lock 82 may be designed to operate in any suitable manner. For example, a cam lock, a thumb screw, a pin, a spring-loaded detent, or the like may be used.
The wall 84 of the positioner 78 may be designed to support substantial loads. The railing 18 and the riser 16 may form a security device against falls, leaning, and the like of workers operating on the decking 13. Accordingly, the longitudinal 62 dimension of the positioner 78 may be designed to support such loads, whether representing a static or impact loading condition.
In certain embodiments, a bolt 86 secured by a nut 88 may fasten the receiver to the positioner 78. Likewise, a second bolt 90 and nut 92 may be provided. In one embodiment, either of the bolts 86, 90 may actually form a pivot, with the other bolt 90, 86 providing a lock. Thus, removal of one of the bolts may provide collapsibility of the riser 16 by rotation (pivoting) of the receiver 80 with respect to the positioner 78.
An aperture 94 may be provided for receiving the end 96 of the riser 16. In one embodiment, a keeper 98 such as a lynch pin 98 may secure a retainer 100, pin 100 or the like, extending through the receiver 80 and riser 16. Similarly, a bolt 86 may be provided in place of the pin 100. Likewise, in one embodiment, the bolt 90 may provide a pivot, while a pin 100 is used in place of the bolt 86. Thereby, a bolt 86 may be used in position of the pin 100.
The receiver 80 may be quickly unpinned and pivoted about the bolt 90 to a position parallel to that of the positioner 78. Accordingly, the riser 16 may be positioned more-or-less parallel to and beside both the foot 14 and the leg 12, without removal from the base 24, when in a completely collapsed position (see FIG. 2).
The bracket 26 may be provided with apertures 102 for receiving nails, screws, and the like penetrating into the railing 18. Accordingly, the rail 18 may be secured from removal during use. For collapse of the receiver 80 to position the riser 16 alongside the foot 14, the nails or screws may be removed from the aperture 102, and the railing 18 may be removed.
In one embodiment, a length 104 of a foot 14 may extend two or even three feet from the leg 12. Meanwhile the depth 106 of the foot 14 may be designed to accommodate the bending loads consistent with the length 104. For example, stress in the flanges 70,72 is substantially increased by positioning a user at a comparatively long length 104 from the leg 12. Support of a heavy user at the full length 104, such as positioned near the riser 16 and leaning against the riser 16, may require an increased depth 106.
The width 108 of the flanges 70, 72 may be increased for increased loads. However, as a practical matter, the stress within the flanges 70, 72 is affected directly by the width 108 but to a third power of the depth 106. Accordingly, for a particularly long length 104, comparatively, an increase in depth 106 may be preferable, for a weight and cost criteria for a foot 14.
In securing and adjusting the foot 14 with respect to the leg 12, a clearance 110 may be provided between the catch 56 and the foot 14. For example, the height 112, and length 114 of each of the plates 52, 54 (hangers 52,54) may be designed to provide a clearance 110 on a diagonal with respect to the foot 14. Accordingly, lifting the foot 14 tends to tilt (pivot) the foot 14 in a circumferential direction 65 and climber 50 with respect to the leg 12.
Accordingly, the catch 56 will rotate circumferentially 65 away from the blocks 34 and leg 12. Thus, the clearance 110, when positioned to extend in a substantially lateral direction 62, with respect to the leg 12, may provide sufficient clearance for the catch 56 to pass by a block 34 as the foot 14 is moved up or down (longitudinally 60) the leg 12. When the foot 14 is released, the flanges 70,72 rotate counter to the upward circumferential direction 65 bringing the catch 56 into contact with the flange 30 and a block 34.
The catch 56 and foot 14, along with the climber 50 may slide down in a longitudinal direction 60 from any position of release until being stopped by the next available block 34. However, if a user rotates the foot 14 in a circumferential direction 65, then the foot 14 may be translated in a longitudinal direction 60 upwardly or downwardly before being released. Thus, a simple lifting motion can adjust the position of the foot 14. A user may require only a single hand positioned somewhere near the middle of the foot 14 in order to adjust the position of the foot 14 and the catch 56 with respect to the leg 12.
The height 112, length 114, width 116, and thickness 118 selected for the climber 50 may be determined by both structural strength requirements and operational requirements such as the clearance 110. Similarly, free motion, with stability in a transverse direction 64 may be provided by close tolerances between the plates 52, 54 and the leg 12.
The pitch 120 of the blocks 34 may be selected to be regular or irregular. In one embodiment, the pitch 120 may be uniform between blocks 34. In alternative embodiments, selected positions for blocks 34 may effectively provide irregular pitch designed for specific locations of the foot 14 suitable for certain tasks by users.
The thickness 122 of the bottom plate 36 or security stop 36 may be designed to survive an impact load of a drop onto a loaded foot 14. However, the foot 14, when loaded, cannot escape a block 34. In one presently preferred embodiment, the security stop 36 may be a plate, although bars, rods, and the like may be used. A security stop 36 may be welded to the leg 12. Since the catch 56 may be bolted, such a construction may provide manufacturing assembly and repair disassembly with less safety risk.
For example, bolted fastening of the security plate 36 represents an additional risk if such a bolting mechanism were to be loosed, corroded, over-tightened, or the like. Accordingly, in one presently preferred embodiment, the security stop 36 may be welded directly to the leg 12. Similarly, the thickness 124 of the spur 40 or stabilizer 40 may be designed to support loading in a transverse direction 64.
In certain embodiments, different tools or attachments may be secured to the stabilizer 40 or spur 40. For example, in working on brick, a user may desire to position a large wooden plate on the spur 40, in order to minimize pressure against previously laid brick and mortar that has not securely set, or to extend to previously set brick.
In another embodiment, a spike may be attached to slightly penetrate wall sheathing, thus preventing motion. In another embodiment, near the vertex 128 near the maximum depth 126 of the spur 40, an aperture 130 or other fixative 130 may be provided for reducing, resisting, or eliminating movement in a transverse direction 64.
In one embodiment, the edges 132 of the plates 52, 54 may resist motion in a transverse direction 64. In another embodiment, the aperture 130 may be provided with a bolt, or multiple apertures 130 may be provided with fasteners suitable for securing a plate extending below the plates 50, 52. Thus, a plate parallel to the stabilizer 40 and extending therebelow, may secure the leg 12 against loading in both longitudinal 60 and transverse 64 directions as a result of activities and loads on the decking 13.
Referring to FIGS. 2-5, portions of the apparatus 10 of FIG. 1 are illustrated in embodiments provided with geometries and assemblies for promoting collapsible storage and transport. In operation, an apparatus 10 may be shipped as illustrated in FIG. 2. Simple retainers, such as straps, elastic bands, wires, and the like may be used to secure the leg 12, foot 14, and riser 16 in relative positions.
The brackets 26 may be built offset from the riser 16 in order to provide clearance between the riser 16 and the foot 14. In one embodiment, the positioner 66 and positioner 78 may have dimensions suitable for providing clearance between the riser 16 and the positioner 66, as well as clearance with respect to the catch 56 and plate 54.
A user may release the members 12, 14, 16 to move with respect to one another. Accordingly, the foot 14 may be pivoted counter to a circumferential direction 65, thus dropping the end plate 76 or end stop 76 clockwise away from the leg 12. The climber 50 will thus pivot the catch 56 upward about a center of rotation defined by a proximate end of the foot 14.
The slide 44 may be extended from the housing 42 a distance suitable for fitting over a top plate. The slide 44 may be secured by the lock 46 to snug the finger 45 as close as is practical to the top plate.
The spur 40 or stabilizer 40 may be secured against sheathing, a stud, or the like to resist transverse 64 motion. The riser 16 may then be pivoted circumferentially 65 to lift the bracket 26 into position for receiving a rail 18. The receiver 80 may be locked into place with respect to the positioner 78.
The positioner 78 may be slid along the foot 14 to a suitable position and locked, using the lock 82. Similarly, decking 13 may be positioned on the foot 14 by the positioner 66 snugging the decking 13 against the positioner 78. The lock 68 may be used to fix the positioner 66 with respect to the foot 14. The rail 18 may be positioned within the bracket 26 and secured by fasteners throughout the apertures 102.
The apparatus 10 may be collapsed for storage by the reverse procedure. The fasteners may be removed from the apertures 102 so the rail 18 may be removed. Thereafter, the riser 16 may be removed from the receiver 80, or the receiver 80 may simply be rotated with respect to the positioner 78 to become parallel to the foot 14. Thereafter, the foot 14 may be pivoted in a circumferential direction 65 to a position parallel to the leg 12. The entire assembly may be wired, strapped, or otherwise restrained to remain in a bundle.
Referring to FIGS. 1-5, and more particularly to FIGS. 2-5, the pivoting mechanisms of the apparatus 10 may be designed in a variety of configurations. In one presently preferred embodiment, a pivot 140 may be provided as a pin, rivet, shaft, or the like. The pivot 140 may be positioned at any appropriate location with respect to the positioner 78 and receiver 80.
In one presently preferred embodiment, the pivot 140 may be centrally located with respect to both the positioner 78 and the receiver 80. In another alternative embodiment, the pivot 140 may actually be positioned as one of the extensions 142, 144. In another embodiment, the pivot 140 may be positioned as illustrated in FIG. 3, with the extensions 142, 144 being designed to act as a service stop 142, and a storage stop 144.
In one embodiment, the storage stop 144 may be positioned to actually serve as a second service stop 142. That is, the receiver 80 may rotate about the pivot 140 in a circumferential direction 65. In an extended or service position in which the riser 16 extends in a longitudinal direction 60 with respect to the leg 12, the receiver 80 is stopped against the service stop 142 and the service stop or storage stop 144, as well.
By proper selection of dimensions, the service stop 142 may also act as a storage stop. For example, when the receiver 80 is rotated or pivoted down to be positioned parallel to the positioner 78, the extensions 142, 144 both may be positioned to engage or stop rotation of the receiver 80 above the pivot 140.
The apertures 146 may be used to receive bolts, fasteners, or the like, such as the pin 100 illustrated in FIG. 1. In one embodiment, a sleeve 148 may be provided as part of a lock 150. The lock 150 may include a pin 152 or slide 152 operating within a sleeve 148. The slide 152 may be restrained from removal from the sleeve 148. Accordingly, once the receiver 80 is rotated about the pivot 140 to stop against the stops 142, 144 the slide 152 may be aligned with another sleeve 154 secured fixedly to the poisoner 78. Thus, a quick and already aligned motion of the slide 152 into the sleeve 154 can lock the receiver 80.
One may note that the cross-sections of the sleeves 148, 154, slide 152, and stops 142, 144 may be rectangular, square, round, tubular, hollow, solid, or the like, according to need. As a practical matter, the stops 144 may be provided with sleeves 156 on shafts 158. The sleeves 156 may be elastomeric, providing a certain resilience and buffering of loads, thus reducing the probability of bending, fracturing, etc. the stops 142, 144.
In another embodiment, the sleeve 156 may be provided of steel, and may be fixed to the receiver 80. Accordingly, the extension 144 may actually be comprised of a sleeve 156 and shaft 158, where the shaft 158 is secured fixedly, such as by welding to the positioner 78.
Likewise, the extension 142 may be comprised of a sleeve 156 and shaft 158, where the shaft 158 is welded or otherwise securely fastened to the positioner 78, and the sleeve 156 is fixed to the receiver 80. Accordingly, the pivot 140 may be manufactured in place of the extension 144 or the extension 142. Nevertheless, in one presently preferred embodiment, the pivot 140 is located as illustrated in FIG. 3, with simple shafts 142, 144 serving as the stops 142, 144.
A detent, such as a shaft, key, or ball, driven by a spring to extend from an aperture within the slide 152, or the like, may be used to secure the pin 152 from removal out of the sleeve 148, and to restrain the slide 152 against simple removal (e.g. by bumping, vibrating) from the sleeve 154.
An advantage of the apparatus illustrated in FIG. 3 is the lack of alignment required by a user. All alignments may be secured, along with tolerances for meeting alignment criteria by the factory manufacturing the apparatus 10.
Referring to FIG. 4, the receiver 80 may be pivoted to a storage position. The geometry of the base 24 may position the sleeve 148 in any of several positions with respect to the stop 144. Leverage of the various stops 142, 144 and sleeves 148, 154 against the receiver 80 and positioner 78 may be designed to support the expected
Referring to FIG. 5, a geometry is illustrated for positioning the receiver 80 with respect to the positioner 78. Several centers 160, 162, 164, 166 of rotation are illustrated. Likewise, several radii 168, 170, 172, 174 of various points on the base 24 are illustrated. The pivot 140 may have a center 160 causing a radius 168 of curvature for a corner or outermost extremity of the receiver 80 to rotate in an arc. Thus, the centers 162, 164 of the respective stops 144, 142 may be designed to engage the receiver 80 within the radius 168. Similarly, the lock 150 may be positioned at a center 166 within a radius 170 for engaging the receiver 80 securely.
In one embodiment, a ball 175 or pin 175 may be spring-loaded and positioned to operate within a race 176 between a depression 178 below the ball 175. Thus, a detent 180 may be created for provided some nominal amount of force for retaining the receiver 80 in a deployed, or a collapsed condition as desired. Thus, the detent 180 may prevent the receiver 80 from moving while a user effects securement of the lock 150.
Referring to FIG. 6, any lock 68, 82, 150 may use a cam, lever, or other suitable mechanism. For example, in FIG. 6, a slide 152 is illustrated having a lever 182 or handle 182 secured for rotating a shaft 184 or spindle 184. The diameter 186 of the shaft 184 may be selected for suitable strength in operation within the sleeves 148, 154 or the like.
However, an offset 188 may be provided in an eccentric 190. Accordingly, the lever 182 may be used to rotate the shaft 184 in order to engage the eccentric 190 against a surface. Thus, for example, the eccentric 190 could be moved into an elliptical sleeve 154 (see FIG. 4) and the cam 190 may be used to secure the shaft 184 against being moved. Similarly, eccentrics 190 or cams 190 may be used to pass completely through a sleeve 154, and rotate to a position of engagement with a tooth, stud, or the like.
Referring to FIG. 7, an alternate embodiment of an apparatus 10 in accordance with the invention is illustrated. In the embodiment of FIG. 7, the foot 14 is illustrated in a cutaway view having the positioners 66, 76 removed. The climber 50 is formed of bar or rod stock rather than the assembly illustrated in FIG. 1. The web 28 is formed with a single flange 32. Thus, a T-shaped cross-section is used to form the leg 12.
The web 28 is fabricated to contain alternating buttresses 192 below notches 194 or seats 194 adapted to receive a hanger 196 of a climber 50. The climber 50, in addition to the hanger portion 196 may be formed to have a shaft portion 198 extending transversely 64 under the foot 14.
In one embodiment, a stop 200 may extend from an attachment to the foot 14, or from a rider 202. The rider 202 may serve the same purpose on each side of the leg 12 as would the plates 52, 54 (see FIGS. 1-2). Nevertheless, the riders 202 primarily limit twisting of the foot 14, and support against transverse 64 motioned by the foot 14. Thus, the shaft portion 198 of the climber 50 may rotate in a bushing 204 or sleeve 204 secured, such as by welding, to the underside of the foot 14.
The security stop 36 and the stabilizer 40 may be formed in any suitable manner to operate with the leg 12. Similarly, the end stop 76 may be provided on the foot 14 in any suitable manner.
In the embodiment of FIG. 7, the leg 14 may be pivoted in a circumferential direction 65 by elevating the end stop 76 above the riders 202. Accordingly, the bushing 204 is rotated closer to the buttresses 192 and notches 194. Thus, the foot 14 will rotate about the proximate end 205 attached to the riders 202. The riders 202 are free, with respect to the leg 12, to slide up and down 60 with the foot 14. The riders 202 may typically be welded to the foot 14, and may be strengthened further with doublers (additional plates) between the flanges 70, 72.
As the foot 14 is rotated about its proximate end 205, the bushing 204 will move the shaft portion 198 closer to the buttresses 192, while the shaft portion 198 rotates with respect to the bushing 204. Accordingly, the hanger portion 196 will be pushed out of the slot 194 or notch 194.
Once the hanger portion 196 has moved out of the slot 194, it may tend to drop, rotating within the bushing 204. Therefore, the stop 200 may extend transversely 64 underneath the climber 50 in order to limit downward rotation. Accordingly, thus restrained, the climber 50 may be drawn (translated) with the foot 14 upward 60 or downward 60 along the leg 12 with the foot 14. Thus, when the foot 14 is released and counter-rotated circumferentially 65 back into its laterally extending position, the bushing 204 draws the hanger portion 196 back into the next available notch 194 in the web 28.
In the embodiment of FIG. 7, the rear flange 30 is absent. The rear flange 30, when used, is subject to a compression component, and the flange 32 a tension component from the bending moment presented by a load applied to the decking 13 over the foot 14. A tensile component of load in the web 28 and flange 32 comes from the weight applied to the foot 14. Accordingly, where buckling is not a realist consideration, a web 28 may not require a flange 30 opposite the flange 32. By any means, the principle of a foot 14 connected by a climber 50 to a leg 12 operates similarly, because of a clearance 110 between a proximate end 205 of a foot 14, and a catch 56, such as the hanger portion 196 that is selectively caught on a block 34 or buttress 192 of the leg 12. Nevertheless, in certain respects, the embodiment of FIG. 1 may tend to operate more rigidly, whereas, by comparison, the embodiment of FIG. 7 tends to operate in reliance on suspension.
Referring to FIG. 8, the hanger 22 at the top end of the leg 12 may be adapted to fit over any suitable top plate in a construction wall. The housing 42 may be provided with a lock 46 such as a pin 46 as hereinbefore described. Accordingly, the lock 46 may be removed and the slide adjusted to extend from the housing 42 an appropriate distance required for the leg 12 and finger 45 to clear or span the opposite sides of the top plate.
The pin 46 may be removed for adjusting the slide 44 with respect to the housing 42. Thus, the pin 46 may be removed from the apertures 206 and reinserted where needed. In one embodiment, the mounting plate 38 may be dispensed with in favor of a tubular cross-section for the housing 42. Thus, the housing 42 may be welded directly to the flanges 30, 32 and web 28.
Additional features and functions of the hanger 22 may be derived from complete and selective separability of the slide 44 from the housing 42. In one embodiment, the slide 44 may be sufficiently long to extend completely through the housing 42. Likewise, the slide 44 may be removed from the back end of the housing 42 into which it is inserted for operation. Thus, upon completion of a project in the area of the hanger 22, the hanger 22 can be dismantled. Thereby, the housing 42 may be removed from one side of a wall while the slide 44 is removed from the other. In this manner, the hanger 22 may be fit into a space or over a top plate that will eventually be closed in. Nevertheless, the hanger 22 may be dismantled for simple removal, despite the large and other wise awkward geometry that may be presented.
In certain embodiments, the slide 44 may be removed, re-inserted, and locked into the front of the housing 42. The finger 45 may thus extend down over a folded (collapsed) foot 14, near the end stop 76. The foot 14 may be moved along the leg 12 to facilitate capture of the foot 14 (e.g. end stop 76) by the finger 45. Thereby, the finger 45 may serve as a detent for maintaining the apparatus in a comparatively small envelope for storage, without additional parts, fasteners, and the like.
In one alternative embodiment, the post 16 may be removed from the base 24 and nested in the leg 12 or foot 14, between the flanges 30, 32 or flanges 70-72, respectively. A clip, retainer, bracket, detent, or other capture mechanism may retain the post for storage and transport. In certain situations, the railing 18 and post 16 may not be appropriate. For example, indoors in a hallway, outdoors between a foundation and the wall of the excavation, hanging from rafters, disposition of a very short deck with short distances between two units 10, etc. may preclude clearance or obviate the need for the railing 18. For example, three or more of the apparatus 10 arranged on alternating sizes of a deck 13 may suspend the deck 13 from rafters. Positioning the foot 14 at a comparatively high elevation above the security stop 36 may preclude use of the railing 18.
Referring to FIGS. 9-10, alternative embodiments of the plates 52, 54 are illustrated. In the embodiment of FIG. 9, the climber 50 may be provided with a gusset portion 210 on the plate 52. The gusset portion 210 may extend further along the foot 14, while still providing substantial clearance for the decking 13 along the top flange 70. Accordingly, loads may be supported by several additional improvements. For example, a doubler 208 may be formed of an additional plate positioned between the flanges 70, 72 further connecting the plate 52, 54 to the foot 14. Thus, a doubler 208 may be welded to the flanges 70, 72 and the plates 52, 54 may be welded to the doubler 208. Likewise, stress-relieving, malleable welds may secure the flanges 70, 72 between the plates 52, 54.
In one embodiment, the plates 52, 54 may be provided with a radius of curvature 212 for distributing and reducing stress. Fracture toughness and stress concentration factors can be substantial in articles having dramatic changes in cross-section. Accordingly, a radius of curvature 212 may relieve stress concentration factors that would otherwise debilitate the structural integrity of the plates 52, 54. To reduce or eliminate stresses or a stress concentration at a sharp corner, the plates 52, 54 may be secured to the doublers 208 and to the flange 72, at any appropriate location. Meanwhile, the plates 52, 54 may be secured to the flange 70 only away from the radius of curvature of 212. Accordingly, the upper edges of the plates 52, 54 may be free to relieve stress concentrations that would otherwise occur at a joint or sharp change in section.
The embodiment of FIG. 10 illustrates a doubler 208 shown in visible and hidden lines between the flanges 70, 72. The doubler 208 extends back to an end 205 of the foot 14, and may attach to an end plate 214. The end plate 214 may provide additional strength, as well as bearing surface for lubrication against the leg 12. Thus, the flanges 70, 72 may provide less binding and receive less damage from impact loads of handling.
The gusset portion 210 of the plates 52, 54 in the embodiment of FIG. 10 may not provide clearance (such as the radius of curvature 212) for decking 13 to be placed substantially against the leg 12. The additional capacity for loading may be provided by the gusset plate 210 extending to the foot 14 at a position away from the leg 12. This may justify a lack of proximity or access to the leg 12, and the increased moment created by positioning the decking 13 farther away from the leg 12. The catch 56 and the blocks 34 operate exactly the same as illustrated in FIGS. 1-2. Similarly, the security stop 36 operates as hereinbefore described.
Referring to FIG. 11, certain alternative embodiments of features are illustrated in accordance with the invention. For example, the flare 41 of the stabilizer 40, the latching assembly of the hanger 22 for storage, with the foot adjusted to be captured thereby, and the alternative pivoting mechanisms and stops (e.g. consistently and selectively designed as members 140, 142, 144), are illustrated as described hereinbefore.
One may see from FIGS. 1-11 that the invention provides a leg 12 suspended from a hanger 22 that may be fitted to a top plate or other surface of a construction wall or other similar, substantially horizontal structure. The leg 12 may be gripped by a climber 50 supporting a foot 14 for extending laterally 62 therefrom. The foot 14 may be provided with positioners 66, 78 for locating decking 13 at a desired proximity to the leg 12.
Similarly, the positioner 78 can support a receiver 80 from which a riser 16 may extend to hold a railing 18 for additional security. The riser 16 and receiver 80 may pivot down from a locked or deployed position to lie parallel to the foot 14 in a storage position. The foot 14 may be rotated about a proximate end 205 of the foot 14 to release the catch 56 from the blocks 34. Accordingly, the foot 14 may be laid approximately parallel to and against the frontal flange 32 of the leg 12. Accordingly, the leg 12 with the foot folded thereagainst, and the riser 16, absent its railing 18, folded therebeside, may form a small package of three substantially parallel members 12, 14, 16 for simple securement, transport, and storage. Alternatively, the post 16 may be removed from the base 24 and nested between the flanges 30, 32 or the flanges 70, 72, being maintained by any appropriate fastener, for storage or for working in situations for which the railing 18 is inappropriate. Any or all of the alternative embodiments of the apparatus 10 or any individual component thereof may be used alone, in combination, or deleted, in any consistent design approach to implementing a desired embodiment of the invention herein described.
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. 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.
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A deck support may be created to hang from a top plate of a wall in residential or other construction. An upright or leg may provide support of the weight of the deck supported on a foot extending laterally from the leg. The foot may be provided with a climber attachment that secures the foot extending horizontally from the leg, and yet is readily adjustable without alignment, line-of-sight adjustment, removal or repositioning of pins, and the like. The apparatus may operate to support a user installing soffits, fascia, trusses and other assemblies near the upper portions of walls at any stage of construction. Adjustment may be done safely by a single user employing a single hand. Alignment and engagement are simple and automatic by the climber securing the foot to the leg. A hanger bracket may extend adjustably across the top plate of a wall to support the leg extending vertically therebelow. The hanger may be opened to release from a wall after construction has been finished around the hanger rendering it otherwise non-removable. The entire assembly may be collapsed, without separation of parts, for transportation and storage.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a power storage device capable of being charged without receiving power from commercial power.
[0003] 2. Description of the Related Art
[0004] Electronic devices such as a cellular phone, a mobile computer, a digital camera, and a digital audio player have been advanced to be downsized, and a large variety of products have been shipped to the market. In such portable electronic devices, a secondary battery as a power supply for driving is incorporated. As a secondary battery, a lithium-ion battery, a nickel-hydrogen battery, or the like is used. The secondary battery is charged by receiving power from commercial power. For example, a user connects an AC adapter to a household plug socket deposited in each home to charge the secondary battery.
[0005] Although portable electronic devices are convenient, the hour of use is restricted by the capacity of the secondary battery. The user of the electronic device needs to pay attention to remaining battery level of the secondary battery and to be always conscious of the charging time. Further, the charging plugs of the electronic devices are different for each device or for each model. Therefore, many AC adapters are required to be possessed.
[0006] In contrast, a power storage device is disclosed, in which a permanent magnet is moved back and forth in a slide where a coil is rolled to generate electromagnetic induced electromotive force, whereby the power storage device is charged (for example, Reference 1: Japanese Published Patent Application No. 2006-149163 (FIG. 1, and p. 4)). According to this device, power storage devices are considered to be capable of being charged without receiving power from commercial power supply.
SUMMARY OF THE INVENTION
[0007] However, the power storage device utilizing electromagnetic induced electromotive force generated by a coil and a permanent magnet needs a movable portion, and therefore, downsizing of the power storage device is structurally difficult. Moreover, such a power storage device is required to move the magnet as well as to possess it, and the weight of the device is increased because the permanent magnet is used. Therefore, the conventional power storage device has a problem that the volume and the weight thereof are increased, and portability is lost.
[0008] Incidentally, in the field of portable electronic devices in the future, portable electronic devices will be desired, which are smaller and more lightweight and can be used for a long time period by one-time charging, as apparent from provision of one-segment partial reception service “1-seg” of terrestrial digital broadcasting that covers the mobile objects such as a cellular phone. Therefore, the need for the power storage device is increased, which is small and lightweight and capable of being charged without receiving power from commercial power.
[0009] It is an object of the present invention to provide a power storage device that can be charged without receiving power from commercial power, in which the charging is performed easily while reduction in size and weight or reduction in weight and thickness is achieved. It is another object of the present invention to maintain durability and required functions in the case where such a power storage device becomes small and downsized.
[0010] The present invention is to provide a power storage device including an antenna for receiving an electromagnetic wave, a capacitor for storing power, and a circuit for controlling store and supply of power. In a case where the antenna, the capacitor, and the control circuit are integrally formed and thinned, a structural body formed of ceramics or the like is used for part of the integral structure.
[0011] The structural body formed of ceramics or the like has resistance to pressing force or bending stress applied from outside. Therefore, in the case of thinning the antenna and the control circuit, the structural body formed of ceramics or the like serves as a protector. In addition, this structural body can have a function as a capacitor.
[0012] According to the present invention, a circuit for storing power of an electromagnetic wave received at an antenna in a capacitor and a control circuit for discharging the given power are provided, whereby lifetime of the power storage device can be extended.
[0013] When the structural body formed of ceramics or the like is used for part of the power storage device, rigidity can be improved. Accordingly, even when the power storage device is thinned, durability and required functions can be maintained.
[0014] For example, even when pressing force is applied with a pointed object such as a tip of a pen, malfunction due to stress applied to the capacitor and the control circuit can be prevented. Moreover, resistance to bending stress can also be provided. In addition, when a wiring for connection is formed in the structural body formed of ceramics or the like so that the antenna and the control circuit are connected, malfunction caused by detachment of a connection portion can be prevented even when bending stress is applied.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a plan view showing one mode of a power storage device of the present invention.
[0016] FIG. 2 is a cross-sectional view showing an example of a structure taken along a line A-B of FIG. 1 .
[0017] FIG. 3 is a cross-sectional view showing an example of a structure taken along a line A-B of FIG. 1 .
[0018] FIGS. 4A to 4C are plan views showing an example of a power storage device that includes a first structural body provided with an antenna, a second structural body provided with a capacitor, and a power supply control circuit.
[0019] FIGS. 5A and 5B are cross-sectional views showing an example of a power storage device that includes a first structural body provided with an antenna, a second structural body provided with a capacitor, and a power supply control circuit.
[0020] FIGS. 6A to 6D are plan views showing an example of a power storage device that includes a first structural body provided with an antenna, a second structural body provided with a capacitor, a power supply control circuit, and a ceramics antenna.
[0021] FIGS. 7A and 7B are cross-sectional views showing an example of a power storage device that includes a first structural body provided with an antenna, a second structural body provided with a capacitor, a power supply control circuit, and a ceramics antenna.
[0022] FIG. 8 is a view showing an example of a power supply control circuit in a power storage device.
[0023] FIG. 9 is a view showing an output waveform of a low-frequency signal generation circuit.
[0024] FIG. 10 is a view showing a structure of a low-frequency signal generation circuit of a power supply control circuit in a power storage device.
[0025] FIG. 11 is a timing chart of a signal output from the low-frequency signal generation circuit shown in FIG. 10 .
[0026] FIG. 12 is a diagram showing a structure of a power supply circuit of a power supply control circuit in a power storage device.
[0027] FIG. 13 is a view showing a structure of a power storage device provided with a plurality of antennas.
[0028] FIG. 14 is a view showing a structure of a power storage device having a function of controlling supply of power stored in a capacitor.
[0029] FIG. 15 is a view showing a structure of a control circuit of a power supply control circuit in a power storage device.
[0030] FIG. 16 is a view showing a structure of a voltage-comparing circuit of a power supply control circuit in a power storage device.
[0031] FIG. 17 is a cross-sectional view for explaining a structure of a thin film transistor used for forming a power supply control circuit.
[0032] FIG. 18 is a cross-sectional view for explaining a structure of a MOS transistor used for forming a power supply control circuit.
[0033] FIG. 19 is a block diagram showing a structure of an active wireless tag.
[0034] FIG. 20 is a view showing an example of distribution management using an active wireless tag.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Hereinafter, an embodiment mode and embodiments of the present invention is described below with reference to the accompanying drawings. Note that the present invention is not limited to the following description and it is easily understood by those skilled in the art that modes and details can be modified in various ways without departing from the purpose and the scope of the present invention. Accordingly, the present invention should not be interpreted as being limited to the description of the embodiment mode below. Note that like portions in the drawings may be denoted by the like reference numerals in a structure of the present invention to be given below.
[0036] A power storage device of the present invention includes a first structural body provided with an antenna, a power supply control circuit formed using a semiconductor layer interposed between insulating layers that are provided over and below the semiconductor layer, and a second structural body provided with a capacitor and having higher rigidity than the first structural body. This second structural body includes at least a dielectric layer inside, and the capacitor is preferably formed using the dielectric layer. The second structural body is formed of ceramics or the like, which has high rigidity, whereby mechanical strength of the power storage device can be maintained even when the power supply control circuit is thinned.
[0037] FIG. 1 shows one mode of such a power storage device. A first structural body 10 is fowled of an insulating material. The thickness of the first structural body 10 is 1 μm to 100 μm, preferably, 5 μm to 30 μm. As the insulating material, a plastic sheet, a plastic film, a glass epoxy resin, a glass plate, paper, a nonwoven fabric, or other variety of objects can be used. An antenna 16 is formed using a conductive material at least on one of surfaces of the first structural body 10 . A structure of the antenna is preferably differentiated depending on a frequency band of an electromagnetic wave used by the power storage device. The antenna may have a suitable shape for a frequency band, when a frequency in a short wave band (electromagnetic wave with frequency of 1 to 30 MHz), an ultrashort wave band (electromagnetic wave with frequency of 30 to 300 MHz), or a microwave band (electromagnetic wave with frequency of 0.3 to 3 GHz) is used. FIG. 1 shows a dipole antenna, which is suited for communication in the ultrashort wave band and the microwave band. A monopole antenna, a patch antenna, a spiral antenna, a loop antenna, or the like can be used as the antenna, other than the dipole antenna shown in FIG. 1 .
[0038] The antenna 16 is provided with an antenna terminal 18 in order to be connected to a power supply control circuit 14 . The power supply control circuit 14 is formed so that at least a part thereof overlaps with the first structural body 10 . A second structural body 12 is used as a connector for tightening connection of the first structural body 10 and the power supply control circuit 14 .
[0039] FIG. 2 shows a cross-sectional structure of the power storage device taken along a line A-B of FIG. 1 . The second structural body 12 is located to face one side on which the antenna terminal 18 of the first structural body 10 is formed. The power supply control circuit 14 is located to face the other side of the second structural body 12 . A through electrode 20 is formed in the second structural body 12 at a position corresponding to that of the antenna terminal 18 . The through electrode 20 is formed so as to be connected to a connection electrode 24 of the power supply control circuit 14 on the other side of the second structural body 12 . The through electrode 20 is formed using a metal foil or metal paste in a through hole formed in the second structural body 12 .
[0040] The second structural body 12 has a thickness of 0.1 μm to 50 μm, preferably 5 μm to 30 μm, and is preferably harder than the first structural body 10 . In addition, the second structural body 12 preferably has toughness and elasticity to certain bending stress. This is because in a case where the first structural body 10 is formed of a flexible material such as a plastic film or a nonwoven fabric, bending stress can be dispersed when the second structural body 12 has uniform elasticity. Accordingly, disconnection failure between the antenna teiininal 18 and the connection electrode 24 which are connected via the through electrode 20 can be prevented. In addition, when the through electrode 20 is formed in the second structural body 12 , the power supply control circuit 14 can be downsized.
[0041] As the second structural body 12 , an insulating substance such as hard plastics or glass can be used, and in particular, the ceramic material is preferably used. This is because the ceramic material realizes the foregoing characteristics and therefore, the material to be used can be selected from a wide range of materials. Further, a plurality of ceramics can be combined to be a compound.
[0042] As a typical example of the ceramic material, alumina (Al 2 O 3 ) is preferably used as a highly insulating material. In addition, barium titanate (BaTiO 3 ) is preferably used as a high capacitance material. When mechanical strength has higher priority, alumina (Al 2 O 3 ), titanium oxide (TiO x ), silicon carbide (SiC), tempered glass, or crystallized glass is preferably used. In addition, when composite ceramics in which nanoparticles of SiC are added to Si 3 N 4 , or composite ceramics which contains hexagonal system BN is used, high strength, oxidation resistance, and high toughness can be obtained, which is preferable.
[0043] These ceramic materials may be used to form a stacked layer structure of a plurality of layers each having a thickness of 0.1 μm to 2 μm in the second structural body 12 . In other words, it is preferable that a stacked-layer substrate be formed and an electrode be formed in each layer to form a stacked layer capacitor in the second structural body 12 .
[0044] The power supply control circuit 14 is formed using an active element formed of a semiconductor layer having a thickness of 5 nm to 500 nm, preferably, 30 nm to 150 nm. Over and below the semiconductor layer, insulating layers are provided. These insulating layers are formed as layers for protecting the semiconductor layer. In addition, they may be used as a functional layer such as a gate insulating layer. A typical example of an active element is a field-effect transistor. Since the semiconductor layer is a thin film as described above, a field-effect transistor formed here is also referred to as a thin film transistor. The semiconductor layer is preferably a crystalline semiconductor layer that is crystallized by heat treatment or energy beam irradiation with a laser beam or the like, after a semiconductor layer is formed by a vapor deposition method, a sputtering method, or the like. This is because when a crystalline semiconductor layer is formed, field-effect mobility of the field-effect transistor becomes 30 to 500 cm 2 /V·sec (electron), which suppresses power loss.
[0045] The power supply control circuit 14 includes a semiconductor layer, an insulating layer, a layer for forming a wiring, and is preferably formed to have a thickness of 0.5 μM to 5 μm in total. When the power supply control circuit 14 is formed to have this thickness, the power supply control circuit 14 can contribute to reduction in thickness of the power storage device. Further, the power supply control circuit 14 can have resistance to bending stress. When the semiconductor layer is separated to be island-shaped semiconductor layers, resistance to bending stress can be improved.
[0046] The first structural body 10 and the second structural body 12 are fixed by an adhesive 28 so that the antenna terminal 18 and the through electrode 20 are electrically connected. For example, as the adhesive 28 , an acrylic-based, urethane-based, or epoxy-based adhesive, in which conductive particles are dispersed, can be used. Alternatively, a connection portion of the antenna terminal 18 and the through electrode 20 may be fixed by a conductive paste or a solder paste and another part may be fixed by acrylic-based, urethane-based, or epoxy-based adhesive. Also, the second structural body 12 and the power supply control circuit 14 are fixed so that the through electrode 20 and the connection electrode 24 are electrically connected.
[0047] A sealant 30 is formed using an acrylic-based, urethane-based, phenol-based, epoxy-based, or silicone-based resin material and is preferably provided in order to protect the power supply control circuit 14 . The sealant 30 is formed to cover the power supply control circuit 14 and to preferably cover side surfaces of the power supply control circuit 14 and the second structural body 12 . When the sealant 30 is provided, the power supply control circuit 14 can be prevented from being damaged. Further, the adhesive strength between the power supply control circuit 14 , the second structural body 12 , and the first structural body 10 can be enhanced. In such a way, a power storage device with a thickness of 2 μm to 150 μm, preferably, 10 μm to 60 μm can be obtained.
[0048] FIG. 3 shows a structure in which the antenna terminal 18 of the first structural body 10 and the connection electrode 24 of the power supply control circuit 14 are located to face and be connected to each other. The second structural body 12 is located on a back side of the power supply control circuit 14 so as to protect the power supply control circuit 14 . In a case where the second structural body 12 is provided with a capacitor, a ceramics antenna-connection electrode 27 may be formed in the power supply control circuit 14 so as to be electrically connected to a capacitor external electrode 22 of the second structural body 12 . The first structural body 10 , the second structural body 12 , and the power supply control circuit 14 are preferably fixed by the adhesive 28 . In a structure shown in FIG. 3 , since the second structural body 12 is located on the back side of the power supply control circuit 14 , the sealant 30 may be provided as appropriate.
[0049] As described above, according to the present invention, when the structural body formed of ceramics or the like is used, rigidity of the power storage device can be improved. Accordingly, even when the power storage device is thinned, durability and required functions can be maintained. When a wiring for connection is formed in the structural body formed of ceramics or the like and an antenna and a power supply control circuit are connected, malfunction caused by detachment of a connection portion can be prevented even when bending stress is applied.
Embodiment 1
[0050] This embodiment will explain an example of a power storage device that includes a first structural body provided with an antenna, a second structural body provided with a capacitor, and a power supply control circuit 14 , with reference to FIGS. 4 A to 4 C and FIGS. 5A and 5B . FIGS. 4A to 4C are plan views of the power storage device, and FIGS. 5A and 5B are cross-sectional views taken along lines A-B and C-D of FIG. 4A .
[0051] FIG. 4A shows a mode in which an antenna 16 having a coil-shape is formed in a first structural body 10 . The first structural body 10 is formed using a plastic material such as PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PES (polyethersulfone), polypropylene, polypropylene sulfide, polycarbonate, polyether imide, polyphenylene sulfide, polyphenylene oxide, polysulfone, polyphthalamide, acrylic, or polyimide, or an insulating material such as nonwoven fabric, or paper.
[0052] The antenna 16 is formed in the first structural body 10 using a low resistance metal material such as copper, silver, or aluminum, by a printing method, a plating method, or the like. The antenna 16 shown in FIG. 4A has a coil-shape which is suitable when an electromagnetic induction method (for example, 13.56 MHz band) is employed. When a microwave method (for example, an UHF band (860 to 960 MHz band), 2.45 GHz band, or the like) is employed, a length and a shape of a conductive layer serving as antenna may be appropriately set in consideration of a wavelength of an electromagnetic wave that is used for transmitting signals. In this case, a monopole antenna, a dipole antenna, a patch antenna, and the like may be used.
[0053] FIG. 4A shows a mode in which a second structural body 12 and a power supply circuit 14 are provided in accordance with an antenna terminal 18 . FIG. 4B is a plan view of the second structural body 12 , and FIG. 4C is a plan view of the power control circuit 14 . An outside dimension of the second structural body 12 and that of the power supply control circuit 14 are preferably almost the same. Alternatively, the outside dimension of the power supply control circuit 14 may be smaller than that of the second structural body 12 .
[0054] In this embodiment, the second structural body 12 is preferably formed of a ceramic material. In this second structural body 12 , a through electrode 20 and a capacitor electrode 34 are formed. In the power supply control circuit 14 , a connection electrode 24 that is connected to the antenna terminal 18 and a capacitor-portion connection electrode 26 that is connected to the capacitor electrode 34 are formed. Subsequently, the details of a connection structure of the second structural body 12 and the power supply control circuit 14 is explained with reference to FIGS. 5A and 5B .
[0055] FIG. 5A is a cross-sectional view taken along a line A-B. The first structural body 10 and the power supply control circuit 14 are connected to each other by the through electrode 20 formed in the second structural body 12 . They are fixed by an adhesive 28 . In the second structural body 12 , layers each including a dielectric layer 32 and the capacitor electrode 34 are stacked so as to be engaged with each other. A capacitor is formed by stacking the dielectric layer 32 and the capacitor electrode 34 in such a manner.
[0056] The dielectric layer 32 is formed by coating a surface of the substrate with a ceramics paste in which a ceramic material such as barium titanate (BaTiO 3 ), strontium titanate (SrTiO 3 ), or a Pb-based complex perovskites compound material contains a binder compound, a plasticizer, and an organic solvent. Then, an electrode paste selected from copper or a copper alloy, nickel or a nickel alloy, silver or a silver alloy, and tin or a tin alloy, is printed thereover to form the capacitor electrode 34 . Note that when the through electrode 20 is formed, the dielectric layer and the capacitor electrode are formed to have an opening in a corresponding position where the through electrode 20 is formed. The dielectric layer and the capacitor electrode are dried, and then, cut into predetermined shapes. Then, the capacitor electrodes 34 are stacked to be engaged with each other. The stacked layers are interposed between protective layers 36 formed of a ceramic material or the like, the binder is removed, and baking and heating treatment are performed to form the capacitor.
[0057] In FIGS. 5A and 5B , the dielectric layer 32 and the capacitor electrode 34 can be fowled to have a thickness of 1 to 10 μm by using nanoparticles. Accordingly, when five dielectric layers 32 each having a thickness of 2 μm are stacked, the thickness thereof is 10 μm. Further, even when ten dielectric layers 32 each having a thickness of 1 μm are stacked, the thickness thereof is not greater than 10 μm.
[0058] FIG. 5B is a cross-sectional view taken along a line C-D and shows a structure of the capacitor electrode 34 and the capacitor-portion connection electrode 26 of the power supply control circuit 14 . In the second structural body 12 , a capacitor external electrode 22 , which is formed in an outer edge portion, is subjected to nickel plating, tin plating, and the like The adhesive 28 can be used for connecting the capacitor external electrode 22 and the capacitor-portion connection electrode 26 .
[0059] As descried above, the power storage device that includes the first structural body 10 provided with an antenna, the second structural body 12 provided with a capacitor, and the power supply control circuit 14 can be obtained. When the second structural body 12 formed of ceramics or the like is used, rigidity of the power storage device can be improved. Accordingly, even when a power storage device including the power supply control circuit 14 is thinned, durability and required functions can be maintained.
Embodiment 2
[0060] This embodiment will explain an example of a power storage device of the present invention provided with a plurality of antennas. An example of a power storage device will be explained with reference to FIGS. 6A to 6D and FIGS. 7A and 7B , which includes a first structural body 10 provided with an antenna, a second structural body 12 provided with a capacitor, a power supply control circuit 14 , and a ceramics antenna 38 . FIGS. 6A to 6D are plan views of the power storage device, and FIGS. 7A and 7B are cross-sectional views taken along lines E-F and G-H.
[0061] In FIG. 6A , an antenna 16 having a coil-shape is formed in the first structural body 10 . The shape of the antenna 16 may be appropriately set in accordance with a frequency band that is used for communication, similarly to in Embodiment 1.
[0062] FIG. 6A shows a mode in which the second structural body 12 , the power supply control circuit 14 , and the ceramics antenna 38 are provided in accordance with an antenna terminal 18 . FIG. 6B is a plan view of the second structural body 12 , FIG. 6C is a plan view of the power supply control circuit 14 , and FIG. 6D is a plan view of the ceramics antenna 38 . Outside dimensions of the second structural body 12 , the power supply control circuit 14 , and the ceramics antenna 38 are preferably almost the same. Alternatively, the outside dimension of the power supply control circuit 14 may be smaller than those of the second structural body 12 and the ceramics antenna 38 .
[0063] In the second structural body 12 that is formed of a ceramic material, a through electrode 20 and a capacitor external electrode 22 are formed. In the power supply control circuit 14 , a connection electrode 24 that is connected to the antenna terminal 18 , a capacitor-portion connection electrode 26 that is connected to the capacitor external electrode 22 , and a ceramics antenna-connection electrode 27 that is connected to the ceramics antenna 38 are formed. Subsequently, the details of connection structures of the second structural body 12 and the power supply control circuit 14 are explained with reference to FIGS. 7A and 7B .
[0064] FIG. 7A is a cross-sectional view taken along a line E-F. In the second structural body 12 , a capacitor is formed using a ceramic material, similarly to Embodiment 1. The structure including the through electrode 20 that connects the antenna terminal 18 of the first structural body 10 and the connection electrode 24 of the power supply control circuit 14 , is similar to that of FIG. 5A . The ceramics antenna 38 is located on the back side of the power supply control circuit 14 . The second structural body 12 and the ceramics antenna 38 , sandwiching the power supply control circuit 14 , have a function for a protective layer.
[0065] FIG. 7B is a cross-sectional view taken along a line G-H and shows a connection structure between the power supply control circuit 14 and the ceramics antenna 38 . The ceramics antenna 38 includes a ground body 44 on one side of a dielectric substance 42 (the power supply control circuit 14 side) and a reflector 46 on the other side. The power supply control circuit 14 is provided with the ceramics antenna-connection electrode 27 to which the ground body 44 and a power feeding body 40 are connected. The reflector 46 may have a slit to enhance directivity. The reflector 46 and the power feeding body 40 are provided with a gap therebetween and are capacitive coupled.
[0066] In the power storage device of this embodiment, the antenna 16 formed in the first structural body 10 and the ceramics antenna 38 are used as an antenna for power feeding, and the power is stored in the capacitor formed in the second structural body 12 . The capacitor includes dielectric layers 32 and capacitor electrodes 34 . Large capacitance can be obtained by stacking a plurality of dielectric layers 32 and capacitor electrodes 34 . In this case, frequencies of an electromagnetic wave received at the antenna 16 and the ceramics antenna 38 are varied, whereby the capacitor can be efficiently charged. In other words, a band of the electromagnetic wave received for charging the capacitor can be extended. In this case, the dielectric layer 32 and the capacitor electrode 34 can be formed to have a thickness of 1 to 10 μm by using nanoparticles. Accordingly, when five dielectric layers 32 each having a thickness of 2 are stacked, the thickness thereof is 10 μm. Further, even when ten dielectric layers 32 each having a thickness of 1 μm are stacked, the thickness thereof is not greater than 10 μm.
[0067] As described above, the power storage device including the first structural body 10 provided with an antenna; the second structural body 12 provided with a capacitor, the power supply control circuit 14 , and the ceramics antenna 38 can be obtained. When the second structural body 12 formed of ceramics or the like and the ceramics antenna 38 are used, rigidity of the power storage device can be improved. Accordingly, even when a power storage device including the power supply control circuit 14 is thinned, durability and required functions can be maintained.
Embodiment 3
[0068] An example of a power supply control circuit of a power storage device of the present invention will be explained with the use of a block diagram shown in FIG. 8 .
[0069] A power storage device 100 of FIG. 8 includes an antenna 102 , a power supply control circuit 104 , and a capacitor 106 . The power supply control circuit 104 includes a rectifier circuit 108 , a low-frequency signal generation circuit 110 , a switching circuit 112 , and a power supply circuit 114 . Power is output from the power supply circuit in the power supply control circuit to a load 118 on the outside of the power storage device.
[0070] The antenna 102 is formed in the first structural body 10 in accordance with Embodiment 1. The capacitor 106 is formed in the second structural body 12 . The power supply control circuit 104 corresponds to the power supply control circuit 14 .
[0071] A structure of the load 118 in FIG. 8 is different depending on electronic devices. For example, in the cellular phones and the digital video cameras, a logic circuit, an amplifier circuit, a memory controller, and the like correspond to a load. Also, in IC cards, IC tags, and the like, a high-frequency circuit, a logic circuit, and the like correspond to a load.
[0072] Further, FIG. 8 is the power storage device 100 having a structure in which an electromagnetic wave supplied by a power feeder 120 is received at the antenna 102 and stored in the capacitor 106 . In FIG. 8 , the electromagnetic wave received at the antenna 102 is rectified at the rectifier circuit 108 and stored in the capacitor 106 . Power obtained by receiving the electromagnetic wave at the antenna 102 is input to the low-frequency signal generation circuit 110 through the rectifier circuit 108 . Further, power obtained by receiving the electromagnetic wave at the antenna 102 is input to the power supply circuit 114 through the rectifier circuit 108 and the switching circuit 112 as a signal. The low-frequency signal generation circuit 110 outputs an on/off control signal to the switching circuit 112 when operation of the low-frequency signal generation circuit 110 is controlled by the input signal.
[0073] In FIG. 8 , the power obtained by receiving the electromagnetic wave is stored in the capacitor 106 . When the power is not sufficiently supplied from the power feeder 120 , power supplied from the capacitor 106 is supplied to the power supply circuit 114 through the switching circuit 112 . The power feeder 120 is a device for emitting an electromagnetic wave that can be received at the antenna 102 .
[0074] A structure of the antenna 102 in FIG. 8 may be selected from an electromagnetic coupling method, an electromagnetic induction method, a micro-wave method or the like, depending on a frequency band of the electromagnetic wave that is received. The antenna 102 can arbitrarily receive an electromagnetic wave and supply a signal to the power supply control circuit 104 , regardless of whether or not an electromagnetic wave supplied by the power feeder 120 exists. For example, an electromagnetic wave of a cellular phone (800 to 900 MHz band, 1.5 GHz, 1.9 to 2.1 GHz band, or the like), an electromagnetic wave oscillated from the cellular phone, an electromagnetic wave of a radio wave clock (40 kHz or the like), noise of a household AC power supply (60 Hz or the like), electromagnetic waves that are randomly generated from other wireless signal output means, and the like can be utilized as an electromagnetic wave received at the antenna 102 in order to be stored in the capacitor 106 of the power storage device 100 .
[0075] Next, operation for charging the capacitor 106 and supplying power to the power supply circuit 114 by receiving an electromagnetic wave in the power storage device 100 of FIG. 8 will be explained. The electromagnetic wave received at the antenna 102 is half-wave rectified and smoothed by the rectifier circuit 108 . Then, the power output from the rectifier circuit 108 is supplied to the power supply circuit 114 through the switching, circuit 112 , and surplus power is stored in the capacitor 106 .
[0076] In the power storage device 100 of this embodiment, by intermittently operating the power storage device 100 depending on strength of the electromagnetic wave, it is attempted that power stored in the capacitor 106 is not consumed wastefully. Although the power storage circuit generally supplies continuous power to a load, continuous power is not always necessary to be supplied depending on use application. In such a case, operation of supplying power from the power storage device 100 is stopped, whereby consumption of the power stored in the capacitor 106 can be suppressed. In this embodiment, only the low-frequency signal generation circuit 110 in FIG. 8 operates continuously. The low-frequency signal generation circuit 110 operates based on the power stored in the capacitor 106 . An output waveform of the low-frequency signal generation circuit 110 is explained with reference to FIG. 9 .
[0077] FIG. 9 shows a waveform of a signal that is output from the low-frequency signal generation circuit 110 to the switching circuit. In an example of FIG. 9 , a duty ratio of the output waveform is set 1:n (n is an integer) so that power consumption can be set approximately 1/(n+1). The switching circuit 112 is driven in accordance with this signal. The switching circuit 112 connects the capacitor 106 and the power supply circuit 114 only during a period where the output signal is high; therefore, power is supplied to a load through the power supply circuit from a battery in the power storage device only during the period.
[0078] FIG. 10 shows an example of the low-frequency signal generation circuit 110 of FIG. 8 . The low-frequency signal generation circuit 110 in FIG. 10 includes a ring oscillator 122 , a frequency-divider circuit 124 , an AND circuit 126 , and inverters 128 and 130 . An oscillation signal of the ring oscillator 122 is frequency-divided with the frequency-divider circuit 124 and the output thereof is input into the AND circuit 126 to generate a low-duty ratio signal with the AND circuit 126 . Further, the output of the AND circuit 126 is input to a switching circuit 112 including a transmission gate 132 through the inverters 128 and 130 . The ring oscillator 122 oscillates with a low frequency, and oscillation is performed at 1 kHz, for example.
[0079] FIG. 11 is a timing chart of a signal output from the low-frequency signal generation circuit 110 shown in FIG. 10 . FIG. 11 shows an example of an output waveform of the ring oscillator 122 , an output waveform of the frequency-divider circuit 124 , and an output waveform of the AND circuit 126 . In FIG. 11 , an output waveform is shown, in which a signal output from the ring oscillator 122 is frequency-divided, where the number of division is 1024. As the output waveform, a frequency-divider circuit output waveform 1 , a frequency-divider circuit output waveform 2 , and a frequency-divider circuit output waveform 3 are sequentially output. When these output waveforms are processed with the AND circuit 126 , a signal with a duty ratio of 1:1024 can be formed. As long as the oscillation frequency of the ring oscillator 122 is 1 KHz at this time, an operation period is 0.5 μsec, and a non-operation period is 512 μsec in one cycle.
[0080] The signal output from the low-frequency signal generation circuit 110 regularly controls on/off of the transmission gate 132 of the switching circuit 112 and controls supply of the power from the capacitor 106 to the power supply circuit 114 . Therefore, supply of the power from the power storage device 100 to the load can be controlled. In other words, the power is intermittently supplied from the capacitor 106 to a signal control circuit portion, whereby supply of the power from the power storage device 100 to the load 118 can be suppressed; and low power consumption can be achieved.
[0081] An example of the power supply circuit 114 in FIG. 8 is explained with reference to FIG. 12 . The power supply circuit 114 comprises a reference voltage circuit and a buffer amplifier. The reference voltage circuit includes a resistor 134 , and transistors 136 and 138 that are diode-connected. In this circuit, a reference voltage (2×Vgs) corresponding to a voltage between a gate and a source (Vgs) of the transistor is generated by the transistors 136 and 138 . The buffer amplifier includes a differential circuit that includes transistors 140 and 142 , a current mirror circuit that includes transistors 144 and 146 , a current supply resistor 148 , and a common source amplifier that includes a transistor 150 and a resistor 152 .
[0082] The power supply circuit 114 shown in FIG. 12 operates in such a manner that when a large amount of current is output from an output terminal, the amount of current that flows through the transistor 150 becomes small, whereas when a small amount of current is output from the output terminal, the amount of current that flows through the transistor 150 becomes large. Thus, a current that flows through the resistor 152 is almost constant. In addition, the potential of the output terminal is almost the same as that of the reference voltage circuit. Here, although the power supply circuit including the reference voltage circuit and the buffer amplifier is shown, the power supply circuit 114 is not limited to the structure in FIG. 12 , and a power supply circuit with a different structure may be used.
[0083] As described above, the power supply control circuit of this embodiment can be applied to the power storage device of Embodiment 1. According to the power supply control circuit of this embodiment, an electromagnetic wave can be received and used as power to be stored in the capacitor. The power stored in the capacitor 106 can be supplied to a load. In addition, supply of the power from the power storage device to the load can be controlled. In other words, the power is intermittently supplied from the capacitor to the signal control circuit portion, whereby supply of the power from the power storage device to the load is suppressed, and power consumption can be reduced.
Embodiment 4
[0084] This embodiment will explain an example of a power storage device corresponding to Embodiment 2 with reference to FIG. 13 . Note that different points from FIG. 8 will be mainly explained below.
[0085] A structure of a power storage device provided with a plurality of antenna circuits is shown in FIG. 13 . An antenna 102 and a second antenna 103 are provided as the plurality of antenna circuits, which is different point from FIG. 8 . The antenna 102 and the second antenna 103 are preferably formed so that compatible reception frequencies are different from each other. For example, the antenna 102 can formed of a spiral antenna as shown in FIG. 6A of Embodiment 2, and the second antenna 103 can be formed of a ceramics antenna (patch antenna).
[0086] The antenna 102 is formed in the first structural body 10 in accordance with Embodiment 2. The second antenna 103 corresponds to the ceramics antenna 38 . A capacitor 106 is formed in the second structural body 12 . A power supply control circuit 104 corresponds to the power supply control circuit 14 .
[0087] Electromagnetic waves received at the antenna 102 and the second antenna 103 are rectified at a rectifier circuit 108 and stored in the capacitor 106 . In the rectifier circuit 108 , the electromagnetic waves received at both antennas can be rectified concurrently and stored in the capacitor 106 . Alternatively, one of the electromagnetic waves received at the antenna 102 and the second antenna 103 , which has stronger field intensity than the other, may be preferentially rectified at the rectifier circuit 108 to be stored in the capacitor 106 .
[0088] Another structure of the power storage device 100 in this embodiment is the same as that of FIG. 8 , and a similar operation effect can be obtained.
Embodiment 5
[0089] This embodiment shows a power storage device having a function for controlling supply of power that is stored in a capacitor. Note that the portion having a similar function as that shown in Embodiment 3 is denoted by the same reference numeral to explain this embodiment.
[0090] A power storage device 100 of FIG. 14 includes an antenna 102 , a power supply control circuit 104 , and a capacitor 106 . The power supply control circuit 104 includes a rectifier circuit 108 , a control circuit 116 , a low-frequency signal generation circuit 110 , a switching circuit 112 , and a power supply circuit 114 . Power is supplied from the power supply circuit 114 to a load 118 .
[0091] The antenna 102 is fowled in the first structural body 10 in accordance with Embodiment 1. The capacitor 106 is fowled in the second structural body 12 . The power supply control circuit 104 corresponds to the power supply control circuit 14 .
[0092] In the power storage device of this embodiment, when power output from the rectifier circuit 108 exceeds power consumption of the load 118 , the power supply control circuit 104 stores the excess power in the capacitor 106 . Alternatively, when power that is output from the rectifier circuit 108 is insufficient for power consumption of the load 118 , the power supply control circuit 104 discharges the capacitor 106 so that power is supplied to the power supply circuit 114 . In FIG. 14 , a control circuit 116 at the subsequent stage of the rectifier circuit 108 is provided for performing such operation.
[0093] In FIG. 15 , an example of the control circuit 116 is shown. The control circuit 116 includes switches 154 and 156 , rectifier elements 158 and 160 , and a voltage comparator circuit 162 . In FIG. 15 , the voltage comparator circuit 162 compares a voltage output from the capacitor 106 with a voltage output from the rectifier circuit 108 . When a voltage output from the rectifier circuit 108 is sufficiently higher than a voltage output from the capacitor 106 , the voltage comparator circuit 162 turns the switch 154 on and turns the switch 156 off. In such a condition, a current flows in the capacitor 106 from the rectifier circuit 108 through the rectifier element 158 and the switch 154 . On the other hand, when a voltage output from the rectifier circuit 108 is insufficient as compared with a voltage output from the capacitor 106 , the voltage comparator circuit 162 turns the switch 154 off and turns the switch 156 on. At this time, when a voltage output from the rectifier circuit 108 is higher than a voltage output from the capacitor 106 , a current does not flow in the rectifier element 160 ; however, when a voltage output from the rectifier circuit 108 is lower than a voltage output from a battery, a current flows in the switch circuit 112 from the capacitor 106 through the switch 156 and the rectifier element 160 .
[0094] FIG. 16 shows a structure of the voltage comparator circuit 162 . In the structure shown in FIG. 16 , the voltage comparator circuit 162 divides the voltage output from the capacitor 106 with resistor elements 164 and 166 , and divides the voltage output from the rectifier circuit 108 with resistor elements 168 and 170 . Then, the voltage comparator circuit 162 inputs the divided voltage into a comparator 172 . Inverter-type buffer circuits 174 and 176 are connected in series by an output of the comparator 172 . Then, an output of the buffer circuit 174 is input to a control terminal of the switch 154 , and an output, of the buffer circuit 176 is input to a control terminal of the switch 156 , whereby on/off of the switches 154 and 156 is controlled. For example each of the switches 154 and 156 is turned on when an output of the buffer circuit 174 or 176 is at the high potential (“H” level), and each of the switches 154 and 156 is turned off when an output of the buffer circuit 174 or 176 is at the low potential (“L” level). In such a manner, each voltage of the capacitor 106 and the rectifier circuit 108 is divided with the resistor to be input into the comparator 172 , whereby on/off of the switches 154 and 156 can be controlled.
[0095] Note that the control circuit 116 and the voltage comparator circuit 162 are not limited to the above structure, and other types of control circuits and voltage comparator circuits may be used as long as they have various functions.
[0096] Operation of the power storage device 100 shown in FIG. 14 is generally as follows. First, an external wireless signal received at the antenna 102 is half-waved rectified by the rectifier circuit 108 and then smoothed. Then, a voltage output from the capacitor 106 and a voltage output from the rectifier circuit 108 are compared at the control circuit 116 . When the voltage output from the rectifier circuit 108 is sufficiently higher than the voltage output from the capacitor 106 , the rectifier circuit 108 is connected to the capacitor 106 . At this time, power output from the rectifier circuit 108 is supplied to the capacitor 106 and the power supply circuit 114 , and surplus power is stored in the capacitor 106 .
[0097] The control circuit 116 compares the output voltage of the rectifier circuit 108 with the output voltage of the capacitor 106 . When the output voltage of the rectifier circuit 108 is lower than that of the capacitor 106 , the control circuit 116 controls the capacitor 106 and the power supply circuit 114 to be connected. When the output voltage of the rectifier circuit 108 is higher than that of the capacitor 106 , the control circuit 116 operates so that the output of the rectifier circuit 108 is input to the power supply circuit 114 . In other words, the control circuit 116 controls the direction of current in accordance with the voltage output from the rectifier circuit 108 and the voltage output from the capacitor 106 .
[0098] Moreover, as shown in FIG. 8 of Embodiment 3, the power is intermittently supplied from the capacitor 106 to the load 118 through the power supply circuit 114 , whereby the amount of power consumption can be reduced. Furthermore, a plurality of antennas may be provided as shown in Embodiment 4.
[0099] In the power storage device of this embodiment, power of an electromagnetic wave received at the antenna and power stored in the capacitor are compared by the control circuit depending on a reception state of an electromagnetic wave, whereby a path of power supplied to the load can be selected. Accordingly, the power stored in the capacitor can be efficiently utilized, and the power can be stably supplied to the load.
Embodiment 6
[0100] This embodiment will describe a transistor that can be applied to the power supply control circuit 14 in Embodiments 1 to 5.
[0101] FIG. 17 shows a thin film transistor formed over a substrate 178 having an insulating surface. A glass substrate such as aluminosilicate glass, a quartz substrate, or the like can be employed as the substrate. The thickness of the substrate 178 is 400 μm to 700 μm; however, the substrate may be polished to have a thin thickness of 5 μm to 100 μm. This is because the mechanical strength can be maintained by using the substrate with the second structural body as shown in Embodiments 1 to 3.
[0102] A first insulating layer 180 may be formed using silicon nitride or silicon oxide over the substrate 178 . The first insulating layer 180 has an effect for stabilizing characteristics of the thin film transistor. A semiconductor layer 182 is preferably polycrystalline silicon. Alternatively, the semiconductor layer 182 may be a single crystalline silicon thin film, of which a crystal grain boundary does not affect drift of carriers in a channel formation region overlapping with a gate electrode 186 .
[0103] As another structure, the substrate 178 may be formed using a silicon semiconductor, and the first insulating layer 180 may be found using silicon oxide. In this case, the semiconductor layer 182 can be formed using single crystalline silicon. In other words, a SOI (Silicon on Insulator) substrate can be used.
[0104] The gate electrode 186 is formed over the semiconductor layer 182 with a gate insulating layer 184 interposed therebetween. Sidewalls may be formed on opposite sides of the gate electrode 186 , and a lightly doped drain may be formed in the semiconductor layer 182 by the sidewalls. A second insulating layer 188 is formed using silicon oxide and silicon oxynitiride. The second insulating layer 188 is a so-called interlayer insulating layer, and a first wiring 190 is formed thereover. The first wiring 190 is connected to a source region and a drain region formed in the semiconductor layer 182 .
[0105] A third insulating layer 192 is formed using silicon nitride, silicon oxynitiride, silicon oxide, or the like, and a second wiring 194 is formed. Although the first wiring 190 and the second wiring 194 are shown in FIG. 17 , the number of wirings to be stacked may be selected as appropriate, depending on the circuit structures. As for a wiring structure, an embedded plug may be formed by selective growth of tungsten in a contact hole, or a copper wiring may be formed by a damascene process.
[0106] A connection electrode 24 is exposed on an outermost surface of the power supply control circuit 14 . The other region than the connection electrode 24 is covered with a fourth insulating layer 196 , for example, so as not to expose the second wiring 194 . The fourth insulating layer 196 is preferably formed using silicon oxide that is formed by coating in order to planarize a surface thereof. The connection electrode 24 is formed by forming a bump of copper or gold by a printing method or a plating method so as to lower contact resistance thereof.
[0107] As described above, an integrated circuit includes a thin film transistor, whereby the power supply control circuit 14 that operates by receiving a communication signal in a microwave band (2.45 GHz) from an RF band (typically, 13.56 MHz) can be formed.
Embodiment 7
[0108] This embodiment will describe another structure of the transistor that is applied to the power supply control circuit 14 in Embodiments 1 to 5 shown in FIG. 18 . Note that a portion having the same function as that of Embodiment 6 is denoted by the same reference numeral.
[0109] FIG. 18 shows a MOS (Metal Oxide Semiconductor) transistor, which is fowled utilizing a semiconductor substrate 198 . A single crystalline silicon substrate is typically employed as the semiconductor substrate 198 . The thickness of the substrate 198 is 100 μm to 300 μm; however, the substrate 198 may be polished to be as thin as 10 μm to 100 μm. This is because the mechanical strength can be maintained when the substrate is used with the second structural body 12 as shown in Embodiments 1 to 3.
[0110] An element isolation-insulating layer 200 is formed over the semiconductor substrate 198 . The element isolation-insulating layer 200 can be formed using a LOCOS (Local Oxidation of Silicon) technique, in which a mask such as a nitride film is formed over the semiconductor substrate 198 and is thermally oxidized to be an oxide film for element isolation. Alternatively, the element isolation-insulating layer 200 may be formed by using a STI (Shallow Trench Isolation) technique in which a groove in the semiconductor substrate 198 is formed and an insulating film is embedded therein and is planarized. When the STI technique is used, the element isolation insulating layer 200 can have a steep side walls, and the distance for element isolation can be reduced.
[0111] An n-well 202 and a p-well 204 are formed in the semiconductor substrate 198 , and accordingly, a so-called double well structure can be formed, in which an n-channel transistor and a p-channel transistor are included. Alternatively, a single-well structure may be used. A gate insulating layer 184 , a gate electrode 186 , a second insulating layer 188 , a first wiring 190 , a third insulating layer 192 , a second wiring 194 , a connection electrode 24 , and a fourth insulating layer 196 are similar to those of Embodiment 6.
[0112] As described above, an integrated circuit includes a MOS transistor, whereby the power supply control circuit 14 can be formed, which operates by receiving a communication signal in a microwave (2.45 GHz) band from an RF band (typically, 13.56 MHz).
Embodiment 8
[0113] This embodiment describes an example of a so-called active wireless tag in which an IC (integrated circuit) with a sensor and a power storage device that supplies driving power to the IC with a sensor are provided which is shown in FIG. 19 .
[0114] This active wireless tag is provided with an IC 206 with a sensor and a power storage device 100 . The power storage device 100 includes an antenna 102 , a power supply control circuit 104 , and a capacitor 106 .
[0115] In the power storage device 100 , an electromagnetic wave received at the antenna 102 generates induced electromotive force at a resonance circuit 107 . The induced electromotive force is stored in the capacitor 106 through a rectifier circuit 108 . When power is supplied to the IC 206 with a sensor, the power is output after an output voltage is stabilized by a constant voltage circuit 109 .
[0116] In the IC 206 with a sensor, a sensor portion 220 has a function for detecting temperature, humidity, illuminance, and other characteristics by a physical or chemical means. The sensor portion 220 includes a sensor 210 and a sensor driving circuit 219 for controlling the sensor 210 . The sensor 210 is formed using a semiconductor element such as a resistor element, a capacitive coupling element, an inductive coupling element, a photovoltaic element, a photoelectric conversion element, a thermoelectric element, a transistor, a thermistor, a diode, or the like. The sensor driving circuit 219 detects changes in impedance, reactance, inductance, a voltage or current; converts signals from analog to digital (A/D conversion); and outputs the signals to a control circuit 214 .
[0117] A memory portion 218 is provided with a read-only memory and a rewritable memory. The memory portion 218 is formed of a static RAM, an EEPROM (Electrically Erasable Programmable Read-Only Memory), a flash memory, or the like, whereby information received through the sensor portion 220 and an antenna 208 can be recorded as needed. In order to memorize the obtained data in the sensor portion 220 , the memory portion 218 preferably includes a nonvolatile memory that is capable of sequentially writing and holding the memorized data. Further, a program for making the sensor portion 220 operate may be memorized in the memory portion 218 . While the program is practiced, the sensor portion 220 can operate at the timing that is set in advance to obtain data without sending a control signal from outside.
[0118] A communication circuit 212 includes a demodulation circuit 211 and a modulation circuit 213 . The demodulation circuit 211 demodulates a signal that is input via the antenna 208 and outputs the signal to the control circuit 214 . The signal includes a signal for controlling the sensor portion 220 and/or information to be memorized in the memory portion 218 . A signal output from the sensor driving circuit 219 and information that is read from the memory portion 218 are output to the modulation circuit 213 via the control circuit 214 . The modulation circuit 213 modulates the signal into a signal capable of wireless communication and outputs the signal to the external device via the antenna 208 .
[0119] Power necessary for operation of the control circuit 214 , the sensor portion 220 , the memory portion 218 , and the communication circuit 212 is supplied from the power storage device 100 . A power supply circuit 216 transforms the power supplied from the power storage device 100 into a predetermined voltage and supplies the voltage to each circuit. For example, in a case where data is written in the above nonvolatile memory, a voltage is temporary boosted to 10V to 20V. Further, a clock signal is generated for making the control circuit operate.
[0120] As described above, by using the power storage device 100 with the IC 206 with a sensor, the sensor portion is effectively utilized, and information can be obtained wirelessly to be memorized.
[0121] FIG. 20 shows an example of distribution management using an active wireless tag 230 . The active wireless tag 230 includes the IC with a sensor and the power storage device shown in FIG. 19 . This active wireless tag 230 is attached to a packing box 228 containing products 229 . A product management system 222 comprises a computer 224 and a communication device 226 connected to the computer 224 , and the system 222 is used for management of the active wireless tag 230 . The communication devices 226 can be located in each portion where the products are distributed, by using the communication network.
[0122] The distribution management can employ various modes. For example, when a temperature sensor, a humidity sensor, a light sensor, or the like is used as a sensor of the active wireless tag 230 , the environments where the packing box 228 is kept during the distribution process can be managed. In this case, the power storage device is provided for the active wireless tag 230 ; therefore, the sensor can operate at a given timing independently from a control signal from the communication device 226 , and the environment data can be obtained. Furthermore, even when the distance between the communication device 226 and the active wireless tag 230 is large, the communication distance can be increased with the use of power of the power storage device.
[0123] As described, the active wireless tag provided with the IC with a sensor and the power storage device is used, whereby a variety of information is obtained wirelessly with sensors, and the information can be managed by the computer.
ADDITIONAL NOTE
[0124] As described above, the present invention includes at least the following structure.
[0125] An aspect of the present invention is a power storage device including a first structural body provided with an antenna, a power supply control circuit formed using a semiconductor layer interposed between insulating layers that are provided over and below the semiconductor layer, and a second structural body provided with a capacitor and having higher rigidity than the first structural body, where the antenna and the power supply control circuit are connected with a through electrode formed in the second structural body, the power supply control circuit includes a rectifier circuit, a switching circuit, a low-frequency signal generation circuit, and a power supply circuit, and the switching circuit controls power that is supplied from the capacitor or the antenna to the power supply circuit in accordance with a signal from the low-frequency signal generation circuit.
[0126] Another aspect of the present invention is a power storage device including a first structural body provided with an antenna, a power supply control circuit formed using a semiconductor layer interposed between insulating layers that are provided over and below the semiconductor layer, and a second structural body provided with a capacitor and having higher rigidity than the first structural body, where the antenna and the power supply control circuit are connected with a through electrode formed in the second structural body, the power supply control circuit includes a rectifier circuit, a control circuit, a switching circuit, a low-frequency signal generation circuit, and a power supply circuit, the control circuit selects power that is output to the switching circuit by comparing power supplied from the antenna with power supplied from the capacitor, and the switching circuit outputs the power selected by the control circuit to the power supply circuit in accordance with a signal from the low-frequency signal generation circuit.
[0127] Another aspect of the present invention is a power storage device including a first structural body provided with an antenna, a power supply control circuit formed using a semiconductor layer interposed between insulating layers that are provided over and below the semiconductor layer, and a second structural body provided with a capacitor and having higher rigidity than the first structural body, where the power supply control circuit has a connection portion of the antenna and the capacitor, which is interposed between the first structural body and the second structural body, the power supply control circuit includes a rectifier circuit, a switching circuit, a low-frequency signal generation circuit, and a power supply circuit, and the switching circuit controls power that is supplied from the capacitor or the antenna to the power supply circuit in accordance with a signal from the low-frequency signal generation circuit.
[0128] Another aspect of the present invention is a power storage device including a first structural body provided with an antenna, a power supply control circuit formed using a semiconductor layer interposed between insulating layers that are provided over and below the semiconductor layer, and a second structural body provided with a capacitor and has higher rigidity than the first structural body, where the power supply control circuit having a connection portion of the antenna and the capacitor, which is interposed between the first structural body and the second structural body, the power supply control circuit includes a rectifier circuit, a control circuit, a switching circuit, a low-frequency signal generation circuit, and a power supply circuit, the control circuit selects power that is output to the switching circuit by comparing power supplied from the antenna with power supplied from the capacitor, and the switching circuit controls an output of power to the power supply circuit, which is selected by the control circuit in accordance with a signal from the low-frequency signal generation circuit.
[0129] This application is based on Japanese Patent Application serial no. 2006-206939 filed in Japan Patent Office on Jul. 28, 2006, the entire contents of which are hereby incorporated by reference.
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In the field of portable electronic devices in the future, portable electronic devices will be desired, which are smaller and more lightweight and can be used for a long time period by one-time charging, as apparent from provision of one-segment partial reception service “1-seg” of terrestrial digital broadcasting that covers the mobile objects such as a cellular phone. Therefore, the need for a power storage device is increased, which is small and lightweight and capable of being charged without receiving power from commercial power. The power storage device includes an antenna for receiving an electromagnetic wave, a capacitor for storing power, and a circuit for controlling store and supply of the power. When the antenna, the capacitor, and the control circuit are integrally formed and thinned, a structural body formed of ceramics or the like is partially used. A circuit for storing power of an electromagnetic wave received at the antenna in a capacitor and a control circuit for arbitrarily discharging the stored power are provided, whereby lifetime of the power storage device can be extended.
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TECHNICAL FIELD
[0001] The following specification relates to an impact attenuator for roadside application, suited for reducing the severity of a collision by absorbing at least part of the kinetic energy of an object, and specifically a vehicle, colliding with said impact attenuator. The specification furthermore relates to a vehicle comprising such an impact attenuator, a trailer comprising such an impact attenuator and a guardrail comprising such an impact attenuator.
SUMMARY
[0002] Roadside impact attenuators are intended to reduce the damage to vehicles, structures and motorists in the event of a (motor) vehicle collision by absorbing the colliding vehicle's kinetic energy. Common impact attenuators hereby deform, or more specifically split material as a method to dissipate kinetic energy. To split the material, a cutting surface is installed and configured to cut into the attenuator structure upon impact of a colliding vehicle. In common cases, the cutting surface hereby progressively splits a steel box beam in its lengthwise direction from the moment of impact up till the standstill of the vehicle. For safety reasons, it is desirable to increase the length over which the attenuator structure is split, as to lengthen the deceleration time for the vehicle as much as possible to minimize the deceleration (G-forces) experienced by the passengers. This means that, from a safety perspective, the attenuator structure must as long as practically possible. However, the total length of the impact attenuator is limited due to transportation requirements. Especially attenuators suited for temporary use in road construction projects or truck mounted attenuators are frequently transported and need to conform to the height, width and length requirements set for road transport.
[0003] An object of the specification is therefore to provide an impact attenuator that offers improved safety, better transportability and/or at least provides a useful alternative to the state of the art.
SUMMARY
[0004] The specification hereto proposes an impact attenuator comprising: an impact head, coupled to; a first end of an energy absorption body, which energy absorption body is arranged for fixation to an external structure at a second end opposing the first end of the energy absorption body, configured to at least partly absorb or dissipate energy from a collision of an object with the impact head, and comprising a first part and a second part extending substantially lengthwise behind each other, wherein the first and second part are mutually moveable; a first and a second cutting edge, wherein upon impact of an object colliding with the impact head, the first cutting edge is arranged for splitting the first part of the energy absorption body, and the second cutting edge is arranged for consecutively splitting the second part of the energy absorption body.
[0005] The impact attenuator according to the specification thus comprises an energy absorption body that extends between the impact head and an external structure, which energy absorption body is specifically configured for being cut into and consequently split by the cutting edges. Upon collision of an object with the impact head, the energy absorption body absorbs at least part of the kinetic energy of the colliding object. Consecutively, the absorbed energy is (at least partly) dissipated by the splitting action of the cutting edges, which plastically deforms the energy absorption body and causes friction that generates thermal energy (heat).
[0006] By dividing the energy absorption body into multiple parts that are moveable with respect to each other, it becomes possible to extend the energy absorption body to its fullest length by letting the individual parts of the energy absorption body extend substantially behind each other in a lengthwise direction. This creates a maximum distance between the impact head and the external structure with which the impact attenuator is coupled, improving the attenuator's inherent safety. Namely, the increase in the distance over which the object is decelerated allows for more time for a colliding object to come to rest or change its direction and therefore, which leads to a more gradual deceleration of the colliding object. At the same time, the multiple parts of the energy absorption body can be moved to a different mutual orientation in which the maximum length of the impact attenuator is reduced to allow for convenient transportation. It is for example possible to remove, fold or retract the individual parts such that the total of parts constituting the impact attenuator adhere to certain predetermined maximum dimensions.
[0007] To ensure the continuous and subsequent splitting of the energy absorption body over its (entire) length, the impact attenuator comprises multiple (at least two) cutting edges, which cutting edges may be part of one or more cutting means. The cutting edges are positioned such that the multiple parts of the energy absorption body are separately and subsequently split by separate cutting edges that are part of either the same or separate cutting means. This creates essentially self-contained parts of the energy absorption body that work independently, making the assembly of said parts fail-safe to at least a certain degree. Moreover, the interface between the separate parts of the energy absorption body, which may create a discontinuity in the construction of the energy absorption body, does not hinder a continuous splitting action, due to the separate and consecutive splitting of the individual parts of the energy absorption body.
[0008] It is also possible that the energy absorption body comprises more than two parts, to further reduce the minimum dimensions of the impact attenuator when transported or to further increase the maximum distance between the impact head and the external structure to improve the impact attenuator's collision safety.
[0009] In a further embodiment the first part and the second part of the energy absorption body are mutually moveable in their lengthwise direction. The direction of mutual movement of the absorption body parts hereby corresponds to the anticipated direction of impact, which ensures that the impact attenuator will behave as predicted in the case of a collision. In addition, relative movement of the energy absorption parts in any other direction may be prevented for similar reasons.
[0010] In yet a further embodiment, the first part and the second part of the energy absorption body may be configured for guiding each other during mutual movement of said first part and the second part of the energy absorption body. As the first part and the second part of the energy absorption body act as each other's guiding structure, mutual movement of these parts will take place along a predetermined path in lengthwise direction of the energy absorption body. The relative motion of the individual parts of the energy absorption body is hereby limited to essentially a single degree of freedom (i.e. a translation along a straight path), which makes that the deformation behaviour of the attenuator in the event of a collision becomes more predictable and therefore more safe. Moreover, the guided movement of the energy absorption body parts benefit the easy conversion of the attenuator from an operational to a transport configuration.
[0011] Additionally, the energy absorption body may comprise rollers provided between the first part and the second part of the energy absorption body. These rollers reduce friction and facilitate the mutual movement of said first part and the second part of the energy absorption body. Alternatively, a similar reduction in friction could be obtained by the application of materials with a low coefficient of friction along the interface of the first part and the second part of the energy absorption body.
[0012] In order to retract the energy absorption body in an efficient way the first cutting edge may be moveable between: an engaged position, wherein the first cutting edge is positioned for splitting the first part of the energy absorption body upon mutual movement the first part and the second part of the energy absorption body, and a retracted position, wherein the first cutting edge is positioned away from the first part of the energy absorption body to allow free mutual movement the first part and the second part of the energy absorption body. The free mutual movement the first part and the second part of the energy absorption body allow for an easy retraction of the impact attenuator in its lengthwise direction, which benefits the transportability of the impact attenuator. Adjustment means may be applied to move the cutting edge (and the associated cutting means) between the engaged and retracted position. Such movement may comprise a rotation or a translation along a path that in part lies within the movement path of the first part of the energy absorption body and in part lies outside the movement path of the first part of the energy absorption body.
[0013] The first cutting edge and the second cutting edge may be provided at an end of the second part of the energy absorption body facing towards the impact head. By placing the cutting mechanisms at an end of the second part of the energy absorption body, the cutting mechanisms can commence cutting into the absorption body at the respective ends of the first and second parts of the energy absorption body, in the case that the separate parts of the energy absorption body are fully extended behind each other. This enables the cutting edges to split the energy absorption body over its entire length, making full use of the body's arresting capacities.
[0014] It is possible that the first part and the second part of the energy absorption body each comprise a thin-walled beam, which thin-walled beams comprise at least a web and a flange plate. A thin-walled beam can be understood as a beam for which the wall thickness is significantly smaller than the other representative dimensions of the beam's cross-section. The use of one or more thin-walled beams allows the energy absorption body to obtain a high bending stiffness per unit cross sectional area, which is much higher than that for solid cross sections, thereby achieving a stiff beam at a minimum weight. To obtain a stable construction for the energy absorption body, multiple parallel beams may be provided between the impact head and the external structure to form (part of) the first part and/or the second part of the energy absorption body.
[0015] In an embodiment of the impact attenuator, the at least one first part of the energy absorption body comprises a H-beam and the at least one second part of the energy absorption body comprises a hollow structural section. The H-beam and hollow structural section type beams give the energy absorption body a high level of strength and stiffness while intact, but can easily be split to obtain a number of elongated, flat plates that can be easily bended.
[0016] Given that the energy absorption body may comprise thin-walled beams, the first and second cutting edges may, by means of relative position to the thin-walled beam of the first part and the second part of the energy absorption body, be configured for splitting the thin-walled beams along an interface of a web and flange plate. Splitting the at least one beam along the interface of web and flange plates yield essentially elongated, flat plates that have little remaining stiffness and can therefore be easily bended.
[0017] Bendability of the split off parts of the energy absorption body is required for bending the parts, resulting from the splitting operation, in a direction away from the colliding object, the external structure and/or other objects that could otherwise be damaged by these split off parts.
[0018] In order to achieve bending of the split off parts of the energy absorption body, at least one first part of the energy absorption body may be provided with at least one deflection surface, which at least one deflection surface is configured for deflecting split off beam plates away from the colliding object. Moreover, the deformation (bending) of the split off beam plates by the deflection surface dissipates, in addition to the splitting, part of the colliding object's kinetic energy.
[0019] In an alternative embodiment, one of the first part and second part of the energy absorption body is nested within the other one of the first part or second part of the energy absorption body. This means that the first part of the energy absorption body may be nested within the second part of the energy absorption body to obtain a telescoping construction, internally comprising the first part of the energy absorption structure, and externally comprising the second part of the energy absorption structure. Alternatively, the second part of the energy absorption body may be nested within the first part of the energy absorption body. The telescoping construction allows the energy absorption body to occupy the least amount of space when in a retracted position.
[0020] In yet another embodiment, the energy absorption body may comprise an adjustable coupling configured for coupling the impact attenuator to an external structure, wherein the adjustable coupling allows adjustment of the angle enclosed between the energy absorption body and the external structure. With the possibility to adjust the angle enclosed between the energy absorption body and the external structure, it becomes possible to set the orientation of the impact attenuator such that it extends parallel to the road surface.
[0021] The specification also relates to a vehicle provided on a rear side thereof with an impact attenuator according to the present specification, which impact attenuator is configured to move between: an essentially horizontal position, wherein the impact attenuator extends substantially parallel to a road surface, and an essentially vertical position, wherein the impact attenuator is folded behind the vehicle. In a common instance, said vehicle is a road construction or maintenance truck that is especially prone to collide with passing traffic. By mounting and deploying the impact attenuator at the rear side of the vehicle, an impact barrier is created between said vehicle and traffic approaching from the rear. In addition, the impact attenuator could also be deployed at the front side of a vehicle, to create an impact barrier in case of a frontal collision. To minimize the length of the vehicle when the impact attenuator is not in use as a roadside barrier, the impact attenuator can be folded behind the vehicle in a essentially vertical position. A hydraulic system may for example be used for rotating or otherwise moving the attenuator to and from a folding position.
[0022] In addition, the specification relates to a trailer comprising an impact attenuator according to the present specification, wherein the impact attenuator is disposed on at least one axle provided with a set of wheels. The impact attenuator itself may act as a chassis onto which one or more axles are installed. An advantage of using such trailer as a temporary roadside barrier, is that the impact attenuator may be used behind a variety of vehicles. Additionally, the trailer may be used as a stand-alone roadside barrier, wherein the trailer is not coupled to any vehicle. In the case of stand-alone use, the trailer may be equipped with additional weights to act as a ballast.
[0023] Last, the specification relates to a guardrail, provided on a front end thereof with an impact attenuator according to the present specification. Such guardrail equipped with an impact attenuator is specifically suited for use at a head piece of a guardrail, for example between a highway and an exit lane, along the most probable line of impact. Hereby, the guardrail itself will only act as an external structure with which the impact attenuator is coupled. The impact attenuator may be (more so than the standard guardrail) optimized for different impact scenarios to guarantee an optimal safety for passing traffic. Moreover, the impact attenuator offers an additional line of protection against accidental fails of the guardrail.
BRIEF DESCRIPTION
[0024] The specification will now be elucidated into more detail with reference to non-limitative exemplary embodiments shown in the following figures. Corresponding elements are indicated with corresponding numbers in the figures.
[0025] FIG. 1 shows a three-dimensional view of a preferred embodiment of an impact attenuator according to the specification in an extended position;
[0026] FIG. 2 shows a three-dimensional view of an impact attenuator according to FIG. 1 in a retracted position;
[0027] FIG. 3 shows a side elevation of a trailer-implemented impact attenuator according to the specification in a retracted position;
[0028] FIG. 4 shows a side elevation of a trailer-implemented impact attenuator according to FIG. 3 in an extended position;
[0029] FIG. 5 shows a three-dimensional view of a part of the impact attenuator according to the specification;
[0030] FIG. 6 shows a three-dimensional view of another part of the impact attenuator according to the specification;
[0031] FIG. 7 shows a three-dimensional view of a yet another part of the impact attenuator according to the specification;
[0032] FIG. 8 shows an adjustable coupling for use in an impact attenuator according to the specification;
[0033] FIG. 9 a shows a three-dimensional view of an impact attenuator according to the specification upon impact with a vehicle;
[0034] FIG. 9 b shows a three-dimensional view of an impact attenuator according to the specification upon impact with a vehicle;
[0035] FIG. 9 c shows a three-dimensional view of an impact attenuator according to the specification upon impact with a vehicle;
[0036] FIG. 9 d shows a three-dimensional view of an impact attenuator according to the specification upon impact with a vehicle;
[0037] FIG. 9 e shows a three-dimensional view of an impact attenuator according to the specification upon impact with a vehicle; and
[0038] FIG. 10 shows a three-dimensional view of a guardrail comprising an impact attenuator according to the specification.
DETAILED DESCRIPTION
[0039] FIG. 1 shows a three-dimensional view of a preferred embodiment of an impact attenuator 1 according to the specification. The impact attenuator 1 is shown in an extended position, which corresponds to the attenuator's operational configuration. The impact attenuator 1 comprises an energy absorption body 2 , on a first end provided with an impact head 3 and on a second end opposing the first end coupled to an external structure by means of an adjustable coupling 4 . Although the adjustable coupling 4 as shown here allows specifically for coupling the impact attenuator 1 to trucks or other vehicles, the impact attenuator 1 could also be coupled to or be part of other external structures, not exclusively including trailers (see for example FIG. 2 ), guardrails (see for example FIG. 10 ) and ground anchors. The energy absorption body 2 comprises a first part 5 and a second part 6 , extending past each other in a lengthwise direction, wherein the first part comprises two H-beam structures 7 and the second part comprises hollow structural sections 8 . The H-beams 7 and hollow structural sections 8 can be provided with through-holes 9 in order to reduce the weight of the structure. Even though the energy absorption body 2 comprising two lengthwise extending beams, which leads to a highly stable and stiff structure, it is also possible that the energy absorption body 2 comprises a single beam structure comprising a single first and second part. Alternatively, more than two lengthwise extending beams can be used in the energy absorption body 2 . The H-beam sections are configured to slide over rollers 10 (visible in FIGS. 5-7 ), contained within the hollow structural sections 8 , which enables the H-beam sections 7 to move in lengthwise direction with respect to the hollow structural sections 8 , thereby performing a telescoping movement. As an alternative to the rollers 10 , materials with a low coefficient of friction could be applied along the interface of the H-beam sections 7 and the hollow structural sections 8 . First cutting means 11 , comprising first cutting edges 12 (shown in FIGS. 6 and 7 ) and second cutting means 13 , comprising second cutting edges 14 , are provided at an end of the second part of the energy absorption body 2 opposing the end of the second part connected to the adjustable coupling 4 . The first cutting means 11 are hereby configured for splitting the first part 5 of the energy absorption body 2 , while the second cutting means 13 are configured for splitting the second part 6 of the energy absorption body 2 . Alternatively, the second cutting means 13 could be mounted one a side of the impact head 3 facing the external structure (truck) 4 . The impact head 3 is furthermore provided with deflection surfaces 15 , which are configured for bending parts of the energy absorption body 2 away from the colliding object after being split-up by the second cutting means 13 .
[0040] FIG. 2 shows a three-dimensional view of an impact attenuator 1 according to FIG. 1 , now depicted in a retracted position, which corresponds to the attenuator's operational configuration. Reference signs similar to those in FIG. 1 hereby correspond to parts similar to those in FIG. 1 .
[0041] FIG. 3 shows a side elevation of a trailer-implemented impact attenuator 30 according to the specification. The impact attenuator 30 is depicted in a fully retracted position, in which it is most suited for transport. In this embodiment of the specification, the impact attenuator 30 constitutes part of a trailer 31 . More specifically, the impact attenuator 30 constitutes (part of) a chassis 32 , that provides a mounting point for an axle 33 with a pair of wheels 34 suspended thereto. The trailer 31 can be coupled to a vehicle by means of a common truck coupling 35 .
[0042] FIG. 4 shows a side elevation of a trailer-implemented impact attenuator 30 according to FIG. 3 . The impact attenuator 30 is now depicted in a fully extended position, in which it is most suited for use as a roadside barrier. Reference signs similar to those in FIG. 3 hereby correspond to parts similar to those in FIG. 3 .
[0043] FIG. 5 shows a three-dimensional view on a front end of a second part 52 of an energy absorption body 51 of an impact attenuator according to the specification. The front end of a second part 52 of the energy absorption body 51 is provided with second cutting means 53 , comprising four second cutting edges 54 , for cutting hollow structural section 55 at its vertices, such that essentially flat, bendable, elongated plates result from the splitting action, which plates constitute the sides of the hollow structural section 55 . Deflection surfaces 56 are provided next to the cutting edges 54 , which are configured for bending the elongated plates away from the colliding object. Rollers 57 are shown, which rollers 57 are contained within the hollow structural sections 55 , for guiding a first part (not visible) of the energy absorption body 51 .
[0044] FIG. 6 shows a three-dimensional view of a part of the impact attenuator according to the specification, which part comprises a structure 58 , contained within the hollow structural section 55 as shown in FIG. 5 , which structure 58 houses both the first cutting means 59 and the second cutting means 53 . Note that reference signs similar to those in FIG. 5 correspond to parts similar to those in FIG. 5 . The structure 58 is configured for guiding the first part 60 of the energy absorption body 51 by means of rollers 57 part the first cutting means 59 . The first cutting means 59 comprise first cutting edges 61 . In this figure, the first cutting means 59 are depicted in a retracted position wherein the cutting edges 61 keep clear of the H-beam 62 that is the first part 60 of the energy absorption body 51 , allowing the H-beam 62 to freely slide along the rollers 57 . This allows the user to retract the impact attenuator (for transport) such that the first part 60 of the energy absorption body 51 is substantially contained within the second part of the energy absorption body 51 . The structure 58 is on its corners provided with blocks 66 that form-fittingly connect to the shape of the hollow structural section 55 and allow the structure 58 to be guided along the hollow structural section 55 , thereby cutting into the hollow structural section 55 by means of the second cutting means 53 . To ensure smooth movement of the structure 58 relative to the hollow structural channel 55 , either the blocks 66 or the contact surface of the hollow structural channel 55 with the blocks 66 could be at least in part be manufactured from materials with a low coefficient of friction. Alternatively, rollers could be provided between the structure 58 and the hollow structural channel 55 . The structure is attached to the hollow structural section 55 by means of shear bolts or pins that are designed to break or shear in the case of a mechanical overload caused by an impact of the impact head 63 with the structure 58 .
[0045] FIG. 7 shows a three-dimensional view of a part of the impact attenuator according to the part shown in FIG. 6 , wherein similar reference signs correspond to similar parts. Again, a first part 60 of the energy absorption body 51 is shown that is coupled to an impact head 63 at a front end thereof. In this figure, the first cutting means 59 are depicted in an engaged position, wherein upon movement of the first part 60 of the energy absorption body 51 , the cutting edges 61 cut into said first part 60 of the energy absorption body 51 , splitting the H-beam 62 alongside the interface of the web plate 64 with the flange plates 65 .
[0046] FIG. 8 shows an adjustable coupling 80 for use in an impact attenuator according to the specification. The adjustable coupling 80 is configured for coupling the impact attenuator to an external structure by means of a pair of brackets 82 . The brackets 82 of the coupling allow the impact attenuator to be hooked around a protruding part of the external structure, which brackets 82 therefore provide for a fast and efficient connection of the impact attenuator to said external structure. Moreover, the adjustable coupling 80 allows adjustment of the angle enclosed between the energy absorption body and the external structure by means of jackscrews 81 .
[0047] FIG. 9 a -9 e show a three-dimensional view of an impact attenuator 90 according to the specification upon impact with a vehicle 91 . The figures show a sequence (a-e) of the impact of a collision of the vehicle 91 on the impact attenuator 90 . From the sequence it becomes clear that the first part 93 of the energy absorption body 92 is first split and then the second part 94 . The first part 93 is split into flat, bendable, elongated plates 98 by means of first cutting means contained within the second part 94 . The second part 94 is consecutively split into flat, bendable, elongated plates 95 that are bend away from the colliding vehicle 91 by deflection surfaces provided next to the second cutting means 97 and onto the impact head 96 as described above with reference to FIG. 1 and FIG. 5 . FIGS. 9 d and 9 e furthermore show that upon splitting of the second part 94 of the energy absorption body 92 , the flat, bendable, elongated plates 98 that previously formed the first part 93 of the energy absorption body 92 will protrude past the rear end of the second part 94 of the energy absorption body 92 . It is also conceivable that the impact attenuator 90 is, e.g. by means of a different arrangement of the cutting edges, configured for splitting the second part 94 of the energy absorption body 92 before splitting the first part 93 of the energy absorption body 92 upon impact of a vehicle 90 with the impact head 96 .
[0048] FIG. 10 shows a three-dimensional view of a guardrail 100 comprising an impact attenuator 101 according to the specification. The guardrail 100 hereby functions as an external structure with which the impact attenuator 101 is coupled. Alternatively, the impact attenuator 101 could be coupled to any other object posing an imminent danger to passing traffic.
[0049] It will be apparent that the specification is not limited to the exemplary embodiments shown and described here, but that within the scope of the appended claims numerous variants are possible which will be self-evident to the skilled person in this field. In particular, bursting may be applicable instead of splitting, and H or I beams may be tubes for instance. It is possible here to envisage that different inventive concepts and/or technical measures of the above described embodiment variants can be wholly or partially combined without departing from the inventive concept described in the appended claims.
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An impact attenuator including an impact head, coupled to a first end of an energy absorption body, which energy absorption body is arranged for fixation to an external structure at a second end opposing the first end of the energy absorption body, configured to at least partly absorb or dissipate energy from a collision of an object with the impact head, and including a first part and a second part extending substantially lengthwise behind each other, wherein the first and second part are mutually moveable and including a first and a second cutting edge, wherein, the first cutting edge is arranged for splitting the first part of the energy absorption body upon impact of an object colliding with the impact head, and the second cutting edge is arranged for consecutively splitting the second part of the energy absorption body upon impact of an object colliding with the impact head.
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[0001] This is a continuation-in-part of U.S. patent application Ser. No. 10/706,248, filed Nov. 11, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/290,183, filed Nov. 8, 2002, now U.S. Pat. No. 6,662,959. The contents of each of the aforementioned applications and patent are hereby incorporated herein by reference in their entirety. Priority to the aforementioned applications is hereby expressly claimed in accordance with 35 U.S.C. §120 and any other applicable statutes.
FIELD OF THE INVENTION
[0002] The present invention is directed to the conversion of a beverage bottle into a stemmed drinking glass by the consumer.
BACKGROUND
[0003] Single serving wine bottles are known in the art. These are essentially smaller versions of standard 750 ml. wine bottles, and generally have a metal cap. Once purchased, the cap is removed and the contents are poured into a separate glass for consumption. In situations when a glass is not available, one could drink the wine directly from the bottle.
[0004] The instant invention overcomes this problem of requiring a separate glass to be employed with a single serving wine bottle by making the single serving wine bottle convertible into a wine glass. The instant invention is such that if all the wine is not consumed, a cap can be replaced on the bottle until it is so desired to be consumed. A wine bottle which converts easily into a wine glass would find utility in the airline industry, the alcoholic beverage industry, bars, hotels, clubs or anywhere wine is served. Such a device may also be employed with wine coolers or other alcoholic beverages. In addition, the novelty of such a new and convertible device may be of interest to the bottling industry in general, where new ways to package beverages often increases their sales.
SUMMARY OF THE INVENTION
[0005] A wine bottle convertible to a wine glass permitting the consumption of the wine directly therefrom is provided. The wine bottle may be sized to house a single serving of wine. The convertible wine bottle comprises four main elements which are assembled and filled with wine in a bottling process. The wine bottle has basically four integrated components with ancillary structure. These four components are assembled and filled with wine at a bottling plant. Once bottled, the convertible wine bottle may be packaged in 4-, 6-, or 8-packs, as well as individually. The wine bottles would then be transported and sold. These four integrated components are manipulated by the consumer to transform the wine bottle into a wine glass with an appropriate portion of wine therein. Such a convertible bottle of wine would give users the pleasure of drinking their wine from a stemmed glass. Once completed, the structure may be reassembled and recycled.
[0006] The first element (stem and base) is the stem and base of the wine glass. The first element may be manufactured from plastic. The base includes a centrally disposed stem depending vertically therefrom. The base is designed to support the glass when the bottle is converted. The top portion of the stem may include a threaded socket or smooth socket. The base also is designed to be snap-fit or otherwise attached to the bottle prior to conversion to the wine glass.
[0007] The second element is a bottom closure which includes a generally cylindrical sidewall which has an interior side and an exterior side. The second element includes a centrally disposed parabolic portion which resides in the interior of the cylindrical sidewall. The interior cylinder sidewall includes threading to securely attach the second element to the third element. The parabolic portion forms a bowl on the exterior side and a displacement element on the interior side. The stem of the first element would reside within the bowl of the parabolic portion in the wine bottle configuration. The second element is manufactured from plastic or metal. It essentially forms a closure which is air and fluid tight with the third element forming a fluid reservoir which may be accessed through an aperture on the opposite side of the third element (the neck).
[0008] The third element comprises the main body of the bottle and has a generally cylindrical sidewall which also has an interior and an exterior side. The cylindrical sidewall has a top portion and a bottom portion along a vertical axis of said cylindrical sidewall. The top portion of the cylindrical sidewall has a neck with an opening. The top portion of the cylindrical sidewall may taper to form the neck. The bottom of the cylindrical sidewall forms a large opening which comprises the lip of the glass from which a user drinks when the bottle is converted to a wine glass. The exterior side of the bottom portion of the cylindrical sidewall has threads. These threads securely engage with the second element's interior sidewall threading. The neck is the portion of the bottle to which a cap will be affixed. Thus, the external portion of the neck is threaded and designed to receive a cap thereon. It is proposed that the third element be manufactured from glass, plastic or other material.
[0009] The third element may also have a lip extending radially outward from cylindrical sidewall at or near the bottom end of the cylindrical sidewall. The lip provides a seal between the second element and the third element, in addition to the seal provided by the engagement of the respective threads. To accommodate the lip, the diameter of the interior side of the cylindrical wall of the second element may be increased, also increasing the diameter of the threads on the interior side. In order to mate with the threads, the cylindrical sidewall of the third element in the area of the threads may thickened to form a band so that the threads can still mate with the threads in the second element's interior sidewall. The thickened band also makes the cylindrical sidewall of the third element stronger and more rigid in the area of the threads. In this way, the seal provided by the threads can withstand greater forces caused by squeezing the bottle or other handling of the bottle.
[0010] In another innovative aspect of the present invention, the threads on the cylindrical sidewall of the third element may be disposed on the interior side of the sidewall, instead of the exterior side as described above. In order to seal effectively to the threads of the interior side of the sidewall, the centrally disposed portion of the second element is cylindrical instead of parabolic. Threads are provided on the exterior side of this centrally disposed cylindrical portion which mate with the threads on the interior side of the sidewall. This configuration provides several advantages, such as eliminating the threads on the exterior side of the sidewall in the area where a user's mouth contacts the sidewall when drinking from the glass. Moreover, the seal between the second element and the third element seals the beverage in the bottle at the mating threads before the beverage reaches the interface between the edge of the sidewall at the large opening of the third element and the interior side of the bottom of the second element. Thus, there is no need to provide a fluid tight seal at the interface. This also eliminates the need for using a lip extending radially outward from cylindrical sidewall at or near the bottom end of the cylindrical sidewall as described above.
[0011] The combination of the second element and the third element forms the reservoir which will be filled with wine. The interior side of the parabolic portion of the second side forms a displacement area which alters the amount of fluid which may be placed in the reservoir (in comparison to a second element with no parabolic portion). This displacement area would also effect the amount of air present. Air tends to oxidize wine therefore it should be minimized. Wine has been bottled for years and the amount of air present in the bottling process has been established to maximize flavor and shelf-life.
[0012] In another aspect of the present invention, the third element may be formed by several different methods. In a first method, the third element may be molded (such as injection molding) in essentially its final form. Accordingly, the cylindrical sidewall, the threads on the neck and the threads on the bottom portion of the cylindrical sidewall are molded in their final form. In addition, the neck and bottom of the third element have openings provided by the molding process.
[0013] Alternatively, the third element may be produced in a two-step process utilizing a preform and a blow-molding process. The preform may have various innovative configurations, including being open and clamped at the small neck opening of the third element during the blow-molding process, being open and clamped at the large opening of the third element, or open at both ends and clamped at one end and sealed at the other end of the third element.
[0014] For example, the preform may comprise a tubular piece having a diameter which is smaller than the finished diameter of the cylindrical sidewall of the third element. The top part of the tubular piece is open and forms the neck of the third element. The threads on the neck may or may not be formed on the preform. The bottom of the tubular piece is closed. The threads on the exterior side of the bottom portion may be formed on the preform but are preferably formed during the blow-molding process. The preform is typically produced by injection molding but may be produced by any suitable method. To form the finished third element, the preform is placed in a blow-molding machine having a mold tool in the shape of the final form of the third element. The preform is clamped at the top part of the tubular piece. Pressurized gas is injected into the preform which forces the material of the preform against the mold tool which shapes the preform into the shape of the mold tool. The threads on the exterior side of the bottom portion of the cylindrical sidewall are formed during the blow-molding process (if the threads were not included in the preform). The bottom end of the cylindrical portion is then trimmed to form the large opening.
[0015] In another blow-molding process, the third element may be produced using a preform with a tubular top portion having the same diameter as the bottom portion of the cylindrical sidewall and the large opening. The threads on the exterior of the side of the bottom portion of the sidewall are preferably formed on the preform but may also be formed during the blow-molding process. The large diameter of the preform tapers down to a narrower tubular bottom portion having a closed end which will comprise the neck of the third element after the blow-molding process. Again, the preform may be fabricated by injection molding or other suitable process. The finished third element is produced by placing the preform in a blow-molding machine having a mold tool in the shape of the final form of the third element. The preform is clamped at the tubular top portion of the preform. Pressurized gas is injected into the preform thereby reshaping the preform into the shape of the mold tool. The threads on the neck of the third element are formed during the blow-molding process (if the threads were not included in the preform). The tip of the closed neck end is then trimmed to form the opening in the neck.
[0016] In yet another blow-molding method, the preform for the third element may comprise a tubular piece which is open on both ends. The tubular piece is the same length as the interior of the blow-mold tool and at least a portion of the tubular piece has a smaller diameter than the finished cylindrical sidewall of the third element. The threads on the neck and on the exterior of the bottom portion of the sidewall may be formed in the preform or during the blow-mold process. During the blow-mold process, one open end of the preform is clamped at the pressurized gas source and the other open end of the preform is sealingly pressed or clamped against the end of the interior of the mold. Pressurized gas is injected into the preform thereby reshaping the preform into the shape of the mold tool. The advantage of this particular “two open end” process is that there is no trimming required as in the two blow-molding processes described above. The trimming processes present a risk of deforming the shape of the openings which could produce a poor fit between the bottom cover and the threaded portion of the third element or the cap (described below) and the neck of the third element.
[0017] The fourth element (cap) is a cap which is secured to the neck of the third element. The wine is delivered to the bottle (which is formed by the combination of the second and third element) through the aperture in the top of the neck. Once filled, the fourth element is secured thereto. The cap is designed to be manufactured from metal or plastic and will seal the bottle to prevent air or fluid from passing either direction.
[0018] The above brief description sets forth rather broadly the more important features of the present invention in order that the detailed description thereof that follows may be better understood, and in order that the present contributions to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. These may include the use of sizes other than single serving wine bottles, use with other bottled alcoholic beverages where it is desirable to have such a convertible bottle, or other non-alcoholic beverages where it is desirable to have such a convertible bottle.
[0019] In this respect, before explaining the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood, that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0020] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0021] It is therefore an object of the present invention to provide a single serving wine bottle which may be converted into a wine glass.
[0022] It is another object of the invention to provide a wine bottle which may be convertible in to a wine glass.
[0023] It is another object of the invention to provide a wine bottle with a central wine reservoir, the wine reservoir including a bottom portion and an intermediate portion, the bottom portion screwed and sealed onto the intermediate portion.
[0024] It is another object of the invention to provide a wine bottle wherein the intermediate portion tapers to a neck, the neck designed to receive a cap thereon.
[0025] It is another object of the invention wherein the bottom portion includes a depression centrally disposed about a lip, the depression designed to receive the stem of the wineglass therein.
[0026] These together with still other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will be better understood and the above objects as well as objects other than those set forth above will become more apparent after a study of the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0028] FIG. 1 is a view of the wine bottle and the components forming the same.
[0029] FIG. 2 is a view of the wine bottle showing the connection between the two central elements of the bottle in preparation for bottling.
[0030] FIG. 3 is a view of the wine bottle showing the connection of a third portion to the central element of the bottle in preparation for bottling.
[0031] FIG. 4 is a view of the wine bottle just prior to being filled with wine.
[0032] FIG. 5 is a view showing the cap secured to the filled wine bottle.
[0033] FIG. 6 is a view of the first step of the wine bottle being converted into a wine glass.
[0034] FIG. 7 is a view of the second step of the wine bottle being converted into a wine glass.
[0035] FIG. 8 is a view of the third step of the wine bottle being converted into a wine glass.
[0036] FIG. 9 is a view of the fourth step of the wine bottle being converted into a wine glass.
[0037] FIG. 10 is a view of the fifth and final step of the wine bottle being converted to a wine glass, showing the wine glass filled with wine ready to be consumed.
[0038] FIG. 11 is a view of a plurality of convertible wine bottles packaged for sale.
[0039] FIG. 12 is a view of a second embodiment of the bottle and its components, in accordance with the present invention.
[0040] FIG. 13 is a view of the second embodiment of the bottle being converted into a drinking glass.
[0041] FIG. 14 is a view of the second embodiment of the wine bottle after it has been converted into a drinking glass.
[0042] FIG. 15 is a view of a third embodiment of the bottle and its components, in accordance with the present invention.
[0043] FIG. 16 is a view of the third embodiment of the bottle fully assembled.
[0044] FIG. 17 is a view of the third embodiment of the bottle being converted into a drinking glass.
[0045] FIG. 18 is a view of the third embodiment of the bottle after it has been fully converted into a drinking glass.
[0046] FIG. 19 is a view of a preform for producing the third element of the bottle, according to the present invention.
[0047] FIG. 20 is a view of the blow-molded preform of FIG. 19 .
[0048] FIG. 21 is a view of the blow-molded preform of FIG. 19 which also depicts the trimming procedure.
[0049] FIG. 22 is a view of the completed third element as produced by the preform of FIG. 19 .
[0050] FIG. 23 is a view of another preform for producing the third element of the bottle, according to the present invention.
[0051] FIG. 24 is a view of the blow-molded preform FIG. 22 .
[0052] FIG. 25 is a view of the blow-molded preform of FIG. 20 which also depicts the trimming procedure.
[0053] FIG. 26 is a view of the completed third element as produced by the preform of FIG. 23 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0054] With reference now to the drawings, a wine bottle convertible to a wine glass embodying the principles and concepts of the present invention will be described. In the case of a bottle being converted into a glass, it is to be understood that this glass is a drinking glass and may be comprised of material other than glass, such as plastic.
[0055] Turning initially to FIG. 1 , the unassembled wine bottle 10 which is convertible into a wine glass is shown. FIG. 1 shows the components employed. Element 1 shows the base 12 with a centrally disposed stem 14 depending therefrom. The bottom portion 15 of the stem 14 includes a hollow aperture 16 with an interior which may be smooth or threaded. Other means may be incorporated to increase the frictional holding capacity of the hollow aperture. Such means may include mechanisms which would increase the co-efficient of friction. The base 12 has a perimeter 18 . A lip portion 20 depends around the perimeter 18 of the base 12 .
[0056] Element 2 includes a generally cylindrical sidewall 22 which has an exterior side 24 and an interior side 26 . Element 2 includes a centrally disposed parabolic portion 28 or depression which resides in the interior of the cylindrical sidewall 22 . It describes a parabolic opening 30 which is surrounded on the top 32 by a ring 34 . The parabolic portion 28 is thin and approximates the thickness of the sidewall 22 . On the interior side 26 of the cylindrical sidewall 22 is a first set of threads 36 . The parabolic portion 28 may also be described as a depression. The depression may assume other shapes other than the parabolic portion 28 which is shown in the figures. The interior area of element 2 is best seen in FIG. 10 .
[0057] Element 1 fits into element 2 . The stem 14 resides in the parabolic opening 30 and the lip portion 20 snap fits about the ring 34 on the top 32 of the second element. Tamper resistant or evident devices may be employed.
[0058] Element 3 also has a generally cylindrical sidewall 38 with a top portion 40 and a bottom portion 42 along a vertical axis of said cylindrical sidewall 38 . The top of element 3 shows the sidewall 38 forming a circular opening 37 . Circular opening 37 is surrounded by lip 35 . Lip 35 would mate with the consumer's mouth when drinking the wine. Element 3 also includes an interior side 44 and an exterior side 46 . A second set of threads 48 are located on the exterior side 46 of the cylindrical sidewall 38 of element 3 . The second set of threads 48 are generally located above the midpoint (MP) between the top portion 40 and the bottom portion 42 . Below the midpoint (MP) the cylindrical sidewall 38 tapers near the bottom portion 42 to a central neck 50 as shown. Central neck 50 includes an opening 52 to the interior side 44 of element 3 . The exterior portion 54 of the central neck 50 includes a third set of threads 56 .
[0059] Element 2 matingly interengages with element 3 . The parabolic portion 28 fits into the circular opening 37 and the first set of threads 36 are mated with and rotated about the second set of threads 48 forming an air and fluid tight seal. Element 3 has a first volume which is reduced proportionally to the amount of the parabolic portion which fits into the interior.
[0060] Element 4 is a cap 58 . Cap 58 includes a fourth set of threads 60 , located on the interior as shown. During the bottling process, once element 2 and element 3 are securely interfit, the bottle or reservoir formed would be filled with wine. At that point cap 58 would be screwed onto element 3 with the third set of threads 56 mating with the fourth set of threads 60 forming an air and fluid tight seal. It is to be noted that once the bottle 10 is filled, cap 58 is sealed.
[0061] FIGS. 1-5 show the construction of the wine bottle 10 at the bottling plant and FIG. 11 shows a possible packaging. FIG. 1 has been discussed above and basically lays out the components and ancillary structure located thereon. Referring now specifically to FIG. 2 , the first step in the construction of the bottle 10 is screwing element 2 about element 3 . This is done by mating the first set of threads 36 into the second set of threads 48 and turning until sealed. It is to be understood that additional devices or structures may be incorporated into this mating arrangement in order to facilitate an air and fluid tight seal. Once element 2 is affixed securely to element 3 , an interior chamber 65 is formed with a single aperture 52 .
[0062] Referring now specifically to FIG. 3 , the next step in the construction of the bottle 10 is placing element 1 into the combination of element 2 and element 3 . The stem 14 is received in the parabolic opening 30 and the lip portion 20 snap fits atop top element 32 of element 2 .
[0063] Referring now to FIG. 4 , the bottle 10 is shown in an orientation which places the cap 58 and the aperture 52 on top. It is at this junction where the interior chamber 65 is filled with wine. Once filled to an appropriate level, certainly above the midpoint (MP), the bottle 10 has the cap 58 placed securely thereon. This is accomplished by mating the third set of threads 56 with the fourth set of threads 60 and screwing the cap on. Again, it is to be understood that additional devices or structures may be incorporated into this mating arrangement in order to facilitate an air and fluid tight seal.
[0064] FIG. 5 shows bottle 10 in its completed form. It can clearly be seen the inter-relationship between element 1 , element 2 , element 3 and element 4 . The interior chamber 65 is shown filled with wine to a level indicated at 70 . This level 70 in no way indicates the desired level, it is for illustrative purposes only. Although the bottle is basically designed to serve a single wine serving, the serving size may vary with type of wine, with the meal that the wine is served with, cultural factors and manufacturing limitations. One of the main embodiments of the invention would be use of such a single serving convertible wine bottle to wine glass on an airline. Referring now specifically to FIG. 11 , a four pack 80 of convertible bottles 10 are shown, ready for sale and consumption.
[0065] FIGS. 6-10 will show the conversion of the wine bottle 10 to a wine glass. This conversion will most likely take place by the consumer, although a flight attendant, waitress or waiter, bartender or partner may actually perform the conversion prior to being handed to the consumer. The conversion is easily performed, so that anyone can easily perform the steps. The first step is removing element 1 from element 2 . This is done by grasping the base 12 and unsnapping the lip portion 20 from the top portion 32 of element 2 .
[0066] The second step is shown in FIG. 7 . Hollow aperture 16 is aligned with cap 58 . Hollow aperture 16 has been chosen to be sized so that it frictionally fits atop cap 58 in a secure fashion. The hollow aperture 16 may also be known as a recess. It is to be understood that additional devices or structures may be incorporated into this mating arrangement in order to facilitate a tight seal. Such an arrangement may include threads. FIG. 8 shows the stem 14 and base 12 of element 1 mated with element 4 . It can be seen that interior chamber 65 with the wine therein is oriented in the proper direction to be consumed.
[0067] FIGS. 9 and 10 shows the removal of the element 2 from element 3 , essentially opening the wine bottle 10 and leaving the wine bottle converted into a wine glass. The second set of threads 48 remain on the exterior side 46 of the generally cylindrical sidewall 38 . This may help the user grasp the glass. In addition, the second set of threads are down low enough on the exterior side 46 of the cylindrical sidewall 38 to prevent one from becoming engaged with it while drinking from the glass.
[0068] Turning to FIGS. 12-14 , a second embodiment of a bottle which is convertible into a drinking glass is shown. This bottle 100 is identical to the bottle described above with respect to FIGS. 1-11 , except that the third element further comprises a lip 102 and element 2 and element 3 are modified to accommodate the addition of the lip. Accordingly, like reference numerals in this second embodiment refer to like elements in FIGS. 1-11 and the description above is equally applicable to the second embodiment.
[0069] The lip 102 extends radially outward from cylindrical sidewall 38 at the circular opening 37 at the top of element 3 . When element 2 is screwed tightly onto element 3 , the lip 102 seals tightly against the interior side 26 of the bottom of element 2 . The lip 102 provides a seal between element 2 and element 3 , in addition to the seal provided by the engagement of the threads 36 and 48 . To accommodate the lip 102 , the diameter of the interior side 26 of the cylindrical wall 22 of element 2 must be increased, also increasing the diameter of the threads 36 on the interior side 26 . In order to mate with the threads 36 , the cylindrical sidewall 38 of element 3 in the area of the threads 48 are thickened to form a band 104 so that the threads 48 will mate with the threads 36 in interior side 26 of element 2 . The band 104 also makes the cylindrical sidewall 38 of element 3 stronger and more rigid in the area of the threads 48 . Therefore, the seal provided by the threads 36 and 48 can withstand greater forces caused by squeezing the bottle 100 or other handling of the bottle 100 .
[0070] Referring now to FIGS. 15-18 , a third embodiment of a bottle which is convertible into a drinking glass is shown. This bottle 200 is very similar to the bottles 10 and 100 described above with respect to FIGS. 1-14 , except that the connection between element 2 and element 3 is provided by threads disposed on the interior side 44 of the sidewall 38 and mating threads on the exterior side of the centrally disposed portion or depression of element 2 . Accordingly, like reference numerals in this third embodiment refer to like elements in FIGS. 1-14 and the descriptions above are equally applicable to this third embodiment.
[0071] As shown in FIGS. 15-18 , element 3 has threads 202 located on the interior side 44 of the sidewall 38 . The threads 202 may be located any desired distance down from the lip 35 , so long as the exterior side 206 of the centrally disposed portion 28 is long enough so that the threads 204 can mate with the threads 202 . Similar to the band 104 described above with respect to the bottle 100 , the cylindrical sidewall 38 in the area of the threads 202 may be thickened to form a band (not shown in FIGS. 15-18 ).
[0072] Element 2 is modified from the configuration shown and described for bottles 10 and 100 so that element 2 will sealingly mate with the modified element 3 of bottle 200 . First, the centrally disposed portion 28 of element 2 is cylindrical instead of parabolic as in bottles 10 and 100 . Threads 204 are located on the exterior side 206 of the centrally disposed portion 28 . The threads 204 sealingly mate with the threads 202 on element 3 .
[0073] The bottle 200 is filled and assembled into a filled bottle 200 as shown in FIG. 16 the same as described above for bottles 10 and 100 . Furthermore, the procedure for converting the bottle 200 into a wine glass as shown in FIGS. 17 and 18 is also the same procedure as described above for bottles 10 and 100 .
[0074] The present invention also includes several innovative methods of fabricating element 3 utilizing a preform and a blow-molding process. With reference to FIGS. 19-22 , a first method for fabricating element 3 will be described. FIG. 19 shows a preform 302 comprising a tubular piece 304 . The tubular piece 304 has a smaller diameter than the finished diameter of the sidewall 38 of element 3 . The preform also has the neck 50 having the open end 52 and threads 56 . The threads 56 may be formed on the preform 302 as shown or may alternatively be formed during the blow-molding process. The preform has a closed bottom 310 . The preform is preferably produced by injection molding for plastic parts, or other suitable method considering the type of raw material. A blow-molding mold tool (not shown) is provided which has substantially the shape of the final form of element 3 . To form element 3 , the preform 302 is placed in the mold tool on a blow-molding machine (not shown). The mold tool clamps onto the neck 50 of the preform 302 . The preform 302 is then blow-molded by injecting pressurized gas into the preform 302 thereby producing the blow-molded preform 312 shown in FIG. 20 . The threads 48 on the sidewall 38 of element 3 are formed during the blow-molding process. In the case of fabricating element 3 for bottle 200 , the threads 202 should be should be included on the preform 302 because it will be difficult to form threads 202 on the interior side 44 of the sidewall 38 by blow-molding. FIG. 21 depicts the final step in the fabrication process which is to trim the bottom surface 314 to create the opening 37 . The result is the final fabricated element 3 as shown in FIG. 22 .
[0075] Another method of fabricating element 3 will now be described with reference to FIGS. 23-26 . The preform 320 shown in FIG. 23 comprises a portion of the cylindrical sidewall 38 of element 3 and the threads 48 (or threads 202 if producing element 3 of bottle 200 ) in the form of the final element 3 . The preform 320 tapers down to a narrower tubular bottom portion 322 having a closed end 324 . As with the preform 302 , the preform 320 may be produced by injection molding or other suitable method depending on the raw material. A blow-molding mold tool (not shown) is provided which has substantially the shape of the final form of element 3 . To form element 3 , the preform 320 is placed in the mold tool on a blow-molding machine (not shown). The mold tool clamps onto the portion of the sidewall 38 . The preform 320 is then blow-molded by injecting pressurized gas into the preform 320 thereby producing the blow-molded preform 326 shown in FIG. 24 . The threads 56 on the neck 50 of element 3 are formed during the blow-molding process. The final step in the fabrication process is trimming the closed end 324 as depicted in FIG. 25 to create the opening 52 . The result is the final fabricated element 3 as shown in FIG. 26 .
[0076] Again, it is to be understood that wine is just one of the beverages which may be utilized with the instant invention. Wine coolers, other low alcohol content mixed style drinks and other beverages may be employed with the convertible bottle.
[0077] It is apparent from the above that the present invention accomplishes all of the objectives set forth by providing a single serving wine bottle which is convertible to a wine glass.
[0078] With respect to the above description, it should be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to those skilled in the art, and therefore, all relationships equivalent to those illustrated in the drawings and described in the specification are intended to be encompassed only by the scope of appended claims.
[0079] While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the invention, it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein. Hence, the proper scope of the present invention should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications and equivalents.
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A beverage container convertible to a stemmed drinking glass and method of fabricating the same. The convertible wine bottle comprises four main elements which are assembled and filled with wine in a bottling process. The wine bottle has basically four integrated components with ancillary structure. These four components are assembled and filled with wine at a bottling plant. Once bottled, the convertible wine bottle may be packaged in 4-, 6-, or 8-packs, as well as individually. The wine bottles can be transported and sold. These four integrated components are manipulated by the consumer to transform the wine bottle into a stemmed drinking glass with an appropriate portion of beverage therein. Such a convertible beverage container provides users the pleasure of drinking their beverage from a stemmed glass. Once completed, the structure may be reassembled and recycled.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2008 046 216.0, filed Sep. 8, 2008; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an apparatus and a method for evaluating control marks on printing materials by an optical sensor connected to a computer, which interprets overshooting of a predefined intensity threshold as it registers the printing material as a line of a printed control mark.
In offset presses, accurate-register and accurate-position printing is important, since otherwise faults can be seen in the image. Here, accurate-register printing is understood to mean the exact overprinting of a plurality of color separations on one side of a printing material. Accurate-position printing usually relates to what is known as reverse positioning, which means that, in the case of recto and verso printing on both sides, the color separations on the front side are arranged at the same distance from the edges of the printing material as those on the rear side. The control marks used for this purpose normally have a plurality of differently arranged and differently thick lines, which are printed in the different colors of the color separations. By printing the register or position lines beside one another and over one another, the register mark or positioning mark is then produced, which is registered and evaluated by an appropriate optical sensor. The lines of the control marks must not exceed a predefined spacing tolerance, otherwise visible image defects are to be expected in the printed image and the printing quality is poor.
Published, non-prosecuted German patent application DE 42 18 762 A1 discloses a scanning arrangement for register marks produced by multicolor printing. The scanning arrangement is configured to register fast-moving register marks in the press. In the scanning arrangement, the gain of a photoreceiver is matched to the contrast relationships of the register mark to be expected in each case. This is done because register marks of different printing inks supply a different intensity signal, for example black printing ink supplies high signal amplitudes while blue printing ink supplies only weak signals. For this purpose, the gain factor is matched to the color of the register marks to be expected, so that the signals to be evaluated have an approximately equal amplitude. However, this procedure functions only if a standard order of colors to be expected is maintained. In the case of unexpected colors or a changed order of colors, on the other hand, the scanning arrangement functions only poorly, since the colors are then allocated erroneous gain factors on the basis of the unexpected order of colors or an unexpected color.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an optimized-intensity control mark measurement, which overcome the above-mentioned disadvantages of the prior art methods and devices of this general type, which function even in the event of unexpected colors in register marks and in the event of a changed order of colors.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method for evaluating control marks on printing materials. The method includes interpreting, via an optical sensor connected to a computer, overshooting of a predefined intensity threshold as the computer registers a printing material being a line of a printed control mark; registering the printed control mark via a color measuring instrument; and calculating an intensity threshold of the optical sensor via the computer in dependence on a measured color value registered by the color measuring instrument.
The present invention is suitable in particular for use for register control in sheetfed offset presses and web fed offset presses. With the present invention, account is taken of the fact that too low an intensity threshold leads to the measured result becoming inaccurate on account of the excessively low signal-to-noise ratio while, in the case of an excessively high intensity threshold, no lines are registered on the control marks. In order to avoid these problems, the control mark is registered by a color measuring instrument, in order in this way to be able to evaluate the color of the control mark exactly. Depending on the color of the control mark registered by the color measuring instrument, the intensity threshold of the optical sensor for registering the control mark is then adjusted, so that the measured result is as accurate as possible and, nevertheless, the lines on the control mark are registered reliably. To this end, the measured color values from the color measuring instrument are transmitted to a computer, which evaluates the measured color values and calculates the suitable intensity threshold of the optical sensor. During this procedure, the order of colors and the color of the respective control mark then no longer play any part since, in the case of each control mark, first the color is registered by the color measuring instrument and then, depending on the color registered, the suitable intensity threshold for the optical sensor is determined automatically.
In one embodiment of the invention, provision is made for the control mark to be illuminated during its registration and for the intensity threshold to be determined by the computer while taking the spectrum of the illumination into account. For the purpose of correct color registration, the color measuring instrument needs predefined, if possible constant, illumination. For this reason, the color measuring instrument normally has a source of illumination whose spectrum is known and which illuminates the printing material. This spectrum of the source of illumination is then likewise taken into account together with the color spectrum of the control mark registered, in order to calculate the suitable intensity threshold.
In a further refinement of the invention, provision is additionally made for the intensity threshold to be determined by the computer while taking the spectrum of the optical sensor into account. As a result of taking the spectrum of the optical sensor into account, the measurement accuracy is increased further. Particular advantages result if both the spectrum of the illumination and the spectrum of the optical sensor are taken into account in the calculation of the intensity threshold, since then all the influencing variables are taken into account. Since the spectrum of the source of illumination and the spectrum of the optical sensor for registering the control mark normally do not change during operation, these spectra can be stored directly in the computer. Together with the measured spectral values from the color measuring instrument, the computer can thus simply calculate the resultant spectrum which is used to define the intensity threshold. The calculation of the resultant spectrum is done mathematically by means of convolution of the spectra of the source of illumination, of the optical sensor and of the measured color values registered by the color measuring instrument. The computer then determines the intensity threshold for the optical sensor from the amplitude of the resultant spectrum, so that an analog-digital converter contained in the optical sensor is driven appropriately.
Provision is advantageously made for the registration of the printing material to be carried out in a press and for the printing material to be held on a cylinder by sheet grippers during the registration. During this procedure, the printing materials are measured directly in the press in a sheetfed rotary press, in that the printing materials transported through under the optical sensor together with the printed control marks are registered while still in the machine. During the registration by the optical sensor and the color measuring instrument, in this case the printing materials are, for example, held on the impression cylinder of the last printing unit by the sheet grippers present there and are thus stabilized during the measuring operation. In this way, both register marks and positioning marks are registered as control marks on each individual printing material directly in the press and used for the appropriate control. In this case, the color measuring instrument, which has a spectral measuring head in order to determine the measured spectral color values, is preferably also integrated in the press in the last printing unit.
If both the color measuring instrument and the optical sensor are arranged at the same point in the press, the optical sensor and the color measuring instrument can form one structural unit. This has the great advantage that there has to be only one mounting holder for both devices and, in addition, optical sensor and color measuring instrument can be removed together. Furthermore, only one set of cabling has to be laid at one location in the press, since both the optical sensor and the color measuring instrument are integrated in the press at the same location because of the structural unit. This location is preferably immediately at the output from the press nip in the last printing unit, where all the register marks are present on the printing material.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an optimized-intensity control mark measurement, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagrammatic, side view of a sheetfed offset press having a plurality of printing units and an integrated optical sensor with a color measuring instrument in a last printing unit;
FIG. 2 is an illustration of a fine register mark;
FIG. 3 is an illustration of a coarse register mark;
FIG. 4 is a graph showing the spectra of a first color to be taken into account when determining the intensity threshold; and
FIG. 5 is a graph showing the spectra of a second printing ink to be taken into account when determining the intensity threshold.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown by way of example, a sheetfed press 1 that has four printing units 4 , 5 , it being indicated in the middle that the press 1 can have still further printing units 4 . Arranged in the last printing unit 5 of the press 1 is an in-line color measuring instrument 6 , which measures the color of the finally printed sheets 12 at the outlet from a press nip 10 in the last printing unit 5 . In addition, the in-line color measuring instrument 6 has a register sensor 15 , which measures control marks in order to determine the positioning accuracy and register accuracy on the printing materials 12 . The color measuring instrument 6 in the form of a measuring beam with the register sensor 15 incorporated forms one structural unit and, mounted jointly on a rail, can be removed laterally from the last printing unit 5 and thus maintained better. In order to have defined illumination conditions during the color measuring operation and during the registration of control marks 17 , 18 on the printing material 12 , in the immediate vicinity of the in-line color measuring instrument 6 there is a source of illumination 16 , which illuminates the sheet 12 with a predefined spectrum. This illumination spectrum B is stored in a control computer 19 , which is connected to the in-line color measuring instrument 6 and the register sensor 15 and can thus be used to determine the intensity threshold of the register sensor 15 .
The press 1 has a feeder 2 , in which sheet printing materials 12 are separated and fed to a first printing unit 4 . The printing units 4 , 5 each have impression cylinders 7 , blanket cylinders 8 and plate cylinders 13 , the latter carrying the printed image. Between the printing units 4 , 5 , the sheets 12 are transported by transport cylinders 9 , the transport cylinders 9 being assisted by a blown air guide 14 , so that the transported sheets 12 have no contact with other parts. The air metering of the blown air guide 14 is also carried out via the control computer 19 . When the sheets 12 leave the press nip 10 between the blanket cylinder 8 and the impression cylinder 7 in the last printing unit 5 , their color is measured by the in-line color measuring instrument 6 , in order to calculate in the control computer 19 the corresponding intensity threshold in each case for the subsequent register and position measurement for the control mark 17 , 18 to be measured. This is done so quickly in the control computer 19 that the register sensor 15 arranged immediately after the color measuring instrument 6 is driven appropriately correctly with the suitable intensity threshold S, so that it is able to register correctly the lines of the respective mark, matched to the color of the respective control mark 17 , 18 on the printing material 12 determined by the color measuring instrument 6 . In order that the sheet 12 is stable during the measuring operations, it is held on one side in the press nip 10 and on the other side by the sheet grippers 11 of the impression cylinder 7 . However, the color measuring instrument 6 of the press 1 can in this case not only be used to determine the suitable intensity threshold S as a function of the control marks 17 , 18 to be measured but, of course, can also be used, in parallel with the registration of measured color values on the sheet 12 , to monitor the correct coloration in the printed image in relation to the printed original. This color monitoring is normally the main task for color measuring instruments 6 in presses 1 .
In FIG. 2 , a fine register mark 17 is depicted by way of example, while FIG. 3 shows a coarse register mark 18 . The register marks 17 , 18 are printed beside one another or above one another in all the colors of the respective print job, appropriate lines being present, from whose spacings the register and positioning accuracy can be determined by the control computer 19 . To this end, the lines of the control marks 17 , 18 must be determined exactly and reliably by the register sensor 15 . For this reason, in the case of the present invention, first the color of the respective control mark 17 , 18 is registered by the color measuring instrument 6 , and then the intensity threshold S of the ND converter in the register sensor 15 is adapted in the computer 19 in accordance with the measured color values registered.
For the purpose of optimal determination of the intensity threshold S, not only is the spectrum of the color F measured by the color measuring instrument 6 taken into account in the control computer 19 but also the known spectrum B of the source of illumination 16 and the likewise known spectrum E of the register sensor. In this case, the two spectra B and E are stored in the control computer 19 and thus do not need to be determined during the measuring operation. In this case, the color spectrum F is determined anew by use of a spectral measurement by the color measuring instrument 6 for each control mark 17 , 18 . From the three spectra B, E, F, the control computer 19 determines a resultant spectrum R by means of the mathematical operation of convolution. The amplitude of the resultant spectrum R is then taken by the control computer 19 as a measure of the intensity threshold S of the register sensor 15 that is to be set. The greater the amplitude of the resultant spectrum R, the higher the intensity threshold S of the register 15 can be set, the converse also being true.
In FIGS. 4 , 5 , two printing inks are depicted by way of example for this purpose. The printing ink in FIG. 4 is a very bright printing ink, so that the intensity threshold S must be set appropriately low. In FIG. 5 , on the other hand, a dark color like black is depicted, in which the intensity threshold S of the analog-digital converter in the register sensor 15 can be set correspondingly high. A high intensity threshold ensures a high measurement accuracy, for which reason the intensity threshold S is always set as high as possible. In the case of bright colors, in particular special colors, the intensity threshold must be reduced, however, since otherwise no lines can be registered by the register sensor 15 any more and there is no measured result. By use of the present invention, it is thus possible to register bright special colors by the register sensor 15 as well and, nevertheless, when possible, to set the intensity threshold S of the register sensor 15 as high as possible, in order to increase the measurement accuracy.
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An apparatus and a method for evaluating control marks on printing materials by an optical sensor connected to a computer, which interprets overshooting of a predefined intensity threshold as it registers the printing material being a line of a printed control mark. The apparatus is distinguished by the fact that the control mark is registered by a color measuring instrument and that the intensity threshold of the optical sensor is calculated by the computer in dependence on the measured color value registered by the color measuring instrument.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/122,102, filed on Apr. 26, 2011 (currently pending), which is incorporated herein by reference in its entirety. U.S. application Ser. No. 13/122,102 is a national stage of International Application Number PCT/CA2009/001391, filed Oct. 1, 2009 (now expired), which is incorporated herein by reference in its entirety.
FIELD
The present invention relates to measuring deformation in general and measuring deformation using Brillouin scattering in particular.
BACKGROUND
Deformation sensing can be achieved by placing point sensors across a certain range. However, this raises a problem when large engineering projects require the sensing to be done over several kilometers because numerous point sensors are required.
Conventionally, a distributed sensor is a device with a linear measurement basis, which is sensitive to a measure and at any of its points. Distributed optical fibre sensing is not well known and has been slow to be accepted into conservative large engineering projects where long sensors would be advantageous. The optical fibre is sensitive over its entire length. A single distributed optical fibre sensor can replace thousands of discrete point sensors. Traditionally, optical fibre connections were thought to be costly and troublesome. However, the cost of using fibre optics has fallen rapidly. Use of optical fibres is advantageous because they are tough, durable, stable, and can be applied in harsh environments. The fibres are also immune to electrical interference common in industrial environments and have small cross-sections, making them suitable for embedment in composite materials.
There are different types of optical fibre distributed sensors—those that measure temperature distributions by detecting Raman scattered light in a fibre, others that measure strain distributions by detecting Rayleigh scattered light, and still others that measure both temperature and strain distributions by detecting Brillouin scattered light. The sensors that are based on measurement of Brillouin scattered light include BOTDA (Brillouin Optical Time Domain Analysis), BOTDR (Brillouin Optical Time Domain Reflectometry), BOFDA (Brillouin Optical Frequency Domain Analysis) and correlation-based Brillouin distributed sensors.
A BOTDA sensor applies Brillouin Scattering, a method of detecting distributed temperature and strain using a non-linear optical effect. Generally, fibre strain and temperature are linearly associated with the frequency shift and hence the wavelength of light, caused by scattered light. Both strain and temperature cause a shift in the Brillouin frequency. The BOTDA sensor measures changes in the local strain and/or temperature conditions of an optical fibre through analysis of the Brillouin frequency of the fibre at any point. Position is determined by the round-trip transit time of the optical signal in the fibre, which is approximately 0.1 m/ns in typical fibres.
Typical fibres exhibit coefficients of change in Brillouin frequency C ε 0.05 MHz per ppm change in length (microstrain, με) and C T ≈1 MHz per ° C. change in temperature. The Brillouin frequency (v B ) at a point z is therefore given by:
v B ( z )= v B0 ( z )+ C ε ·ε( z )+ C T ·T ( z ) Eq.1
where v B0 (z) is the reference Brillouin frequency and T(z) and ε(z) are the local temperature and strain conditions respectively.
Typical BOTDA sensors can resolve around 1 MHz changes in Brillouin frequency resulting in a strain resolution of about 20 με or a temperature resolution of about 1° C. Since both temperature and strain affect the Brillouin frequency in the same way, it is normally impossible to identify which parameter has changed without further information or assumption (for instance, an assumption that the sensor is isothermal, or knowledge that the fibre is strain-free).
Some prior art sensors use a single strand of optical fibre. This is problematic since the Brillouin frequency is dependent on both local strain and temperature variables. Therefore, two strands of sensing fibre are often used in proximity of each other and placed in parallel—one detects strain and temperature, and the other detects temperature only. The fibre that detects temperature only is situated in a mechanically isolated tube to replicate a strain-free environment. Calculations of Brillouin frequency using such a set-up are inaccurate, however, since they are made with the assumption that the temperature is the same for both fibres; however, in reality, it is common for the temperatures to differ. In addition, even when the temperatures of the fibres are the same, thermal expansion of the host material will cause additional temperature-dependant strain that is not compensated for by the temperature-only fibre.
Other prior art sensors comprise at least two optical fibres in a single substrate with one of them measuring strain and temperature, and another measuring temperature only. Although this increases the likelihood that the fibres experience the same temperature conditions, thermal expansion can cause additional strain in the strain-measuring fibre that is not compensated for by the temperature-measuring fibre. In addition, these devices place the strain-sensing fibre along the neutral axis of the substrate and therefore cannot measure the curvature or displacement of the substrate itself.
SUMMARY OF THE INVENTION
This invention in one embodiment discloses an optical fibre distributed sensing apparatus that uses a cable having multiple strands of optical fibre mechanically attached longitudinally to a tape substrate.
In one embodiment of this invention, the cross-section of the cable shows a strand of fibre above and below the tape.
In another embodiment of this invention, the cross-section of the cable shows a strand of fibre on all sides of the tape.
In another embodiment of this invention, the tape is tubular and the cross-section of the cable shows multiple strands of fibres positioned equidistant from one another on the substrate. These fibres can extend longitudinally on the tape or helically around the tape to detect curvature.
A sensor according to this invention converts the raw strain measurement into curvature, displacement, or shape information over lengths which can be very long lengths. As opposed to point sensors, this invention requires only a single sensor to monitor, for example, soil or snow displacement for avalanche predictions over kilometers at one time.
Unlike in prior art BOTDA sensor systems, a tape is situated between the two fibres in accordance with one embodiment of this invention. Preferably, the tape is made of thermal conducting material such as steel, such that the difference in temperature between the two fibres is minimized; however, non-conducting tape can also be used. The temperature detected by one fibre can be subtracted from the temperature detected by the second fibre at every point across the thermal conducting substrate, which allows deformation to be detected independent of temperature. Likewise, any measurement of axial strain (i.e., pulling apart force) due to thermal expansion of the substrate can also be subtracted to remove axial strain sensitivity. Since the single strand of fibre wraps to effectively form two strands of fibre, sensitivity is doubled and two strain measurements are obtained.
Unlike strain sensors of prior art where results are obtained by analyzing and interpreting spikes on a Strain vs. Time graph, the output of the optical fibre sensor in this invention is presented in terms of displacement, which is easier to understand.
An optical fibre sensor of this invention can also be packaged in a rugged tube suitable for industrial settings and will require little expertise to install or use.
According to another embodiment, this invention relates to a cable for distributed fibre optic sensing, which includes a flexible tape that is attached to an optical fibre suitable for Brillouin scattering measurement. The optical fibre can be one strand or multiple strands forming at least two lengths that span at least a section of the longitudinal length of the flexible tape. The tape is situated between the fibre lengths, and the fibre lengths and tape flex together. The fibre lengths are in close proximity such that a temperature gradient between the two lengths is minimized. The fibre lengths may be in optical communication with each other. There is at least one free end that is connectable to a reading unit, such as a Brillouin sensor.
According to another embodiment, this invention relates to a method for measuring displacement by providing a cable having at least two lengths of optical fibre, wherein the optical fibre experiences a Brillouin effect in response to strain and temperature, introducing a first light into the first length of optical fibre such that the Brillouin effect in the optical fibre affects the first light to produce a second light, receiving the second light from the second length of optical fibre, measuring the Brillouin effect from the second light, measuring the strain and temperature from the Brillouin effect, and subtracting a measurement taken from a first point on the first length of the fibre from a measurement taken from a second point on the second length of the fibre, whereby a line drawn between the first and second point is perpendicular to a line selected from the group comprising the tangent of the curvilinear direction of the tape and the linear direction of the tape.
BRIEF DESCRIPTION
FIG. 1 is a photograph of a cable in accordance with one embodiment of the present invention.
FIG. 2A is a graph of strain distribution of the circularly wrapped tape of FIG. 1 .
FIG. 2B is a graph of processed strain data captured from the tape of FIG. 2A .
FIG. 3A is a graph of strain differential along the tape of FIG. 2A due to temperature.
FIG. 3B is a graph of processed strain data captured from the tape of FIG. 3A .
FIG. 4A is a perspective schematic of the cross-section of a cable in accordance with one embodiment of the present invention.
FIG. 4B is a perspective schematic of the cross-section of a cable in accordance with another embodiment of the present invention.
FIG. 4C is a perspective schematic of the cross-section of a cable in accordance with another embodiment of the present invention.
FIG. 4D is a perspective schematic of the cross-section of a cable in accordance with another embodiment of the present invention.
FIG. 4E is a perspective schematic of the cross-section of a cable in accordance with another embodiment of the present invention.
FIG. 5 is a schematic diagram of a cable in operation in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a fibre optic sensing apparatus 100 is constructed using a 12 m steel tape 102 , optical fibre 104 , adhesive, and conventional sensor (not shown). A length of optical fibre was bonded to both sides of the tape on the longitudinal axis, preferably using epoxy, with a turn around loop at one end 106 . A BOTDA sensor, connected to the optical fibre in the conventional method, was used to measure the strain and temperature conditions of the sensing fibre. Because of the configuration of the fibre on the tape, the sensor will first measure the pass of fibre on the ‘top’ surface of the tape from z=0 m to z=12 m, followed by the pass on the ‘bottom’ of the tape from z=12 m back to z=0 m (with a small dead zone between, corresponding to the turn around loop). In FIG. 1 , the tape is 12 m long for illustrative purposes. However, the length of the tape is determined and limited only by the strength of the Brillouin sensor. Using conventional Brillouin sensors, the tape can range in length from about 10 m to about 100 km. Measuring less than 10 m is possible, but is not usually cost effective. The measuring tape 108 is not part of the embodiment of the invention.
At any point z along the tape, a BOTDA measurement is made of both passes of fibre. Since the steel tape is thermally conductive and thin, the temperature will be substantially the same on both surfaces. Measurements of Brillouin frequency are taken from two points on two fibre lengths, whereby if a line were to join the two points, the line would be perpendicular to the direction of the tape and would intersect point z along the tape. By subtracting the Brillouin frequency v B (z) measured at these two points on the two fibre lengths, the terms containing v B0 (z), T(z) and any common-mode axial strain will cancel, leaving only the frequency shift due to any differential strain between the two surfaces, such as would be caused by flexure of the tape. From the differential strain measurement, the radius of curvature of the tape can be determined.
In FIG. 1 , the strain data is superimposed on the actual sensing device to show that the graph retains the same shape as the actual tape. The four thin circles of the graph 110 represent the displacement measured from each of the four loops of the tape. As in FIG. 1 , the shapes of the graphs of the processed strain data in FIGS. 2B and 3B are very similar to the shape of the real tape.
FIGS. 4A to 4E show five different embodiments of the invention. In FIG. 4A , strain displacement can be measured two-dimensionally on a single plane. The cable 120 comprises a tape 102 situated between two lengths of optical fibre 104 . The tape 102 is attached to the two lengths 104 . When the cable bends, the tape 102 bends with the lengths of fibre 104 . When the cable bends on the horizontal plane, the two lengths of fibre 104 experience a different Brillouin effect in response to different strain. The fibre length at the outer curvature would experience positive strain (i.e., stretching) and the fibre length at the inner curvature would experience negative strain (i.e., compression) during flexion. The magnitude of the strain in both lengths is substantially the same as the lengths are substantially parallel. The existence of a differential strain indicates that the shape of the cable, which may be attached to an object or structure, has changed. Measuring the difference in strain between the lengths of fibre determines the magnitude of displacement.
A similar embodiment having two lengths of fibre can be designed to measure displacement on a vertical plane (not shown) by positioning the fibre lengths along the two sides of the tape rather than on the top and bottom of the tape as shown in FIG. 4A .
FIG. 4B shows another embodiment of the invention, where strain displacement can be measured three-dimensionally on both the horizontal and vertical planes. As bending occurs in the cable 120 , the lengths of fibres that are diametrically opposed to each other will experience different strains occurring on one plane.
A similar embodiment (not shown) that performs the same way as the sensor design in FIG. 4B involves positioning two lengths of fibre on the top of the tape and two lengths of fibre on the bottom of the tape. When viewed in cross-section, there would be a strand of fibre at each of the four corners of a rectangular or square tape.
FIG. 4C and FIG. 4D further show other embodiments of the invention. FIG. 4C shows a cable configuration having a tape of triangular cross-section and three fibre lengths 104 extending longitudinally along at least a section of the sides of tape 102 . FIG. 4D shows a cable configuration having a tape of circular cross-section and three fibre lengths 104 extending longitudinally along at least a section of the sides of tape 102 . To measure data from each of the odd numbered fibre lengths, three in the exemplary embodiments shown in FIGS. 4C and 4D , a conventional sensor system that only requires access to one fibre end for measurement can be used. Single-ended sensors require access to launch one or more lights into and to receive one or more lights from one end of the fibre only. Examples of such a sensor that uses the single-ended configuration include Yokogawa's AQ8603 optical unit and Smartec's DiTeSt reading unit. Alternatively, if a sensor system that requires access to two fibre ends to launch and/or receive lights is used, then an additional fibre length can be added to make the total number of lengths an even number. This additional fibre length does not have to be used for measurement purposes, although it could be used to measure temperature only if it is suitably shielded from strain. An example of a conventional sensor that uses the dual-ended configuration is OZ Optics's Foresight™ DSTS.
FIG. 4E shows another embodiment of the invention, where only torsion (i.e., shape changes due to twisting) is measured. The fibre lengths 400 and 402 are in a helical configuration around the tape 102 . A twist in the clockwise direction will compress the clockwise-wound fibre length (i.e., length 400 ) and tension the anti-clockwise-wound fibre length. A twist in the anti-clockwise direction will compress the anti-clockwise-wound fibre length (i.e., length 402 ) and tension the clockwise-wound fibre length. Axial strain or temperature changes will strain both fibre lengths equally and thus give no net result. Changes in shape due to bending will likewise tense and compress regions of both fibre lengths equally and thus produce no net result.
Another embodiment of the invention (not shown) combines two configurations—one that measures bending shape changes (i.e., FIG. 4D ) and another that measures twisting shape changes (i.e., FIG. 4E ). The resulting configuration would have a total of five fibre lengths comprising three lengths for t-axis bending and two lengths for differential twist.
FIG. 5 shows an embodiment of the invention assembled to a reading unit 450 , such as a Brillouin Sensor System. The reading unit displays the shape of the optical fibre.
It would be obvious to a person of ordinary skill in the art that different fibre configurations are possible depending on a combination of factors including the number of fibre strands, the number of fibre lengths running the length of the tape, and type of reading unit used (i.e., single-ended or dual-ended systems). Fibre lengths that run along the length of the tape can be connected such that they are in optical communication or they can be separate strands. However, each separate strand would need to be attached to a reading unit.
The following non-limiting examples are illustrative of the present disclosure:
EXAMPLE #1
A 46.15 cm radius circle was made from wrapping a 12 m steel tape onto itself. Approximately four concentric circles were wrapped one on top of the other to form the circle.
Data was gathered on the circle configuration. FIG. 2A shows the strain distribution data collected over the length of the circularly wrapped tape.
As shown in FIG. 2A , a region of compression exists from 410 ns to 530 ns (located between 41.87 m and 54.13 m along the sensing fibre), and a region of tension exists from 530 ns to 650 ns (between 54.13 m and 66.38 m). This is exactly what is expected from a circular shape, since one side of the tape will be in tension, and the opposite in compression.
FIG. 2B shows the result of the processed strain data captured from the tape. The radius of the circle was determined with a measuring tape to be 46.15 cm; the average radius of curvature as measured with the sensor was 46.065 cm. This yields a 0.184% error or 0.170 cm. The standard deviation accompanying the average radius of curvature is 1.043 cm.
EXAMPLE #2
An incandescent lamp was used to heat a small portion of the tape, changing the local temperature and introducing some axial strain due to the thermal expansion of the steel. The room temperature during the experiment was 21.8° C. The temperature of the heated section varied between 50.6° C. and 53.2° C. during the data acquisition. FIG. 3A shows the difference between the tape's strain with the lamp placed on it and at room temperature. As in Example #1, the top fibre strain occurs between 410 ns and 530 ns, and the bottom fibre strain occurs between 530 ns and 650 ns. Since a shift in temperature has the same effect on the fibre Brillouin frequency as a shift in strain, periodic peaks of ‘strain’ were expected.
Periodic spikes are shown in the graph of FIG. 3A . The spikes occur, approximately, every 30 ns, or 300 cm. Just below 530 ns to 540 ns, there is a distortion representing the turn around at the end of the fibre. Given the radius of the circle is 46.15 cm, it is expected that the heat lamp induced ‘strain’ increases should occur once every circumferential length of 290 cm.
FIG. 3B shows the processed data from the heated tape. The results show the configuration of the fibres in accordance with this invention to be temperature independent. The circular shape remains despite the temperature and expansion-induced strain changes. The average radius of curvature was 45.94 cm. This yields a 0.455% error or 0.210 cm (when compared to the actual 46.15 cm radius). The standard deviation accompanying the average radius of curvature is 1.02 cm.
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A cable for distributed fiber optic sensing comprising a flexible tape, an optical fiber suitable for Brillouin scattering measurement forming at least two lengths, and at least one free end of at least one length being connectable to a reading unit, wherein at least a section of the longitudinal length of the flexible tape is situated between at least a section of the two lengths such that the two lengths are in close proximity such that a temperature gradient between the two lengths is minimized, and wherein the section of the tape and the section of lengths can flex together.
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FIELD OF THE INVENTION
The present invention relates to the use of electromagnetic (EM) measurements to determine reservoir formation properties. More particularly, the invention relates to the determination and/or mapping of one or more of the reservoir properties such as wettability, clay content and/or rock texture. The method according to the invention can be applied to any type of EM data including, but not limited to, borehole measurements, cross-well surveys and surface surveys.
BACKGROUND OF THE INVENTION
Hydrocarbon exploration typically involves various geophysical methods to detect the presence of hydrocarbons in the natural void space of the rock (measured as “porosity’) or to map structural features in a formation of interest which are capable of trapping hydrocarbons.
To be mapped geophysically, the formation containing the hydrocarbon must possess a physical property contrast that the geophysical method responds to. For example, the electrical conductivity (c,), or its inverse, resistivity (p), is a physical property that can be measured with electrical or electromagnetic (EM) methods. The resistivity of a rock depends strongly on the resistivity of the pore fluid and even more strongly on the porosity of the rock. Typical brine in sedimentary rock is highly conductive. The presence of brine in bulk rock renders the rock conductive.
Hydrocarbons are electrically non-conductive. Consequently, bulk resistivity of a rock is reduced when hydrocarbons are present. In general, different rocks in a given sedimentary section have different porosities, so even in the absence of hydrocarbons, information about the sedimentary section can be determined.
Resistivity is typically measured with a direct current (DC) source that injects current into the ground or with low frequency time varying fields. Alternatively, one may measure the magnetic fields produced by the induced current. Thus, by measuring the magnitude of the induced current or the secondary magnetic fields arising from these, it is possible to infer the conductivity of the earth formation.
Electromagnetic surveys typically make use of the fact that the complex formation resistivity is typically measured as a function of the frequency of excitation signal. The complex formation resistivity can be defined as ρ=1/σ+jω∈, where σ is the formation conductivity and ∈ is the formation dielectric constant.
However, at present the inversion of electromagnetic (EM) surveys (aka Deep Electromagnetic Prospecting) is limited to mapping the real part of the formation resistivity with the aim of inferring the saturation distribution in the reservoir. EM methods are ideal in geologic situations where rocks of greatly different electrical resistivity are juxtaposed.
However, conventional inversion of the deep electromagnetic (EM) surveys is limited to determining and mapping of the real part of the formation resistivity with the aim of inferring the saturation distribution in the reservoir.
One aim of an embodiment of the present invention is to describe a method to use EM prospecting or borehole complex resistivity data to determine petrophysical information regarding an earth formation.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
SUMMARY OF THE INVENTION
Preferably, according to a preferred embodiment of the invention, it is provided a method for determining a reservoir formation properties comprising: i) exciting the reservoir formation with an electromagnetic exciting field; ii) measuring an electromagnetic signal produced by the electromagnetic exciting field in the reservoir formation; iii) extracting from the measured electromagnetic signal a spectral complex resistivity as a function of frequency; iv) fitting the spectral complex resistivity with an induced polarization (IP) model and v) deducing the reservoir formation properties the fitting with the induced polarization model.
Preferably, the step of fitting the spectral complex resistivity with an induced polarization model comprises fitting the real and imaginary part of said complex resistivity with said induced polarization model.
Advantageously, the step of fitting the spectral complex resistivity with an induced polarization model comprises fitting the imaginary part of said complex resistivity with said induced polarization model.
Preferably, the reservoir formations properties comprises wettability of the reservoir formation.
Advantageously, the reservoir formation properties comprises one of clay content, rock texture or hydraulic permeability of the reservoir formation.
In a preferred embodiment, the step of exciting the reservoir formation comprises exciting the reservoir formation with an electromagnetic field at a plurality of frequencies.
Preferably the method comprises the step of repeating steps i) to v) for each of the plurality of frequencies in order to produce a map of the reservoir formation properties for a complete region of the reservoir formation.
Advantageously, the method further comprises the step of repeating steps i) to v) for each of the plurality of frequencies in order to produce a map of the reservoir formation properties at multiple depths along a borehole drilled through the reservoir formation.
Preferably, the method further comprises the step of: vi) repeating steps i) to v) at various time intervals; vii) comparing the reservoir formation properties for the various time intervals in order to monitor changes in said reservoir formation properties as a function of time.
Advantageously, the reservoir formations properties comprises wettability of the reservoir formation and wherein the step of comparing the reservoir formation properties for the various time intervals allows to map movement of a flood front into the reservoir formation.
In an advantageous embodiment, it is proposed a computer-implemented method for determining a reservoir formation properties, said method comprising: i) acquiring in a computer software program an electromagnetic signal received from a electromagnetic tool; ii) extracting from the measured electromagnetic signal a spectral complex resistivity; iii) fitting the spectral complex resistivity with an induced polarization (IP) model and iv) deducing the reservoir formation properties the fitting with the induced polarization model.
In yet another advantageous embodiment, it is proposed a method for determining the wettability of a reservoir formation comprising the steps of: i) exciting the reservoir formation with an electromagnetic exciting field; ii) measuring an electromagnetic signal produced by the electromagnetic exciting field in the reservoir formation; iii) extracting from the measured electromagnetic signal a spectral complex resistivity as a function of frequency; iv) extracting the imaginary part from the spectral complex resistivity; v) deducing the wettability of the reservoir formation from said extracted imaginary part.
An embodiment of the present invention explores the interpretation of the imaginary part of the complex formation resistivity for determining, and optionally further mapping one or more of wettability, clay content, rock texture and hydraulic permeability of said formation. Water-wet reservoir rocks show measurable imaginary part of the complex formation resistivity. The imaginary part of the resistivity arises due to several polarization mechanisms commonly referred as the “Induced Polarization (IP) effects”. In the non-metallic rocks the IP effect is attributed to the polarization of the double layer and wettability is expected to impact the double layer properties and, consequently, the magnitude of the imaginary part of the resistivity. Therefore, the imaginary part of the complex formation resistivity can be used for wettability mapping.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the induced polarization effect.
FIGS. 2 and 3 are diagrams showing a cation-selective membrane.
FIGS. 4 and 5 are diagrams showing a Granular Model and a Capillary Model respectively.
FIG. 6 is a graph showing frequency versus phase (Φ) for sample of varying brine saturations.
FIG. 7 is a diagram of a hypothetical anticline trap forming an oil reservoir and shows the real part of the complex resistivity.
FIG. 8 is a diagram of a hypothetical anticline trap forming an oil reservoir and shows the imaginary part of the complex resistivity for a water-wet reservoir.
FIG. 9 is a diagram of a hypothetical anticline trap forming an oil reservoir and shows the imaginary part of the complex resistivity for an oil-wet reservoir.
FIG. 10 is a graph of time constant versus average grain size.
FIG. 11 is a graph of vertical hydraulic conductivity versus Cole-Cole relaxation time.
FIG. 12 is a graph of weight percent of montmorillonite versus chargeability.
FIG. 13 is a diagram showing a complex resistivity model for geophysical inversion.
FIGS. 14 and 15 are experimental data fitted with the general complex resistivity model for various laboratory data ( 14 ) impedance versus frequency and ( 15 ) phase angle versus frequency.
FIG. 16 is a graph of the field data fitted with the general complex resistivity model for the dependence of the phase angle on frequency.
FIG. 17 is a diagram of a three-layered Earth.
FIGS. 18 and 19 are graphs of impedance versus frequency and phase versus frequency respectively.
FIG. 20 is a depiction of a time lapse ( 4 D) EM survey.
FIG. 21 is an interpretation workflow for multi-frequency data
FIG. 22 is an interpretation workflow for a single-frequency data
DETAILED DESCRIPTION
The imaginary part of the complex formation resistivity arises due to the low-frequency polarization effects commonly referred to as “Induced Polarization effects”. The induced polarization phenomenon was discovered by Conrad Schlumberger in 1912. It manifests itself in a relatively slow decay of the electric field following the cessation of an excitation current pulse (induced polarization, IP, in the time domain), and in a frequency dependence of the real part of the complex formation resistivity (induced polarization in the frequency domain).
In simple terms, the IP response reflects the degree to which the subsurface is able to store electrical charge, analogous to a capacitor. A number of field parameters were adopted during the development of IP for mineral exploration. These include the time domain chargeability, percentage frequency effect, and the phase angle.
The EM prospecting data is obtained over a wide range of frequencies and it is important to understand its frequency dependence and, if needed, to correct for it. Indeed, if one knows how the complex formation resistivity behaves as a function of frequency then it becomes possible to correct the real part of the resistivity for the dispersion effects that otherwise would be interpreted as a change of the formation resistivity. Also, the analysis of the frequency dependence of the formation resistivity can potentially yield additional information about the probed formation.
See Lancaster U.: Binley, A., Slater, L. D., Fukes, M. and Cassiani, G., 2005, “Relationship between Spectral Induced Polarization and Hydraulic Properties of Saturated and Unsaturated Sandstone”, Water Resources research and FIG. 1 . The FIG. 1 is actually a general illustration of the IP effect in time domain and in frequency domain that manifests itself in a frequency dependence of the impedance and the phase angle.
Several physio-chemical phenomena and conditions are responsible for occurrence of the IP effect. Strong IP effect is observed when certain minerals are present (such as pyrite, graphite, some coals, magnetite, pyrolusite, native metals, some arsenides, and other minerals with a metallic lustre). There also is a non-metallic IP effect in rocks that is caused by “ion-sorting” or “membrane effects”. For example, FIGS. 2 and 3 show a cation-selective membrane zone 1 and 10 respectively in which the mobility of the cation is increased relative to that of the anion, causing ionic concentration gradients and therefore polarization.
Subsurface polarization results from the presence of interfaces at which local charge concentration gradients develop upon application of electric current. Polarization is enhanced at interfaces associated with metals and clays, but it is also significant and measurable in clay-free and metal-free sediments where it is associated with predominantly tangential ion displacement in the electrical double layer (EDL) forming at the grain-fluid interface. Ionic mobility contrasts at interfaces between wide and narrow pores are also considered a source of polarization enhancement in sandy sediments.
There are two main types of the ion-selective models explaining the origin of the non-metallic IP effect. It has been argued that dominant relaxation time of the polarization is controlled by the grain size as depicted in FIG. 4 . In this approach, also referred to as “Granular Model”, the relaxation time of the induced charge is proportional to the square of the particle radius and inversely proportional to the diffusion coefficient.
The Granular Model may be described in equation (1):
τ = R 2 2 D ( 1 )
where D is the ion diffusion coefficient and R is the particle radius.
The second ion-selective model, the “Capillary Model”, can be formulated in terms of interfaces between ion-selective pore-throats and larger pores, relating the IP mechanism to pore-throat size (shown on FIG. 5 ). In this model the relaxation time is proportional to the square of the length of the ion-selective zone and inversely proportional to the diffusion coefficient, as described in equation (2)
τ = l 2 4 D ( 2 )
where l is the length of the pore throat and D is the diffusion coefficient.
Even at low water saturation, reservoir rocks can possess a measurable imaginary part of the complex resistivity (i.e., a measurable phase angle). As shown in FIG. 6 , laboratory data shows dependence of the phase angle on water saturation. The magnitude of the phase angle peak is unchanged with saturation, as can be seen from 100%, 83%, 58%, 50%, 42% and 30% water saturation curves, but the peak frequency changes. (See also Lancaster et al. (2005)).
This suggests that even oil-bearing sections of water-wet reservoirs have non-vanishing imaginary part of the complex receptivity.
The origins of the IP effect in ion-conductive rocks and the existence of the IP effect at partial saturations suggests that the IP effect can be used, according to one embodiment of the method of the invention, as an indicator of wettability of the formation. IP effect in ion-conductive media arises due to polarization of the double layer. The wettability is expected to influence the properties of double-layer and therefore the magnitude of the IP effect. In water-wet reservoirs, the imaginary part of the formation resistivity will still be present. By contrast, in oil-bearing sections of the oil-wet reservoirs the imaginary part of the complex resistivity should vanish in hydro-carbon-bearing zones. FIG. 7 shows a hypothetical anticline trap forming an oil reservoir. The non-conductive tight rock layer 2 forms a cap of the reservoir 3 . FIG. 7 displays the profile of the real part of the complex formation resistivity. Resistive layers include cap 2 and hydrocarbon bearing zone 4 , which are shown in darker areas. The transition zone and the water leg are shown in light grey area 5 .
The wettability is expected to influence the properties of double-layer and therefore the magnitude of the IP effect. FIG. 8 shows the profile of the imaginary part of the complex formation resistivity for a water-wet reservoir. The imaginary part is non-vanishing in both water-filled and the hydrocarbon-bearing part. The light color zone 6 corresponds to the non-zero imaginary part of the resistivity and the dark color zone 7 outlines vanishing formation resistivity.
FIG. 9 shows the profile of the imaginary part of the complex formation resistivity for an oil-wet reservoir. The imaginary part vanishes in the oil-wet hydrocarbon-bearing zone 8 . The lower water-filled section 9 remains water-wet and displays measurable complex part of the formation resistivity.
According to another embodiment of the method of the invention, IP effects may also be used to determine and map the rock texture of a formation. Time-domain IP measurements were experimentally obtained on a collection of sieved sands with different grain sizes. FIG. 10 shows correlation between relaxation time of the IP effect and the average grain size (or rock texture for sandstones): crosses are experimental data, solid line is an approximate theory (See St. Petersburg U.: Titov, K, Komarov, V, Tarasov. V, and Levitski, A., 2002 , “Theoretical and Experimental Study of Time - Domain Induced Polarization in Water - Saturated Sands”, J. of Applied Geophysics , vol. 50, pp. 417-433).
According to another embodiment of the method of the invention, IP effect may be used to determine and map hydraulic permeability. IP spectra at full water saturation for various sandstones were fitted with the empirical Cole-Cole model. The correlation between the characteristic relaxation time, τ, in the Cole-Cole model and hydraulic conductivity, κ, is shown in FIG. 11 . (See Binley, A., Slater, L. D., Fukes, M. and Cassiani, G., 2005 , “Relationship between Spectral Induced Polarization and Hydraulic Properties of Saturated and Unsaturated Sandstone”, Water Resources research , vol. 41, W12417).
IP effect may also be used to determine clay content and for clay content mapping. FIG. 12 is a summary of a laboratory investigation of the electrical properties of artificial mixtures of glass beads and clay (Ca-montmorillonite) (See U. of Utah: Klein, J. D., and Sill, W. R., 1982 , “Electrical Properties of Artificial Clay - Bearing Sandstones”, Geophysics , vol. 47, No. 11, pp. 1593-1605). Samples shown here were saturated with 0.003 molar NaCl. Generalized Cole-Davidson model was used to fit the experimental IP data. Dependence of chargeability on dry weight percent of the clay is observed in this data.
In order to be able to interpret the field EM prospecting data for wettability, textural parameters and Cation Exchange Capacity (CEC) and to correct the real part of the formation resistivity for the IP effects a general IP model (a general complex resistivity formation model) applicable to a wide variety of formations might be necessary. Such a model is described in Da Rocha, B. R., and Habashy, T. M., 1997 , “Fractal Geometry, Porosity and Complex Resistivity: from Rough Pore Interface to Hand Specimens”, Developments in Petrophysics, Geological Soc . Special Pub. No. 122, pp. 277-286, herein incorporated by reference in its entirety, and is graphically shown in FIG. 13 . The model is considered to be general and it encompasses some other commonly used models as special cases.
This general complex resistivity model developed by Tarek Habashy et al has been shown to adequately describe complex resistivity response of a wide variety of rocks (which other models, like Cole-Cole, are lacking) and, therefore, is a preferred candidate for the inversion of the field EM data. A database developed for the model parameters for common oilfield and sedimentary formations can be used to correct the mapping of the real part of the formation resistivity for the IP effect. Analysis of the spectra of the complex formation resistivity over the range of prospecting frequencies can yield additional petrophysical information. Correlation exists between the characteristic relaxation time of the IP and the characteristic pore throat size. Also, the chargeability is proportional to the formation cation exchange capacity.
Interpretation of the complex formation resistivity among other quantities yields the “characteristic relaxation time” that is indicative of the time scale of the IP effects. This time correlates with textural properties of the rocks such as pore throat size. The pore throat size is what mainly controls hydraulic permeability. Chargeability is another parameter obtained from the analysis of the complex formation resistivity spectra. It is related to the magnitude of the IP effect and strongly correlates with clay content.
Analysis of the complex formation resistivity can be used to map these petrophysical parameters.
As represented on FIG. 13 , the model can be utilized to interpret the electrical behavior of rocks containing metallic or clay particles. It includes an impedance zw which simulates the effects of the fractal rough pore interfaces between the conductive grains (metallic or clay minerals which are blocking the pore paths) and the electrolyte. This generalized Warburg impedance is in series with the resistance r of the blocking grains and both are shunted by the double layer capacitance Cdl. This combination is in series with the resistance of the electrolyte R 1 in the blocked pore passages. The unblocked pore paths are represented by a resistance Ro which corresponds to the normal DC resistivity of the rock. The parallel combination of this resistance with the bulk sample capacitance Co is finally connected in parallel to the rest of the above-mentioned circuit.
Assuming the e iωt dependence, the complex electrical rock resistivity Z is defined as a function of chargeability, double-layer relaxation time, sample relaxation time, and grain percent resistivity (see equation (3))
Z = R 0 1 + ⅈ ω τ [ 1 - m ( 1 - 1 1 + 1 δ 1 + δ 2 ( 1 + u ) ) ] ( 3 ) i . m = R 0 R 1 + R 0 ( 4 ) τ 1 = r C dl ( 5 ) a . τ 2 = R 0 C 0 ( 6 ) δ r = r R 0 ( 7 ) δ 1 = r R 1 + R 0 = m δ r ( 8 ) δ 2 = K ( ⅈ ω ) - η R 1 + R 0 = m R 0 K ( ⅈ ω ) - η ( 9 ) a . u = ⅈ ω τ ( 1 + δ 2 δ 1 ) ( 10 )
where:
ρ 0
is the DC resistivity of the material (influenced by the rock porosity)
and
m = ρ 0 - ρ ∞ ρ 0 = ρ 0 ρ 0 + ρ 1
is the chargeability parameter (relates to the low and high frequency asymptotes of the rock resistivity): strongly influenced by the rock's texture
and;
τ 1 =rC dl
is the relaxation time constant related to the double-layer oscillations and influenced by the grain size and the type of the blocking minerals (normally metallic minerals or clay particles); and
K
is the diffusivity of the charged ions in the electrolyte, which depends on the type and the concentration of ions present in the electrolyte; and
η
is a parameter is directly related to the fractal geometry of the medium and is determined by the type and distribution of the mineral causing the low-frequency polarization; and
τ 2 =R 0 C 0
is the bulk time constant associated with the material as a whole, which depends on the rock fabric, the matrix properties and the total amount of water present in the rock; and
δ r = r R 0
is resistivity factor (or ratio) that relates the resistivity of the conductive grains with the DC resistivity value of the rock. Its value will be larger than unity for very good conductive grains and lower than unity for oxides.
This model, which can be used in one embodiment of the method of the invention, was tested over a wide range of frequencies against experimental data obtained for amplitude and phase of resistivity or conductivity as well as for the complex dielectric constant. The samples studied are those of sedimentary, metamorphic and igneous rocks.
For demonstrative purposes some typical electrical data is shown in FIG. 14 featuring impedance versus frequency and on FIG. 15 showing phase angle versus frequency (straight lines are given by the model as opposed to dots and crosses that are experimental data). The model is capable of adequately reconstructing the experimental data in a wide frequency range. The inversion of the spectral complex resistivity data with the general model yields a number of model parameters, such as chargeability, double layer relaxation time, sample relaxation time, grain percent resistivity, etc. These parameters can be related to the petrophysical properties of interest.
Experimental and fitted curves for the phase of complex resistivity for Jokisivu, Au deposit as shown in FIG. 16 , see Vanhala, Heikki; Peltoniemi, Markku 1992. Spectral IP studies of Finnish ore prospects. Geophysics 57 (12), 1545-1555. The model is capable of adequately reconstructing the field data and, therefore, is suitable for the interpretation of the EM surveys
In order to test if the fractal parameters could be observed (and, therefore, measured), the response was calculated for a three-layer Earth, in which the second layer is a polarizable medium, with the intrinsic electrical properties given by the fractal complex resistivity. FIG. 17 shows the layered Earth response for thickness of the overburden layer equal to 1 m. As shown in FIGS. 18 and 19 the phase is mainly affected by the parameters of the polarizable layer while the amplitude is more dependent on the combined layering. The value of the phase will be dependent on the layering, while the shape of the curve will be dependent on the fractal parameters. This indicates that it is possible to determine the parameters of the polarizable layer even in the presence of a thick overburden. For FIGS. 17 to 19 :
ρ 0 =100 Ωm
m= 0.5
τ=10 −6 s
δ r =1.0
τ r =10 −3 s
τ 0 =10 −12 s
Fields that undergo water-flooding often experience wettability changes. Time-lapse EM surveys mapping the imaginary part of the complex formation resistivity can help monitor such wettability changes (See FIG. 20 ). It can be difficult to map the movement of the flood front from only the real part of the complex formation resistivity (in case of low contrast in flooding water resistivity). According to the method of the invention, mapping of the imaginary component of the formation resistivity can help to improve mapping the water-flooded regions.
While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims. The method according to the invention could also be used for cross-well data that supplies the real and imaginary parts of the formation resistivity as a function of the coordinates and frequency can be used in a same way as the surface surveys.
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A method for determining reservoir formation properties that consists of exciting the reservoir formation with an electromagnetic exciting field, measuring an electromagnetic signal produced by the electromagnetic exciting field in the reservoir formation, extracting from the measured electromagnetic signal a spectral complex resistivity as a function of frequency, fitting the spectral complex resistivity with an induced polarization model and deducing the reservoir formation properties from the fitting with the induced polarization model.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application 11/096,725, filed Apr. 1, 2005, which claims the benefit of and priority to Great Britain Patent Application Serial No. 0408164.2, filed Apr. 13, 2004, the disclosures of each of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to novel antigen delivery constructs and their use in immunisation methods. In particular, the invention relates to constructs useful in immunising against human immunodeficiency virus.
BACKGROUND OF THE INVENTION
Recent advances in our comprehension of mammalian immunological responses have led to the prevention of certain diseases in man through prophylactic vaccination and the control and treatment of diseases by the use of immunotherapeutics. The types of diseases which may be addressed through immunological intervention include those caused by infectious agents, cancers, allergies and autoimmune diseases. In these cases, most commonly, the premise of the medical treatment is the efficient delivery of antigens to appropriate immune recognition cells. For example, prophylactic vaccination has successfully eradicated smallpox worldwide through the administration of a live attenuated strain of the virus bearing all the antigens of the wild type virus. Similarly infections due to the Haemophilus influenzae serotype b bacterium have been significantly reduced in Western countries following the development of a vaccine based upon the polysaccharide antigen from the bacterial cell wall. Moreover, some cancers such as human melanoma respond to immunotherapy using autologous dendritic cells (DC) as a cellular adjuvant and defined peptides derived from the melanosomal protein gp100 as the source of tumour-specific antigen to generate a cell-mediated immune response.
Self-tolerance to autoantigen can be restored in the treatment of experimental autoimmune encephalomyelitis by injection of a specific neuroantigen that is the target of the destructive immune response. Hence specificity can be afforded by such treatment without the need for long-term immunosuppression.
For infectious diseases, the most rapid progress in disease control has occurred where antibody raised to the administered antigen is capable of neutralising the infectious agent or toxin secreted therefrom, whether this be mediated through IgM, IgG or IgA. Likewise, autoimmune diseases have been treated with antigens that can ameliorate the action of auto-antibodies. However, for the eradication of virus-infected cells, cancer cells and cells harbouring intracellular bacteria, cellular immune responses are also required. For example, intracellular viruses (e.g. retroviruses, oncornaviruses, orthomyxoviruses, paramyxoviruses, togaviruses, rhabdoviruses, arenaviruses, adenoviruses, herpesviruses, poxviruses, papovaviruses and rubella viruses) are able to replicate and spread to adjacent cells without becoming exposed to antibody. The importance of cell-mediated immunity is emphasised by the inability of children with primary T-cell deficiency to clear these viruses, whilst patients with immunoglobulin deficiency but intact cell-mediated immunity do not suffer this handicap. A small, but important, number of bacteria, fungi, protozoa and parasites survive and replicate inside host cells. These organisms include Mycobacteria (tuberculosis and leprosy), Legionella (Legionnaires Disease), Rickettsiae (Rocky Mountain spotted fever), Chlamydiae, Listeria monocytogenes, Brucella, Toxoplasma gondii, Leishmania, Trypanosoma, Candida albicans, Cryptococcus, Rhodotorula and Pneumocystis . By living inside cells, these organisms are inaccessible to circulating antibodies. Innate immune responses are also ineffective. The major immune defense against these organisms is cell-mediated immunity; involving both CD8+ cytolytic T Lymphocytes and CD4 helper T Lymphocytes.
The development of vaccines and immunotherapeutics capable of eliciting an effective and sustained cell-mediated immune response remains one of the greatest challenges in vaccinology. In particular the development of a safe and efficacious vaccine for the prevention and treatment of Human Immunodeficiency Virus (HIV) infection has been hindered by the inability of vaccine candidates to stimulate robust, durable and disease-relevant cellular immunity.
The host cell-mediated immune response responsible for eradicating intracellular pathogens or cancer cells is termed the Th1 response. This is characterised by the induction of cytotoxic T-lymphocytes (CTL) and T-helper lymphocytes (HTL) leading to the activation of immune effector mechanisms as well as immunostimulatory cytokines such as IFN-gamma and IL-2. The importance of Th1 responses in the control of viral infection has recently been shown by Lu et al. (Nature Medicine (2004)). This clinical study with chronically HIV-1 infected individuals demonstrated a positive correlation between the suppression of viral load and both the HIV-1-specific IL-2- or IFN-gamma-expressing CD4+ T cells and specific HIV-1 CD8+ effector cell responses. Current immunological strategies to improve the cellular immunity induced by vaccines and immunotherapeutics include the development of live attenuated versions of the pathogen and the use of live vectors to deliver appropriate antigens or DNA coding for such antigens. Such approaches are limited by safety considerations within an increasingly stringent regulatory environment. Furthermore, issues arising from the scalability of manufacturing processes and cost often limit the commercial viability of products of biological origin.
In this context, rationally defined synthetic vaccines based on the use of peptides have received considerable attention as potential candidates for the development of novel prophylactic vaccines and immunotherapeutics. T cell and B cell epitopes represent the only active part of an immunogen that are recognized by the adaptive immune system. Small peptides covering T or B cell epitope regions can be used as immunogens to induce an immune response that is ultimately cross-reactive with the native antigen from which the sequence was derived. Peptides are very attractive antigens as they are chemically well-defined, highly stable and can be designed to contain T and B cell epitopes. T cell epitopes, including CTL and T helper epitopes, can be selected on the basis of their ability to bind MHC molecules in such a way that broad population coverage can be achieved (The HLA Factsbook, Marsh, S., Academic Press. 2000). Moreover, the ability to select appropriate T and B cell epitopes enable the immune response to be directed to multiple conserved epitopes of pathogens which are characterised by high sequence variability (such as HIV, hepatitis C virus (HCV), and malaria).
In order to stimulate T lymphocyte responses, synthetic peptides contained in a vaccine or an immunotherapeutic product should preferably be internalized by antigen presenting cells and especially dendritic cells. Dendritic cells (DCs) play a crucial role in the initiation of primary T-cell mediated immune responses. These cells exist in two major stages of maturation associated with different functions. Immature dendritic cells (iDCs) are located in most tissues or in the circulation and are recruited into inflamed sites. They are highly specialised antigen-capturing cells, expressing large amounts of receptors involved in antigen uptake and phagocytosis. Following antigen capture and processing, iDCs move to local T-cell locations in the lymph nodes or spleen. During this process, DCs lose their antigen-capturing capacity turning into immunostimulatory mature Dcs (mDCs).
Dendritic cells are efficient presenting cells that initiate the host's immune response to peptide antigen associated with class I and class II MHC molecules. They are able to prime naïve CD4 and CD8 T-cells. According to current models of antigen processing and presentation pathways, exogeneous antigens are internalised into the endocytic compartments of antigen presenting cells where they are degraded into peptides, some of which bind to MHC class II molecules. The mature MHC class II/peptide complexes are then transported to the cell surface for presentation to CD4 T-lymphocytes. In contrast, endogenous antigen is degraded in the cytoplasm by the action of the proteosome before being transported into the cytoplasm where they bind to nascent MHC class I molecules. Stable MHC class I molecules complexed to peptides are then transported to the cell surface to stimulate CD8 CTL. Exogenous antigen may also be presented on MHC class I molecules by professional APCs in a process called cross-presentation. Phagosomes containing extracellular antigen may fuse with reticulum endoplasmic and antigen may gain the machinery necessary to load peptide onto MHC class I molecules. It is well recognised, however, that free peptides are often poor immunogens on their own (Fields Virology, Volume 1, Third Edition, 1996).
To optimise the efficacy of peptide vaccines or therapeutics, various vaccine strategies have been developed to direct the antigens into the antigen-presenting cell in order to target the MHC class I pathway and to elicit cytotoxic T-lymphocyte (CTL) responses. As an example of a synthetic delivery system, fatty acyl chains have been covalently to linked to peptides as a means of delivering an epitope into the MHC class I intracellular compartment in order to induce CTL activity. Such lipopeptides, for example with a monopalmitoyl chain linked to a peptide representing an epitope from HIV Env protein are described in the U.S. Pat. No. 5,871,746. Other technologies have been delivered that aim to deliver epitopes into the intracellular compartment and thereby induce CTLs. These include vectors such as Penetratin, TAT and its derivatives, DNA, viral vectors, virosomes and liposomes. However, these systems either elicit very weak CTL responses, have associated toxicity issues or are complicated and expensive to manufacture at the commercial scale.
There is therefore a recognised need for improved vectors to direct the intracellular delivery of antigens in the development of vaccines and drugs intended to elicit a cellular immune response. A vector in the context of immunotherapeutics or vaccines is any agent capable of transporting or directing an antigen to immune responsive cells in a host. Fluorinated surfactants have been shown to have lower critical micellar concentrations than their hydrogenated counterparts and thus self-organise into micelle structures at a lower concentration than the equivalent hydrocarbon molecule. This physicochemical property is related to the strong hydrophobic interactions and low Van der Waal's interactions associated with fluorinated chains which dramatically increase the tendency of fluorinated amphiphiles to self-assemble in water and to collect at interfaces. The formation of such macromolecular structures facilitates their endocytic uptake by cells, for example antigen-presenting cells (Reichel F. et al. J. Am. Chem. Soc. 1999, 121, 7989-7997). Furthermore haemolytic activity is strongly reduced and often suppressed when fluorinated chains are introduced into a surfactant (Riess, J. G.; Pace, S.; Zarif, L. Adv. Mater. 1991, 3, 249-251) thereby leading to a reduction in cellular toxicity.
SUMMARY OF THE INVENTION
This invention seeks to overcome the problem of delivering antigens to immune responsive cells by using a novel fluorocarbon vector in order to enhance the immunogenicity of administered antigens. The fluorocarbon vector may comprise one or more chains derived from perfluorocarbon or mixed fluorocarbon/hydrocarbon radicals, and may be saturated or unsaturated, each chain having from 3 to 30 carbon atoms. In order to link the vector to the antigen through a covalent linkage, a reactive group, or ligand, is incorporated as a component of the vector, for example —CO—, —NH—, S, O or any other suitable group is included; the use of such ligands for achieving covalent linkages are well-known in the art. The reactive group may be located at any position on the fluorocarbon molecule. Coupling of the fluorocarbon vector to the antigen may be achieved through functional groups such as —OH, —SH, —COOH, —NH 2 naturally present or introduced onto any site of the antigen. Examples of such linkages include amide, hydrazone, disulphide, thioether and oxime bonds. Alternatively, non-covalent linkages can be used, for example an ionic interaction may be formed via a cation linking together a histidine residue of a peptide antigen and a carboxylic acid on the fluorocarbon vector. Optionally, a spacer element (peptidic or non-peptidic) may be incorporated to permit cleavage of the antigen from the fluorocarbon element for processing within the antigen-presenting cell and to optimise steric presentation of the antigen. The spacer may also be incorporated to assist in the synthesis of the molecule and to improve its stability and/or solubility. Examples of spacers include polyethylene glycol (PEG), amino acids such as lysine or arginine that may be cleaved by proteolytic enzymes and hydrocarbons.
Thus, in a first aspect, the present invention provides a fluorocarbon vector having a chemical structure C m F n —C y H x -L, or derivatives thereof, where m=3 to 30, n<=2m+1, y=0 to 15, x<=2y, (m+y)=3-30 and L is a ligand to facilitate covalent attachment to an antigen.
In the context of the present invention “derivatives” refers to relatively minor modifications of the fluorocarbon compound such that the compound is still capable of delivering the antigen as described herein. Thus, for example, a number of the fluorine moieties can be replaced with other halogen moieties such as Cl, Br or I. In addition it is possible to replace a number of the fluorine moieties with methyl groups and still retain the properties of the molecule as discussed herein.
In a particular embodiment of the above formula the vector may be perfluoroundecanoic acid of the following formula (I):
or alternatively 2H, 2H, 3H, 3H-perfluoroundecanoic acid of the following formula (II):
or heptadecafluoro-pentadecanoic acid of the following formula (III):
In a second aspect the invention provides a vector-antigen construct C m F n —C y H x -(Sp)-R where Sp is an optional chemical spacer moiety and R is an antigen.
The antigen associated with the vector may be any antigen capable of inducing an immune response in an animal, including humans Preferably the immune response will have a beneficial effect in the host. Antigens may be derived from a virus, bacterium or mycobacterium, parasite, fungus, or any infectious agent or an autologous antigen or allergen.
Examples of viruses include, but are not limited to, Human Immunodeficiency Virus-1 (HIV-1) or -2, influenza virus, Herpes virus HSV-1 and HSV-2), hepatitis A virus (HAV), hepatitis B virus (HBV), or hepatitis C virus (HCV).
Examples of bacteria and mycobacteria include, but are not limited to Mycobacterium tuberculosis, Legionella , Rickettsiae, Chlamydiae, and Listeria monocytogenes . Examples of parasites include, but are not limited to Plasmodium falciparum and other species of the Plasmodial family.
Examples of fungi include, but are not limited to Candida albicans, Cryptococcus, Rhodotorula and Pneumocystis.
Autologous or self-antigens include, but are not limited to the following antigens associated with cancers, HER-2/neu expressed in breast cancer, gp 100 or MAGE-3 expressed in melanoma, P53 expressed in colorectal cancer, and NY-ESO-1 or LAGE-1 expressed by many human cancers.
Allergens include, but are not limited to phospholipase A 2 (API ml) associated with severe reactions to bee, Derp-2, Der p 2, Der f, Der p 5 and Der p 7 associated with reaction against the house-dust mite Dermatophagoides pteronyssinus , the cockroach allergen Bla g 2 and the major birch pollen allergen Bet v 1.
Thus in a embodiment, the present invention provides a vector-antigen construct where the antigen is, or represents, an antigen from a virus, bacterium, mycobacterium, parasite, fungus, autologous protein or allergen.
Antigens may be proteins, protein subunits, peptides, carbohydrates, lipid or combinations thereof, provided they present an immunologically recognisable epitope. Such antigens may be derived by purification from the native protein or produced by recombinant technology or by chemical synthesis. Methods for the preparation of antigens are well-known in the art. Furthermore antigens also include DNA or oligonucleotide encoding an antigenic peptide or protein.
Thus in yet a further embodiment, the present invention provides a vector-antigen construct where the antigen is a protein, protein subunit, peptide, carbohydrate or lipid or combinations thereof.
For the construct to be immunologically active the antigen must comprise one or more epitopes. Peptides or proteins used in the present invention preferably contain a sequence of at least seven, more preferably between 9 and 100 amino-acids and most preferably between around 15 to 35 amino acids. Preferably, the amino acid sequence of the epitope(s) bearing peptide is selected to enhance the solubility of the molecule in aqueous solvents. Furthermore, the terminus of the peptide which does not conjugate to the vector may be altered to promote solubility of the construct via the formation of multimolecular structures such as micelles, lamellae, tubules or liposomes. For example, a positively charged amino acid could be added to the peptide in order to promote the spontaneous assembly of micelles. Either the N-terminus or the C-terminus of the peptide can be coupled to the vector to create the construct. To facilitate large scale synthesis of the construct, the N- or C-terminal amino acid residues of the peptide can be modified. When the desired peptide is particularly sensitive to cleavage by peptidases, the normal peptide bond can be replaced by a noncleavable peptide mimetic; such bonds and methods of synthesis are well known in the art.
As a specific example, the peptide NNTRKRIRIQRGPGRAFVTIGK-NH 2 (SEQ ID NO: 37) represents an epitope from the Env (301-322) protein of HIV-1, which has been shown to be immunologically active. This represents yet another embodiment of the present invention. (Reference http://www.hiv.lanl.gov/content/immunology/index.html).
More than one antigen may be linked together prior to attachment to the ligand. One such example is the use of fusion peptides where a promiscuous T helper epitope can be covalently linked to one or multiple CTL epitopes or one or multiple B cell epitope which can be a peptide, a carbohydrate, or a nucleic acid. As an example, the promiscuous T helper epitope could be the PADRE peptide, tetanus toxoid peptide (830-843) or influenza haemagglutinin, HA(307-319).
In another embodiment therefore, the vector-antigen construct is one where R is more than one epitope or antigen linked together. Epitopes may also be linear overlapping thereby creating a cluster of densely packed multi-specific epitopes.
Due to the strong non-covalent molecular interactions characteristic to fluorocarbons, the antigen may also be non-covalently associated with the vector and still achieve the aim of being favourably taken up by antigen-presenting cells
The present invention also provides vaccines and immunotherapeutics comprising one or more fluorocarbon vector-antigen constructs. Multi-component products of this type are desirable since they are likely to be more effective in eliciting appropriate immune responses. For example, the optimal formulation of an HIV immunotherapeutic may comprise a number of epitopes from different HIV proteins. In this case each epitope may be linked to a common fluorocarbon vector or each epitope could be bound to a dedicated vector. Alternatively, multiple epitopes may be incorporated into a formulation in order to confer immunity against a range of pathogens. A multi-component product may contain one or more vector-antigen construct, more preferably 2 to about 20, more preferably 3 to about 8 such constructs.
Compositions of the invention comprise fluorocarbon vectors associated to antigens optionally together with one or more pharmaceutically acceptable carriers and/or adjuvants. Such adjuvants, capable of further potentiating the immune response, may include, but are not limited to, muramyldipeptide (MDP) derivatives, CpG, monophosphoryl lipid A, oil in water adjuvants, water-in-oil adjuvants, aluminium salts, cytokines, immunostimulating complex (ISCOMs), liposomes, microparticules, saponins, cytokines, or bacterial toxins and toxoids. Other useful adjuvants will be well-known to one skilled in the art. The choice of carrier if required is frequently a function of the route of delivery of the composition. Within this invention, compositions may be formulated for any suitable route and means of administration. Pharmaceutically acceptable carriers or diluents include those used in formulations suitable for oral, ocular, rectal, nasal, topical (including buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous, intradermal) administration.
The formulation may be administered in any suitable form, for example as a liquid, solid, aerosol, or gas. For example, oral formulations may take the form of emulsions, syrups or solutions or tablets or capsules, which may be enterically coated to protect the active component from degradation in the stomach. Nasal formulations may be sprays or solutions. Transdermal formulations may be adapted for their particular delivery system and may comprise patches. Formulations for injection may be solutions or suspensions in distilled water or another pharmaceutically acceptable solvent or suspending agent. Thus in a further aspect, the present invention provides a prophylactic or therapeutic formulation comprising the vector-antigen construct with or without a suitable carrier and/or adjuvant.
The appropriate dosage of the vaccine or immunotherapeutic to be administered to a patient will be determined in the clinic. However, as a guide, a suitable human dose, which may be dependent upon the preferred route of administration, may be from 1 to 1000 μg. Multiple doses may be required to achieve an immunological effect, which, if required, will be typically administered between 2 to 12 weeks apart. Where boosting of the immune response over longer periods is required, repeat doses 3 months to 5 years apart may be applied.
The formulation may combine the vector-antigen construct with another active component to effect the administration of more than one vaccine or drug. A synergistic effect may also be observed through the co-administration of the two or more actives. In the treatment of HIV infection, an example of one such drug is Highly Active Anti-Retroviral Therapy (HAART).
In other aspects the invention provides:
i) Use of the immunogenic construct as described herein in the preparation of a medicament for treatment or prevention of a disease or symptoms thereof. ii) A method of treatment through the induction of an immune response following administration of the constructs or formulations described herein; iii) The use of the fluorocarbon vectors and fluorocarbon vector-antigen constructs in medicine.
BRIEF DESCRIPTION OF THE DRAWINGS
The examples refer to the figures in which:
FIG. 1 : shows HPLC chromatograms of various peptides and constructs at T=0;
FIG. 2 : shows HPLC chromatograms of various peptides and constructs stored at 40° C. for 27 days;
FIG. 3 : shows critical micelle concentration evaluation for two peptides, FAVS-3-ENV and FAVS-1-ENV;
FIG. 4 : shows particle size analysis by quasi light scattering spectrometry after 20 hours standing for various peptide constructs;
FIG. 5 : shows cellular immune response assessed by ex vivo IFN-gamma ELISPOT assay in mice after single immunisation (A,B), first boost (C,D) and second boost (E,F);
FIG. 6 shows nature of T lymphocytes primed in vivo by various fluorocarbon-peptide constructs;
FIG. 7 : shows cellular immune response assessed by ex vivo IFN-g ELISPOT assay in mice after three immunisations with FAVS-1-ENV alone or in combination with murabutide;
FIG. 8 : cytokine measurement after three injections with FAVS-1-ENV alone or in combination with murabutide; and
FIG. 9 : shows cellular immune response assessed by ex vivo IFN-g ELISPOT assay in mice after two intranasal administrations with FAVS-1-ENV alone or in combination with murabutide.
DETAILED DESCRIPTION
Example 1
Synthesis of Fluorocarbon-vectored Peptides
The following fluorocarbon-vector peptides were synthesised:
(SEQ ID NO: 38)
FAVS-1-ENV:
NNTRKRIRIQRGPGRAFVTIGK-C 8 F 17 (CH 2 ) 2 CO-K-NH 2
(SEQ ID NO: 38)
FAVS-2-ENV:
NNTRKRIRIQRGPGRAFVTIGK-C 8 F 17 (CH 2 ) 6 CO-K-NH 2
(SEQ ID NO: 39)
FAVS-3-ENV:
IRIQRGPGRAFVTIGKK-CO(CH 2 ) 2 -(PEG) 4 -C 8 F 17 (CH 2 ) 6 CO-K-NH 2
Where the standard amino acid one letter code is utilised and PEG is CH 2 —CH 2 —O. NNTRKRIRIQRGPGRAFVTIGK (SEQ ID NO: 37) is the ENV(301-322) peptide of the Human Immunodeficiency Virus.
Peptide synthesis was carried out on an ABI 430 or ABI 433 automatic peptide synthesizer, on Rink amide resin (0.38 mmol/g loading) using Nsc (2-(4-nitrophenylsulfonyl)ethoxycarbonyl), or Fmoc ((9-fluorenylmethylcarbonyl) amino acids. Coupling was promoted with HOCt (6-Chloro-1-oxybenzotriazole) and DIC (1,3-diisopropylcarbodiimide), and Fmoc/Nsc deprotection was carried out using 20% piperidine in DMF (Dimethylformamide). Uncoupled N-termini were capped with acetic anhydride as part of each cycle. Cleavage of the peptide from resin and concomitant side-chain deprotection was achieved using TFA, water and TIS (Diisopropylsilane) (95:3:2), with crude isolation of product by precipitation into cold diethyl ether. Purification was performed by preparative HPLC using Jupiter C5 or Luna C18 (2) columns (250×22 mm) and peptide mass was verified by mass spectrometry.
Peptide purity was verified prior to conducting the experiments by HPLC (HP 1050) using a column from Supelco (C5, 250×4.6 mm, 300A, 5 μm) under gradient elution. Solvent A (90% Water, 10% Acetonitrile, 0.1% TFA), Solvent B (10% Water, 90% Acetonitrile, 0.1% TFA). A gradient 0 to 100% of B in 30 minutes was used and column temperature was 40° C. The wavelength of the UV detector was set up at 215 nm. Purity of the fluorocarbon-vector peptides in each case was greater than 90%.
The chemical stability of hermetically sealed samples containing lyophilised vector-peptides was assessed at 4° C., 20° C. and 40° C. together with the unvectored peptide as a comparator (NNTRKRIRIQRGPGRAFVTIGK-NH 2 (SEQ ID NO: 37)). The stability over the time was monitored by HPLC using the conditions described above. The data is shown in FIGS. 1 and 2 .
For each peptide conjugate, no sign of degradation was observed after 27 days at 40° C. incubation, with a single peak eluting at the same retention time as found at T=0.
Example 2
Physicochemical Analysis of Fluorocarbon-vectored Peptides
(i) Solubility
The solubility of the fluorocarbon-vector peptides in aqueous solution at concentrations useful for a pharmaceutical formulation was confirmed. Solutions of peptides were prepared at 20° C. by dissolving the lyophilised peptide powder with PBS (0.01M, pH 7.2) across a range of concentrations. Preparations were then vortexed for one minute. An aliquot was collected and the remainder of the solution was centrifuged for 10 minutes at 12,000 rpm. To a 96-well flat bottom plate containing 25 μl aliquots of serial dilutions of each peptide was added 200 μl of the BCA working reagent (Pierce, UK) containing the solution A (bicichoninic acid, sodium carbonate, sodium tartrate in a sodium hydroxyde 0.1M solution, 50 vol,) and B (4% cupric sulphate solution, 1 vol.). After incubating for 45 minutes at 37° C. and cooling for 10 minutes, the absorbance was measured at 570 nm. The plates were analysed by a Wallac Victor multilabel counter (Perkin Elmer). For each peptide a calibration curve was plotted and used to determine the peptide concentration in the soluble fraction, expressed in nmol/ml. Data are presented Table 1. All the peptides were found to be fully soluble at the concentration of antigen used for murine immunisation studies.
TABLE 1 Summary of the solubility assay performed by the protein assay method Peptide Solubility Free peptide >3300 nmol/ml FAVS-1-ENV >4000 nmol/ml FAVS-2-ENV >500 nmol/ml FAVS-3-ENV >3000 nmol/ml
(ii) Critical Micelle Concentration [CMC]
The Critical Micelle Concentration of the fluorocarbon-vectored peptides in physiological phosphate buffered saline was determined by dye bonding with 8-anilino-1-naphthalene-sulphonic acid (ANS). Starting from 300 μg peptide/ml solutions, serial two-fold dilutions of the peptide and peptide-vector solutions in PBS (0.01M, pH 7.2) were prepared at 20° C., from which 200 μl were added to the wells of a microplate. 40 μl of freshly dissolved ANS in PBS was then added to each well. After two minutes the plate was excited at 355 nm and scanned at 460 nm on a Victor microplate fluorimeter. The ratio (Intensity of fluorescence of the sample/Intensity of fluorescence of the blank) was plotted on a linear scale versus the concentration on a logarithmic scale. Data are presented FIG. 3 .
(iii) Particle Size Analysis
Particle size analysis was performed on a Malvern 4700C Quasi Light Scattering spectrometer (Malvern Ltd, UK) equipped with an Argon laser (Uniphase Corp., San Jose, Calif.) tuned at 488 nm. Samples were maintained at a temperature of 25° C. The laser has variable detector geometry for angular dependence measurement. Measurements were performed at angles of 90° and 60°. Solutions were prepared by dissolving the peptide in filtered 0.01M phosphate buffered saline to a concentration of 500 nmol/ml and vortexing for 1 minute. Solutions were then dispensed into cuvettes (working volume of 1 ml). Measurements were taken after 15 minutes at an angle of 90° ( FIG. 4 ). The Kcount value output is proportional to the number of particles detected; in all cases the Kcount was >10 in order to ensure that reliable size distribution measurements were obtained.
TABLE 2
Particle size of micellar solution in PBS.
Stand-
ing
size (nm)
Average
Poly-
Time
Popula-
Popula-
size
disper-
ITS reference
(h)
Kcount
tion1
tion2
(nm)
sity
FAVS-1-ENV
0.25
177
28
—
28.3
0.151
20
230
32
—
32.7
0.180
FAVS-2-ENV
0.25
190
15
120
28.5
0.450
20
245
20
300
68.4
0.539
FAVS-3-ENV
0.25
201
70
400
209
0.659
20
225
105
800
207
0.647
Example 3
(i) Immunogenicity of Fluorocarbon-vectored Peptides
Specific-pathogen-free mice (6-8 week female Balb/c) were purchased from Harlan (UK). Peptides ENV, FAVS-1-ENV, FAVS-2-ENV or FAVS-3-ENV were dissolved in PBS (0.01M, pH 7.2). Each dose was normalised to 50 nmol peptide per ml based on the net peptide content obtained from amino-acid analysis. Mice (3 per group) were immunized subcutaneously under the skin of the interscapular area with 50 nmol peptide in a volume of 100 μl PBS, pH 7.2. Three doses were administered at ten day intervals. A mouse group receiving a priming dose of free peptide admixed with Complete Freund's adjuvant (50 nmol peptide in PBS emulsified in an equal volume of adjuvant) and booster doses of Incomplete Freund's adjuvant served as a positive control. Ten days after the final immunisation mice were sacrificed and spleens removed to assess the cellular immune response to the peptide. To determine the progress of the immune response development, groups of mice receiving a single and two doses of peptide were also set up.
The in vivo cellular response primed by the vectored peptides was monitored by IFN-gamma ELISPOT on fresh spleen cells in order to enumerate the ex-vivo frequency of peptide-specific IFN-gamma producing cells and more specifically peptide-specific CD8+T lymphocytes primed following immunisation. Spleen cells were restimulated in vitro with the ENV(301-322) NNTRKRIRIQRGPGRAFVTIGK (SEQ ID NO: 37) peptide containing a well-known T-helper epitope and ENV(311-320) RGPGRAFVTI (SEQ ID NO: 40) a shorter peptide corresponding to the CD8 epitope (MHC class I H-2Dd-restricted known as P18-I10) in order to cover both components of the cellular immune response (T Helper and CD8 T cell activity).
The spleens from each group of mice were pooled and spleen cells isolated. Cells were washed three times in RPMI-1640 before counting. Murine IFN-g Elispot assays were performed using Diaclone Kit (Diaclone, France) according to the manufacturer's instructions with the following modifications. Duplicate culture of spleen cells at cell density of 5×10 5 /well were distributed in anti-IFN-gamma antibody coated PVDF bottomed-wells (96-well Multiscreen™-IP microplate-Millipore) with the appropriate concentration of peptide (10μ, 1, 0 mg/ml of T helper EN-(301-322) or P18-I10 CTL epitope) in culture medium (RPMI-1640), 5 μM β-mercaptoethanol, 5 mM glutamine supplemented with 10% Foetal Calf Serum during 18 hours at 37° C. under 5% CO 2 atmosphere. The spots were counted using a Carl Zeiss Vision ELlspot reader unit. The results correspond to mean values obtained with each conditions after background subtraction. Results are expressed as spot forming units (SFC) per million input spleen cells ( FIG. 5 ).
(ii) Nature of T Lymphocytes Primed in vivo by the Fluorocarbon-peptides (CD4 and CD8 T Cell Separation)
Spleen Cells from immunized mice were distributed in 48-well microplates at cell density of 2.5×10 6 /well with 1 μg/ml of T helper EN-(301-322) or P18-I10 CTL peptides. At day 3, 5 ng/ml of recombinant murine IL-2 was added to each well. At day 7, pre-stimulated spleen cells were harvested, washed three times in RPMI 1640, counted and separated by magnetic cell sorting using magnetic beads conjugated with monoclonal rat anti-mouse CD8a and CD4 antibodies (MACS, Microbeads Miltenyi Biotec, UK) according to manufacturer's intructions. CD4 and CD8+ T cells were distributed at cell density of 2.5×10 5 /well in duplicate in antibody coated PVDF bottomed-wells (96-well Multiscreen™-IP microplate, Millipore) with 1 mg/ml of peptide in culture medium (RPMI-1640, 5 μM β-mercaptoethanol, Glutamine, non-essential amino-acids, sodium pyruvate supplemented with 10% Foetal Calf Serum for 12 hours at 37° C. under 5% CO 2 atmosphere. The spots were counted using a Carl Zeiss Vision ELlspot reader unit. The results correspond to mean values obtained with each conditions after background subtraction (<10 spots). Results are expressed as spot forming units (SFC) per million input spleen cells.
According to the ex vivo IFN-γ ELISPOT assays, the FAVS-peptide constructs were able to prime a strong cellular immune response against both the long (ENV301-322) and the short ENV peptides (P18-I10 CTL epitope) after a single in vivo exposure to the antigen ( FIGS. 5 A and B). FIG. 6 demonstrates that both CD4+ and CD8+ ENV-specific T cells were efficiently primed in vivo.
The intensity of the response after priming with the FAVS-peptides was in the same range as the responses obtained from mice immunized with the native peptide emulsified in Freund's adjuvant. ENV-specific T cell responses are clearly amplified after a first and a second boost with the FAVS-1-ENV formulation ( FIGS. 5C , D, E, F) as summarized in FIG. 6 .
This clearly demonstrates the ability of the FAVS-peptides to be taken up by antigen presenting cells in vivo in order to reach the MHC class I and MHC class II pathways and thereby prime strong cellular immune responses.
Example 4
Immunogenicity of Fluorocarbon-vectored Peptides Co-administered with Synthetic Adjuvant
In order to assess the potential impact of a synthetic immunostimulant on the quantitative and qualitative immunogenicity of the FAVS-peptides, FAVS-1-ENV was injected alone and in combination with Murabutide. Murabutide (N-acetyl-muramyl-L-alanyl-D-glutamine-O-n-butyl-ester; a synthetic derivative of muramyl dipeptide and NOD-2 agonist) is a synthetic immune potentiator that activates innate immune mechanisms and is known to enhance both cellular and humoral responses when combined with immunogens (“Immune and antiviral effects of the synthetic immunomodulator murabutide: Molecular basis and clinical potential”, G. Bahr, in: “Vaccine adjuvants: Immunological and Clinical Principles”, eds Hacket and Harn (2004), Humana Press).
Specific-pathogen-free mice (6-8 week female Balb/c) were purchased from Harlan (UK). The FAVS-1-ENV construct was used at two different dose levels, one group of mice receiving 50 nmoles and a second group received 5 nmoles of construct. Mice (3 per group) were immunized subcutaneously under the skin of the interscapular area with FAVS-1-ENV either alone or in combination with 100 μg of Murabutide in a total volume of 100 μl PBS, pH 7.2. Three doses were administered at ten day intervals. A control group receiving murabutide alone was also set up.
Ten days after the final immunisation mice were sacrificed and spleens removed to assess the cellular immune response to the T helper EN-(301-322) or P18-I10 CTL epitope peptides. Interferon-gamma Elispot and Th-1 and Th-2 cytokine measurements were performed on the isolated spleens as described in Example 3. Briefly, spleen cells were cultured with the appropriate concentration of peptide (10 or 0 μg/ml of T helper ENV (301-322) or P18-I10 CTL epitope) in culture medium during 18 hours at 37° C. under 5% CO 2 atmosphere. IFN-g Elispot assay was then performed. The spots were counted using a Carl Zeiss Vision Elispot reader unit. The results correspond to mean values obtained with each conditions after background subtraction (<10 spots). Results are expressed as spot forming units (SFC) per million input spleen cells ( FIG. 7 ).
Multiplex cytokine measurements (IL-2, IFN-g, IL4, IL5, IL-10, IL-13) were performed on fresh spleen cells re-stimulated with the ENV (301-322) peptide from mice immunised with the 5 nmol dose of FAVS-1-ENV. Supernatants were collected at 24 hours and 48 hours. Levels of cytokines (IL2, IL4, IL-5, IL-10, IL-13, IFN-γ) in cell culture supernatant samples were measured using the Cytokine specific Sandwich ELISA according to the mutiplex format developed by SearchLight™ Proteomic Arrays (Pierce Biotechnology, Woburn, Mass.). Results were expressed in pg cytokine/ml.
FAVS-1-ENV administered alone was shown to induce predominantly Th-1 cytokine production (i.e. IL-2 and IFN-g) with low levels of Th-2 cytokines also being produced. The inclusion of murabutide within the formulation led to the induction of a more balanced Th-1/Th-2 response with higher levels of Th-2 cytokines such as IL-5, IL-10 and IL-13 ( FIG. 8 ).
Example 5
Immunogenicity of Fluorocarbon-vectored Peptides Administered Mucosally
Specific-pathogen-free mice (6-8 week female Balb/c) were purchased from Harlan (UK).
FAVS-1-ENV (50 nmoles per mouse) was administered twice intranasally in 0.01M PBS alone or in combination with 100 μg of Murabutide with 10 days interval between both administration. Mice were slightly anaesthetised with Isoflurane (Isoflo, Solvay, UK). 20 μl of soluble peptide solution (10 μl/nostril) was administered using a micropipette. A control group received PBS only. Each dosing group comprised six animals. Mice were sacrificed 10 days after the last administration by carbon dioxide asphyxiation. Spleens were removed, pooled for each group of mice and spleen cells were isolated. Cells were washed three times with RPMI-1640 before counting. Counting was performed using a Thomas counting slide. Spleen cells from individual mice were cultured with the appropriate concentration of peptide (10 or 0 μg/ml of T helper ENV (301-322) or P18-I10 CTL epitope) in culture medium during 18 hours at 37° C. under 5% CO 2 atmosphere. IFN-g Elispot assay was then performed using the Diaclone Kit as described in Example 3. The spots were counted using a Carl Zeiss Vision Elispot reader unit. The results correspond to mean values obtained with each conditions after background subtraction (<10 spots). Results are expressed as spot forming units (SFC) per million input spleen cells. The data represent the average for 6 mice.
All six mice per group immunised intranasally either with FAVS-1-ENV alone or in combination with murabutide produced a robust systemic T-cell response. Combination with murabutide led to modest increases in the frequency of IFN-gamma producing T cells ( FIG. 9 ).
Example 6
Example HIV Peptides
Candidate peptides for attachment to the fluorocarbon vector to produce a prophylactic or therapeutic vaccine for HIV may include the following one or more peptides or fragments thereof, or homologues (including the corresponding consensus, ancestral or central tree sequences from HIV-1 representing different clades such as but not limited to clades A, B, C, D, F, G and H as referred to in the 2004 Los Alamos National Laboratory database) or natural and non-natural variants thereof, but not necessarily exclusively. The standard one letter and three-letter amino acid codes have been utilised. Homologues have at least a 50% identity compared to a reference sequence. Preferably a homologue has 80, 85, 90, 95, 98 or 99% identity to a naturally occurring sequence. The sequences provided below are 35 amino acids in length. Fragments of these sequences that contain one or more epitopes are also candidate peptides for attachment to the fluorocarbon vector.
SEQ ID N o 1
WKGEGAVVIQDNSDIKVVPRRKAKIIRDYCKQMAG
Trp-Lys-Gly-Glu-Gly-Ala-Val-Val-Ile-Gln-Asp-Asn-
Ser-Asp-Ile-Lys-Val-Val-Pro-Arg-Arg-Lys-Ala-Lys-
Ile-Ile-Arg-Asp-Tyr-Gly-Lys-Gln-Met-Ala-Gly
SEQ ID N o 2
EIYKRWIILGLNKIVRMYSPTSILDIRQGPKEPFR
Glu-Ile-Tyr-Lys-Arg-Trp-Ile-Ile-Leu-Gly-Leu-Asn-
Lys-Ile-Val-Arg-Met-Tyr-Ser-Pro-Thr-Ser-Ile-Leu-
Asp-Ile-Arg-Gln-Gly-Pro-Lys-Glu-Pro-Phe-Arg
SEQ ID N o 3
EHLKTAVQMAVFIHNFKRKGGIGGYSAGERIVDII
Glu-His-Leu-Lys-Thr-Ala-Val-Gln-Met-Ala-Val-Phe-
Ile-His-Asn-Phe-Lys-Arg-Lys-Gly-Gly-Ile-Gly-Gly-
Tyr-Ser-Ala-Gly-Glu-Arg-Ile-Val-Asp-Ile-Ile
SEQ ID N o 4
WEFVNTPPLVKLWYQLEKEPIVGAETFYVDGAANR
Trp-Glu-Phe-Val-Asn-Thr-Pro-Pro-Leu-Val-Lys-Leu-
Trp-Tyr-Gln-Leu-Glu-Lys-Glu-Pro-Ile-Val-Gly-Ala-
Glu-Thr-Phe-Tyr-Val-Asp-Gly-Ala-Ala-Asn-Arg
SEQ ID N o 5
GERIVDIIATDIQTKELQKQITKIQNFRVYYRDSR
Gly-Glu-Arg-Ile-Val-Asp-Ile-Ile-Ala-Thr-Asp-Ile-
Gln-Thr-Lys-Glu-Leu-Gln-Lys-Gln-Ile-Thr-Lys-Ile-
Gln-Asn-Phe-Arg-Val-Tyr-Tyr-Arg-Asp-Ser-Arg
SEQ ID N o 6
FRKYTAFTIPSINNETPGIRYQYNVLPQGWKGSPA
Phe-Arg-Lys-Tyr-Thr-Ala-Phe-Thr-Ile-Pro-Ser-Ile-
Asn-Asn-Glu-Thr-Pro-Gly-Ile-Arg-Tyr-Gln-Tyr-Asn-
Val-Leu-Pro-Gln-Gly-Trp-Lys-Gly-Ser-Pro-Ala
SEQ ID N o 7
NWFDITNWLWYIKIFIMIVGGLIGLRIVFAVLSIV
Asn-Trp-Phe-Asp-Ile-Thr-Asn-Trp-Leu-Trp-Tyr-Ile-
Lys-Ile-Phe-Ile-Met-Ile-Val-Gly-Gly-Leu-Ile-Gly-
Leu-Arg-Ile-Val-Phe-Ala-Val-Leu-Ser-Ile-Val
SEQ ID N o 8
ENPYNTPVFAIKKKDSTKWRKLVDFRELNKRTQDF
Glu-Asn-Pro-Tyr-Asn-Thr-Pro-Val-Phe-Ala-Ile-Lys-
Lys-Lys-Asp-Ser-Thr-Lys-Trp-Arg-Lys-Leu-Val-Asp-
Phe-Arg-Glu-Leu-Asn-Lys-Arg-Thr-Gln-Asp-Phe
SEQ ID N o 9
VASGYIEAEVIPAETGQETAYFLLKLAGRWPVKTI
Val-Ala-Ser-Gly-Tyr-Ile-Glu-Ala-Glu-Val-Ile-Pro-
Ala-Glu-Thr-Gly-Gln-Glu-Thr-Ala-Tyr-Phe-Leu-Leu-
Lys-Leu-Ala-Gly-Arg-Trp-Pro-Val-Lys-Thr-Ile
SEQ ID N o 10
PDKSESELVSQIIEQLIKKEKVYLAWVPAHKGIGG
Pro-Asp-Lys-Ser-Glu-Ser-Glu-Leu-Val-Ser-Gln-Ile-
Ile-Glu-Gln-Leu-Ile-Lys-Lys-Glu-Lys-Val-Tyr-Leu-
Ala-Trp-Val-Pro-Ala-His-Lys-Gly-Ile-Gly-Gly
SEQ ID N o 11
NRWQVMIVWQVDRMRIRTWKSLVKHHMYISRKAKG
Asn-Arg-Trp-Gln-Val-Met-Ile-Val-Trp-Gln-Val-Asp-
Arg-Met-Arg-Ile-Arg-Thr-Trp-Lys-Ser-Leu-Val-Lys-
His-His-Met-Tyr-Ile-Ser-Arg-Lys-Ala-Lys-Gly
SEQ ID N o 12
HPDKWTVQPIVLPEKDSWTVNDIQKLVGKLNWASQ
His-Pro-Asp-Lys-Trp-Thr-Val-Gln-Pro-Ile-Val-Leu-
Pro-Glu-Lys-Asp-Ser-Trp-Thr-Val-Asn-Asp-Ile-Gln-
Lys-Leu-Val-Gly-Lys-Leu-Asn-Trp-Ala-Ser-Gln
SEQ ID N o 13
PAIFQSSMTKILEPFRKQNPDIVIYQYMDDLYVGS
Pro-Ala-Ile-Phe-Gln-Ser-Ser-Met-Thr-Lys-Ile-Leu-
Glu-Pro-Phe-Arg-Lys-Gln-Asn-Pro-Asp-Ile-Val-Ile-
Tyr-Gln-Tyr-Met-Asp-Asp-Leu-Tyr-Val-Gly-Ser
SEQ ID N o 14
MRGAHTNDVKQLTEAVQKIATESIVIWGKTPKFKL
Met-Arg-Gly-Ala-His-Thr-Asn-Asp-Val-Lys-Gln-Leu-
Thr-Glu-Ala-Val-Gln-Lys-Ile-Ala-Thr-Glu-Ser-Ile-
Val-Ile-Trp-Gly-Lys-Thr-Pro-Lys-Phe-Lys-Leu
SEQ ID N o 15
EKAFSPEVIPMFSALSEGATPQDLNTMLNTVGGHQ
Glu-Lys-Ala-Phe-Ser-Pro-Glu-Val-Ile-Pro-Met-Phe-
Ser-Ala-Leu-Ser-Glu-Gly-Ala-Thr-Pro-Gln-Asp-Leu-
Asn-Thr-Met-Leu-Asn-Thr-Val-Gly-Gly-His-Gln
SEQ ID N o 16
NLLRAIEAQQHLLQLTVWGIKQLQARVLAVERYLK
Asn-Leu-Leu-Arg-Ala-Ile-Glu-Ala-Gln-Gln-His-Leu-
Leu-Gln-Leu-Thr-Val-Trp-Gly-Ile-Lys-Gln-Leu-Gln-
Ala-Arg-Val-Leu-Ala-Val-Glu-Arg-Tyr-Leu-Lys
SEQ ID N o 17
ASVLSGGELDRWEKIRLRPGGKKKYKLKHIVWASR
Ala-Ser-Val-Leu-Ser-Gly-Gly-Glu-Leu-Asp-Arg-Trp-
Glu-Lys-Ile-Arg-Leu-Arg-Pro-Gly-Gly-Lys-Lys-Lys-
Tyr-Lys-Leu-Lys-His-Ile-Val-Trp-Ala-Ser-Arg
SEQ ID N o 18
ELYKYKVVKIEPLGVAPTKAKRRVVQREKRAVGIG
Glu-Leu-Tyr-Lys-Tyr-Lys-Val-Val-Lys-Ile-Glu-Pro-
Leu-Gly-Val-Ala-Pro-Thr-Lys-Ala-Lys-Arg-Arg-Val-
Val-Gln-Arg-Glu-Lys-Arg-Ala-Val-Gly-Ile-Gly
SEQ ID N o 19
FPISPIETVPVKLKPGMDGPKVKQWPLTEEKIKAL
Phe-Pro-Ile-Ser-Pro-Ile-Glu-Thr-Val-Pro-Val-Lys-
Leu-Lys-Pro-Gly-Met-Asp-Gly-Pro-Lys-Val-Lys-Gln-
Trp-Pro-Leu-Thr-Glu-Glu-Lys-Ile-Lys-Ala-Leu
SEQ ID N o 20
QIYQEPFKNLKTGKYARMRGAHTNDVKQLTEAVQK
Gln-Ile-Tyr-Gln-Glu-Pro-Phe-Lys-Asn-Leu-Lys-Thr-
Gly-Lys-Tyr-Ala-Arg-Met-Arg-Gly-Ala-His-Thr-Asn-
Asp-Val-Lys-Gln-Leu-Thr-Glu-Ala-Val-Gln-Lys
SEQ ID N o 21
NLLRAIEAQQHLLQLTVWGIKQLQARVLAVERYLK
Asn-Leu-Leu-Arg-Ala-Ile-Glu-Ala-Gln-Gln-His-Leu-
Leu-Gln-Leu-Thr-Val-Trp-Gly-Ile-Lys-Gln-Leu-Gln-
Ala-Arg-Val-Leu-Ala-Val-Glu-Arg-Tyr-Leu-Lys
SEQ ID N o 22
AGLKKKKSVTVLDVGDAYFSVPLDKDFRKYTAFTI
Ala-Gly-Leu-Lys-Lys-Lys-Lys-Ser-Val-Thr-Val-Leu-
Asp-Val-Gly-Asp-Ala-Tyr-Phe-Ser-Val-Pro-Leu-Asp-
Lys-Asp-Phe-Arg-Lys-Tyr-Thr-Ala-Phe-Thr-Ile
SEQ ID N o 23
TTNQKTELQAIHLALQDSGLEVNIVTDSQYALGII
Thr-Thr-Asn-Gln-Lys-Thr-Glu-Leu-Gln-Ala-Ile-His-
Leu-Ala-Leu-Gln-Asp-Ser-Gly-Leu-Glu-Val-Asn-Ile-
Val-Thr-Asp-Ser-Gln-Tyr-Ala-Leu-Gly-Ile-Ile
SEQ ID N o 24
VSQNYPIVQNLQGQMVHQAISPRTLNAWVKVVEEK
Val-Ser-Gln-Asn-Tyr-Pro-Ile-Val-Gln-Asn-Leu-Gln-
Gly-Gln-Met-Val-His-Gln-Ala-Ile-Ser-Pro-Arg-Thr-
Leu-Asn-Ala-Trp-Val-Lys-Val-Val-Glu-Glu-Lys
SEQ ID N o 25
EAELELAENREILKEPVHGVYYDPSKDLIAEIQKQ
Glu-Ala-Glu-Leu-Glu-Leu-Ala-Glu-Asn-Arg-Glu-Ile-
Leu-Lys-Glu-Pro-Val-His-Gly-Val-Tyr-Tyr-Asp-Pro-
Ser-Lys-Asp-Leu-Ile-Ala-Glu-Ile-Gln-Lys-Gln
SEQ ID N o 26
TPDKKHQKEPPFLWMGYELHPDKWTVQPIVLPEKD
Thr-Pro-Asp-Lys-Lys-His-Gln-Lys-Glu-Pro-Pro-Phe-
Leu-Trp-Met-Gly-Tyr-Glu-Leu-His-Pro-Asp-Lys-Trp-
Thr-Val-Gln-Pro-Ile-Val-Leu-Pro-Glu-Lys-Asp
SEQ ID N o 27
EPFRDYVDRFYKTLRAEQASQEVKNWMTETLLVQN
Glu-Pro-Phe-Arg-Asp-Tyr-Val-Asp-Arg-Phe-Tyr-Lys-
Thr-Leu-Arg-Ala-Glu-Gln-Ala-Ser-Gln-Glu-Val-Lys-
Asn-Trp-Met-Thr-Glu-Thr-Leu-Leu-Val-Gln-Asn
SEQ ID N o 28
NEWTLELLEELKSEAVRHFPRIWLHGLGQHIYETY
Asn-Glu-Trp-Thr-Leu-Glu-Leu-Leu-Glu-Glu-Leu-Lys-
Ser-Glu-Ala-Val-Arg-His-Phe-Pro-Arg-Ile-Trp-Leu-
His-Gly-Leu-Gly-Gln-His-Ile-Tyr-Glu-Thr-Tyr
SEQ ID N o 29
EGLIYSQKRQDILDLWVYHTQGYFPDWQNYTPGPG
Glu-Gly-Leu-Ile-Tyr-Ser-Gln-Lys-Arg-Gln-Asp-Ile-
Leu-Asp-Leu-Trp-Val-Tyr-His-Thr-Gln-Gly-Tyr-Phe-
Pro-Asp-Trp-Gln-Asn-Tyr-Thr-Pro-Gly-Pro-Gly
SEQ ID N o 30
HFLKEKGGLEGLIYSQKRQDILDLWVYHTQGYFPD
His-Phe-Leu-Lys-Glu-Lys-Gly-Gly-Leu-Glu-Gly-Leu-
Ile-Tyr-Ser-Gln-Lys-Arg-Gln-Asp-Ile-Leu-Asp-Leu-
Trp-Val-Tyr-His-Thr-Gln-Gly-Tyr-Phe-Pro-Asp
SEQ ID N o 31
FPVRPQVPLRPMTYKAAVDLSHFLKEKGGLEGLIY
Phe-Pro-Val-Arg-Pro-Gln-Val-Pro-Leu-Arg-Pro-Met-
Thr-Tyr-Lys-Ala-Ala-Val-Asp-Leu-Ser-His-Phe-Leu-
Lys-Glu-Lys-Gly-Gly-Leu-Glu-Gly-Leu-Ile-Tyr
SEQ ID N o 32
FPQITLWQRPLVTIKIGGQLKEALLDTGADDTVLE
Phe-Pro-Gln-Ile-Thr-Leu-Trp-Gln-Arg-Pro-Leu-Val-
Thr-Ile-Lys-Ile-Gly-Gly-Gln-Leu-Lys-Glu-Ala-Leu-
Leu-Asp-Thr-Gly-Ala-Asp-Asp-Thr-Val-Leu-Glu
SEQ ID N o 33
LVITTYWGLHTGERDWHLGQGVSIEWRKKRYSTQV
Leu-Val-Ile-Thr-Thr-Tyr-Trp-Gly-Leu-His-Thr-Gly-
Glu-Arg-Asp-Trp-His-Leu-Gly-Gln-Gly-Val-Ser-Ile-
Glu-Trp-Arg-Lys-Lys-Arg-Tyr-Ser-Thr-Gln-Val
SEQ ID N o 34
APPEESFRFGEETTTPSQKQEPIDKELYPLASLRS
Ala-Pro-Pro-Glu-Glu-Ser-Phe-Arg-Phe-Gly-Glu-Glu-
Thr-Thr-Thr-Pro-Ser-Gln-Lys-Gln-Glu-Pro-Ile-Asp-
Lys-Glu-Leu-Tyr-Pro-Leu-Ala-Ser-Leu-Arg-Ser
SEQ ID N o 35
KRRVVQREKRAVGIGAMFLGFLGAAGSTMGAASMT
Lys-Arg-Arg-Val-Val-Gln-Arg-Glu-Lys-Arg-Ala-Val-
Gly-Ile-Gly-Ala-Met-Phe-Leu-Gly-Phe-Leu-Gly-Ala-
Ala-Gly-Ser-Thr-Met-Gly-Ala-Ala-Ser-Met-Thr
SEQ ID N o 36
GLGQHIYETYGDTWAGVEAIIRILQQLLFIHFRIG
Gly-Leu-Gly-Gln-His-Ile-Tyr-Glu-Thr-Tyr-Gly-Asp-
Thr-Trp-Ala-Gly-Val-Glu-Ala-Ile-Ile-Arg-Ile-Leu-
Gln-Gln-Leu-Leu-Phe-Ile-His-Phe-Arg-Ile-Gly
Candidate peptides for inclusion into a prophylactic or therapeutic vaccine for HIV may be peptides from any of the structural or functional domains Gag, Pol, Nef, Env, Vif, Vpr, Vpu, Tat or Rev in any such combination.
Incorporation by Reference
The entire disclosure of each of the publications, web sites and patent documents referred to herein is incorporated by reference in its entirety for all purposes to the same extent as if each individual publication, web site or patent document were so individually denoted.
Equivalents
The invention may be embodied in other specific forms without departing form the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the invention described herein. Scope of the invention is thus indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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The present invention relates to fluorocarbon vectors for the delivery of antigens to immunoresponsive target cells. It further relates to fluorocarbon vector-antigen constructs and the use of such vectors associated with antigens as vaccines and immunotherapeutics in animals.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to devices which can detect a small loss of refrigerant charge from refrigeration systems while in operation, and function to trigger an audible and/or visual alarm during any time the system is operating.
2. Description Of The Related Prior Art
The need for a method and apparatus to determine the amount of refrigerant in a refrigeration system, particularly a large system, has long been recognized. There are several reasons why this measurement is important, but the main concern for most refrigeration systems is the need to detect a low refrigerant condition as the result of a steady loss of refrigerant over time due to leaks in the pressurized system. A low refrigerant condition initially results in a gradual loss of cooling capacity which, if not detected and corrected, can result in such a critical loss of refrigerant that expensive damage can occur to a refrigerant compressor due to lubrication failure.
U.S. Pat. No. 4,553,400, issued Nov. 19, 1985 to Michael A. Branz, discloses a comprehensive refrigerant monitor and alarm system with emphasis on the electrical and electronic features of the system. When adapted to commercial refrigeration systems for supermarket display cases, it is seen that the level of refrigerant in a large common receiver is to be monitored by a conventional liquid level sensing float. A liquid level indicator provides a constant readout of the level in the receiver, triggers a timer controlled alarm when a critically low level is reached. By contrast, the present invention reliably detects a loss of refrigerant at a convenient, accessible location which can be located remotely from the receiver.
U.S. Pat. No. 4,308,725, issued Jan. 5, 1982 to Tsuneyuki Chiyoda discloses a simplistic device for detecting the quantity of refrigerant in a liquid receiver. In one embodiment, a floating hollow ball within a float guide can rise or fall with the refrigerant level, and as the level drops due to the loss of refrigerant, ultimately the ball comes in contact with a pair of electrical conducting elements, and the ball, being made of conductive material, then completes an alarm circuit through the contacts to energize an external alarm. An ingenious electronic circuit filters out very short electrical contact times in the detector which may be caused by mechanical vibrations. The positive make-or-break characteristics of the switching device of the present invention renders it largely immune to such rapid short contact times, as would be induced by mechanical vibration.
U.S. Pat. No. 4,745,765, issued May 24, 1988 to Edward D. Pettitt, discloses a refrigerant detecting device which illustrates a new inventive trend in liquid level sensors. This type of sensor responds to "condition sensing" and can determine a low refrigerant charge level without actually being located within or near a receiver containing the bulk of the liquid charge. This condition sensing device, located in the discharge line from an evaporator, detects refrigerant super heat temperature and also contains a bi-metal ambient air temperature sensor. An internal electrical contact closes to activate an alarm when a predetermined combination of evaporator super heat and ambient air temperature occurs indicating an undesirably low amount of refrigerant in the system. It is a complex precision device compared to the simplicity of the present invention.
U.S. Pat. No. 4,856,288, issued Aug. 15, 1989 to Robert C. Weber, discloses a refrigerant detection device which is to be installed at a predetermined location in a refrigerant high pressure liquid line. It consists of a preferably transparent hollow cylinder, a few inches in height in which a float of conductive material is disposed. As the conductive float follows the liquid level down in the cylinder, it eventually reaches a pair of electrically conductive contact points and thereby completes an electrical circuit which is indicative of refrigerant loss and therefore can activate a refrigerant low level alarm. Several embodiments of the invention are disclosed including versions having two conductive floats. A time delay means is suggested to avoid activation of the alarm during the compressor startup phase.
The conductive float sensor of this invention may be subject to short, rapid electrical contact times which can be caused by mechanical vibrations, same as referred to above for the Chiyoda Patent, but the present invention is immune to the effects of mechanical vibration and the resultant rapid contact cycling.
None of the above inventions and patents taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY AND OBJECTS OF THE INVENTION
By the present invention, an improved low cost reliable refrigerant loss detector is disclosed and claimed. It is capable of detecting the loss of a small amount of refrigerant in a closed system compared to the total system capacity. It is further provided with an electrical circuit containing a time delay apparatus which acts to prevent unnecessary and undesired false alarm signals, during transient refrigeration conditions which occur during the first minute of system operation. An audible alarm and/or visual alarm may sound after one minute, signaling a low refrigerant condition, and the alarm will continue as long as the refrigeration compressor is operating and the low refrigerant condition persists.
Accordingly, it is a principal object of the present invention to provide a refrigerant loss detector which may be mounted at a point in a closed system remote from the refrigerant receiver, and which reliably determines that a small amount of refrigerant charge in the closed system has been lost.
It is another object of the present invention to provide a refrigerant loss detector that can initiate and maintain an electrical circuit to an audible or visual alarm during continued operation of a refrigeration compressor in a system in which a loss of refrigerant has been detected.
It is a further object of the present invention to include an interval time delay apparatus which functions to prevent the transmission of false alarm signals which may be initiated by the loss detector during the unstable, non-typical refrigerant conditions which exist during the brief system startup phase.
Still another object of the present invention is to provide a refrigerant loss detector which can be readily installed in a refrigerant liquid line either by an original equipment manufacturer (OEM) at the factory, or by tradesmen during construction of a new system, or as a retrofit to an existing system.
It is an object of the present invention to energize the refrigerant loss detector and alarm circuitry and maintain it in a monitoring status continuously during the time that the refrigeration compressor is operating.
It is an object of the present invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purpose.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section elevational view of an embodiment of the refrigerant loss detector in which the float is buoyant at a high level of refrigerant.
FIG. 2 is a cross-section elevational view of the embodiment of FIG. 1 in which the float is buoyant at a lower level of refrigerant.
FIG. 3 is a cross-section elevational view of the buoyant float and mercury switch assembly.
FIG. 4 is a top view of the loss detector removable cap.
FIG. 5 is a wiring schematic of the refrigerant loss detector and alarm system.
FIG. 6 is a piping schematic of a typical commercial refrigerant system showing the refrigerant loss detector installed.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The instant invention includes five major components, as shown on FIG. 5. Electric contacts in the compressor operating control 12 provide the source of power, generally 110 volts or 220 volts A.C. The loss detector 10 and alarm system are operational whenever the compressor operates. The control transformer 14 steps down the primary voltage which is generally 110 volts or 220 volts A.C., to a secondary voltage of 24 or 30 volts A.C. or D.C., which powers the warning device 16 through a time delay device 18 and the refrigerant sensor 10. The warning device 16 may produce an audible signal, such as a bell or horn, or a visual signal, or both, or an automatic printout. Refrigerant sensor 10 will be further described herein.
Since the refrigerant loss detector 10 will be incorporated into standard closed loop refrigeration systems, the system of FIG. 6 will be explained in some detail as background for understanding the operating principles and preferred embodiment of the instant invention.
A closed loop refrigeration system 20 including a refrigerant loss detector device 10 embodying the present invention is shown in FIG. 6. This system could apply to any large refrigeration system utilizing a liquid/vapor phase change refrigerant, examples of which include such materials as halogenated fluorocarbons (freon), ammonia, and sulfur dioxide. For a general application, the refrigerant system shall be considered a so-called "split system", one in which the refrigeration evaporator 22 apparatus is remotely located from the refrigerant compressor 24 and condensing apparatus 26. The refrigerant is a halogenated fluorocarbon (freon) for the preferred embodiment. Halogenated fluorocarbons are the most common refrigerants in use today.
The description of FIG. 6 begins with the evaporator 22, of well known fin and tube construction, not further described herein. Air from the conditioned space moved by a power driven fan 28, passes across the heat transfer surface of the evaporator 22 wherein a refrigerant, having a boiling temperature that is lower than the temperature of the space to be cooled, permits the transfer of heat from the air passing through the evaporator 22 to the boiling refrigerant therein. The boiling refrigerant referred to undergoes a phase change from a liquid to a gas during this process. The liquid, now vaporized and exiting from the evaporator 22, courses through an accumulator 30 where any unvaporized liquid exiting from the evaporator is separated out. The refrigerant gas is then withdrawn from the accumulator 30 and enters the compressor 24 wherein both the pressure and the temperature of the gas are sharply increased. The now compressed refrigerant gas exiting from the compressor 24 at its discharge pressure has a saturation temperature low enough that it may be condensed in the condenser 26 by the condensing medium, usually air, as in this embodiment, but may also be water, using a suitable shell and tube heat exchanger (not shown) which is well known in the art. The vaporized refrigerant is condensed to a liquid in the condenser 26, from which the heat of vaporization is removed by ambient air circulated through the condenser 26 by fan 32. Excess liquid refrigerant is stored in receiver 34 and, upon demand of the throttling device or expansion valve 40, refrigerant will flow from the receiver 34 through filter dryer 35, sight glass 38, the refrigerant detector 10 of the instant invention and then through the expansion valve 40 completing the circuit into the evaporator 22. All of the above stated components are well known in the refrigeration art, except for refrigerant detector 10.
As explained above, the pressure of the refrigerant gas leaving the compressor 24 and entering the condenser 26 need be great enough that the refrigerant exiting the condenser will have been liquified. Under a "standard operating condition" of 95 degrees F. ambient air temperature, with air as the cooling medium, and using R-22 as the refrigerant, the compressor 24 will need to discharge the refrigerant gas at a pressure of at least 230 pounds per square inch gauge, in order to assure that the refrigerant in the piping between the condenser 26 and the expansion valve 40 remains liquid. Upon a gradual loss of refrigerant from the system, the compressor is handling a reduced mass flow rate, and as a result the design discharge pressure can no longer be maintained. While the discharge pressure is falling, the condensing temperature does not fall proportionately; it can fall no lower than the ambient air temperature, using air as the cooling medium in this case. Thus, through leakage, the liquid refrigerant pressure is gradually falling toward the pressure at which it will flash into vapor, the vaporization pressure.
Referring to FIG. 1, a preferred embodiment of the refrigerant sensor 10 comprises a generally vertical canister 42, within which is disposed a buoyant member 44 containing an inexpensive, sealed mercury switch 46 of the type generally used in the electronic industry to deactivate electrical circuits in the event of equipment tip over. The mercury switch 46 is connected through insulated copper conductors 48 within the vertical canister 42, and final connections being 1/64 inch thick copper braid 1/4 inch in length to provide hinge type flexible connections 48A. The insulated conductors are connected to spade type electrical connectors 50, suitably mounted in insulated plug-like members 52. The top 54 of canister 42 is threadably removable from the canister. An `O` ring 56 provides pressure sealing for the removable top 54. The refrigerant detector 10 is in communication with the liquid refrigerant through two tubular ports 58, and, preferably, is mounted as shown in FIG. 6, in a pressurized liquid line between the sight glass 38 and the expansion valve 40. Consequently when liquid refrigerant enters refrigerant detector 10 at a pressure close to the vaporization pressure, vapor bubbles will be forming and collecting in the top most volume of the canister 42 of sensor 10. Gradually the vapor will displace the liquid surface downward causing the buoyant member 44 to descend (FIG. 2) and also display a partial rotation owing to the restraint of the conductors 48.
As shown in FIG. 2, the mercury bead 64 will move so as to bridge the two electrodes 60 and 60a (see FIG. 3), providing a positive electrical "make" circuit through the mercury switch 46.
Referring to FIG. 5, a make circuit in refrigerant detector 10 completes a series electrical circuit from the transformer 14 secondary (not shown) through the time delay device 18 and also through the warning device 16. During the timed interval, the electronic time delay device provides only a weak current through the warning device 16, insufficient to activate it. After the delay period, full current flows from the secondary of the control transformer 14, through the time delay device 18, the refrigerant detector 10, and warning device 16 causing the warning device 16 to activate. As mentioned previously, the warning device 16 may be either audible, visual or a printout on a recording device.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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A refrigerant loss detector and alarm, the detector device suitable for installation in the piping of a refrigeration system which utilizes a liquid/vapor phase change substance as the refrigerant. Upon detection of refrigerant vapor accumulating in the loss detector, thereby displacing refrigerant liquid therefrom, the orientation of a float element containing a mercury switch is affected. Upon a fall in refrigerant liquid level in the loss detector, the mercury switch becomes activated, thereby completing an external electrical circuit which contains a time delay device and an alarm device.
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BACKGROUND
[0001] The field of the invention relates generally to cooling of structures, and more specifically, to methods and apparatus for a micro-truss based structural insulation layer.
[0002] Multiple solutions have been utilized in thermal protection of structures. Many of these solutions include low density core materials as a part of the structure, which allow air to pass through while also providing an insulation factor. These core materials include one or more of carbon foam, silicon carbide foam, alumina tile, and slotted honeycomb. Other core materials may be known.
[0003] Ceramic foams have been used for thermal protection systems and heat exchanger applications. However, due to their random foam cell orientation, they are not as mechanically efficient as is desired. Also, the random foam cell orientation results in some degree of difficulty, when attempting to pass forced air through the foam. In addition, the random reticulated foam also provides limited design variables (primarily foam cell size) for optimizing these foam structures from a thermal-mechanical performance perspective.
[0004] One solution incorporates a ceramic thermal protection system, in which the ceramic is porous, allowing cooling air to pass therethrough. However, this porous ceramic has many of the same features as does the reticulated foam. Specifically, the randomness of the individual cells results in inefficient air passage through the ceramic.
BRIEF DESCRIPTION
[0005] In one aspect, an apparatus for maintaining a temperature differential between a component and a source of heat is provided. The apparatus includes a micro-truss structure having a plurality of nodes and members which define a first surface and a second surface. The second surface is operable for attachment to the component. The apparatus further includes a skin material attached to the first surface of the micro-truss structure such that the skin material is operable for placement between the heat source and the micro-truss structure. The skin material defines at least a portion of a fluid flow path through the micro-truss structure.
[0006] In another aspect, a structure for protecting a surface from heat fluctuations emanating from a heat source is provided. The structure includes a micro-truss structure having a plurality of hollow members intersecting at nodes. The hollow members define a first surface and a second surface and a plurality of spaces therebetween. The second surface is configured for placement proximate the surface that is to be protected from the heat source, while the hollow members and nodes are configured such that a fluid flow may be directed therethrough. The structure further includes an insulating material filling the spaces defined by the hollow members and the nodes of the micro-truss structure.
[0007] In still another aspect, a method for insulating a surface from a source of heat that is proximate the surface is provided. The method includes attaching a micro-truss structure to the surface, the micro-truss structure between the surface and the source of heat, and associating a fluid flow with the micro-truss structure such that operation of the fluid flow removes heat from an area associated with the micro-truss structure.
[0008] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the present invention or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a cross sectional view of a micro-truss based actively cooled insulation layer that includes an impermeable skin.
[0010] FIG. 2 is a cross sectional view of a micro-truss based actively cooled insulation layer that includes a porous skin.
[0011] FIG. 3 is a cross sectional view of a micro-truss based actively cooled insulation layer that includes directional cooling holes incorporated into a skin.
[0012] FIG. 4 is a cross sectional view of a micro-truss based actively cooled insulation layer where cooling air is directed through hollow truss members.
[0013] FIG. 5 is an illustration of a micro-truss structure.
[0014] FIG. 6 is an illustration of a micro-truss structure that includes hollow truss members.
[0015] FIG. 7 is a close up view of a hollow truss member.
DETAILED DESCRIPTION
[0016] The described embodiments relate to a thermal insulation structural element having a truss structure therein. In various embodiments, the truss structure includes a plurality of members extending from a node and attached to a skin surface. In certain embodiments, the truss structure and its members are ceramic. In certain embodiments, the truss members are hollow. With regard to both hollow and non-hollow truss embodiments, an overall structure may include a skin and one surface of the truss structure attached to the skin. An opposite surface of the truss structure is attached to a surface that is to be protected from heat flux. With the truss structure between the skin and the surface, a fluid flow path is formed that allows for a less constricted air flow across the truss structure.
[0017] One purpose of the described structures is to maintain a thermal differential (ΔT) between a surface and an incident heat flux. An ability to adjust the flow of cooling air through the structure of the micro-truss enables control of the surface temperature. Several advantages of such a micro-truss structure include a variety of material options, such as ceramics and metals, a potential for net shape fabrication, no additional machining operations for cooling air flow channels, and the micro-truss architecture is capable of providing additional structural functionality.
[0018] One identified application for the below described embodiments, is in the environment associated with an aircraft exhaust nozzle. However, other applications that require surface temperature control are certainly contemplated.
[0019] More specifically, the truss structure relates to embodiments of a micro-truss that are attached to a surface requiring protection from a high heat flux source. Referring to FIG. 1 , a skin material 10 is attached to a micro-truss structure 12 along a first surface 16 of the micro-truss structure 12 . A second surface 18 of micro-truss structure 12 is attached, using an attachment 20 , such that the second surface 18 of micro-truss structure 12 is adjacent a surface 30 of a device, or substructure 32 , that is to be protected from heat flux 40 . In the illustrated embodiment, the surface 30 of the substructure 32 is protected from the high heat flux 40 by convective cooling that is provided by cooling air 50 passing through the micro-truss structure 12 . One purpose of the skin 10 is to enclose an interior region 60 of the micro-truss structure 12 to allow for the flow of cooling air 50 .
[0020] As described elsewhere herein, micro-truss structure 12 may be fabricated from a polymer, a metal (or alloy), or from a ceramic material. For temperatures exceeding approximately 200 degrees Celsius, micro-truss materials must be converted to either a metal or a ceramic. One preferred embodiment utilizes a ceramic micro-truss. Silicon carbide and alumina are two examples of such a ceramic, though there are others. The reasons are many, and include: because ceramic materials are generally lower density than metals, because ceramic materials are generally more thermally stable in higher temperature environments, and because ceramic materials generally have a lower thermal conductivity, which inhibits the conduction of heat through the truss members to the surface that requires protection from the heat flux.
[0021] In the case of the impervious skin material 10 , incident thermal energy conducts through the material from which the members of micro-truss structure 12 are fabricated towards the surface 30 requiring protection from the high heat flux 40 . Cooling air 50 is directed through the micro-truss structure, providing a convective cooling mechanism to maintain a desired ΔT. One embodiment of an impervious skin material is a ceramic fiber reinforced ceramic matrix composite (CMC).
[0022] For the impervious skin material 10 , the temperature of the cooling air 50 directed through the micro-truss structure 12 will increase as the cooling air 50 removes heat from the individual members of micro-truss structure 12 . This phenomenon reduces the efficiency of the cooling air 50 as the effective path length through the micro-truss structure increases, due to a decreasing temperature differential between the cooling air 50 and the skin material(s) 10 . Limitations on the cooling air flow rate will ultimately determine if this cooling mechanism is sufficient to maintain a safe ΔT for the required temperature conditions in a specific application.
[0023] As shown in FIG. 1 and in subsequent figures, the micro-truss structure 12 is attached to the surface 30 requiring protection from the high heat flux 40 . Bonding or mechanical attachment approaches may be utilized. In one preferred embodiment, the micro-truss structure 12 is attached to the surface 30 with a high temperature silicone adhesive, which provides an efficient strain relief layer. If a lower thermal gradient were expected at the bonding surface, other commercially available bonding approaches could be utilized.
[0024] As is the case with other embodiments described herein, a temperature differential between the skin material 10 and the surface 30 is controlled/maintained by passing the cooling air 50 through the natural flow channels of the structure associated with micro-truss structure 12 . In addition, and as shown in FIG. 2 , a skin material 100 may be porous, enabling cooling air to flow from the interior region 60 of the micro-truss structure 12 , through a porous skin material 100 , and onto the high heat flux 40 , providing a transpiration mechanism. In the illustrated embodiment, the surface 30 of the substructure 32 is protected from the high heat flux 40 by convective cooling of the micro-truss structure 12 and transpiration cooling at the surface 102 of skin 100 .
[0025] As one described embodiment, transpiration cooling can be achieved by utilizing a porous skin material 100 that will enable the cooling air 50 to “transpire” from the interior region 60 of the micro-truss structure 12 towards the direction of the incident heat flux 40 . This active cooling mechanism reduces the skin temperature for a given heat flux (compared to an impervious skin material with a similar thermal conductivity), thus reducing the amount of heat conducted through the truss members. Examples of porous skin materials 100 include sintered particles and/or fibers that create an open porosity of >10%. In the case of a porous ceramic skin material, the particles and/or fibers may be comprised of oxide or non-oxide constituents.
[0026] FIG. 3 illustrates that the skin material 150 may be fabricated to include a plurality of aligned holes 152 that enable cooling air 50 to flow from the interior region 60 of the micro-truss structure 12 , through the aligned holes 152 , towards the heat source 40 providing a film cooling mechanism. The other aspects of this configuration are as before, specifically, the surface 30 of the substructure 32 is also protected from the high heat flux 40 by convective cooling of the micro-truss structure 12 and by film cooling at the surface of skin 150 .
[0027] In one embodiment, and as illustrated in FIG. 3 , skin material 150 may include an array of directional cooling holes 152 to accomplish the above mentioned film cooling: In alternative embodiments, the material for skin material may be the impervious skin material 10 described with respect to FIG. 1 , or may the porous skin material 100 described with respect to FIG. 2 . In either embodiment, cooling air 50 exits the interior region 60 of the micro-truss structure 12 and forms a protective cooling film adjacent to the surface 154 of the skin material 150 . Similar to transpiration cooling, a cooling air film reduces the surface temperature of the skin material 150 , which is adjacent to the incident heat flux 40 , and thus the amount of heat conducted through the micro-truss members. The array of cooling holes 152 in the skin material 150 can be conventionally drilled or laser machined perpendicular to, or at an angle off the normal of the surface 154 . The architecture of micro-truss structure 12 can be configured such that the cooling holes 152 are located between nodes 160 of the micro-truss structure 12 , enabling a predictable cooling air flow pattern.
[0028] FIG. 4 illustrates another alternative embodiment, where film cooling can be achieved by passing cooling air 50 through hollow members 200 of a micro-truss structure 202 to a surface 210 of a skin material 212 . In this embodiment, the interior 220 of the micro-truss structure 202 can optionally be filled with a highly insulating material 224 , such as an aerogel. The cooling air 230 is directed into the hollow truss members 200 through separate cooling channels 230 formed between the micro-truss structure 202 and the surface 30 of the sub-structure 32 requiring thermal isolation from the high heat flux 40 . The separate cooling channels 230 , in one embodiment, are formed by the placement of a flow channel 240 to the surface 30 of the substructure 32 to be protected from the high heat flux. In this embodiment, a separate skin material, such as skin material 100 or skin material 150 , is optional depending on the air-flow permeability and durability of the insulating material 224 filling the interior 220 of the micro-truss structure 202 .
[0029] FIG. 5 is an illustration of one embodiment of a micro-truss structure 250 which illustrates the channels 252 through which cooling air can flow. FIG. 6 is a close up illustration of a micro-truss structure 300 that includes hollow truss members 302 . FIG. 7 is a further close up view of a hollow truss member 302 .
[0030] With regard to dimensions, a total thickness of the actively cooled insulation layer including one of the above described micro-truss structures 12 and 202 is between approximately 0.1 inch and two inches, in a specific embodiment. In one preferred embodiment, the thickness of the micro-truss structure ranges between 0.3 inch and one inch. The skin material ranges from about one percent to about fifty percent of the total thickness. A solid volume fraction, or relative density, of the micro-truss structure ranges between about one percent to about fifty percent.
[0031] In addition to enabling cooling flow through the structure of an actively cooled insulation layer, the micro-truss materials are utilized as a sandwich structure core material that can transfer load between the sub-structure and the skin material. This structural functionality of the micro-truss structures 12 and 202 may reduce parasitic weight of the insulation layer.
[0032] Other embodiments are contemplated that combine one or more of the features described with respect to FIGS. 1-4 . For example, rather than using insulating material 224 , cooling air could be routed through the hollow truss members 200 and through the interior 220 of the structure, around the micro-truss structure 202 as is described with respect to FIGS. 1-3 . In addition, the optional skin may be the porous skin material 100 of FIG. 2 or the skin material 150 of FIG. 3 , with the holes 152 aligning with the hollow truss members 200 .
[0033] In any of the embodiments, the micro-truss structure can be optimized by changing one or more of a unit cell size, unit cell architecture, truss member diameter, and truss member angle when the micro-truss structure is grown and/or fabricated.
[0034] In one application, the described embodiments may be utilized as part of a thermal protection system for an aircraft. The described embodiments are directed to an integrated thermally resistant structure that uses a truss element to form a composite like sandwich structure to direct heat away from a surface. The truss elements are formed, in one embodiment, using developed processes that result in hollow micro-truss elements. One focus of the present disclosure is to a truss structure where a fluid flow (air) is passed though one or more of a truss structure and hollow truss members to provide cooling for surfaces that need to be protected from large thermal gradients.
[0035] This written description uses examples to disclose various embodiments, which include the best mode, to enable any person skilled in the art to practice those embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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An apparatus for maintaining a temperature differential between a component and a source of heat is described. The apparatus includes a micro-truss structure having a plurality of nodes and members which define a first surface and a second surface. The second surface is operable for attachment to the component. The apparatus further includes a skin material attached to the first surface of the micro-truss structure such that the skin material is operable for placement between the heat source and the micro-truss structure. The skin material defines at least a portion of a fluid flow path through the micro-truss structure. A skin material is not utilized with certain configurations of the micro-truss structure.
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FIELD OF THE INVENTION
[0001] The present invention relates to a successive approximation Analog to Digital Converter, and in particular to a converter where the sequence for controlling switches connecting capacitors in a capacitor array to first or second reference voltages has been modified so as to improve the speed of the analog to digital converter.
BACKGROUND OF THE INVENTION
[0002] Successive approximation converters using switched capacitor arrays are well known.
[0003] An example of an idealized differential input successive approximation switched capacitor analog to digital converter is shown in FIG. 1 . This converter receives a differential signal on its signal inputs Vinp and Vinn, and fixed inputs Vref, and GND. The Vref input and the GND input define an allowable operating range of the converter such that −(Vref-GND)≦(Vinp-Vinn)≦(Vref-GND). The converter comprises two switched capacitor arrays, designated DAC-P and DAC-N (but which may also be referred to as P array and N array herein) which connect to the positive input and negative input, respectively, of a comparator 12 . The capacitor arrays DAC-P and DAC-N are mirror images of one another and, for convenience, only the array DAC-P will be described in detail.
[0004] The array DAC-P comprises a plurality of binary weighted capacitors C 1 P to C 6 P plus C 6 T whose total capacitance sums to a value C. In this example capacitor C 1 P represents the most significant bit and capacitor C 6 P represents the least significant bit of the array. Capacitor C 1 P has a value of C/2. Consequently C 2 P has a value of C/4, capacitor C 3 P has a value of C/8, capacitor C 4 P has a value of C/16, capacitor C 5 P has a value of C/32 and capacitor C 6 P has a value of C/64. In order to ensure that the array sums to its correct value of C, then a further terminating capacitor C 6 T , having a value corresponding to the value of the least significant bit is included.
[0005] Each of the capacitors have first and second plates which, in a commonly used nomenclature are referred to as “top” and “bottom” plates. The top plates of capacitors C 1 P to C 6 T are connected to a common rail designated TOP-P which is connected to the positive input of the comparator 12 . The bottom plates of capacitor C 1 P to C 6 P are connected to respective switches S 1 P to S 6 P . The switches are fabricated from transistors. The switch S 1 P is a three position switch such that the bottom plate of capacitor C 1 P can either be connected to a positive signal input Vinp, to the positive reference voltage Vref or to a negative reference voltage, e.g. ground. Switches S 2 P to S 6 P are two position switches such that the bottom plate of the respective capacitor can either be switched to ground or to Vref. Capacitor C 6 T (which is a repeat of the least significant bit capacitor) is not associated with a switch and its bottom plate is permanently connected to the negative reference voltage, e.g. the ground rail.
[0006] The negative capacitor array SAR-N is identical to that in SAR-P with the exceptions that all capacitors and switches are designated with the subscript N, switch S 1 N can now connect to a negative signal input Vinn, and that the top plates of capacitors C 1 N to C 6 N connect to a common rail designated TOP-N that connects to the negative input of the comparator 12 .
[0007] Sample switches SS P and SS N are provided to connect the common node TOP-P and the common node TOP-N to a bias voltage, Vbias, during sampling. Vbias can be freely chosen by the circuit designer although in practice it is generally constrained to lie within the voltage range −Vref<Vbias<+Vref. A convenient choice for Vbias is ground because this avoids the need to create a voltage generator solely for the purpose of creating the Vbias voltage. Vbias acts as a reference voltage during sampling of the differential input signal by the converter.
[0008] With reference to FIG. 2 , it can be seen that each of the switches are implemented as pairs of transistors. For each capacitor its associated switch, such as switch S 2 P comprises a first transistor 22 , which for convenience can be regarded as a high side transistor, which connects it to Vref and a second transistor 24 , which for convenience can be regarded as a low side transistor, which connects it to ground. In this example Vref represents the first reference voltage and ground represents the second reference voltage. In use, it is generally considered to be undesirable for the first and second switches, that is the high side and low side switches, to be simultaneously conducting as this provides a short circuit between the first and second reference voltages which either results in unnecessary dissipation within the device and perturbs the reference voltages thereby leading to inaccuracies in the converted result. In order to avoid the high side and low side switches being conducting at the same time, non-overlap generating circuits 25 , for example like the type shown in FIG. 2 are provided. Thus, if we consider capacitor C 2 P of FIG. 1 then a first plate of that capacitor is connected to a node 20 which represents the midpoint of a series connection between the two field effect transistors 22 and 24 . The first field effect transistor 22 is the high side transistor which is operable to connect to the first plate of the capacitor C 2 P to Vref, whereas the second field effect transistor 24 is the low side transistor which operable to connect the first plate of the capacitor C 2 P to ground. Clearly if both transistors 22 and 24 are conducting at the same time then current will flow from Vref to ground and the voltage at node 20 is undefined.
[0009] In order to overcome these problems a non-overlap generator is used. An example of a prior art non-overlap generator is shown which comprises two NOR gates 26 and 27 and an inverter 28 . These are connected together in the configuration shown in FIG. 2 .
[0010] Suppose we start with a configuration in which each of the transistors 22 and 24 can be made conducting by sending it a “high” or “1”, and can be made non-conducting in response to a zero or “0” applied to its gate.
[0011] Starting at a steady state condition where an output 36 of the first NOR gate 26 is high, and output 42 of the second NOR gate is low and the input signal at node 30 is low, then this is a stable configuration as:
1) input 32 and 34 of NOR gate 26 are both low so output 36 remains high. 2) input 40 of NOR gate 27 is high, and the effect of the inverter 28 makes input 38 high so the output 42 remains low.
[0014] Now consider a transition, where each gate has a propagation delay D.
[0015] At switching time t=0 node 30 switches from “0” to “1”. At t=0 input 32 becomes “1” while input 34 is still zero. The output of NOR gate 26 starts to change so that it will become “0” at time t=D.
[0016] Thus as t=D input 40 of NOR gate 27 goes low. Similarly the action of the inverter causes input 38 to go low at t=D. Thus this gate starts to change state and the output 42 goes high at t=2 D.
[0017] This gain represents a stable state with node 30 =“1”, output 36 =“0” and output 42 =“1”.
[0018] It can be seen that there was a period from t=D to t=2 D when both transistors were non-conducting.
[0019] Suppose now that the signal on node 30 changes from 1 to 0 at t=0. Input 32 goes low but 34 remains high so NOR gate 26 remains with its output at “0”. Meanwhile the inverter 28 is changing state such that its output becomes high. Thus at time t=D input 40 is low but input 38 is high so the NOR gate 27 starts to transition between states such that at t=2 D its output is “0”. At this time the output of NOR gate 26 is also “0” but both inputs 32 and 34 have gone low so it starts to change state such that its output becomes high at t=3 D.
[0020] Thus once again there was a period when both transistors 22 and 24 were non-conducting.
[0021] It is clear however that the high side and low side transistors 22 and 24 are effectively controlled in unison with one being on whilst the other is off except during a very brief window generated by the non-overlap circuit. This mode of operation is widely held by persons skilled in the art to be the way that switches for successive approximation converters are and must be driven.
[0022] For simplicity the foregoing discussion assumed that a transistor was conducting when its input was “1” and not conducting when its input was “0”. Of course this need not be the case and use of other technologies, such as CMOS, may result in the formation of the transistors who conduct when their input voltage is low. As a consequence inverters may be required to achieve the desired operation.
SUMMARY OF THE INVENTION
[0023] According to a first aspect of the present invention there is provided a successive approximation analog to digital converter comprising a plurality of capacitors which during a successive approximation conversion are selectively connectable to a first reference or a second reference under the command of a controller, wherein during a conversion step where the connections of a given capacitor may be varied the switches to the given capacitor are both placed in a high impedance state during a decision period of a comparator.
[0024] Thus the inventors have realized that, rather than the switches being driven in anti-phase during the bit trials of a successive approximation conversion, that the transistors could beneficially be individually controlled such that capacitors which potentially could be altered as part of a present bit trial or would be altered in order to set a test in a succeeding bit trail could have both their high side and low side transistors placed into a high impedance state before a decision had been made by the comparator whether to keep or reject the bit being tested in the current bit trial.
[0025] This has the advantage of allowing the overlap generator to be dispensed with and consequently the switching delay introduced by the overlap generator in the prior art following a decision by the comparator is no longer incurred. This in turn means that the throughput of the analog to digital converter can be increased.
[0026] Advantageously each of the transistor switches, whether they be high side or low side switches are driven by a latch which can be latched so as to turn the transistor on or turn the transistor off. Advantageously the circuit responsible for switching a transistor into a conducting state is provided in contact with a control terminal, generally a gate, of the transistor switch such that the transistor can be switched on rapidly by that control circuit. The control circuit also has the ability to force the latch to transition to a state for holding the transistor in a conducting state. Thus, following the decision to switch a transistor on, the control signal does not incur propagation delays associated with propagating through a latch or a non-overlap generator, but instead is applied to the gate of the relevant transistor switch whilst also directly forcing the latch to transition, or alternatively causing other combinational logic to instigate a transition of the latch, to a new state. Thus not only is the switch off time for the transistors brought into the period whilst the comparator is regenerating, that is making its decision, but additionally the propagation delay between the output of the comparator and the relevant transistor switch is much reduced because the control signal does not have to propagate through a latch or through a non-overlap generator.
[0027] According to a second aspect of the present invention there is provided a successive approximation converter comprising a plurality of capacitors, wherein the switches associated with a capacitor representing a bit weight in a bit trial can be individually controlled such that a capacitor can be connected to either a first reference voltage or to a second reference voltage by electronically controlled switches, and during a bit trial the switches can be controlled such that a capacitor that is being trialled, or that will be altered for the next bit trial, is disconnected from the reference voltages prior to the completion of the bit trial so as to reduce a switching time to change a connection status of the capacitor.
[0028] According to a third aspect of the present invention there is provided a capacitive digital to analog converter wherein a controller controls switches connecting individual capacitors to either a first voltage or a second voltage and wherein the controller can prepare to change a capacitor's connection between the first and second voltage by placing the switches for the capacitor in a high impedance state until a trigger event occurs.
[0029] According to a fourth aspect of the present invention there is provided a control circuit for a transistor, comprising a latch having an output connected to a control terminal of the transistor, and a switch on circuit connected to the output of the latch such that activation of the switch on circuit causes the transistor to switch on and also forces the latch to transition to an on state so as to hold the transistor on after the switch on circuit has switched off.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The present invention will further be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0031] FIG. 1 schematically illustrates the switched capacitor successive approximation converter;
[0032] FIG. 2 shows a prior art non-overlap generator for ensuring that switching transistors are not simultaneously conducting during a transition of a capacitor status;
[0033] FIG. 3 schematically illustrates transistor switch control circuits in a successive approximation converter constituting an embodiment of the present invention;
[0034] FIG. 4 is a circuit diagram of a transistor control and latch apparatus constituting an embodiment of the present invention;
[0035] FIG. 5 is a flow diagram showing the sequence of operations performed during a bit trial in a prior art converter;
[0036] FIG. 6 shows the equivalent sequence of operations in a successive approximation converter constituting an embodiment of the present invention;
[0037] FIG. 7 schematically illustrates how the transistors that are selected to be placed in a high impedance state during comparator regeneration vary during the conversion;
[0038] FIG. 8 shows an alternative arrangement for part of the circuit shown in FIG. 7 ;
[0039] FIG. 9 shows an alternative latch circuit.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] FIG. 3 schematically illustrates a drive arrangement for one pair of high side and low side switches which are used to connect a capacitor of a capacitor array to either first or second reference voltages, Vref+ and Vref− within a successive approximation converter. For simplicity, the same capacitor and switching transistors are considered in FIG. 3 as were illustrated in FIG. 2 .
[0041] The sequence of transistor switching performed as part of the successive approximation conversion process is controlled by a state machine 50 which selects which capacitors are to be trialled, and hence which transistors are to be selected for potential switching within any given bit trial. Each transistor has an associated transistor control circuit of which circuit 52 is arranged to control transistor 22 and the circuit 54 is arranged to control transistor 24 . The circuits 52 and 54 may receive their control signals solely from the state machine 50 or, as shown in FIG. 4 , they may incorporate some of the memory functionality required to select a bit during the successive approximation conversion bit trials and to maintain that bit as being set if the result of the comparison decides that a bit is to be kept. However it can be seen that the circuits 52 and 54 are separate and hence each has the ability to switch its associated transistor off irrespective of whether the other control circuit has placed its transistor in a conducting or non-conducting state. Thus the control signals to the transistors are no longer inverted versions of one another, subject to the very brief and transitory modification of the signals made as a result of the operation of the non-overlap generator.
[0042] FIG. 4 is a circuit diagram of a further embodiment of the present invention. The arrangement shown in FIG. 4 has a first transistor controller, generally labelled 52 so as to maintain conformity with FIG. 3 , driving the high side transistor 22 and a further transistor controller 54 driving a low side transistor 24 . Each controller 52 and 54 comprises a latch of which only the latch generally designated 60 within the controller 52 will be described in detail. The corresponding latch 62 in the second controller 54 is identical. The latch 60 comprises four transistors 70 , 72 , 74 and 76 of which transistor 70 and 74 are P type transistors and transistors 72 and 76 are N type transistors. Sources of transistors 70 and 74 are connected to the positive supply rail VDD whereas sources of the N type transistors 72 and 76 are connected to the negative supply rail VSS. A drain of transistor 70 is connected to a drain of transistor 72 and also to a first latch control node 80 . A drain of transistor 74 is connected to a drain of transistor 76 and also to a second latch control node 82 . Gates of the transistors 70 and 72 are connected to the second latch control node 82 whereas gates of the transistors 74 and 76 are connected to the first latch control node 80 . The control nodes 80 and 82 represent nodes indicative of the state of the latch and can be used as both input and output nodes. Each of the latches 60 and 62 has circuits 90 and 92 connected to their first control nodes 80 . Each of the circuits 90 and 92 comprises transistors arranged to pull the node 80 down to ground, or VSS, as appropriate. Thus the circuit 90 mainly comprises a further transistor 93 which can be switched into a conducting state during a sample period so as to pull the node 80 low. The circuit 92 comprises transistors 100 and 102 which are selected by a Johnson or ring counter within the state machine 50 so as to identify those capacitors within a given bit trial of a successive approximation conversion which could be subject to change in either this trial or which are to be set to a trial state in the succeeding trial. The transistors 100 and 102 are in parallel such that they act as an OR gate and then their output is effectively ANDed with a strobe pulse control signal by a further transistor 104 . Thus, if either transistors 100 or 102 are in a conducting state because they have been turned on by the ring counter within the state machine, then upon assertion of a strobe pulse signal the control node 80 will be taken low. In an alternative embodiment one of the transistors can be omitted.
[0043] If the control node 80 is pulled down by either circuit 90 or 92 then the N type transistor 76 becomes non-conducting and the P type transistor 74 becomes conducting. As a consequence the node 82 goes high. This in turn causes the P type transistor 70 to become non-conducting and the N type transistor 72 to become conducting. This sets the latch in a stable condition where node 80 will remain low even when the circuits 90 or 92 stop pulling it low.
[0044] In the embodiment shown in FIG. 4 transistor 22 is a P type transistor such that node 82 going high causes transistor 22 to become non-conducting. The circuits 90 and 92 are repeated for each of the latches 60 and 62 and operated in unison such that nodes 80 and 80 ′ where ′ designates the second latch 62 on both latches 60 and 62 are driven low simultaneously and consequently the output nodes 82 and 82 ′ on each latch go (or remain) high simultaneously. As transistor 24 is an N type transistor an inverter 110 is provided so as to switch the transistor 24 off. Alternatively the circuits 90 and 92 associated with the second latch 62 could be arranged to pull the node 80 up rather than down. Thus activation of the sample signal or the strobe pulse signal when either transistor 100 or 102 is conducting causes the latches 60 and 62 to place their respective transistors 22 and 24 into a non-conducting state. The strobe pulse signal “strb-pulse” is also used to instruct the comparator 12 of FIG. 1 to start making comparison. Therefore it can be seen that the transistors 22 and 24 are switched into a high impedance state immediately the comparator starts regenerating, that is entering its decision process. Prior to the start of regeneration one of the transistors would have been conducting whereas the other would not be conducting.
[0045] The output node 82 is connected to two further circuits 110 and 112 which each comprise field effect transistors in series extending between the output node 82 and VSS so as to be able to pull the output node 82 down, thereby switching transistor 22 on irrespective of the state of the latch 60 . Circuit 110 comprises a transistor 120 which is driven by the ring counter in the state machine so as to enable the node 82 to be pulled low thus turning transistor 22 on so as to set the bit for trialling. Transistor 120 is in series with a further transistor 122 driven with an inverted version of the strb-pulse signal.
[0046] The circuit 112 comprises a field effect transistor 130 which is also responsive to the output of the state machine so as to select the transistor 22 for potentially being changed when it is participating in the current (Nth) bit trial and a further transistor 132 in series with it which is responsive to an output of the comparator 12 and which is switched on if the comparator decides that the current bit in the bit trail should be kept. Therefore if the latch 60 is in a state where node 82 is high such that transistor 22 is non-conducting, but the capacitor associated with the transistor 22 is the capacitor which is being tested in the current bit trial then the state machine will select transistor 130 so as to be conducting. The comparator's outputs COMP and COMP are both held low whilst the comparator is making a decision in response to the strobe signal. However once a decision period has elapsed then one or other of the outputs can go high at the end of a decision period. Assuming that the comparator selects the current bit to be kept then the input to transistor 132 goes high such that both transistors 130 and 132 become conducting thereby enabling the voltage at the latch node 82 to be pulled down. This immediately causes transistor 22 to become conducting and also causes the latch to initiate a state transition such that it will become stable and hold node 82 low.
[0047] The circuit at the output of latch 62 is similar in that a circuit 112 ′ comprising transistors 130 ′ and 132 ′ with transistor 130 ′ being switched on at the same time as transistor 130 .
[0048] However transistor 132 ′ is connected to the complimentary latch output COMP and hence remains low after the comparator has decided to keep the current bit on trial.
[0049] If, however, the comparator had decided to reject the current bit on trial then COMP would have gone high such that transistors 130 ′ and 132 ′ would have dragged node 82 ′ of the latch 62 low thereby switching transistor 24 on whereas transistor 132 would remain non-conducting thereby leaving node 82 of the latch 60 high.
[0050] It can thus be seen that, in each bit trial, the transistors which are associated with the capacitor currently under trial or with the capacitor which will be set for the subsequent trial are both placed into a high impedance state immediately the comparator is instructed via the strobe pulse to commence regeneration. It can also be seen that immediately the comparator makes a decision the transistors are switched to an appropriate state by opening a current path via transistors 120 , 130 and 132 as appropriate that acts to turn them on and that this path exists between an output node 82 of the latch and a ground or supply rail. Thus propagation delays associated with changing the state of the latch are avoided.
[0051] The second latch 62 is also associated with a further pull down transistor 140 which is responsive to a “DACON” pulse in order to reset the capacitor array to an initial state at the start of each conversion cycle.
[0052] FIGS. 5 and 6 compare the operation of a analog to digital converter operating in accordance with the prior art and an analog to digital converter operating in accordance with the present invention. In the prior art arrangement shown in FIG. 5 , during each bit trial within a complete conversion the bit being trialled is set. After a settling time a strobe signal is sent to the comparator in order to enable the comparator to perform its test. Thus, as shown in FIG. 5 , the signal to strobe the comparator is issued at step 200 . From then a time out period is normally allowed to elapse to allow the comparator to make its decision, thus, from step 200 control passes from step 202 where the time out period is counted. From there control passes to step 204 where the or each output of the comparator is examined in order to determine whether the bit which has just been trialled is to be kept or discarded. From step 204 the comparator output is used to set the transistor control latches at step 206 which are used to remember the decision made at each bit trail. From step 206 control is passed to step 208 where the output of the latch, which has been subject to latch propagation delay, is passed to the non-overlap circuit shown in FIG. 2 in order to generate the control signals for the transistors 22 and 24 and then cause them to switch. It can therefore be seen that in the prior art no attempt is made to switch the transistor states of the high side and low side transistors involved in a bit trial and which could be subject to change until such time as the comparator has made its decision. The decision from the comparator is then subject to gate propagation delays in both the latch used to record the decision of the comparator and then the non-overlap generator circuit.
[0053] If this is compared with the present invention, as set out in FIG. 6 , we can see that control commences at step 199 and then moves up to step 200 where following set up of the bit trial the comparator is instructed to start its comparison. Simultaneously a strobe pulse signal is also supplied to the input node 80 and 80 ′ of the latches 60 and 62 causing each of them to switch their respective transistor 22 and 24 (being transistors associated with a capacitor whose switching state will be changed in the current bit trial or which will be set for the succeeding bit trial) into a high impedance state. Thus, effectively, the switching stage formed by transistor 22 and 24 is placed into a tri-state, i.e. high impedance, condition. Control then passes to step 222 where the result of the comparator is awaited. After the comparator decision period has finished control passes to step 224 where the result of the comparator's decision is applied to the control inputs of the high side and low side transistors 22 and 24 . Simultaneously the result of the comparator's decision is also applied to the output nodes 82 and 82 ′ of the latches 60 and 62 so as to cause them to transition, if necessary, to the state appropriate to the decision of the comparator. Crucially, the signals for controlling the high side transistor 22 and the low side transistor 24 do not become delayed by propagation delays in proceeding through the latches or through a non-overlap generating circuit. As a result the time to propagate the result of the comparator through the various gates so as to effect the desired changes at the high side and low side switches is much reduced compared to the prior art arrangement and consequently there is less digital dead time within the successive approximation conversion process. As a result the total conversion time required to complete a successive approximation conversion is reduced and hence the converter throughput is increased.
[0054] It is thus possible to provide an improved analog to digital converter.
[0055] It should be noted that because the switched capacitor array effectively forms a digital to analog converter within the analog to digital converter the present invention can also be used to increase the throughput of a digital to analog converter by enabling the transistors thereof to be switched into non-conducting states just prior to a transition from one digital word to the next. This again would avoid the risk of crow barring occurring as a result of both the high side and low side transistors inadvertently conducting current at the same time.
[0056] As noted hereinbefore with respect to the discussion of FIG. 4 transistors 100 and 102 , and similarly 120 and 130 are responsive to a ring counter within a state machine in order to cause the latches to place their respective transistors into a high impedance mode during bit trials in which the capacitor may be changed or where it will be set for the following bit trial. This can be considered in more detail with respect to FIG. 7 . Consider the bits within an 8 bit converter (8 bits are chosen for simplicity but in reality the converter is likely to have 14 or 16 bits if not more). Suppose bit 1 represents the most significant bit and bit 8 represents the least significant bit. At the start of the conversion process the sample signal is asserted in order to cause the high side and low side transistors of each and every single capacitor to be placed into a high impedance state. Then a sample switch (not shown) can be opened in order to allow a charge to be sampled onto the capacitor array. The sample signal (provided to transistor 93 ) is then released, but the high side and low side transistors will remain non-conducting because of the operation of the latches 60 and 62 . Transistor 120 is then selected to be conducting for the most significant bit so as to place a “1” on the most significant bit whilst the remaining bits in the DAC array are zero.
[0057] Where, as shown in FIG. 1 , a differential analog to digital converter is used then the initial word “10000000” is placed on the P array and the complimentary word 01111111 is placed on the N array. The strobe signal is then asserted and simultaneously the state machine increments the ring counter therein so as to select the second bit. As a consequence the high side and low side transistors associated with the most significant bit and the next most significant bit, bit 2 are placed into a high impedance state whilst the comparator is regenerating. Once the comparator has reached the end of its decision, its output is provided to transistors 132 and 132 ′ whilst the signal strb-pulse is de-asserted to avoid contention across the latch so as to set the most significant bit to be either kept or discarded, as appropriate. Additionally, whilst the comparator is in its decision period the bit for the second bit is asserted. Following a wait period of sufficient duration to enable settling to occur within the capacitor array the strobe pulse is asserted causing the comparator to consider the result of the second bit trial, and also placing the high and low side transistors for the current bit trial, bit 2 and the next bit trial, bit 3 into a high impedance state. Once the comparator has made its decision the transistors 22 and 24 for the second capacitor are set depending upon the output of the comparator and substantially simultaneously the capacitor for the third bit is set in preparation for the third bit trial. The process then repeats as indicated in FIG. 7 where the “*” represents the transistors associated with the binary weighted capacitors of the capacitor array which are based into a high impedance state pending the result of the current bit trial.
[0058] Because the transistors associated with the nodes 80 and 82 of the latch 60 pull these nodes down, then VDD does not have to be at the same voltage as the supply rail used for logic gates driving the latch 60 . Thus the latch can also be used as a level shifting circuit.
[0059] The arrangement shown in FIG. 4 is suitable for all the capacitors in the converter, although the arrangement can usefully be modified for the MSB by supplying the “DAC_ON” pulse to transistor 120 and omitting transistor 140 .
[0060] The stage formed by transistors 130 and 132 may be modified such that, for example, the source of transistor 130 is connected directly to the output of the comparator 12 whose outputs are inverted and transistor 132 is omitted so that the drain of transistor 130 connects to node 82 . A similar arrangement can be implemented in relation to node 82 ′ for the low side transistors, and this alternative arrangement is shown in FIG. 8 .
[0061] In the example given the transistors 120 and 130 in combination with 132 act to cause the node 82 to be pulled down. It can be seen that this functionality could also be achieved by a suitable modification of the control signal applied to transistor 76 .
[0062] FIG. 9 shows an alternative embodiment of the latch 60 . Like parts have been designated with like references numerals. The latch includes cascode devices 73 and 75 . A node 82 b is used to control transistor 22 while circuits 110 and 112 couple to the input node 82 a. The cascode devices limit the voltage seen by the circuits 90 , 92 , 110 and 112 allowing lower geometry and thus faster devices to be used in these circuits. The gates of the cascode devices can be driven directly by the lower supply voltage or can be biased a little higher which has the effect of increasing the speed of the latch.
[0063] In the example described, strb-pulse goes high at substantially the same time as the counter controlling the bit trials is incremented. In an alternative embodiment which requires a slightly modified arrangement of switches controlling nodes 80 and 82 , the negative edge of strb-pulse occurs at substantially the same time as the counter increments and the comparator result is fed to transistor 132 and 132 ′ just after the counter increments.
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A successive approximation analog to digital converter comprising a plurality of capacitors which during a successive approximation conversion are selectively connectable to a first reference or a second reference under the command of a controller, wherein during a conversion step where the connections of a given capacitor may be varied the switches to the given capacitor are both placed in a high impedance state during a decision period of a comparator.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to medical probes. In particular, the invention relates to a system for positioning a medical probe.
[0003] 2. Description of Related Art
[0004] There are many medical procedures that require the insertion of a probe or needle along a specific path or to a specific location within the human body. The execution of these procedures often relies solely upon the vision and tactile sense of the practitioner For example, a hypodermic needle may be inserted into the jugular vein of a patient as a prelude to catheritization. Incorrect insertion of a hypodermic needle into the jugular may result in a punctured lung or other complications, thus, a post catheritization X-ray is frequently taken to verify the success of the procedure.
[0005] Realtime visual information (e.g., ultrasound imaging) regarding internal tissue structures is helpful in avoiding complications during medical procedures; however, realtime imaging techniques may make a procedure significantly more complex. Also, additional personnel or an increased amount of time may also be required.
[0006] Optical coherence tomography (OCT) is frequently used for realtime imaging and may be integrated with a number of instruments. Such integrated instruments typically require sterilization before reuse and thus are not well suited to high-volume procedures.
[0007] Thus, a need exists for a system and method for positioning a probe that does not require sterilization before reuse. There is also a need for a system and method for positioning a probe that is suitable for use in high-volume procedures.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides an adapter that couples one or more optical fibers to a hollow probe. The adapter contains a length of optical fiber that is longer than the adapter itself. The optical fiber may be extended into the hollow probe.
[0009] In one embodiment of the invention the length of optical fiber is fixed to an optical coupler at a proximal end of the adapter and is maintained in a curved configuration by features located in an internal cavity of the adapter.
[0010] In further embodiment, a conical needle adapter at the distal end of the adapter is configured to accept a hypodermic needle. The conical adapter may have a Luer taper.
[0011] In another embodiment, a pair of rollers are used to advance the length of optical fiber. The rollers may be composite with a hard core and soft surface, and may also be sealed with in the adapter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A shows a top perspective view of an optical probe adapter in accordance with an embodiment of the present invention.
[0013] FIG. 1B shows a top view of the optical probe adapter of FIG. 1A .
[0014] FIG. 1C shows a front view of the optical probe adapter of FIG. 1A .
[0015] FIG. 1D shows a front perspective exploded view of the optical probe adapter of FIG. 1A .
[0016] FIG. 1E shows a back perspective exploded view of the optical probe adapter of FIG. 1A .
[0017] FIG. 2A shows an optical probe adapter with an attached hypodermic needle in accordance with an embodiment of the present invention.
[0018] FIG. 2B shows an alignment of an optical fiber at the tip of an attached hypodermic needle in accordance with an embodiment of the present invention.
[0019] FIG. 3 shows a diagram of a probe positioning system in accordance with an embodiment of the present invention.
[0020] FIG. 4 shows a flow chart diagram for a method embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1A shows a top perspective view 100 of an embodiment of an optical probe adapter. The optical probe adapter 100 has a optical fiber coupler 105 at the proximal end and a probe a probe coupler 125 at the distal end. A fiber receiver 110 and cover 115 serve as a handle and also as a housing for an optical fiber, or optical fiber bundle.
[0022] FIG. 1B shows a top view 101 of the optical probe adapter of FIG. 1A . A knob 120 provides a means of advancing or retracting the fiber housed within the optical fiber adapter. The probe coupler 125 has a conical taper 130 that accepts a probe (e.g., hypodermic needle). The conical taper 130 may be a Luer taper. A Luer lock or other interlocking connector may be used in conjunction with the probe coupler 125 . However, since the optical probe adapter is only temporarily coupled to the probe, ease of removal is desired so that the probe position is not perturbed during removal.
[0023] FIG. 1C shows a front view 102 of the optical probe adapter of FIG. 1A . The optical fiber coupler 105 has two optical fiber terminals 140 . In alternative embodiments, the optical fiber coupler 105 may have a greater or lesser number of optical fiber terminals.
[0024] The optical fiber coupler 105 has two detents 135 that provide a means for locking the coupler into a mated connector. There are many types of optical fiber couplers that may be used. However, most conventional optical fiber adapters are designed for many make-and-break connections. For disposable or single use optical probe adapters, it is preferable that the optical fiber coupler 105 be kept mechanically simple. Any complexity associated with obtaining a reliable connection should reside in the non-disposable component with which the optical coupler 105 may be mated.
[0025] FIG. 1D shows a front perspective exploded view 103 of the optical probe adapter of FIG. 1A . An optical fiber bundle 140 is connected to the optical fiber coupler 105 . In other embodiments, a single fiber may be substituted for the optical fiber bundle 140 . The optical fiber bundle 140 resides in a cavity 145 in the receiver 110 . The cavity 145 has a series of radiused edges 150 that allow the optical fiber bundle to be compactly housed.
[0026] In general, housing of the optical fiber bundle 140 requires that at least a portion of the optical fiber bundle 140 be stored in a curved configuration. For efficient packing at least one portion will typically have an arc of at least 90 degrees and may have a variable radius. The length of the optical bundle that is ultimately advanced through the probe coupler 125 is derived from the straightening of a curved portion. Although spirals or coils may also be used as housing configurations for the optical fiber bundle 140 , the serpentine configuration shown in FIG. 1D has the advantage of avoiding twisting of the fiber during assembly and use. An arc length of 180 degrees is used in the serpentine configuration.
[0027] The optical fiber 140 is advanced and retracted by a drive roller 160 acting against a pinch roller 170 . The driver roller 160 has a soft outer covering 164 that reduces localized stress in the area of contact with the optical fiber bundle 140 . Similarly, the pinch roller 170 has a soft outer covering 172 . The conformation of the soft outer coverings 164 and 172 with the optical fiber bundle 140 increases the contact area and the overall friction that provides the force for advancing and retracting the optical fiber bundle 140 . In alternative embodiments other fiber advancing mechanisms may be used.
[0028] An optional gasket 175 provides a seal between the face of the drive roller 160 and the cover 115 . Alternatively, a seal may be established between the drive roller axle portion 165 a and the surface of the drive roller axle bore 180 . A keyway 162 in the driver roller bearing portion accepts a key 168 ( FIG. 1E ) that transmits torque applied to the knob 120 .
[0029] The receiver 110 includes a drive roller axle bearing cavity 166 a and a pinch roller axle bearing cavity 176 a . The drive roller axle bearing cavity 166 a and a pinch roller axle bearing cavity 176 a are blind cavities; however, through holes may be used in other embodiments.
[0030] An optional storage cavity 155 provides a volume adjacent to drive roller 160 and pinch roller 170 . Upon retraction, the optical fiber bundle 140 will not easily resume its initial configuration and the storage cavity provides a local storage site. Although retraction may not be required to complete a particular medical procedure, it may be desirable to retract the optical fiber 140 for easier handling.
[0031] FIG. 1E shows a back perspective exploded view of the optical probe adapter of FIG. 1A . The cover 115 has an optional storage cavity 155 similar to that associated with the receiver 110 . The cover 115 includes a drive roller axle bearing cavity 166 b and a pinch roller axle bearing cavity 176 b.
[0032] An axle 174 supports pinch roller 170 . Since it is desirable to minimize resistance to rotation, it is preferable that axle 174 not be fixed to pinch roller 170 . In contrast, drive roller axle portions 165 a and 165 b are integrated with drive roller 160 . A minimum resistance to rotation is desirable in the drive roller 160 so that it can hold the optical fiber 140 in a fixed position after alignment.
[0033] A key 168 transmits the torque applied to knob 120 to the pinch roller 160 . The knob 120 , key 168 , and drive roller 160 may be fabricated as an integrated unit or as components that are separable in whole or in part. A removable knob 120 and key 168 are desirable when they would interfere with positioning of an attached probe after extension of the optical fiber bundle 140 .
[0034] FIG. 2A shows a perspective view 200 of an embodiment of an optical probe adapter 205 with an attached hypodermic needle 210 . In alternative embodiments a cylindrical cross-section may be substituted for the rectangular cross-section. Although the rectangular cross-section minimizes the size of the optical probe adapter, the radial symmetry of a cylindrical cross-section may provide greater ease of handling.
[0035] Although the hypodermic needle 210 is shown as shorter than the optical probe adapter 205 , the hypodermic needle 210 may be longer than the optical probe adapter 205 . For example, the optical probe adapter may have a length of about 10 centimeters and the hypodermic needle may have a length of 10 to 15 centimeters. FIG. 2B shows an alignment of an optical fiber 240 at the tip of the attached hypodermic needle 210 of FIG. 2A .
[0036] FIG. 3 shows a diagram 300 of an embodiment of a probe positioning system. An optical coherence tomography (OCT) instrument 305 a provides illumination and receives a reflected light signal through an optic fiber 310 that has a connector 315 . The optical coherence tomography (OCT) instrument 305 a may be a battery powered portable instrument. The connector 315 mates to the optical fiber adapter 320 via the fiber optic coupler 320 a . The housing 320 b contains a length of optical fiber that may be advanced to align with the distal tip 330 of a probe 325 .
[0037] FIG. 4 shows a flow chart diagram 400 for an embodiment of a method for inserting a probe using a system similar to that shown in FIG. 3 . At step 405 an optical coherence tomography (OCT) instrument is attached to an optical fiber probe adapter. This connection will typically be made using a cable. A probe is also attached to the optical fiber probe adapter. The probe may be connected by a simple press fit or it may be connected by a mechanical interlock such as a thread, bayonet, or twist lock.
[0038] At step 410 the optical fiber is advanced from the optical fiber probe adapter and aligned within the probe. Generally, the optical fiber will be advanced to the vicinity of the distal tip of the probe. However, if a portion of the probe is transparent, the optical fiber may reside entirely within the probe.
[0039] At step 415 the probe is inserted to the desired location using the visual image provided by the OCT instrument. Probes for procedures such as catheterization and nerve blocks may be inserted with the optical fiber probe adapter.
[0040] At step 420 the probe is disconnected from the optical fiber probe adapter. The probe may be disconnected without changing the alignment of the optical fiber within the probe, or the optical fiber may be realigned prior to being disconnected.
[0041] At step 425 the optical fiber is withdrawn from the probe. At step 430 the optical fiber is retracted into the probe. Retraction of the optical fiber into the probe is an optional step and may be performed prior to withdrawal of the optical fiber from the probe. At step 435 a therapeutic device such as a syringe or a catheter is coupled to the probe.
[0042] While the invention has been described in detail with reference to preferred embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention.
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An adapter couples a length of optical fiber to a hollow probe and to an optical coherence tomography instrument. The length of optical fiber may be greater than the than the length of the adapter itself. The optical fiber is fixed to an optical coupler at a proximal end of the adapter and may be maintained in a curved configuration by features located in an internal cavity of the adapter. An optical fiber advance mechanism be used to advance and/or retract the length of optical fiber to align it within the hollow probe.
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REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 62/117,193, filed Feb. 17, 2015, with title BOTTLE CARRIER, the entire disclosure of which is hereby incorporated by reference.
FIELD
The present invention relates to carriers for carrying bottles. More specifically, the present invention relates to structures and assembly of cartons for carrying bottles, the cartons being made of paper board and the like and having a handle for carrying the same.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a flat that may be formed into a bottle carrier according to a first embodiment.
FIG. 2 is a plan view of a flat that may be formed into a carrier according to a second embodiment.
FIG. 3 is a plan view of a flat that may be formed into a carrier according to a third embodiment.
FIG. 4 is a plan view of a flat that may be formed into a carrier according to a fourth embodiment.
FIG. 5 is an expanded plan view of a detail of the flat of FIG. 4 .
FIG. 6 is a flowchart depicting a method of forming a carrier from a flat.
DESCRIPTION
For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one skilled in the art to which the invention relates.
Generally, one form of the present apparatus is a carrier that holds two bottles, such as those used for craft beer. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles. This embodiment, illustrated in FIG. 1 , is a flat form 100 that is die-cut from beverage board (such as that known as “20 pt board” available from most paper merchants), though other materials may also be used as will occur to those skilled in the art. FIG. 1 shows one side (e.g., a front) of flat 100 , and it will be understood that the opposing side (e.g., the corresponding rear) is essentially a mirror image of the view shown. As discussed in further detail below, form 100 may be assembled or formed into an assembled configuration to form the carrier.
As shown, form 100 includes front panel 110 , back panel 120 , side panels 130 , 135 , bottom panels 140 , 145 , and tab 170 that collectively define a container portion 148 . In the embodiment shown, panels 110 , 120 , 130 , 135 define a top edge extending along a line 149 . Form 100 further includes risers 150 and handle flaps 160 from which carrying holes 165 are fully or partially cut out, extending substantially from line 149 away from top edge, to define a handle portion 158 . In alternative embodiments, portions of handle portion may extend below line 149 . For example, segment 180 may extend below line 149 , thus causing portions of handle flaps 160 to lie below line 149 . It will be understood that in some embodiments, after form 100 is assembled into the assembled configuration, some portions of handle portion 158 , such as portions of handle flaps 160 , may lie below line 149 , due to manufacturing or assembly-related anomalies or inconsistencies. In the embodiment shown, holes 165 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration.
Container portion 148 includes a plurality of fold lines 10 , 12 , 14 , 16 , 18 , 20 , 22 , 24 along which portions of form 100 may be folded in order to form the assembled configuration of form 100 . More particularly, fold line 10 extends between panels 135 , 110 , while fold line 12 extends between panels 110 , 130 . Fold line 14 extends between panels 130 , 120 , and fold line 16 extends between panel 160 and flap 170 . Fold line 18 extends between panels 120 and the adjacent bottom panel 140 , while fold line 20 extends between panel 130 and the adjacent bottom panel 145 . Fold line 22 extends between panel 110 the adjacent bottom panel 140 , and fold line 24 extends between panel 135 and the adjacent bottom panel 145 . Fold lines 190 extend between handle flap 160 and riser 150 . In the embodiment shown, fold lines 10 , 12 , 14 , 16 , 190 are parallel to one another and perpendicular to fold lines 18 , 20 , 22 , 24 . As shown, fold lines 18 , 20 , 22 , 24 are co-linear when form 100 is unassembled. In the embodiment shown, fold lines 10 , 12 , 14 , 16 , 18 , 20 , 22 , and 24 represent imaginary lines along which form 100 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 10 , 12 , 14 , 16 , 18 , 20 , 22 , 24 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 100 . Edges and/or fold lines shown herein as parallel or perpendicular might be substantially (but not precisely) parallel or perpendicular, or may have other relative orientations as will occur to those skilled in the art.
As form 100 is formed by a die cutting process, for example, handle edge segments 180 are also cut, separating each handle flap 160 from its respective neighboring panel 110 or 120 . Moreover, in the embodiment shown, fold lines 190 are scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 100 . However, in other embodiments, one or both of fold lines 190 may not include such features such that fold lines 190 represent imaginary lines along which flaps 160 may be folded. Moreover, in other embodiments, segments 180 and creases 190 may be treated before or after form 100 is created through a die cutting process.
After form 100 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 135 , 110 , 130 , and 120 are folded at approximately 90-degree angles to form a rectangular shape, in cross section, such as in cross section along line 149 (e.g., block 302 of FIG. 6 ). Tab 170 is likewise folded to be inside side panel 135 and attached with any suitable glue or other adhesive or bonding agent or non-adhesive technique such as a tab-and-slot configuration (all generically “glued” or “attached” herein) as will occur to those skilled in the art (e.g., block 304 of FIG. 6 ). More particularly, panel 135 is folded along fold line 10 , panel 110 is folded along fold line 12 , and panel 120 is folded along fold line 14 , such that panels 110 , 120 end up being parallel to one another and each end up perpendicular to panels 130 , 135 . As mentioned above, tab 170 is folded inside panel 135 and bonded thereto, such that a bonding is provided between tab 170 and panel 135 along a third plane that is substantially perpendicular to line 149 and parallel to a second plane (block 306 of FIG. 6 ). More specifically, in the illustrated embodiment, tab 170 is bonded to the back of panel 135 . Thus, panels 110 , 120 , 130 , 135 will remain in the substantially rectangular cross-sectional shape, due at least in part to the bonding between tab 170 and panel 135 . As shown, panels 110 , 120 define a length of the rectangular cross-sectional shape, and panels 130 , 135 define a width of the rectangular cross-sectional shape. In the present embodiment, the length as defined by panels 110 , 120 is longer than the width defined by panels 130 , 135 . However, other suitable relative dimensions of panels 110 , 120 , 130 , 135 and other portions of flat 100 that may be provided in order to accommodate a particular amount and/or size of bottles or articles will be apparent to persons skilled in the art in view of the teachings herein.
In order to form the bottom portion of the expanded carrier configuration of form 100 , bottom panels 140 and 145 are folded up along their respective fold lines 18 , 20 , 22 , 24 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 140 , 145 lie substantially perpendicularly to each of the panels 110 , 120 , 130 , 135 . Thus, in the embodiment shown, panels 110 , 120 , 130 , 135 , 140 , 145 in the assembled configuration define a single compartment extending substantially from bottom panels 140 , 145 to line 149 (e.g., block 302 of FIG. 6 ). More particularly, panels 110 , 120 , 130 , 135 define sidewalls of a compartment, while bottom panels 140 , 145 collectively define a bottom portion or bottom wall of a compartment.
Handle flaps 160 are folded at fold lines 190 so that they extend perpendicular to risers 150 and parallel to side panels 130 and 135 (blocks 308 , 310 of FIG. 6 ). The rear portions of each of handle flaps 160 are glued together such that each of the holes 165 is aligned with the other to form a single opening in handle portion 158 , and such that flaps 160 lie substantially along a second plane in order to form a unitary handle of handle portion 158 (blocks 312 , 314 of FIG. 6 ). In the embodiment shown, the second plane essentially bisects container portion 148 such that the handle formed by handle portion 158 lies at the midpoint between panels 130 , 135 . Thus, in the embodiment shown, handle portion 158 essentially defines two cells above line 149 that are each suitable for holding a bottle. Accordingly, while carton portion 148 defines a single compartment as described above, handle portion 158 allows for an effective separation of bottles or other articles that may be placed in the compartment of carton portion 148 .
In some implementations, before or after form 100 is cut out, form 100 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 100 . In some of these implementations, the text and/or graphics are customized by a third party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities and/or digital printing technology. Because of the configuration of form 100 as described herein, text and graphics need only be applied to one side of form 100 in its flattened configuration in order to display such text and/or graphics on the surfaces of form 100 that are on the outside when form 100 is in its expanded, carrier configuration.
FIG. 2 shows another embodiment of a form 200 that may be constructed or formed into an assembled configuration to make a carrier configured to hold four bottles. However, it will be understood that the carrier may be configured to hold any suitable number of bottles and/or size of bottles or other articles as will occur to those having ordinary skill in the art in view this disclosure. This embodiment, illustrated in FIG. 2 , is also a form 200 that is die-cut from beverage board, though other materials may also be used as will occur to those skilled in the art. Form 200 is similar to form 100 , except for the differences below. Moreover, while FIG. 2 shows one side (e.g., a front) of flat 200 , it will be understood that the opposing (e.g., rear) side is essentially a mirror image of the view shown in FIG. 2 .
Form 200 includes front panel 210 , back panel 220 , side panels 230 , 235 , bottom panels 240 , 245 , and tab 270 that collectively define a container portion 248 . In the embodiment shown, panels 210 , 220 , 230 , 235 define a top edge extending along a line 249 . Form 200 also includes risers 250 a , 250 b and handle flaps 260 a , 260 b extending substantially from line 249 away from top edge, that define a handle portion 258 . As shown, handle flap 260 a and riser 250 a extend from panel 230 such that a portion of flap 260 a is outboard of panel 230 and flap 270 . Handle flap 260 b extends from panels 235 , 210 , and riser 250 b extends from panel 235 .
As form 200 goes through the die-cutting process, handle edge segments 280 a , 280 b are also cut, separating handle flap 260 a from panel 230 , and separating handle flap 260 b from panels 235 , 210 . In the embodiment shown, fold lines 290 are scored, perforated, or otherwise treated or configured to facilitate later handling or assembly of the form 200 during the die cutting process. However, in other embodiments, one or both of fold lines 290 do not include such features, so fold lines 290 represent imaginary lines along which flaps 260 a , 260 b may be folded relative to risers 250 a , 250 b . Moreover, in other embodiments, segments 280 a , 280 b and fold lines 290 may be treated before or after form 200 is created through a die cutting process. In the embodiment shown, handle flaps 260 a , 260 b each include carrying holes 265 that are cut out from handle flaps 260 a , 260 b . As shown in the present embodiment, holes 265 are sized and configured to receive at least one finger of a person carrying the carrier in the assembled configuration. In the embodiment illustrated in FIG. 2 , holes 265 include an obround shape, but in other embodiments may include any other suitable shape as will occur to persons skilled in the art in view of the teachings herein.
In alternative embodiments, portions of handle portion 258 may extend below line 249 . For example, segments 280 a , 280 b may extend below line 249 , thus causing portions of handle flaps 260 a , 260 b to lie below line 249 . It will be understood that in some embodiments, after form 200 is formed into the assembled configuration, some portions of handle portion 258 , such as portions of handle flaps 260 a , 260 b , may lie below line 249 , due to manufacturing or assembly related anomalies or inconsistencies.
Container portion 248 comprises a plurality of fold lines 26 , 28 , 30 , 32 , 34 , 36 , 38 , 40 along which portions of form 200 may be folded in order to form the assembled configuration of form 200 . As shown, fold line 26 extends between panels 220 , 235 , while fold line 28 extends between panels 235 , 210 . Fold line 30 extends between panels 210 , 230 , and fold line 32 extends between panel 230 and flap 270 . Fold line 32 extends between panel 230 and the adjacent bottom panel 240 , while fold line 36 extends between panel 210 and the adjacent bottom panel 245 . Fold line 38 extends between panel 235 and the adjacent bottom panel 240 , and fold line 40 extends between panel 220 and the adjacent bottom panel 245 . Fold lines 290 extend between handle flap 260 a , 260 b and riser 250 a , 250 b . In the embodiment shown, fold lines 26 , 28 , 30 , 32 , 190 are parallel to one another and perpendicular to fold lines 34 , 36 , 38 , 40 . As shown, fold lines 34 , 36 , 38 , 40 are collinear when form 200 is unassembled. In the embodiment shown, fold lines 26 , 28 , 30 , 32 , 34 , 36 , 38 , 40 represent imaginary lines along which form 200 may be folded to form the carrier. However, in some embodiments, any or all of fold lines 26 , 28 , 30 , 32 , 34 , 36 , 38 , 40 may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 200 .
After form 200 is cut, it is passed through forming equipment as is known by those skilled in the art. In this case, panels 230 , 210 , 235 , and 220 are folded at approximately 90-degree angles with each other to form a rectangle, in cross section, such as in cross section along line 249 (e.g., block 302 of FIG. 6 ). Tab 270 is likewise folded to be inside side panel 220 such that it is glued to the back of panel 220 (e.g., block 304 of FIG. 6 ). Accordingly, a bonding or non-bonding attachment (as will occur to those skilled in the art) is provided between tab 270 and panel 220 along a third plane that is substantially perpendicular to line 249 and parallel to a second plane (block 306 of FIG. 6 ).
In order to form the bottom portion of the expanded carrier configuration of form 100 , bottom panels 240 and 245 are folded up along their respective fold lines 34 , 36 , 38 , 40 and glued together. In the embodiment shown, in the assembled configuration, bottom panels 240 , 245 lie substantially perpendicularly to each of the panels 210 , 220 , 230 , 235 . Thus, in the embodiment shown, panels 210 , 220 , 230 , 235 , 240 , 245 in the assembled configuration define a single compartment extending substantially from bottom panels 240 , 245 to line 249 (block 302 of FIG. 6 ). More particularly, panels 210 , 220 , 230 , 235 define sidewalls of a compartment while bottom panels 240 , 245 collectively define a bottom portion or bottom wall of a compartment.
Handle flaps 260 a , 260 b are folded at fold lines 290 so that they extend perpendicular to risers 250 a , 250 b , and parallel to front and rear panels 210 , 220 (blocks 308 , 310 of FIG. 6 ). The rear portions of each of handle flaps 260 a , 260 b are glued together such that each of the holes 265 is aligned with the other to form a single opening in handle portion 258 , and such that flaps 260 a , 260 b lie substantially along a second plane in order to form a unitary handle of handle portion 258 (blocks 312 , 314 of FIG. 6 ). In the embodiment shown, the second plane essentially bisects container portion 248 such that handle of handle portion 258 lies at the midpoint between panels 210 , 220 . Thus, in the embodiment shown, handle portion 258 essentially defines two cells above line 249 that are each suitable for holding two bottles. Accordingly, while container portion 248 defines a single compartment as described above, handle portion 258 allows for an effective separation of bottles or other articles that may be placed in the compartment of container portion 248 .
In some implementations, before or after form 200 is cut out, form 200 may be passed through a digital printer that selectively applies text and/or graphics to one or both sides of the form 200 . In some of these implementations, the text and/or graphics are customized by a third-party, automatically computer-generated per a remote customer's request, programmatically and even uniquely generated, or otherwise designed to take advantage of short-run capabilities. Due to the configuration of form 200 as described herein, text and graphics need only be applied to one side of form 200 in its flattened configuration in order to display such text and/or graphics on the front or outer portion of form 200 in its expanded, carrier configuration.
FIG. 3 shows another embodiment of a form 300 that may be constructed or formed into an assembled configuration to make a carrier. Form 300 is substantially similar to form 100 , discussed above with reference to FIG. 1 , except for the differences below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form 300 includes exemplary alternative bottom panels 340 , 342 , 344 , 346 that are configured differently than bottom panels 140 , 145 . As shown, panels 340 , 344 include a substantially rectangular shape. Panels 342 , 346 include features that allow those panels to lock together as bottom panels 340 , 342 , 344 , and 346 are folded upwardly to form a bottom of carrier. As shown, panel 344 includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel 344 has substantially the same width as panel 110 and a height that substantially matches the width of panel 130 so that panel 344 substantially covers the bottom of the container portion of the carrier when it is assembled. Other suitable configurations (including relative size, shape, and other features) of bottom panels 340 , 342 , 344 , 346 will be apparent to persons skilled in the art in view of the teachings herein.
Form 300 includes an exemplary alternative handle portion 358 . Particularly, handle portion 358 includes an alternative segment (cut) 380 that includes a substantially straight, horizontal portion 380 a and a curved portion 380 b , as seen best in FIG. 5 . Thus, segment is cut along horizontal portion 380 a and curved portion 380 b . Including the curved portion 380 b in segment 380 may decrease the tendency of handle portion 358 to tear at the junction between the risers 150 and adjoining panels 110 , 120 , respectively. Form 300 also includes an alternative fold line 390 . Fold line 390 comprises an upper portion 390 a , middle portion 390 b , and lower portion 390 c . As shown, middle portion 390 b is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 300 , such as folding of the handle flaps 160 . As shown, upper and lower portions 390 a , 390 c represent imaginary lines along which form 100 may be folded to form the carrier. However, in other embodiments, upper and lower portions 390 a , 390 c may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 300 . In some embodiments, such a configuration may give additional strength to handle portion 358 . For example, such a configuration may decrease the tendency of handle portion 358 to tear at the junction between the risers 150 and adjoining panels 110 , 120 , respectively. Other suitable configurations of handle portion 358 will be apparent to persons skilled in the art in view of the teachings herein.
FIG. 4 shows another embodiment of a form 400 that may be constructed or formed into an assembled configuration to make a carrier. Form 400 is substantially similar to form 200 , except for the differences below. For that reason, substantially similar or identical structures are not labeled with reference numerals. As shown, form 400 includes exemplary alternative bottom panels 440 , 442 , 444 , 446 that are configured differently from bottom panels 240 , 245 . Panels 442 , 446 include features that allow those panels to lock together or be attached more securely to bottom panels 440 , 444 as bottom panels 440 , 442 , 444 , and 446 are folded upwardly to form a bottom of carrier. As shown, panel 444 includes dimensions that allow it to substantially cover the surface area of the bottom portion of carrier in the expanded configuration. For example, panel 444 has substantially the same width as panel 235 and a height that substantially matches the width of panel 210 . Other suitable configurations of bottom panels 440 , 442 , 444 , 446 will be apparent to persons skilled in the art in view of the teachings herein.
Form 400 includes an exemplary alternative handle portion 458 . Particularly, handle portion 458 includes an alternative segment 480 that includes a horizontal portion 480 a and a curved portion 480 b , as seen best in FIG. 5 . It will be understood that although segments 380 , 480 and fold lines 390 , 490 are different, respectively, the portions shown in the close-up view of FIG. 5 are substantially identical. Thus, FIG. 5 is used to demonstrate and show such structures of form 400 as well.
As shown, segment 480 is cut along horizontal portion 480 a and curved portion 480 b . Including the radius of curved portion in segment 480 may decrease the tendency of handle portion 458 to tear at the junction between the risers 250 a , 250 b and adjoining panels 230 and 210 , 235 , respectively. Form 400 also includes an alternative fold line 490 . Fold line 490 comprises an upper portion 490 a , middle portion 490 b , and lower portion 490 c . As shown, middle portion 490 b is scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 400 , such as folding of the handle flaps 260 a , 260 b . As shown, upper and lower portions 490 a , 490 c represent imaginary lines along which form 100 may be folded to form the carrier. However, in other embodiments, upper and lower portions 490 a , 490 c may be scored, perforated, or otherwise treated or configured in a manner that facilitates later handling or assembly of the form 400 . Such a configuration may provide for additional strength of handle portion 458 . For example, such a configuration may decrease the tendency of handle portion 458 to tear at the junction between the risers 150 and adjoining panels 110 , 120 , respectively. Other suitable configurations of handle portion 458 will be apparent to persons skilled in the art in view of the teachings herein.
All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A method of constructing a carrier for bottles (such as two or four craft beer bottles), wherein the layout fits through a digital printer, is disclosed. A flat of beverage board is printed upon (on one side or both, though all exterior surfaces are derived from one side of the board) with individualized and/or short-run graphics. The flat is die-cut and folded into a square or rectangle closed by a tab that is glued on the back of one of side panels, and bottom flaps are folded and glued into place. A riser extends up from each of a pair of opposite sides to support a handle flap, and the handle flaps are glued together across the top of the rectangle.
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[0001] The present application claims priority from PCT Patent Application No. PCT/EP2014/001689 filed on Aug. 17, 2015, which claims priority from German Priority Application No. 20 2014 007 564.6 filed on Sep. 22, 2014, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] It is noted that citation or identification of any document in this application is not an admission that such document is available as prior art to the present invention.
[0003] The invention is directed to a mechanical or mechatronic closure system comprising an actuating means such as socket wrench receptacle or swivel handle which is swivelably and rotatably supported in a housing or tray and a retaining nut or bearing piece which can be screwed on with the housing or with the tray with the intermediary of a thin wall such as door panel of a sheet-metal cabinet or sheet-metal housing.
[0004] Reference is made to documents D1=DE 198 05 771 A1 and D2=US 2010/142215 A1 as prior art.
[0005] An LED ring for the operating buttons for elevator installations is known to the present applicant.
SUMMARY OF THE INVENTION
[0006] The object of the invention is to provide an LED ring or LED indicator for closure systems of the type mentioned above which is suitable for a sheet-metal cabinet or sheet-metal box and serves as integrated closure indicator.
[0007] The above-stated object is met through a light ring surrounding the flange of the housing or tray and with a flexible foil which is arranged between light ring and thin wall and which carries light emitting diodes (LEDs) and relays the light thereof.
[0008] According to a further development of the invention, an electronics module or a base plate with printed circuit board is screwed to the tray or to the housing with the intermediary of flexible foil and LEDs.
[0009] According to yet another embodiment form of the invention, the electronics module has in integrated heat sink.
[0010] According to a further embodiment form of the invention, the base plate supports a contact sensor which cooperates with a sensor adaptor moved by the drive.
[0011] According to another embodiment form of the invention, the base plate has a sensor at one longitudinal end for determining the presence of the door frame.
[0012] According to yet another embodiment form of the invention, the contact sensor is part of the printed circuit board or part of the electronics module.
[0013] According to a further embodiment form of the invention, the sensor has a cable connection to the electronics module or to the printed circuit board for detecting the frame (closed door).
[0014] According to yet another embodiment form, the LED ring is made of glass, transparent plastic, optionally with integrated optical waveguides.
[0015] According to a further embodiment form of the invention, the LED ring is characterized in that the door sensor for detecting the state of the door is a reed sensor, Hall sensor, reflection-type photo-switch, light barrier, mechanical feeler, pressure sensor, light sensor, proximity sensor (inductive, capacitive, ultrasonic), temperature sensor, rotational angle sensor, and in that the sensor is placed by the customer (existing sensor) on the door frame, hinge.
[0016] According to a further embodiment form of the invention, the LED ring is characterized in that a closing sensor for detecting the closing state of the cylinder lock is carried out by a fork light barrier, light barrier, reflection-type photo-switch, mechanical feeler, pressure sensor, potentiometer, proximity sensor (inductive, capacitive, ultrasonic), rotational angle sensor, reed sensor, Hall sensor, with a sensor placement: with extension/adaptor outside of the rotary latch or integrated in the rotary latch.
[0017] In an alternative not according to the invention, a light guide is part of the wall of the tray and is made of translucent plastic and is arranged and shaped in such a way that the wall lights up at the desired location during operation of the light emitting diode.
[0018] The light guide can be removed as part of the wall and replaced by a part of a different color.
[0019] There can be two such parts of the wall which are connected by a carrier plate.
[0020] The carrier plate can also form a receptacle for a button cell.
[0021] According to another alternative, the light guide can be characterized in that a light emitting diode is arranged in the vicinity of the shaft on the underside of the tray and has light contact with parts of the wall of the tray.
[0022] On the other hand, the light guide can also be characterized in that a light emitting diode is arranged in the vicinity of the shaft and has light contact with the wall of the hand lever.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will be described in more detail in the following with reference to embodiment examples which are shown in the drawings.
[0024] FIG. 1 shows a schematic view of an LED ring for mechatronic systems.
[0025] FIG. 2 shows an exploded view of the system from FIG. 1 .
[0026] FIG. 3 shows an exploded view of the system from FIG. 1 from another angle.
[0027] FIG. 4A shows a rear view of the system from FIG. 1 .
[0028] FIG. 4B shows a side view.
[0029] FIG. 4C shows a top view.
[0030] FIG. 5 shows a schematic view of a system with an LED ring for a mechanical rotary latch system.
[0031] FIG. 6 shows a perspective exploded view of the LED ring at a rotational angle of observation at a first angle.
[0032] FIG. 7 shows the exploded view of the system from FIG. 6 from another angle.
[0033] FIG. 8A shows a top view of the assembled system from FIG. 5 .
[0034] FIGS. 8B and 8C shows a view of the side wall from above the open closure.
[0035] FIG. 9A shows the closed closure position of the closure from FIG. 5A or 8C .
[0036] FIG. 9B shows the view from FIG. 9A from above.
[0037] FIG. 9C shows the view from FIG. 9A from the rear.
[0038] FIG. 10A shows a view as in FIG. 8A .
[0039] FIG. 10B shows a sectional view along line B-B from FIG. 10A .
[0040] FIG. 10C shows a sectional view along line C-C from FIG. 10A .
[0041] FIG. 11A shows a top view of an alternative, not according to the invention, of a mechatronic system working with light guides.
[0042] FIG. 11B shows a side view.
[0043] FIG. 11C shows a front view.
[0044] FIGS. 11D to 11F shows three top views of different actuation levers.
[0045] FIG. 11G shows a rear view of the swivel lever in a position in which it is folded into the tray.
[0046] FIG. 11H shows a perspective view of the lever from FIG. 11H in folded-in position.
[0047] FIG. 11I shows a side view of the lever from FIG. 11H in folded-out position.
[0048] FIG. 12A shows a perspective view of the removeable light guide with holder for a button cell.
[0049] FIG. 12B shows the back of the light guide arrangement.
[0050] FIG. 13A shows a top view of a swivel lever closure with light conducted into the free end of the hand lever.
[0051] FIG. 13B shows a rear view of the swivel lever closure of FIG. 13A with the position of the light source (LED).
DETAILED DESCRIPTION OF EMBODIMENTS
[0052] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements which are conventional in this art. Those of ordinary skill in the art will recognize that other elements are desirable for implementing the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
[0053] The present invention will now be described in detail on the basis of exemplary embodiments.
[0054] FIG. 1 shows a light ring 28 according to the invention comprising a LED ring for a mechatronic swivel lever system, wherein the swivel lever system comprises a closure system, further, an actuating means, namely a swivel handle 12 , rotatably supported in a housing 110 or tray 10 , which swivel handle 12 is articulated at a joint pin 14 , which joint pin 14 is rotatably supported in the tray 10 . The bearing support can also be carried out at bearing piece 16 .
[0055] The bearing piece 16 is screwed by means of screws 18 to the tray 10 with the intermediary of a thin wall 42 , 142 (shown in FIGS. 4B and 9C ) such as a door panel. A hexagon nut 20 with clamping part 21 , washer 22 and, on the other side of the bearing piece 16 , a spring washer 24 provide for a stable bearing support of the joint pin. The tray 10 forms a flange 26 by which the tray 10 secures a light ring 28 . The light ring can be illuminated by LEDs 30 arranged with a flexible foil 32 , see also FIG. 3 . The power supply of the light emitting diodes is carried out via foil contacts or foil conductors 34 . The light emissions are controlled by an electronics module 36 which comprises an integrated heat sink 38 .
[0056] In FIG. 4A , fastening screws 40 are provided for the electronics component 36 .
[0057] Thin wall 42 is shown in FIG. 4B . This thin wall 42 is clamped by the bearing piece 16 with screw 18 on one side and by the electronics part 36 by means of screws 40 between the foil and the light ring 28 on the other side of the thin wall.
[0058] With respect to the power required, this power can be supplied to the module 36 via a cable line 44 . This power can originate from the electrical grid or from a battery.
[0059] The swivel handle 12 can be locked by means of a cylinder closure 46 and the closing cam 48 extends into the electronics module 36 . The position of the closing cam can be sensed by the electronics module 36 .
[0060] FIG. 5 shows an LED ring for a mechanical rotary latch system. The rotary latch system comprises a housing 110 with an actuating means 112 , a rod drive with stop 113 , with a tongue 148 and a sensor adaptor 152 . The housing 110 is held on a door panel 142 . A light ring 125 which comprises a flexible foil with light emitting diodes is arranged between door panel 142 and the flange 126 of housing 110 . A printed circuit board 136 which is mounted on a base plate 138 is also provided with a lead 156 . The base plate 138 carries a door sensor 144 and the printed circuit board 136 carries a sensor 154 which cooperates with a sensor adaptor 152 and determines a position of the tongue 148 .
[0061] According to FIGS. 8A, 8B , this is shown, for example, in three different arrangements in which the tongue 148 engages behind the door frame 139 and accordingly holds the door 142 shut.
[0062] Power supply 144 is provided at the door 142 between door leaf 142 and tongue 148 .
[0063] FIG. 8A shows a top view, FIG. 8B shows a side view and FIG. 8C shows a plan view from above of the embodiment form with rotary latch 118 which is also shown in FIGS. 5, 6 and 7 .
[0064] Further views and the manner of functioning are shown in FIGS. 9A, 9B, 9C and the sectional views in FIGS. 10B and 10C , wherein the sections are disposed according to FIG. 10A , see section lines BB and CC. Light ring 28 , 128 comprises a carrier for the light emitting diodes, wherein the light ring is made of glass, plastic which is transparent and can have, e.g., PC, PMMA with diffuser compounded therein and/or can have a roughened surface, e.g., an erosion structure, and can also be outfitted with integrated optical waveguides. This material is arranged on one side and embedded in a flexible foil 132 and provided with connections which are guided out of the flexible material and can be connected to a power source such that current flows through the LEDs.
[0065] FIG. 10C schematically shows the flexible foil 132 , the manner in which the latter is secured by the flange 14 of the housing and forms a current-free transition surface. The light emitting diodes are arranged as individual piece or as a plurality in series or as group. The LEDs can be red, yellow or monochromatic of one color or can also emit different colors at different voltages. The layout can be carried out in a free-form manner or can be adapted to the contour of the system. The flexible foil or flexible film has the advantage that it can be adapted easily to different contours of the actuating means, for example, to the round housing shape of the embodiment form according to FIGS. 5 to 10 , for example, or also to the rectangular housing shape of the embodiment form according to FIGS. 1 to 4 .
[0066] Other similar materials can also be used for the printed circuit board, e.g., CM1, CM3, FR2, FR3, FR4, FR5, FR5BT, polyamide, Teflon (PTFE), or ceramic. The electronics module 136 for detecting the state of the door can comprise a reed sensor, a Hall sensor, a reflection-type photo-switch, a light barrier, mechanical feeler, pressure sensors, light sensors, proximity sensors which can operate inductively, capacitively or by ultrasound, temperature sensors, or rotational angle sensors. The placement of the sensor can be carried out by the customer (in case of an existing sensor) or on the door frame, on the hinge, provided for a minimum quantity of a sensor in the system and at least one externally switchable sensor.
[0067] Sensors can also be provided for detecting the actual state of the lock 146 , for example, a fork light barrier, a light barrier, a reflection-type photo-switch, a mechanical feeler, a pressure sensor, a potentiometer, a proximity sensor which can operate inductively, capacitively or by ultrasound, a rotational angle sensor, a reed sensor, and a Hall sensor.
[0068] The sensor placement for detecting the closing state, i.e., the position of the rotary latch 148 , can be carried out by an extension or an adaptor 152 outside of the rotary latch, for example, with the arrangement of the extension according to reference numeral 152 , 154 or also integrated in the rotary latch.
[0069] Depending on external factors, a network device or battery operation can be provided for power supply, see power cable 156 in FIG. 9C, 144 in FIGS. 1, 4A to 4C . The invention according to the arrangement is connected in a network-ready manner via cable or wirelessly to other systems. An interface for external program units is possible. The switching elements are advisably protected by a cover cap. The system according to the invention with an LED ring can be configured as rotary latch closure, swivel lever closure, compression closure, latch closure, snap closure, bar closure or as recessed handle. To this extent, the embodiment forms shown only represent examples which are particularly favorable.
[0070] In an alternative not according to the invention, a light guide 258 is part of the wall of the tray 210 and is made of a translucent plastic and arranged and shaped in such a way that the wall 260 is illuminated at the desired location during operation of the light emitting diode 262 . The light guide 258 can be removed as part of the wall 260 and may be replaced by a part of another color.
[0071] Two parts 260 of this kind can be provided and connected by a carrier plate 264 . The carrier plate 264 can also form a receptacle for a button cell 266 .
[0072] According to another further development, the light guide can be characterized in that a light emitting diode 262 is arranged in the vicinity of the shaft on the underside of the tray and has light contact with parts of the wall 268 of the tray 210 .
[0073] On the other hand, the light guide can be characterized in that a light emitting diode 262 is arranged in the vicinity of the shaft 214 and has light contact with the wall 261 of the hand lever 214 .
INDUSTRIAL APPLICABILITY
[0074] The invention is commercially applicable in a switch cabinet construction.
[0075] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the inventions as defined in the following claims.
LIST OF REFERENCE NUMERALS
[0000]
10 , 110 , 210 tray, housing
12 , 112 swivel handle, actuating means, rod drive with stop
13 rod drive
14 , 114 , 214 joint pin, actuating means, shaft
16 , 116 bearing piece, retaining nut
18 screw
20 , 120 hexagon nut with clamping part, self-locking screw
21 clamping part
22 washer
24 spring washer
26 , 126 flange
28 , 128 light ring
30 , 130 LED
32 , 132 flexible foil
34 , 134 foil conductor
36 , 136 electronics module, printed circuit board
38 , 138 heat sink, base plate
139 door frame
40 fastening screws
42 , 142 thin wall
44 , 144 power supply electronics
46 , 146 cylinder closure
48 , 148 closing cam, tongue
50 , 150 power supply LED
152 sensor adaptor
154 closing sensor
156 cable connection
258 light guide
260 wall
261 wall
262 light emitting diode
264 carrier plate
266 button cell
268 wall
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An LED ring or light guide for a mechanical or mechatronic closure system that includes an actuating means, such as socket wrench receptacle or swivel handle, which is rotatably supported in a housing or tray. The LED ring or light guide also includes a retaining nut or bearing piece that can be screwed on with the housing or with the tray with the intermediary of a thin wall such as door panel of a sheet-metal cabinet or sheet-metal housing. A light ring surrounds a flange of the housing or of the tray, and a flexible foil is arranged between light ring and thin wall. The flexible foil carries light emitting diodes (LEDs) and relays the light thereof. A closure indicator integrated in the actuating means is achieved in this way.
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FIELD OF THE INVENTION
[0001] The present invention relates to a brake disc for vehicles; in particular, the present invention relates to brake discs that are suitable for being used on motorcycles.
BACKGROUND OF THE INVENTION
[0002] As we know, in some motorcycles the front or back wheels often comprise an integrally formed brake disc, in other words comprising a portion for connecting to the hub, a braking band and a plurality of spokes made in a single piece.
[0003] During braking, these brake discs may suffer vibrations that cause an irritating whistling.
[0004] Solutions suitable for eliminating this inconvenience are not known in the art.
SUMMARY OF THE INVENTION
[0005] The problem of the present invention is to make a brake disc for vehicles that resolves the inconveniences stated with reference to the prior art.
[0006] These inconveniences are resolved by a brake disc for vehicles according to claim 1 .
[0007] Other brake disc embodiments according to the invention are described in the subsequent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Further characteristics and advantages of the present invention will be appreciated from the following description of a preferred embodiment, which is given by way of example and not limiting, wherein:
[0009] FIG. 1 represents a perspective view of a brake disc according to an embodiment of the present invention;
[0010] FIG. 2 represents a front view of the disc in FIG. 1 , from the side of the arrow II in FIG. 1 ;
[0011] FIG. 3 represents a front view of a brake disc according to a further embodiment of the present invention;
[0012] FIG. 4 represents a perspective view with separate parts of a disc according to a further embodiment of the present invention;
[0013] FIG. 5 represents a front view of the disc in FIG. 4 , from the side of the arrow V in FIG. 4 ;
[0014] FIG. 6 represents a section view of the disc in FIG. 5 , along the VI-VI section line in FIG. 5 ;
[0015] FIG. 7 represents a perspective view with separate parts of a brake disc according to a further embodiment of the present invention;
[0016] FIG. 8 represents a perspective view of the disc in FIG. 7 in an assembly configuration, from the side of the arrow VIII in FIG. 7 ;
[0017] FIG. 9 represents a perspective view of the disc in FIG. 7 in an assembly configuration, from the side of the arrow IX in FIG. 7 ;
[0018] FIG. 10 represents a perspective view of a disc according to a further embodiment of the present invention;
[0019] FIG. 11 represents a front view of the disc in FIG. 10 , from the side of the arrow XI in FIG. 10 ;
[0020] FIG. 12 represents a section view of the disc in FIG. 10 , along the XII-XII section line in FIG. 11 ;
[0021] FIG. 13 represents a perspective view of a disc according to a further embodiment of the present invention;
[0022] FIG. 14 represents a front view of the disc in FIG. 13 , from the side of the arrow XIV in FIG. 13 ;
[0023] FIG. 15 represents a section view of the disc in FIG. 13 , along the XV-XV section line in FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] The elements or parts of elements in common between the subsequently described embodiments will be indicated with the same numeral references.
[0025] The term radial direction means a direction that is substantially perpendicular to an X rotation axis of the disc.
[0026] The term axial direction means a direction that is substantially parallel to the X rotation axis of the disc.
[0027] The term tangential direction means a direction that is substantially perpendicular to the axial direction and to the radial direction.
[0028] With reference to the above drawings, a brake disc for vehicles with an X rotation axis is generally indicated with reference numeral 4 .
[0029] The brake disc 4 comprises a connecting portion 8 to a wheel hub of a vehicle, a braking band 12 and at least one spoke 16 for the connection between the connecting portion 8 and the braking band 12 .
[0030] The braking band 12 is preferably connected to the connecting portion 8 by means of a plurality of spokes 16 that are preferably arranged in step.
[0031] The brake disc 4 is formed integrally, in particular, the braking band 12 is integral with the connecting portion 8 and with the spokes 16 .
[0032] Advantageously, at least one spoke 16 comprises an active section reduction 18 to exhibit reduced rigidity in relation to the corresponding integral section.
[0033] According to an embodiment of the present invention, said section reduction 18 is made with a lightening 19 that is suitable for reducing the axial thickness of a portion of the spoke.
[0034] According to an embodiment ( FIGS. 11 , 12 ), the lightening 19 exhibits a tangential course that is sufficient to influence the whole tangential width of the spoke 16 . The lightening 19 can be defined by one or more chamfers or flares 20 , which are arranged tangentially and parallel between each other.
[0035] According to a further embodiment ( FIGS. 13-15 ), the lightening 19 exhibits a circular course defining a cylindrical pocket.
[0036] Said lightening 19 with a circular course is preferably defined by a chamfer or flare 20 arranged on the side of one face of the disc.
[0037] The lightening 19 preferably limits the active section of the spoke 16 to maintain the continuity, level with said spoke 16 , between the connecting portion 8 and the braking band 12 . In other words, the lightening 19 reduces the active section of the spoke 16 but does not completely interrupt the continuity of the same spoke, or rather the mechanical connection that the spoke forms between the braking band 12 and the connecting portion 8 .
[0038] The lightening 19 preferably reduces the active section of the spoke 16 to no more than 40% of the active section of the integral spoke 16 . In other words, the lightening 19 reduces the active section of the spoke 16 by at least 60% compared with the corresponding section of the integral spoke 16 .
[0039] According to an advantageous embodiment ( FIGS. 1-5 ), said section reduction 18 creates an interruption 22 of the spoke 16 so as to divide the spoke 16 into two parts and interrupt the continuity between the connecting portion 8 and the braking band 12 .
[0040] According to an embodiment, said interruption 22 is arranged level with a portion of the spoke 16 next to the braking band 12 .
[0041] According to an embodiment, the interruption 22 comprises a direct channel 24 that is substantially tangential to the braking band 12 so as to affect the whole tangential thickness of the spoke 16 dividing it into two separate parts.
[0042] Said interruption 22 preferably comprises at least one indentation 28 in relation to a radial direction, which is suitable for defining a slot 32 with said channel 24 .
[0043] According to an embodiment, the interruption 22 comprises a pair of indentations 28 that are radially facing and arranged on each of the ends of the opposite portions of the spoke 16 facing each other, said indentations 28 defining a slot 32 with said channel 24 .
[0044] The slot 32 is preferably symmetrical in relation to a radial direction passing the X rotation axis of the disc 4 .
[0045] Said slot 32 is also preferably symmetrical in relation to a tangential direction, perpendicular to a radius of the disc.
[0046] According to an advantageous embodiment, the disc 4 comprises at least one bush 40 contained in said slot 32 and said channel 24 so it is constrained by said indentations 28 in relation to a tangential direction.
[0047] According to an embodiment, the bush 40 comprises a bush body 44 and constraining means 48 . According to an embodiment the bush 40 is formed integrally and level with an axial end, said constraining means comprise a first head 50 , and at the opposite end they comprise a second head 51 , which is achieved, for example, by riveting. These heads 50 , 51 exhibit a greater diameter than the diameter of the slot 32 so as to axially constrain the bush 40 in relation to the slot 32 .
[0048] An elastic element 52 is preferably inserted between said bush body 44 and one of said heads 50 , 51 , suitable for pre-charging the bush body 44 and the constraining means 50 , 51 in relation to an axial direction.
[0049] According to an embodiment, said elastic element 52 is a washer spring.
[0050] The mass of said bush 40 is preferably substantially equal to the mass of material removed from the spoke 16 to form said interruption.
[0051] According to a further embodiment, said disc comprises at least one small plate 60 suitable for being connected to said slot 32 or said channel 24 so as to cover the interruption 22 at least partially.
[0052] The small plate 60 preferably has a plate body 64 , for example that is flat and equipped with a pair of fastening flaps 68 that are suitable for being constrained by clicking or mortising to special fastening holes 72 , which are arranged, for example, on the spoke on the side of the connecting portion 8 and the braking band 12 .
[0053] According to an embodiment, the plate body 64 comprises two flaps 76 suitable for being hooked by clicking onto side edges 78 of the spoke, which are separated by the interruption 22 .
[0054] The plate body 64 preferably has a tangential extension so as to completely cover the interruption 22 .
[0055] The mass of said plate 60 is preferably substantially equal to the mass of material removed from the spoke 16 to form the interruption 22 .
[0056] Advantageously, in an assembly configuration of the disc 4 on the relative wheel hub, the disc is oriented angularly to bring the interruption 22 and the connectable bush 40 or plate 60 into a diametrically opposite position in relation to the inflation valve of the relative tyre to be connected to the rim.
[0057] According to a further embodiment, at least two spokes 16 of the disc 4 comprise an active section reduction 18 to exhibit reduced rigidity in relation to the corresponding integral section.
[0058] Said active section reduction 18 can be made with a lightening 19 or an interruption 20 . In an embodiment comprising two spokes 16 , with an active section reduction 18 , said spokes 16 are preferably arranged in diametrically opposite positions in relation to said X rotation axis of the disc 4 .
[0059] In an embodiment comprising at least two spokes 16 or a plurality of spokes 16 , comprising an active section reduction 18 , said spokes 16 , comprising an active section reduction 18 are preferably arranged in step in relation to the X rotation axis.
[0060] As we can appreciate from the description, the brake disc of the present invention enables the inconveniences exhibited by the brake disc of the prior art to be overcome.
[0061] In particular, the disc according to the invention does not vibrate and whistle during braking.
[0062] The disc in the present invention maintains a gyroscopic effect, as well as a reduced, non suspended mass.
[0063] In order to satisfy specific and contingent needs, a person skilled in the art can make numerous modifications and variations to the above described brake discs, all of which are included in the scope of the invention, as defined by the following claims.
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A brake disc of the type comprising a braking band, a connecting portion and connecting spokes made in a single piece. In said disc at least one spoke exhibits an active section reduction that is sufficient to prevent vibrations and whistling during the braking phase. The disc, according to the present invention, is not subject to vibrations and possesses a limited gyroscopic effect and mass.
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TECHNICAL FIELD
[0001] The present invention relates to a thin-film solar cell, and more specifically, to a thin-film solar cell including a coordination polymer.
BACKGROUND ART
[0002] In recent years, sunlight has attracted attention as a source of green energy, and solar cells that use sunlight have been actively developed. Examples of solar cells include silicon solar cells, solar cells that use inorganic compounds, and thin-film solar cells typified by a bulk heterojunction thin-film solar cell that uses organic compounds.
[0003] Among these various types of solar cells, thin-film solar cells are solar cells having a structure in which a p-type organic semiconductor and an n-type organic semiconductor are formed into a thin film. Since the structure of thin-film solar cells is simple, the production cost is low. In addition, a sealing technique used in organic electroluminescence (EL) devices can also be used. Thus, in recent years, expectation of the practical use of thin-film solar cells as new-type solar cells has been rapidly increasing.
[0004] Among the thin-film solar cells, as described in NPL 1 and NPL 2, bulk heterojunction thin-film solar cells in which 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM), poly-3-hexylthiophene (P3HT), and the like are used as organic semiconductors are widely known.
[0005] In recent years, various technical developments for improving the conversion efficiency have been conducted. For example, PTL 1 discloses a bulk heterojunction thin-film solar cell whose conversion efficiency is improved by mixing inorganic nanoparticles together with organic semiconductors.
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Unexamined Patent Application Publication No. 2009-158730
Non Patent Literature
[0000]
NPL 1: S. E. Shaheen, C. J, Brabec, N. S. Sariciftic, F. Padinger, T. Framherz, and J. C. Hummelen, Appl. Phys. Lett., Vol. 78, 2001, pp. 841-843
NPL 2: Y. Kim, S. Cook, S. M. Tuladhar, S. A. Choulis, J. Nelson, J. R. Durrant, D. D. C. Bradley, M. Giles, I. Mcculloch, C. Ha, and M. Ree, Nature, Materials, Vol. 5, 2006, pp. 197-203
SUMMARY OF INVENTION
Technical Problem
[0009] However, common thin-film solar cells disclosed in NPL 1 and NPL 2 have low conversion efficiencies, namely, 2.5% and 4.4%, and thus have a drawback in that these solar cells are inadequate for practical use.
[0010] In the bulk heterojunction thin-film solar cell described in PTL 1, the conversion efficiency is improved as follows: Light taken into a cell is scattered by the inorganic nanoparticles, whereby the light taken into the cell is effectively used as much as possible without the light being emitted to the outside of the cell.
[0011] However, in this case, the following problems occur: Since the inorganic nanoparticles are not involved in light absorption, when the amount of inorganic nanoparticles added is excessively large, a ratio of the presence of an organic semiconductor necessary for absorbing visible light in the cell decreases. In addition, it becomes more difficult for light to be taken into the cell, or the transmission of generated photocarriers may be inhibited. Because of these various factors, the conversion efficiency is decreased instead, and thus there is a limit in the improvement in the conversion efficiency.
[0012] The present invention has been made in view of the above problems in the related art. An object of the present invention is to provide a thin-film solar cell in which a coordination polymer used absorbs light and efficiently supplies generated electrons and holes to organic semiconductors or electrodes, thereby increasing the charge separation efficiency and improving the conversion efficiency.
Solution to Problem
[0013] To achieve the above object, a thin-film solar cell according to Claim 1 of the present invention includes at least one organic semiconductor; and a coordination polymer, in which the coordination polymer contains a repeating unit which includes a complex produced by coordinating at least one ligand to at least one metal ion, the metal ion being selected from ions of transition metal elements, and the ligand being capable of coordinating to the metal ion and selected from sulfur-containing compounds, nitrogen-containing compounds, oxygen-containing compounds, and phosphorus-containing compounds.
[0014] In a thin-film solar cell according to Claim 2 of the present invention, the transition metal element is at least one metal element selected from Fe, Co, Ni, Cu, Ru, Rh, Pd, Ag, Os, Ir, Pt, and Au.
[0015] In a thin-film solar cell according to Claim 3 of the present invention, the ligand is at least one derivative selected from derivatives of a dithiocarbamate ion, the derivatives being represented by Chem. 1 and Chem. 2 below:
[0000]
[0000] (where R 1 and R 2 may be the same or different and each represent an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group, or a substituted heterocyclic group.)
[0000]
[0000] (where R 3 represents a heterocyclic group or substituted heterocyclic group having at least one nitrogen atom.)
[0016] In a thin-film solar cell according to Claim 4 of the present invention, the coordination polymer further contains a bromine ion or an iodine ion.
[0017] In a thin-film solar cell according to Claim 5 of the present invention, the organic semiconductor is at least one substance selected from fullerene, fullerene derivatives, oligothiophene, oligothiophene derivatives, polythiophene, polythiophene derivatives, phthalocyanine, phthalocyanine derivatives, metal phthalocyanine, metal phthalocyanine derivatives, polyphenylene, polyphenylene derivatives, polyphenylene vinylene, polyphenylene vinylene derivatives, polyvinylcarbazole, polyvinylcarbazole derivatives, polysilane, polysilane derivatives, polyfluorene, polyfluorene derivatives, pentacene, pentacene derivatives, anthracene, anthracene derivatives, rubrene, rubrene derivatives, perylene, perylene derivatives, tetracyanoquinodimethane, tetracyanoquinodimethane derivatives, tetrathiafulvalene, tetrathiafulvalene derivatives, oxadiazole, and oxadiazole derivatives.
[0018] In a thin-film solar cell according to Claim 6 of the present invention, the organic semiconductor is 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM) and poly-3-hexylthiophene (P3HT), and the coordination polymer contains copper as the transition metal element, piperidinedithiocarbamic acid as the ligand, and an iodine ion.
[0019] First, a thin-film solar cell of the present invention will be described below.
[0020] The thin-film solar cell of the present invention includes a coordination polymer together with an organic semiconductor. Furthermore, the thin-film solar cell of the present invention includes, as an essential component, a coordination polymer having a repeating unit which includes a complex produced by coordinating at least one ligand to at least one metal ion, the metal ion being selected from ions of transition metal elements, and the ligand being capable of coordinating to the metal ion and selected from sulfur-containing compounds, nitrogen-containing compounds, oxygen-containing compounds, and phosphorus-containing compounds.
[0021] Herein, the term “coordination polymer” in the present invention refers to a polymer having a structure in which metal complexes are connected to each other, the metal complexes each including a metal ion located at the center and ligands composed of an organic compound and bonded to the periphery of the metal ion. Schematic examples thereof include a coordination polymer having a one-dimensional structure illustrated in FIG. 14 , a coordination polymer having a two-dimensional structure illustrated in FIG. 15 , and a coordination polymer having a three-dimensional structure illustrated in FIG. 16 .
[0022] Examples of the coordination polymer include not only a coordination polymer having a repeating structure in which metal ions located at the center of respective metal complexes are cross-linked by a ligand, but also a coordination polymer containing a cross-linking agent component, such as a bromine ion or an iodine ion described below, other than a ligand, so as to cross-link units of a metal complex as required, and having a repeating structure in which cross-link is also formed by the other cross-linking agent component.
[0023] In the case where a coordination polymer skeleton is positively charged or negatively charged, in order to cancel the electric charges, an anion or a cation such as a ferrocenium ion or an ammonium ion may be incorporated in the coordination polymer skeleton typified by the structures illustrated in FIGS. 14 , 15 , and 16 . Such compounds are also covered by the coordination polymer.
[0024] Examples of requirements for a coordination polymer necessary for the thin-film solar cell of the present invention include the following: The coordination polymer is to exhibit high absorption in the visible light region, the coordination polymer is to have a capability of transporting generated electrons and holes, the energy level of the lowest unoccupied molecular orbital (LUMO) of the coordination polymer is to be higher than the LUMO of an organic n-type semiconductor or the Fermi level of an anode, and the energy level of the highest occupied molecular orbital (HOMO) of the coordination polymer is to be lower than the HOMO of an organic p-type semiconductor or the Fermi level of a positive electrode.
[0025] Next, components constituting the coordination polymer will be described.
[0026] As the metal ion, metal ions of at least one element selected from transition metal elements are used in the present invention. Among transition metal elements, metal ions of elements of the so-called group 8 and group 1B such as Fe, Co, Ni, Cu, Ru, Rh, Pd, Ag, Os, Ir, Pt, and Au are preferably used. Furthermore, among these, a copper ion is preferably used from the standpoint that electrons can be delocalized over the entire coordination polymer by coordinating a ligand described below, and the cost is low.
[0027] Regarding these metal ions, by using not only one metal ion but also different types of metal ions in combination, characteristics of respective metal ions can be exhibited. For example, by using a metal ion having a heavy-atom effect, such as a platinum ion or an iridium ion, in combination with a copper ion, it is possible to exhibit not only the electron delocalization effect achieved by the copper ion but also the effect of extending the excitation lifetime, the effect being achieved by the platinum ion, the iridium ion, or the like.
[0028] As the ligand, at least one selected from sulfur-containing compounds, nitrogen-containing compounds, oxygen-containing compounds, and phosphorus-containing compounds that can coordinate to the above metal ion is used in the present invention. Examples of the sulfur-containing compounds include ligands having a dithiooxalate substituent, a tetrathiooxalate substituent, or a dithiocarboxylic acid substituent. Examples of the nitrogen-containing compounds include ligands having a pyrazine skeleton, a bipyridine skeleton, or an imidazole skeleton. Examples of the oxygen-containing compounds include oxalate, chloranilate, 2,5-dihydroxy-1,4-benzoquinone, benzene dicarboxylate, and catechol. Examples of the phosphorus-containing compounds include triphenylphosphine, diphenylphosphino ethane, diphenylphosphino propane, and 1,1′-bis(diphenylphosphino)ferrocene.
[0029] Among these compounds, derivatives of a dithiocarbamate ion, the derivatives being represented by Chem. 1 and Chem. 2 below, are preferably used.
[0000]
[0000] (R 1 and R 2 may be the same or different and each represent an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group, or a substituted heterocyclic group.)
[0030] R 1 and R 2 each preferably have 1 to 50 carbon atoms and more preferably have 1 to 30 carbon atoms.
[0000]
[0000] (R 3 represents a heterocyclic group or substituted heterocyclic group having at least one nitrogen atom.)
[0031] Specific examples of R 3 include heterocyclic groups and substituted heterocyclic groups represented by Chem. 3 below. Examples of R 3 that can be used further include groups in which groups that may be the same or different and that are each selected from aliphatic hydrocarbon groups, substituted aliphatic hydrocarbon groups, aromatic hydrocarbon groups, substituted aromatic hydrocarbon groups, heterocyclic groups, and substituted heterocyclic groups are bonded to any of the heterocyclic groups and substituted heterocyclic groups represented by Chem. 3.
[0000]
[0032] The coordination polymer of the present invention may include, besides the metal ion and the ligand, a halogen element as a cross-linking agent component for cross-linking the metal ions. Among halogen elements, from the standpoint of improving the electron delocalization effect, a bromine ion or an iodine ion is preferably used.
[0033] By using this cross-linking agent component, energy bands are formed by the highest occupied molecular orbital (HOMO) and the lowest unoccupied molecular orbital (LUMO) of each of the components. Consequently, the transporting properties of the generated electrons and holes can be improved.
[0034] For example, as illustrated in Chem. 4, a mononuclear complex in which hexamethylenedithiocarbamic acid functioning as a ligand is coordinated to a copper ion functioning as a metal ion is cross-linked by using a bromine ion or an iodine ion. With this structure, an energy band is formed by overlapping of orbitals, and thus a high carrier transporting property can be realized.
[0000]
[0000] (X represents Br or I.)
[0035] The molecular weight and the number (n) of repeating units of the coordination polymer of the present invention are not particularly limited, and are appropriately determined in accordance with the organic semiconductor used. The molecular weight is preferably 1,000 or more, and the number of repeating units is preferably 100 or more. The upper limit of the molecular weight and the upper limit of the number (n) of repeating units can be appropriately determined within a range in which problems do not occur in the use of the coordination polymer.
[0036] The mixing ratio of the coordination polymer of the present invention to the organic semiconductor is also not particularly limited, and is appropriately determined in accordance with the organic semiconductor used. The mixing ratio of the coordination polymer is preferably 1% by weight or more relative to the amount of organic semiconductor.
[0037] The reason for this is that when the mixing ratio is less than 1% by weight, the effect due to the coordination polymer may not be sufficiently achieved.
[0038] The coordination polymer of the present invention can be produced by a known method, for example, by mixing compounds used as raw materials in an organic solvent. In the case where a bromine ion or an iodine ion is used as a cross-linking agent component, the coordination polymer can be produced by preparing a mononuclear complex, and then mixing the mononuclear complex with a bromine ionic compound or an iodine ionic compound. Specifically, for example, such a coordination polymer is produced by preparing a mononuclear complex in which hexamethylenedithiocarbamic acid is coordinated to a copper ion using a copper salt and hexamethylenedithiocarbamic acid, and then mixing the prepared mononuclear complex with copper bromide in an organic solvent.
[0039] An organic semiconductor used in the present invention functions as an n-type semiconductor or a p-type organic semiconductor. Compounds that have been used in thin-film solar cells can be used as the organic semiconductor.
[0040] Examples of the compounds include fullerene, fullerene derivatives, oligothiophene, oligothiophene derivatives, polythiophene, polythiophene derivatives, phthalocyanine, phthalocyanine derivatives, metal phthalocyanine, metal phthalocyanine derivatives, polyphenylene, polyphenylene derivatives, polyphenylene vinylene, polyphenylene vinylene derivatives, polyvinylcarbazole, polyvinylcarbazole derivatives, polysilane, polysilane derivatives, polyfluorene, polyfluorene derivatives, pentacene, pentacene derivatives, anthracene, anthracene derivatives, rubrene, rubrene derivatives, perylene, perylene derivatives, tetracyanoquinodimethane, tetracyanoquinodimethane derivatives, tetrathiafulvalene, tetrathiafulvalene derivatives, oxadiazole, and oxadiazole derivatives. Among these compounds, 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM) and poly-3-hexylthiophene (P3HT) are preferably used because a higher conversion efficiency can be realized.
[0041] In the case where the coordination polymer used in the present invention functions as an n-type semiconductor or a p-type organic semiconductor, only one of the above organic semiconductors may be used.
Advantageous Effects of Invention
[0042] According to the thin-film solar cell of the present invention, a thin-film solar cell having a high conversion efficiency can be obtained at a low cost by using a coordination polymer which is a metal complex.
[0043] Among the ligands, when a derivative of a dithiocarbamate ion is used, the coordination polymer also functions as a sensitizing dye and thus a coordination polymer that efficiently absorbs visible light can be obtained.
[0044] The reason for this is as follows: Since the ionization energy of a transition metal element and the ionization energy of a derivative of a dithiocarbamate ion are close to each other, photoexcitation of the transition metal element, which is originally a forbidden transition, becomes allowed by hybridization of the orbital of the metal ion and the orbital of the ligand. As a result, the resulting coordination polymer including the derivative of a dithiocarbamate ion can efficiently absorb visible light as a whole. In addition, since an energy band is formed by the hybridization of the orbitals, the carrier transporting property is increased. As a result, electrical conductivity is exhibited.
[0045] In addition, by using a coordination polymer including a derivative of a dithiocarbamic acid, a metal ion of a transition metal element, and a bromine ion or an iodine ion, a thin-film solar cell having a higher conversion efficiency can be obtained.
[0046] Furthermore, when a coordination polymer including piperidinedithiocarbamic acid, a copper ion, and an iodine ion is used, the energy level of the HOMO of the coordination polymer can be made lower than the HOMO level of a p-type semiconductor (in particular, P3HT), and the energy level of the LUMO of the coordination polymer can be made higher than the LUMO level of an n-type semiconductor (in particular, PCBM). Thus, electrons and holes generated by charge separation on the coordination polymer can be efficiently supplied to the organic semiconductors, and a thin-film solar cell having an even higher conversion efficiency can be obtained.
BRIEF DESCRIPTION OF DRAWINGS
[0047] FIG. 1 is a schematic view illustrating an example of a cross-sectional structure of a thin-film solar cell according to the present invention.
[0048] FIG. 2 is a schematic view illustrating a cross-sectional structure of an existing thin-film solar cell.
[0049] FIG. 3 is a laser microscope photograph of an organic layer of a thin-film solar cell according to the present invention.
[0050] FIG. 4 is a laser microscope photograph of an organic layer of an existing thin-film solar cell.
[0051] FIG. 5 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 8.
[0052] FIG. 6 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 16.
[0053] FIG. 7 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 17.
[0054] FIG. 8 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 18.
[0055] FIG. 9 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 19.
[0056] FIG. 10 is a schematic view illustrating a three-dimensional structure of a coordination polymer of Production Example 20.
[0057] FIG. 11 is a graph showing current density-voltage characteristics of a thin-film solar cell of Example 1.
[0058] FIG. 12 is a graph showing current density-voltage characteristics of a thin-film solar cell of Example 2.
[0059] FIG. 13 is a graph showing current density-voltage characteristics of a thin-film solar cell of Example 3.
[0060] FIG. 14 is a schematic view illustrating a coordination polymer having a one-dimensional structure.
[0061] FIG. 15 is a schematic view illustrating a coordination polymer having a two-dimensional structure.
[0062] FIG. 16 is a schematic view illustrating a coordination polymer having a three-dimensional structure.
DESCRIPTION OF EMBODIMENTS
[0063] Next, in Production Examples 1 to 7, a detailed description will be made of production examples of a mononuclear complex which is a raw material of a coordination polymer used in a thin-film solar cell of the present invention. It should be understood that the Production Examples described below are only examples that embody the present invention and do not limit the technical scope of the present invention.
Production Example 1
Preparation of Mononuclear Complex Cu(Pip-dtc) 2
[0064] First, 10 mmol of piperidine was added to 100 mL of a methanol solution in which 10 mmol of sodium hydroxide was dissolved, and 10 mmol of carbon disulfide was further allowed to react with the solution.
[0065] Next, a solution prepared by dissolving 5 mmol of copper chloride dihydrate in 100 mL of methanol was added to the resulting solution, and allowed to react for five minutes while stirring.
[0066] The resulting precipitate was collected by filtration, and then dissolved in 200 mL of chloroform. To the solution, 200 mL of methanol was added, and the resulting solution was concentrated to about 100 mL under reduced pressure. Furthermore, 200 mL of methanol was added thereto, and the resulting solution was concentrated to about 50 mL under reduced pressure. Subsequently, the obtained microcrystals were collected by suction filtration, washed with a small amount of ether, and dried. Thus, a mononuclear complex Cu(Pip-dtc) 2 represented by Chem. 5 was obtained.
[0000]
Production Example 2
Preparation of Mononuclear Complex Cu(Hm-dtc) 2
[0067] A mononuclear complex Cu(Hm-dtc) 2 represented by Chem. 6 was obtained as in Production Example 1 except that hexamethyleneimine was used instead of piperidine used in Production Example 1.
[0000]
Production Example 3
Preparation of Mononuclear Complex Cu(Pyr-dtc) 2
[0068] A mononuclear complex Cu(Pyr-dtc) 2 represented by Chem. 7 was obtained as in Production Example 1 except that pyrrolizine was used instead of piperidine used in Production Example 1.
[0000]
Production Example 4
Preparation of Mononuclear Complex Cu(Ocm-dtc) 2
[0069] A mononuclear complex Cu(Ocm-dtc) 2 represented by Chem. 8 was obtained as in Production Example 1 except that octamethyleneimine was used instead of piperidine used in Production Example 1.
[0000]
Production Example 5
Preparation of Mononuclear Complex Cu(nPr 2 -dtc) 2
[0070] A mononuclear complex Cu(nPr 2 -dtc) 2 represented by Chem. 9 was obtained as in Production Example 1 except that dipropylamine was used instead of piperidine used in Production Example 1.
[0000]
Production Example 6
Preparation of Mononuclear Complex Cu(nBu 2 -dtc) 2
[0071] A mononuclear complex Cu(nBu 2 -dtc) 2 represented by Chem. 10 was obtained as in Production Example 1 except that dibutylamine was used instead of piperidine used in Production Example 1.
[0000]
Production Example 7
Preparation of Mononuclear Complex Ni(Hm-dtc) 2
[0072] First, 10 mmol of piperidine was added to 100 mL of a methanol solution in which 10 mmol of sodium hydroxide was dissolved, and 10 mmol of carbon disulfide was further allowed to react with the solution.
[0073] Next, a solution prepared by dissolving 5 mmol of nickel chloride hexahydrate in 100 mL of methanol was added to the resulting solution, and allowed to react for five minutes while stirring.
[0074] The resulting precipitate was collected by filtration, and then dissolved in 200 mL of chloroform. To the solution, 200 mL of methanol was added, and the resulting solution was concentrated to about 100 mL under reduced pressure. Furthermore, 200 mL of methanol was added thereto, and the resulting solution was concentrated to about 50 mL under reduced pressure. Subsequently, the obtained microcrystals were collected by suction filtration, washed with a small amount of ether, and dried. Thus, a mononuclear complex Ni(Hm-dtc) 2 represented by Chem. 11 was obtained.
[0000]
[0075] Next, in Production Examples 8 to 23, a detailed description will be made of production examples of a coor5dination polymer which is a raw material of a thin-film solar cell of the present invention. It should be understood that the Production Examples described below are only examples that embody the present invention and do not limit the technical scope of the present invention.
Production Example 8
Preparation of Coordination Polymer [Cu 5 I 3 (Pip-dtc) 4 ] n
[0076] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Pip-dtc) 2 of Production Example 1 was dissolved. In a mixed solvent of 10 mL of propionitrile and 10 mL of acetone, 0.1 mmol of copper iodide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for two days. Thus, a coordination polymer ([Cu 5 I 3 (Pip-dtc) 4 ] n , black single crystal of (CuIPip1D)) of Production Example 8 was prepared.
[0077] FIG. 5 illustrates a three-dimensional structure obtained from a structural analysis of the coordination polymer of Production Example 8. The coordination polymer has a structure in which the mononuclear complex Cu(Pip-dtc) 2 is bonded to both sides of a complex of copper(I) iodide, the complex having a one-dimensional ladder structure.
[0078] The coordination polymer of Production Example 8 had a HOMO of −5.09 eV and a LUMO of −3.92 eV. The coordination polymer of Production Example 8 had a conductivity σ 300K of 1.1×10 −7 S/cm (E a =0.31 eV).
Production Example 9
Preparation of Coordination Polymer [Cu 3 Br (Hm-dtc) 2](CH 3 CN) 2 ] n
[0079] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Hm-dtc) 2 of Production Example 2 was dissolved. In a mixed solvent of 3 mL of acetonitrile and 17 mL of acetone, 0.2 mmol of copper bromide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 3 Br 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n , black single crystal of (CuBrHm1D)) of Production Example 9 was prepared.
[0080] The coordination polymer of Production Example 9 had a HOMO of −5.20 eV and a LUMO of −3.72 eVeV. The coordination polymer of Production Example 9 had a conductivity σ 340K of 1.7×10 −7 S/cm (E a =0.56 eV).
Production Example 10
Preparation of Coordination Polymer [Cu 3 I 2 (Hm-dtc) 2 ](CH 3 CN) 2 ] n
[0081] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Hm-dtc) 2 of Production Example 2 was dissolved. In a mixed solvent of 10 mL of acetonitrile and 10 mL of acetone, 0.2 mmol of copper iodide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 3 I 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n black single crystal of (CuIHm1D)) of Production Example 10 was prepared.
[0082] The coordination polymer of Production Example 10 had a HOMO of −5.10 eV and a LUMO of −3.63 eVeV. The coordination polymer of Production Example 10 had a conductivity σ 340K of 2.46×10 −7 S/cm (E a =0.48 eV).
Production Example 11
Preparation of Coordination Polymer {[Cu 6 Br 4 (Pyr-dtc) 4 ]CHCl 3 } n
[0083] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Pyr-dtc) 2 of Production Example 3 was dissolved. In 10 mL of acetonitrile, 0.4 mmol of CuBrS(CH 3 ) 2 was dissolved, and the solution was then diluted with 10 mL of acetone. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ({[Cu 6 Br 4 (Pyr-dtc) 4 ]CHCl 3 } n , black single crystal of (CuBrPyr3D)) of Production Example 11 was prepared.
[0084] The coordination polymer of Production Example 11 had a HOMO of −5.28 eV and a LUMO of −4.27 eV. The coordination polymer of Production Example 11 had a conductivity σ 300K of 5.2×10 −7 S/cm (E a =0.29 eV).
Production Example 12
Preparation of Coordination Polymer [Cu 3 Br 2 (Ocm-dtc) 2 ] n
[0085] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Ocm-dtc) 2 of Production Example 4 was dissolved. In a mixed solvent of 4 mL of acetonitrile and 16 mL of acetone, 0.2 mmol of copper(I) bromide-dimethyl sulfide complex was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for three days. Thus, a coordination polymer ([Cu 3 Br 2 (Ocm-dtc) 2 ] n , black single crystal of (CuBrOcm1D)) of Production Example 12 illustrated in Chem. 12 was prepared.
[0086] The coordination polymer of Production Example 12 had a HOMO of −5.24 eV and a LUMO of −3.96 eV. The coordination polymer of Production Example 12 had a conductivity σ 300K of 3.4×10 −8 S/cm (E a =0.39 eV).
[0000]
Production Example 13
Preparation of Coordination Polymer [Cu 3 I 2 (Ocm-dtc) 2 ] n
[0087] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Ocm-dtc) 2 of Production Example 4 was dissolved. In a mixed solvent of 10 mL of acetonitrile and 10 mL of acetone, 0.2 mmol of copper(I) iodide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for three days. Thus, a coordination polymer ([Cu 3 I 2 (Ocm-dtc) 2 ] n , black single crystal of (CuIOcm1D)) of Production Example 13 illustrated in Chem. 13 was prepared.
[0088] The coordination polymer of Production Example 13 had a HOMO of −5.19 eV and a LUMO of −3.90 eV. The coordination polymer of Production Example 13 had a conductivity σ 300K of 1.1×10 −9 S/cm (E a =0.24 eV).
[0000]
Production Example 14
Preparation of Coordination Polymer [Cu 7 Cl 7 (nPr 2 -dtc) 2 ] n
[0089] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(nPr 2 -dtc) 2 of Production Example 5 was dissolved. In a mixed solvent of 20 mL acetone, 0.4 mmol of copper chloride dihydrate was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 7 Cl 7 (nPr 2 -dtc) 2 ] n , black single crystal of (CuClnPr2D)) of Production Example 14 was prepared.
[0090] The coordination polymer of Production Example 14 had a HOMO of −5.28 eV and a LUMO of −4.76 eV. The coordination polymer of Production Example 14 had a conductivity σ 300K of 5.7×10 −5 (E a =0.21 eV).
Production Example 15
Preparation of Coordination Polymer [Cu 8 Br 7 (nBu 2 -dtc) 2 ] n
[0091] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(nBu 2 -dtc) 2 of Production Example 6 was dissolved. Next, 0.2 mol of copper bromide was mixed with a few drops of water, and the resulting mixture was then dissolved in 20 mL of acetone. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 5 Br 7 (nBu 2 -dtc) 2 ] n , black single crystal of (CuBrnBu2D)) of Production Example 15 was prepared.
[0092] The coordination polymer of Production Example 15 had a HOMO of −5.22 eV and a LUMO of −4.54 eV. The coordination polymer of Production Example 15 had a conductivity σ 300K of 2.7×10 −5 S/cm (E a =0.21 eV).
Production Example 16
Preparation of Coordination Polymer [Cu 3 Br 2 (Pip-dtc) 2 (CH 3 CN) 2 ] n
[0093] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Pip-dtc) 2 of Production Example 1 was dissolved. In a mixed solvent of 4 mL of acetonitrile and 16 mL of acetone, 0.2 mmol of copper(I) bromide was dissolved. These solutions were then mixed, and the mixed solution was allowed to stand at room temperature for one day. Thus, a coordination polymer ([Cu 3 Br 2 (Pip-dtc) 2 (CH 3 CN) 2 ] n , black single crystal of (α-CuBrPip1D)) of Production Example 16 was prepared. FIG. 6 is a schematic view illustrating a three-dimensional structure of the coordination polymer.
[0094] The coordination polymer of Production Example 16 had a HOMO of −5.14 eV and a LUMO of −3.74 eV. The coordination polymer of Production Example 16 had a conductivity σ 300K of 3.8×10 −10 S/cm (E a =0.66 eV).
Production Example 17
Preparation of Coordination Polymer [Cu 3 I 2 (Pip-dtc) 2 (CH 3 CN) 2 ] n
[0095] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Cu(Pip-dtc) 2 of Production Example 1 was dissolved. In a mixed solvent of 10 mL of acetonitrile and 10 mL of acetone, 0.1 mmol of copper(I) iodide was dissolved. These solutions were then mixed, and the mixed solution was allowed to stand at room temperature for one day. Thus, a coordination polymer ([Cu 3 I 7 (Pip-dtc) 2 (CHCN) 2 ] n , black single crystal of (α-CuIPip1D)) of Production Example 17 was prepared. FIG. 7 is a schematic view illustrating a three-dimensional structure of the coordination polymer.
[0096] The coordination polymer of Production Example 17 had a HOMO of −5.20 eV and a LUMO of −3.90 eV. The coordination polymer of Production Example 17 had a conductivity σ 300K of 4.1×10 −10 S/cm (E a =0.50 eV).
Production Example 18
Preparation of Coordination Polymer [Cu 2 NiBr 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n
[0097] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Ni(Hm-dtc) 2 of Production Example 7 was dissolved. In a mixed solvent of 10 mL of acetonitrile and 10 mL of acetone, 0.2 mmol of copper(I) bromide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 2 NiBr 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n , black single crystal of (NiBrHm1D)) of Production Example 18 was prepared. FIG. 8 is a schematic view illustrating a three-dimensional structure of the coordination polymer.
[0098] The coordination polymer of Production Example 18 had a HOMO of −5.28 eV and a LUMO of −3.90 eV. The coordination polymer of Production Example 18 was an insulator.
Production Example 19
Preparation of Coordination Polymer [Cu 2 NiI 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n
[0099] In 20 mL of chloroform, 0.1 mmol of the mononuclear complex Ni(Hm-dtc) 2 of Production Example 7 was dissolved. In a mixed solvent of 10 mL of acetonitrile and 10 mL of acetone, 0.1 mmol of copper(I) iodide was dissolved. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 2 NiI 2 (Hm-dtc) 2 (CH 3 CN) 2 ] n , black single crystal of (NiIHm1D)) of Production Example 19 was prepared. FIG. 9 is a schematic view illustrating a three-dimensional structure of the coordination polymer.
[0100] The coordination polymer of Production Example 19 had a HOMO of −5.22 eV and a LUMO of −3.70 eV. The coordination polymer of Production Example 19 was an insulator.
Production Example 20
Preparation of Coordination Polymer [Cu 2 NiBr 2 (Hm-dtc) 2 ] n
[0101] In 20 mL of chloroform, 0.3 mmol of the mononuclear complex Ni(Hm-dtc) 2 of Production Example 7 was dissolved. Next, 0.2 mmol of copper(II) bromide was mixed with a few drops of water, and the resulting mixture was then dissolved in a mixed solvent of 20 mL of acetone. These solutions were then mixed, and the mixed solution was left to stand at room temperature for one day. Thus, a coordination polymer ([Cu 2 NiBr 2 (Hm-dtc) 2 ] n , black block-shaped crystal of (NiBrHm3D)) of Production Example 20 was prepared. FIG. 10 is a schematic view illustrating a three-dimensional structure of the coordination polymer.
[0102] The coordination polymer of Production Example 20 had a HOMO of −5.40 eV and a LUMO of −4.39 eV. The coordination polymer of Production Example 20 had a conductivity σ 300K of 3.4×10 −10 S/cm (E a =0.39 eV).
Production Example 21
Preparation of Coordination Polymer [Cu(dahex-dtc)] n
[0103] In about 500 mL or methanol solvent, 20 mmol of potassium hydroxide was dissolved. Subsequently, 10 mmol of N,N′-diethyl-1,6-diaminohexane, 20 mmol of carbon disulfide, and 10 mmol of copper chloride dihydrate were sequentially added to the solution, thus obtaining a brown precipitate. The brown precipitate was subjected to suction filtration, then dissolved in about 500 mL of chloroform, and filtered. Subsequently, the chloroform was evaporated using an evaporator to some extent, and the resulting precipitate was then diffused with a large amount of hexane. Thus, a coordination polymer (brown precipitate of [Cu(dahex-dtc)] n ) of Production Example 21 illustrated in Chem. 14 was prepared.
[0104] The coordination polymer of Production Example 21 had a HOMO of −5.05 eV and a LUMO of −3.85 eV. The coordination polymer of Production Example 21 had a conductivity σ 300K of 1.2×10 −5 S/cm (E a =0.41 eV).
[0000]
Production Example 22
Preparation of Coordination Polymer [Fe 2 (dahex-dtc) 3 ] n
[0105] In about 500 mL or methanol solvent, 15 mmol of potassium hydroxide was dissolved. Subsequently, 10 mmol of N,N′-diethyl-1,6-diaminohexane, 15 mmol of carbon disulfide, and 10 mmol of iron chloride hexahydrate were sequentially added to the solution, thus obtaining a black precipitate. The black precipitate was subjected to suction filtration, then dissolved in about 500 mL of chloroform, and filtered. Subsequently, the chloroform was evaporated using an evaporator to some extent, and the resulting precipitate was then diffused with a large amount of hexane. Thus, a coordination polymer (black precipitate of [Fe 2 (dahex-dtc) 3 ] n ) of Production Example 22 illustrated in Chem. 15 was prepared.
[0106] The coordination polymer of Production Example 22 had a HOMO of −4.85 eV and a LUMO of −3.50 eV. The coordination polymer of Production Example 22 had a conductivity σ 300K of 2.2×10 −11 S/cm (E a =0.67 eV).
[0000]
[0107] Next, thin-film solar cells of the present invention will be described in detail using Examples and Comparative Example and with reference the drawings. It should be understood that the Examples described below are only examples that embody the present invention and do not limit the technical scope of the present invention.
Example 1
Preparation of Thin-Film Solar Cell
[0108] First, poly(3,4-ethylenedioxythiophene) (PEDOT) to which polystyrenesulfonic acid (PPS) was added was applied onto an etched transparent electrode 5 (ITO) using a spin coater at a rotation speed of 2,000 rpm, and dried at 160° C. for 10 minutes. This operation was repeated three times to form a PEDOT-PSS film 6 on the transparent electrode 5.
[0109] Next, 20 mg of poly-3-hexylthiophene (P3HT), 15 mg of 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM), and 0.5 mg of the coordination polymer (CuIPip1D) of Production Example 8 were added to 1 mL of chlorobenzene, and the resulting mixed solution was stirred at 60° C. for six hours. Subsequently, the mixed solution was applied onto the PEDOT-PSS film 6 using a spin coater at a rotation speed of 1,000 rpm, and dried at 100° C. for 30 minutes.
[0110] Furthermore, LiF (0.7 nm) and Al (70 nm) were respectively deposited thereon by vacuum evaporation to form a LiF/Al film 7. Thus, a thin-film solar cell 1 of Example 1 was produced.
[0111] FIG. 1 illustrates an example of a cross-sectional structure of the thin-film solar cell 1 of the present invention. It is believed that, unlike a cross-sectional structure of an existing thin-film solar cell which is illustrated in FIG. 2 and in which no coordination polymer is present, the thin-film solar cell 1 of the present invention has a structure in which a coordination polymer 2 is present at an interface between a p-type semiconductor 3 and an n-type semiconductor 4.
[0112] FIG. 3 shows a laser microscope photograph of an organic layer of a thin-film solar cell according to the present invention. Unlike a laser microscope photograph of an organic layer of an existing thin-film solar cell illustrated in FIG. 4 , fine particles of a coordination polymer having a size from 1 μm or less to about 10 μm are scattered. This result shows that the coordination polymer 2 is present in the thin film.
Example 2
Preparation of Thin-Film Solar Cell
[0113] First, poly(3,4-ethylenedioxythiophene) (PEDOT) to which polystyrenesulfonic acid (PPS) was added was applied onto an etched transparent electrode (ITO) using a spin coater at a rotation speed of 2,000 rpm, and dried at 160° C. for 10 minutes. This operation was repeated three times to form a PEDOT-PSS film on the transparent electrode.
[0114] Next, 20 mg of poly-3-hexylthiophene (P3HT), 15 mg of 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM), and 0.5 mg of the coordination polymer (CuBrOcm1D) of Production Example 12 were added to 1 mL of chlorobenzene, and the resulting mixed solution was stirred at 60° C. for six hours. Subsequently, the mixed solution was applied onto the PEDOT-PSS film using a spin coater at a rotation speed of 1,000 rpm, and dried at 100° C. for 30 minutes.
[0115] Furthermore, LiF (0.7 nm) and Al (70 nm) were respectively deposited thereon by vacuum evaporation to form a LiF/Al film. Thus, a thin-film solar cell of Example 2 was produced.
Example 3
Preparation of Thin-Film Solar Cell
[0116] First, poly(3,4-ethylenedioxythiophene) (PEDOT) to which polystyrenesulfonic acid (PPS) was added was applied onto an etched transparent electrode (ITO) using a spin coater at a rotation speed of 2,000 rpm, and dried at 160° C. for 10 minutes. This operation was repeated three times to form a PEDOT-PSS film on the transparent electrode.
[0117] Next, 20 mg of poly-3-hexylthiophene (P3HT), 15 mg of 1-(3-methoxycarbonyl)propyl-1-phenyl-[6,6]-C61 (PCBM), and 0.5 mg of the coordination polymer (CuIOcm1D) of Production Example 13 were added to 1 mL of chlorobenzene, and the resulting mixed solution was stirred at 60° C. for six hours. Subsequently, the mixed solution was applied onto the PEDOT-PSS film using a spin coater at a rotation speed of 1,000 rpm, and dried at 100° C. for 30 minutes.
[0118] Furthermore, LiF (0.7 nm) and Al (70 nm) were respectively deposited thereon by vacuum evaporation to form a LiF/Al film. Thus, a thin-film solar cell of Example 3 was produced.
Comparative Example
[0119] A thin-film solar cell of Comparative Example was produced as in Examples except that a mixed solution was prepared without using any of the coordination polymers used in Examples.
[0120] Next, current density-voltage characteristics of the thin-film solar cells of Examples 1 to 3 and Comparative Example produced as described above were measured.
(Measurement of Current Density-Voltage Characteristics)
[0121] The current density-voltage characteristics were measured using a solar simulator (AM 1.5, 100 mW/cm 2 ). FIGS. 11 to 13 show the measurement results.
[0122] On the basis of the results shown in FIGS. 11 to 13 , a current density at a voltage of zero was defined as a short-circuit current density (Jsc), a voltage when a load voltage was applied and the current density became zero was defined as an open-circuit voltage (Voc), a value calculated by dividing the maximum output obtained from a current density-voltage curve by the product of the short-circuit current density and the open-circuit voltage was defined as a fill factor (FF), and a value calculated by dividing the maximum output by the incident light intensity was defined as a conversion efficiency η.
[0123] According to the results, the thin-film solar cell of Example 1 had a Jsc of 5.51 mA/cm 2 , a Voc of 0.59 V, an FF of 0.32, and an η of 1.05%. In contrast, the thin-film solar cell of Comparative Example had a Jsc of 3.2 mA/cm, a Voc of 0.58 V, an FF of 0.39, and an η of 0.71%. The thin-film solar cell of Example 2 had a Jsc of 7.204 mA/cm 2 , a Voc of 0.529 V, an FF of 0.396, and an η of 1.508%. The thin-film solar cell of Example 3 had a Jsc of 9.710 mA/cm, a Voc of 0.629 V, an FF of 0.309, and an η of 1.890%.
[0124] The above results show that, by using the coordination polymer (Example 1), the short-circuit current density (Jsc) is increased, and consequently, the conversion efficiency η is also improved by 0.34% (48% up), as compared with the case where the coordination polymer is not used (Comparative Example).
(Measurement of HOMO and LUMO of Coordination Polymer)
[0125] As described in paragraph [0050], the coordination polymer (CuIPip1D) of Production Example 8 used in Example 1 has a HOMO of −5.09 eV and a LUMO of −3.92 eV. Furthermore, it is known that the p-type semiconductor (P3HT) used in Example 1 has a HOMO of −5.0 eV and the n-type semiconductor (PCBM) used in Example 1 has a LUMO of −4.0 eV.
[0126] From the relationship of the above energy levels, it is believed that an improvement in the efficiency of the thin-film solar cell of the present invention is caused by the function of the coordination polymer as a sensitizing dye in addition to the known charge separation due to the charge transfer from the p-type semiconductor to the n-type semiconductor. Specifically, first, the coordination polymer absorbs light and causes charge separation to generate electrons and holes. Next, the holes are transported to the HOMO of the p-type semiconductor, whose energy level is higher than the HOMO level of the coordination polymer (CuIPip1D), and the electrons are transported to the LUMO of the n-type semiconductor, whose energy level is lower than the LUMO level of the coordination polymer. It is believed that an electromotive force is generated on the coordination polymer as described above.
[0127] Accordingly, it is believed that the short-circuit current density is increased by the sensitizing effect of this additional coordination polymer and the conversion efficiency is improved.
[0128] Regarding the coordination polymers other than the coordination polymers prepared in Production Examples 8, 12, and 13, thin-film solar cells including these coordination polymers were not produced. However, the same advantages as those of the thin-film solar cells described in Examples 1 to 3 are achieved by using any of these coordination polymers in combination with a p-type semiconductor having an appropriate HOMO and an n-type semiconductor having an appropriate LUMO.
[0129] As described above, according to the thin-film solar cell of the present invention, the conversion efficiency can be improved by selecting an appropriate coordination polymer even in a thin-film solar cell including any organic semiconductor. Thus, the thin-film solar cell of the present invention has a significantly wider range of applications than existing thin-film solar cells including organic semiconductors.
INDUSTRIAL APPLICABILITY
[0130] The present invention can be used in a thin-film solar cell.
REFERENCE SIGNS LIST
[0000]
1 thin-film solar cell
2 coordination polymer
3 p-type semiconductor
4 n-type semiconductor
5 transparent electrode
6 PEDOT-PSS film
7 LiF/Al film
8 metal ion
9 ligand
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[Object] A thin-film solar cell which can be produced using an inexpensive raw material and has improved conversion efficiency has been desired.
[Solution] A thin-film solar cell according to the present invention includes at least one organic semiconductor and a coordination polymer. The coordination polymer contains a repeating unit which includes a complex produced by coordinating at least one ligand to at least one metal ion, the metal ion being selected from ions of transition metal elements, and the ligand being capable of coordinating to the metal ion and selected from sulfur-containing compounds, nitrogen-containing compounds, oxygen-containing compounds, and phosphorus-containing compounds.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This United States Non-Provisional patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/555,862, filed on Nov. 4, 2011, which is incorporated in its entirety herein by reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to electromagnetic devices in general and more particularly to electromagnetic induction devices having straight wires interfaced in a parallel electric circuit, and applications of such a device in embodiments such as an induction device, an electricity generator having no moving parts whose voltage and current is induced by magnetic phenomena.
BACKGROUND OF THE INVENTION
[0003] Many devices utilize magnetic phenomena in their utilization of electricity, most of which devices utilize solenoids or coils. Among these devices are electromagnets and electromagnetic induction devices. Stationary electromagnetic induction devices include transformers and “chargers” for portable devices. “Chargers” are necessary in devices that are not directly linked to an electric outlet; in such chargers, an induction coil is linked to an electric source and inductively transfers electric energy to an inductee. Current-art induction devices, comprising solenoids and coils, efficiently utilize volumes that are cylindrical but are not well suited in devices having a parallelepiped volume. Further, current-art induction devices are inherently inefficient, as only a part of the magnetic field of the inductor is utilized. A Halbach Array is a device that concentrates its magnetic field in a particular manner, and the template herein disclosed is utilized in electromagnetic Halbach Array configurations. Other well-known devices that utilize magnetic phenomena include generators, which transform some type of energy into electric energy. It is well known that a voltage, and a current, can be induced in a wire by the movement of a magnetic field relative to that wire. Electricity generators that depend on magnetic phenomena require an external energy source to generate electricity by the movement of a magnet (the rotor), which induces a voltage and current into a coil (the stator). Generating stations usually require a costly infrastructure whatever the external energy source. Natural and inexhaustible energy sources such as falling water, wind and tidal currents generate electricity by employing that external source in a direct manner to turn turbines or to move magnets. Geothermal generation is also natural and inexhaustible; it is indirect, using the earth's heat where relatively easily accessible, to generate steam which is used to turn turbines. Non-renewable fossil fuels such as coal, petroleum and natural gas are sources of energy that are employed in an indirect method to produce electricity; the fuels are burned to create steam which turn turbines, and the burning of any such fuel is known to create environmental problems. Some sources of petroleum, such as shale oil and offshore oil deposits, require considerable resources to develop and their extraction may entail significant undesirable environmental consequences. The recovered oil requires refinement, which also requires significant resources and also may entail significant undesirable environmental consequences. Further, the sites of such energy sources (falling water, wind, tidal currents and geothermal) may be distant from the sites of consumption, requiring transmission facilities from the generating station. Such transmission facilities not only also require significant infrastructure and land, but also are thought to create environmental problems. Not only do fossil fuel-based generating systems generally require significant energy for extraction, but also there are generally intrinsic inefficiencies in their use for electricity generation. Coal-based generating systems produce approximately 50% of the electricity produced in the US, and only 33% of the energy units in mined coal end up at the point of use; 65% is lost in generation and 2% is lost in transmission. Further, when coal burns to produce electricity, undesirable elements are released into the atmosphere: for every 1 Kvah of electricity generated by coal-fired plants, 0.0234 mg of mercury, as well as carbon dioxide, sulfur dioxide and nitrogen oxide, are released. Natural gas is currently a cheap source of fuel for generating stations. Inexhaustible nuclear energy employs the indirect method, requires the most significant infrastructure, and appears to be subject to far-reaching and possibly dangerous consequences for the environment and populations. Most terrestrial vehicles, marine propulsion systems and aircraft use petroleum-based sources of energy. Recently, propulsion systems for automobiles have been developed using large batteries as the energy source, and some naval propulsion systems use nuclear power.
[0004] Thus, what is desired is an electromagnetic device, configurable as an induction device, that is efficient in and parallelepiped volumes and a variant of which is efficient in cylindrical volumes; that is configurable in such manner that it enables an electromagnetic Halbach Array as well as an electricity generator which utilizes inexhaustible magnetic phenomena in a direct manner to generate electricity.
SUMMARY OF THE INVENTION
[0005] The electromagnetic induction device presently disclosed serves as a template for other electromagnetic devices, embodiments and configurations thereof, as will be disclosed hereinafter. Whereas current-art electromagnetic devices generally are comprised of solenoids and/or coils, and efficiently utilize the space of volumes that are cylindrical, the electromagnetic induction device of the present disclosure efficiently utilizes the space of volumes that are generally parallelepiped. The device includes at least one inductor and at least one inductee, each including a number of coated straight wires preferably having a square cross-section and sharp corners, that are closely assembled in at least one layer in the height and in the width and along the length of the device between the hereinafter-described conductor plates, and in such manner that at least one straight wire of at least one layer is parallel both to at least one other straight wire of that same layer and at least one straight wire of at least one other layer, and preferably that all said wires of both the at least one inductor and at least one inductee are mutually parallel. Conductor plates, preferably fabricated of a material that is a good conductor of electricity such as copper, are situated at the ends of both the at least one inductor and at least one inductee, enabling both a parallel circuit interface with the ends of the straight wires thereof as well as providing an interface for power and output leads. At least one magnetically-permeable core is preferably included in the at least one inductor; such a core increases the strength of the magnetic field generated in and about the aforesaid device by a factor of up to thousands, compared to an air core. While certainly a round wire may be utilized in such a device, a square cross-sectioned wire is preferable, as it has a greater area in the same lateral and vertical space as would be occupied by a round wire. Greater area means not only that a square cross-sectioned wire can carry a higher amperage for a given voltage, but also that the wire offers less resistance to current flow. The straight wires are preferably fabricated of a material that is a good conductor of electricity and has a low magnetic permeability such as copper. The coating of an aforesaid wire has characteristics which preferably include good electric insulation, thinness, high-temperature tolerance, magnetically impermeability and resistance to fraying; it is important that no electric contact be established between the wires of the device, for then the effective number of wires (discussed hereinafter) would be reduced, which is an undesirable effect. In an induction device, it is preferable that there be no air gap between the at least one inductor and the inductee, as it is known that a magnetic field is weakened by a traverse through an air gap. That is an undesirable characteristic, as the strongest moving magnetic field possible is desirable in and around the at least one inductor. However, there obviously could be an air gap if the functioning of the device, such as a charger, would require that the inductee must be removable from the inductor, for example. It is desirable that the colors of the coatings of the wires of the inductors be different from that of the inductees, and that the various electrical components of each have different color-coding, to avoid cross circuiting in the assembly of a device. It may be desirable to use resonant inductive coupling of the inductor and inductee, as this would allow a greater air gap without the normal attendant loss of field strength.
[0006] One obvious utilization of the template disclosed herein is an electromagnet that efficiently utilizes volumes that are parallelepiped, comprised of square wires instead of a solenoid. The advantage of square wires in an electromagnet is that square wires, having a greater area in the same cross-section, can carry a higher amperage than a round wire, thus enabling a stronger electromagnet. Another utilization is as a “charger” in volumes that are parallelepiped. Other embodiments and variants are disclosed hereinafter.
[0007] Another device that employs the template disclosed herein is an electromagnetic induction device including subassemblies among which are at least one “inductor” and at least one “inductee”. An inductor is defined as an electromagnetic element comprised of wires in and around which a moving magnetic field comprised of concentric circles is created when a cyclic current flows through the said the at least one inductor's wires. An inductee is defined as an electromagnetic element comprised of wires in which a voltage and current is induced by a magnetic field traversing (cutting) its wires. The operating principles of induction devices are well known: when a cyclic current flows through the wires of an inductor, it induces a voltage and a current flow in the inductee with which it is inductively coupled. Whereas current-art induction devices using solenoids or coils are efficient in devices whose form-factor is cylindrical, a first preferred embodiment of an induction device is an induction device that is more efficient in spaces that are parallelepiped, which could be a magnet or a “charger”. A second embodiment disclosed hereinafter is an electricity generator, which exists in two variants: one that is efficient in parallelepiped volumes, and another that is efficient in cylindrical volumes. A third embodiment is an electromagnetic Halbach Array and its derivative, an electromagnetic Halbach Array Induction Device.
[0008] In the presently-disclosed electromagnetic induction device, both the at least one inductor and the at least one inductee are preferably include straight wires preferably having a square cross-section and sharp edges closely assembled in the height and in the width and along the length of the device between the hereinafter-described conductor plates, and in such manner that: (1) at least one straight wire of at least one layer of an inductor is parallel both to at least one other straight wire of that same layer and to at least one other straight wire of another layer in the said inductor and (2) at least one straight wire of at least one layer of an inductee is parallel both to at least one other straight wire of that same layer and to at one straight wire of at least one other layer in the said inductee and (3) at least one straight wire of an inductor is parallel to at least one straight wire of an inductee. Preferably, all straight wires of both the inductors and inductees are mutually parallel. Square cross-sectioned wires are preferable as they have a greater area in the same space as would be occupied by a round wire, and thus can carry current of a higher-amperage. It is preferable that the inductee includes a greater number of straight wires than the inductor, as thereby a greater voltage is induced in the wires of the inductee for the same frequency of inducing current. Conductor plates, preferably fabricated of a material that is a good conductor of electricity such as copper, are situated at the ends of both the at least one inductor and at least one inductee, enabling both a parallel circuit interface with the ends of the straight wires thereof as well as providing an interface for power and output leads. At least one magnetically-permeable core is preferably included in the at least one inductor; such a core increases the strength of the magnetic field generated in and about the aforesaid device by a factor of up to thousands, compared to an air core. The said at least one magnetically-permeable core, is preferably fabricated of a magnetically-permeable material preferably comprised of metal sheets having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with an insulation between the metal sheets. The said metal sheets preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. Such a core increases the strength of the magnetic field generated in and about the aforesaid inductor by a factor of up to thousands, compared to an air core. The cases of both the inductor and the inductee are preferably fabricated of a magnetically impermeable material, whose object is not only to contain the at least one inductor and at least one inductee, but also to concentrate the concentric circles of the moving magnetic field that has traversed the wires of the at least one inductee such that they do not escape to the exterior of the case, as well as to protect the device from external magnetic fields. An inductor and inductee include conductor plates at their ends, said plates not only enabling a parallel circuit interface with the straight wires thereof, but also enabling an interface with power leads for the at least one inductor and output leads for the at least one inductee. The said leads are interfaced in a parallel circuit linking all said inductors and all said inductees. Whatever the thickness of the said conductor plates it is obvious that, were they to be configured along the major dimension of the device, they would occupy a greater volume of space, reducing that available for the straight wires, which is undesirable. Thus, it is preferable that the conductor plates of any straight-wire device be situated at those ends having the minor dimension. It is important that the conductor plates of an inductor not be in electrical contact with those of the inductee; if they were, the device would not function, as the current flowing in the inductor's wires would flow directly into those of the inductee without causing any induced current in the inductees. The coatings of the wires of the inductors and inductees are preferably differently color-coded, and the various electrical components of each in all devices preferably have different color-coding in order to avoid cross circuiting in the assembly of a device.
[0009] The electromagnetic induction device previously disclosed may be configured as an electricity generator, which generates useable electricity by the direct conversion of inexhaustible potential magnetic energy. Whereas current-art electricity generators move wires through a magnetic field to generate electricity, requiring external energy to do so, the novel generator disclosed herein moves a magnetic field through wires, and only the cyclic reversal of an AC inducing current or a switched or pulsed DC inducing current, is required to do so. An electricity generator, comprising a number of assemblies and subassemblies that include a number of the aforesaid electromagnetic induction devices, exists in a number of variants. Each variant includes at least two volumes: at least one “primary” volume including a number of inductors and at least one “secondary” volume including a number of inductees, which said secondary volume(s) preferably surround or enclose the primary volume(s). This configuration is a key element in the optimal functioning of all variants of a generator of the present disclosure, as it not only enables the most efficient use of the moving magnetic field generated in and around the at least one inductor when a cyclic current flows through their wires, but also it enables there to be a greater number of wires, or a greater length of wire, in the inductees than in the inductors, thus generating a higher voltage in the inductees for the same frequency of current in the inductors.
[0010] It is desirable at this juncture to describe how the configuration of an electricity generator of the present disclosure is determined by the very volume in which the generator is configured. If that volume is parallelepiped, a first or second preferred variant of a generator of the present disclosure is efficiently configured therein; it includes inductors and inductees having straight wires described here in before. If that volume is cylindrical, a third or fourth preferred variant of a generator of the present disclosure is efficiently configured therein. The third variant has a toroidal form-factor utilizing straight wires; the fourth includes solenoid inductors and a coil inductees. In all preferred variants of an electricity-generator embodiment, an inductor includes at least one magnetically permeable core that may also serve other functions. The inductors and inductees are physically configured in length in their respective volumes in such manner that their wires are mutually parallel, and that their adjacent ends have complementary polarities when a cyclic current flows through the parallel circuit of their wires. Thus, the number of inductors in the primary volume acts like a long electromagnet, with magnetically permeable cores enhancing the magnetic field. In a preferred variant of an electricity-generator, the wires comprising an inductor and an inductee are electrically interfaced in their respective parallel circuit, and all inductors and inductees are electrically interfaced in their respective parallel circuit. The (straight wire) variants of an electricity generator configured in a parallelepiped, flat or toroidal volume have an inherent advantage over the cylindrical variant having solenoids and coils, which is related to resistance of the circuits. As the wires of any straight wire generator variant are shorter than those of a cylindrical variant, it follows that in any given volume; there will be more straight wires than there could be “turns” of the solenoid inductors and “loops” of the coil inductees. Thus, there will be a greater number of parallel circuits of wires in the inductors and inductees, and thus a reduced resistance of the circuits. This subject of resistance is discussed hereinafter.
[0011] In a preferred variant of an electricity generator variant configured in a parallelepiped, flat or toroidal volume, both the at least one inductor and the at least one inductee include a number of preferably square cross-sectioned coated straight wires having sharp corners closely assembled in the height and in the width and along the length of the device between the hereinafter—described conductor plates, and in such manner that: (1) at least one straight wire of at least one layer of an inductor is parallel both to at least one other straight wire of that same layer and to at least one other straight wire of another layer in the said inductor and (2) at least one straight wire of at least one layer in an inductee is parallel both to at least one other straight wire of that same layer and to at one straight wire of at least one other layer in the said inductee and (3) at least one straight wire of an inductor is parallel to at least one straight wire of an inductee; that preferably all straight wires of both inductors and inductees are mutually parallel. Conductor plates, preferably fabricated of a material that is a good conductor of electricity such as copper, are situated at the ends of both the at least one inductor and at least one inductee, enabling both a parallel circuit interface with the ends of the straight wires thereof as well as providing an interface for power and output leads. At least one magnetically-permeable core is preferably included in the at least one inductor; such a core increases the strength of the magnetic field generated in and about the aforesaid device by a factor of up to thousands, compared to an air core. In a preferred embodiment of an electricity generator variant configured in a cylindrical volume, an inductor is a solenoid defined as a device preferably having many turns of preferably square cross-sectioned coated wires having sharp corners, tightly wound in many layers in the same direction around a magnetically permeable core, and preferably between at least two magnetically-permeable cores. An inductee is defined as a coil defined as a device preferably comprised of square cross-sectioned coated wires having sharp corners tightly wound in the same direction in many layers of loops along the length of the coil. Whatever the circumference of a layer, it remains one “loop” or “turn”, as one straight wire of a herein-disclosed inductor or inductee is a “turn-equivalent” irrespective of its length. The number of “turns” or “turn-equivalents” of an inductor directly affects the density of the magnetic field that traverses the wires of the inductees of a generator variant of the present disclosure. The number of “loops” or “turn-equivalents” of an inductee directly affects the voltage output of a generator of the present disclosure: for a given frequency of inducing current, a greater number of loops or turn equivalents in the inductee compared to that of the inductor, induces a higher voltage in the inductee.
[0012] It is desirable at this juncture to provide a summary description of the how the electromagnetic induction device of the present disclosure enables an electricity generator. There are a number of inductors in a primary volume surrounded by, and inductively coupled with, a number of inductees in a secondary volume, the two volumes preferably being concentric. In any preferred variant of an electricity generator, there are a greater number of wires (or a greater length of wires) in the inductees configured in the secondary volume(s) than there are wires (or lengths of wires) of the inductors configured in the primary volume(s). The wires of each inductor and each inductee are electrically interfaced in a parallel circuit of that respective component, and all said inductors and inductees are electrically interfaced in their respective parallel circuits. A battery, which is the only external energy source required, supplies current for the initial cycle(s) to the control module, where it is regulated by electronic apparatus, then supplied as current of a certain frequency and amperage to the parallel circuit of inductors. In a preferred variant of a generator, the inductors are physically configured end to end in the primary volume such that their adjacent ends have complementary polarities when a cyclic current flows through the parallel circuit of their wires. It is known that, when a cyclic current flows through a wire, the wire acts as an electromagnet, creating a moving magnetic field comprised of concentric lines of force in and around itself.
[0013] Thus, the number of inductors in the primary volume acts like an electromagnet, with a magnetically permeable core in each inductor enhancing the moving magnetic field of the number of inductors so configured. The inductors and the inductees are physically configured in their respective volumes such that their wires are mutually parallel. The aforesaid concentric lines of force of the moving magnetic field created in and around the inductors traverse the wires of all inductees in a perpendicular manner, propagating then collapsing according to the frequency of the cyclic current, thereby inducing a cyclic voltage across the leads of the wires of the inductees. The propagating magnetic field induces a voltage of one polarity, and the collapsing magnetic field induces a voltage of the opposite polarity. The voltage will cause a current to flow in the aforesaid wires of the parallel circuit of the inductees if there is a completed circuit, of one polarity caused by the propagation of the field, and of the opposite polarity caused by the collapse of the field. The generator's output in the parallel circuit of the inductee's wires is either AC or FWDC, depending upon which type of current was supplied to the inductors as the inducing current. A part of the induced current output is supplied through a feedback circuit in the control module, to become the current subsequent to the initial cycle(s) in the parallel circuit of the wires of the inductors, and the battery is thereupon removed from the circuit. The major part of the induced current is supplied to a load.
[0014] One aspect of the present disclosure of a preferred variant of an electricity generator configured in a parallelepiped volume is that it includes at least one “primary” volume. A “primary” volume is defined as preferably including a number of inductors joined in interlocking sections; each said section is further defined as an assembly preferably including a number of quadrant subassemblies. A quadrant subassembly comprises a number of the previously disclosed electromagnetic devices. It is the object of the aforesaid quadrant subassembly inductors to generate a moving magnetic field therein and there-around when a cyclic current flows their wires. The aforesaid subassembly preferably includes a number of coated straight wires having sharp corners closely assembled in the height and in the width and along the length of the device between the hereinafter-described conductor plates, and in such manner that: (1) at least one straight wire of at least one layer of the said subassembly is parallel both to at least one other straight wire of that same layer and to at least one other straight wire of another layer in the said subassembly and (2) at least one straight wire of an inductor is parallel to at least one straight wire of an inductee; that preferably all straight wires of both the inductors and inductees are mutually parallel. An inductor is, in effect, a subassembly of the previously disclosed electromagnetic device. Conductor plates, preferably fabricated of a material that is a good conductor of electricity such as copper, are situated at the ends of both the at least one inductor, enabling both a parallel circuit interface with the ends of the straight wires thereof as well as providing an interface for power leads. At least one magnetically-permeable core is preferably included in the at least one inductor; such a core increases the strength of the magnetic field generated in and about the aforesaid device by a factor of up to thousands, compared to an air core. When current flows through each inductor, their polarity is the same, such that their polarities when assembled end-to-end in the primary volume, are complementary. It is known that parallel wires carrying current flowing in the same direction, attract each other. Thus, the bundle of straight wires in the inductor will remain closely assembled. The coating of an aforesaid wire has characteristics which preferably include thinness, high-temperature tolerance, resistance to fraying, good electric insulation and non-magnetically permeable; the color of the coating is different from that of the inductee. It is desirable that no electric contact be established between the wires of an inductor, for then the effective number of inductor turn-equivalents would be reduced, which is an undesirable effect. The aforesaid wires preferably have a square cross-section and sharp corners, and are preferably fabricated of a material having a low magnetic permeability and good conductivity, such as copper. While certainly a round wire may be utilized, a square cross-sectioned wire is preferable, as it has a greater area in the same lateral and vertical space as would be occupied by a round wire. Greater area means not only that a square cross-sectioned wire can carry a higher amperage for a given voltage, but also that the wire offers less resistance to a current flow. However, the smallest cross-section adequate to carry the amperage supplied to the aforesaid straight wires in the inductors is preferred, resulting in the greatest number of wires in the volume occupied by the aforesaid inductors. It is obvious that any generator variant could have inductor and inductee configurations different from those configurations described herein.
[0015] A further aspect of the present disclosure of a preferred variant of an electricity generator configured in a parallelepiped, flat or toroidal volume is that it includes at least one “secondary” volume. A “secondary” volume is further defined as preferably surrounding or enclosing a “primary” volume and being concentric with it. The said secondary volume includes a number of inductee assembly interlocking sections, each such section defined herein as preferably including a number of coated straight wires closely assembled in the height and in the width and along the length of the device between the hereinafter-described conductor plates, and in such manner that: (1) at least one straight wire of at least one layer of the inductee is parallel both to at least one other straight wire of that same layer and to at least one other straight wire of another layer in the said inductee and (2) at least one straight wire of an inductee is parallel to at least one straight wire of an inductor; that preferably all straight wires of both the inductors and inductees are mutually parallel. An inductee is, in effect, a subassembly of the previously disclosed electromagnetic device. Conductor plates, preferably fabricated of a material that is a good conductor of electricity such as copper, are situated at the ends of both the at least one inductee, enabling both a parallel circuit interface with the ends of the straight wires thereof as well as providing an interface for output leads. At least one magnetically-permeable core is preferably included in the at least one inductor; such a core increases the strength of the magnetic field generated in and about the aforesaid device by a factor of up to thousands, compared to an air core. When a current flow is induced in the inductees, as the orientation of all wires is the same, the polarity of all inductees is the same. It is known that parallel wires carrying current flowing in the same direction, attract each other. Thus, the bundle of straight wires in the inductees will remain closely assembled. In preferred embodiments, while the number of inductees is the same as the number of inductors, surrounding the inductors as the do, the inductees are larger than the inductors such that the total number of wires (or loops of wires) of the inductees, and thus their area, is multiples of that of the inductors. This is another key characteristic in the efficient functioning of a generator of the present disclosure: the moving magnetic field generated in and around the wires of the inductors traverses a greater number of wires of the inductees; the higher the ratio of the number of inductee's wires compared to that of the inductors, the higher is the voltage induced for a given frequency of inducing current. This subject is discussed in further detail hereinafter.
[0016] In any electricity generator variant, it is the object of the inductors to generate a moving magnetic field that propagates in and therefrom and collapses therein and thereto according to the frequency of the cyclic current flowing in their wires. It is the object of the inductees to have a voltage and current induced in their wires when the said wires are traversed (cut) by the aforesaid moving magnetic field generated in and around the wires of the aforesaid inductors. The coating of an aforesaid wires has characteristics which preferably include thinness, high-temperature tolerance, resistance to fraying, good electric insulation and non-magnetically permeable; the color of the inductee's coating is different from that of the inductors. It is desirable that no electric contact be established between the wires of an inductee, for then the effective number of the inductee's wires (“turn-equivalents”) would be reduced, which is an undesirable effect. The aforesaid wires preferably have a square cross-section and sharp corners, and are preferably fabricated of a material having a low magnetic permeability and good conductivity, such as copper. While certainly a round wire may be utilized, a square cross-sectioned wire is preferable, as it has a greater area in the same lateral and vertical space as would be occupied by a round wire. This means not only that a square cross-sectioned wire can carry a higher amperage for a given voltage, but also that the wire offers less resistance to a current flow. Further, the smallest square cross-section wire adequate to carry the amperage induced in the wires of the inductees is preferred. Small cross-sectioned wires in an aforesaid inductee achieve three objectives: (1) reduction to a minimum the section of the inductees, thus reducing to a minimum the distance that the magnetic field, generated in and around the inductors, must traverse; (2) presentation of the minimum sections that must be penetrated by the inducing current, enabling higher frequencies of current to be utilized, as described hereinafter; (3) enabling a greater number of wires in a given cross-sectioned inductee. It is important that the ratio of wires in an inductee compared to an inductor, or that the ratio of the length of wires of the inductee compared to the inductor be as great as possible, as the greater is the ratio, the higher is the voltage induced for a given frequency of inducing current.
[0017] A further aspect of the present disclosure of a preferred variant of an electricity generator configured in a parallelepiped volume is that the interlocking inductor assembly sections also preferably include common-core subassemblies including vanes mounted onto a preferably square hollow spine fabricated of the same materials as the vanes. The common-core subassembly functions both as a core and as a structural beam. The vanes and hollow spine are preferably comprised of metal sheets having a high relative permeability and low coercion, a uniform grain orientation and uniform scribing to reduce hysteresis loss, such as laminated mu-metal or sheet silicon steel, with non-conducting insulation sheets between the metal sheets, the said sheets being joined adhesively. The exterior metal sheets have hooks extending therefrom in an offset pattern along the length thereof. The hollow spine has slots perforated therein in an offset pattern generally corresponding to the offset pattern of the aforesaid hooks, into which the said hooks are force-fit, enabling the configuration of the common core subassembly. Such a core increases the strength of the magnetic field generated in and about the aforesaid inductors by a factor of up to thousands, compared to an air core. While there is preferably no “separator” between the wires of an inductor and the wires of an inductee (as this would create an undesirable air gap between them) it may be necessary in some embodiments to have a thin separator to prevent any electrical contact between the wires of the inductors and inductees in the contact zone. The female-configured hollow spine is configured to accept a force-fit male hollow-spine connector that: (1) joins the aforesaid interlocking section; (2) through an opening, allows male blade connectors extending from the conductor plates (described hereinafter), to interface with magnetically-shielded two-conductor cable sections housed in the hollow spine. The two-conductor cable sections have color-coded negative and positive male blade connector terminals which, by means of FFF female blade connectors (described hereinafter) housed in the aforesaid male hollow-spine connector, interface with male blade connectors of the conductor plates (described hereinafter), thus enabling completion of the parallel electrical interfaces of all quadrant subassemblies of all inductors. The aforesaid insulation sheets are configured not only between the aforesaid metal sheets, but also on the outsides of the vanes. Further, insulation strips are affixed adhesively to the ends of the aforesaid vanes. The object of the “outside” insulation sheets is to assure that the metal vanes are not in electrical contact with the aforesaid conductor plates; the object of the insulation strips is to assure that the vanes are not in electrical contact with the vertical or lateral interface bands (described hereinafter) as, in either case, an electrical contact between those elements would cause a current to flow in the vanes, which current flow would diminish the current flow in the straight wires of the inductors, an undesirable effect.
[0018] In all straight-wire generator variants, a negative and a positive conductor plate is preferably situated at each end of an inductor assembly interlocking section having the minor dimension. The said conductor plates are preferably fabricated of a material that is a good conductor of electricity, such as copper, and enable both a parallel circuit interface with all the straight wires included in each inductor subassembly, as well as providing a parallel electrical interface for the input leads to the said subassemblies. At each end of a said inductor assembly interlocking section is situated an insulator plate, preferably fabricated of a material whose characteristics include high electrical insulation, magnetic impermeability, good mechanical resistance and rigidity, and thermal stability, and which insulator plate includes projections and channels on both its sides. In the parallelepiped variant, these channels accept force-fit color-coded vertical interface bands providing a parallel electrical interface for the inductor's conductor plates, and a force-fit color-coded lateral interface band that provides a parallel electrical interface for the quadrant subassemblies. Each aforesaid lateral interface band includes a male color-coded blade connector, laterally offset from its center, which fits through an opening in the aforesaid hollow-spine connector. The insulator plate has an opening at the position of a hollow spine-connector to allow the said hollow spine-connector to be configured therein. The projections on both sides of the insulator plate enable it to be clipped into the said conductor plates, separating the negative and positive conductor plates from each other at the end of an aforesaid interlocking inductor assembly section, and joining them. It is important that no electrical contact be established between the conductor plates of the inductors and those of the inductees, as this would cause the current in the inductors to flow into the inductee's conductor plates and thus through the wires of the inductees, without generating any inducing magnetic field; this would effectively shut down the generator. Negative and positive leads, connectors and interfaces, have like color codes to insure against cross circuitry in assembling the interlocking sections. It may also be advisable to provide electrical connectors that have different forms, for additional protection against cross circuitry.
[0019] Yet another aspect of the present disclosure of a preferred variant of an electricity generator configured in a parallelepiped volume is that the inductees are also configured in interlocking sections, each interlocking section preferably partially enclosed by a magnetically impermeable case having a hollow portion, which hollow case-portion includes a partially-evacuated portion at the ends of the said interlocking sections. The hollow portion of the case houses a magnetically impermeable color-coded two-conductor output cable section. At the ends of each inductee are situated negative and positive conductor plates, the said plates are preferably fabricated of a material that is a good conductor of electricity, such as copper, and enable both a parallel circuit interface with all the straight wires included in each inductee subassembly, as well as providing an parallel electrical interface for the output leads from the subassemblies. Male blade connectors, or the like, extend from each said conductor plate, which blade connectors fit through the aforesaid partially evacuated parts of the hollow portions of the walls, and interface with their respective negative or positive female blade connector of FFF female color-coded blade connectors or the like. The remaining two FF female color-coded connectors interface with the male color-coded blade-connectors of a color-coded magnetically shielded two-conductor output cable section housed in the hollow portion of the aforesaid case. The said cable section enables completion of the parallel electrical interfaces of all inductees. An insulator plate having projections on both sides, preferably fabricated of a material whose characteristics include high electrical insulation, magnetic impermeability, good mechanical resistance, rigidity, thermal stability, is configured on each side of the said inductee interlocking section. The projections on both sides of the insulator plate enable it to be clipped into the aforesaid conductor plates of adjoining inductee interlocking sections, separating the negative and positive conductor plates of those adjoining sections from each other at the ends of the inductee interlocking sections, and joining the sections. Negative and positive leads, connectors and interfaces, have like color codes to insure against cross circuitry in assembling the interlocking sections. It may also be advisable to provide electrical connectors that have different forms, for additional protection against cross circuitry.
[0020] The case of a parallelepiped, flat or toroidal generator is preferably fabricated of a material whose characteristics include good mechanical resistance and rigidity, high electric insulation, thermal stability, and magnetic impermeability. This last characteristic is preferable in order to concentrate any part of the magnetic field that has completely traversed the wires of the inductees, acting to prevent the magnetic field from exiting the generator. The outermost layer of wires of the inductors is preferably in physical but not electrical contact with the innermost layer of wires of the inductees. Thus, there is no air gap between them; this is preferable, as an air gap decreases the strength of the magnetic field traversing it. However, there obviously could be an air gap if it were desirable to include a thin separator between the said wires, to protect the wires of an inductor from establishing an electrical connection with the wires of an inductee in the “contact area” as will be described hereinafter. It is important that no electric contact be established between the straight wires of an inductor, for then the effective number of straight wires (“turn equivalents”) would be reduced, which is an undesirable effect.
[0021] The aforesaid case is preferably completely enclosed by an outer casing and two end caps. The outer casing preferably includes a lining having the characteristics of good electric insulation and high magnetic impermeability, and which is hermetically sealed to prevent its interior from being fouled by environmental elements. The primary object of the magnetic impermeability of the lining and the outer casing is magnetic shielding: to concentrate the lines of force of the magnetic field that may have propagated through the magnetically impermeable case enclosing the inductees, so that the magnetic field may collapse there-through, not allowing the field to be wasted by leaking to the exterior. A secondary object of the magnetic impermeability of the lining and outer casing is to protect the generator from external magnetic fields. The outer casing is preferably hermetically sealed and fabricated of plastic; if it is of metal, it is preferably grounded. One of the two end caps includes power and output terminals having color-coded female blade connectors for the male color-coded blade connectors of the ultimate magnetically-shielded two-conductor cable section (a negative and positive connector for both the inductor section's and inductee section's parallel circuits), and the electrical interface to the generator's control module (not shown). Both end caps enable the fixed attachment of the hollow spine sections and the insulator plates of both the final inductor and inductee interlocking sections.
[0022] Another variant of an electricity generator employing the herein-before described straight-wire template has a generally flat form-factor, wherein the secondary volume(s) including the inductees also surrounds or encloses the primary volume(s) including the inductors, and are concentrically configured. There is preferably a greater number of inductees than inductors, and a greater total number of wires in the inductees than in the inductors. This variant is another version of the template herein-before disclosed, and may comprise a lesser number of interlocking inductor and inductee sections than the larger-dimensioned variants, as well as a lesser number of square cross-section sharp-edged straight wires in the inductors and inductees. The operating principle is the same as all variants of an electricity generator: a cyclic current of a certain frequency is supplied to the inductors configured in a parallel circuit, which generates a moving magnetic field in and around the said inductors also configured in a parallel circuit, which said field traverses (cuts) the wires of the inductees in a perpendicular manner, creating a cyclic propagating and collapsing magnetic field therein. The said field creates a voltage across the leads of the said inductee's wires, and a current flow is the circuit is completed. A small battery, of the type usually found in hearing aids, etc., may supply 16 Ma at 3 DC volts, regulated to PDC preferably at least 400 Hz by devices in the control module for the initial cycle(s) of current in the inductors. The battery is thereupon removed from the circuit. A major part of the inductee's output is supplied to a load, and a minor part is supplied to the inductors through a feedback circuit in the control module. Although small, this variant would still be capable of supplying a high wattage (see [ 104 ]). The output of this variant would be FWDC. The FWDC would be regulated to DC, as this variant would generally be configured in small devices utilizing DC.
[0023] Apart from the obvious advantage of its ability to fit in spaces where other variants could not be configured, a flat variant is fabricated with materials that render it somewhat bendable and, as such, may be partially or wholly wrapped around an object. This capability is attained by utilizing a flexible conducting material, such as graphene, which is high-strength, flexible and highly-conductive, for the conducting elements (the wires, conductor plates and cabling (having a non-conducting rubber-like material for the coating). Insulator plates, the components of the magnetically permeable core as well as the case, would be fabricated with the rubber-like material. Obviously, it is possible that, in bending the device, the concentric circles of the magnetic field generated in and around the inductors would not be totally coherent as they traverse the wires of the inductees, leading to a reduction in efficiency of the device.
[0024] Another variant of an electricity-generator utilizes solenoids in the primary volume as inductors and coils in the secondary volume as inductees. As stated hereinbefore, solenoids and coils are well suited to a space that is cylindrical. While the form-factors of the generator variants disclosed herein are different, and thus also the forms of their inductors and inductees, the physical concept of both is unifying and identical: the primary volume(s) including the inductors is (are) concentric and are configured within the secondary volume(s) including the inductees; the wires of the inductees are parallel to those of the inductors; inductors and inductees are interfaced in their respective parallel electric circuit; the number of wires, or the total length of wires, in the inductees is greater than that of the inductors. The operating principles are identical as well: a current of a certain cyclic frequency is supplied to the parallel circuit of the inductors in the primary volume, which current creates a moving magnetic field comprised of concentric lines of force therein and there-around; the concentric lines of force traverse the wires of the surrounding inductees in a perpendicular manner, propagating then collapsing cyclically through the said coil inductees, thereby inducing a cyclic voltage across the leads of the said inductees, and inducing a cyclic flow of current therein if a complete circuit is provided.
[0025] A cylindrical variant of an electricity generator comprises at least one “primary” volume which preferably includes a number of solenoid inductors, whose object is to generate a moving magnetic field therein and there-around when a cyclic current flows through their wires, and which volumes are concentric with the generator's surrounding preferably at least two “secondary” volumes. A solenoid inductor is herein defined as a device including “turns” of wire tightly wound in the same direction and in more than one layer around and along the length of a magnetically-permeable cylindrical core section, with a second said cylindrical magnetically-permeable core section configured on top of the said turns. Thus, the said cylindrical magnetically permeable core sections physically enclose the turns of the solenoid inductors. It is preferable that the aforesaid core section be comprised of at least one sheet of a material having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with an insulation sheet between the metal sheets. The said metal sheets preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. A magnetically permeable core increases the strength of the magnetic field generated in and about the said primary solenoids by a factor of up to thousands, compared to an air core. As the turn directionality of the wires of each of the number of solenoid inductors is the same, the polarities of the solenoid inductors assembled end-to-end in the generator are complementary; as each solenoid inductor is interfaced in a common parallel circuit, they form a long electromagnet in the primary volume.
[0026] The secondary volumes of a cylindrical variant of an electricity generator comprise interior and exterior coils as inductees, each such coil defined as including “loops” of wire tightly wound in the same direction in more than one layer. The object of a coil inductee is to have a voltage induced in the wires thereof when the “loops” are traversed (cut) by the aforesaid moving magnetic field generated in and around the aforesaid solenoid inductors, and to have a current induced therein if a complete circuit is provided. The wires of the coil inductees of the secondary volumes of each interlocking combined-assembly section are thus preferably configured directly under and over the cylindrical magnetically-permeable cores of the solenoid inductors, their wires being wound in the same direction, and the solenoid inductors being concentric with the coil inductees. The loops of an interior coil inductee are wound around a hollow magnetically-impermeable section which houses two sets of conductor cables, one of two-conductors for the solenoid inductors, and one of four-conductors, for the two coil inductees. The diameter of the loops of the interior coil is less than that of the windings of the solenoid inductor while the diameter of the loops of an exterior coil inductee is greater. Thus, the total length of the wires of both an interior and exterior coil inductee is multiples of the length of wire of a solenoid inductor, and the total length of wires in the coil inductees is multiples of that of the solenoid inductors. This is another key characteristic in the efficient functioning of a generator of the present disclosure: the moving magnetic field generated in and around the wires of the solenoid inductors traverses a greater length of wires of the coil inductees; the greater the length of wires, the higher is the voltage induced in the wires of the coil inductees for a given frequency of inducing current.
[0027] A terminal-disc is situated at each end of an interlocking combined assembly section. The disc is preferably fabricated of a material whose characteristics include magnetic impermeability, good mechanical resistance and rigidity, high electric insulation, and thermal stability. One side of a terminal-disc is smooth, (that facing the solenoid and coils when assembled); the other side of the terminal-disc, herein defined as the “assembly side”, includes: (1) channels for the leads from the solenoid inductor and coil inductees; (2) projections and depressions configured in mirror images of each other, in such manner that these sides of the terminal-discs of adjacent combined assemblies clip into each other, allowing the formation of interlocking sections of combined assemblies; (3) arcuate perforations allowing the leads of the solenoid inductors and the coil inductees to pass through the terminal-disc to the “assembly side” of the disc and into the aforesaid channels. The terminal-disc has an opening situated in its central portion to allow the positioning of the female magnetically impermeable hollow core as well as for the passage of the magnetically impermeable male hollow-core connector. This connector is inserted into the female ends of the aforesaid magnetically impermeable hollow cores of the combined assembly sections. The male hollow-core connector has an opening which allows passage of male color-coded blade connectors, or the like, situated at the ends of the leads from the solenoid inductors and coil inductees. These male blade connectors interface with the aforesaid (magnetically-shielded) two- and four-conductor cable sections having male blade connectors, which is housed in the aforesaid hollow core sections, and which cable sections enable completion of the parallel electrical interface of all solenoid inductors and coil inductees. The male blade connectors of the solenoid inductors and the coil inductees interface with the male blade connectors of the two- and four-conductor cable sections by means of FFF color-coded female blade connectors which are also housed in the male hollow core connector. Like leads, connectors and interfaces have like color codes, to insure against cross circuitry in assembling the generator. It may also be advisable to provide electrical connectors that have different forms, for additional protection against cross circuitry. It is important that no electric contact be established between the wires of a solenoid inductor or coil inductee, for then the effective number of “turns” and “loops” would be reduced, which is undesirable.
[0028] Another aspect of an electricity generator variant configured in a cylindrical volume is that an interlocking combined assembly is preferably enclosed by a circumferential outer casing and by two end caps. The outer casing preferably includes a lining having the characteristics of good electric insulation and highly magnetic impermeability, and which is hermetically sealed to prevent its interior from being fouled by environmental elements. The primary object of the magnetic impermeability of the lining and outer casing is that of magnetic shielding: to concentrate the lines of force of the magnetic field that may have propagated through the magnetically impermeable walls enclosing the inductees, so that they may collapse there-through, not allowing the field to be wasted by leaking to the exterior. A secondary object of the magnetic impermeability of the lining and outer casing is to protect the generator from external magnetic fields. The circumferential outer casing is preferably fabricated of plastic; if it is of metal, it is preferably grounded. At least one of the two end caps includes power and output terminal boxes having color-coded female blade connectors (or the like) for the male blade connectors (or the like) of the ultimate magnetically-shielded four-conductor cable section of the parallel circuits of inductors and inductees (negative and positive male blade connectors for both the solenoid inductors and the coil inductees), and the electrical interface to the control module (not shown) of the generator. Both end caps enable the fixed attachment of the hollow cores and the terminal discs of the ultimate combined assemblies.
[0029] The aforesaid wires of both the solenoids and the coils preferably have a square cross-section and sharp corners, and are preferably fabricated of a material having a low magnetic permeability and good conductivity, such as copper. While certainly a round wire may be utilized, a square cross-sectioned wire with sharp corners is preferable, as it has a greater area in the same lateral and vertical space as would be occupied by a round wire. This means not only that a square cross-sectioned wire can carry a higher amperage for a given voltage, but also that the wire offers less resistance to a current flow. The smallest square cross-section wire adequate to carry the amperage supplied to the inductors and that induced in the wires of the inductees is preferred. Small cross-sectioned wires in an aforesaid coil inductees achieve three objectives: (1) reduction to a minimum the section of the coil inductees, thus reducing to a minimum the distance that the magnetic field, generated in and around the solenoid inductors, must traverse; (2) presentation of the minimum sections that must be penetrated by the inducing current, enabling higher frequencies of inducing current to be utilized; (3) enabling a greater number of wires in a given cross-sectioned coil inductee translates into more “loops” and, for a given frequency of inducing current, a higher induced voltage. The coating of an aforesaid wire has characteristics which preferably include thinness, high-temperature tolerance, resistance to fraying, good electric insulation and non-magnetically permeable. The color code of the solenoid inductor's wires coating is different from that of the coil inductees. It is desirable that no electric contact be established between the wires of an inductee, for then the effective number of inductee turn-equivalents would be reduced, which is an undesirable effect. It is important that the number of loops of the coil inductees, and thus the length of the coil's wires, be greater the number of turns of the solenoid's wires and thus the length of its wires; this is the case, as the coils are preferably configured on both sides of the solenoids. A greater number of “loops” of the coils relative to the “turns” of the solenoid results in a higher induced voltage for a given frequency of inducing current.
[0030] A further aspect of a variant of an electricity generator configured in a cylindrical volume is that the orientation of the wires of the coil inductees is parallel to the orientation of the wires of the solenoid inductors (or the turns of the solenoid inductors is parallel to the windings of the coil inductees) such that, when a cyclical inducing current flows through the wires of the solenoid inductors, concentric lines of force of a moving magnetic field are generated in and around the wires of the solenoid inductors, which lines of force traverse the wires of the coil inductees in a perpendicular manner. It is known that a perpendicular traverse of the wires by the magnetic field's lines of force induces the maximum voltage and current therein. Thus, in each propagation of the moving magnetic field in and around the solenoid inductors, the field's moving concentric lines of force traverse (cut) the wires of all coil inductees, inducing a voltage of a certain polarity across the leads of the said wires and inducing therein a current flow of a certain polarity if a complete circuit is provided. Each collapse of the field's concentric lines of force induces a voltage of the opposite polarity to that of the propagation, and induces a current flow of an opposite polarity to that of the propagation if a complete circuit is provided. Thus, there is always a cyclic voltage across the output leads of the coil inductees, and an alternating current will flow in the wires of the inductees if a full path is provided (as described hereinafter, this is always the case). The induced current in all wires of the parallel circuit of the coil inductees is of the same phase. One part of the aforesaid alternating current output is filtered and regulated by electronic components (not shown) in the control module (not shown) before it is supplied to a load, as described hereinafter.
[0031] Another aspect of a variant of an electricity generator configured in a cylindrical volume is that the primary volume and the secondary volumes are preferably concentric; preferably the primary volume(s) being physically configured within the secondary volume(s). The primary and secondary volumes are differentiated in diameter in an interlocking combined assembly, wherein the inductee coil's loops are wound under and over the turns of the solenoids wires. As the solenoid inductors are interfaced in a parallel circuit, and are configured in the primary volume end-to-end such that they have complementary polarities when electrified forming a long electromagnet, the concentric lines of force of the moving magnetic field created in and around the wires of the solenoid inductors have the same directionality at the same point in the frequency cycle of the inducing current. Thus, the voltage induced in the wires of the coil inductees, as well as the current flowing in them, have the same polarity at the same point in the frequency cycle. As this is an electromagnetic induction device, an air gap between an inductor and an inductee weakens the strength of the inducer's magnetic field as it propagates; thus, it is desirable that the aforesaid be closely assembled with no air gap between the volumes, and that the outermost layers of wires of the solenoid inductors be in physical, but not electrical, contact with the innermost layers of wires of the coil inductees.
[0032] As indicated hereinbefore, there may be spatial restrictions controlling the volume in which a variant of a generator of the present disclosure may be configured, and a toroidal or cylindrical variant may be the only configurations possible. A straight-wire toroidal electricity generator is able to utilize very high inducing frequencies, because of the short lengths of its straight wires. As discussed hereinafter relative to resistance, circuit resistance is systemically reduced in all variants through the utilization of square wires, but principally through the use of parallel circuitry. However, while high inducing current frequency is desirable (as discussed hereinafter), high frequencies are known to create high resistance, even in short wires. It is possible to mitigate the effects of this phenomenon by shortening the length of the generator's wires. In any given length of a parallelepiped or flat generator variants, this may be achieved by reducing the lengths of the interlocking sections, and thus the lengths of their straight wires, and compensating for this reduction by increasing the number of the said sections. While this would obviously maintain the total volume of straight wires, each wire would be shorter (able to accept a higher frequency) and there would be a greater number of parallel circuits of wires (further reducing the resistance of the circuits). The toroidal variant of an electricity generator inherently provides very short wire lengths and a high number of parallel circuits; thus it has very low circuit resistance, making it especially adapted to very high inducing frequencies. It employs the hereinbefore described straight-wire template as the basic unit of the device; its overall form-factor is also quasi-cylindrical, comprised of toroidal interlocking sections and thus may be configured in a cylindrical volume. It operates in the same manner as other generator variants. This variant is scalable and its output, as are all variants of a generator of the present disclosure, could either be AC or Full Wave DC (FWDC).
[0033] A straight-wire toroidal electricity generator includes at least one secondary volume each including at least one toroidal inductee configured surrounding the at least one primary volume including at least one toroidal inductor, all volumes being concentric. Each toroidal inductee includes inductee square-sectioned sharp-edged coated straight wires closely assembled in the width and at least one layer in the height along the length of each said toroidal inductee, and in such manner that (1) at least one straight wire of at least one layer of a said toroidal inductee is parallel to at least one straight wire of at least one other layer of the said toroidal inductee and that preferably all said straight wires are mutually parallel. Between said toroidal inductees are configured a number of toroidal inductors, each including inductor square-sectioned sharp-edged coated straight wires closely assembled in the width and at least one layer in the height along the length of each said toroidal inductor, and in such manner that (1) at least one straight wire of at least one layer of a said toroidal inductor is parallel to at least one straight wire of at least one other layer of the said toroidal inductor and that preferably all said straight wires are mutually parallel, as well as being parallel to aforesaid inductee square-sectioned sharp-edged coated straight wires of toroidal inductees. Thus, there are more inductees than inductors, and the total number of wires included in the inductees is multiples of that of the wires included in the inductors. Although obviously the width and height dimensions of the inductors and inductees are different, each aforesaid inductor and inductee preferably have a uniform length such that their respective straight wires have a uniform length, and thus the strength of the inducing and induced magnetic fields are uniform. A negative conductor plate is situated on one end of both the inductors and inductees and a positive conductor plate is situated on the other end. The said conductor plates are preferably fabricated of a material that is a good conductor of electricity, such as copper, and enable both a parallel circuit interface with all the straight wires included in each inductor and inductee; the said conductor plates also provide a parallel electrical interface for the input leads to the said inductors and the output leads from the said inductees. Each inductor and inductee is contained in a rigid magnetically impermeable compartmental case. The said case includes a hollow portion housing electrical interfaces enabling parallel circuits of the respective inductors and inductees, and allows the said inductors and inductees to be configured in interlocking sections. Magnetically permeable cores having hollow portions are configured between the inductor and the inductees, serving respectively as a top and a bottom for the said inductors. Said cores are comprised of at least one sheet of a material having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with an insulation sheet between the metal sheets. The said metal sheets preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. The generator is enclosed in a magnetically impermeable hermetically sealed case having a magnetically impermeable lining, the object of which is not only to concentrate the magnetic field which has traversed the wires of the exterior inductees, not allowing it to be wasted by escaping to the exterior of the device, but also to protect the generator from external magnetic fields. End caps provide the respective electrical power input and output interfaces with the exterior of the generator.
[0034] The operating principle of a toroidal generator variant is the same as all variants of an electricity generator: a cyclic current of a certain frequency (discussed hereinafter) is supplied to the inductors configured in a parallel circuit, which cyclic current flow generates a moving magnetic field in and around the said inductors also configured in a parallel circuit, which said field traverses (cuts) the wires of the inductees in a perpendicular manner, creating a cyclic propagating and collapsing magnetic field therein. The said moving magnetic field creates a voltage across the leads of the said inductees' wires, and a current flow if the circuit is completed. If the input current is AC, the said induced voltage and current is of one polarity when the said magnetic field is propagating and of an opposite polarity when the said field is collapsing, and the output is AC. If the input current is Pulsed DC, the said induced voltage and current is of uniform polarity when the said magnetic field is propagating and collapsing, and the output is Full Wave DC (FWDC). A battery (not shown) supplies the current, regulated by devices in the control module, for the initial cycle(s) of current in the inductors and it is thereupon removed from the circuit. A major part of the inductees' output is supplied to a load, and a minor part is supplied to the inductors through a feedback circuit (not shown) in the control module (not shown).
[0035] Another aspect of variants of an electricity generator concerns the output of the inductees. One part of the aforesaid current output is regulated by electronic components (not shown) in the control module (not shown) before it is supplied to a load. Another part of the aforesaid current output is supplied to the inductors through a “feedback” circuit, as current for cycles subsequent to that (those) cycles of initial current cycle(s), in the wires of the. To insure consistent voltage and current of the desired frequency and amperage to the wires of the solenoid inductors, this part of the alternating current output is preferably filtered through dedicated electronic components that may include a voltage and current regulator (not shown) included in the aforesaid feedback circuit (not shown) in the control module (not shown). Should the system shut down for any reason, the battery will be brought on-line again automatically for a re-start cycle, which is programmed in the CPU in the control module (not shown). The voltage, amperage and frequency of the current supplied to the parallel circuit of solenoid inductors are of critical importance.
[0036] A further aspect of an electricity generator variant concerns parallel circuitry. All inductors and inductees of all interlocking sections are wired in their respective parallel circuit. Thus, the same flow of current in the parallel circuit of the wires of the solenoid inductors generates an identical moving magnetic field of concentric circles at the same time in and around all the wires of all said inductees. The concentric circles of the magnetic field propagates, then collapses, in the same manner and with the same directionality, through the wires of all inductees at the same time, inducing a cyclic voltage across the leads of the aforesaid inductees and inducing a cyclic current flow therein if a complete circuit is provided. There are two significant advantages that accrue from parallel circuitry in the present disclosure: (1) redundancy, and (2) reduction of resistance.
[0037] The aspect of redundancy allows an electricity generator to continue functioning even if one or more of the wires of an inductor, or an entire inductor, and/or one or more of the wires of an inductee, or an entire inductee, becomes defective or is damaged, albeit at a level of efficiency that is more or less reduced. Obviously, the redundancy aspect of a generator is increased the more inductors and inductees it includes.
[0038] The aspect of reduction of resistance is important for the efficiency of the circuits of both the inductors and inductees of the present disclosure of all variants of an electricity generator. The resistance of a parallel circuit to current flow is an inverse function of the total of each resistance in the circuit: the greater the number of resistances in a parallel circuit, the less is the resistance to current flow of the whole circuit. Less resistance in a circuit means that a higher current flow is possible for a given voltage. Less resistance also means that there is less heat loss in the circuit, which subject will be discussed hereinafter. It is expected that the resistances of wires of the circuits of both inductors and inductees should be quite low, as: (1) the wires in both the aforesaid elements are connected in a parallel circuit and (2) all such elements are connected in their respective parallel circuit and (3) there are many inductors and inductees having many square wires each providing a greater area than would a round wire in that same section, resulting in an appreciable total area for all the wires; greater total area in the wires means less resistance. As will be discussed hereinafter, it is desirable that the inducing current has the highest possible cyclical frequency, as this will provide the highest induced voltage for a given ratio of wires (or the lengths thereof) of inductees to inductors. However, increasing the frequency of the inducing current creates the undesirable phenomenon of increased resistance in the inductee's wires, even if they are short. Thus, one solution is the shortest possible length of inductee's wires (as is the case of the toroidal variant of a generator, discussed hereinafter). A straight-wire configuration easily allows for the shortest possible length of wires in the inductees whereas, on the contrary, the wires of the coil inductees, surrounding the solenoid inductors as they do, are necessarily long. A further consideration relates to the resistance of the inductee circuit compared to that of the inductor circuit: it is not desirable that the resistance of the inductee circuit be less than that of the inductor circuit, as described hereinafter. However, as the voltage and number of wires in the inductees preferably will always be multiples of the voltage and the number of wires in the inductors, the resistance of the inductee circuit will always be significantly less than the resistance of the inductor's circuit. Thus, for the reason stated above, it is advisable that a resistance be included in the inductee circuit.
[0039] A further aspect of an electricity generator variant concerns that part of the inductee's current output that is supplied through a “feedback” circuit, defined herein as the circuit from the control module to the parallel circuit of inductors, supplying the current for cycles subsequent to that (those) cycles of initial current cycle(s). As the circuit of the feedback circuit is always completed, it always provides a path for part of the current output of the inductees, even if there is no load on the other part of the current output. Thus, there is always current flowing in the wires of the parallel circuit of the inductees. As this current is filtered through the aforesaid electronic components, the resistance of the parallel circuit of the wires of the inductees is expected always to be higher than the resistance of the parallel circuit of the wires of the inductors. As will be described hereinafter, the wires at the exterior of the inductors are in physical contact with wires on the interiors of the inductees, such that the higher resistance of the circuit of inductees has a positive ramification in the event that wires become frayed in that “contact” area. A magnetic field exerts a force on wires situated in its field: the force of the moving magnetic field of the inductors is different from the force exerted on the wires of the inductees by the current induced therein. As the wires situated in the interiors of those components would move in unison in response to that force, there would be little chance of fraying, and they are protected by their coatings. If fraying were to occur in the coating of one or more of those wires in their interior, and there were electric contact between the wires, it could reduce the effective number of wires in the element, but the effect would be minimal. But if the wires in the “contact” area were to become frayed by a friction caused by the different magnetic forces exerted upon them, a wire or wires of an inductor could come into electric contact with a wire or wires of an inductee. In such a case, if the resistance of the parallel circuit of the inductors were greater than the resistance of the parallel circuit of the inductees, the inducing current flowing in the wires of the inductors would choose the path of least resistance, and flow into the wires of the inductees, causing a short circuit. This would cause the generator to shut down, as the two parallel circuits would be joined; thus there would be no voltage induced in the wires of the inductees. However, as the resistance of the parallel circuit of the inductees is expected to be greater than that of the resistance of the parallel circuit of the inductors such fraying, if it were to occur, would have no effect: the current in the parallel circuit of wires of the inductors would not flow into the parallel circuit of wires of the inductees. If the total resistance of the parallel circuit of the inductees were not greater, a resistance should be added, in the control module.
[0040] As described herein-before, the only external source of energy required for the functioning of an electricity generator of the present disclosure, for the initial cycle(s) only, is preferably at least one rechargeable-type battery (not shown). The battery or batteries is (are) selected according to the voltage and ampere ratings to ensure the capability of supplying the amperage to the inductors for the initial cycle(s), enabling the creation of a moving magnetic field of sufficient density and strength to traverse completely the wires of the inductees. An automobile battery, for example, may supply 300 amps at 12 v or 550 amps at 24 v. Small batteries, AA's for example, supply 2.5 amps at 1.5 volts, and are usually linked in series. Small round batteries, usually found in hearing aids, etc., may supply 16 Ma at 3 volts. In some smaller configurations, the battery may occupy more space than the generator. This may be an inconvenience, which it is possible to remove by having a “staged” initial power supply, wherein a small battery supplies the “starting” power for a small generator, whose output is the starting power for a larger generator, continuing until the required starting power of the final-stage generator is achieved. The power outputs of these intermediate generators obviously continues even after the final-stage generator is on-line and, while neither their voltage of amperage is that of the final-stage generator, they may be either transformed or used for ancillary circuits. The amperage and frequency of the current supplied to the parallel circuit of inductors of the final-stage generator is of critical importance, and this subject is discussed hereinafter.
[0041] Two further aspects of the present disclosure of variants of an electricity generator concern the density and the strength (intensity) of the moving magnetic field created in and about the inductors. It is important that the aforesaid moving magnetic field be of such density that the desired voltage and current be induced in the wires of the inductees. The “density” is the number of flux lines per square inch, known as the “B” field. The number of wires (“turn-equivalents”) in an inductee, multiplied by the amperage in the wires, is the “ampere-turn”; the greater the number of turn-equivalents and the higher the amperage, the denser the field. As indicated herein-before, the reason square wires are preferable to round ones is that a square cross-sectioned wire has a greater area for the same lateral and vertical dimension as round wire, and greater area means that a wire can carry a higher-amperage current.
[0042] The density of the “B” field is affected by the magnetic permeability of the cores of the inductors of an electricity-generator embodiment: when enhanced by the relative permeability of those cores, it becomes the “H” field. Relative permeability is a multiplying factor: the higher the relative permeability, the greater the enhancement of the magnetic field, the stronger the “H” field. A strong “H” field, having the densest flux lines possible, is desirable in the present disclosure of a generator embodiment. It is important that the density and strength of the field be such that it may propagate with sufficient density, in and around the inductors, and through to the outermost wires of the inductees. As the concentric circles of a magnetic field propagate, each flux line of the field stretches to cover a greater arc, such that the line's density is reduced. In a like manner, as a propagating field expands to cover a greater area, the distance between the flux lines increases, diminishing its density over said greater area. The fields strength is inversely proportional to the square of the distance from the center of the inductors to the outermost wires of the inductees. Thus, the stronger the moving magnetic field and the less distance it must traverse to the said outermost wires, the more effective it is. The distances involved obviously vary in differently sized generators, such that the desired strength of the magnetic field will vary.
[0043] There are a number of aspects relative to the power output of the inductees of all embodiments and variants of the induction devices of the present disclosure: (1) the type of current input to the inductors determines the type of current output of the inductees; (2) for all straight-wire embodiments and variants, the number of inductee's current output if a complete circuit is provided is quantified by the following formulas (where F=the frequency of the current supplied to the number of inductors, N=number of wires, prim=primary, sec=secondary, I=the amperage of the current supplied to the number of inductors: (a) the voltage induced in the number of inductees is quantified by the formula: Vsec=(Nsec)/Nprim(Fprim); (b) the current induced in the number of inductees if a complete circuit is provided is quantified by the formula: Isec=Nprim/Nsec(Iprim); (3) For all embodiments and variants having solenoids as inductors and coils as inductees, the inductee's output if a complete circuit is provided is quantified by the following formulas, where L=total length of the wires: (a) the voltage induced in the number of solenoid inductees is quantified by the formula Vsec=Lsec/Lprim(Fprim); (b) the current induced therein if a complete circuit is provided is expressed by the formula: Isec=Lprim/Lsec(Iprim).
[0044] Thus, the inductee's wattage output is quantified by the reduced formula Wsec=(Fprim)(Iprim). It is evident that, for any given generator: (1) the induced voltage may be increased by (a) increasing the number of wires in the number of straight-wire inductees, or the length of the wires of the number of coil inductees. This leads to a reduction of the amperage as the wire ratio becomes the reciprocal, and there is always greater number of wires in the inductees than the inductors. Increasing the frequency of the inducing current is the easiest manner by which to increase the output of the inductees, as this frequency is the multiplier for the voltage formula, and increasing it does not decrease the amperage of the current output; (b) increasing the amperage of the current supplied to the number of inductors. This will generally require increasing the cross-section of the inductor's wires, and would be utilized in large-scale installations. (2) the strength and intensity of the magnetic field (the “H” field) must be such that it attains the outermost wires of the number of inductees and, the utilization of a highly permeable core for the inductors will generally insure that this is the case. It may be that the “H” field's strength is sufficient to add layers to the number of inductees; (4) as discussed hereinafter, the current for the initial pulse(s) is supplied from a battery: it may remain pulsed DC if the desired inductee output is Full Wave Direct Current (FWDC). Obviously, the battery's supply may be converted to AC if the desired output is AC. The succeeding current supply from the feedback circuit to the control module and therefrom to the inductors is thus either FWDC or AC. DC is the preferable output for small generators, since the apparatus to which they would supply electricity would generally be small (requiring DC at a low amperage), whereas AC is the preferable output for larger apparatus (requiring higher wattage).
[0045] While the current induced in the wires of the number of inductees of a variant of an electricity generator is a function of variables, which depend upon the configuration of the generator, the formulas given above provide some generalities. Also, Faraday's law states that a current is equal to voltage divided by resistance. The induced voltage in the number of inductees of the preferred configuration of generators herein described is a function of: (1) the ratio of the number of wires (“turn-equivalents”) of the number of inductees that are traversed by the concentric circles of the moving magnetic field, compared to the number of wires of the number of inductors and; (2) the frequency of the inducing current in the inductors (both as expressed in the formulas given herein-before); (3) amperage of the inducing current; (4) the density and strength of the magnetic field. This last element has been discussed hereinbefore, and resistance will be discussed hereinafter.
[0046] As concerns the number of wires (“turn-equivalents”) of the inductees of variants of an electricity generator: it is obvious that the smaller the cross-section of the wires therein, the wider and higher is the inductee containing the wires, the higher is the ratio, and thus the higher the voltage induced in the inductees for a given inducing frequency. The number of wires in a generator may be increased by decreasing the lengths of the inductors and decreasing the corresponding lengths of the inductees, but increasing their volume, such that there would be a greater number of wires in the secondary volume. Obviously, the number of layers of wire of an inductee should be the maximum consistent with the strength of the magnetic field generated, the objective being that the field should at least traverse the outermost layer of wires of the inductees. For a given amperage in the wires of the circuit of inductors, a greater number of wires or “loops” in the inductees translates into a higher induced voltage in the wires of the inductees.
[0047] As concerns the frequency of the cyclic current in the wires of the parallel circuit of the inductors of an electricity generator variant, there are a number of considerations, among which are: (1) penetration depth of the magnetic field lines into and through the wires of the inductee, and (2) power output.
[0048] As to (1), the penetration depth of the magnetic field lines into and through the wires of the inductors, the frequency of the inducing current must be such that the magnetic field lines, whose movement is at a relativistic speed, would have the time to penetrate and traverse the wires of the inductees and collapse therefrom, before the initiation of a following cycle. Higher frequencies penetrate a lesser distance into wires than lower frequencies simply because there may not be enough time in one half cycle of high-frequency alternating current or one pulse of high-frequency pulsed direct current, to penetrate the wires. Obviously, the cross-section of the wires of the inductees is a major determinant of the dimension of a generator. As concerns copper wire, current at a frequency of 50-60 Hz penetrates approximately 8.6 mm; at 300 Hz approximately 7 mm; at 1.2 KHz approximately 5 mm; at 300 KHz, approximately 0.12 mm. Copper wire having a square cross-section of 5 mm is the equivalent of an approximately 8-9 US gauge round wire, capable of carrying 64-73 amps of current, and accepts a frequency between 1.65 and 2.05 Kilohertz with no skin effect. If there is a skin effect problem, there are solutions that may be appropriate, either individually or in combination: (1) reduce the section of the wires of the inductors, making them compatible with the penetration factor of the desired frequency. Thus, the wires of the inductees could have a flat cross-section instead of square, while retaining the area of the wire; (2) choose a different material for the wires. If frequencies of 300 KHz (which is classified as Medium-Frequency) or higher, are utilized as the inducing current, then wires fabricated of magnesium-zinc may be preferable in either or both aforesaid components of the induction device. The penetration depth characteristic of such wires is sufficient even for the thickest wires at frequencies even exceeding 1.2 MHz. Such wires have the lowest core loss and high saturation characteristics (up to 60 amps); (3) choose a different type of wire for the wires of the inductees, such as braided wires. Such wires are known as “Litz” wires, and consist of several smaller strands of wire that are insulated from each other and wound in a braid. The braid pattern ensures that each wire stand spends the same amount of its length on the outside of the braid, so any skin effect distributes the high-frequency induced current equally between the strands, resulting in a larger cross-sectional conduction area than an equivalent single wire.
[0049] As to (2), the power output of a generator of the present disclosure, the frequency of the current supplied to the parallel circuit of the inductors is the major determinant of the induced voltage and most easily controllable. The formula for the induced voltage is [V secondary=N number of wires of secondary/N number of wires of primary×(frequency of the induced current in the primary)]. For a given frequency, a high ratio of wires (sec/prim) is advantageous. However, the opposite is true for the induced current, according to the formula for induced current [Is=Np/Ns(Ip)]. Thus, while larger generators could have larger cross-sectioned wires, capable of higher ampacity, the amperage in the inductees will always be relatively low, because of the inverse ratio of wires. Whereas current-art electricity generators move wires through a magnetic field, the novel generator disclosed herein moves a magnetic field through wires. While the movement of the wires is subject to significant limiting factors, the only limiting factor to the frequency of the inducing current is the “skin effect” (discussed herein-before), such that the inducing frequency may be extremely high. The frequency utilized in the US and Canada is 60 Hz, and generally 50 Hz in other countries and, while such a frequency could theoretically be utilized as the frequency of the inducing current, such frequencies will not induce sufficiently high voltage in the inductees, even with a high ratio of inductee wires to inductor wires (described herein-before). Thus, a common higher multiple of those frequencies is preferred, such as 300 Hz or 600 Hz (considered “Medium Frequency”) and from which either aforesaid currently used frequency may be derived easily. But higher frequencies are even more preferable, as they produce higher voltages (thus a higher wattage for a given generator). Thus, as permitted by the cross-sections of the inductees' wires, frequencies between 600 Hertz and 300 Kilohertz, and frequencies exceeding 300 KHz could be utilized. Solid-state frequency converters capable of supplying up 800 KHz are currently available, and frequency converters capable of supplying higher frequencies could be developed. Thus, the frequency ranges of the inducing current preferred for use in a generator embodiment are: (1) 50 Hz to 300 Hz; (2) (preferred) 300 Hz to 300 KHz; (3) (more preferred) exceeding 300 KHz. Electronic apparatus in the control module (not shown) would permit the voltage and current induced in the parallel circuit of inductees to be regulated or transformed, and any frequency to be converted to another. Computer addressable devices would permit separate parallel circuits of inductees, thus enabling any number of phases of current to be output. It must be borne in mind that higher frequencies of inducing current generate higher resistance in the inductee's wires, which is offset by the lower resistance of the parallel circuit and the high number of wires. This subject is discussed hereinafter.
[0050] There are three possibilities for the types of cyclic current supplied to the parallel circuit of inductors of variants of an electricity generator: (1) that all cyclic current be Alternating Current; (2) that all cyclic current be Pulsed Direct Current (PDC); (3) that the cyclic current be composed of a hybrid of pulsed direct and alternating current. If a hybrid cyclic current were utilized, it would consist partly of PDC (either as the initial pulse or as subsequent pulses) and partly of AC (either as the initial current or the current subsequent to the initial pulse of DC). This possibility does not present any apparent advantage, and thus it is not preferred.
[0051] The preferred possibility for the cyclic current supplied to the parallel circuit of inductees is that it be all alternating current. It is known that a reversal of the polarity (a characteristic of AC) of an inducing current in an inductor will generate a moving magnetic field in and around the inductor. As described herein-before, for the initial cycle(s) of current to the parallel circuit of wires of the inductors, a battery (in the control module (not shown) supplies direct current to other electronic components (not shown) in the control module, including an inverter, a capacitor, a voltage regulator and a frequency regulator and controller (programmed to supply the desired frequency of current as the “starting cycle(s)”), This (these) starting cycles(s) of current would create the first propagation(s) and collapse(s) cycles of the moving magnetic field in and around the wires of the inductors. For the subsequent current supply, a part of the current induced in the wires of the inductees is fed back to the parallel circuit of wires of the inductors through a feed-back circuit, as described herein-before.
[0052] If all direct current is utilized for the inducing current, it must obviously be pulsed DC (PDC), which is a cyclic current having only a positive waveform, and would induce Full Wave DC (FWDC) in the inductees. This may be smoothed and regulated to DC, and is the preferable output for small generators, since the apparatus to which they would supply electricity would generally be small (requiring DC at a low amperage). Each pulse in the inductors creates a propagating magnetic field and a collapsing field in the inductees, each of which induces a DC voltage pulse in the inductee's wires, a Full Wave DC. The succeeding current supply through feedback circuit to the control module and therefrom to the inductors is Full Wave DC. The initial DC pulse(s) is (are) supplied from a battery (not shown) preferably through a capacitor in the control module (not shown). This current is treated by electronic apparatus (not shown) in the control module (not shown), to regulate the frequency of the PDC to that frequency desired. While all DC pulses could be supplied by means of a computer-controlled solid-state on/off switch, the utilization of such a switch for all pulses has a disadvantage. When such a switch is opened to end a pulse, a “switching surge” effect is caused, which surge would cause arcing damage and the possibility of failure over time. Thus the use of such a switch is not preferred; a capacitor or the like is preferred for the initial pulse(s) and such a switch is obviously not necessary with FWDC inductee output.
[0053] An important aspect of a generator variant of the present disclosure is that it is capable of delivering electricity “on demand”. As there is no fuel cost involved, in times of lower demand, a generator may simply be taken “off line”. Alternatively, a generator may be shut down, to be started again when demand requires it.
[0054] Additional aspects of the present disclosure of variants of electricity generator are that: (1) its principal elements (the inductors and the inductees) are configured in interlocking sections, of which there may be any number and which sections may be of any size. A generator may be large, small, or very small, or may be composed of a number of generators, the parallel circuits of which are interconnected. Thus, a generator has inherent modularity and scalability: each generator may be thought of as a module of a larger-dimensioned generator. A module may be removed from the circuit, or added thereto, forming yet a higher-powered generator. Even the largest generators would require minimal infrastructure and operating costs. A generator not only may they be sited in or near the sites of consumption, but they may also be used in propulsion systems for all types of vehicles; (2) elements of a generator may vary from one configuration to another, For example, the dimensions of a both inductors and inductees, their volumes, the sections of their wires, the material of which the wires are fabricated, as well as their respective number of wires (turns or turn-equivalents) may be different. The magnetically permeable core of the inductor may have a different number of layers, or be fabricated of a different material, or have a different form. Obviously, differently sized generators of the present disclosure will have different power outputs. However, the current induced in the wires of the inductees of any generator is without significant variations in its voltage, amperage or frequency, as it is modulated by apparatus in the control module; it is of grid quality.
[0055] Further aspects of the present disclosure generator variants are that they: (1) are characterized by their universality: as magnetism is a universal phenomenon, a generator of the present disclosure will function anywhere; (2) scalable (3) have significant inherent redundancies, allowing them to continue functioning even if many elements become unusable; (4) preferably include no moving parts; (5) inherently safe.
[0056] One of the reasons a generator of the present disclosure is efficient is because its output is derived from conversion of potential magnetic energy to electric energy, which conversion requires no fuel or energy input, although it consumes a part of the current output from inductees to provide current to the inductors for cycles subsequent to the initial cycle(s), as described herein-before. A generator having no moving parts is, by definition, more dependable (less likely to break down) than one having moving parts. Accessibility is another aspect: a generator may be more or less accessible for maintenance and/or repair and it follows therefore that accessibility is of less importance for a generator that has no moving parts; not only does movement require energy, it also creates friction which consumes energy dissipated as heat, which is undesirable. Obviously, a generator of the present disclosure may have moving parts but as that would serve no useful purpose it is not preferred.
[0057] Cost through life cycle is another aspect to consider: devices having moving parts generally require at least preventive maintenance at some intervals if proper functioning is to be assured; they may require repair(s) at some intervals and, as they are subject to wear, certain replacement either totally or partially at some point(s) in their life cycle. On the contrary, a generator of the present disclosure, having no moving parts, is less likely to be subject to those requirements.
[0058] As a generator of the present disclosure requires no fuel, there is no fuel tank and thus no possibility of a fuel tank leakage, rupture, fire or explosion, and there is no carbon footprint. As there are no moving parts in a generator, there is no energy component in a part, which, in the event of the part's failure, could result in a catastrophic failure of the generator. Any event, internal or external, which would cause a partial failure, would simply cause a part of the generator to cease functioning, as described hereinbefore. A large-scale external event could cause the generator to simply cease functioning, in a “shut down” having no external consequences.
[0059] A further aspect of the disclosure of variants of an electricity generator is that systemic losses are reduced to a minimum. The current flowing in the wires of the inductors, as well as the movement of the magnetic field there-around, will inevitably cause undesirable effects, such as hysteresis, vibrations thereof, and eddy currents. Eddy currents and coercion are reduced by the use of an insulated laminated scribed core in the inductors; vibrations are reduced by the use of rigid walls and enclosures for the aforesaid elements. Further, in spite of the parallel circuitry of the inductors and relatively low resistivity due to the total area of the wires thereof, certain generators could have current flows that could generate considerable heat. Where considerable heat is produced in a generator by any phenomenon, it flows towards thermistors (not shown) to create electricity, which current flows to an ancillary circuit (not shown).
[0060] Another aspect of the present disclosure of variants of an electricity generator is that an ancillary circuit (not shown) preferably provides current to sensor circuits and other circuits (not shown), which current is another small part of the current induced in the inductees. The control module (not shown) includes at least one of the following apparatus: battery, capacitor, inverter, voltage rectifier, voltage and current regulators, CPU, DSP, sensor controller, phase controller, master on/off switch, secondary solenoid-equivalent device output controller (none of which are shown). Reliance on sensors and computer control is necessary for the proper functioning of the generator described herein. Methods and embodiments to perform such functions are well known in the art, and thus are not shown herein. Circuitry, cabling and wiring connectors and electric interfaces and sensors are not shown, ancillary and/or electronic devices well known in the art are not shown in the drawings herein. It may be desirable in certain induction devices, notably the generator configurations, to have computer-addressable switches, sensors and controllers located in strategic locations.
[0061] Other aspects of the present disclosure of variants of an electricity generator are the relationships of the magnetic fields of the inductors and the inductees, as well as the creation of a phenomenon in the wires of the inductors known as “back emf”. The current flowing in the inductors is slightly out of phase with the current induced in the inductees; thus, even though their magnetic fields are complementary there is no repulsion as the fields are not in phase. However, back emf is produced. Back emf is the self-inductance of the wires of the said inductor, which is function of the number of its turn-equivalents and the current frequency therein. When cyclic current flows through the wires of the inductors, it creates a propagating magnetic field of concentric circles that first traverses the inductor's wires and then traverses the wires of the inductees. As the magnetic field traverses the wires of the inductors, a voltage and a current surge is created therein. This is the back-emf, or counter emf, which is of a polarity opposite to the polarity of the current that created the magnetic field, thus temporarily reducing the voltage across the leads of the wires of the inductors. When the concentric circles of the magnetic field collapse, they collapse not only through the wires of the number of inductees, but also back through the wires of the number of inductors, wherein a second back emf is produced. These effects are not material in the functioning of any induction device of any configuration disclosed herein.
[0062] There is a further aspect somewhat analogous to the movement of the wires of the inductors and inductees in response to the magnetic field in which they are situated, described hereinbefore. In a preferred variant of a generator, the number of inductors forms a long electromagnet, as described hereinbefore. However, the number of inductees also forms an electromagnet when the inducing current flows through their wires. Although they are not exactly in phase, the polarities of both the inductors and inductees are the same throughout the cyclic pattern of current flow, such that they constantly repel each other. However, as the secondary volume(s) surround(s) the primary volume(s) in all preferred variants of an electricity generator, the repelling forces are exerted equally on all sides of the inductors, and should thus cancel out. In any case, as the preferred frequency of the inducing current is relatively high, if vibrations do occur because of inequalities in the magnetic fields, they should be small.
[0063] It is informative to view the calculations relative to a nominal electricity generator of the present disclosure, given in the section entitled Calculations for a Nominal electricity generator presented below.
[0064] As has been mentioned herein-before, induction devices are generally inefficient, as they utilize only a part of the magnetic field generated by the inductor, which is that part of the moving magnetic field facing the inductee. As the Halbach Array concentrates its magnetic field in a particular manner, they have found uses that take advantage of this particularity. There are a number of patents relating to Halbach Arrays having different configurations and uses, all using permanent magnets, which appears to have limited its use somewhat. In all single-layer current-art Halbach Arrays, adjacent magnets have polarities at 90 degrees of each other; in multilayer arrays, and an adjacent magnet of an adjacent layer may have the same polarity. U.S. Pat. No. 5,6312,618 discloses an electromagnetic Halbach Array comprising coils, and its use in a levitation device. As indicated hereinbefore, coils and solenoids are efficient in volumes that are cylindrical, but not in volumes that are parallelepiped. Further, it is evident that an electromagnet offers distinct advantages over a permanent magnet in many electromagnetic devices.
[0065] Thus, a third preferred embodiment using the template herein-before disclosed, is a straight-wire electromagnetic Halbach Array and its derivations, an electromagnetic Halbach-Array Induction Device and an electromagnetic Halbach-Array electromagnet. As in current art, an electromagnetic Halbach-Array may exist in different form-factors: flat single layer, flat multilayer, toroidal having a single ring or toroidal having multiple concentric rings, all of which function on the same operating principle. These novel electromagnetic Halbach Arrays provide an advantage over current-art permanent-magnet Halbach Arrays in that being electromagnets, the magnetism of the electromagnetic array not only may be temporary, but the strength of the fields may be enhanced with magnetically permeable cores configured in each electromagnetic inductor or element of an electromagnet. The individual electromagnets in such an array must be physically constrained; the polarities of the adjacent electromagnets are such that the electromagnets would repel each other when a current flows through their wires.
[0066] The electromagnetic Halbach Array utilizing straight wires herein-before disclosed may be configured as the first stage of an electromagnetic Halbach Array Induction Device, defined as a configuration of Halbach-Array electromagnets in an embodiment having inductors and inductees both comprised of straight wires. The physical orientation of the adjacent inductors is such that, when a current flows through their wires, the adjacent inductors become electromagnets having polarities that may be neither opposite nor alike such that, as in a current-art Halbach Array, the magnetic field of the inductors is concentrated in one direction, towards the inductees. Further, as the straight wires of the inductees are preferably parallel to the straight wires of the inductors, the polarity of adjacent individual inductees may be neither opposite nor alike when a current is induced in the wires thereof, but is the same as the inductor with which the inductee is coupled. Both the inductor and inductee are comprised of straight wires preferably having a square cross-section and sharp corners, and are closely assembled in the width and at least one layer in the height along the length of both the inductor and inductee and in such manner that: (1) at least one straight wire of at least one layer of at least one inductor is parallel to at least one straight wire of at least one other layer of the said at least one inductor and (2) at least one straight wire of at least one layer of the at least one inductor is parallel to at least one straight wire of at least one layer of the at least one inductee.
[0067] Whatever the form-factor of an electromagnetic Halbach Array or an electromagnetic Halbach-Array Induction Device, be it flat single layer or multilayer, single-ring toroid or a toroid having more than one ring, the dimensions of both the inductors and the inductees are preferably substantially the same. In all configurations of an electromagnetic Halbach-Array Induction Device, the inductors become bar electromagnets when a Pulsed Direct cyclical current flows through their wires, and a moving magnetic field comprised of concentric circles is generated in and about their wires, inducing a voltage in the inductees, and a current therein (if a complete circuit is provided). In all embodiments and configurations of an electromagnetic Halbach Array, the operating principle is the same: (1) the individual inductors of the device are interfaced in a parallel electric circuit such that all said individual inductors are electrified at the same time, and the same phase of the current is induced in the wires of all said individual inductees at the same time; (2) the individual inductors of the device are configured in a specific manner such that: (a) when PDC current flows through the individual inductors, the polarities of adjacent individual inductors may be neither opposite nor alike; (b) each individual inductor is inductively coupled with an individual inductee which has the polarity of its coupled individual inductor when a cyclic inducing current flows through the inductor's wires; (c) the individual inductees of the device are interfaced in a parallel electric circuit. Preferably, both inductor and inductee have the same dimensions and the inductee has at least the same number of straight wires having a particular physical orientation as the inductor has straight wires having that physical orientation. It is known that, for the same frequency of inducing current, the greater the number of straight wires traversed by the said magnetic field, the higher the induced voltage in the inductees.
[0068] When a PDC current flows through the parallel electrical circuit of the wires of each individual Halbach-Array inductor, a moving magnetic field is created in and around each wire of the said inductor (and thus in and around the said inductor), which said magnetic field is concentrated towards the inductee with which it is coupled. The inducing current must be Pulsed DC, otherwise the side of the device on which the magnetic field is concentrated would be switched. In an electromagnetic Halbach Induction Device, the inductors must be physically constrained or their polarities would cause them to be repelled from each other when a cyclic current flows through their wires. The inductees must also be physically constrained as, when a current is induced in their wires, their polarities would be such that the inductees would repel each other. Both the inductors and inductees are, in effect, the electromagnetic device previously disclosed herein. Both include conductor plates at their ends enabling a parallel circuit interface with the straight wires thereof. The conductor plates are electrically interfaced with cable sections and other electrical interfaces (not shown), enabling a parallel circuit of all inductors and inductees. Inductors and inductees of all configurations are physically contained in a constraining case, preferably fabricated of a material that is magnetically impermeable, that both separates each individual inductor and inductee and provides a housing in a hollow part of the case's wall for a color-coded magnetically-shielded two-conductor cable interface (not shown) that enables completion of the parallel circuits of both the inductors and inductees. The coating of the inductor's wires is preferably of a different color than that of the inductee's coating, and leads, connectors and interfaces of the inductors and inductees have respective like color codes to insure against cross circuitry in assembling the induction device.
[0069] As with the Halbach inductors described previously, each magnetic subassembly of the toroidal form-factor preferably includes a magnetically-permeable core preferably comprised of a number of metal sheets having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with insulation sheets between the metal sheets. Said metal sheets preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. A magnetically permeable core increases the strength of the magnetic field generated in and around the aforesaid elements of the array by a factor of up to thousands compared to an air core, when a current flows through its wires. The individual magnetic subassemblies of the toroidal form-factor: (1) are interfaced in a parallel electric circuit such that all said magnetic subassemblies are electrified at the same time; (2) are configured in a specific manner such that when a current flows through the individual magnetic subassemblies, the polarities of adjacent individual magnetic sub-assembles may be neither opposite nor alike; (3) preferably have the same dimensions and the same number of straight wires. All magnetic subassemblies include conductor plates at their ends enabling a parallel circuit interface with the straight wires thereof. The conductor plates are electrically interfaced with cable sections and other electrical interfaces (not shown), enabling a parallel circuit of all magnetic subassemblies of the toroidal electromagnet. All magnetic subassemblies of the toroidal form-factor are physically contained in a case, preferably fabricated of a material that is magnetically impermeable, that both separates each magnetic subassembly of the toroidal electromagnet and provides a housing in a hollow wall for a magnetically-shielded two-conductor cable interface (not shown) that enables completion of the parallel circuits of all magnetic subassemblies of the toroidal form-factor. When the magnetic subassemblies are electrified, the magnetic field of the toroidal Halbach Array is directed to one side of the said electromagnet, where it is a concentrated coherent field.
[0070] To form an electromagnet, a magnetically permeable plate is configured directly adjacent the array in the zone of concentration of its magnetic field, to protect the magnetic subassemblies from damage; this plate obviously becomes an electromagnet. Such an electromagnet may have either a flat or toroidal form-factor whose configuration, while somewhat more complex than current-art solenoid electromagnets, offers a significant advantage: that its magnetic field is directed towards the object to be attracted (whereas the magnetic field of a current-art electromagnet utilizing solenoids, is not). This concentrated directionality provides a more efficient electromagnet, by allowing a given current to generate a more powerful magnetic field on the side towards which it is directed. Each magnetic subassembly of the electromagnet is, in effect, the electromagnetic device disclosed hereinbefore. The preferred form-factor for such a Halbach-Array electromagnet is toroidal, having at least one ring, wherein while no adjacent magnetic subassembly has a polarity that is complementary or alike when electrified. If the configuration comprises more than one ring, said rings are concentric; adjacent magnetic subassemblies of an adjacent concentric ring may have polarities that are complementary or alike. The electric interfaces in the hollow-wall portions are not shown.
[0071] These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0073] FIG. 1 presents a side elevation view of a first exemplary electromagnetic induction device;
[0074] FIG. 2 presents a sectioned end elevation view of the electromagnetic induction device originally introduced in FIG. 1 , the section being taken along section lines 2 - 2 of FIG. 1 ;
[0075] FIG. 3 presents a side elevation view of a second exemplary electromagnetic induction device, illustrating inductor and inductee subassemblies in position of inductive coupling;
[0076] FIG. 4 presents a sectioned end elevation view of electromagnetic induction device originally introduced in FIG. 1 , the section being taken along section lines 4 - 4 of FIG. 3 ;
[0077] FIG. 5 presents an isometric side view of an exemplary inductor assembly interlocking section of a parallelepiped variant of a generator;
[0078] FIG. 6 presents an sectioned end view of the inductor assembly interlocking section of FIG. 5 , the section being taken along section lines 6 - 6 of FIG. 5 ;
[0079] FIG. 7 presents a side elevation view of the inductor assembly interlocking section originally introduced in FIG. 5 ;
[0080] FIG. 8 presents an isometric side view of two vane sections of the inductor assembly interlocking section, illustrating an assembly interface for joining vanes to the hollow core;
[0081] FIG. 9 presents an isometric side view of a common core subassembly of the inductor assembly interlocking section originally introduced in FIG. 5 ;
[0082] FIG. 10 presents an isometric side view of the quadrant subassembly of the inductor assembly interlocking section originally introduced in FIG. 5 ;
[0083] FIG. 11 presents an isometric front view of an exemplary insulator plate of an inductor assembly interlocking section;
[0084] FIG. 12 presents an isometric top view of a male hollow spine connector;
[0085] FIG. 13 presents an isometric side view of the male hollow-spine connector assembled within the insulator plate;
[0086] FIG. 14 presents an isometric front view of negative vertical and lateral interface bands assembled within channels of the insulator plate;
[0087] FIG. 15 presents an isometric front view of positive vertical and lateral interface bands assembled within channels of the insulator plate;
[0088] FIG. 16 presents an isometric front view of a negative male blade connector extending from the lateral interface band into an opening of the male hollow-spine connector;
[0089] FIG. 17 presents an isometric front view of a positive male blade connector extending from the lateral interface band into the opening of the male hollow-spine connector;
[0090] FIG. 18 presents an isometric side view of two female hollow-core sections having a male hollow-spine connector inserted therein, further illustrating a pair of two-conductor cable sections with their male blade connectors configured in the hollow spine sections;
[0091] FIG. 19 presents a partially assembled isometric view of a plurality of inductor assembly interlocking sections assembled in length in a primary volume;
[0092] FIG. 20 presents an isometric front view of an exemplary inductee assembly section, illustrating an inductor subassembly assembled within an inductee subassembly section;
[0093] FIG. 21 presents a side view of a hollow wall portion, illustrating a cable section;
[0094] FIG. 22 presents an end view of the inductee assembly interlocking-section originally introduced in FIG. 20 , the section taken along section line 22 - 22 of FIG. 20 ;
[0095] FIG. 23 presents a cut-away view of an inductee assembly interlocking section of FIG. 22 , showing an inductor assembly interlocking-section, particularly illustrating the non-coincident relationship of their respective conductor plates;
[0096] FIG. 24 presents a cut-away isometric front view illustrating a plurality of inductee assembly interlocking-sections configured end-to-end, forming a secondary volume of a parallelepiped generator variant surrounding the primary volume;
[0097] FIG. 25 presents an exploded isometric view of the parallelepiped generator embodiment, illustrating assembly of a pair of end caps;
[0098] FIG. 26 presents an isometric view of an exemplary flat electricity generator embodiment;
[0099] FIG. 27 presents an end view of a magnetically-permeable core integrated in the flat electricity generator originally introduced in FIG. 26 ;
[0100] FIG. 28 presents a front view of an end cap integrated into the flat electricity generator originally introduced in FIG. 26 ;
[0101] FIG. 29 presents an isometric view of an exemplary cylindrical electricity generator embodiment;
[0102] FIG. 30 presents an end view of a central portion of the cylindrical electricity generator embodiment originally introduced in FIG. 29 ;
[0103] FIG. 31 presents a partial detail end view of a magnetically-permeable cylinder of the cylindrical electricity generator embodiment originally introduced in FIG. 29 ;
[0104] FIG. 32 presents a front view of a terminal disc of the cylindrical electricity generator embodiment originally introduced in FIG. 29 ;
[0105] FIG. 33 presents a side view of a hollow magnetically impermeable core integrated into the cylindrical electricity generator embodiment originally introduced in FIG. 29 , illustrating a female hollow spine, a male hollow-core connector and a four-conductor cable;
[0106] FIG. 34 presents a side view of the male hollow-core connector of the cylindrical electricity generator embodiment originally introduced in FIG. 29 , introducing four FFF female blade connectors on each side;
[0107] FIG. 35 presents an exploded isometric view of the cylindrical electricity generator embodiment originally introduced in FIG. 29 , illustrating assembly of a pair of end caps;
[0108] FIG. 36 presents an isometric view of an exemplary embodiment of a straight-wire parallelepiped electromagnetic Halbach Array;
[0109] FIG. 37 presents a side elevation view of the straight-wire parallelepiped electromagnetic Halbach Array electromagnet originally introduced in FIG. 36 ;
[0110] FIG. 38 presents an isometric side view of the straight-wire parallelepiped electromagnetic Halbach Array originally introduced in FIG. 36 ;
[0111] FIG. 39 presents a side elevation view of the straight-wire parallelepiped electromagnetic Halbach Array originally introduced in FIG. 36 ;
[0112] FIG. 40 presents an end view of the straight-wire parallelepiped electromagnetic Halbach Array originally introduced in FIG. 36 ;
[0113] FIG. 41 presents an isometric exploded assembly view of the straight-wire parallelepiped electromagnetic Halbach-Array Induction device originally introduced in FIG. 36 , illustrating both the inductors and inductees;
[0114] FIG. 42 presents an exploded assembly side view of a straight-wire parallelepiped electromagnetic Halbach-Array Induction device originally introduced in FIG. 36 , illustrating both the inductors and inductees;
[0115] FIG. 43 presents an exploded assembly end view of the straight-wire parallelepiped electromagnetic Halbach-Array Induction device originally introduced in FIG. 36 , illustrating both the inductors and inductees;
[0116] FIG. 44 presents an isometric exploded assembly view of an exemplary embodiment of a Toroidal Electricity Generator;
[0117] FIG. 45 presents a frontal view of a toroidal ring of the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0118] FIG. 46 presents an isometric exploded assembly view of a toroidal inductor that is utilized within the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0119] FIG. 47 presents a front elevation view of a magnetically permeable core that is utilized within the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0120] FIG. 48 presents an isometric front view of an external toroidal inductor that is utilized within the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0121] FIG. 49 presents an isometric front view of an internal toroidal inductor that is utilized within the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0122] FIG. 50 presents an isometric view of a toroidal ring that is utilized within the Toroidal Electricity Generator originally introduced in FIG. 44 ;
[0123] FIG. 51 presents an exploded isometric view of the Toroidal Electricity Generator originally introduced in FIG. 44 , illustrating assembly of a pair of end caps
[0124] Like reference numerals refer to like parts throughout the various views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0125] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1 . Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0126] FIG. 1 illustrates straight-wire electromagnetic induction device 100 in its simplest embodiment, comprising at least one inductor 102 and at least one inductee 104 . While such a configuration will induce a voltage and a current in inductee 104 when a cyclic current flows through the wires of inductor 102 , it is inherently inefficient. This is so because the moving magnetic field created in and around inductor 102 traverses (cuts) the wires of only one inductee 104 . Notwithstanding, it is sufficient for tasking as a charger or a magnet, and is the straight-wire counterpart of a current-art induction device comprising a solenoid inductor and a coil inductee. To increase its inductive power, it is therefore preferable that inductees 104 be configured in such manner that they completely surround or enclose inductors 102 . Each inductor 102 and each inductee 104 include a number of preferably square cross-sectioned sharp-edged straight wires 106 closely assembled in at least one layer in its height and its width, said wires 106 having a length hereinafter-described, in such manner that all said straight wires 106 of straight-wire electromagnetic induction device 100 are parallel to each other. Said inductor 102 also preferably includes magnetically-permeable core 110 preferably comprised of metal sheets 112 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with insulation sheets 114 between metal sheets 112 . Said metal sheets 112 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. Magnetically permeable core 110 increases the strength of the magnetic field generated in and around aforesaid inductor 102 by a factor of up to thousands compared to an air core, when a current flows through its wires. Magnetically impermeable case 108 concentrates the moving magnetic field generated in and around aforesaid inductor 102 , preventing the said magnetic field from exiting said electromagnetic induction device 100 . At one end of straight wires 106 of inductor 102 is situated negative inductor conductor plate 116 and, at the other end is situated positive inductor conductor plate 118 . Aforesaid square cross-sectioned sharp-edged straight wires 106 have the length existing between said plates 116 and 118 , as well as plates 124 and 126 . Both aforesaid plates 116 , 118 are preferably fabricated of a material that is a good conductor of electricity, such as copper, and provide both a parallel electrical interface for all aforesaid straight wires 106 of inductor 102 as well as an electrical interface to the exterior of the device for current input by means of negative color-coded input lead 120 and positive color-coded input lead 122 . At one end of straight wires 106 of inductee 104 is situated negative inductee conductor plate 124 and, at the other end is situated positive inductee conductor plate 126 . Both aforesaid plates 124 , 126 are preferably fabricated of a material that is a good conductor of electricity, such as copper, and provide both a parallel electrical interface for all aforesaid straight wires 106 of inductee 104 as well as an electrical interface to the exterior of the device for its current output, by means of negative color-coded output lead 128 and positive color-coded output lead 130 . Inductor conductor plates 116 , 118 are not in physical or electrical contact with inductee conductor plates 124 , 126 .
[0127] FIG. 2 illustrates straight-wire electromagnetic device 100 , along the line 2 - 2 of FIG. 1 , illustrating the same components.
[0128] FIG. 3 illustrates electromagnetic induction device 200 , which, comprising more than one inductee for each inductor, is more efficient than electromagnetic induction device 100 previously described. This is so, as the moving magnetic field created in and around an inductor traverses (cuts) the wires of more than one inductee. An inductor subassembly 202 is preferably enclosed by more than one inductee subassembly 222 . Inductor subassembly 202 includes a number of preferably square cross-sectioned sharp-edged straight wires 204 closely assembled in at least one layer in its height and its width, said wires 204 having a length hereinafter-described, in such manner that at least one straight wire 204 of at least one layer is parallel to at least one straight wire 204 of another layer of straight wires 204 of inductor subassembly 202 . Said inductor subassembly 202 also includes at least one magnetically-permeable core 208 preferably comprised of metal sheets 210 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel, with insulation 212 between metal sheets 210 . Said metal sheets 210 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. Magnetically permeable core 208 increases the strength of the magnetic field generated in and around the aforesaid inductor 202 by a factor of up to thousands. Magnetically impermeable case 206 concentrates the moving magnetic field generated in and around inductor subassembly 202 when a cyclic current flows through the straight wires 204 thereof, and which said field has completely traversed the aforesaid wires, preventing the said magnetic field from escaping to the exterior of case 206 (where it would be wasted); thus, the said field may collapse through inductee subassembly 222 . At one end of inductor subassembly 202 is situated negative conductor plate 214 and, at the other end is situated positive conductor plate 216 , both aforesaid plates 214 , 216 are preferably fabricated of a material being a good conductor of electricity, such as copper; aforesaid square cross-sectioned sharp-edged straight wires 204 have the length existing between said plates 214 and 216 . Said conductor plates 214 , 216 provide both a parallel electrical interface for all aforesaid straight wires 204 of inductor subassembly 202 , as well as the respective interfaces with negative color-coded input lead 218 and positive color-coded input lead 220 . Enclosing inductor subassembly 202 are preferably more than one inductee subassembly 222 , which also include a number of preferably square cross-sectioned sharp-edged straight wires 224 closely assembled in at least one layer in its height and its width, said wires 224 having a length hereinafter-described, in such manner that at least one straight wire 224 of one layer is parallel to at least one straight wire 224 of another layer of inductee subassembly 222 . The object of magnetically impermeable case 226 is to prevent the magnetic field that has traversed said inductee's straight wires 224 from escaping to the exterior of case 226 . At one end of inductee subassembly 222 is situated negative conductor plate 228 and at the other end is positive conductor plate 230 ; aforesaid square cross-sectioned sharp-edged straight wires 224 have the length existing between said plates 228 and 230 . Said conductor plates 228 , 230 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide both a parallel electrical interface for all aforesaid straight wires 224 of inductee subassembly 222 , as well as an interface with negative color-coded output lead 232 and positive color-coded output lead 234 . The orientation of square cross-sectioned straight wires 204 of inductor subassembly 202 is parallel to the orientation of square cross-sectioned straight wires 224 of inductee subassembly 222 such that, when a cyclic current flows through aforesaid straight wires 204 of inductor subassembly 202 , they are inductively coupled with straight wires 224 of inductee subassembly 222 , allowing said straight wires 224 to be traversed in a perpendicular manner by the concentric lines of force of the moving magnetic field generated in and around straight wires 204 of inductor subassembly 202 , inducing a cyclical voltage and current in straight wires 224 of inductee subassembly 222 . Inductor subassembly 202 is configured such that its conductor plates 214 , 216 are not in physical or electrical contact with inductee conductor plates 228 , 230 .
[0129] FIG. 4 illustrates induction device 200 , along the line 4 - 4 of FIG. 3 , and illustrates the same components.
[0130] FIG. 5 illustrates inductor assembly interlocking section 304 of parallelepiped variant of a generator 300 , illustrating common-core subassembly 306 and quadrant subassembly sections 308 . Common-core subassembly 306 comprises laminated magnetically-permeable vane section 310 said vane section 310 comprising more than one metal sheet 312 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel and preferably have a uniform grain orientation and uniform scribing, to reduce hysteresis loss. Insulation sheet 314 is configured between and on the outsides of metal sheets 312 . Insulation strips 315 are affixed to ends of said vane sections 310 . Said vane sections 310 are affixed to rigid square magnetically permeable female hollow-spine sections 318 . Quadrant subassembly sections 308 include inductor square cross-sectioned straight wires 326 electrically interfaced with both negative-conductor plate 328 and positive-conductor plate 330 , providing a parallel electrical circuit for said inductor square cross-sectioned straight wires 326 . Said conductor plates 328 , 330 include depressions 332 .
[0131] FIG. 6 illustrates inductor assembly interlocking section 304 along the line 6 - 6 of FIG. 5 , illustrating substantially the same elements as FIG. 5 .
[0132] FIG. 7 illustrates inductor assembly interlocking section 304 , illustrating substantially the same elements as FIG. 5 , as well as insulator plate 336 having insulator plate opening 362 .
[0133] FIG. 8 illustrates two vane sections 310 of inductor assembly interlocking section 304 , illustrating the mechanism of fixation of said vane sections 310 to rigid square magnetically permeable female hollow-spine section 318 . Metal sheets 312 of vane section 310 include a number of hooks 316 extending from said metal sheets 312 in an offset configuration along the length thereof. Said hooks 316 enable physical mating of said vane section 310 with rigid square magnetically-permeable female hollow-spine section 318 , said female hollow-spine section 318 having a number of slots 320 perforated along the length thereof in an offset configuration generally corresponding to the offset configuration of hooks 316 . Said hooks 316 are forcibly received in, and cooperate with said slots 320 to accomplish the physical mating of said vane section 310 with said female hollow-spine section 318 , forming common-core subassembly section 306 . Also shown are outer insulation sheet 314 insulation strips 315 .
[0134] FIG. 9 illustrates common core subassembly 306 , illustrating vane sections 310 comprising more than one metal sheet 312 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon steel and preferably have a uniform grain orientation and uniform scribing, to reduce hysteresis loss. Insulation sheet 314 is configured between and on the outsides of metal sheets 312 . Insulation strips 315 are affixed to ends of said vane sections 310 . Said vane sections 310 are affixed to rigid square magnetically permeable female hollow-spine sections 318 .
[0135] FIG. 10 illustrates quadrant subassembly section 308 , illustrating inductor square cross-sectioned straight wires 326 electrically interfaced with both negative color-coded conductor plate 328 and positive color-coded conductor plate 330 , each including depressions 332 . Said plates 328 , 330 provide a parallel electrical circuit for said inductor square cross-sectioned straight wires 326 . Inductor square cross-sectioned straight wires 326 are closely assembled in the width and at least one layer in the height, along the length of each said quadrant subassembly section 308 . Inductor assembly interlocking sections 304 are configured in primary volume 302 in such manner that all like color-coded conductor plates 328 , 330 are facing in the same direction.
[0136] FIG. 11 illustrates insulator plates 336 having projections 334 on both sides of said insulator plate 336 , which said projections 334 cooperate with depressions 332 of conductor plates 328 , 330 allowing said projections 334 to be force-fit therein. Also illustrated are channels 350 as well as insulator plate opening 362 . Said insulator plate 336 separates respective negative and positive color-coded conductor plates 328 , 330 of adjoining inductor assembly interlocking sections 304 , enabling the interlocking thereof and thus the formation of primary volume 302 .
[0137] FIG. 12 is a side perspective view of a male non-conducting hollow-spine connector 32 having opening 324 .
[0138] FIG. 13 illustrates male non-conducting hollow-spine connector configured in opening 324 of insulator plate 336 .
[0139] FIG. 14 illustrates insulator plate 336 illustrating negative color-coded conducting vertical interface band 338 and negative color-coded lateral conducting interface band 340 force-fit in aforementioned channels 350 of insulator plate 336 . Said interface bands 338 , 340 include projections 334 , which are force-fit into depressions 332 of aforesaid negative conductor plate 328 , thus providing an electrical interface between said interface bands 338 , 340 and said negative conductor plate 328 .
[0140] FIG. 15 illustrates insulator plate 336 illustrating positive color-coded conducting vertical interface band 342 and positive color-coded conducting lateral interface band 344 force-fit in aforementioned channels 350 of insulator plate 336 . Said positive interface bands 342 , 344 include projections 334 , which are force-fit into depressions 332 of aforesaid positive conductor plate 330 , thus providing an electrical interface between said interface bands 342 , 344 and said positive conductor plate 330 .
[0141] FIG. 16 illustrates insulator plate 336 illustrating negative color-coded conducting vertical interface band 340 and laterally offset negative color-coded male blade connector 346 extending therefrom into opening 324 of male non-conducting hollow-spine connector 322 .
[0142] FIG. 17 illustrates insulator plate 336 illustrating positive color-coded conducting vertical 9 interface band 342 and laterally-offset positive color-coded male blade connector 348 extending therefrom into opening 324 of male non-conducting hollow-spine connector 322 .
[0143] FIG. 18 illustrates two female hollow core sections 318 into which are configured male hollow-spine connectors 322 having opening 324 , illustrating also two magnetically-shielded two-conductor cable sections 360 having negative and positive male blade connectors 356 , 358 configured in said female hollow spine sections 318 and male hollow-spine connector 322 . A negative color-coded FFF female blade connector 352 and a positive color-coded FFF female blade connector 354 are also illustrated. Aforementioned laterally offset negative and positive color-coded male blade connectors 346 , 348 are respectively interfaced into one of FFF negative and positive color-coded female blade connector 352 , 354 . The two remaining FF negative and positive color-coded female blade connectors 352 , 354 interface respectively with male negative color-coded blade connector 356 and male positive color-coded blade connector 358 of magnetically-shielded two-conductor color-coded cable sections 360 , which cable sections 360 . Said cable sections 360 enable the parallel electrical circuit of all quadrant subassemblies sections 308 . Thus, when they are cyclically electrified, said inductor assembly interlocking-sections 304 form a bar electromagnet in primary volume 302 . Sensor cabling (not shown) may be housed in aforesaid hollow-spine sections 318 as well.
[0144] FIG. 19 illustrates inductor assembly interlocking-sections 304 configured in length in primary volume 302 .
[0145] FIG. 20 illustrates inductee assembly interlocking-section 366 illustrating inductor subassembly 304 configured therewithin. Said inductee assembly interlocking-section 366 includes square cross-sectioned straight wires 368 closely assembled in the width and at least one layer in the height along the length of case section 370 . Said case section 370 substantially encloses inductee subassembly 366 , and has magnetically permeable walls 372 , one of which walls 372 has hollow-wall portion 374 with an evacuated section 376 . Hollow-wall portion 374 houses square magnetically shielded two-conductor output cable section 378 terminating in negative and positive color-coded male blade connectors 380 , 382 . All straight wires 326 at one end of case section 370 are electrically interfaced with negative color-coded conductor plate 384 extending to negative color-coded male blade connector 386 ; those at other end are electrically interfaced with positive color-coded conductor plate 388 extending to positive color-coded male blade connector 390 . Said negative and positive male blade connectors 388 , 390 extend through evacuated section 376 to interface with one of negative FFF female color-coded blade connectors 391 and positive FFF female color-coded blade connectors 392 , which are also housed in aforesaid hollow-wall portion 374 . The other two FF negative and positive color-coded female blade connectors interface with aforesaid negative and positive male blade connectors 380 , 382 of aforesaid two-conductor output cable section 378 . In this manner, a parallel electrical circuit is established for all said straight wires 326 of all inductee assembly interlocking sections 366 . Insulator plate 393 clips into both aforesaid negative and positive color-coded conductor plates 384 , 388 by means of cooperating projections 394 on both sides of said negative and positive color-coded conductor plates 384 , 388 as well as depressions 395 on both sides of aforesaid insulator plates 393 into which said cooperating projections 394 are force-fit. Insulator plates 393 both separate conductor plates 384 , 388 at each end of aforesaid inductee assembly interlocking sections 366 and enable a number of inductee assembly interlocking-sections 366 to be configured in a lengthwise manner in secondary volume 364 . In such a configuration, all like color-coded negative and positive conductor plates 384 , 388 face the same direction. Sensor cabling (not shown) may be included in aforesaid hollow-wall portion 374 .
[0146] FIG. 21 illustrates hollow-wall portion 374 illustrating, in addition to some of the same elements of FIG. 21 , negative and positive color-coded male blade connectors 380 , 382 that terminate two-conductor cable section 378 . Hollow-wall portion 374 has evacuated section 376 into which extend negative and positive male blade connectors 386 , 390 . Said blade connectors 386 , 390 interface with respective FFF female color-coded blade connectors 391 , 392 , with which also interface aforesaid negative and positive male blade connectors 380 , 382 of aforesaid two-conductor cable section 378 .
[0147] FIG. 22 illustrates inductee assembly interlocking-section 366 along the line 22 - 22 of FIG. 20 illustrating, in addition to those elements of FIG. 20 , evacuated sections 376 of hollow-wall portion 374 into which extends negative male color-coded blade connector 386 and positive color-coded male blade connector 390 , and magnetically-shielded two-conductor output cable section 378 in hollow-wall portion 374 .
[0148] FIG. 23 illustrates an inductor assembly interlocking-section 304 configured within an inductee assembly interlocking-section 366 , particularly illustrating the non-coincident relationship of conductor plates 328 , 330 of inductor assembly interlocking-section 304 with conductor plates 384 , 388 of inductee assembly interlocking-section 366 .
[0149] FIG. 24 illustrates a number of inductee assembly interlocking-sections 366 configured end-to-end, forming secondary volume 364 of parallelepiped generator variant 300 .
[0150] FIG. 25 illustrates inductor assembly interlocking-sections 304 forming primary volume 302 configured within inductee assembly interlocking-sections 366 forming secondary volume 364 . Magnetically impermeable outer casing 396 encloses said secondary volume 364 , with end caps 397 completing the enclosure at both ends, thus forming parallelepiped generator variant 300 . The object of outer casing 396 is also to concentrate the concentric circles of the moving magnetic field that has traversed the wires of the at least one inductee such that they do not escape to the exterior of the case, as well as to protect the device from external magnetic fields. One end cap 397 provides power-input terminal 398 from control module (not shown) to color-coded magnetically-shielded two-conductor cable section 360 of parallel circuit of inductor assembly interlocking-sections 304 , as well as providing power output terminal 399 for color-coded magnetically-shielded two-conductor cable section 378 of parallel circuit of inductee assembly interlocking-sections 366 , which is the power output of or parallelepiped generator variant 300 .
[0151] FIG. 26 illustrates a flat electricity generator variant 400 , showing one inductor 402 and two inductees 404 , configured in such manner that the said two inductees 404 enclose said inductor 402 . Inductor 402 includes straight wires 406 as well as negative conductor plate 410 and positive conductor plate 412 which interface with said straight wires 406 , also providing a parallel circuit interface for all said inductor straight wires 406 as well as a parallel circuit interface for inductors 402 of all interlocking sections 418 . Inductees 404 include straight wires 408 as well as negative conductor plate 414 and positive conductor plate 416 which interface with said straight wires 408 , also providing a parallel circuit interface for all said inductee straight wires 408 as well as a parallel circuit interface for inductees 404 of all interlocking sections 418 . Insulator plate 420 separates the aforesaid positive and negative conductor plates 412 , 410 , 416 , 414 of each interlocking section 418 . Magnetically permeable core 422 is configured between inductor 402 and inductee 404 . Magnetically impermeable case 428 having hollow walls 430 enclose the device on all sides. The object of magnetically impermeable case 428 is to concentrate the concentric circles of the moving magnetic field that has traversed the wires of the at least one inductee such that they do not escape to the exterior of the case, as well as to protect the device from external magnetic fields. Hollow walls allow passage of wiring (not shown) for inductors 402 and inductees 404 , and cabling (not shown) for parallel circuits. Insulator plate 420 and conductor plates 410 , 412 , 414 , 416 include cooperating projections and depressions (not shown, similar to 544 , 546 of terminal-disc 538 of cylindrical electricity generator variant 500 ), allowing the aforesaid interlocking sections 418 to clip there with, forming a long flat generator variant 400 .
[0152] FIG. 27 illustrates magnetically-permeable core 422 having at least one metal sheet 424 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, with insulation sheets 426 between said metal sheets 424 . Said metal sheets 424 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. Insulating sheets 424 separate coincident negative conductor plates 410 and 414 of inductor 402 and inductee 404 , and coincident positive conductor plates 412 and 416 of inductor 402 and inductee 404 .
[0153] FIG. 28 illustrates end cap 432 having negative and positive input terminals 434 , 436 for inductors 402 , and negative and positive output terminals 438 , 440 for inductees 404 .
[0154] FIG. 29 illustrates cylindrical generator variant 500 , including primary volume 502 comprising a number of solenoid inductor sections 504 , and secondary volumes 506 comprising a number of interior coil inductee sections 508 configured under aforesaid solenoid inductor sections 504 , and a number of external inductee sections 509 configured over aforesaid solenoid inductor section 504 . A solenoid inductor section 504 preferably includes square cross-sectioned wires 512 configured between and along the length of two magnetically permeable cylinders 514 . Said square cross-sectioned wires 512 are tightly wound in the same direction in many layers around and along the length of one aforesaid magnetically permeable cylinder 514 and under a second magnetically permeable cylinder 514 , such that said square cross-sectioned wires 512 are configured between two aforesaid magnetically-permeable cylinders 514 . An aforesaid magnetically-permeable cylinder 514 is constructed of at least one metal sheet 516 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, with insulation sheets 518 between said metal sheets 516 . Said metal sheets 516 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. Coil inductee sections 508 include square cross-sectioned wires 512 tightly wound in the same direction in many layers below and above solenoid inductor section 504 . Also shown is magnetically shielded two-conductor cable section 519 and magnetically-shielded four-conductor cable section 520 housed in hollow magnetically impermeable female hollow-core section 521 , whose length generally corresponds to the width of interlocking combined assembly 510 .
[0155] FIG. 30 illustrates some of the components of FIG. 29 , and particularly solenoid inductor 504 , interior and exterior coil inductees 508 , 509 , as well as magnetically permeable cylinder 514 and four-conductor cable section 520 .
[0156] FIG. 31 illustrates a portion of magnetically permeable cylinder 514 , constructed of at least one metal sheet 516 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, with insulation sheets 518 between metal sheets 516 .
[0157] FIG. 32 illustrates the front side, the “assembly side” of terminal-disc 538 of cylindrical electricity generator variant 500 , showing terminal-disc opening 540 , arcuate terminal-disc perforations 542 , projections 544 and depressions 546 , and channels 548 .
[0158] FIG. 33 illustrates two female hollow-core sections 521 housing two-conductor cable 519 and four-conductor cable section 520 . Said two-conductor cable 519 has negative and positive color-coded power input connectors 522 , 524 for the parallel circuits of the solenoid inductors 504 . Four-conductor cable section 520 has four male blade connectors on each end of said sections 520 , two are negative and positive color-coded output connectors 526 , 527 for the parallel circuits of the internal coil inductees 508 and the other two are negative and positive color-coded output connectors 528 , 529 for the parallel circuits of the external coil inductees 509 . The said female hollow-core sections 521 are connected by male hollow-core connector 550 having opening 552 , through which pass aforesaid blade connectors.
[0159] FIG. 34 illustrates male hollow-core connector 550 of cylindrical electricity generator variant 500 , illustrating the four FFF female blade connectors on each side of opening 552 , negative color-coded FFF female blade power connector 530 and positive color-coded FFF female blade power connector 532 ; negative color-coded FFF female blade output connector 534 positive color-coded FFF female blade output connector 536 . Female FFF power connectors 530 , 532 , 534 , 536 enable the completion of electrical interfaces with negative and positive power leads 554 , 556 to solenoid inductors 504 and negative and positive output leads 558 , 560 from interior and exterior coil inductees 508 , 509 and with male blade connectors 530 , 532 , 534 , 536 (of cable sections 520 of FIG. 29 ), enabling the parallel circuitry of all solenoid inductors 504 and coil inductees 508 , 509 of all interlocking combined assembly sections 510 .
[0160] FIG. 35 illustrates a cylindrical electricity generator variant 500 showing circumferential magnetically impermeable outer casing 554 having magnetically impermeable lining 556 enclosing generator variant 500 . The object of magnetically impermeable outer casing 554 and magnetically impermeable lining 556 is to concentrate the concentric circles of the moving magnetic field that has traversed the wires of the at least one inductee such that they do not escape to the exterior of the case, as well as to protect the device from external magnetic fields. End caps 558 complete the closure at both ends thereof. One end cap 558 includes power input terminal 560 and power output terminal 562 .
[0161] FIG. 36 illustrates toroidal electromagnetic Halbach Array 600 , comprised of at least one concentric ring 602 of magnetic subassemblies 604 , all of which are of the same dimension, and each of which is, in effect, an electromagnetic device disclosed herein-before. Square cross-sectioned straight wires 606 are closely assembled in the height, width and length of said magnetic subassemblies 604 , said straight wires 606 having the orientation indicated by arrows 607 , said orientation being a property of a Halbach Array. Each said magnetic subassemblies 604 preferably has the same form-factor such that, whatever the orientation of straight wires 606 in rigid magnetically impermeable case 614 , the number of wires and their length, and thus the strength of their magnetic field, is the same, forming a coherent magnetic field on one side of toroidal Halbach-Array 600 . Magnetic subassemblies 604 are housed in rigid magnetically impermeable case 614 such that straight wires 606 of each magnetic subassembly 604 are aligned in a specific manner such that (1) the straight wires 606 of a magnetic subassembly 604 may not be parallel to the straight wires 606 of an adjacent magnetic subassembly 604 of the same ring 602 (but may be parallel to the straight wires 606 of an adjacent magnetic subassembly 604 of an adjacent ring 602 if the configuration comprises more than one ring 602 ) and; (2) when a Pulsed DC current flows through the wires of the said magnetic subassemblies 604 , their polarities are those shown by arrows 607 in the figure, such that the magnetic field remains concentrated on the desired side of the device. Magnetically permeable core 608 is constructed of at least one metal sheet 610 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, with insulation sheets 612 between said metal sheets 610 . Said metal sheets 610 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss. On one end of each said array subassembly 604 is situated negative conductor plate 618 and positive conductor plate 620 is situated on the other end. Said conductor plates 618 , 620 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide a parallel electrical interface for said straight wires 606 of each said magnetic subassembly 604 as well as providing a parallel electrical interface for all said magnetic subassemblies 604 of said toroidal electromagnetic Halbach Array 600 . Magnetically impermeable case 614 having hollow wall 616 encloses each said magnetic subassembly 604 . The objects of said magnetically impermeable case 614 are: to concentrate the magnetic field that is created in and around said straight wires 606 of each said magnetic subassembly 604 when a current flows in the said wires 606 ; to contain and to restrain the said magnetic subassemblies 604 from movement caused by the non-complementary magnetic field of an adjacent magnetic subassembly 604 . Hollow walls 616 allow passage of wiring and cabling (not shown).
[0162] FIG. 37 illustrates electromagnetic Halbach Array electromagnet 622 comprising a toroidal Halbach Array 600 having a magnetically permeable plate 624 configured directly adjacent the toroidal array 600 , on the side of concentration of its magnetic field. The object of magnetically permeable plate 624 is to protect the ### from damage when the said electromagnet 622 is operating. Plate 624 obviously becomes an electromagnet when current flows through the wires 606 of magnetic subassemblies 604 of Toroidal Halbach-Array 600 . Electrical interfaces for the parallel electrical circuit of all magnetic subassemblies 604 housed in hollow-wall 816 , are not shown. When a Pulsed DC current flows through the wires of the said magnetic subassemblies 604 , their polarities are those shown by arrows 607 in the figure, such that the magnetic field remains concentrated on the desired side of the device.
[0163] FIG. 38 illustrates parallelepiped electromagnetic Halbach-Array 700 having square-sectioned sharp-edged coasted straight wires 702 closely assembled in the width and at least one layer in the height along the length of each of a number of array subassembly 704 which is, in effect, an electromagnetic device disclosed herein-before. Each said array subassembly 704 is enclosed in magnetically impermeable compartmental case 712 having a hollow wall 714 . On one end of each said array subassembly 704 is situated negative conductor plate 716 and positive conductor plate 718 is situated on the other end. Said conductor plates 716 , 718 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide a parallel electrical interface for said straight wires 702 of each array subassembly 704 as well as a parallel electrical interface for all said array subassembly 704 . Negative color-coded power lead 720 and positive color-coded power lead 722 of magnetically-shielded two-conductor color-coded power cable sections 724 housed in hollow wall 714 and other electrical interfaces (not shown) provide a parallel circuit for all array subassemblies 704 . When a Pulsed DC current flows through the wires of the said magnetic array subassemblies 704 , their polarities are those shown by arrows 726 in the figure, such that the magnetic field remains concentrated on the desired side of the device. Each said array subassembly 704 preferably has the same form-factor such that, whatever the orientation of straight wires 702 in compartmental case 712 , the number of wires and their length, and thus the strength of their magnetic field, is the same, forming a coherent magnetic field on the side of parallelepiped electromagnetic Halbach Array 700 .
[0164] FIG. 39 illustrates array subassemblies 704 of parallelepiped electromagnetic Halbach-Array 700 in magnetically impermeable compartmental case 712 . Each said array subassembly 704 includes magnetically permeable core 706 , as well as negative conductor plate 716 and positive conductor plate 718 .
[0165] FIG. 40 illustrates magnetically impermeable compartmental case 712 of parallelepiped electromagnetic Halbach-Array 700 along the lines 39 - 39 of FIG. 39 . Magnetically impermeable compartmental case 712 also includes hollow wall 714 , into which negative power lead 720 and positive power lead 722 from negative conductor plate 716 and positive conductor plate 718 are fed. Magnetically permeable core 706 includes more than one metal sheet 708 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, with insulation sheets 710 between metal sheets 708 . Said metal sheets 708 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss.
[0166] FIG. 41 illustrates electromagnetic Halbach-Array Induction device 726 of which inductor assembly 728 on the bottom of the figure is the Halbach Array 700 of FIG. 38 and having the same numbering sequence. Inductee assembly 730 is also a Halbach Array including magnetically impermeable compartmental-case 736 including hollow wall 738 and having individual inductees 732 . Each said inductor subassembly 728 includes negative conductor plate 740 and positive conductor plate 742 providing parallel electrical interface for square cross-sectioned straight wires 734 . Hollow wall 738 houses two-conductor output cable 748 having negative power lead 744 and positive power lead 746 and other electrical interfaces (not shown), providing a parallel electrical circuit for all inductee subassemblies 730 . When a Pulsed DC current flows through the wires of the said inductor assemblies 728 , their polarities are those shown by arrows 725 in the figure, such that the magnetic field remains concentrated on the desired side of the device. Inductee assemblies 730 are inductively coupled with said inductor assemblies 728 , and thus have the polarities of said inductor assemblies 728 . As induction device 726 , inductee assembly 730 is positioned proximate to inductor assembly 728 . Each said inductor assembly 728 preferably has the same form-factor such that, whatever the orientation of straight wires 702 in compartmental case 712 , the number of wires and their length, and thus the strength of their magnetic field, is the same, forming a coherent magnetic field on the side of inductor assemblies 728 facing inductee assembly 730 and individual inductees 734 .
[0167] FIG. 42 illustrates straight-wire parallelepiped electromagnetic Halbach-Array Induction device 726 of which inductor assembly 728 on the bottom of the figure is the Halbach Array 700 of FIGS. 38 and 41 , having the same numbering sequence. Inductee assembly 730 is also a Halbach Array having individual inductees 730 including magnetically impermeable compartmental-case 736 . Each said inductee subassembly 730 includes negative conductor plate 740 and positive conductor plate 742 . When a Pulsed DC current flows through the wires of the said inductor assemblies 728 , their polarities are those shown by the arrows in the figure, such that the magnetic field remains concentrated on the desired side of the device. Inductee assemblies 730 are inductively coupled with said inductor assemblies 728 , and thus have the polarities of said inductor assemblies 728 . As induction device 726 , inductee assembly 730 is positioned proximate to inductor assembly 728 .
[0168] FIG. 43 illustrates straight-wire parallelepiped electromagnetic Halbach-Array Induction device 726 of FIG. 42 , along the line 42 - 42 . Inductor assembly 728 is the Halbach Array 700 of FIGS. 38 and 41 , having the same numbering sequence. Inductee assembly 730 is also a Halbach Array having individual inductees 730 including magnetically impermeable compartmental-case 736 having hollow wall 738 , in which is housed two-conductor cable 748 . As induction device 726 , inductee assembly 730 is positioned proximate to inductor assembly 728 .
[0169] FIG. 44 illustrates Toroidal Electricity Generator Variant 800 , which includes a number of internal toroidal inductees 802 configured in internal secondary volumes 804 , and a number of external toroidal inductees 806 configured in external secondary volume 808 which surround toroidal inductor 810 . Each said toroidal inductee 802 , 806 includes inductee square-sectioned sharp-edged coated straight wires 812 closely assembled in the width and at least one layer in the height along the length of each said toroidal inductee 802 , 806 , and in such manner that (1) at least one straight wire 812 of at least one layer of a said toroidal inductees 802 , 806 is parallel to at least one straight wire 812 of at least one other layer of the said toroidal inductees 802 , 806 , and that (2) preferably all said straight wires 812 are mutually parallel. Toroidal inductees 802 , 806 are, in effect, the electromagnetic device disclosed hereinbefore. Between said toroidal inductees 802 and 806 are configured a number of toroidal inductors 810 in primary volume 814 . Each said toroidal inductor 810 includes inductor square-sectioned sharp-edged coated straight wires 816 closely assembled in the width and at least one layer in the height along the length of each said toroidal inductor 810 , and in such manner that (1) at least one straight wire 816 of at least one layer of a said toroidal inductor 810 is parallel to at least one straight wire 816 of at least one other layer of said toroidal inductor 810 and that (2) preferably all said straight wires 812 are mutually parallel, as well as being parallel to aforesaid inductee square-sectioned sharp-edged coated straight wires 812 of toroidal inductees 802 , 806 .
[0170] FIG. 45 illustrates interlocking toroidal ring 801 a number of which are included in Toroidal Electricity Generator Variant 800 . Interlocking toroidal ring 801 comprises a number of internal toroidal inductees 802 of internal secondary volume 804 concentrically nested in toroidal inductors 810 of primary volume 814 , both of which are concentrically nested in external toroidal inductees 806 of external secondary volume 808 .
[0171] FIG. 46 illustrates details of a toroidal inductor 810 housed in magnetically impermeable inductor case 818 on one end of which is situated negative inductor conductor plate 820 and positive inductor conductor plate 822 situated on the other end. Said inductor conductor plates 820 , 822 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide a parallel electrical interface for all said straight wires 816 of each toroidal inductor 810 as well as a parallel electrical interface for all toroidal inductors 810 . Negative and positive inductor blade extensions 824 , 826 project from aforesaid inductor negative and positive inductor conductor plates 820 , 822 into longitudinal hollow case channels 828 of magnetically impermeable case 818 . Said longitudinal hollow case channels 828 include negative inductor connector band 830 and positive inductor connector band 832 with which aforesaid negative and positive inductor blade extensions 824 and 826 interface physically and electrically, and which provide a parallel electrical circuit for all toroidal inductors 810 .
[0172] FIG. 47 illustrates details of magnetically permeable core 834 , which serve respectively as top and bottom of aforesaid toroidal inductor 810 . Magnetically permeable cores 834 include at least one metal sheet 836 having a high relative permeability and low coercion, such as laminated mu-metal or sheet silicon-steel, and at least one insulation sheet 838 . Said metal sheets 836 preferably have a uniform grain orientation and are uniformly scribed, to reduce hysteresis loss.
[0173] FIG. 48 illustrates details of external toroidal inductee 806 housed in magnetically impermeable external inductee case 840 , on one end of which situated negative internal inductee conductor plate 842 and positive internal inductee conductor plate 844 is situated on the other end. Said inductee conductor plates 842 , 844 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide a parallel electrical interface for all aforesaid straight wires 816 of external toroidal inductee 806 as well as providing a parallel electrical interface for all external toroidal inductees 806 . Negative and positive external inductee blade extensions 846 , 848 project from aforesaid negative and positive inductee conductor plates 842 , 844 into longitudinal hollow case channels 850 of magnetically impermeable external inductor case 840 . Said longitudinal hollow case channels 850 include negative and positive external inductee connector bands 852 , 854 with which aforesaid negative and positive external inductee blade extensions 846 , 848 physically and electrically interface, providing a parallel electrical interface for all toroidal external inductees 806 .
[0174] FIG. 49 illustrates details of internal toroidal inductee 802 housed in magnetically impermeable internal inductee case 856 , on one end of which is situated negative internal inductee plate 858 and positive internal inductee conductor plate 860 is situated on the other end. Said inductee conductor plates 858 , 860 are preferably fabricated of a material being a good conductor of electricity such as copper, and provide a parallel electrical interface for all aforesaid straight wires 816 of internal toroidal inductee 802 as well as providing a parallel electrical interface for all internal toroidal inductees 802 . Negative and positive internal inductee blade extensions 862 , 864 project from aforesaid negative and positive internal inductee conductor plates 858 , 860 into longitudinal hollow case channels 866 of magnetically impermeable internal inductor case 856 . Said longitudinal hollow case channels 866 include negative and positive external inductee connector bands 868 , 870 with which aforesaid negative and positive external inductee blade extensions 862 , 864 physically and electrically interface, providing a parallel electrical interface for all toroidal internal inductees 802 .
[0175] FIG. 50 illustrates interlocking toroidal ring 801 . Said rings 851 interlock with its adjacent interlocking toroidal rings 851 by means of projections and depressions (not shown, but similar to those shown in FIG. 32 ) configured on connector plate 872 which attaches to sides of aforesaid magnetically impermeable cases 818 , 840 and 856 by means of projections and depressions (not shown, but similar to those shown in FIG. 32 ). Said connector plate 872 has appropriate openings (not shown) for the passage of female blade connectors (not shown). Said female blade connectors interface physically and electrically with aforesaid connector bands 830 , 832 and 852 , 854 , as well as 862 , 864 of adjacent interlocking toroidal ring 851 .
[0176] FIG. 51 illustrates Toroidal Electricity Generator 800 configured in its magnetically impermeable outer case 874 having magnetically impermeable lining 876 . Said outer case 874 is preferably fabricated of plastic; if it is metal, it is preferably grounded. The objects of the magnetic impermeability of said outer case 874 and said lining 876 are to concentrate the magnetic field that has traversed the wires of the external inductee 806 , preventing it from exiting Toroidal Electricity Generator 800 and thus being wasted, as well as to prevent external magnetic fields from penetrating Toroidal Electricity Generator 800 . Magnetically impermeable end caps 878 are configured at each end of Toroidal Electricity Generator 800 , one of which includes negative and positive inductor input terminal 880 , 882 and the other with includes negative and positive inductee output terminals 884 , 886 .
[0177] The above descriptions are considered that of preferred embodiments only. Modifications of the disclosures will occur to those skilled in the art and to those who make or use the disclosures. Therefore, it is understood that the embodiments and variants shown in the drawings and described above are merely for illustrative purposes, not to scale, and are not intended to limit the scope of the disclosures, which are defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
Preferred and Non-Preferred Embodiments
[0178] A non-preferred embodiment of a generator is one in which the secondary volume(s) are only situated within the primary volume. If it were composed of inductors and inductees having straight wires, the primary volume would be comprised of “electromagnetic Halbach-Array Induction Devices” as inductors, and the magnetic field of the primary volumes would thus be concentrated in its interior where the secondary volumes would be configured. While this configuration would provide the concentration of inductor's magnetic field inside the perimeter of the primary volume, it would necessarily mean that the area of the wires of the inductees in the secondary volume would be inferior to those of the primary volume; this is the opposite of what is desirable. It also means that the magnetic field traversing the secondary volume would not be totally coherent in terms of an inducing field, which is the opposite of what is desired.
[0179] Another non-preferred embodiment of a generator is one in which a portion of the current generated, or part of the initial pulse(s) of current to the wires of the primary volume, were utilized to create a motion, such as the vibratory movement of the type found in cell phones. While this would generate electricity, it would require energy to create and sustain that motion while being less effective as a generator that the embodiments having no moving parts disclosed herein, defeating some of its objectives, and eliminating some of the advantages described herein-before.
[0180] Calculations for a Nominal Electricity Generator
[0181] Dimensions of Generator
[0182] The generator has 10 interlocking inductor and inductee sections. The overall dimension of the nominal generator is approximately H4.5 cm×W4.5 cm×L35 cm, not including the casing=708 cm 3 (43 In3), not including the automobile battery or computerized control module.
[0183] Inductors
[0184] The inductors are in a parallel circuit comprised of 1000 lengths of wire, the ampacity of which is 64-73 amps. Each inductor interlocking section has a common permeable core of laminated sheets.
[0185] Inductees
[0186] The inductee interlocking sections are in parallel circuit, comprised of 11040 lengths of wire.
[0187] Current Supply from Battery to Inductor's Parallel Circuit
[0188] For the first cycle of AC to the inductor's parallel circuit, the 24 v 550-amp DC automobile battery's power is transformed into 240 v 55 amp AC (13.2 Kva), and regulated to the desired frequency. Thereafter, the feedback circuit from the control module supplies the AC current at that frequency from one part of the output cycle. The inductor's input may be a DC pulse (PDC), in which case the output is Full Wave DC (FWDC).
[0189] Induced Voltage
[0190] Vs=Ns/Np (Fp).=11040/1000 (Fp)=11.04 (Fp). At 400 Hz AC inducing current, the induced voltage=4416 volts; at 800 Hz=8832 volts; at 3 KHz=33.12K volts; at 6 KHz=66.24K volts; at 60 KHz=662.4K volts; at 600 KHz=6,624K volts; at 780 KHz=8,611.2K volts.
[0191] Induced Current
[0192] Is=Np/Ns (Ip)=1000/11040 (55)=4.98 amps (Note: while larger units could have larger cross-sectioned wires, capable of higher ampacity, the amperage in the inductees will always be relatively low, because of the inverse ratio of wires).
[0193] Resistance of Circuits (R=I/V)
[0194] Inductors=55/240=0.229 ohms; Inductees=4.98/4416 volts at 400 Hz=0.00113 ohns. At higher voltages, resistance is lower. At higher frequencies, circuit resistance increases
[0000] Flux(Inductor's Voltage× T [frequency]/ N [number of wires in inductor]= V ( T/N )
[0195] 240(400/1000)=96000/1000=96 webers; at 800 Hz=192 webers; at 3 KHz=720 webers; at 6 Khz=1,440 webers; at 60 Khz=14400 webers; at 600 KHz=144,000 webers; at 780 KHz=187,200 webers.
[0000] “ B ” Field=Flux/ A
[0196] Length of Inductors is 0.35 m, height is 0.08 m, Area=0.35×0.08=0.028=96/0.028=3428.57 webers
[0000] “ H ” Field= I/ 2 Pi ( r ) r =average distance from inductor to inductee
[0197] I=55 amps, r=0.025 m
[0198] 55/2(3.1416)(0.025)=350 amps/meter
[0199] Net Power Output after Feedback of 13.32 Kva
[0200] The net output at 400 Hz is 16.871 Kva (22.6 Hp); at 800 Hz, 33.7 Kva (45.2 Hp); at 3 KHz=128 Kva (171.5 Hp); at 6 KHz=256 Kva (343 Hp); at 60 Khz=2.560 Kva; at 600 KHz=25.60 Kva; at 780 KHz=33.254 Kva.
[0201] Generator Rating Per Hour and Observations
[0202] The cyclic output per second is multiplied by 3600 to indicate the generator's hourly rating. Thus, at 400 Hz=60.7 Kva/h; at 800 Hz=121.4 Kva/h; at 3 KHz=460.8 Kva/h; at 6 KHz=921.6 Kva/h; at 60 KHz=9.26 Mw/h; at 600 KLHz=92.166 Kw/h; at 780 KHz=119.7 Mw/h. A large home typically requires 15-20 Kva AC; an electric automobile 20-30 Kva DC. A medium-sized heliostat installation may generate 20 Mw; a large one 280 Mw. Three linked nominal generators operating at a frequency of 780 Mhz (see above) provide more power, with incomparably less investment. The simplest method to increase output of a given generator is to increase the frequency of the inductors current, as shown in the calculations above. Obviously, the output of smaller generators may be combined via a parallel circuit, thus increasing the output of the installation. Full Wave DC is the preferable output for small generators, since the apparatus to which they would supply electricity would generally be small (requiring DC at a low amperage).
[0203] In the foregoing description those skilled in the art will readily appreciate that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims expressly state otherwise.
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An electromagnetic induction device having an array of linearly arranged wires spanning between a pair of conductor plates forming a parallel circuit between each of the wires. The wires are arranged forming a plurality of planes, which are stacked into layers. Multiple induction devices are assembled together providing at least one “inductor” and at least one “inductee”. A moving magnetic field comprised of concentric circles is created in and around the at least one inductor when a cyclic current flows in the said wires. A voltage and current is induced by the said moving magnetic field. The field propagates then collapses through the wires of the inductees in a perpendicular manner, inducing therein a cyclic voltage and a current flow. The “inductor” and “inductee” can be shaped and assembled in a variety of form factors, including a linear arrangement, a toroidal arrangement, a stacked arrangement, and the like.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the United States National Stage Application pursuant to 35 U.S.C. §371 of International Patent Application No. PCT/DE2014/200703, filed on Dec. 11, 2014, and claims priority to German Patent Application No. DE 10 2014 205 767.1 of Mar. 27, 2014, which applications are incorporated by reference in their entireties.
FIELD
[0002] The invention relates to a method for operating an internal combustion engine comprising at least one cylinder and a variable valve drive, particularly embodied as a reciprocating piston engine, whereby its speed can fall below the idling speed.
BACKGROUND
[0003] A camshaft adjustment device for automobiles is known from EP 2 591 215 B1, with which a phase position of a camshaft can be changed or adjusted to a temporarily constant phase position. In a motor start operating mode, a range of valve opening angles is adjusted via the camshaft adjustment device, which is smaller than a geometric normal range of opening angles. Using the distinctly dynamic features of the camshaft adjustment device, it shall be possible to reduce the range of valve openings to a value which results from the difference of the standard range of opening angles to an almost equivalent range of camshaft settings. Upon reaching the idling speed, according to EP 2 591 215 B1, a switching is provided to a standard operating mode, in which a constant phase position of the camshaft is adjusted.
[0004] An operating mode of a camshaft adjuster is already known for shutting off the internal combustion engine, for example from JP 2011-094581 A.
SUMMARY
[0005] The objective of the invention is based on providing an operating method for an internal combustion engine showing variable control times, which is particularly suitable for operating phases below the idling speed, particularly for vehicles with a start-stop system.
[0006] This objective is attained according to the invention in a method for operating at least one cylinder and one internal combustion engine comprising at least one cylinder and an adjustable valve drive, as well as a control unit for an internal combustion engine, which is embodied for executing this method.
[0007] The method is used in operating phases of the internal combustion engine, in which the speed of the internal combustion engine changes. Here, the speed may increase or reduce, with the speed level sometimes being above or below the idling speed. In particular, it may relate to an operating phase in which the speed initially falls below the idling speed and then is increased again. Such a scenario is also called a “change-of-mind” situation. In this scenario, it is assumed that a shutoff process is initiated in the internal combustion engine, for example, by issuing a stop signal to the still rolling vehicle by the start-stop system, for example, when approaching a red traffic light. Due to a changed traffic situation, for example when a traffic light switches to “green,” and/or upon a command of the driver and within the scope of a “change-of-mind” situation, the speed of the internal combustion engine can be increased again before the engine comes to a complete stop, whereby for this process no starter of the internal combustion engine is required if the speed has not fallen below a certain required speed.
[0008] The invention is based on the notion that, in internal combustion engines with adjustable valve drives, typically several adjustment mechanisms are provided with which the filling of the cylinder or, in the case of motors with several cylinders, the cylinders, can be influenced. These different adjustment mechanisms are generally called peripheral adjustment devices on the one hand, and near-cylinder adjustment devices on the other hand. Here, the gas flow towards the cylinder is decisive for the classification of the adjustment devices as “peripheral” or “near-cylinder.” The gas flowing in the direction toward the cylinder initially impinges on the peripheral adjustment device, particularly a throttle flap. Additionally, an intake manifold with an adjustable length is included in the term “peripheral adjustment device.”
[0009] After flowing through the peripheral adjustment device, the inflowing gas reaches at least one element, particularly an inlet valve, which can be influenced by the near-cylinder adjustment device. The near-cylinder adjustment device can represent, for example, a camshaft adjuster, particularly an electro-mechanically operated camshaft adjuster, a valve drive with switchable cam followers, for example rocker arms, variable bucket lifters, or tappets, a sliding cam system, or an electro-hydraulically operated valve drive, if this is provided with sufficient oil pressure even at lowest speeds. Additionally, the near-cylinder adjustment device may be a part of a valve drive, which shows no mechanical connection to the crankshaft of the internal combustion engine.
[0010] In all cases, the cylinder filling of the internal combustion engine can be influenced both by the peripheral as well as the near-cylinder adjustment device, with the various adjustment devices being adjusted, according to the invention, in an unevenly acting fashion during a change of speed. This may mean, for example, that one of the adjustment devices is adjusted in the direction towards a higher cylinder filling, while the second adjustment device is adjusted in the direction of a lower filling of the cylinder.
[0011] It is also possible during a change of speed, particularly a lowering of speed, to keep one of the adjustment devices unchanged, particularly the peripheral adjustment device, while the other adjustment device is adjusted.
[0012] According to one potential embodiment of the method, during the lowering of the speed of the internal combustion engine, the peripheral adjustment device is adjusted to a higher cylinder filling compared to the near-cylinder adjustment device. This comes into consideration particularly in situations where the speed is lower than the idling speed, however, rapid acceleration of the internal combustion engine shall be possible. The peripheral adjustment device, set to a relatively high cylinder filling compared to the near-cylinder adjustment device, ensures in this case that the pressure of the intake manifold remains high in reference to a common shutoff process, which has beneficial effects upon the restart capabilities of the engine.
[0013] The method according to the invention can be used not only when restarting within the scope of a “change-of-mind” situation, but also for simply shutting off the internal combustion engine. When shutting off an internal combustion engine, there are various options for adjusting the adjustment devices which influence the cylinder filling. On the one hand, adjustments are possible which lead to a strong flow of gas and accordingly high current loss. This results in a very rapid reduction of the speed, i.e., the motor is stopped quickly, however, this coincides with the development of considerable vibrations. From an NVH (Noise Vibration Harshness) point of view, it is therefore not optimal to shut off the internal combustion engine rapidly. Any stopping of the internal combustion engine optimized from an NVH viewpoint therefore provides that the cylinder filling is minimized during the shutoff process, resulting in a soft “putting down” of the internal combustion engine. Here, though, the longer period of time for the shutdown process is disadvantageous.
[0014] These conflicting goals are attained according to the invention such that the different adjustment devices of the internal combustion engine are adjusted in a seemingly contradictory fashion with the elements adjustable by the different adjustment devices, particularly the throttle flap and the gas exchange valves, not only influencing the cylinder filling but also the pressure in the space between the above-mentioned elements.
[0015] During the shutoff process of the internal combustion engine, the near-cylinder adjustment device, particularly the camshaft adjustment unit, is preferably adjusted to an inlet valve closing time of the internal combustion engine, which is equivalent to an angular value of the crankshaft, amounting to at least 20° or 25°, preferably at least 40°, particularly preferred at least 60°, ahead or behind the lower dead center of the lower charge change of the internal combustion engine.
[0016] In a vehicle equipped with a start-stop system and when the internal combustion engine is coasting, if the speed is already below the idling speed and falls even further, preferably before reaching the speed limit at which an automatic acceleration of the internal combustion engine is no longer possible, the near-cylinder adjustment device is adjusted in the direction of a higher cylinder filling. This measure promotes a particularly rapid restart of the internal combustion engine, which cancels the shutoff process abruptly. This also applies when, in this phase of operation of the internal combustion engine, the different adjustment devices are adjusted in similar fashion. In any case, a restart signal, if it is issued before the above-mentioned speed limit is reached, can trigger a rapid and, from an NVH viewpoint, still comfortable acceleration of the internal combustion engine, with at least the near-cylinder adjustment device being adjusted in the direction of a further increased cylinder filling.
[0017] The subsequent acceleration of the internal combustion engine to idling speed occurs preferably under a significant further adjustment of the near-cylinder adjustment device. Here, starting with the time the restart signal was issued until the idling speed is reached, a change occurs from a first adjustment position to a second adjustment position, with the adjustment range of the near-cylinder adjustment device available being preferably utilized by at least one quarter, particularly by at least half. At least one of the above-mentioned adjustment positions of the near-cylinder adjustment device may coincide with an extreme position of the adjustment device. This particularly applies for near-cylinder adjustment devices, which only show discrete adjustment options. In near-cylinder adjustment devices with continuous adjustment options, during a restart process, each of the above-mentioned adjustment positions preferably differs more strongly from the other adjustment position than from the extreme position of the adjustment device, which most closely resembles the respective adjustment position.
[0018] Further, when accelerating the internal combustion engine up to idling speed and beyond, any known measures may be introduced which contribute to a higher cylinder filling. Of particular importance in this context is a potential charging of a mechanically or electrically driven compactor, for example, or a turbocharger. During the acceleration of the internal combustion engine triggered by a “change-of-mind” request, beginning at a speed below the idling speed, even brief commands issued by the driver or issued automatically, for example by a system for detecting the environment of the vehicle, may be generated within the scope of the so-called acceleration strategy. For example, the engine control can be influenced by a signal issued during the so-called re-acceleration of the internal combustion engine, i.e., the renewed acceleration after falling below the idling speed, contrary to a previously issued command, with no torque emission being requested here, but only idling operation. With such an intervention, it is already possible during the re-acceleration to reduce the filling of the cylinders to be sparked by adjusting the near-cylinder and/or peripheral adjustment device.
[0019] However, if the above-mentioned speed limit is not reached, any automatic acceleration of the internal combustion engine is by definition no longer possible here. In this case, when shutting down the internal combustion engine or when lowering the speed to a level allowing the operation of a starter, the near-cylinder adjustment device is preferably adjusted to a low cylinder filling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:
[0021] FIG. 1 is a diagram showing the speed progression, as well as the settings of various adjustment devices, when shutting down an internal combustion engine;
[0022] FIG. 2 is a diagram, according to FIG. 1 , showing a “change-of-mind” situation when operating the internal combustion engine; and,
[0023] FIG. 3 is a flow chart showing the interrelation of a “change-of-mind” situation.
DETAILED DESCRIPTION
[0024] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.
[0025] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.
[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.
[0027] It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,” “immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “approximately” is intended to mean values within ten percent of the specified value.
[0028] The following assumes the operation of an internal combustion engine embodied as a reciprocating piston engine, particularly showing four cylinders, also called internal combustion engine or motor for short and installed in a motor vehicle. As discernible from FIG. 1 , the internal combustion engine is initially operated with speed n, which is equivalent to idling speed n L . From this situation, the internal combustion engine is shut off, with a stop signal being issued, for example, by a start-stop system of the motor vehicle.
[0029] In addition to speed n of the crankshaft of the internal combustion engine, FIG. 1 shows a setting of a camshaft adjuster of the internal combustion engine, as well as a throttle flap of the internal combustion engine.
[0030] Here, the camshaft adjuster can be adjusted between first setting Sa and second setting Sb. In FIG. 1 , DS indicates potential throttle flap settings of the internal combustion engine. The hatched area opening over time t symbolizes different strategies for adjusting the throttle flap when shutting down the internal combustion engine, which is discussed in greater detail in the following description. The setting of the phase angle of the camshaft, namely the inlet camshaft of the internal combustion engine in reference to the angular position of the crankshaft, camshaft setting for short, is marked NS in FIG. 1 .
[0031] The adjustment of the camshaft adjuster from first setting Sa to second setting Sb represents an adjustment in the direction towards higher cylinder filling when the internal combustion engine is coasting. Here, the throttle flap may be kept constant. In the case of a closed throttle flap, this leads to particularly good NVH behavior and, in the case of an open throttle flap, to less optimal behavior from an NVH viewpoint. As an alternative to a constant throttle flap setting, during the shutdown of the internal combustion engine, its throttle flap or throttle flaps may be at least slightly opened, which can seem initially paradoxical. Both measures relate on the one hand to the camshaft adjuster and on the other hand to the throttle flap, which can also be applied in a combined fashion and lead to low-vibration and yet fast shutdown of the internal combustion engine. These features are particularly important when, as shown in FIG. 2 , the internal combustion engine shall be restarted during the shut-off process.
[0032] The point of time, at which a restart signal is issued, is marked t w . The speed limit, i.e., the minimal speed up to which the internal combustion engine can be restarted, is marked n w . In the scenario according to FIG. 2 , speed limit n w is reached approximately at the latest acceleration time marked t H . Even before the restart signal is issued, thus within this scenario in which a shutdown of the motor is assumed, the throttle flap of the internal combustion is adjusted so that rapid restarting is possible. This way, sufficiently high pressure is upheld in the intake manifold of the internal combustion engine in order to, by a rapid adjustment of the camshaft adjuster, also called near-cylinder adjustment device, allow a rapid acceleration of the internal combustion engine. As a distinction from the camshaft adjuster, the throttle flap is called a peripheral adjustment device.
[0033] Particularly when re-accelerating the internal combustion engine, the advantages of the apparently contradictory activation of different adjustment devices are effective in the speed rate below idling speed n L . In particular in an initial phase of the shutdown process, when the speed is reduced, the near-cylinder adjustment device may be adjusted at least slightly in the direction of a higher cylinder filling in order to prepare for a potential “change-of-mind” situation.
[0034] Based on FIG. 3 , some conditions are explained in the following, which must be fulfilled for the scenario according to FIG. 2 , i.e., the restart of the internal combustion engine within the scope of a “change-of-mind” situation.
[0035] A shutdown process is initiated in processing step Sl. This can occur either by the explicit desire of the driver or by a start-stop system. The start-stop system can, for example, be capable of detecting a red traffic light so that the shutdown process is already introduced when the vehicle is still rolling.
[0036] After the shutdown process has been initiated, with the motor still running, a permanent check occurs in processing step S 2 to determine if a restart of the internal combustion engine is still possible, i.e., if a “change-of-mind” situation could be considered. Simultaneously, a check is made in processing step S 3 to determine if a “change-of-mind” request was issued by the driver. Alternatively, a “change-of-mind” decision could also be rendered automatically, for example, by a visual detection and evaluation of the environment of the motor vehicle.
[0037] If both conditions set in steps S 2 and S 3 are fulfilled, in step S 4 the decision is automatically rendered to initiate the restart. The restart process itself, i.e., the acceleration of the internal combustion engine at least to idling speed n L , is marked as step S 5 in FIG. 3 .
[0038] It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
LIST OF REFERENCE CHARACTERS
[0039] DS Throttle flap setting
[0040] n Speed
[0041] n L Idling speed
[0042] n w Speed limit
[0043] NS Camshaft setting
[0044] Sa First setting of the camshaft adjuster
[0045] Sb Second setting of the camshaft adjuster
[0046] S 1 Processing step
[0047] S 2 Processing step
[0048] S 3 Processing step
[0049] S 4 Processing step
[0050] S 5 Processing step
[0051] t Time
[0052] t H Acceleration point of time
[0053] t w Time for requesting restart
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The invention relates to a method for operating an internal combustion engine with varying speed comprising at least one cylinder. Said internal combustion engine comprises different adjusting devices for influencing the filing of the cylinder, that is, at least one peripheral adjusting device and at least one adjusting device which is close to the cylinder. According to the invention, the various adjusting devices are adjusted unevenly when changing the engine speed.
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[0001] This application claims priority to a previously filed provisional application, Ser. No. 60/288,099, filed May 3, 2001.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to telecommunications networks and, in particular, to security management and controls for broadband switching nodes, gateway devices, routers, and multimedia applications servers in an Internet.
[0003] As is known in the art, the Internet is a huge collection of globally interconnected computers networks. The computer networks include Internet devices such as switching nodes, gateways, servers or routers. Networks are interconnected by routers that route traffic from a source device (e.g., switching node) to a destination device (e.g., services server) passing through some number of intervening networks. The Internet devices have computing abilities and utilize protocols conforming to the open system interconnection (OSI) model of which the transmission control protocol over Internet protocol (TCP/IP) is a widespread implementation. All information transported over the Internet is parcelled into TCP/IP packets, which are routed to an intended destination.
[0004] Because of the low-cost, global access provided by the Internet, one desired use is in electronic business (e-Business) services and applications. For the purposes of this application, e-business services and applications shall be any type of process, communication or transaction that may be undertaken in a revenue generating business. Such service and applications include, but are not limited to telephony, facsimile, electronic-mail, data transfer, electronic-commerce, e-mobile, video-on-demand, remote access to business services (including Business-to-Business and Business-to-Consumer), and any kind of transactions that are used to access digitized information.
[0005] Electronic business (e-Business) services are increasing rapidly for businesses and consumers. But without security and trust, there wouldn't be a notable shift towards commercial and financial transactions on the Internet. As e-Business consumers take advantage of the permanent broadband access and connections to the Internet, they will face security challenges
[0006] In today's network, security incidents with dialup access are limited because consumers dial-up for a service and then terminate the connection. Further, most digital subscriber line (DSL) and cable subscribers are permanently connected to the Internet without firewalls and they are vulnerable to security breaches.
[0007] The growth in public Internet use and the security concerns that exist created a strong demand for firewalls and other security capabilities for all broadband technologies including DSL, cable, and fixed and mobile wireless.
[0008] In the Internet, the traffic flows from multiple subscribers get aggregated over high-speed connections to backbone or core routers that transport such aggregated traffic over high-speed backbones. In this environment, service provider lacks the visibility into each individual subscriber's traffic flows. For example, while edge devices with Remote Authentication Dial-In User Service (RADIUS) provide service providers complete knowledge, control, and visibility of the subscriber and their traffic flows. Visibility of subscriber's traffic flows is not complete at other devices in the Internet, (e.g., services servers).
[0009] For Internet security management, edge device firewalls work as a form of perimeter defence to allow acceptable traffic, as defined by the service provider, and drops all other traffic before it enters the network. Firewalls perform this defensive function by monitoring packets and sessions, making decisions based on the established rules in order to determine the appropriate action to take.
[0010] There are various firewall products for enterprise, small, medium, large service providers, and also for personal computer (PC) users. These overlaid firewalls solutions complicate the service provider's network by increasing the cost of subscription per user, software updates, or network complexity. In a scenario in which the provider does not offer the firewall as part of their service offer, it is highly unlikely that the provider can support trouble calls nor validate whether the source of subscriber problems is due to network problems or the subscriber firewall configuration. In a scenario in which a service provider does provide personal firewalls, the provider will need to maintain records on individual firewalls and will be responsible for the software update, as appropriate.
[0011] In addition to the fact that the management and maintenance of firewalls in the Internet can be difficult, they often cannot protect the Internet against so-called “spoof” attacks. Spoof attacks involve sending traffic that appears to be a legitimate source IP address and therefore acceptable to the firewall, but the source address has been hijacked and used illegitimately. Even the most advanced firewalls can and have been spoofed by the serious hacker.
[0012] In today's network, providers use identity verification in order to validate users requesting access to their networks. The authentication mechanisms will take many forms and identification information will typically reside in a Remote Authentication Dial-In User Service (RADIUS) or other Authentication, Authorization, and Accounting (AAA) server.
[0013] Spoof attacks typically take advantage of the authentication mechanisms in order to cripple the server. The Internet Denial-of-Service (DoS) attacks prevent a target services device (or victim server) from performing its normal functions through the use of flooding of or irregular sizes of certain types of protocols, such as “Ping” requests aimed at the “victim” server. The DoS attacks are launched from a single machine to a specific server to overload the processor or monopolize the bandwidth for that server so that legitimate users cannot use the resource. Another type of spoof attack takes advantage of the Distributed DoS (DDoS) in much the same way, however, they are launched from multiple machines for the same intentions. Most of the DDoS attacks are done through propositioned code on the offending machine, also known as a “slave”, so that the remote or “master” machine can command the “slave” to launch the attack at any time.
[0014] Because many attacks are bandwidth attacks, very few solutions are available to avoid such an attack. The attacks continue until all bandwidth or server resources are monopolized and no further traffic is permitted through. For broadband edge device, it is difficult for such attacks to quickly consume the entire bandwidth. Other devices in the Internet, including services servers will be victimized by the DoS and DDoS attacks and the device will fail.
[0015] Currently there is no way any device can entirely defend against DoS and DDoS attacks. Here, attacks come from thousands of computers fooled into launching the attacks on the services server.
SUMMARY OF THE INVENTION
[0016] It is an object of the present invention to provide a new and improved apparatus and functionality for IP-based network security management and overload controls for legitimate and threatening (or illegitimate) content.
[0017] The invention, therefore, according to a first broad aspect provides a method for managing network security comprising the steps of: maintaining respective protocols counters for all contents (threatening or legitimate) running on an IP device, where each counter identifies a specific content which is offered by the IP device, maintaining a threshold indicator for each counter per content running on the IP device and throttling the traffic when the content requests caused its relevant counter to reach the pre-set value for its threshold level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be better understood from the following description of a preferred embodiment together with reference to the accompanying drawing, in which:
[0019] [0019]FIG. 1 is a schematic illustrating a typical Internet environment;
[0020] [0020]FIG. 2 is a schematic illustrating an exemplary embodiment of IP devices in accordance with the present invention that enables the Internet Service Provider (ISP) to block requests from their network and their subscribers;
[0021] [0021]FIG. 3 illustrates exemplary components that are used in the present invention;
[0022] [0022]FIG. 4 is a flow diagram illustrating of the process flow for Internet security management with IP configured according to the present invention.
DETAILED DESCRIPTION
[0023] With reference to FIG. 1, as is well known, an exemplary multimedia telecommunications network 10 is shown. This telecommunications network 10 may be any type of landline, wireless or combination IP network interconnecting any type of transmitting devices. In one embodiment the network 10 of FIG. 1 includes an Integrated Optical and Wireless Internet 12 , coupled to a plurality of wireless, optical or physically coupled devices 14 a - 14 c. The Internet 12 may offer users immediate availability of electronic business (e-Business) services and applications including telephony, facsimile, electronic-mail, data transfer, electronic-commerce, e-mobile, video-on-demand, remote access to business services (including Business-to-Business and Business-to-Consumer), and any kind of digitized information. In FIG. 1, the Internet 12 is configured as access optical rings to the Mobile Switching Centres (MSCs), although such an arrangement is not a necessary limitation of the invention. The MSCs themselves are part of the metropolitan optical ring connecting to the Internet service providers (ISPs), Inter-exchange carrier (IXCs), and Incumbent local exchange carrier (ILEC).
[0024] According to one aspect of the invention, an Internet security management method and apparatus monitors and collects data at the various IP devices on threatening or legitimate traffic received at the device, and causes receipt of the traffic to be stopped, or throttled, if the traffic for an item of content exceeds a pre-determined set value. Throttling the receipt of threatening traffic increases the service reliability and security of an Internet device by preventing spoofing attacks from overloading the Internet device.
[0025] Referring now to FIG. 2, an exemplary request flow in the Internet 12 is shown. Subscriber requests are received on input data stream 18 . The requests may be legitimate requests from subscribers for content, or may include threatening requests; i.e., requests aimed at adversely affecting the performance of the devices in the Internet. In FIG. 2, the threatening requests are illustrated as double dashed lines, such as communication line 26 , while legitimate requests are shown as straight lines such as line 24 . Server 25 receives requests, both legitimate and threatening from IP gateway 20 . Server 25 also receives threatening requests from IP device 22 . As shown in FIG. 2, the server 25 , implementing the present invention, monitors the threatening requests and discards requests for content when the requests have exceeded a pre-selected threshold.
[0026] Referring now to FIG. 3, an exemplary table that may be used by the server, such as server 25 , for implementing the present invention are shown. As is known in the art, under the TCP/IP protocol, a content request includes the source device IP address (the IP address of the device issuing the request), the IP address of the destination device storing the desired content, and an identifier for the particular content at that device identifies a content information request.
[0027] In one embodiment of this invention, a counter is associated with each content identifier. Each time the content corresponding to the content identifier is requested, the associated content counter is incremented. In FIG. 3, table 30 is shown to include the content identifier 33 and content counter 35 for each content requested at the server 25 .
[0028] Table 30 is shown apportioned into two sections; legitimate content identifiers 32 and threatening content identifiers 31 . As discussed previously, certain types of content requests, such as Ping requests, and DDoS requests request certain content that is known to be used to adversely affect a device. In one embodiment, requests for this type of content are identified as “threatening” requests. Other types of requests for general content are referred to as legitimate requests.
[0029] In one embodiment, a threshold is stored in the table. The threshold is the maximum number of requests for the content that are responded to before the requests for that content are discarded or re-directed. In one embodiment, two thresholds are provided, one for threatening requests and another for legitimate requests. The threatening request threshold will likely be less than the threshold for legitimate request. In another embodiment, separate thresholds 36 may be provided for each type of content request. Such an embodiment is illustrated in FIG. 3.
[0030] The ISP programs the threshold values for threatening and legitimate requests. The optimal values for the thresholds can be determined by monitoring typical traffic on the network, to identify when content requests are higher than expected.
[0031] Threshold values for threatening requests differ from the threshold values for legitimate requests.
[0032] In one embodiment, a threshold indicator flag is stored with content identifier, and is set when the count exceeds the threshold. By storing a flag with the content identifier, it can be quickly determined that requests to the content should be re-directed or discarded.
[0033] When a threshold has been reached, one of two things can happen. For threatening requests, when a threshold is reached, any incoming requests for the content are discarded. For legitimate requests, the requests could be discarded, or, in an alternative embodiment, the extra requests are forwarded to its mated devices over the connecting data link as per the teaching of (MOHARRAM U.S. Pat. No. 5,825,860), incorporated herein by reference, and pending application Ser. No. 08/815,258, entitled “COMMUNICATIONS LINK INTERCONNECTING SERVICE CONTROL POINTS OF A LOAD SHARING GROUP FOR TRAFFIC MANAGEMENT CONTROL”, filed on Mar. 11, 1997 by Moharram and incorporated herein by reference.
[0034] Referring now to FIG. 4, an exemplary flow chart illustrating the security management process of the present invention is shown. At step 40 , the IP device receives content requests from other devices in the Internet. It should be noted the IP device might be any of the devices coupled in the Internet. At step 42 , the content identifier is identified, and it is determined whether this is a request for legitimate or threatening content. If it is threatening content, at step 44 the counter associated with threatening content is compared against the threshold. If it is greater than the threshold, then the request is discarded. If it is less than the threshold, then, at step 45 the counter associated with the threatening content is incremented
[0035] If, at step 42 it is determined that the content is legitimate, then at step 46 it is determined whether the counter for the content has exceeded its threshold. If not, the request is processed. If at step 46 it is determined that the threshold has been exceeded, then the request is forwarded to IP device (B), and at step 48 the counter of mated IP device (B) is compared against its threshold for that content identifier. Again, if the threshold is not exceeded, it is processed at IP device (B). If so, it is forwarded to any other mated device. If the threshold has been exceeded at all the mated IP devices, the packet is discarded.
[0036] Accordingly, an Internet security management functionality process includes monitoring and control functions aimed at the detection of abnormal load conditions and excessive traffic congestion caused by specific content requests; activation of threshold mechanism that flags overload condition, activation and de-activation of a traffic throttling feature to discard excess content requests, when device congestion is detected by the threshold indicator. These controls minimize congestion conditions, due to spoof attacks, for example, at the device, and prevent the congestion from spreading to the subtending devices and throughout the rest of the network.
[0037] Persons possessing ordinary skill in the art to which this invention pertains will appreciate that various modifications and enhancements may be made without departing from the spirit and scope of the claims that follow. The various hardware and software configurations that have been disclosed above are intended to educate the reader about preferred and alternative embodiments, and are not intended to constrain the limits of the invention.
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In a networked environment, where multiple Internet Service Providers and multi-vendor equipment are involved in e-Business services and applications offering, the risk of overloading the Internet devices are real and security management is a challenge. Internet device traffic overloads could result from spoof attacks, (Denial-of-Service (DoS) or Distributed DoS (DDoS) attacks), device failures, special events, or widespread loads above engineered levels. To solve the problem of Internet security management for integrated optical and wireless devices, a new apparatus and functions running on IP devices are defined in this invention. Each Internet device includes counters and thresholding feature to manage the security attacks and prevent failure of the device being attacked.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the art of establishing the three-dimensional positions of a set of points on a body with contactless measuring means, and more particularly to a system for determining the deviation of a set of points from a set of reference points in a three-dimensional cartesian coordinates system. Once these positions have been determined, they are either numerically or graphically compared to a set of reference points. Even more particularly, the system may be used in conjunction with motor vehicle repair and maintenance, for example body or frame straightening and repair or wheel alignment, to compare the actual position of certain points on the vehicle to the manufacturer's specifications for that vehicle.
2. Description of the Related Art
It is frequently necessary to know the actual position of a point on a body relative to the desired position of such a point. This is particularly true with regard to motor vehicle repair and maintenance. A system that could detect a discrete set of points on a vehicle body or frame element and compare the actual positions of those points to their desired positions would be helpful in such operations as body repair, frame straightening and wheel alignment.
In particular, in detecting and correcting defects in a vehicle frame, a straightening rack is often used. For example, such a rack may consist of chains, cables or other means attached to hydraulic cylinders and to the vehicle frame to push and/or pull the frame back into its proper configuration. Examples of such devices are shown in U.S. Pat. No. 3,590,623 issued to Hunnicutt et al. on July 6, 1971, and reissued U.S. Pat. No. Re. 31,000, issued to LeGrand et al. on July 27, 1982.
Examples of wheel alignment systems that would benefit from incorporating the present system are U.S. Pat. No. 3,793,736 issued to Cufrini on Feb. 26, 1974, U.S. Pat. No. 4,097,157 issued to Lill on June 27, 1978 and U.S. Pat. No. 4,344,234 issued to Lill et al. on Aug. 17, 1982.
With respect to means used to acquire measurement data there are no such systems known to applicant in the auto body and wheel alignment art which employ acoustic measuring techniques. However, many methods and means have been disclosed in prior patents for distance measurement. A number of such devices require direct physical contact between the measuring means and the point whose position is to be determined. Several of these devices mechanically measure the position being touched by a probe, as in U.S. Pat. No. 4,536,962 issued to Hense et al. on Aug. 27, 1985 and U.S. Pat. No. 4,549,359 also issued to Hense et al. on Oct. 29, 1985. Other devices require physical contact to provide a conductive path for a travelling signal. In U.S. Pat. Nos. 4,035,762 and 4,231,260 issued to Chamuel on July 12, 1977 and Nov. 4, 1980, respectively, a delay element acts as the medium for a measuring signal. The position of the measured point is determined by measuring the phase shift in the travelling signal.
These devices all suffer the same shortcomings. If readings are to be taken more than once, when straightening an auto frame, for example, the delay element or other position sensor must be positioned identically a number of times. In addition to the potential inaccuracy, it is time consuming to have to reposition the element or sensor for every point each time a new reading is to be taken. A device that avoids these problems would be an important improvement.
Several devices incorporating contactless measuring means have been developed. One such device is described in U.S. Pat. No. 3,176,263 issued to Douglas on Mar. 30, 1965. Douglas generally shows a drape of small explosives over the body of the object to be measured. Surrounding the area of the body are a number of microphones. The small explosive charges are detonated and the response times measured by the microphones. By compiling and processing the times measured by the microphones, the general shape of the body and its proportions can be measured and recorded. The system as disclosed by Douglas would be impractical for purposes of measuring and recording positions on an auto body or frame since the explosions would, no doubt, have an adverse effect on the paint and structure of the body. In addition, a new drape of explosive charges would be required for each reading, which would be totally impractical.
Another contactless measuring device is shown in U.S. Pat. No. 3,731,273 issued to Hunt on May 1, 1973. The Hunt patent shows a mechanical triggered spark gap which is contained in a probe shown in FIG. 5 of Hunt. To measure a a given position, one places the spark gap at the tip of the probe at the point to be measured. By applying pressure to the probe, physical contact between electrical leads is made allowing a spark to be generated. The travel time of the acoustic wave is measured by two microphones and the position calculated. Several problems are encountered with the Hunt device, However. First, the spark gap must be mechanically and physically triggered. This means applying pressure to the probe which may dislocate the probe a slight distance. In a system measuring small distances, such as applicants' system, such dislocation could easily be greater than the accuracy of the device. Second, the device shown in Hunt requires that the spark gap be located at the position to be measured. Therefore, a point which is inaccessible to the probe's spark gap or which is not able to be accurately measured by such a configuration, cannot be measured by the device shown in Hunt. Finally, Hunt suffers from one other deficiency. If a number of measurements are to be taken at the same point while the body measured is moving or changing shape, the Hunt device does not provide for a consistent and accurate means of measuring the identical point a number of times.
U.S. Pat. No. 3,821,469 issued to Whetstone et al. On June 28, 1974 shows another device for measuring the position of a point in space. Whetstone uses a stylus similar to the probe found in Hunt and a series of orthogonally positioned receptors. The device shown in Whetstone requires that the receptors define the entire space throughout which the stylus moves. This obviously is an impractical restriction on the device if it is to be used to measure along the length, width and depth of an automobile or truck body or frame.
U.S. Pat. No. 3,924,450 issued to Uchiyama et al. on Dec. 9, 1975 also shows a device for measuring three-dimensional coordinates. The device shown uses a supersonic oscillator to generate a signal to be timed. The signal is generated at a point P and is received at at least three points, A, B and C. Uchiyama does not disclose the means or method for converting or for measuring the travel time of a continuous supersonic wave. The known methods for accomplishing this suffer from the same shortcoming. The accuracy available with such a system is extremely poor when compared with the digital systems used in applicants' device. Because the device disclosed is used for measuring models of large scale operations, such as marine engine rooms and landbase plants, the accuracy is not as important and, therefore, the high resolution required in applicants' device is not considered important in the area of art addressed by Uchiyama.
In U.S. Pat. No. 3,937,067 issued issued to Flambard et al. on Feb. 10, 1976, a device is disclosed that is used to measure angular displacements. Flambard uses the reflective properties of an ultrasonic wave to measure displacement. This technique is naturally not desirable, applicable or practical in applicants' system where any reflection will only distort the measurement of the travel time.
Another patent showing a distance measuring scheme is U.S. Pat. No. 4,276,622 issued to Dammeyer on June 30, 1981. Dammeyer generally shows a circuit used to measure the distance between an ultrasonic transmitter and an ultrasonic receiver. The transmitter generates an ultrasonic energy burst in response to an energizing signal. The receiver receives the ultrasonic burst and generates a detection signal in response thereto. While the ultrasonic signal is in transit, a ramp generator is activated, allowing a capacitor to linearly charge for a period of time. The distance the signal travelled is therefore in direct proportion to the accumulated voltage potential of the capacitor, in this case capacitor C5 in FIG. 4. The rate of potential increase is controlled by adjusting resistor R10. The method used by Dammeyer, while providing a coarse measurement of distance, suffers, as does uchiyama, from the fact that the analog signals used are only a rough approximation when compared to those available with digital circuitry and suffer from both time and temperature dependency. Therefore, while the measured potential of capacitor C5 is representative generally of the distance covered by the ultrasonic signal, it does not approach the accuracy and resolution possible with the digital circuit and software employed by applicants in their invention.
Finally, U.S. Pat. No. 4,357,672 issued to Howells et al. on Nov. 2, 1982, discloses another distance measuring apparatus using acoustic signals. During the transit time of an acoustic signal, a microprocessor counts the number of instruction cycles it executes, thereby generating a count which is generally indicative of the amount of time the acoustic signal takes to travel from the stylus to the microphone. In the claims and specification, however, Howells specifically states that the timing mechanism will be the internal instruction count of the microprocessor. He states that no additional clock or scaler is necessary to operate the system. He thus limits the accuracy and resolution of the system by limiting the timing frequency to the execution timing of instruction cycles.
There are a number of other acoustical devices which may be used to detect defects in various objects. These devices base their calculations on different arrival times of a signal reflected off of a defect in an object. Therefore, many of the principles used to construct and use such devices are inapplicable to a system in which no reflection is desired and a homogeneous transit medium is required. Examples of such devices include U.S. Pat. No. 3,875,381 issued to Wingfield, deceased et al. on Apr. 1, 1975; U.S. Pat. No. 4,096,755 issued to Hause et al. on June 37, 1978; and U.S. Pat. No. 4,523,468 issued to Derkacs et al. on June 18, 1985.
OBJECTS AND SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a system for accurately determining the positions of a number of points on or in an object.
It is a further object of the present invention to provide a system for determining the positions of a set of points on or in a vehicle body chassis or frame and comparing these measured positions to a set of reference positions.
It is another object of the present invention to provide a system which operates in real time and can be repeatedly operated to provide the operator of the system with feedback regarding the change in position of any of the points being measured.
It is yet another object of the present invention to provide a system for measuring positions of a set of points which provides higher resolution and greater accuracy than the systems found in related areas of the art.
It is still another object of the present invention to provide a system for measuring a set of points which can consistently yield a number of accurate readings on the identical point on or in a body regardless of the position of said point or movement of the point.
Another object of the present invention is to provide a systemwhich will graphically or numerically illustrate and compare for the operator the deviations of the measured set of points from the set of reference points.
Still another object of the present invention is to provide a system which can be incorporated in the procedure for repair and maintenance of vehicle bodies with respect to unibody or frame straightening and/or wheel alignment. Therefore, the system must be compatible with the environment of the body shop or repair garage.
Still another object of the present invention is to provide a system which does not require calibration to account for discrepancies in the propagation velocity through the medium in which the measurements are taken.
A different object of the present invention is to provide a system which can be adapted to measure and compare actual body, wheel or frame conditions to a number of model specifications.
How these and other objects of the invention are accomplished will be described by reference to the following description of certain preferred embodiments of the invention taken in conjunction with the FIGS. Generally, however, the objects are accomplished in a system for determining the positions of a set of points on a vehicle and comparing those points to a set of reference points provide by the vehicle manufacturer or other source. The system includes a data acquisition apparatus comprised of emitters, receivers, and microprocessor control means. The emitters are mounted at various predetermined positions on the vehicle body or frame and are triggered in an optimal fashion by the microprocessors. Triggering causes a spark to be generated on each of the emitters which in turn generates a single acoustic burst with a definite wavefront. An array of microphones acts as the receiver. After generation of the spark and resulting acoustic wavefront, the microprocessor initializes an external clock which measures the travel time of the pulse wavefront from the emitter post to the microphone receivers. By repeating this process a number of times, data can be acquired which will yield the three-dimensional coordinates of a given point in space when processed by the microprocessor. The microprocessors further convert this data into a form that can be used by the overall system to determine the positions of all points measured on the vehicle body or frame. The data is transmitted to an operator display unit where it is either plotted graphically or displayed numerically in tabular form for the operator. Reference data, provided by specifications of the manufacturer or independently determined, is also inputted into the operator display unit via an optical decoder or other data input device. This data appears in either graphical or numerical form with the measured data and thus provides a comparison of the two sets of data. Based on the graphical or tabular data comparison, the operator can then determine whether and to what extent repair work or further maintenance work on the automobile body or frame is necessary. Other variations, applications, or modifications of the system may appear to those skilled in the art after reading the specification and are deemed to fall within the scope of the present invention if they fall within the scope of the claims which follow the description of the preferred embodiment.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a vehicle mounted on a frame straghtening rack incorporating the preferred embodiment of the present invention.
FIG. 1B shows an alternate embodiment of the data acquisition means of the present invention.
FIG. 2A is a top plan view of the collector bridge of the preferred embodiment of the present invention.
FIG. 2B is an expanded perspective view of an arm of the collector bridge of FIG. 2A.
FIG. 2C is a cross-section of a collector bridge arm taken along the line 2C--2C of FIG. 2B.
FIG. 3A is a timing diagram of the circuit of FIG. 3B.
FIG. 3B is a schematic diagram of one of the control circuits of the present invention.
FIG. 4A is a side view of a standard emitter post of the preferred embodiment of the present invention utilizing a mounting attached to a nut.
FIG. 4B is a side view of the emitter post of FIG. 4A using an added swivel element.
FIG. 4C is a side view of the emitter post of FIG. 4A using an added knee element.
FIGS. 4D and 4E are side views of standard emitter posts mounted to holes of differing diameters.
FIG. 4F is a side view of an alternate embodiment of an emitter post with a single support and vertically mounted spark gaps.
FIG. 4G is a side view of an alternate embodiment of an emitter post with a single support and horizontally mounted spark gaps.
FIG. 5 is a generic example of a reference data sheet of the present invention.
FIG. 6A is a perspective geometric diagram of the quantities measured by the present invention and the relative orientations of those quantities.
FIG. 6B is a top view diagram of FIG. 6A.
FIG. 6C is a perspective geometric diagram of the measuring configuration used by the emitter posts of FIGS. 4A-4G.
FIG. 6D is a perspective geometric diagram of the quantities measure by an alternate embodiment of the present invention and the relative orientations of those quantities.
FIG. 7 is a side perspective view of the system of the present invention as used to aid in vehicle wheel alignment.
FIG. 8 is a top view of the system of FIG. 7 in use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is shown in FIG. 1A. A vehicle 20 is positioned on a body or frame straightening rack 22 and held on rack 22 by pinch clamp 23. The specific type of rack with which the present invention is used is not essential to the invention and is therefore illustrated in schematic form only. Located immediately beneath vehicle 20 is a collector bridge 24. Collector bridge 24 generally includes a central beam 26 and adjustable arms 28. In addition to the arms 28, the system may incorporate a number of array towers 27, one of which is shown in FIG. 1A. Array tower 27 gives the system the ability to measure positions found higher on the vehicle or inaccessible to an arm located below the vehicle 20. The tower 27 is essentially identical in operation to that of the arms 28. Therefore, any description of arms 28 is equally descriptive of tower 27. Cables 30 attach arms 28 to a number of emitter posts 32. Emitter posts 32 are mounted to the vehicle frame 34 in FIG. 1A. It should be noted that the system disclosed herein may be used to take measurements on a vehicle body, frame, unibody and/or chassis to obtain both upper and lower body measurements, and therefore reference to a vehicle frame is not to be limiting in that respect. Also mounted on each arm 28 is an array of microphones 36. Collector bridge 24 is connected by cable 38 to an operator display unit 40.
Operator display unit 40 includes a central processing unit (CPU) 42, a cathode ray tube video screen (CRT) 44, a printer 46 and an optical code reader 48. Power for the entire system is supplied by power cable 50 via CPU 42. The reference data for the system and a given model and year of vehicle is inputted by a data sheet 52 into the CPU via optical code reader 48.
General System Configuration
Initially, vehicle 20 is mounted above collector bridge 24. It is important to note that the vehicle 20 does not directly touch bridge 24 at any time. In an alternate embodiment of collector bridge 24 to be described below, the bridge configuration may be replaced by a set of miniature, portable collector arrays 29, as seen in FIG. 1B. The alternate configuration of FIG. 1B uses portable arrays 29 instead of the arms 28 to hold a number of microphones 36. Like the arms 28, portable arrays 29 have sockets 31 for plugging in cables 30. Arrays 29 can be utilized in situations where a permanent or anchored bridge 24 is impractical. Each portable array 29 is connected by a cable 38a to the operator display unit 40 via junction box 39 and cable 38. Once the vehicle 20 is properly mounted, the reference data is read into the CPU 42 by optical code reader 48. The data is provided by an optical code 54 on data sheet 52. The operator selects a set of control points on the vehicle 20 which act as the basis for the locus of measured position points on the vehicle 20.
Emitter posts 32 are attached adjacent to the positions to be measured. Posts 32 generate a number of sparks which result in acoustic signals. Time measurements of these signals are made utilizing the microphones 36 and subsequently yield the three-dimensional coordinates of each point to which an emitter post 32 is attached. These coordinates are generated by CPU 42 after the time measurements are processed by microprocessors to be described below. The measurements are transferred via cable 38 to the CPU 42. There they are further processed and compared to the set of reference points obtained from data sheet 52. The comparison may be in either graphical or numerical tabular form and may be displayed on CRT 44 or a hard copy may be created on printer 46.
If, for example, the operator is straightening a damaged vehicle frame, as seen in FIG. 1A, the displayed comparison gives the operator information needed to make the next adjustment to the frame 34. By frequently generating the comparison, the operator receives, constant, real time feedback on the status of the repair process. The actual repair operations are accomplished using rack 22 in its normal fashion, i.e. by pushing or pulling on certain components of the vehicle, all as described in several of the aforementioned frame straightening patents and as is generally well known in the art.
Data Acquisition Means
The data acquisition means generally consists of the collector bridge 24 and its accessories. The bridge 24 and its arms 28 can be seen in detail in FIG. 2A and 2B. The center beam 26 is comparable to the length of a vehicle body, in the preferred embodiment approximately 3 meters. As can be seen in FIG. 2A, the collector bridge 24 includes 8 arms 28 in the preferred embodiment. Each arm 28 extends transversely from the beam 28 and is slidable therealong. As seen in FIG. 3B, which illustrates a single data acquisition channel within arm 28, there is a central controller 56 for each arm 28. Controller 56 consists of a microprocessor 58 and an external clock generator 64. Each arm 28 has one such controller 56. In the preferred embodiment, each arm 28 also has 6 microphones 36 embedded therein. A given microphone 36 is connected to the controller 56 for the arm 28 in which it is located via signal channel 66. Channel 66 consists of a microphone excitation source 68, a noise filter 69, a voltage amplifier 70, a high speed comparator 72, a count control flip-flop 60 and a 16-bit counter 62. The counter 62 of each channel 66 and the clock 64 of controller 56 are used in synchronous operation. The operation of all of these elements will be explained below. There are 6 signal channels 66 and one controller 56 in each arm 28 in the preferred embodiment. The noise filter 69 acts to sift out ambient background noise that is received along with the shock wave. The filter 69 acts as a band pass in the preferred embodiment so that acoustic wave energy not generally matching the frequency profile of the shock waves generated by gaps 80 does not pass through filter 69. There is in turn a communication port 74 connecting each microprocessor 58 to the operator display unit 40 via cable 38.
Cable 30 connects the trigger output of the microprocessor 58 to an emitter pod 76 which is one of two mounted on the emitter post 32. In the preferred embodiment of the system, the emitter pod 76 consists of a high voltage power supply (not shown) and a capacitive-discharge circuit (also not shown). The emitter pod 76 is linked to primary spark coil 78 which, in the preferred embodiment is a transformer with a 1:30 ratio. The secondary coil of the transformer is connected to a spark gap 80. Alternately, the spark coils may be replaced by other means for generating a high voltage across spark gap 80.
In the preferred embodiment of the invention, there are two emitter pods 76 connected to the triggering output of the microprocessor 58 and six microphones 36 with their accompanying signal conditions 66. The controller 56 is capable of controlling which emitter pod 76 is triggered and knowing from which microphone 36 signals are received.
The exact positions of coplanar microphones 36 must be known for the data acquisition means to work properly. Any suitable means for determining and communicating the positions of the microphones may be employed. In the preferred embodiment, a series of position sensors provide the microprocessor 58 with exact two dimensional coordinates for each of the arms 28. In the preferred embodiment, all of the microphones 36 are situated on the same coordinate plane. In an alternate embodiment, this coplanar configuration is unnecessary because the system has vertical position sensors. On beam 26 of the collector bridge 24 in the preferred embodiment are a number of longitudinally spaced optical position indicators 82. There are also corresponding holes 84 between the sensors 82. Each arm 28 has, extending through it, a setting pin 86 the end of which fits into a hole 84. In the preferred embodiment, the indicators 82 are spaced 50 millimeters apart. Thus, as the arms 28 are moved longitudinally, optical readers 88 (seen in FIG. 2A) within each arm 28 feed the longitudinal position into the microprocessor 58 in each arm 28. Similarly, there are transverse position sensors 90 in the upper segment 23 of the arms 28, as seen in FIG. 2C. As with beam 26, there are holes in lower arm segment 25 into which pin 92 fits, thus locking upper arm segment 23 into place. Adjacent each such hole is a position indicator 93 which provides the microprocessor 58 with transverse position data. In the preferred embodiment, position data is generated using an optical system. The transverse locking positions are 100 millimeters apart in the preferred embodiment as seen in FIG. 2C.
In the preferred embodiment, the spacing between microphones 36 is 180 millimeters. Therefore, by knowing the position of the arms 28 relative to stationary beam 26 and the position of microphones 36 on each arm 28, the precise position of each microphone 36 is known.
The emitter posts 32 are the other major components of the data acquisition means. Different mountings for the emitter posts 32 of the preferred embodiments are shown in FIGS. 4A-4E. FIG. 4A shows one means for mounting a post 32 to a nut 94. Mounting 96 is attached to nut 94 with a set of teeth 98. Mounting 96 is secured by tightening teeth 98 around nut 94 by an appropriate mechanical means, such as a screw. End piece 102 must be kept in contact with surface 104 for a reason to be discussed below. Mounting 96, and the other related mounting element 97, will ensure that the emitter 32 will generate signals from the identical point each time that point is polled by the system. The post 32 itself is snapped onto the mounting by appropriate means. In FIGS. 4A-4E, post 32 consists of two supports 106 between which are found identical spark gaps 80. Spark gaps 80 generally are positioned so that the two centers of the gaps 80 define a line 109 passing through the point 108 to be measured. The reason for this will be described below.
FIGS. 4B-4G show other emitter post configuraions. In FIG. 4B, the post 32 has a swivel element 110 connecting it to the mounting 96. This swivel element 110 permits rotational adjustment of the spark gaps 80 to provide a clear path between the gaps 80 and receiver microphones 36. FIG. 4C shows a knee element 112 that permits mounting the gaps 80 so that the line 100 that they define is parallel to surface 104 rather than perpendicular thereto. Line 100 is perpendicular toline 105 which is also perpendicular to surface 104 and passes through point 108. As with the swivel 110, knee 112 is used to ensure a clear path from each spark gap 80 to the appropriate microphones 36.
FIGS. 4D and 4E show hole mounting 97 similar to mounting 96 except that they are designed to anchor the post 32 to a hole 118 in the vehicle rather than a protrusion such as a nut. Teeth 114 tighten outward and engage the hole 118. This anchoring means again ensures that the spark gaps 80 define a line 109 that passes through the point 108 to be measured, even if point 108 is an open space. FIG. 4D shows the post 32 anchored to a small hole 118, while FIG. 4E illustrates how the post 32 can be anchored to a larger hole 118.
Alternate embodiments of the two support configurations of post 32 are shown in FIGS. 4F and 4G. Post 32a in FIG. 4F uses a single support 107a on which to mount the gaps 80. Once again the gaps' centers define a line 109 passing through the point 108 to be measured. In FIG. 4F the gaps 80 are mounted in a vertical fashion and support 107a is attached to amounting 96. In FIG. 4G, the gaps 80 are mounted horizontally to support 107b to form post 32b.
As can be seen from the mounting and configuration of the emitter posts 32, more than a single point can be located using the system. With each emitter post 32 defining two distinct points in three dimensional space, and knowing the relative position of the mounting point 108 on the body, an infinite number of points may be located. Using the emitter posts 32 shown in FIGS. 4A, 4B and 4D-4G, line 109 passing through the two spark gaps 80 and the mounting point 108 is defined. Because the relative positions of these three points is known, any of an infinite number of points on the line 109 can be measured and/or monitored.
Using the emitter posts shown in FIG. 4C, a plane including the two spark gaps 80 and the mounting point 108 is defined. Again, because the relative positions of these three points are known, any of the infinite number of points in the plane can be measured and/or monitored. The points to be measured and/or monitored on these lines and in these planes may be on, in and adjacent to the body. They do not have to be on the body's surface.
Operator Control Unit
As stated above, the operator control unit 40 consists of a CPU 42, a CRT display 44, a printer 46 and an optical decoder 48. In the preferred embodiment, the CPU 42 has 16-bit internal registers and at least 256K memory capability. It preferably has a printer port and three serial communication ports. These three serial communication ports provide access to the CPU for the printer 46, the cable 38 and the optical decoder 48. Cable 38 transmits data drom the controller 56 in each arm 28 to the CPU 42.
Vehicle Reference Data
Reference data for each vehicle is provided by a series of data sheets 52. A generic example of such a sheet is shown in FIG. 5. Each sheet 52 in the preferred embodiment will provide the operator with an optically coded set of specification data 54 an end view 120, a side view 122 and a bottom view 124 of the vehicle. As can be seen in FIG. 5, each view will give the operator a graphic perspective of the height (z coordinate) and planar (x, y coordinates) position of each reference point 108. The optical code 54 provides the CPU 42 with the identical data in a form that is more quickly entered into the computer than by manually inputting the data. In an alternate embodiment of the present invention, other data means such as a laser card with optically encoded data may be used to input reference data. An operator, such as a service mechanic, can maintain an extensive library of data sheets or laser cards covering all of the makes and models he or she services.
Operation
The system of the preferred embodiment is initialized when the operator inputs reference data from data sheet 52 to the CPU 42 via optical decoder 48. This lets the system know where the points to compare with the reference data will be measured. In addition, all of the controllers 56 are initialized. As stated above, the circuit illustrated in FIG. 3B is duplicated throughout the system. The operation of one such circuit will be described here for purposes of illustration, with the understanding that all such circuits operate in a similar manner and their coordination is managed by controllers 56 and the CPU 42.
With reference to FIGS. 3A and 3B, the microprocessor 58 initializes the counter 62 after receiving an initialization signal from the CPU 42. Microprocessor 58 then issues a "start" signal 210 to both the emitter pod 76 and the gate flip-flop 60. Emitter pod 76 discharges a capacitor, preferably having a substantial DC charge stored therein into the transformer 78. The transformer 78 generates a spark 220 across gap 80. The generation of spark 220 creates a shock wave having a generally spherical wavefront. This wavefront is picked up by microphone 36 and is converted into an electrical signal 230. The electrical signal 230 is then converted into a "stop" signal 240 fed into the gate flip-flop 60. The "start" signal 210 issued by microprocessor 58 opens a count gate 250 for counter 62 which is closed upon reception of the "stop" signal 240 by flip-flop 60. While gate signal 250 is open (while the shock wave is in transit from spark gap 80 to microphone 36) an external clock 64, preferably operating at a frequency of at least 4 MHz, generates a count pulse train 260 synchronously accumulated by counter 62. Generally, the external clock or pulse generator 64 operates at a frequency considerably higher than the execution rate of instruction cycles in microprocessor 58. This provides the overall system with higher resolution and accuracy than would be available by using the microprocessor 58 alone. The individual counts of the clock 64 and counter 62 of the preferred embodiment resolve into spatial increments of approximately 0.086 millimeters. After the counting is halted by the closing of gate 250, the final count 270 is fed to the microprocessor 58 when the data read signal 280 is generated. A number of calculations are then performed by the microprocessor 58.
The microphones from which the signals are received are chosen by the microprocessor 58. The selection is based on arrival times of the shock waves produced by spark gaps 80. The microprocessor 58 accepts signals from the first three noncollinear microphones 36 that receive the shock wave, rejecting later received signals. The microprocessor 58, when using the alternate equations discussed below and illustrated in FIG. 6D, selects signals from the first four microphones to receive the shock wave where the microphones are arranged so that three are collinear and the fourth is located off of that line.
In the preferred embodiment, an added feature aids in assuring system accuracy. Each shock wave will have a minimum distance to travel between any given gap 80 and an individual microphone 36. During the time it takes the wave to travel this minimum distance, an inhibit period 290 exists. During the inhibit period 290 no "stop" signal can be generated. Therefore, a "stop" signal that might have been triggered as a result of background noise, in a repair shop or garage for example, is prevented.
FIGS. 6A-6C help illustrate the basic calculations performed by the microprocessor 58 in processing the raw data provided by the counter 62. In FIGS. 6A and 6B, the position 111 of a spark gap 80 can be determined in terms of the x, y, z coordinates of the point using three noncollinearly placed microphones. These gap position coordinates (X p , Y p , Z p ) define the precise location 111 of the spark gap 80. The position of a point so measured is given by the following equations in Equation Set I derived from Pythagorean principles: ##EQU1##
Each emitter post 32 has two such gaps 80. As seen in FIG. 6C, posts 32 are designed so that the distance from the point P 3 (or 108) to be measured to the first spark gap center P 2 is K 2 , and from the first gap P 2 to the second gap P 1 is K 1 . The end piece 102 of the post 32 must be kept in contact with surface 104 to ensure consistency and accuracy in extrapolated measurements of the points. Using the diagram in FIG. 6C and the equations in Equation Set II the position of the actual point on the vehicle to be measured can be determined. Thus a point to be measured may exist on a surface, in open space or within a solid object and still be accurately measured by the present system. A separate spark gap and microphone receiver are present in each arm 28 and act as a calibrating means 126 (as seen in the cut-away view of FIG. 2B) to account for deviations in the ambient conditions that might affect the speed of sound, and thereby create errors in the distance measurements of the system. The microprocessor 58 compensates for such ambient conditions as well as the circuit time delays in the circuits of FIG. 3B in making the coordinate determinations. The microprocessor 58 additionally takes into account use of a knee element 112 as seen in FIG. 4C and performs statistical filtering and averaging calculations to provide consistent data. The positions of the point to be measured (P 3 ) is thus given by the following equations: ##EQU2##
In an alternate embodiment, the microprocessor 58 software uses the principles illustrated by the diagram of FIG. 6D. In this configuration, the need for calibrating data is eliminated. The positional data may be generated by the microprocessor 58 with reference only to the travel times measured by the counter 62. As can be seen in the diagram of FIG. 6D, this embodiment requires the addition of another microphone 36 so that there are three linearly placed microphones 36 with known separation distances and a fourth position off the line of the first three. The position 111 of the point is generated, but the velocity of sound (v) can be eliminated with the following equation: ##EQU3##
Once the microprocessor 58 has generated the data in this form, it is transferred to the communication port 74 and then via cable 38 to the CPU 42. CPU 42 then compares the measured data to the reference data inputted to the optical decodeer 48 for a given vehicle model. The CPU 42 issues commands to the individual controllers 56 to poll various positions and optimize the measuring process.
The CPU 42 provides a numeric comparison of the measured data and reference data in tabular form or a graphic result. The graphic result will be shown from three perspectives, preferably the end, side and bottom views, so that a true three-dimensional representation of any deviation from the reference data can be illustrated. Because of the extremely high accuracy and resolution of the system, closer inspection of the deviation between measured point and reference point may be necessary to determine whether they coincide. Therefore, "zoom" and image rotation features may be incorporated in the software whereby a point or points may be more closely examined. The CPU 42 may also transmit or receive data or results via a modem or other link to or from other computers. The CPU software additionally provides fault-sensing, error-checking and diagnostic functions upon startup and periodically during operation, reporting the results to the operator. When the operator wishes to preserve the data comparison in tabular and/or graphic form, the printer 46 can create a "hard" copy of the comparison.
In an alternate embodiment, the deviation measurement system of the present invention is used to aid in wheel alignment of a vehicle 20. As seen in FIGS. 7 and 8, three emitter posts 32 are used on each rim 314 of each wheel 300. On the rim 314 are three mounting positions 310. Two of the posts 32 are mounted in a way so that they define a line 312 which intersects the center 316 of rim 314. Thus the section of line 312 between these posts 32 is a diameter of rim 314. The third post 32 is mounted on the rim 314, but not on line 312. Adjacent each wheel 300 is a receiver array 33, similar in configuration and operation to arms 28, towers 27 and modules 29. Arrays 33 transmit data via cables 38 to the CPU (not shown).
From the posts 32 the system can get the positions of the wheel rim centers 316 and the orientations of the planes defined by the rims 314. As with the preferred embodiment, a number of measurements of each point can be made consistently and accurately since the posts 32 need not be removed. The data is then used to assist in computing the seven components of wheel alignment--caster, camber, toe-in, steering axis inclination, turning radius, wheel tracking, and wheel rim run out.
It will be readily apparent and obvious to those skilled in the art that other applications of the basic measuring system exist and that a number of changes and modifications may be made without departing from the spirit and scope of the present invention. For example, the CPU may be programmed to poll the measuring points at regular intervals to provide the operator with constant and consistent feedback of the status of the vehicle body. This closed-loop, real-time feedback would be valuable in the repair and wheel alignment operations. In an alternate embodiment of the present invention, the microphones 36 and spark gaps 80 may be interchanged, the resulting system using the same equipment and equations with no loss of accuracy or resolution. Therefore, the above illustrated and described preferred embodiment is illustrative rather than limiting, the scope of the invention being limited only by the claims that follow.
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A system is disclosed for determining the positions of a set of points on a body and comparing those points to a set of reference points. The system includes a data acquisition apparatus comprised of emitters, receivers, and microprocessor controls. The emitters are mounted at various predetermined positions on the body, for example a vehicle body or frame, and are triggered in an optimal fashion by the microprocessors. Triggering generates a single acoustic burst signal from an emitter. An array of microphones acts as the receiver. After generation of the signal, the microprocessor initializes an external clock which measures the travel time of the signal from the emitter to the receivers. By repeating this process a number of times, data is acquired which yields the three-dimensional coordinates of a given point when processed by a microprocessor. Microprocessors further convert this data into a form that can be used by the overall system to determine the positions of all points measured on the vehicle body or frame. The data is transmitted to an operator display unit where it is plotted graphically. Reference data is inputted into the operator display unit via an optical decoder. This data and a comparision of the two sets of data is displayed. Based on the data comparison, the operator can then determine whether and to what extent repair work or further maintenance work on the automobile body, frame or wheels is necessary.
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FIELD OF THE INVENTION
[0001] This invention relates to the medical field and patient care, specifically to thermal dressings intimately conforming to the shape of the patient's body. For the purposes of this disclosure, heat and cold refer to temperatures above and below the normal body temperature, respectively.
BACKGROUND OF THE INVENTION
[0002] The medical use of thermal therapy, both hot and cold, is well known to treat various maladies and traumas. Usually, application of heat is used stimulate the body to increase blood flow in an area in order to dissipate the heat build-up. This acts to prevent stiffness in a traumatized joint or appendage. The application of a cold pack reduces swelling and lessens perceived pain. Both of these standard treatments have a place in caring for a patient.
[0003] In a hospital or office, thermal appliances may be in stock to apply to various portions of the anatomy. However, in emergency medical services where space and/or weight may be limited, hot and cold treatment is generally restricted to simple containers or absorbent pads, having the desired temperature, applied directly to the affected part of the patient's body. Because of the infinite sizes and shapes of the body, the few thermal devices available do not always conform to the patient in such a way to provide the most effective treatment. To alleviate this problem, small thermal packs have been developed.
[0004] To eliminate the problem of maintaining both hot and cold packs at a predetermined temperature for prolonged periods of time, the use of pliant containers enclosing ingredients which, when combined, create an endo- or exo-thermic reaction are used to apply cold or heat to the desired location on the body. However, a by-product of these endo- or exo-thermic reactions is gas. The gas becomes trapped in the container rendering the thermal pack rigid and lacking in the ability to conform to the anatomy. In the extreme, the container may rupture putting the reacting chemicals in direct contact with the patient's body.
DESCRIPTION OF THE PRIOR ART
[0005] U.S. Pat. No. 6,248,125 issued to Helming discloses a thermal pack for treating the perineal and rectal area with either heat or cold. Both the hot pack and the cold pack have an envelope within which are two separate compartments housing ingredients that cause a thermal reaction when mixed together. To use the device the compartments are ruptured allowing the components to mix. There is no indication of any provision for the volume of ensuing gas that is created inside the fixed volume of the container.
[0006] Dunshee, U.S. Pat. No. 4,953,550, discloses a chemical thermal pack with two compartments and separated ingredients which will create an exo- or endo-thermal reaction when mixed. A portion of the outer container has a wall with capillary tubes formed there-through. The capillary tubes allow for the drainage of water from the interior of the pack. Additionally, the capillaries act as an insulator to prolong the effects of either the hot or cold pack.
[0007] Vakharia and Jessup et al, U.S. Pat. No. 5,171,439 and U.S. Pat. No. 4,203,445, respectively, disclose gas vents for plastic bags. The vents permit gases to migrate into or out of the bags to equalize pressure while preventing liquid from escaping.
[0008] What is needed in the art is a hot or cold pack that allows gas to escape and remains compliant after the initiation of the endo- or exo-thermic reaction so that it can conform intimately with the injured portion of the body.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is an objective of the instant invention to teach a medical device to apply heat or cold to a patient by intimately conforming to the anatomy.
[0010] It is a further objective of the instant invention to teach a medical device that creates a thermic reaction within a compliant container by mixing two or more chemical compounds.
[0011] It is yet another objective of the instant invention to teach a medical device having a vented container which allows escape of gaseous by-products of a thermic reaction and remains compliant during use.
[0012] It is a still further objective of the invention teach a medical device with a vented compliant container which has two compartments separated by a frangible partition with each compartment enclosing an ingredient necessary to create a thermic reaction. By applying pressure to the container, the partition is ruptured allowing the ingredients to mix within the container producing a temperature change, a liquid or gel residue and gases. The gases pass through the vent to the atmosphere.
[0013] 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
[0014] [0014]FIG. 1 shows a perspective of the thermal pack of the invention;
[0015] [0015]FIG. 2 shows a cross section of the thermal pack of FIG. 1 including separate compartments;
[0016] [0016]FIG. 3 shows a schematic cross section of the vent;
[0017] [0017]FIG. 4 shows a perspective of another embodiment of the thermal pack;
[0018] [0018]FIG. 5 shows a cross section of the closed vent valve along line A-A of FIG. 4; and
[0019] [0019]FIG. 6 shows a cross section of the open vent valve.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The thermal pack 10 , shown in FIG. 1, is a generally rectangular container. The container may be made in different shapes as a matter of choice and for special applications. The container 10 is made of supple plastic films forming walls 11 and 12 which have seals 13 , 14 , 15 and 16 closing the corresponding edges to form a liquid tight container. The films may be single ply or co-extrusions of different polymers or laminated films having the same properties or different properties. The walls are formed of materials that will be impervious to each of the ingredients and to the resulting combination. The container may be made using a tubular plastic film which is sealed at the opposite ends. The plastic film may be thermoplastic and the seals may be formed by heat and pressure. If other plastic films are used, the seals may be formed by adhesives or solvents. As illustrated, the container 10 encloses, as one ingredient, a chemical compound 21 which will initiate a thermal reaction when mixed with another ingredient, in the form of a catalyst. Preferably, when the chemical compound is mixed with the catalyst a gel-like substance is formed. The gel acts to prolong the thermal effects.
[0021] As shown in FIG. 1 and 2 , the container 10 encloses another tube having opposing walls 17 and 18 . The walls 17 and 18 are preferably continuous plastic film with end seals 19 and 20 . These films and seals may be formed in the same manner as the films and seals in container 10 . Also, the tube may be formed by superimposing film layers and sealing the superposed periphery. The opposing walls 17 and 18 have a structure or are made of material that will rupture before the container 10 , when placed under a compressive load. This insures the integrity of the container 10 and prevents the thermal compound from coming into contact with the user.
[0022] The catalyst 22 , for the thermal reaction, is enclosed within the inner container until the inner container is ruptured. Once the thermal compound and catalyst come into contact with each other, the outer container is kneaded to thoroughly mix the ingredients.
[0023] As the thermal reaction progresses, there is generated a gaseous by-product. The volume of the gas is released from the interior of the container through aperture 23 and porous membrane 24 . The porous membrane is made from a material that will allow passage of gas, including any air trapped in the interior, but not liquid. The membrane spans the aperture 23 and has a continuous edge seal 25 joining the membrane to the container. The edge seal 25 may be formed by heat and pressure, solvent or adhesives. The material of the membrane may be in the nature of a semipermeable membrane or it can be a microporous nonwoven material.
[0024] The thermal pack 40 , shown in FIG. 4, is substantially similar to the thermal pack 10 of FIG. 1. The thermal pack 40 has a peripheral seal 41 and encloses a catalyst 43 inside the bag in separated from the thermal composition 44 by a frangible wall. The thermal pack has a manual one-way valve 45 which has an annular valve 48 on the internal end of a valve body that reciprocates through a collar 46 sealed into an aperture in the thermal pack wall 42 . The annular valve is seated into an annular recess 49 .
[0025] As shown in FIG. 5, the gas by-product of the thermal reaction caused by mixing the catalyst and the thermal composition will act against the annular valve 48 to seat the valve in the recess 49 closing the valve. The gas pressure closing the valve may be overcome by manually depressing valve actuator 47 . The valve body moves displacing the annular valve 48 and opening a vent passageway 50 . The gaseous by-product and any other trapped gases are released through the passageway.
[0026] As an example of the thermal pack, the outer container may be fabricated from polyethylene film, alone, or laminated with other materials, the thermal compound may be ammonium nitrate, either alone or mixed with other chemicals, disposed inside the outer container. The ammonium nitrate is in the form of dry particles.
[0027] The inner container may be made of the same plastic composition as the outer container. The inner container may have a weakened portion of a wall or the container may be of a thinner film. The catalyst, enclosed in the inner container, is water.
[0028] The vent may be a hydrophobic microporous nonwoven plastic material such as TYVEK made by DuPont Co. The vent material will allow gas to pass through while repelling liquid.
[0029] In use, the thermal pack may be stored indefinitely until the ingredients are mixed. To provide a cold treatment to a patient, the compliant envelope is squeezed or put under compressive pressure to rupture the inner tube. The container is then kneaded to thoroughly mix the chemicals and produce a temperature change. As the chemical endothermic reaction proceeds, gas evolves and escapes from the container through the semipermeable vent leaving the gel. The cold compliant container is then intimately wrapped about the injured part of the patient's body.
[0030] 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 of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings.
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A flexible thermal pack to be intimately applied to a patient's body is in the form of a plastic container enclosing a chemical compound capable of an endo- or exo-thermic reaction when intermixed with a catalyst. The plastic container has a vent in one wall covered by a semipermeable membrane for passage of gas but not liquid. Also enclosed in the container is another frangible container housing a suitable catalyst for the compound.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims priority to: U.S. Provisional Patent Application Ser. No. 62/136,412, having title “Barrier Undergarment for Oral Sex,” filed on Mar. 20, 2015; U.S. Provisional Patent Application Ser. No. 62/247,754, having title “Barrier Garment,” filed on Oct. 29, 2015; and U.S. Provisional Patent Application Ser. No. 62/253,006, having title “Barrier Garment,” filed on Nov. 9, 2015, each of these three patent applications being hereby incorporated by reference in its entirety. Cross-reference is made to U.S. patent application Ser. No. ______, having title “Methods of Manufacturing a Garment Apparatus,” filed on Mar. 18, 2016, having Attorney Docket No. 037204.00005, the entirety of which is hereby incorporated by reference in its entirety. Cross-reference is made to U.S. patent application Ser. No. ______, having title “Shaping Mold Apparatuses for Manufacturing a Garment Apparatus,” filed on Mar. 18, 2016, having Attorney Docket No. 037204.00004, the entirety of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a system, method, method for manufacturing, and apparatus, among other things, for a garment, specifically a garment to serve as a barrier. More specifically, the present invention relates to a manufactured good, a method for manufacturing the good, a mold to be used in manufacturing the good, and a method of using the good. More specifically, the present invention relates to a prophylactic or barrier for sexual activity, including prophylactics and barriers for performing oral sex on the vulva, perineum, and/or anus.
RELATED INFORMATION
[0003] Prophylactics for sexual activity have been made available for years. These prophylactics, however, address limited modes of sexual activity and do not necessarily allow for additional modes of sexual activity. For example, cunnilingus, while once stigmatized, is now commonplace in people's sex lives, and oral-anal sex has increased in popularity over the past few years. But, not everyone who enjoys oral sex can receive it as frequently as they might wish.
[0004] For example, couples might engage in a less-than-optimal amount of oral sex due to one or both partners' known sexually transmitted infection(s) (STIs) or fear of an unknown infection. Diseases such as herpes, human papillomavirus (HPV), human immunodeficiency virus (HIV), hepatitis, chlamydia, syphilis, and gonorrhea can each be spread through one or more components of oral sex: fluid transfer, contact of one person's skin with another's ulcerations, and even contact of one person's skin with another's un-ulcerated skin. The areas with risk of spreading a disease include not only the vulva, perineum, and anus, but also the lower abdomen, the upper thighs, and the buttocks. A person can transmit a disease without knowledge and/or physical evidence that the person is infected. The Centers for Disease Control estimate that men and women in the United States have a total of 110 million STIs. Researchers also estimate that, in the United States, one out of every five adults has genital herpes, and one out of every four adults has HPV. Further, it is estimated that one out of every two sexually active Americans will contract an STI by age 25.
[0005] In addition to STIs, couples might engage in a less-than-optimal amount of oral sex due to the oral-sex performer's personal preference regarding the taste and scent of the oral-sex receiver's vaginal, perineal, or anal area; due to the receiver's feelings about their own taste or scent; or because the receiver is menstruating.
[0006] Many of these concerns could be fully or partially ameliorated through the use of a prophylactic or another barrier; and, in a better scenario, oral sex would be equally pleasurable—if not more pleasurable—while using such a barrier. Available techniques tend to decrease oral-sex participants' pleasure in one or more of the following ways. For example, an apparatus must be held in place while in use. This can prevent the full use of the performer's and recipient's hands for additional sexual stimulation or other activity. For example, an apparatus—while designed to be hands-free—is insufficiently stable, and moves around on the body during the act of oral sex or other physical activity. This slippage can allow for transfer of anal bacteria to the vagina, leading to urinary tract infections. In addition, this slippage can allow for the very consequences described above that prophylactics are intended to prevent, i.e., fluid transfer and skin-to-skin contact. For example, an apparatus, even if it were to stay properly in place, does not cover enough surface area of the body to prevent transmission of certain diseases. For example, an apparatus is too thick and/or stiff for a recipient to feel movements of the performer, leading to less pleasure for the recipient and additional fatigue for the performer. For example, an apparatus has too much excess material, thus diminishing sensation for the recipient and causing difficulty in breathing or even gagging or choking for the performer. For example, an apparatus is physically unattractive and detracts from the aesthetics of sexual activity. This, in turn, decreases the apparatus's utility because if it is too unappealing for people to be willing to use it, then either couples will choose to not engage in cunnilingus or disease will continue to spread. For example, an apparatus includes multiple parts making it costly to manufacture, and thus, too expensive for a typical consumer. The prohibitive cost lessens the likelihood that the product will be used as needed and can create undue pressure on the couple to make each sexual encounter worthwhile to justify the cost.
[0007] These drawbacks of available apparatuses, especially when in combination, make it more difficult for couples to enjoy oral sex. Female recipients are particularly susceptible to these drawbacks due to, according to documented research, women being more easily distracted during sex and less likely to achieve climax than men.
[0008] In practice, the two apparatuses most commonly used for protection during cunnilingus were developed for entirely different, non-sexual purposes. These two apparatuses suffer from several of the drawbacks described above.
[0009] First, some couples use sheets of latex known as dental dams, which were originally developed for use in dentistry, for protection during oral sex. Dental dams (also known as “oral dams” or merely “dams”) suffer from many of the problems listed above. For example, the dam must be held in place during sexual activity, requiring concentration and agility, thus detracting from the participants' focus and enjoyment. For example, if the recipient moves during sexual activity, it becomes very difficult to hold the dam in place. If the dam undesirably moves even a few inches, bacteria can be transmitted from the anus to the vagina, among other unwanted events. Or, for example, if the dam moves while the performer is engaging in oral sex, the performer's mouth can touch the recipient's skin, allowing potential disease to be spread. Further, for example, the material of the dam can gather in the performer's mouth during sexual activity and lead to difficulty breathing, gagging, and/or choking. And, even when the dam is properly held in place, the dam is not large enough to simultaneously cover portions of the thighs, lower abdomen, and buttocks, which can carry and transmit diseases such as HPV and herpes. Further, for example, such dams may be untasteful and/or emit undesired odors due to material and/or due to the loose fit on the wearer. While oral sex on both males and females appears to be increasing, according to various studies, condoms on males appear to be used much more frequently than dental dams on females. Possible conclusions drawn from this include that dental dams do not satisfy the apparent market need and are not perceived to be as easy or as desirable to employ as the male prophylactic counterpart.
[0010] Second, some couples use ordinary plastic wrap, which was originally developed for wrapping and sealing food items, for protection during oral sex. Certain varieties of plastic wrap are known to be porous and can allow for the transmission of viruses, bacteria, scent, and taste. Further, plastic wrap suffers from many of the problems listed above when held against a recipient's body for oral sex. For example, the plastic wrap during sexual activity becomes very wrinkled, making it difficult for the performer to navigate the vulva, clitoris, anus, and perineum, i.e., the “genital region”. For example, the plastic wrap during sexual activity can get sucked into the nostrils of the performer, causing difficulty breathing and/or a suffocating feeling. For example, the plastic wrap can gather in the performer's mouth and lead to gagging. Further, for example, similar to the dental dam, the plastic wrap must be held in place during use. The plastic wrap can easily slip out of place—particularly when the recipient moves their body—allowing the spread of disease and bacteria, among other things.
[0011] In an effort to allow hands-free use of dental dams and plastic wrap, straps have been attached to the dental dams and/or plastic wrap. See, for example, U.S. Pat. No. 5,388,592 to Williams (1995) and U.S. Pat. No. 4,862,901 to Green (1989). In theory, the attached straps are used in order to allow the hands to be free during sexual activity. However, in practice, the thin material of the straps provides insufficient support, and the dam moves around the genital region when the performer provides pressure and/or vigorous movement. DUe to the dam moving, it is difficult to prevent contact between the performer's mouth and the receiver's body, and inter alia, for example, prevent bacteria transfer from the anus to the vagina. Such apparatuses cover an insufficient amount of surface area to protect against skin-to-skin contact with areas such as the inner and upper thighs and the lower buttocks. Such apparatuses often include multiple components causing them to be expensive to manufacture and for the consumer to purchase. Such apparatuses in their complexity also cause a consumer additional time in figuring out how to properly utilize the apparatuses and take additional time to put on, decreasing the enjoyment and spontaneity of sexual activity.
[0012] Other available apparatuses include novelty rubber underwear that some suggest be used as a barrier during cunnilingus. Novelty rubber underwear is meant as a fashion item for people with a latex fetish. It is not a feasible barrier because, for example, oral sex cannot be comfortably or safely performed using novelty rubber underwear and similar novelty products. Further, these types of novelty products are not usually made for oral use, and, accordingly, latex and other materials allergies can be an impediment. For example, at 0.33 to 0.50 millimeters in thickness, these novelty garments are several times thicker than typical dental dams. The novelty garments are so thick that only a minimal amount of pressure or sensation can be transferred from the performer's mouth and tongue to the recipient's genital region, leading to less pleasure for the recipient. Further, the thickness of the novelty garments requires the performer to exert more energy and pressure performing oral sex, leading to fatigue. Further, the novelty garments do not have nearly enough pliability for a tongue to penetrate a vagina or anus. Further, the thickness of these novelty garments causes them to be difficult and time-consuming to put on, making the novelty garments unsuitable for spontaneous sexual activity. Further, these novelty garments cannot be used safely as a prophylactic because they are not quality-checked for porousness and they do not provide adequate coverage of portions of the body (such as the inner and upper thighs and the lower buttocks) that can contain STIs.
[0013] Accordingly, there is a need in the industry for a hands-free apparatus to use during oral sex on a vulva, perineum, and anus that is both aesthetically attractive and stays in place. There is also a need in the industry for such an apparatus that provides adequate coverage and prevents skin-to-skin contact with bodily areas other than and including the genital region, i.e., the vulva, perineum, and anus. There is also a need for a hands-free apparatus to use during oral sex that fits a variety of different body shapes, while still providing adequate coverage. Further, there is a need in the industry for a hands-free apparatus that is directed towards allowing a variety of pleasurable interactions, and not directed solely towards penetration.
SUMMARY
[0014] The present invention is a barrier—as well as a shaping mold, a method of use, and a method of manufacture for said barrier—shaped like an undergarment that is worn during oral-vaginal and oral-anal sex to protect another person's mouth, lips, tongue, saliva, nose, and breath from contact with the wearer's vulva, perineum, anus, and surrounding areas, in order to prevent the transmission of bacteria, sexually transmitted infections, taste, and scent. The barrier is thin, substantially non-porous, elastic, skin-tight, and aesthetically attractive. The barrier can be, for example, a device, a panty, a boyshort, a short, a lingerie item, a garment, an undergarment, a membrane, an apparatus, and/or a system.
[0015] Advantages of one or more aspects of embodiments of the present invention are as follows: to provide a barrier for oral sex on a vulva, perineum, and/or anus that need not be held in place during sexual activity, that is sufficiently stable and relatively immobile during sexual activity, that is not loose or movable enough to allow anal bacteria to be easily transferred to the vagina during sex, that covers up enough surface area of the body to prevent transmission of a variety of diseases, that is fluid impermeable, that is virus impermeable, that is pliable enough to allow full penetration by a tongue but not so pliable as to create excess material, that is pliable enough to stretch to fit bodies of multiple sizes, that includes only a single thin layer of material between the oral cavity of the performer and the genital area of the wearer, that is substantially skin tight and curves around crevices while at rest, that causes few aesthetic and/or operational distractions for the participants, that includes few parts, that allows for disposability for cost and/or environment reasons and/or ease of use, and that is inexpensive for a manufacturer to produce and for a consumer to purchase. Other advantages of one or more aspects will be apparent from a consideration of the drawings and ensuing description.
[0016] Further, embodiments of the present invention can be used in the film industry, at sporting events, and in other arenas. For example, an embodiment of the present invention provides for a translucent, thin garment which allows a specific flexibility, movement, and/or sensation.
[0017] An embodiment of the present invention provides for a garment having: a membrane formed of elastomeric material, the membrane including: a front portion, a back portion, an outer thigh portion on a right side of the membrane, an outer thigh portion on a left side of the membrane, and a genital portion; wherein the front portion and the back portion of the membrane are joined via the outer thigh portion on the respective right and left sides of the membrane so as to form an opening at a top portion of the membrane; and wherein the front portion and the back portion of the membrane are joined via the genital portion, and each outer thigh portion of the respective right and left sides of the membrane are joined via the genital portion to form a respective opening on each of the right and left sides of the membrane.
[0018] An embodiment of the present invention provides for a garment having: a membrane formed of elastomeric material, the membrane including: a front portion, a back portion, an inner thigh portion and an outer thigh portion on a right side of the membrane, an inner thigh portion and an outer thigh portion on a left side of the membrane, and a genital portion; wherein the front portion and the back portion of the membrane are joined via the outer thigh portion on the right and left sides of the membrane so as to form an opening at a top portion of the membrane; and wherein the front portion and the back portion of the membrane are joined via the genital portion and the inner thigh portions, respectively, on the right and left sides of the membrane, the front and back portions and the inner thigh portions of the right and left sides of the membrane all joining the genital portion of the membrane, and the inner and outer thigh portions, respectively, on the right and left sides of the membrane form an opening on each of the right and left sides of the membrane.
[0019] An embodiment of the present invention provides for a garment having: a membrane formed of elastomeric material which is at least one of: a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material, the membrane including: a front portion, a back portion, an outer thigh portion on a right side of the membrane, an outer thigh portion on a left side of the membrane, and a genital portion; wherein the front portion and the back portion of the membrane are joined via the outer thigh portion on the respective right and left sides of the membrane so as to form an opening at a top portion of the membrane; and wherein the front portion and the back portion of the membrane are joined via the genital portion, and each outer thigh portion of the respective right and left sides of the membrane are joined via the genital portion to form a respective opening on each of the right and left sides of the membrane; and wherein the membrane includes at least one seam in the genital portion so as to maximize a skin-tight fit effect of the membrane.
[0020] An embodiment of the present invention provides for a garment having: a membrane formed of elastomeric material which is at least one of: a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material, the membrane including: a front portion, a back portion, two thigh portions, and a genital portion; wherein the front portion and the back portion of the membrane are joined so as to form an opening at a top portion of the membrane; wherein the front portion and the back portion of the membrane are joined so as to form the genital portion for covering a human genital region and to form the two thigh portions for covering at least part of two respective thigh regions; wherein the membrane includes at least one crease in the genital portion so as to maximize a skin-tight fit effect of the membrane.
[0021] In an embodiment of the present invention, the membrane is seamless. In an embodiment of the present invention, the front portion and the back portion of the membrane are interchangeable. In an embodiment of the present invention, the membrane is at least one of: a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material. In an embodiment of the present invention, the partially non-permeable material has at least one of: a microscopic opening, a deficiency in the material, a weakness in the material, and an opening for design purposes. In an embodiment of the present invention, the partially pliable material is at least one of: material having a non-flexible region and material having a reduced flexibility region.
[0022] In an embodiment of the present invention, the top portion of the membrane fits a torso snugly. In an embodiment of the present invention, the membrane fits a thigh region snugly. In an embodiment of the present invention, the entire membrane fits a wearer's body snugly. In an embodiment of the present invention, the outer thigh portions on the right and left sides of the membrane fit a human wearer's respective thigh areas snugly. In an embodiment of the present invention, the two thigh portions of the membrane fit the respective thigh regions snugly. In an embodiment of the present invention, the membrane is made as one size fits all. In an embodiment of the present invention, the membrane is made in different sizes from molds of different sizes to account for different wearers' different sizes.
[0023] In an embodiment of the present invention, the membrane thickness is at least one of: 0.33 millimeters, less than 0.33 millimeters, and greater than 0.33 millimeters. In an embodiment of the present invention, the two outer thigh portions each have a height of at least one of: at least 10 millimeters, at least 1 inch, at least 2 inches, at least 3 inches, at least 4 inches, at least 5 inches, at least 6 inches, at least 8 millimeters, at least 0.8 inches, at least 1.8 inches, at least 2.8 inches, at least 3.8 inches, at least 4.8 inches, at least 5.8 inches, and at least a length which extends from at least 8 millimeters below a user's genital region to a top of a pelvic bone of the user. In an embodiment of the present invention, at least one of a respective outer thigh portion of the right side and the left side and a respective outer edge of a right side and a left side of the genital portion adjacent to the respective outer thigh portion each have a height of at least one of: at least 1 millimeter, at least 8 millimeters, at least 0.8 inches, at least 1.8 inches, at least 2.8 inches, at least 3.8 inches, at least 4.8 inches, at least 5.8 inches, and at least a length measuring from 8 millimeters below a human user's genital region to a top of a pelvic bone of the human user. In an embodiment of the present invention, the membrane is one of disposable and reusable. In an embodiment of the present invention, the membrane embodies at least one of: a thong shape, a bikini shape, a legging shape, a capri pant shape, high thigh cut shape, a low-rise cut shape, a tanga shape, a cheeky shape, a boy short shape, and a boxer brief shape. In an embodiment of the present invention, the genital portion of the membrane—that is, the area extending from thigh to thigh covering what would be a human wearer's genital region—has a width greater than the human genital region. In an embodiment of the present invention, the genital portion of the membrane has a width that extends past each of a respective inner thigh portion of a right and a left side, being adjacent to the respective outer thigh portion of the right and the left sides, so that an excess membrane material is gathered next to at least one of the respective inner thigh portion of the right and the left side. In an embodiment of the present invention, the genital portion has a width such that the right side and left side provide an excess membrane material, such that when worn the excess membrane material gathers at at least one of the inner thigh portion of the right side and the inner thigh portion of the left side. In an embodiment of the present invention, a first portion of the membrane is adjacent to the top opening, and a second and a third portion of the membrane is adjacent to the respective opening formed by the respective outer thigh portions and the genital portion, the first, second and third portions being a part of the membrane and having a thickness greater than a remaining part of the membrane. In an embodiment of the present invention, a first portion of the membrane is adjacent to the top opening, the first portion being a part of the membrane, the first portion of the membrane having a smaller circumference than a remaining part of the membrane. In an embodiment of the present invention, a second portion of the membrane is adjacent to the opening on the right side and wherein a third portion of the membrane is adjacent to the opening on the left side, the second and third portions each having a smaller circumference than the remaining part of the membrane.
[0024] In an embodiment of the present invention, the membrane includes material of at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of these materials. In an embodiment of the present invention, the membrane includes at least two layers of material. In an embodiment of the present invention, the membrane includes at least one of: a design, a color, and a pattern. In an embodiment of the present invention, the membrane includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives. In an embodiment of the present invention, the membrane includes a residing substance of at least one of: a lubricant, a powder, a flavoring, and a scent, on at least a part of the membrane. In an embodiment of the present invention, the membrane includes at least one: texture beads in the genital portion, accordion fold in the genital portion, small protuberance in the genital portion. In an embodiment of the present invention, the garment is manufactured using dip-molding. In an embodiment of the present invention, the garment is a liquid-impermeable and body-odor-reducing membrane formed in the shape of an undergarment comprised of elastomeric material. In an embodiment of the present invention, the membrane closely fits a human wearer's body, using friction between the membrane and the wearer's body to assist in keeping the membrane in place on the wearer's body during inactivity and activity. In an embodiment of the present invention, a surface area of the membrane provides for frictional contact on a user so that the membrane remains in a fixed position during use.
[0025] An embodiment of the present invention provides a process for using a garment including: inserting each of a wearer's legs through the opening at the top portion of the membrane; inserting one each of the wearer's legs through one of the respective two thigh portions; pulling the membrane so that the front portion and back portion cover the human torso and the genital portion covers the human genital region; and stretching the two thigh portions according to their lengths along the wearer's legs. An embodiment of the present invention provides a process for using a garment including inserting each of a wearer's legs through the opening at the top portion of the membrane; inserting one each of the wearer's legs through one of the respective two thigh portions; pulling the membrane so that the front portion and back portion cover the human torso and the genital portion covers the human genital region; stretching the two thigh portions according to their lengths along the wearer's legs; and contacting an exterior portion of the genital portion of the membrane with a protuberance. An embodiment of the present invention provides a process for using a garment including: inserting each of a wearer's legs through the opening at the top portion of the membrane; inserting one each of the wearer's legs through one of the respective two thigh portions; pulling the membrane so that the front portion and back portion cover the human torso and the genital portion covers the human genital region; stretching the two thigh portions according to their lengths along the wearer's legs; and contacting an exterior portion of the genital portion of the membrane with a protuberance, wherein the protuberance is at least one of: a tongue, mouth, nose, and finger.
[0026] The various embodiments described above, as well as those described below, can be used with and without each other, in various combinations, for the present invention.
[0027] An embodiment of the present invention provides for a method of manufacturing a garment including: providing a shaping mold; contacting the shaping mold with at least one solution simultaneously or one after the other; removing the shaping mold from the at least one solution when at least one of a gelled and a solidified coating of a desired thickness is produced on the shaping mold; drying the coating on the shaping mold; separating the coating from the shaping mold; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment, the excising of the excess material is to form the membrane into a specific garment type such as a boy short, a bikini, a panty, or other desired shape, et al.
[0028] An embodiment of the present invention provides a method of manufacturing a garment, including: providing a shaping mold; contacting the shaping mold with a solution, the solution being at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of the foregoing materials; removing the shaping mold from the solution when at least one of: a gelled and a solidified coating of a desired thickness, is produced on the shaping mold; drying the coating on the shaping mold; separating the coating from the shaping mold; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment of the present invention, the solution includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives.
[0029] An embodiment of the present invention provides for a method of manufacturing a garment including providing a shaping mold; contacting the shaping mold with a first solution, wherein the first solution when in contact with a second solution, causes the second solution to solidify; contacting the first solution covered shaping mold with the second solution, the second solution being at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of the foregoing materials; removing the shaping mold from the second solution when at least one of a gelled and a solidified coating of a desired thickness is produced on the shaping mold; drying the coating on the shaping mold; separating the coating from the shaping mold; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment of the present invention, the second solution includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives.
[0030] An embodiment of the present invention provides for a method of manufacturing a garment, including: providing a shaping mold; contacting the shaping mold with a first solution, wherein the first solution when in contact with a second solution, causes the second solution to solidify; contacting the first solution covered shaping mold with the second solution, the second solution being at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of the foregoing materials; removing the shaping mold from the second solution when at least one of a gelled and a solidified coating of a desired thickness is produced on the shaping mold; drying the coating on the shaping mold; contacting the second solution covered shaping mold with at least one third solution; drying the at least one third solution coating on the shaping mold; separating the coating from the shaping mold; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment of the present invention, the second solution includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives.
[0031] In an embodiment of the present invention, the shaping mold is in the shape of a rectangle, dual cones extending from a rectangular portion, and a planar curved portion. In an embodiment of the present invention, the shaping mold is one of: rectangular-shaped; cylindrical-shaped; curved planar shaped; planar shaped; flat planar shaped; shaped such that said front and back portions are two parallel flat planes connected via at least two edges; shaped such that said front and back portions are two parallel curved planes connected via at least two edges; and rectangular-shaped and curved into a spiral shape. In an embodiment of the present invention, the first solution is a coagulant. In an embodiment of the present invention, the coating is at least one of: a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material. In an embodiment of the present invention, the partially non-permeable material has at least one of a microscopic opening, a deficiency in the material, a weakness in the material, and an opening for design purposes, and the partially pliable material is at least one of material having a non-flexible region and material having a reduced flexibility region. In an embodiment of the present invention, the coating is an elastomeric material having a thickness of one of: 0.33 millimeters, greater than 0.33 millimeters, and less than 0.33 millimeters. In an embodiment of the present invention, the excising of the excess material occurs so that there is a front portion and a back portion of the coating joined so as to form an opening at a top portion of the coating, and so that two thigh portions for covering at least part of two respective thigh regions are provided.
[0032] An embodiment of the present invention provides a method of manufacturing a garment, including: providing a shaping housing; contacting the shaping housing with a solution; removing the shaping housing from the solution when at least one of: a gelled and a solidified coating of a desired thickness, is produced on the shaping housing; drying the coating on the shaping housing; separating the coating from the shaping housing; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment, the solution is at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of the foregoing materials. In an embodiment of the present invention, the solution includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives. In an embodiment, the coating is at least one of: seamless and wearable by a human. In an embodiment, the coating is at least one of a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material. In an embodiment, the partially non-permeable material has at least one of: a microscopic opening, a deficiency in the material, a weakness in the material, and an opening for design purposes. In an embodiment, the partially pliable material is at least one of: material having a non-flexible region and material having a reduced flexibility region. In an embodiment, the shaping housing is put into contact with the at least one solution more than once to create the coating that has a thickness is at least one of: 0.33 millimeters, less than 0.33 millimeters, and greater than 0.33 millimeters.
[0033] An embodiment of the present invention provides a system of manufacturing a garment, including: a shaping mold, wherein the shaping mold has a front portion, a back portion, a right and a left side portions, and a bottom portion, so that the front, back, right side, left side, and bottom portions are connected to form the shaping mold as a three-dimensional structure; at least one solution, wherein the at least one solution when in contact with the shaping mold solidifies; removing the shaping mold from a second of the at least one solution when at least one of a gelled and a solidified coating of a desired thickness is produced on the shaping mold; drying the coating on the shaping mold; contacting the second solution covered shaping mold with at least one third solution; drying the at least one third solution coating on the shaping mold; separating the coating from the shaping mold; and excising any excess material from at least one of a thigh portion and a torso portion of the coating. In an embodiment, the at least one solution is a first and a second solutions, wherein the first solution is put in contact with the shaping mold, and the second solution is put in contact with the first solution on the shaping mold, wherein the first solution when in contact with the second solution causes the second solution to solidify. In an embodiment, the at least one solution is at least one of: latex, natural rubber latex, synthetic latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and a combination of any of the foregoing materials. In an embodiment of the present invention, the at least one solution includes additives of at least one of: ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives.
[0034] An embodiment of the present invention provides for an apparatus for forming a garment embodiment according to the embodiment described herein and those that would be readily apparent variations.
[0035] An embodiment of the present invention provides for an apparatus in the form of a shaping mold. In an embodiment, the shaping mold is a planar mold or a curved planar mold. In an embodiment, the shaping mold is a planar mold or curved planar mold that is curved as a S-shaped form, an e-shaped form, a c-shaped form, a u-shaped form, or other form in order to reduce the width of the mold. This can be useful in production, or in storage of the molds. In an embodiment, the shaping mold includes a first portion resembling a rectangular mold and two conical portions attached to the first portion. In an embodiment, the shaping mold is hollow or solid. In an embodiment, the mold is usable for a dip molding process. In an embodiment, the shaping mold is of a material that functions well with the various elastomeric-type and other type materials used. In an embodiment, the shaping mold is made of more than one material, allowing for a base material to provide a strong or resilient mold along with a different material coating which reacts appropriately with the solutions encountered to form the membrane and/or to remove the membrane. In an embodiment, the shaping mold has a coating or is made entirely of the same coating which allows for the formation of the membrane and/or easy removal of the membrane. In an embodiment, certain portions of the membrane are excised or removed before removing the membrane from the shaping mold. In an embodiment, the excising of the membrane can be effected by use of a solution in discrete manner so that the solution removes only a desired portion of the membrane. In an embodiment, the excising of the membrane can be effected by the use of a knife, scissors, or other device used to cut or remove a desired portion of the membrane.
[0036] An embodiment of the present invention provides for a mold with a housing having a front portion, a back portion, a right and a left side portions, and a bottom portion, so that the front, back, right side, left side, and bottom portions are connected to form the housing as a three-dimensional structure, wherein the housing allows for being dip-molded in a solution which at least semi-solidifies on the housing. In an embodiment, the housing is one of: rectangular-shaped; cylindrical-shaped; curved planar shaped; planar shaped; flat planar shaped; shaped such that said front and back portions are two parallel flat planes connected via at least two edges; shaped such that said front and back portions are two parallel curved planes connected via at least two edges; and rectangular-shaped which is curved into a spiral shape. In an embodiment, the front and back portions are planar curved. In an embodiment, the mold is a flat planar mold in a U-shape with curved corners to allow for less waste of material and/or solution. In an embodiment, the mold is a curved planar mold in a U-shape with curved corners to allow for less waste of material and/or solution. In an embodiment, a flat planar mold has a cut-out in the middle of the bottom part of the mold simulating the legs of a boy-short version. In an embodiment, a curved planar mold has a cut-out in the middle of the bottom part of the mold simulating the legs of a boy-short version. In an embodiment, the housing is at least one of: filled with solid material, hollow, and partially filled with material. In an embodiment, the housing allows for the use of an apparatus to attach to a top portion of the housing, the apparatus being used to do at least one of: holding the housing during dip-molding, holding the housing during drying, and holding the housing during removal of material. In an embodiment, the apparatus is at least one of: a gripping device, a wire, a hanging device, a screwed-in device, a magnetic device, or other attachment or positioning or holding device. In an embodiment, the housing is made of at least two materials wherein a first of the at least two materials is a material resistant to corrosion, and a second of the at least two materials is a material which does not permanently bind with polymer solution, wherein the second of the at least two materials is layered over the first of the at least two materials. In an embodiment, the housing is composed of a material that is coatable with a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material. In an embodiment, the housing is coatable by a coating that is an elastomeric material having a thickness of one of: 0.33 millimeters, less than 0.33 millimeters, and greater than 0.33 millimeters. In an embodiment, the housing has a material coating which allows for at least one of: a formation of a membrane from a solidifying solution, a removal of a membrane formed from a solidifying solution on the housing, and resistance to sharp cutting instruments.
[0037] An embodiment of the present invention provides for a mold on which a garment can be formed, including: a rectangular-shaped housing having a front portion, a back portion, a left side portion, and a right side portion, wherein the front portion, back portion, and left side and right side portions, are connected to each other to form a three-dimensional rectangular-shaped housing; a first cylindrical housing, wherein a top portion edge of the first cylindrical housing is connected to a bottom portion edge of the rectangular-shaped housing, so that the top portion edge of the first cylindrical housing is connected with the left side portion, the front portion, and the back portion; a second cylindrical housing, wherein a top portion edge of the second cylindrical housing is connected to the bottom portion edge of the rectangular-shaped housing, so that the top portion edge of the first cylindrical housing is connected with the right side portion, the front portion, and the back portion; and, a middle portion having a front edge, a back edge, a right side edge and a left side edge, wherein the middle portion front edge is connected to the rectangular-shaped housing front edge, the middle portion back edge is connected to the rectangular-shaped housing back edge, the middle portion right side edge is connected to the second cylindrical housing, and the middle portion left side edge is connected to the first rectangular-shaped housing. In an embodiment, the first cylindrical housing and the second cylindrical housing are each at least one of: an ellipsoid and an ovoid. In an embodiment, a mold includes a first conical portion connected to a bottom portion edge of the first cylindrical housing; and a second conical portion connected to a bottom portion edge of the second cylindrical housing. In an embodiment, the housing is made of at least two materials wherein a second of the at least two materials is a material which does not bind with coagulants, wherein the second of the at least two materials is layered over a first of the at least two materials. In an embodiment, the housing is coatable with a completely non-permeable material, a partially non-permeable material, a partially pliable material, and a completely pliable material. In an embodiment, the housing has a material coating which allows for at least one of: a formation of a membrane from a solidifying solution, a removal of a membrane formed from a solidifying solution on the housing, and resistance to sharp cutting instruments. In an embodiment, the housing is at least one of: filled with solid material, hollow, and partially filled with material. In an embodiment, the housing allows for the use of an apparatus to attach to a top portion of the housing, the apparatus being used to do at least one of: holding the housing during dip-molding, holding the housing during drying, and holding the housing during removal of material. In an embodiment, the apparatus is at least one of: a gripping device, a wire, a hanging device, a screwed-in device, and a magnetic device. In an embodiment, the first and second cylindrical shaped housings are sized to fit a thigh of a human.
[0038] In an embodiment of the present invention, a mold for forming the barrier garment is solid material, not having a hollowed interior. In an embodiment of the present invention, the solid material can be chosen to allow for a transfer of heat or a non-transfer of heat. In an embodiment of the present invention, a mold for forming the barrier garment is a hollowed structured housing. In an embodiment of the present invention, a mold is a hollowed structured housing allowing for less cost of materials and process for manufacturing the mold. In an embodiment of the present invention, a mold for forming the barrier garment is planar curved, planar flat, planar S shaped, planar curved C shaped, planar curved E shaped, planar curved U shaped, or another type of planar curved shape for manufacturing, and a three dimensional rectangular-like shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1A shows a front view of an embodiment of the present invention.
[0040] FIG. 1B shows a rear view of an embodiment of the present invention.
[0041] FIG. 1C shows a left side view of an embodiment of the present invention folded such that the back portion and the front portion touch.
[0042] FIG. 2 shows a front view of an embodiment of the present invention disposed on a body's lower torso and upper legs.
[0043] FIG. 3 shows a rear view of an embodiment of the present invention disposed on a body's lower backside and upper legs.
[0044] FIG. 4A shows a side view of an embodiment of the present invention disposed on a body's right lower torso and upper leg.
[0045] FIG. 4B shows a caudal view of an embodiment of the present invention.
[0046] FIG. 5A shows a front view of an embodiment of the present invention.
[0047] FIG. 5B shows a rear view of an embodiment of the present invention.
[0048] FIG. 5C shows a left side view of an embodiment of the present invention folded such that the back portion and the front portion touch.
[0049] FIG. 6 shows a front view of an embodiment of the present invention disposed on a body's lower torso and upper legs.
[0050] FIG. 7 shows a rear view of an embodiment of the present invention disposed on a body's lower backside and upper legs.
[0051] FIG. 8A shows a side view of an embodiment of the present invention disposed on a body's right lower torso and upper leg.
[0052] FIG. 8B shows a caudal view of an embodiment of the present invention.
[0053] FIG. 9A shows a front view of an embodiment of the present invention.
[0054] FIG. 9B shows a rear view of an embodiment of the present invention.
[0055] FIG. 9C shows a left side view of an embodiment of the present invention folded such that the back portion and the front portion touch.
[0056] FIG. 9D shows a front view and measurements of an embodiment of the present invention.
[0057] FIG. 9E shows a front view and measurements of an embodiment of the present invention.
[0058] FIG. 10A shows a front view of an embodiment of the present invention disposed on a body's lower torso and upper legs.
[0059] FIG. 10B shows a rear view of an embodiment of the present invention disposed on a body's lower backside and upper legs.
[0060] FIG. 10C shows a side view of an embodiment of the present invention disposed on a body's right lower torso and upper leg.
[0061] FIG. 10D shows a caudal view of an embodiment of the present invention.
[0062] FIG. 11A shows a front and rear view of an embodiment of the present invention as worn on a body.
[0063] FIG. 11B shows a front and rear view of an embodiment of the present invention as worn on a body.
[0064] FIG. 11C shows a front and rear view of an embodiment of the present invention as worn on a body.
[0065] FIG. 11D shows a front and rear view of an embodiment of the present invention as worn on a body.
[0066] FIG. 11E shows a front and rear view of an embodiment of the present invention as worn on a body.
[0067] FIG. 11F shows a front and rear view of an embodiment of the present invention as worn on a body.
[0068] FIG. 11G shows a front and rear view of an embodiment of the present invention as worn on a body.
[0069] FIG. 11H shows a front and rear view of an embodiment of the present invention as worn on a body.
[0070] FIG. 12 shows a front view of multiple embodiments of the present invention as worn on a body.
[0071] FIG. 13 shows a rear view of multiple embodiments of the present invention as worn on a body.
[0072] FIG. 14A shows a front view of an embodiment of the present invention.
[0073] FIG. 14B shows a side and rear view of an embodiment of the present invention.
[0074] FIG. 14C shows a rear view of an embodiment of the present invention.
[0075] FIG. 14D shows a front view of an embodiment of the present invention.
[0076] FIG. 14E shows a rear view of an embodiment of the present invention.
[0077] FIG. 15A shows a front view of an embodiment of the present invention.
[0078] FIG. 15B shows a right side view of an embodiment of the present invention.
[0079] FIG. 15C shows a rear view of an embodiment of the present invention.
[0080] FIG. 16A shows a caudal view of an embodiment of the present invention having pleats in the vulval area.
[0081] FIG. 16B shows a caudal view of an embodiment of the present invention having pleats in the vulval and anal area.
[0082] FIG. 16C shows a caudal view of an embodiment of the present invention having texture beads.
[0083] FIG. 17 shows a chart illustrating a comparison of thicknesses of the state of the art.
[0084] FIG. 18 shows a chart illustrating an approximate expandability of the state of the art.
[0085] FIG. 19 shows a flow chart illustrating a method of using an embodiment of the present invention.
[0086] FIG. 20 shows a flow chart illustrating a manufacturing process embodiment for manufacturing a garment embodiment of the present invention.
[0087] FIG. 21A shows a front view of a flat mold embodiment for manufacturing a garment embodiment of the present invention.
[0088] FIG. 21B shows a top view of a flat mold embodiment for manufacturing a garment embodiment of the present invention.
[0089] FIG. 21C shows a front view of a flat mold embodiment for manufacturing a garment embodiment of the present invention.
[0090] FIG. 21D shows a front view of a flat mold embodiment for manufacturing a garment embodiment of the present invention.
[0091] FIG. 21E shows a front view of a flat mold embodiment for manufacturing a garment embodiment of the present invention.
[0092] FIG. 22A shows a front and top view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0093] FIG. 22B shows a front and top view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0094] FIG. 22C shows a front and top view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0095] FIG. 22D shows a front and top view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0096] FIG. 22E shows a side and bottom view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0097] FIG. 22F shows a front and top view of a curved mold embodiment for manufacturing a garment embodiment of the present invention.
[0098] FIG. 23 shows a flowchart of a manufacturing process embodiment using a substantially planar flat mold form embodiment of the present invention.
[0099] FIG. 24 shows a flowchart of a manufacturing process embodiment using a substantially planar curved mold form embodiment of the present invention.
[0100] FIG. 25A shows a semi-anatomical mold embodiment with a flat bottom for manufacturing a garment embodiment of the present invention.
[0101] FIG. 25B shows a semi-anatomical mold embodiment with a conical bottom for manufacturing a garment embodiment of the present invention.
[0102] FIG. 25C shows a semi-anatomical mold embodiment with a conical bottom for manufacturing a garment embodiment of the present invention.
[0103] FIG. 25D shows a semi-anatomical mold embodiment with a conical bottom for manufacturing a garment embodiment of the present invention.
[0104] FIG. 26 shows a flowchart of a manufacturing process embodiment using a semi-anatomical mold form embodiment of the present invention.
[0105] FIG. 27A shows a front view of an embodiment of the present invention as held up by a hand.
[0106] FIG. 27B shows a front top view of an embodiment of the present invention when a hand is inserted into it.
[0107] FIG. 28 shows a top view of a pattern used for manufacturing a garment embodiment of the present invention.
[0108] FIG. 29 shows an example method of manufacturing according to an embodiment of the present invention.
[0109] FIG. 30 shows an example garment apparatus.
DETAILED DESCRIPTION
[0110] An embodiment of the barrier is illustrated in FIGS. 1A, 1B, 1C . FIG. 1A is a front view of an embodiment, and FIG. 1B is a rear view of the embodiment. The barrier, generally designated 10 , is configured in the overall shape of an undergarment. Barrier 10 includes a front portion 12 , a genital portion 14 , and a back portion 16 . In this embodiment, genital portion 14 and back portion 16 include a crease 15 . This embodiment also includes thigh portions 18 and 19 , which are each connected to front portion 12 and to back portion 16 . FIG. 1C is a left view of the embodiment folded such that back portion 16 and front portion 12 are touching.
[0111] An embodiment of barrier 10 is illustrated in FIG. 2 , FIG. 3 , and FIGS. 4A to 4B , in front, rear, side, and caudal views, respectively. In FIG. 2 , FIG. 3 , and FIGS. 4A, 4B , barrier 10 is being worn by a wearer or body or receiver 11 , depicted here as female. Wearer 11 's sexual partner is described herein as the “performer” of oral sex. In FIG. 2 , FIG. 3 , and FIGS. 4A, 4B , front portion 12 extends from the vicinity above wearer 11 's pelvis downward and meets with genital portion 14 . Genital portion 14 covers wearer 11 's vulva, perineum, anus, and groin and extends to back portion 16 . Back portion 16 covers wearer 11 's buttocks. In some embodiments, inner-thigh portions 28 and 29 extend down the wearer's inner thighs at least 2 mm and as far as knee-length, in order to anchor the barrier in place, to prevent skin-to-skin contact between the performer and the wearer's thighs, and to provide for extra material that can slide up the inner thighs to allow penetration beyond the elastomeric capabilities of the material.
[0112] An embodiment of the barrier is illustrated in FIGS. 5A to 5C . FIG. 5A is a front view, and FIG. 5B is a rear view. In this embodiment, genital portion 14 does not include a crease. This embodiment includes thigh portions 18 and 19 , which have less curvature than in some other embodiments, and which are each connected to front portion 12 and to back portion 16 , which also has less curvature than in some other embodiments. FIG. 5C is a left view folded such that back portion 16 and front portion 12 are touching.
[0113] An embodiment of barrier 10 is illustrated in FIG. 6 , FIG. 7 , and FIGS. 8A, 8B in front, rear, side, and caudal views, respectively. In FIG. 6 , FIG. 7 , and FIGS. 8A, 8B , barrier 10 is worn by a human wearer 11 . In this embodiment, genital portion 14 does not have a crease.
[0114] An embodiment of the barrier is illustrated in FIGS. 9A to 9E . FIG. 9A is a front view, and FIG. 9B is a rear view. In this embodiment, the genital portion 14 is wider than in some other embodiments and wider than the genital area of most female humans, and the bottom edges for the legs extend up from the genital portion 14 and out to the thigh portions 18 and 19 . FIG. 9C is a left view folded such that back portion 16 and front portion 12 are touching. In the various embodiments illustrated in the Drawings, certain edges 54 in FIGS. 11 to 15 can show different curvatures due to the drafting of the embodiment drawing rather than an indication of a specific curvature. In fact, these edges 54 can be straight, curved, scalloped, etc.
[0115] An embodiment of barrier 10 is illustrated in FIGS. 10A, 10B, 10C, 10D , in front, rear, side, and caudal views, respectively. In FIGS. 10A to 10D , barrier 10 is being worn by a wearer 11 . In this embodiment, the genital portion 14 is wider than in some other embodiments, and when placed on the body the outside edges of genital portion 14 form inner-thigh portions 28 and 29 . The bottom edges for the legs extend up from the genital portion 14 and out to the thigh portions 18 and 19 . In an embodiment, the outside edges of the genital portion 14 forming inner-thigh portions 28 and 29 provide for some slight or small excess material to gather on each of the outer sides of the labia adjacent to the wearer's inner thigh. In an embodiment, it is possible that a very slight excess or a crease will form in the inner labia when some wearers don the barrier 10 —but this very slight excess is much less than the slight excess material gathering at the outside edges of the genital portion 14 . This slight excess material allows for the excess material of the genital portion 14 to move slightly in response to small penetrations or touching in the vaginal or inner labia regions of a wearer, without exposing portions of the outer and/or inner labia. For example, in this embodiment, the excess material does not leave the outer sides of the labia unless there is a vaginal or inner labia penetration or touching necessitating a movement of the slight excess material as the material stretches to accommodate the penetration or touching. In an embodiment, the T-shape barrier shown in FIGS. 9A to 9E , when worn by a person can look like FIGS. 10A to 10D . In some embodiments, as shown in FIG. 9D , the top edge is approximately 15 inches wide and has a circumference of approximately 30 inches, the genital portion is approximately 7 inches wide, the garment is approximately 10 inches high when laid flat, and the thigh portion is approximately 6 inches high. In an embodiment similar to FIGS. 9A to 9E and FIGS. 10A to 10D , thigh portions 18 and 19 are shorter, such that the barrier when worn resembles a bikini style. In some embodiments, as shown in FIG. 9E , the top edge is approximately 15 inches wide and has a circumference of approximately 30 inches, the genital portion is approximately 7 inches wide, the garment is approximately 10 inches high when laid flat, and the thigh portion is approximately 2 inches high.
[0116] One feature of embodiments of the barrier including bottom edges (e.g., bottom edges 54 ) as depicted in FIGS. 9A to 9E , FIGS. 10A to 10D , FIGS. 11C, 11H , FIGS. 14A to 14E , and FIGS. 15A to 15C , or bottom edges 57 as depicted in FIG. 11G , FIG. 12 , and FIG. 13 , is that the material along the groin portion 14 gathers in useful ways on different bodies—on some bodies the material gathers into wrinkles, and on other bodies the material rests along the inner thighs—and the material along the groin portion 14 can be moved inward on the groin to allow additional penetration into the vagina, beyond what is possible from the material's elastomeric qualities.
[0117] Some embodiments cover more or less surface area than other embodiments, as shown in FIGS. 11A to 11H , FIG. 12 , and FIG. 13 . Some embodiments have bottom edges 50 that extend several centimeters down the thighs and are parallel to the ground, bottom edges 52 that extend only a few centimeters or millimeters down the inner thighs and are parallel to the ground, or bottom edges 54 or 57 that extend only a few millimeters down the inner thighs and extend up on the outer thighs. Other embodiments do not cover the inner thighs and have bottom edges 56 or 58 that extend from each side of the genital portion to the sides of the waist in a boy-short ( 56 ) or bikini ( 58 ) style. Any of these embodiments could have top edges 60 , 62 , or 64 that extend to various heights of a body's torso and backside. FIGS. 11A to 11H show various embodiments of the barrier including an assortment of top edges 60 , 62 , or 64 and bottom edges 50 , 52 , 54 , 56 , 57 , and 58 . The embodiment depicted in FIG. 11H also includes seam 68 .
[0118] FIGS. 14A to 14E and FIGS. 15A to 15C show photographs of an embodiment including the bottom edges 54 depicted in FIGS. 9A to 9E and FIGS. 10A to 10D . On a female human wearer, FIG. 14A shows a front view (redacted for modesty), FIG. 14B shows a side and rear view, FIG. 14C shows a rear view, FIG. 14D shows a front view (redacted for modesty), and FIG. 14E shows a rear view. FIG. 15A shows a front view, FIG. 15B shows a right side view, and FIG. 15C shows a back view, of an embodiment as worn on an (anatomically female) mannequin.
[0119] In an embodiment, all portions, including genital portion 14 , are configured to fit tightly to the body, both at rest and while engaging in sexual activity. Genital portion 14 contours the body, unlike conventional barriers, for several reasons. First, the aesthetics of sexual activity are very important in maintaining arousal, particularly among partners who may be distracted by concern regarding STIs. Sexual partners utilizing a prophylactic want to view the body-contouring look of many contemporary fashions. Some embodiments so tightly contour the body that wrinkles 20 are created by folds of the material and shadows 22 are created by the barrier's contour of the wearer's anatomy, as in FIG. 2 , FIG. 3 , FIGS. 4A to 4B , FIGS. 10A to 10D , FIGS. 14A to 14E , and FIGS. 15A to 15C . In an embodiment, for example, those wrinkles 20 and shadows 22 , while most likely to appear on the creases between the inner thighs and the genital region and under the curves of the buttocks, will appear in different locations when worn by wearers of different shapes and sizes. Also, some embodiments, such as that depicted in FIG. 6 , FIG. 7 , and FIGS. 8A, 8B , do not have wrinkles 20 or shadows 22 . Also, genital portion 14 fits snugly such that in most cases only one layer of material—rather than additional layers created by the folding of excess material, such as a long protrusion—exists between the performer and the wearer. If additional layers created by the folding of excess material are present, they could diminish sensation for the wearer and prevent breathing and cause gagging for the performer. Furthermore, the excess material could allow bacteria from the anus to reach the vaginal cavity. In some embodiments, the sides of the garment provide for a friction between the material of the garment and the wearer's hips and/or thighs. The friction or resistance to movement allows for better staying ability on the wearer, so that the garment does not move or shift significantly during activity, while preventing the necessity of tight or uncomfortable straps used in other apparatuses to hold dental dams in place. In an embodiment, the friction of the garment against the wearer's body provides a close, stable fit. This can provide a more stable and relatively non-moving garment on the wearer's body, in a comfortable-like manner, so that the material is held in place on the wearer specifically in the genital area, without the addition or use of tight uncomfortable straps or ties.
[0120] In an embodiment, barrier 10 is formed of one or more layers, with each layer including one or more substantially impervious material(s) such as natural rubber latex, synthetic latex, latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, superelastomer, vegan material, hypoallergenic material, organic material, other elastomer, other polymer, other copolymer, other polyolefin, and/or a combination of any of these materials. The material can also include additives such as ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives. The barrier 10 is flexible enough for the wearer to comfortably reposition her body; pliable enough to show an outline of the wearer's anatomy for aesthetic appeal and for easy identification by the performer; strong enough to prevent breakage during vigorous use; and of a thickness similar to a conventional condom or a dental dam, to allow the greatest degree of tactile sensitivity and to prevent fatigue of the performer.
[0121] In an embodiment, the garment can be one or more layers of an elastomeric material or other flexible-type material such as a moisture-resistant spandex or other textile. In an embodiment, the garment can be composed of more than one type of material in the same garment or layers of the garment. In an embodiment, the garment can include material that is dipped in or otherwise coated in a solution or material. In an embodiment, the garment can include at least one printed pattern. For example, the printed pattern/coloring can be included in the solution, be added as a subsequent solution for dipping, be painted/sprayed on, and/or be added in another available manner to the garment. In some embodiments, items of material known in the fashion arts are attached to the barrier for decorative purposes.
[0122] Some embodiments of the barrier have an interchangeable front and back, such that the wearer can quickly put on the garment without determining which side is the front portion and which side is the back portion. For example, the barrier depicted in FIGS. 14A to 14E and FIGS. 15A to 15C has an interchangeable front and back. Other embodiments include a different cut, seam, embellishment, and/or design in the front as compared to the back, such that there is a designated front portion and a designated back portion of the garment. For example, the barrier embodiment depicted in FIG. 11H has a different cut in the front and the back.
[0123] In some embodiments of the barrier, color, pattern, scent, and taste are varied, and some embodiments of the barrier are coated with lubricant and/or powder. In an embodiment, the material of the barrier, the powder dusted on the barrier, and/or the lubricant applied to the barrier is scented and/or has a taste. For example, the scent and/or taste can be strawberry, raspberry, any other fruit flavor, chocolate, vanilla, caramel, any other confectionery flavor, bacon, steak, chicken, pistachio, peanut, any other food flavor, spearmint, peppermint, sage, any other herb flavor, and/or any other flavor known in the art. For example, the scent and/or taste can be organic/vegan.
[0124] Some embodiments include texture to increase sensation, such as (but not limited to) the accordion folds 80 depicted in FIG. 16A over the vulva and FIG. 16B over the full genital region and the texture beads 82 depicted in FIG. 16C (which, in addition to providing texture, can also decrease the wearer's insecurity regarding bumps that are characteristic of STI outbreaks). In some embodiments, creases and/or seams such as crease or seam 68 , as depicted in FIG. 12 and FIG. 13 —or the shorter crease 15 as depicted in FIGS. 1A to 1C , FIG. 3 , and FIGS. 4A to 4B —increase sensation through texture and allow greater access for the performer to the area between the wearer's right and left labia majora and to the anus and perineum. Some embodiments include texture or cut-outs in a “figure eight”, a swirl, an alphanumeric symbol, a heart, a logo, a brand name, a brand initial, and/or another shape, either as a decorative element, to keep the garment in place, and/or to instruct the performer where to move their tongue. Some embodiments include other textures including bumps, ruched material, et al. Some embodiments include lubricant, cooling lubricant, warming lubricant, cooling liquid, and/or warming liquid to increase sensation.
[0125] In some embodiments, the genital region of the garment is manufactured as a wider area than that of fashion undergarments, to allow different uses. In some embodiments, the genital region of the garment is manufactured as a wider area to allow for less pulling of garment material away from the thigh regions or the sides of the genital region. In some embodiments, as the garment with a wider area is pulled up over the legs, the material on the sides of the genital region will drag along the inner thighs; on some users that material will rest into place on the top of the inner thighs, and in other users that material will gather on the sides of the genital region, i.e., between each outer labia and its adjacent leg. Due to this excess width, while oral sex is being performed on a wearer of such an embodiment, the material that sits at the inner thighs and/or on the sides of the genital region can move slightly in response to vaginal penetration by a tongue, fingers, or other objects without exposing portions of the outer and/or inner labia, as would a garment with a genital region having the width of fashion undergarments. In an embodiment, material can gather slightly between a left outer side of the labia and the respective adjacent left thigh region, and/or between a right outer side of the labia and the respective adjacent right thigh region. For example, in this embodiment, the material does not gather in the inner labia and/or vaginal area unless, or gathers only minimally in the inner labia and/or vaginal area until, the user effects a vaginal or other penetration or touching which necessitates the movement of the slight material excess as the material stretches due to such penetration or action.
[0126] In an embodiment, the outer edges of the thigh regions and/or the torso region are a smaller circumference to enforce an effective seal or closure to prevent fluids from escaping during use.
[0127] In some embodiments, the top edges are straight across the waist or hips. In some embodiments, the top edges are scooped in the front and/or the back such that the thigh portions extend higher than the middle portion and/or the back portion. This scooping can be achieved through cutting, die-cutting, excising, or any other method known in the art. In some embodiments, other functional and/or design options are available for the top edges or the bottom edges, including a downward diamond cut, scalloped cuts, fringing, and so forth. Likewise, after the manufacturing of the barrier garment, in embodiments, additional embellishments can be glued, heated, or attached to the barrier garment including lace, spandex, cotton, and other materials for aesthetic and/or functional purposes. For example, different material can be added to the barrier garment in order to increase the usability, design, and/or aesthetic of the barrier garment for a different texture or a handle device to pull on the barrier garment.
[0128] Some embodiments have bottom edges 50 , 52 , 54 , 56 , or 58 and/or top edges 60 , 62 , or 64 that are rolled, reinforced, sewn, heated, cut, multi-layered, sealed, and/or manufactured in another way so as to provide additional strength to the edges and, in some embodiments, to prevent ingress and/or egress of fluids. Some embodiments have bottom edges 50 , 52 , 54 , 56 , 57 , or 58 and/or top edges 60 , 62 , or 64 that are tighter than the remainder of the barrier. Some embodiments have bottom edges 50 , 52 , 54 , 56 , 57 , or 58 and/or top edges 60 , 62 , or 64 that are cut in a decorative manner, for example scalloped, fringed, or any other manner known in the art.
[0129] The thickness of the barrier is varied in some embodiments. FIG. 17 shows a chart 170 that depicts the thickness (in millimeters) of the state of the art. The thickness of novelty rubber underwear, at 0.33 mm or thicker, is more than four times thicker than an oral dam, more than five times thicker than a condom, and more than six times thicker than a thin condom. As a result, the novelty rubber underwear transfers substantially less sensation from the performer's side to the recipient's side, causing a less-pleasurable sexual experience. In some embodiments, the barrier has a thickness comparable to a thin condom, condom, and/or oral dam and therefore is substantially thinner than novelty rubber underwear. FIG. 27A and FIG. 27B show a thickness of a barrier embodiment of the present invention. FIG. 27A shows that the barrier embodiment is extremely thin when held up by a hand, and it drapes down gracefully. FIG. 27B shows that the barrier embodiment curves along the anatomy of the hand. The barrier responds similarly when placed on a genital region.
[0130] Some embodiments have more expandability than other embodiments. For example, FIG. 18 contains chart 180 that depicts the expandability of the state of the art. The condom, thin condom, and oral dam have expandability of 250-350%, or more, of their length at rest. (For example, a 10 mm piece of a thin condom will stretch to 40 mm.) Plastic wrap and novelty rubber underwear are significantly less expandable. In some embodiments, the barrier has an expandability comparable to a condom, thin condom, and/or oral dam.
[0131] In an embodiment, the barrier responds to the application of pressure by expanding, though it need only be expandable enough to fit slightly-different sized wearers and to allow insertion of a tongue. In an embodiment, the barrier is manufactured in a range of sizes, reducing the need for expandability of the material. In another embodiment, the barrier is sufficiently expandable such that a single barrier can expand to fit wearers of most shapes and sizes.
[0132] In an embodiment, the barrier is donned before sexual activity takes place, either immediately before or as an undergarment worn for non-sexual activity. To don the barrier, one leg of the wearer is inserted in each of the spaces between the genital portion and the thigh portions, with the front portion facing forward. If desired, a lubricant can be applied inside the barrier for ease of donning and to increase sensation for the wearer. A performer then contacts the exterior portion of the membrane with their tongue, mouth, nose, fingers, and/or other small protuberances. After use, the device is pulled off or rolled downward off the wearer.
[0133] As process 190 depicted in FIG. 19 shows, a method of oral-sexual relations includes:
[0134] Step 1 ( 191 ): Don the undergarment by: (i) inserting each of the wearer's legs between the top opening and one side of the membrane, and (ii) pulling the membrane against the genital area and around the torso of the wearer.
[0135] Step 2 ( 192 ): A person other than the wearer contacts the exterior portion of the membrane with said person's tongue, mouth, nose, fingers, or other small protuberances.
[0136] In some embodiments, the barrier is formed by cutting a sheet of material in a pattern and creating seams 152 to connect portions of said material. Seams can be created using adhesive, liquid latex, UV-cured adhesive, tape, glue, thread, or any method known in the art. In some embodiments, said seams 152 can be located on the sides of the thighs (e.g., as shown in FIG. 15B ), in the genital region of the barrier, and/or in any other location(s) suitable for a seam. FIG. 28 shows a pattern that can be cut into a sheet of material to create an embodiment of the barrier. Front portion 281 connects to genital portion 282 , which connects to back portion 283 . Side portion 286 is seamed with side portion 284 , and side portion 287 is seamed with side portion 285 .
[0137] FIG. 29 shows an embodiment 290 of a method of manufacturing a barrier garment (for example, one such as that shown in FIG. 30 ) from a sheet of latex as follows:
[0138] Step 1 ( 291 ): Prepare a sheet of latex or other material, as described herein, for a barrier garment for use in sexual relations. The sheet of material can be a continuous sheet or roll of material that is extended when needed either manually or via a machine.
[0139] Step 2 ( 292 ): Stamp out or cut out an I-shaped form in the sheet of material. For example, the stamp out can be by a machine having the shape predetermined. For example, the cut out can be done manually or by a machine to cut away with a blade, laser, or other device, unneeded material from the sheet of material. For example, the I-shaped form can be a variety of different measurements, depending upon the intended wearer or needs. In an embodiment, the I-shaped form has measurements according to those provided in FIG. 9D or FIG. 9E , or, for example, in FIG. 30 .
[0140] Step 3 ( 293 ): Apply an adhesive, liquid latex, UV-cured adhesive, tape, glue, thread, or any binding method available to approximately an outer edge of the garment. In an embodiment, the binding method is applied to only the outer edges of the longer horizontal region. See, e.g., FIG. 30 , binding method applied 309 , 310 .
[0141] Step 4 ( 294 ): Fold the I-shaped form in half so that the two horizontal regions of the I-shaped form meet flush against their top edges, and so that the outer edges having the binding method applied on the longer horizontal region are not touching the opposing shorter horizontal region.
[0142] Step 5 ( 295 ): Fold each of the outer edges of the longer horizontal region onto the shorter horizontal region so that the two bind via the binding method applied, forming a seam on each side.
[0143] Step 6 ( 296 ): Trim any unwanted material from the edges of the formed seams.
[0144] In FIG. 30 , an example garment material is shown in the either stamped out or cut out or made I-shaped form 300 . For example, in an embodiment, the measurement of a first horizontal region 308 is of a shorter width than the second horizontal region 307 . For example, in an embodiment, the first horizontal region 308 has a width of approximately 15 inches. For example, in an embodiment, the second horizontal region 307 has a width longer than approximately 15 inches. For example, the second horizontal region 307 has an approximate width of 15.5 inches, 16 inches, 17 inches, or longer. In an embodiment, the form 300 has a total length 301 which encompasses the first horizontal region length 302 , the vertical region length 303 , and the second horizontal region length 304 . For example, the form's total length 301 can be approximately 20 inches. For example, the form's total length 301 can be more or less than approximately 20 inches depending upon the size of the intended wearer or of the intended garment. For example, the first horizontal region length 302 and the second horizontal region length 304 are equal in length. For example, the horizontal region lengths 302 , 304 are each approximately 6 inches. For example, the horizontal region lengths 302 , 304 are each approximately 2 inches. For example, the horizontal region lengths 302 , 304 are a size that is useful for a specific type of garment (e.g., boyshort, panty, bikini, et al.). For example, one of the first or second horizontal region lengths 302 , 304 is longer in length than the second or first horizontal region lengths 304 , 302 , respectively. For example, when the first and second horizontal region lengths 302 , 304 are different, then, when binding the two horizontal regions as in FIG. 29 , for example, the side seams formed on the horizontal region can be ruched seams. The vertical region length 303 is equal in length to the vertical region length 305 plus the vertical region length 306 . In an embodiment, the vertical region lengths 305 , 306 are equal in length. For example, the vertical region lengths 305 , 306 are approximately 4 inches each. For example, the vertical region lengths 305 , 306 are approximately 8 inches each. In an embodiment, the vertical region lengths 305 , 306 are different in length. For example, the difference in length can be to handle a specific body type or desired fit or aesthetic look. The vertical region width 311 is less than the horizontal region widths 308 , 307 . For example, the vertical region width 311 is approximately 7 inches. For example, the vertical region width is greater than or less than approximately 7 inches. For example, the vertical width is wider than the gusset of fashion underwear.
[0145] In an example, referring to the form of FIG. 30 , the first horizontal region width 308 is approximately 15 inches, and the second horizontal region width 307 is more than approximately 15 inches, e.g., approximately 16 inches. The first and second horizontal region lengths 302 , 304 are each approximately 6 inches. The vertical region lengths 305 , 306 are each approximately 4 inches. The vertical region width 311 is approximately 7 inches.
[0146] In an example, referring to the form of FIG. 30 , the first horizontal region width 308 is approximately 15 inches, and the second horizontal region width 307 is more than approximately 15 inches, e.g., approximately 16 inches. The first and second horizontal region lengths 302 , 304 are each approximately 2 inches. The vertical region lengths 305 , 306 are each approximately 8 inches. The vertical region width 311 is approximately 7 inches.
[0147] For example, in FIG. 30 , the I-shaped garment form 300 shown can be stamped cut or somehow removed from a sheet of material such as latex or other material. A binding material can be applied to the outer edges 309 , 310 of at least one horizontal region. The I-shaped garment form 300 can then be folded in half along the dotted line shown, separating the vertical region lengths 305 , 306 in half or essentially half. The top edges of the horizontal regions can be flush. The outer edges having the binding material 309 , 310 can then be folded over to make a seam, thus forming a barrier garment embodiment.
[0148] In some embodiments, the barrier is formed as one integrated unit through dip molding or dipping. Some embodiments of the barrier, as well as other garments, are manufactured using a mold form or mandrel or former or mold. The mold is made of any suitable material, including but not limited to ceramic, glass, metal and/or alloy, and/or hard plastic. The garments that can be made with a mold form embodiment include the barrier, latex or non-latex novelty underwear, and other garments.
[0149] In an embodiment, dip molding allows for a thin material to be used as the garment. Current fashion undergarments are not dip molded. In an embodiment, dip molding allows for a variety of different solutions to be used as the undergarment—which allows for flexibility of taste, smell, texture, and appearance values. This also allows for a change of underlying material due to discovered attributes of viruses, user's allergies, and/or materials regulations. In an embodiment, dip molding as described allows for a manufacturer to avoid having to glue, sew, or otherwise attach pieces of a garment together to form a wearable garment. In an embodiment, dip molding allows for an inexpensive and/or biodegradable version of the garment to be manufactured, thus supporting, e.g., the disposability of the garment.
[0150] Some embodiments of the mold form are shaped in a semi-anatomical manner. FIGS. 25A to 25D show several embodiments of a semi-anatomical mold 250 that can be used to manufacture some embodiments of the barrier. This mold embodiment includes a general shape of a barrier. FIG. 25A shows a mold form that contains a genital-portion crease 253 and a back-portion crease 251 that can produce an embodiment of a barrier similar to that shown in FIGS. 1A to 1C , FIG. 2 , FIG. 3 , and FIGS. 4A to 4B . FIG. 25B shows a mold form that does not contain creases 251 or 253 and instead has a smooth genital portion 256 and a smooth torso and back portion 255 ; this mold embodiment can produce an embodiment of the barrier similar to that shown in FIGS. 5A to 5C , FIG. 6 , FIG. 7 , and FIGS. 8A to 8B . FIG. 25C and FIG. 25D show additional views of the embodiment of the mold shown in FIG. 25B . The bottom portion of the semi-anatomical mold embodiment can be flat 252 , can be conical 257 , or can be any other shape known in the art. When a barrier 10 is created using a semi-anatomical mold form 250 and is then flattened to cut leg openings, the conical shape 257 or another shape of the bottom can ease the cutting process while minimizing loss of material.
[0151] Other embodiments of the mold form are substantially planar and are not anatomically shaped. FIGS. 21A to 21E and FIGS. 22A to 22F show substantially planar mold embodiments. FIG. 21A shows a planar flat mold embodiment 210 . FIG. 21B and FIG. 21C show additional views of the embodiment of the mold shown in FIG. 21A . FIGS. 22A to 22D show planar curved mold embodiments 220 . Planar curved mold embodiments 220 create a similar shape of the material as do planar flat mold embodiments 210 once the material has been dried and removed from the mold, yet planar curved mold embodiments 220 take up less space in a production line and can allow for ease of dip molding, mass dip molding, and/or removal of the garment from the mold. Planar curved mold embodiments 220 can be curved in any manner to optimize their usability in an existing production line. The mold embodiments can produce an embodiment of the barrier similar to that shown in FIGS. 9A to 9E and FIGS. 10A to 10D , can produce other embodiments of the barrier, or can produce other garments. FIG. 22E and FIG. 22F show additional views of the substantially planar, curved mold embodiment 220 shown in FIG. 22A .
[0152] In some embodiments, semi-anatomical mold embodiment 250 , planar flat mold embodiment 210 , and/or planar curved mold embodiment 220 have a top portion 258 , 212 , or 222 (respectively) manufactured with any of the various fasteners available in the art, such that the molds 250 , 210 , and 220 can be attached to dip-molding machinery. In some embodiments, the mold embodiment is hollow. In some embodiments, the mold embodiment is not hollow. In some embodiments of planar mold forms, sides 214 , sides 224 , bottom 216 , and bottom 226 , are curved to minimize the appearance of edges in the garment. In some embodiments, the mold used is a planar mold that is bent or curved into a shape to allow for ease of dip molding, mass dip molding, and/or removal of the garment from the mold. In some embodiments, such as in FIG. 21D , the mold is a planar mold in a U-shape with curved corners 217 to allow for less waste of material and/or solution. In some embodiments, such as in FIG. 21E , the planar mold has a cut-out 219 in the middle of the bottom part of the mold simulating the legs 218 of a boy-short version. Planar curved mold embodiments similar to those shown in FIGS. 22A to 22F can also contain curved corners 217 or cut-out 219 .
[0153] Various embodiments of a manufacturing process to produce a barrier garment embodiment described herein can also be used to produce a latex, non-latex, or other material garment, underwear, etc. To manufacture an embodiment of barrier 10 or another garment, a process 200 illustrated in FIG. 20 is followed:
[0154] Step 1 ( 201 ): The mold is contacted with a solution or material that can be used to cause a second solution or other material to solidify; the former solution or material can be a coagulant. The mold is removed from the coagulant, such that a layer of coagulant of a desired thickness remains on the mold. The removal of the mold from the coagulant can be by machine, by hand, and/or by air. The desired thickness is dependent upon the necessary thickness of the coagulant needed for reacting with and/or acting in concert with the later solution or material(s) added, for example, one or more of the materials listed in Step 2 below. In some embodiments, Step 1 is repeated before Step 2 occurs. In some embodiments, the coagulant-coated mold is dried before Step 2 occurs.
[0155] Step 2 ( 202 ): The mold is contacted with a material such as natural rubber latex, synthetic latex, latex, butyl rubber, polyethylene, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene, polypropylene, olefin copolymer, styrene/butadiene rubber (SBR), polyurethane, polyisoprene, polyvinylidene chloride, polychloroprene, carboxylated acrylonitrile butadiene rubber, nitrile, graphene, spinifex grass, other grass, nanocellulose, vegan material, hypoallergenic material, organic material, superelastomer, other elastomer, other polymer, other copolymer, other polyolefin, and/or a combination of any of these materials, for a sufficient period of time to form a gelled and/or solidified coating of a desired thickness on the mold. The material can also include additives such as ammonia, water, soap, softening agents, accelerators, antioxidants, salts, stabilizers, defoamers, dispersants, wetting agents, de-aeraters, antifungal and antibacterial compounds, preservatives, pigments, anticoagulants, lubricants, potassium laureate, potassium oleate, potassium hydroxide, sulfur, zinc oxide, corn starch, sulfur, chlorine, chalk, silica, clay, and other additives. The material-coated mold is removed from the excess material. The removal of the mold from the material can be by machine, by hand, and/or by air. In some embodiments, this step is repeated one or more times before Step 4 occurs; in some embodiments, a different material is used upon a different contact with the mold.
[0156] Step 3 ( 203 ): The coated mold is dried. In an embodiment, the drying can involve any of the various methods available in the art.
[0157] Step 4 ( 204 ): The material is removed from the mold. In an embodiment, the removal from the mold is described herein. In an embodiment, the removal from the mold can involve any of the various methods available in the art.
[0158] Step 5 ( 205 ): Excess material is removed from the legs and/or the torso portions of the barrier. In an embodiment, the removal can involve die-cutting. In an embodiment, the removal can involve any of the various methods available in the art. In an embodiment, both the front and back of the garment are cut in a similar fashion at the same time with a cutting press.
[0159] In some embodiments, the mold is never in contact with and/or removed from the coagulant. For example, the manufacturing process begins with Step 2 as listed above.
[0160] In some embodiments, the mold is shifted and/or rotated while being contacted with material and/or coagulant to spread the material and/or coagulant along a portion of and/or the entire surface of the mold.
[0161] In some embodiments, the temperature of the mold is varied to extend or to limit the amount of time the mold is contacted with material and/or to change the properties of the material and/or the texture of the barrier.
[0162] In some embodiments, the mold is coated with material more than one time. In some embodiments, the mold is coated with more than one type of material.
[0163] In some embodiments, the thickness of the barrier can be varied by changing the ingredients in the coagulant and/or the material, and/or by dipping certain portions of the barrier more than once.
[0164] In some embodiments, the mold is contacted with coagulant by dipping said mold into said coagulant. In some embodiments, the mold is contacted with material by dipping said mold into said material. In some embodiments, the mold is contacted with coagulant by pouring said coagulant into said mold, and then excess coagulant is removed from said mold. In some embodiments, the mold is contacted with material by pouring said material into said mold, and then excess material is removed from said mold.
[0165] In some embodiments, between Step 3 and the end of the process described above, one or more of the following steps occurs, in any order: (a) the material-coated mold is leached to remove impurities; (b) the material is cured in an oven to set the material; (c) the material is vulcanized; (d) the edges of the material are thickened, by adding additional material, rolling the existing material, or by another means; and/or (e) powder is applied to said material.
[0166] In some embodiments, Step 4 is facilitated by applying powder to the material prior to removing it from the mold. In some embodiments, the material is removed from the mold by hand. In other embodiments, the material is removed from the mold by a stream of air.
[0167] FIG. 26 shows an embodiment of a manufacturing process 260 that can be used to manufacture a barrier 10 or another garment. A mold form embodiment 260 (shown in 261 ) is dipped into and removed from coagulant (C) (shown in 262 ) and then dipped into and removed from material (M) (shown in 263 ). 264 shows mold form embodiment 260 after it has been removed from material and is coated with material. 265 shows the material after it has dried and has been removed from said mold form embodiment. 266 shows where the leg holes will be cut.
[0168] FIG. 23 and FIG. 24 show embodiments of manufacturing processes 230 and 240 , respectively, that can be used to manufacture a barrier 10 or another garment. A planar flat mold form embodiment 210 or a planar curved mold form embodiment 220 (shown in 231 and 241 ) is dipped into and removed from coagulant (C) (shown in 232 and 242 ) and then dipped into and removed from material (M) (shown in 233 and 243 ). 234 shows planar flat mold form embodiment 210 after it has been removed from material and is coated with material. 244 shows planar curved mold form embodiment 220 after it has been removed from material and is coated with material. 235 shows the material after it has dried and has been removed from planar flat mold form embodiment 210 , and 235 shows the material after it has dried and has been removed from planar curved mold form embodiment 220 . 236 shows where the leg holes will be cut on planar flat mold form embodiment 210 , and 246 shows where the leg holes will be cut on planar curved mold form embodiment 220 .
[0169] In some embodiments, the barrier is manufactured so as to include an extra piece of material not removed from the thigh region. This extra piece of material still attached to the thigh region is used to cover the barrier when folded into a compact item. In some embodiment, the extra piece or extension of material extends from a portion of the top of the torso, and folds down since there is no opposing piece of material to serve as tension or friction inducing in order to keep the extended material from folding down. In some embodiments, a separate carrying case is provided to hold the garment. The case may be made of similar material, or a different material, than the garment.
[0170] The modifications listed herein and other modifications can be made by those in the art without departing from the ambit of the invention. Although the invention has been described above with reference to specific embodiments, the invention is not limited to the above embodiments and the specific configurations shown in the drawings. For example, some components shown can be combined with each other as one embodiment, and/or a component can be divided into several subcomponents, and/or any other known or available component can be added. The operation processes are also not limited to those shown in the examples. Those skilled in the art will appreciate that the invention can be implemented in other ways without departing from the substantive features of the invention. For example, features and embodiments described above can be combined with and without each other. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive. Other embodiments can be utilized and derived therefrom, such that structural and logical substitutions and changes can be made without departing from the scope of this disclosure. This Specification, therefore, is not to be taken in a limiting sense, along with the full range of equivalents to which such claims are entitled.
[0171] Such embodiments of the inventive subject matter can be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose can be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations and/or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of ordinary skill in the art upon reviewing the above description.
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A barrier garment apparatus and methods of its use are provided. In an embodiment, the barrier garment apparatus is shaped like an undergarment and worn during oral-vaginal and/or oral-anal sex to protect another person's mouth, lips, tongue, saliva, nose, and breath from contact with the wearer's vulva, perineum, anus, and surrounding areas, in order to prevent the transmission of bacteria, sexually transmitted infections, fluids, tastes, and scents. The barrier garment apparatus is thin, substantially non-porous, elastic, effectively skin-tight, and aesthetically attractive. The barrier garment apparatus can be, for example, a device, a panty, a boyshort, a short, a lingerie item, a barrier, a garment, an undergarment, a membrane, a prophylactic, and/or a system.
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TECHNICAL FIELD
[0001] The present invention relates generally to methods for making nanoparticles and, more particularly, to a method for making nanoparticles via reactive precipitation.
BACKGROUND
[0002] Nanoparticles, one of many advanced materials in the field of nanotechnology, have tremendous potential applications in many industries.
[0003] In the past decade, significant international research efforts have been directed towards the synthesis of nanoparticles. Many methods for preparing nanoparticles have been developed and reported. The methods can be classified as physical vapor deposition, chemical vapor deposition, sol-gel processing, wet chemical techniques, microemulsion processing, sonochemical processing, supercritical chemical processing, and so forth. However, no current technique can provide a reliable, simple, and low-cost method for production of nanoparticles of a specific size. Some current methods may produce particles of a desirable size, but with high cost. Other techniques suffer from an inability to control the distribution of sizes around a desired nanoparticle size. Still other techniques require specialized equipment, long processing times, or expensive special chemicals.
[0004] One potentially attractive wet chemical technique for synthesis of nanoparticles is reactive precipitation. Typical reactive precipitation processes are often carried out by mixing reactants in a stirred tank. A reactive precipitation process consists of three main steps: mixing reactants, chemical reaction, and crystal growth. However, typical reactive precipitation process can only provide macro-scaled mixing, which may limit the size and the homogeneity of the precipitate.
[0005] What is needed, therefore, is a simple, and low cost reactive precipitation process for making nanoparticles, which can provide nanoparticles with well-controlled particle-size and particle-size distribution.
SUMMARY
[0006] In one embodiment thereof, a method for making nanoparticles is provided. Firstly, a reaction chamber and at least two reactants are provided. One of the reactants is a liquid reactant, and at least one high-pressure injector is disposed in the reaction chamber. Secondly, the liquid reactant is atomized by the injector, and simultaneously mixes with the other reactants in the reaction chamber. Thereby, nanoparticles can be precipitated from the mixture of the reactants. Finally, the nanoparticles are isolated from the mixture.
[0007] Other advantages and novel features will become more apparent from the following detailed description of preferred embodiments when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Many aspects of the method for making nanoparticles can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the method for making nanoparticles. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0009] FIG. 1 is a flow chart of a method for making nanoparticles in accordance with the present invention;
[0010] FIG. 2 is a schematic view of an apparatus in accordance with a first preferred embodiment of the present invention;
[0011] FIG. 3 is a schematic view of an apparatus in accordance with a second preferred embodiment of the present invention,
[0012] FIG. 4 is a schematic view of an apparatus in accordance with a third preferred embodiment of the present invention; and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] FIG. 1 shows a method for making nanoparticles, including steps 100 to 400 . In step 100 , several reactants, one of which is a liquid reactant, are prepared. In step 200 , the liquid reactant is atomized and mixed with other reactants. In step 300 , a nano-structured powder is precipitated from the mixture of the reactants. In step 400 , the powder is isolated from the mixture, thus obtaining the nanoparticles.
[0014] Referring to FIG. 2 , an apparatus 6 for carrying out the above-mentioned method in accordance with a first preferred embodiment of the present invention, includes two solution containers 10 , two injectors 30 , an extra injector 40 , a reaction chamber 50 , a valve 60 , a pump 70 , a tank 80 , a stirrer 90 , and a plurality of pipes 190 . The injectors 30 are disposed on the inside wall 501 of the reaction chamber 50 . Each injector 30 is connected to a corresponding one of the solution containers 10 by the pipe 190 . The tank 80 is connected to the bottom of the reaction chamber 50 by the pipe 190 and the stirrer 90 is disposed in the tank 80 . The tank 80 , the valve 60 , the pump 70 , and the extra injector 40 are connected in series by the pipes 190 .
[0015] The first embodiment of the method for making nanoparticles is carried out by spray atomizing two liquid reactants to mix them together. The liquid reactants may be an aqueous sodium carbonate (Na 2 CO 3 ) solution and an aqueous strontium nitrate (Sr(NO 3 ) 2 ) solution.
[0016] Firstly, the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution are prepared in appropriate molarities and are then each introduced into their respective solution containers 10 .
[0017] Secondly, the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution are each atomized by their respective injectors 30 , and simultaneously sprayed into the reaction chamber 50 at a rate of 2.0 liters per hour to mix together. The injectors 30 may be high-pressure swirl injectors, and the atomization pressure of the solutions may be in the range of 2˜20 Mpa (megapascals). Therefore, micro-droplets of the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution are obtained with a diameter in the range of 20˜60 μm (micrometers), which allows the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution to mix on a molecular scale.
[0018] After spray mixing the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution in the reaction chamber 50 , nucleation, which forms nuclei of strontium carbonate (SrCO 3 ) particles, occurs in the chamber 50 according to the following reaction:
Sr(NO 3 ) 2 (l)+Na 2 CO 3 (l)→SrCO 3 (s)+2NaNO 3 (l)
[0019] Thirdly, the mixture of the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution is transported into the tank 80 via the pipe 190 , and agitated by the stirrer 90 . The growth of the nuclei of strontium carbonate (SrCO 3 ) particles may be well controlled with the agitation of the stirrer 90 . Thereby a final mixture consisting of sodium nitrate (NaNO 3 ), strontium carbonate (SrCO 3 ) particles, and a small amount of sodium carbonate (Na 2 CO 3 ) and strontium nitrate (Sr(NO 3 ) 2 ) is obtained. The mixture of the sodium carbonate (Na 2 CO 3 ) solution and the strontium nitrate (Sr(NO 3 ) 2 ) solution may be returned to the reaction chamber 50 via the valve 60 , the pump 70 and the extra injector 40 , and be reacted again to precipitate more strontium carbonate (SrCO 3 ).
[0020] Finally, the strontium carbonate (SrCO 3 ) particles are separated from the final mixture, and the strontium carbonate (SrCO 3 ) particles are dried to obtain an end-product nano-structured powder.
[0021] Referring to FIG. 3 , an apparatus 7 for carrying out the above-mentioned method in accordance with a second preferred embodiment of the present invention, includes a solution container 11 , an injector 12 , two gas nozzles 13 , two gas pressure controllers 131 , two gas supply apparatuses, a reaction chamber 14 , a valve 15 , a pump 16 , a stirrer 17 , a tank 18 and a plurality of pipes 19 . The injector 12 is disposed on the top of the inside wall 141 of the reaction chamber 14 and connected to the solution container 11 by the pipe 19 . The gas nozzles 13 are disposed on the inside wall 141 of the reaction chamber 14 and connected to the gas supply apparatuses 132 via the gas pressure controllers 131 to provide gases. The tank 18 is connected to the bottom of the reaction chamber 14 by the pipe 19 , and the stirrer 17 is disposed in the tank 18 . The tank 18 , the valve 15 , the pump 16 and the solution container 11 are connected in series by the pipes 19 .
[0022] The second embodiment of the method for making nanoparticles is carried out by spray atomizing a liquid reactant and mixing the liquid reactant with a gas reactant. The liquid reactant may be an aqueous sodium aluminate (NaAlO 2 ) solution, and the gas reactant may be carbon dioxide (CO 2 ).
[0023] Firstly, the aqueous sodium aluminate (NaAlO 2 ) solution is prepared in an appropriate molarity and introduced into the corresponding solution container 11 .
[0024] Secondly, the sodium aluminate (NaAlO 2 ) solution is atomized by the injector 12 and sprayed into the reaction chamber 14 at a rate of 2.0 liters per hour. Simultaneously, a carbon dioxide (CO 2 ) gas provided by the gas supply apparatuses 132 is also injected into the reaction chamber 14 via the gas nozzles 13 , and meets the atomized sodium aluminate (NaAlO 2 ) solution. The injector 12 may be a high-pressure swirl injector and the atomization pressure of the solution may be in the range of 2˜20 Mpa (megapascals). Therefore, micro-droplets of the sodium aluminate (NaAlO 2 ) solution are obtained with a diameter in the range of 20-60 μm (micrometers), which allows the sodium aluminate (NaAlO 2 ) solution to mix with the carbon dioxide (CO 2 ) on a molecular scale.
[0025] After spray mixing the sodium aluminate (NaAlO 2 ) solution and the carbon dioxide (CO 2 ) in the chamber 14 , nucleation, which forms nuclei of aluminum hydroxide (Al(OH) 3 ) particles, occurs in the reaction chamber 14 according to the following reaction:
2NaAlO 2 (l)+3H 2 O(l)+CO 2 (g)→Na 2 CO 3 (l)+2Al(OH) 3 (s)
[0026] Thirdly, the mixture of the sodium aluminate (NaAlO 2 ) solution and the carbon dioxide (CO 2 ) is transported into the tank 18 via the pipe 19 , and agitated by the stirrer 17 . The growth of nuclei of the aluminum hydroxide (Al(OH) 3 ) may be well controlled with agitation of the stirrer 17 . Thereby a final mixture consisting of sodium carbonate (Na 2 CO 3 ), aluminum hydroxide (Al(OH) 3 ) particles, and a small amount of aluminate (NaAlO 2 ) that has incompletely reacted with the carbon dioxide (CO 2 ) is obtained. The mixture of the sodium aluminate (NaAlO 2 ) solution and the carbon dioxide (CO 2 ) may be returned into the reaction chamber 14 via the valve 15 , the pump 16 , the solution container 11 and the injector 12 , for reaction with carbon dioxide (CO 2 ) again to precipitate more aluminum hydroxide (Al(OH) 3 ).
[0027] Finally, the aluminum hydroxide (Al(OH) 3 ) particles are separated from the final mixture, and the aluminum hydroxide (Al(OH) 3 ) particles are dried to obtain an end-product nano-structured powder.
[0028] Referring to FIG. 4 , an apparatus 8 for carrying out the above-mentioned method in accordance with a third preferred embodiment of the present invention, includes a solution container 21 , an injector 22 , two gas nozzles 23 , two gas pressure controllers 231 , two powder nozzles 330 , two powder supply apparatuses 331 , a reaction chamber 24 , a valve 25 , a pump 26 , a stirrer 27 , a tank 28 and a plurality of pipes 29 . The injector 22 is disposed on the top of the inside wall 241 of the reaction chamber 24 and connected to the solution container 21 by the pipe 29 . The gas nozzles 23 are disposed on the inside wall 241 of the reaction chamber 24 and connected to a corresponding one of the gas supply apparatuses 232 via the gas pressure lock 231 to provide gases. The powder nozzles 330 are disposed on the inside wall 241 of the reaction chamber 24 and connected to a corresponding one of the powder supply apparatuses 331 . The tank 28 is connected to the bottom of the reaction chamber 24 by the pipe 29 , and the stirrer 27 is disposed in the tank 28 . The tank 28 , the valve 25 , the pump 26 , and the solution container 21 are connected in series by the pipes 29 .
[0029] The third embodiment of the method for making nanoparticles is carried out by spray atomizing a liquid reactant and mixing the liquid reactant with a gas reactant and a solid reactant. The liquid reactant, the gas reactant, and the solid reactant may be a distilled water, a carbon dioxide (CO 2 ) gas, and a calcium hydroxide (Ca(OH) 2 ) powder respectively.
[0030] Firstly, the distilled water, the carbon dioxide (CO 2 ), and the calcium hydroxide (Ca(OH) 2 ) powder are provided.
[0031] Secondly, the water is atomized by the injector 22 and sprayed into the reaction chamber 24 at a rate of 2.0 liters per hour. Simultaneously, the carbon dioxide (CO 2 ) gas and the calcium hydroxide (Ca(OH) 2 ) powder are also injected into the reaction chamber 24 via the gas nozzles 23 and the powder nozzles 30 respectively, and meet the atomized water to mix with each other. The injector 22 may be a high-pressure swirl injector and the atomization pressure of the solution may be in the range of 2˜20 Mpa (megapascals). Therefore, micro-droplets of the water can be obtained with a diameter in the range of 20-60 μm (micrometers), which allows the distilled water to mix with the calcium hydroxide (Ca(OH) 2 ) powder and the carbon dioxide (CO 2 ) on a molecular scale.
[0032] After the spray mixing of the distilled water, the calcium hydroxide (Ca(OH) 2 ) powder and the carbon dioxide (CO 2 ) in the reaction chamber 24 , nucleation, which forms nuclei of calcium carbonate (CaCO 3 ) particles occurs in the chamber 24 according to the following reaction:
Ca(OH) 2 (l)+H 2 O(l)+CO 2 (g)→CaCO 3 (s)+2H 2 O(l)
[0033] Thirdly, the mixture of the water, the calcium hydroxide (Ca(OH) 2 ) powder and the carbon dioxide (CO 2 ) is transported into the tank 28 via the pipe 29 , and agitated by the stirrer 27 . The growth of nuclei of the calcium carbonate (CaCO 3 ) may be well controlled with agitation of the stirrer 17 . Thereby a final mixture consisting of water, calcium carbonate (CaCO 3 ) particles, and a small amount of calcium hydroxide (Ca(OH) 2 ) that has incompletely reacted with the carbon dioxide (CO 2 ) is obtained. The mixture of the distilled water, the calcium hydroxide (Ca(OH) 2 ) powder and the carbon dioxide (CO 2 ) may be returned to the reaction chamber 24 via the valve 25 , the pump 26 , the solution container 21 and the injector 22 in succession, and reacted with carbon dioxide (CO 2 ) again to precipitate more calcium carbonate (CaCO 3 ).
[0034] Finally, the calcium carbonate (CaCO 3 ) particles are separated from the final mixture, and the calcium carbonate (CaCO 3 ) particles are dried to obtain an end-product nano-structured powder.
[0035] It is to be understood, however, that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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In a method for making nanoparticles, a reaction chamber and at least two reactants are firstly provided. One of the reactants is a liquid reactant, and at least one high-pressure injector is disposed in the reaction. Secondly, the liquid reactant is atomized by the injector, and simultaneously mixes with the other reactants in the reaction chamber. Nanoparticles can be precipitated from the mixture of the reactants thereby. Finally, the nanoparticles are isolated from the mixture. The reactants can mix on the micro-scale via the atomization of the liquid reactant, which efficiently reduces the mixing scale and increase the effective contact area between the reactants. Thus the particle-size distribution of the precipitate can easily be controlled.
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FIELD OF INVENTION
This invention related to heat shrinkable labels and to related containers employing such labels.
BACKGROUND
In the packaging of liquids, metal and plastic cans are employed which bear external printing. The printing identifies the source of the packaged substances and exhibits other information such as weight and analysis of the contents. This printing has heretofore been directly applied to the cans, which fact greatly limits the flexibility of the user's inventory. For example, if a packager or canner of soda orders a large number of pre-printed cans and desires to switch to a different liquid soda to be placed therein, the pre-printed cans become useless.
In any event, it is recognized that it would be a matter of great convenience, if it were to be possible for canners to be able to stock unprinted cans and to be able to apply labels thereto subsequently and selectively as it becomes determined specifically what materials are to be canned therein.
Many labels are available for the delayed labelling of metal and plastic cans. Paper labels have been known for years. However, direct printing has now established standards which canners are reluctant to give up. Direct printing is glossy, the colors and data exhibited are more easily perceived, the printing is generally more scuff resistant and so forth.
There are also specific problems which have been developed which derive from the specific shapes of cans which have been developed. That is, modern day cans taper inwardly at the upper and lower extremities thereof and a label must either avoid extending to these extremities or must conform closely to the shapes thereof.
Many plastic or copolymer labels have been developed for various purposes. These include the labels disclosed in U.S. Pat. Nos. 3,955,020; 3,979,000; 4,038,446; 4,120,225; 4,172,152; 4,253,892; 4,281,769; and Re. 30,805. In U.S. Pat. No. 3,955,020 J. Cavanagh discloses a glass container wrapped in a plastic laminate which is held to the glass by an adhesive. The laminate protects the user against the shattering of the glass. The laminate is not intended to cup around tapered portions of the associated bottle inasmuch as this is accomplished by spraying onto these tapered portions a plastic material which thereby conforms to the tapered shape. Alternatively, covering structures are described which have been preformed and are shrunk fit onto the associated bottle.
J. Karabedian discloses in U.S. Pat. No. 3,797,000 a glass container which is provided externally thereof with a heat shrunk cellular thermoplastic member circumferentially and snugly engaging the sidewall portion thereof. The thermoplastic member which is heat shrunk onto the glass container is a layer of polystyrene into which is incorporated a copolymer of ethylene and alkyl ester or the like. The intention is to provide improved gas retention characteristics. Over the first layer is provided a non-cellular polymeric material preponderantly of ethylene moieties having other substances incorporated into the same. The non-cellular layer is disposed between the container and the cellular layer.
In U.S. Pat. No. 4,038,446, R. Rhoads discloses a container provided with a heat shrunk cellular thermoplastic member engaging a sidewall portion of the container. The thermoplastic member is a laminate of a closed cellular polymeric layer in which the polymer is of predominantly olefin moieties with a non-cellular polymeric layer thereon of predominantly olefin moieties.
E. Bailey discloses in U.S. Pat. No. 4,129,225 a glass bottle with a covering of an organic polymeric material such as foamed polystyrene or the like.
In U.S. Pat. No. 4,172,152, R. Carlisle discloses a container structure for carbonated beverages with a multiple wall structure having an inner wall and an outer wall. The inner wall is formed of a material through which a gas might be able to migrate. The outer wall is formed of a material which is impervious to the gas. The walls are formed of thin heat sealable sheet material to provide a flexible thermally insulated carbonated beverage container.
In U.S. Pat. No. 4,253,892, J. D'Angelo et al discloses a bag defined between layers of polypropylene microfoam material with protective outer kraft paper layers. The kraft paper is burned away during heat sealing of a polyethylene coating on the inner surfaces of the kraft paper.
R. Ignell discloses in U.S. Pat. No. 4,281,769 a container with dished end portions. A tubular member is included which is formed of a laminate including a layer of polypropylene, polyvinyl chloride and a polyester.
R. Rhoads discloses in U.S. Pat. No. Re. 30,805 a heat shrunk cellular thermoplastic member in which olefin moieties predominate.
None of the above-noted labels or other known labels would be useful for the labelling of cans as contemplated in accordance with the invention. The reasons for this unacceptability are of wide variety. Known labels would distort during the process of applying the same to cans of the afore-described shape such as by, for example, heat shrinking. The printing thereon would be abused by handling during label application. Such labels, moreover, would not be able to conform readily and intimately to the can shapes especially at the tapered extremities. Printing on the labels would be difficult due to stretching.
In fact, there are many more reasons why previously available labels would not be satisfactory for the uses contemplated in accordance with the invention and these reasons have led to the development of the novel label discussed hereinafter.
SUMMARY OF INVENTION
It is an object of the invention to provide an improved label capable of avoiding the various problems noted above as well as other problems which characterize the application of labels to containers such as metal and plastic cans.
It is another object of the invention to enable packagers to stock plain containers devoid of decoration or information and to apply labels to the containers immediately preceding the filling of the containers.
Yet another object of the invention is to provide an improved label of laminated materials, the characteristics of which are beneficially combined to result in clearly displayed printing which may be perceived without distortion while adequate physical strength is maintained in the label to withstand handling by mechanical equipment during the labelling process.
Still another object of the invention is to enable the canner, who is not a can manufacturer, to do his own labelling despite the use of can shapes which are not perfectly cylindrical.
It is yet a further object of the invention to provide an improved label of multi-ply construction to obtain characteristics which would not be provided by any single layer of the label.
Still another object is to provide an improved label adapted to heat shrinkage while resistant to breakage and stretching as might otherwise result during printing and application procedures.
Another object is to enable the use of water-based inks in the printing of labels to be used in a heat shrinking process.
Yet another object is to provide a moisture and scuff proof label having a layer which functions as a lubricated layer when passing through label applying equipment and after it is applied, thereby facilitating the handling of a multitude of such containers in gross.
In achieving the above and other objects of the invention there is contemplated the provision of a label or label material comprising a lamination of first and second layers. The lamination has a determinable longitudinal direction. The first layer is of a material which is both dimensionally stable at room temperature and shrinkable at temperatures substantially elevated above room temperature. The first layer is of a material which is resistant to elongation at least in the aforesaid longitudinal direction. The first layer is moreover an ink receptive layer having an ink receptive surface adjacent the second layer. In accordance with the invention, printing is comprised which is located on a surface between the layers. The material of the second layer is transparent and free of optical distortion whereby to permit clear perception of the aforesaid printing. The material of the second layer is moreover glossy and slippery to enable the second layer to function as a lubricated layer during application. Still further the material of the second layer is moisture resistant, resistant to dimensional change at elevated temperatures and scuff resistant.
In further accordance with the invention, a bending material is located between the aforesaid layers. Moreover the materials of the first and second layers are respectively by-axially oriented and non-oriented. In accordance with a preferred embodiment of the invention, the first layer is of biaxially oriented polystyrene having a thickness of 0.0005-0.003 inches. The second layer is preferably of non-oriented polypropylene having a thickness of 0.00025-0.002 inches. Preferably these layers have a thickness in the order of magnitude of about 0.001 inches.
According to a preferred embodiment of the invention, the first layer is opaque thereby concealing the surface of the container being covered. The bonding material mentioned above may be a urethane adhesive. The polypropylene which has been mentioned is preferably a non-oriented polypropylene such as cast or blown polypropylene which has not been substantially oriented such as by reheating, stretching and/or setting. The label material is preferably provided in the form of a roll including an inner core with a diameter in the order of magnitude of six inches. The material is adapted to form labels having dimensions, for example, in the order of magnitude of 45/8 inches in width and 8.6395 inches in length. Other dimensions are also possible.
According to another aspect of the invention there is provided a container comprising a cylindrical wall of metal or plastic, a top and a bottom on said wall to form therewith a storage space, said wall tapering inwardly adjacent the top and bottom to form top and bottom tapered portions. A heat shrinkable layer, of the form noted above, encircles the wall and conforms to the tapered portions. As aforesaid, the label comprises first and second layers in laminated relationship and of a form which has been referred to hereinabove.
The above and other objects, advantages and features of the invention will become more apparent from the detailed description which follows hereinbelow as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF DRAWING
In the drawing:
FIG. 1 is a diagrammatic illustration of the application of the label to a glass bottle container in accordance with the prior art;
FIG. 2 is a partially sectional and broken away view of a metal can to which has been applied a label in accordance with the invention;
FIG. 3 is a fragmentary cross sectional view of a lamination employed as a label in accordance with the invention; and
FIG. 4 is a diagrammatic view of the lamination in the form of a roll.
DETAILED DESCRIPTION
FIG. 1 illustrates the application of heat shrinking labels onto a glass or plastic bottle in accordance with the description in U.S. Pat. No. 4,416,714 (W. Hoffmann). In this prior art patent is disclosed a machine and method for applying heat shrinkable labels having cylindrical body portions and end portions adjoining the body portion and sloping inwardly with respect thereto. The label is of a length such that its leading end overlaps the trailing end and a seam is formred at the overlap. The label is secured to the article by adhesive between the leading end and the container and by adhesive between the overlapping leading end and trailing end. The label is of a width such that it projects beyond the junctions of the end portions with the body portion resulting in free standing edges. In FIG. 1 the container is indicated at 10, with the label been indicated at 12, the free standing portions are indicated at 14 and 16.
In further accordance with the aforesaid prior art patent, tongues indicated at 18 and 20 are interposed between heat sources (not shown) and the label extremities. These tongues serve as heat shields to moderate the application of heat to the label. Each of the tongues is formed with a shape such that, as it is extended, it acts as a wedge to urge the associated free standing edge toward the article. Heat is applied so that the free standing edges are shrunk so as to conform to the tapered portions 22 and 24 of the container 10.
The invention is concerned with applying the afore-described techniques in the labelling of metallic or plastic cans and further to the object of avoiding the need for employing mechanical elements such as tongues 18 and 20 for the purpose of conforming the applied label to the tapered portions of the associated container. FIG. 2 illustrates a can 30 having a cylindrical sidewall 32 and upper tapered portion 34 and lower tapered portion 36. The can is moreover provided with a bottom 38 and a top 40. To this can is applied a label as indicated at 42. This label eventually acquires a tapered portion 44 associated with tapered portion 34 and a tapered portion 46 associated with tapered portion 36. At A in FIG. 2 is illustrated the magnitude of the deflection of the tapered portion 34. This would generally be found to lie in the dimensional range of 1/16-1/4 of an inch. Dimension B in FIG. 2 illustrates the magnitude of deflection of the lower sloped portion 36. Dimension B lies in the range of from about 1/8-3/8 of an inch.
FIG. 3 illustrates a fragmentary portion of a lamination constituting a label according to the invention. This label is shown applied in FIG. 2. In FIG. 3 the lamination is shown as including a layer 50 associated with a second layer 52. Ink printing is indicated at 54 and a bonding agent or adhesive is indicated at 56. The layer 50 is applied adjacent the can or container and the layer 52 is outermost relative to the container. The purpose and function of these layers will be discussed in greater detail hereinbelow.
The preferred form in which the labels are presented to the canner or packager for use is illustrated in FIG. 4. Therein is illustrated a roll 60 having a leading edge portion 62 and provided with an inner core 64. The diameter of this inner core is indicated at C. It is preferably in the order of magnitude of 6 inches. The diameter of the roll in its original form is generally and preferably in the order of magnitude of 24 inches. The width W indicated with respect to leading edge portion 62, may comprise the width of one or more labels. Each label will have a width in the order of magnitude of 4 and 5/8 inches. Each label in a preferred application will have a length in the order of magnitude of 8.6395 inches.
Referring again in FIG. 3, layer 50 will preferably have a thickness in the order of magnitude of 0.0005 to 0.003 inches. Layer 52 will preferably have a thickness in the order of 0.00025 to 0.002 inches. Layer 50 more specifically has a preferred dimension of 0.001 inches plus or minus 15%. The combined materials preferably provide characteristics in cooperative manner to be enumerated hereinbelow.
Layer 50 is preferably of polystyrene. The purpose of this layer is to provide a heat shrinkable material which is stable at room temperature. Layer 50 is moreover to provide a printable surface as indicated at 60. The material must moreover be stiff enough and resistant to elongation such as to enable handling on a printing machine. Preferably the material of layer 50 may be opaque thereby to conceal the material of the container to which it is applied. It may also be clear for certain applications. Furthermore, the material is preferably adaptable to being metallized. Its thickness is a compromise between strength, stiffness and cost.
The lamination of layer 50 with layer 52 can be effected by means of extrusion lamination or co-extrusion. In the preferred form the layers are bonded together by a suitable bonding agent. One such suitable bonding agent is a urethane curing type adhesive. One specific such adhesive is MORTON THIOKOL LAMAL HSA. MORTON THIOKOL is located at 110 N. Wacker Drive, Chicago, Ill.
The ink indicated at 54 may be a water-based or solvent-based ink. The ink is trapped between the two layers and is protected thereby. One such ink is identified as Multi-Lam provided by Converters Ink Company of 1301 S. Park Avenue, Linden, N.J.
A polystyrene employed in accordance with the invention is one mil XD65019.01 (white) provided by Dow Chemical Corp. of Midland, Mich. This polystyrene is characterized by a very low level elongation and is in fact highly resistant to elongation. This characteristic is important in providing for the printing operation since any non-negligible amount of elongation could provide distortion in the printing. The sides indicated at 70 and 72 in FIG. 3 should be receptive to various adhesives as may be necessary to apply the label to the associated contianer and also to bond the overlaping ends of the label.
Layer 52 is formed of non-oriented polypropylene such as Extrel 11, provided by Exxon Chemical Americas of Park Terrace South, Houston, Tex. This includes cast and blown polypropylene. The function of layer 52 is to provide a clear transparent layer through which the print on layer 50 may be seen without distortion. The surface indicated at 72 in FIG. 3 is preferably glossy with a coefficient of friction adapted to make the same extremely slippery so that the surface acts as a lubricated surface.
This characteristic has two goals. One of these goals is to provide for "lubrication" of the label with respect to the equipment which applies the label to the associated can. The second goal is to provide that the cans have slippery surfaces to enable the cans to be processed after the cans have been formed and are herded together in mass production handling techniques. Thus the outer surface 72 must provide for sliding of the labels over the plastic or metal elements in the labelling machinery and must also provide for friction-free encounters between the cans themselves when they are grouped together and shuffled along in processing equipment.
In addition to the aforesaid characteristics, layer 52 must be of a material which is resistant to moisture and heat shrinkage and which is also scuff and puncture resistant. It must also be strong at least in tensile or longitudinal direction, to prevent undue elongation or breakage of the label as it is being employed in the labelling equipment.
The combination of materials specifically employed (namely polystyrene and polyproplylene) has been found peculiarly capable of resisting elongation, providing adequate tensile strength and providing resistance to spurious tear, while nevertheless providing a facility for directional tearing, which aids in cutting the labels. The resultant label is normally formable without requiring mechanical assistance. The temperature applied for shrinking will generally lie in the order of magnitude of 250°-300° F. This heat need only be applied for a period of 3 to 4 seconds to enable obtaining the desired result.
The polypropylene, employed in accordance with the invention, is preferably non-oriented polypropylene. No known substitute has been found for this material, while taking into account the economical aspects of providing labels in accordance with the invention. Labels of the invention provide a skin type wrap which is capable of being heat shrunk at the top and bottom into conformation with the sloped upper and bottom portions of metal and plastic cans or the like. Bottles may also be labeled with the lamination of the invention. The materials employed affect one another, since the polyestyrene if employed alone would distort and scuff, whereas the polypropylene would stretch too much to permit the use thereof. No known single material would be heat shrinkable and have the other characteristics essential to the invention.
The invention may be considered directed to a lamination suitable for use as a label material or may be considered in the form of a container complete with the heat shrunk label applied thereto.
The aforesaid XD65019.01 film is a rubber modified high impact styrene of the following properties:
______________________________________Property Test Method Typical Value.sup.1______________________________________Ultimate Tensile Strength, psi ASTM D-882 MD 4,800 TD 3,100Yield Tensile Strength, psi ASTM D-882 MD 4,400 TD 3,100Ultimate Elongation, % ASTM D-882 MD 25 TD 251% Secant Modulus, psi ASTM D-882 MD 300,000 TD 250,000Opacity TAPPI T-425 78Yield (based on nominal 1.0 mil) 25,000in.sup.2 /#______________________________________
There will now be obvious to those skilled in the art, many modifications and variations of the construction set forth hereinabove. These modifications and variations will not depart from the scope of the invention if defined by the following claims.
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A label is provided consisting of a lamination of two layers. One of these layers is a printable layer capable of being heat shrunk onto a can the upper and bottom parts of which are tapered inwardly. The preferred material for this layer is polystyrene. The other layer is polypropylene the function of which is to add strength to the first layer and to trap there against the printing ink which is printed onto the polystyrene layer. The polypropylene permits undistorted perception of the printed material. The two materials cooperate to permit printing and label application processes.
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CROSS REFERENCED APPLICATIONS
[0001] This application is a continuation-in part of co-pending U.S. patent application Ser. No. 10/036,303, filed Dec. 28, 2001, which is a divisional of U.S. patent application Ser. No. 09/741,949, filed Dec. 20, 2000, now abandoned.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to MOS transistors. More particularly, the present invention relates to MOS transistors having improved total radiation-induced leakage currents.
[0004] 2. The Prior Art
[0005] It is known that MOS transistors exhibit increased radiation-induced leakage along channel ends at the birds beak region of the field oxide edges caused by electron-hole pair charge buildup. This effect is only seen in n-channel devices. P-channel devices are not negatively affected. It is known to reduce this radiation-induced current leakage by increasing the boron field channel-stop implant dose under the birds beak edges of the field oxide isolation regions. Typically, field channel-stop implant doses may be increased from about 6e13 up to about 1.2e14.
[0006] While increasing the field channel-stop implant dose is known to decrease this radiation-induced current leakage, the increased field channel-stop implant dose has the unwanted effect of decreasing the junction breakdown voltage of the MOS transistor. The need to avoid unwanted lowering of the junction breakdown of the transistor limits the use of increased field channel-stop implant dose as a means of decreasing the radiation-induced current leakage in MOS transistors.
[0007] Recently, shallow-trench isolation has been used as an isolation technique. Use of this technique, in which trenches are etched in the silicon substrate and filled with deposited silicon dioxide, provides a deep isolation and a much more planarized surface than can be obtained by using the traditional field oxide isolation techniques. In transistors formed using shallow-trench isolation techniques, the top surface of the silicon dioxide at the edges of the trenches can lie below the level of the bottom of the source/drain implants in the active transistor regions. The polysilicon gates formed over the gate oxides of the transistors follow the contours formed by the lowered edges of the silicon dioxide used to fill the trenches and thus can also extend vertically below the level of the bottom of the source/drain implants in the active transistor regions. Because there is no field channel-stop implant in the shallow-trench isolation structures, radiation-induced current leakage can occur at the edges of the source and drain regions where the polysilicon transistor gate extends below the source and drain implants.
[0008] Attempts have been made to correct this problem by modifying the geometries of the silicon and silicon dioxide interface at the trench edges. These attempts have met with varying degrees of success.
SUMMARY
[0009] A shallow-trench isolation transistor according to the present invention includes a sidewall channel-stop implant around the side and bottom walls of the trench. This implant surrounds the transistor and extends below the level of the source and drain implants in the active transistor region and significantly lowers the radiation-induced leakage currents that would otherwise exist in the shallow-trench isolation transistor.
[0010] A method for fabricating a shallow-trench isolation transistor according to the present invention includes forming isolation trenches to define active regions in a silicon substrate; performing sidewall isolation impants on the side and bottom walls of the isolation trenches in the n-channel (p-well) areas only; depositing a dielectric isolation material in the isolation trenches; planarizing the top surface of the silicon substrate and the dielectric isolation material using CMP techniques; forming a gate oxide layer over the active regions in the silicon substrate; forming and defining gate regions over the gate oxide layer in the active regions in the silicon substrate; and forming source and drain regions in the active regions in the silicon substrate. The method of the present invention requires the use of one additional mask for sidewall implant in the n-channel (p-well) areas only.
[0011] Another exemplary method is disclosed. The method for fabricating a shallow-trench isolation transistor on a semi-conductor substrate includes forming a single isolation trench having a uniform cross section to define an active region in the silicon substrate. The method includes performing sidewall isolation implants on the side and bottom walls of said isolation trench. The method includes depositing a dielectric isolation material in said isolation trench. The method includes planarizing the top surface of said silicon substrate and said dielectric isolation material. The method includes forming a gate oxide layer over said active region in said silicon substrate. The method includes forming and defining gate regions over said oxide layer in said active region in said silicon substrate. The method includes forming source and drain regions in the active region in the silicon substrate.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0012] FIG. 1 is a cross-sectional view of a conventional field oxide isolated MOS transistor.
[0013] FIG. 2 is a cross-sectional view of a conventional shallow-trench isolated MOS transistor.
[0014] FIG. 3 is a cross-sectional view of a shallow-trench isolated MOS transistor according to the present invention.
[0015] FIGS. 4A through 4C are cross-sectional views of a shallow-trench isolated MOS transistor showing the structure formed at different times during the progression of a fabrication process according to the method of the present invention.
[0016] FIG. 5 is a top view of a shallow-trench isolated MOS transistor according to the present invention.
DETAILED DESCRIPTION
[0017] Those of ordinary skill in the art will realize that the following description of the present invention is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons.
[0018] Referring first to FIG. 1 , a cross-sectional view taken at the channel end of a conventional field oxide isolated MOS transistor 10 is shown. Transistor 10 is formed in silicon substrate 12 between two field oxide isolation regions 14 as is well known in the art. Gate oxide layer 16 insulates polysilicon gate 18 from the surface of substrate 12 . Channel stop field implants 20 , usually comprising a boron implant, underlie the birds beak edges of the field oxide regions.
[0019] The structure of FIG. 1 is well known in the art. It is known that MOS transistors such as the one illustrated in FIG. 1 exhibit increased radiation-induced leakage along channel ends at the birds beaks at the edges of the field oxide regions 14 caused by electron-hole pair charge buildup. It is known to reduce this radiation-induced current leakage by increasing the dose of the field channel-stop implant 14 under the birds beak edges of the field oxide isolation regions 14 . Typically, field channel-stop implant doses may be increased from about 6e13 atoms/cm 2 up to about 1.2e14 atoms/cm 2 .
[0020] As previously noted, while increasing the field channel-stop implant dose is known to decrease this radiation-induced current leakage, the increased field channel-stop implant dose has the unwanted effect of decreasing the junction breakdown voltage of the MOS transistor 10 . The need to avoid unwanted lowering of the junction breakdown of the MOS transistor 10 limits the use of increased field channel-stop implant dose as a means of decreasing the radiation-induced current leakage in MOS transistors.
[0021] Referring now to FIG. 2 , a cross-sectional view taken at the channel end of a conventional shallow-trench isolated MOS transistor 30 is shown. Transistor 30 is formed in silicon substrate 32 surrounded by a shallow trench isolation structure filled with deposited silicon dioxide 34 as is well known in the art. Gate oxide layer 36 insulates polysilicon gate 38 from the surface of substrate 32 . Unlike transistor 10 of FIG. 1 , no channel-stop field implants are employed.
[0022] In transistors 32 formed using shallow-trench isolation techniques, edges 40 of the top surface of the silicon dioxide regions 34 at the edges of the trenches can lie below the level of the bottom of the source/drain implants (not shown) in the active transistor regions 42 . The polysilicon gates 38 formed over the gate oxides 36 of the transistors 32 follow the contours formed by the lowered top surfaces 40 of the silicon dioxide regions 34 used to fill the trenches and thus can also extend vertically below the level of the bottom of the source/drain implants in the active transistor regions 42 . Because there is no field channel-stop implant in the gate edge region of conventional shallow-trench isolation structures, radiation-induced current leakage can occur at the edges of the source and drain regions where the polysilicon gate 38 of MOS transistor 32 extends below the source and drain implants.
[0023] Referring now to FIG. 3 , a cross-sectional view of a shallow-trench isolated MOS transistor 50 illustrates the features of the present invention. Shallow-trench isolated MOS transistor 50 is formed in silicon substrate 52 and is surrounded by a shallow portion, shown in FIG. 3 , of an annular shallow trench isolation structure filled with deposited silicon dioxide 54 as in the prior-art shallow-trench isolated MOS transistor of FIG. 2 . Gate oxide layer 56 insulates polysilicon gate 58 from the surface of substrate 25 illustrates a top view of transistor 50 in which trench 50 has a front portion, rear portion, and side portions which surround the active region of transistor 50 .
[0024] Unlike the prior-art shallow-trench isolated MOS transistor of FIG. 2 , a sidewall implant 60 is formed in the walls of the isolation trenches prior to the deposition of the oxide fill regions 54 . The implant is performed at an angle so that it penetrates the sidewalls of the trenches. The substrate may be rotated or other techniques may be employed to assure implanting all four of the sidewalls shown in FIG. 3 as well as implanting on all four sidewalls of the front and rear portions of the trench not shown in FIG. 3 .
[0025] As will be appreciated by persons of ordinary skill in the art, different species will be used for the sidewall implant 60 depending on whether N-Channel or P-Channel MOS transistors are being formed. For example, to form N-Channel MOS transistors according to the present invention, boron may be implanted at a dose of about 2.0e12. P-Channel MOS transistors do not need the sidewall trench implant according to the present invention.
[0026] Turning now to FIGS. 4A through 4C , a method for fabricating shallow-trench isolated MOS transistors according to the present invention is illustrated. FIGS. 4A through 4C are cross-sectional views of a shallow-trench isolated MOS transistor showing the structure formed at different times during the progression of a fabrication process according to the method of the present invention. One skilled in the art will recognize that the shallow isolation trench 62 completely surrounds transistor 50 . However, to better describe the invention, FIGS. 4A to 4 C only illustrate cross sections showing two sides of trench surrounding transistor 50 . Structures in FIGS. 4A through 4C corresponding to structures in FIG. 3 will be given the same reference numerals as seen in FIG. 3 .
[0027] Referring now to FIG. 4A , substrate 52 is shown after formation of annular isolation trench 62 . As will be appreciated by persons of ordinary skill in the art, isolation trench 62 is formed using conventional masking and etching techniques to a depth of about 400 nm, after which the mask layer is removed using conventional semiconductor processing techniques.
[0028] As shown in FIG. 1 , sidewall implants 60 are formed in the side and bottom walls of isolation trench 62 . As will be appreciated by persons of ordinary skill in the art, sidewall implants 60 may be formed using an angled ion-implant process during which the substrate 52 may be rotated as known in the art to assure coverage of all of the sidewalls of the isolation trench 62 . FIG. 4A shows the structure existing after the performance of the sidewall implant step for one type of transistor before removal of implant mask layer 64 .
[0029] In accordance with the present invention, sidewall implants for isolation of N-Channel MOS transistors according to the present invention may be performed by, for example, implanting boron at a concentration of about 2.0e12 at an angle of about 25°.
[0030] Referring now to FIG. 4B , implant mask layer 64 has been removed. Silicon dioxide regions 54 have been formed in annular isolation trench 62 using conventional CVD or PECVD techniques and the surfaces of silicon dioxide regions 54 and the top surface of substrate 52 have been planarized using conventional CMP techniques. Note that, as an artifact of the planarizing process and oxide etching steps, the edges of the top surface of silicon dioxide regions 54 lie below the edges of isolation trench 62 .
[0031] Referring now to FIG. 4C , gate oxide layer 56 and polysilicon gate layer 58 have been formed and defined using conventional photolithographic and semiconductor processing techniques. Source and drain regions (outside of the plane of the cross-section of FIG. 4C and therefore shown as dashed lines 66 ) are implanted using the edges of the gate 58 as a mask in a conventional self-aligned gate process sequence. Note that the polysilicon gate regions adjacent to the edges of the isolation trench 62 lie below the level of the source and drain implants.
[0032] Persons of ordinary skill in the art will understand that, after performing the steps illustrated in FIGS. 4A through 4C , other conventional and well known processing steps, such as passivation and contact formation (not shown), will need to be performed top complete the integrated circuit.
[0033] An alternate technique to perform the function of the present invention involves performing an additional implant in the channel region at the time of the Vt implant in place of the trench sidewall implant in order to help negate leakage at the channel edges. According to this aspect of the present invention, a boron implant of between about 1.0e12 to about 1.5e12, preferably about 1.2e12, is made at an energy of between about 50 to about 100 keV, preferably about 80 keV. This implant is performed at the time of the Vt threshold adjusting implant prior to formation of the polysilicon gate.
[0034] While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications than mentioned above are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A method for fabricating a shallow-trench isolation transistor an a semi-conductor substrate includes forming a single isolation trench having a uniform cross section to define an active region in the silicon substrate. The method includes performing sidewall isolation implants on the side and bottom walls of said isolation trench. The method includes depositing a dielectric isolation material in said isolation trench. The method includes planarizing the top surface of said silicon substrate and said dielectric isolation material. The method includes forming a gate oxide layer over said active region in said silicon substrate. The method includes forming and defining gate regions over said oxide layer in said active region in said silicon substrate. The method includes forming source and drain regions in the active region in the silicon substrate.
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BACKGROUND OF THE INVENTION
This invention relates to steam turbines and in particular to double flow steam turbines.
In general, steam turbines operate to convert energy stored in high-pressure, high-temperature steam into rotational mechanical movement. The steam turbines employed by electric utilities in the generation of electric power, typically comprise a plurality of turbine buckets radially mounted on a rotor shaft and disposed so as to form a plurality of bucket wheels. The rotor shaft, with its bucket wheels, is mounted on bearings with the bucket wheels disposed inside an inner shell which is in turn surrounded by an outer shell. These double shells serve the function of forming a pressurizable housing in which the bucket wheels rotate and of preventing potentially damaging thermal gradients. The bucket wheels are disposed between stationary nozzle rings. These nozzle rings are formed by circular arrays of stationary curved partitions. These partitions are generally referred to as nozzle partitions and the spaces between the partitions as nozzles. As steam passes through the pressurizable inner shell it alternately passes through sequences of stationary nozzle partitions and rotating turbine bucket wheels to produce rotational movement of the rotor shaft. These concepts are elementary and are generally well known in the turbine arts.
Modern large steam turbines generally comprise several sections such as high-pressure section, intermediate pressure section and low-pressure sections. These sections possess various design characteristics so as to permit the extraction of the largest possible amount of energy from the expansion of steam through the turbine sections. It is a common practice to have one or more of these sections configured in a double flow arrangement, in which steam entering a middle portion of the section encounters a diverging flow path. Following entry into this middle portion of one of the turbine sections, the steam exits in opposite directions with both flows directed to rotate the turbine shaft in the same direction. Thus for example, steam entering from the top or bottom exits toward the left and right. This double flow configuration contributes to the overall machine efficiency.
One of the important parts of a double flow turbine section is the inner web of the diaphragm. Before the steam flowing in opposite directions encounters any turbine bucket wheels, it encounters a first set of nozzle partitions which direct the steam against the turbine buckets at optimal angles. There are two sets of these nozzle partitions, each arranged in an annular spoked pattern on opposite sides of the middle (that is, steam entrance) portion of the double flow turbine diaphragm. Along their radially outward tips, these partitions are affixed to, as by welding, outer annular rings which are fitted into recesses within the inner turbine shell. Of greater interest in the present invention, however, is the fact that along the radially inner portion of these nozzle partitions, they are affixed to the inner web of the diaphragm, again typically by welding. Thus this inner web has two sets of annularly configured nozzle partitions affixed to it (one on each end of the diaphragm). Its primary function is to support this particular set of nozzle partitions. These are the first nozzle-defining partitions encountered in the steam flow path of the particular double flow section under consideration. The remaining nozzle partitions are disposed between the rotating turbine bucket wheels using differently configured diaphragms. In addition to supporting these first rings of nozzle partitions, the inner web also serves another important function, in that it significantly helps to define the steam flow path. In particular it prevents direct contact between the incoming steam and the rotor shaft. The design of this web ensures that the entire steam flow is directed between the nozzle partitions and thence to the turbine bucket wheels.
In previous designs of this inner web, single piece fabrication was employed. However, this design can be difficult to implement in practice. In particular it may be difficult to keep two individual steam path assemblies flat, parallel, circumferentially aligned and properly axially spaced during the thermal distortions inherent during weld fabrication. Moreover, during machining, both ends of the web have to be concentrically aligned, joint pitches must be aligned, and steam paths machined separately and leveled. As a result of accumulated variances in machining, assembly and distortion in welding, rework is often required to assure that all dimensions are satisfactory. In one proposed solution to this problem the inner web is fabricated in two axial pieces bolted together at the midline. While being an improvement over the single piece design for low-temperature applications, this bolted-together-web design is undesirable in high-temperature applications. In addition, neither the single piece nor the bolted-together design permit relative axial movement due to transient or steady-state thermal expansion forces.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment of the present invention an inner web of a diaphragm for use in a double flow section of a steam turbine comprises a first cylindrical shell formed in two joinable halves and a second cylindrical shell also formed in two joinable halves for surrounding an end of the first shell which surrounds the turbine rotor shaft. More particularly, the inner web of the present invention comprises a means for holding the second shell in a relatively fixed position around the first shell while permitting limited axial motion between the shells. Furthermore, the first shell possesses a surface to which the first ring of nozzle partitions of the steam turbine are attached. Likewise, the second shell possesses a similar surface for like attachment of the first ring of nozzle partitions in the opposite steam flow direction. In a preferred embodiment of the present invention the first and second shells are joined together by means of a rabbet joint; in another embodiment they are held together by a hook fit. Lest confusion arise it should be noted that the first and second shells discussed herein are distinct from the inner and outer pressurizable shells mentioned above.
In another embodiment of the present invention the second cylindrical shell is bolted onto one end of the first shell. While this embodiment does not permit axial movement, it is nonetheless much simpler to fabricate since all distortion from welding the partitions onto the shells is easily compensated for.
Accordingly, it is an object of the present invention to provide a two-piece inner web for use in a double flow steam turbine.
It is a further object of the present invention to provide an inner web in which fabrication of each portion occurs separately so as to permit precise machining of both portions independently.
It is also an object of the present invention to provide limited flexibility in dimensioning at the rabbet fit; this permits limited differential expansion between the first and second shell portions without distortion of the diaphragm.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an isometric view illustrating one half of a first cylindrical shell portion of the inner web in accordance with the present invention.
FIG. 2 is a partial cross-sectional diagram of the inner web of the present invention shown in place relative to other turbine components.
FIG. 3 is similar to FIG. 2 except that one form of hook-fit joint is shown.
FIG. 4 is similar to FIG. 2 but shows an embodiment of the present invention which does not exhibit axial expansion.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows one of four separable pieces of the present invention. In particular there is shown an isometric view of one of the halves of a first cylindrical shell forming the major part of the structure of the invention. This cylindrical shell is not to be confused with the inner and outer pressurizable shells surrounding the entire turbine assembly. The first cylindrical shell in particular possesses lip 30 which meets with a corresponding recess in the second cylindrical shell of the present invention. Both the first and second cylindrical shells are formed in two halves (hence, the four pieces to the structure). The first cylindrical shell possesses halves which are joined together to surround the turbine rotor shaft. The second shell (not seen in FIG. 1) comprises two halves which are joined about lip 30 to surround the first shell, as indicated in FIG. 2. Shell half 10 also possesses pegs 38 to assist in alignment of the two shell halves. Pegs 38 fit into alignment holes on the other half of the first shell. Shell half 10 also possesses a raised key portion 48 which serves a further alignment function and also a sealing function. The raised portion 48 mates with a corresponding key slot recess in the other first shell half. To facilitate joining of the shell halves, each shell half possesses bosses 42 with holes therein for receiving bolts which join the two halves of the first shell. Additionally, the first cylindrical shell of the present invention possesses circular grooves 24 along the inner circumference thereof for insertion of steam packing seal material which is disposed in the two circular grooves so that the shell halves are spaced apart, by a predetermined clearance, from the rotor shaft. Typically this clearance is 30 to 40 mils. At least one of the shell halves possesses aperture 44 through a large metal boss which is typically cast as part of the shell. This serves several functions. First, it provides a passage for the introduction of somewhat lower temperature steam for rotor cooling during normal operation. Second, it provides a passage for steam which performs a prewarming function for the turbine so as to reduce thermal stress. Third, the aperture 44 may be employed as an access hole through which entry to the rotor shaft is gained. In particular, it is desirable to install rotor balancing weights, if needed, in holes along that portion of the rotor shaft which rotates beneath this aperture. This facilitates rotor balancing. Thermocouples 46 may be positioned on the first shell as shown to provide accurate indications of steam temperature.
FIG. 2 illustrates the inner web of the present invention comprising first and second shells 10 and 20 respectively. Shells or inner webs 10 and 20 are shown in relation to curved nozzle partitions 18 and outer annular rings 14 and 16 which are fitted into recesses in the inner pressurizable turbine shell. A first end of shell 10 has an outer peripheral surface to which is attached nozzle partition 18 as illustrated in FIG. 2. A second end of shell 10 is displaced along the axis of the rotor shaft from the first end and is surrounded by shell 20 as is shown in the drawings. Shells 10 and 20 are held together by a joint or means which permits limited axial movement between the shells. The outer peripheral surface of shell 20 is attached to another nozzle partition 18 and outer rings 14 and 16 are affixed to both nozzle partitions 18 as illustrated in FIG. 2. Outer rings 14 and 16 typically possess slots 22 for the insertion of tip spill strips which are set at a specified radial clearance from the turbine rotor wheels. An important aspect of this embodiment of the present invention is the fact that the inner web comprising shells 10 and 20 is a two-part structure possessing a joint which permits limited axial movement. The joint or means which holds shell 20 in a relatively fixed position around one end of shell 10 is illustrated in FIGS. 2, 3 and 4. This joint preferably comprises a rabbet joint as indicated by lip 30 in first shell 10 and recess 40 in second shell 20. As described above, the two nozzle partitions 18 are axially displaced and join outer ring 14 to shell 20 and outer ring 16 to shell 10, as shown. The steam flow direction through these nozzles is generally indicated by arrows 26. Shells 10 and 20 also preferably possess root spill strips 28 which are spaced apart from a radially inner portion of the turbine buckets.
The inner web of the present invention preferably comprises a material such as steel and in particular high-temperature alloys of steel. An important aspect of this invention is that the material is machined to produce lip 30 and recess 40 so as to form the preferred rabbet joint. Other joints such as hook-fit joint may also be employed as shown in FIG. 3. In the case of the rabbet joint, the spacing between the vertical faces of the rabbet joint are typically set at approximately 5 mils with a slightly larger spacing being desired for the left-most vertical joint face in FIG. 2.
FIG. 3 illustrates one embodiment of the present invention in which double hook joint 31 is employed to join the first and second shells. A single hook-fit joint may also be employed. Because of the extra machining involved in this form of joint, as compared with the straight rabbet joint, this is not the preferred embodiment of the present invention. This is also the case because assembly with this form of joint is more difficult and involves a sliding rotation of the pieces.
FIG. 4 illustrates an embodiment of the present invention in which the second shell 21 is bolted to the first shell 10. Even though this embodiment does not permit relative axial movement, it nonetheless permits an easier fabrication process in which nozzle partitions 18 are first affixed between ring 14 and shell 21 and between ring 16 and shell 10. Following this, circumferential rabbet joint 54 is machined into shells 21 and 10. It is here that distortion and alignment problems created by welding of partitions 18 are corrected. This latter advantage is also present in the embodiment shown in FIGS. 2 and 3 which possess the additional advantage of limited axial motion.
The diaphragm of the present invention is particularly useful in those situations in which reheat steam is employed. In particular, this diaphragm is also most advantageously employed in the reheat section of the turbine.
From the above it may be appreciated that the inner web of the diaphragm of the present invention provides a means for accurately and precisely supporting the first stage of nozzle ring partitions and for appropriately defining a portion of the steam flow path. In particular, the two-part construction of the diaphragm not only permits easy and accurate machining, but also produces a structure which permits a limited amount of axial movement to compensate for differential thermal expansion. This avoids warping or damage to the diaphragm. Many of the benefits of the present invention are obtained because its structure permits a fabrication process in which the joints are machined into the structure after completion of the fabrication process. It is at this stage that final alignment and mating of the first and second shells is accomplished.
While the invention has been described in detail herein in accord with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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In a double flow section of a steam turbine, the inner web of the diaphragm surrounding the rotor shaft in the region of divergence of the steam flow paths, is fabricated in the form of two cylindrical shells which are held together either in a fixed position or in a relatively fixed position which permits some slight axial motion between the shells. This form of diaphragm eliminates a number of machining and fabrication alignment problems and additionally permits differential axial expansion of the two pieces occurring as a result of internal thermal steam conditions.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 10/163,976 filed Jun. 6, 2002, now U.S. Pat. No. 6,712,988, which was a divisional of U.S. patent application Ser. No. 09/418,657 filed Oct. 15, 1999, now U.S. Pat. No. 6,426,142, which claimed the benefit of U.S. provisional patent application 60/146,487 filed on Jul. 30, 1999.
The present invention relates to a spin finish for synthetic fiber.
BACKGROUND OF THE INVENTION
Upon emerging from a spinneret, many synthetic fibers require the application of a spin finish in order to further process the spun yarn. Because a spin finish may be present in a minimal layer on fiber, the spin finish acts as an interface between the fiber and the metallic surfaces such as guides and rollers which contact the fiber during such processing as drawing or relaxing.
The art teaches many spin finishes for conventional industrial, carpet, and textile yarn. For example, spin finishes comprising lubricants of polyalkylene glycols with molecular weights of 300 to 1,000 and a second component are taught by U.S. Pat. No. 4,351,738 (see Comparative Examples) and commonly assigned U.S. Pat. Nos. 3,940,544; 4,019,990; and 4,108,781. U.S. Pat. No. 4,340,382 teaches a finish comprising a nonionic surfactant of polyalkylene glycol block copolymer.
Spin finishes comprising lubricants of polyalkylene glycols with molecular weights of greater than 1,000 and other components such as esters, an anionic compound, or polyalkylene oxide modified polysiloxane are taught by U.S. Pat. Nos. 3,338,830; 4,351,738 and 5,552,671 and Research Disclosures 19432 (June 1980) and 19749 (September 1980). See also Kokai Patent Publication 15319 published Jan. 23, 1987. Unfortunately, spin finishes comprising polyalkylene glycols wherein the preferred or lowest molecular weight exemplified is ≧2,000 may form deposits on the metallic surfaces which they contact during manufacturing.
U.S. Pat. No. 5,507,989 teaches a spin finish wherein the boundary lubricant is a polyalkylene glycol having a molecular weight of ≧9,000.
U.S. Pat. No. 4,442,249 teaches a spin finish comprising an ethylene oxide/propylene oxide block copolymer with a molecular weight greater than 1,000; an alkyl ester or dialkyl ester or polyalkyl ester of tri- to hexaethylene glycol lubricant; and a neutralized fatty acid emulsifier. Unfortunately, spin finishes comprising these block copolymers also may form deposits on the metallic surfaces which they contact during manufacturing and these textile spin finish compositions may be inadequate for the more severe conditions used in industrial fiber production.
Commonly assigned U.S. Pat. Nos. 3,681,244; 3,781,202; 4,348,517; 4,351,738 (15 moles or less of polyoxyethylene); and U.S. Pat. No. 4,371,658 teach the use of polyoxyethylene castor oil in spin finishes.
Another spin finish composition for conventional industrial yarn is taught by commonly assigned U.S. Pat. No. 3,672,977 which exemplifies a spin finish comprising coconut oil, ethoxylated lauryl alcohol, sodium petroleum sulfonate, ethoxylated tallow amine, sulfonated succinic ester, and mineral oil. See also commonly assigned U.S. Pat. Nos. 3,681,244; 3,730,892; 3,850,658; and 4,210,710.
Over the years, processes for manufacturing industrial yarns have become more demanding. See for example the processes for making dimensionally stable polyester fiber taught by commonly assigned U.S. Pat. Nos. 5,132,067; 5,397,527; and 5,630,976. Further, a general trend exists in the yarn converting industry towards direct cabling machines to reduce conversion costs. Cost reductions are achieved in part, as direct cabling machines operate at considerably higher speeds (30-50% greater) and complete two steps at once compared to conventional ring twisters. However, the demands placed on the yarn finish to preserve yarn mechanical quality are much greater with direct cabling machines. Thus, a spin finish which enhances yarn processability and contributes to improved yarn performance is needed in the art.
SUMMARY OF THE INVENTION
We have developed a spin finish which responds to the foregoing need in the art. The present spin finish composition comprises at least about 10 percent by weight based on the spin finish composition of components (a) and (b) having the formula
R 1 —(CO) x —O—(CH(R 2 )—CH 2 —O) y —(CO) z —R 3
wherein each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to 22 carbon atoms or an alkylene hydroxy group having from one to 22 carbon atoms,
x is zero or one, R 2 may vary within component (a) or component (b) and is selected from the group consisting of hydrogen or an alkyl group having from one to four carbon atoms, y is zero, or from one to 25, and z is zero or one, in component (a), x and z are equal to zero and the average molecular weight of component (a) is less than or equal to 1,900 and if R 2 varies, component (a) is a random copolymer; and in component (b), at least x or z is equal to one or component (b) is a complex polyoxyethylene glyceride-containing compound having greater than 10 polyoxyethylene units; up to five percent by weight based on the spin finish composition of component (c) of an alkoxylated silicone; and at least about one percent by weight based on the spin finish composition of component (d) having the formula
R 4 (CH 2 O(CO) a R 5 ) b
wherein R 4 is —C— or —COC—; a is 0 or 1; R 5 is —H; from —CH 3 to —C 18 H 37 ; or —CH(R 6 )—CH 2 O; b is 4 or 6; and R 6 is —H or —CH 3 or —H and —CH 3 in a ratio of 10:90 to 90:10.
The present invention is advantageous compared with conventional spin finishes applied to industrial yarn because the present spin finish enhances yarn processability as evidenced by low fuming, improved mechanical quality at lower amounts of spin finish per yarn, improved mechanical quality at higher draw ratios, and minimal depositing and improves yarn performance as evidenced by improved strength and wicking.
Other advantages of the present invention will be apparent from the following description and attached claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the thermogravimetric analysis for a known spin finish and Inventive Example 1.
FIG. 2 illustrates the quality for a given amount of spin finish for a known spin finish and Inventive Example 1.
FIG. 3 illustrates the quality for a given draw ratio for a known spin finish and Inventive Example 1.
FIG. 4 shows the strength translation improvement on a direct cabling machine for a known spin finish and Inventive Example 1.
FIG. 5 shows the wicking length for a known spin finish and Inventive Example 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Component (a) of the present spin finish composition has the formula
R 1 —(CO) x —O—(CH(R 2 )—CH 2 —O) y —(CO) z —R 3
wherein each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to 22 carbon atoms, x and z are zero, R 2 may vary and is selected from the group consisting of hydrogen or an alkyl group having from one to four carbon atoms, and y is zero, or from one to 25. The average molecular weight of component (a) is less than or equal to 1,900.
Preferably, the average molecular weight of component (a) is greater than 500. More preferably, the average molecular weight of component (a) is less than about 1,500.
Preferably, in component (a), each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to ten carbon atoms, R 2 varies and is selected from the group consisting of hydrogen and an alkyl group having one or two carbon atoms, and y is zero or between one to 20. The term “R 2 varies” means that R 2 may be hydrogen and methyl, hydrogen and ethyl, or methyl and ethyl. More preferably, in component (a), each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to five carbon atoms atoms, R 2 is selected from the group consisting of hydrogen and an alkyl group having one carbon atom, and y is zero or between one to 16.
Preferred component (a) is a so-called random copolymer, and more preferably, a random copolymer made from ethylene oxide and propylene oxide. Ethylene oxide, propylene oxide, and an alcohol are reacted simultaneously to form mixed polyalkylene glycol compounds with an alcohol terminated end. Preferred compounds are condensation products of about 30 to about 70 percent by weight ethylene oxide and about 30 to about 70 percent by weight propylene oxide and are terminated with an alcohol having one to four carbon atoms. Useful random copolymers are commercially available.
Preferably, component (a) is present in an amount of at least about 10 percent by weight based on the spin finish composition. More preferably, component (a) is present in an amount of at least about 20 percent by weight based on the spin finish composition.
Component (b) of the present spin finish has the formula
R 1 —(CO) x —O—(CH(R 2 )—CH 2 —O) y —(CO) z —R 3
wherein each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to 22 carbon atoms or an alkylene hydroxy group having from one to 22 carbon atoms, x is zero or one, R 2 may vary and is selected from the group consisting of hydrogen or an alkyl group having from one to four carbon atoms, z is zero or one, and at least x or z is equal to one. Component (b) may be a mixture of components or may be a complex polyoxyethylene glyceride-containing compound having greater than 10 polyoxyethylene units.
Preferably, in component (b), each of R 1 and R 3 is selected from the group consisting of hydrogen or an alkyl group having from one to 18 carbon atoms or alkylene hydroxy group having from one to 18 carbon atoms, R 2 does not vary and is selected from the group consisting of hydrogen or an alkyl group having one or two carbon atoms, and y is from 5 to 25. More preferably, in component (b), x is one and z is zero.
Useful complex esters are commercially available.
The most preferred component (b) is a polyoxyethylene glyceride-containing compound having greater than 10 polyoxyethylene units and the most preferred polyoxyethylene glyceride-containing compound having greater than 10 polyoxyethylene units is ethoxylated castor oil.
Preferably, component (b) is present in an amount of at least about five percent by weight based on the spin finish composition.
Component (c) is an alkoxylated silicone. Preferably, the alkoxylated silicone has a siloxane backbone with organic polyalkylene oxide pendants. Useful alkoxylated silicones are commercially available. The alkoxylated silicone is used in an amount of up to about five percent by weight based on the spin finish composition.
Component (d) of the present spin finish has the formula
R 4 (CH 2 O(CO) a R 5 ) b
wherein R 4 is —C— or —COC—; a is 0 or 1; R 5 is —H; from —CH 3 to —C 18 H 37 ; or —CH(R 6 )—CH 2 O; b is 4 or 6; and R 6 is —H or —CH 3 or —H and —CH 3 in a ratio of 10:90 to 90:10. Examples of useful component (d) include dipentaerythritol hexaheptanoate; dipentaerythritol triheptanoate trinonanoate; dipentaerythritol triheptanoate triisononanoate; dipentaerythritol monocarboxylic (C 5-9 ) fatty acids hexaester; dipentaerythritol enanthate, oleate; dipentaerythritol mixed ester of valeric acid, caproic acid, enanthylic acid, acrylic acid, pelargonic acid, and 2-methylbutyric acid; pentaerythritol tetrapelargonate; and dipentaerythritol hexapelargonate. Useful component (d) is commercially available.
Preferably, component (d) is present in an amount of at least about one percent by weight based on the spin finish composition.
The present spin finish may be used on any synthetic fiber. Useful synthetic materials include polyesters and polyamides. Useful polyesters include linear terephthalate polyesters, i.e., polyesters of a glycol containing from 2 to 20 carbon atoms and a dicarboxylic acid component containing at least about 75% terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboxylic acid such as sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4′-dibenzoic acid, or 2,8-dibenzofurandicarboxylic acid. The glycols may contain more than two carbon atoms in the chain, e.g., diethylene glycol, butylene glycol, decamethylene glycol, and bis-1,4-(hydroxymethyl)cyclohexane. Examples of linear terephthalate polyester include poly(ethylene terephthalate); poly(butylene terephthalate); poly(ethylene terephthalate/5-chloroisophthalate)(85/15); poly(ethylene terephthalate/5-[sodium sulfo]isophthalate)(97/3); poly(cyclohexane-1,4-dimethylene terephthalate), and poly(cyclohexane-1,4-dimethylene terephthalate/hexahydroterephthalate). These starting synthetic materials are commercially available.
Another useful polymer is the copolymer taught by commonly assigned U.S. Pat. No. 5,869,582. The copolymer comprises: (a) a first block of aromatic polyester having: (i) an intrinsic viscosity which is measured in a 60/40 by weight mixture of phenol and tetrachloroethane and is at least about 0.6 deciliter/gram and (ii) a Newtonian melt viscosity which is measured by capillary rheometer and is at least about 7,000 poise at 280° C.; and (b) a second block of lactone monomer. Examples of preferred aromatic polyesters include poly(ethylene terephthalate)(“PET”), poly(ethylene naphthalate)(“PEN”); poly(bis-hydroxymethylcyclohexene terephthalate); poly(bis-hydroxymethylcyclohexene naphthalate); other polyalkylene or polycycloalkylene naphthalates and the mixed polyesters which in addition to the ethylene terephthalate unit, contain components such as ethylene isophthalate, ethylene adipate, ethylene sebacate, 1,4-cyclohexylene dimethylene terephthalate, or other alkylene terephthalate units. A mixture of aromatic polyesters may also be used. Commercially available aromatic polyesters may be used. Preferred lactones include ε-caprolactone, propiolactone, butyrolactone, valerolactone, and higher cyclic lactones. Two or more types of lactones may be used simultaneously.
Useful polyamides include nylon 6; nylon 66; nylon 11; nylon 12; nylon 6,10; nylon 6,12; nylon 4,6; copolymers thereof, and mixtures thereof.
The synthetic fiber may be produced by known methods for making industrial fiber. For example, commonly assigned U.S. Pat. Nos. 5,132,067 and 5,630,976 teach methods for making dimensionally stable PET. After the synthetic fiber emerges from a spinneret, the present spin finish may be applied to the synthetic fiber by any known means including bath, spray, padding, and kiss roll applications. Preferably, the present spin finish is applied to the synthetic yarn in an amount of about 0.1 to about 1.5 percent by weight based on the weight of the synthetic yarn.
The following test methods were used to analyze fiber having the present spin finish composition thereon.
1. Thermogravimetric Analysis: Thermogravimetric analysis was conducted on a Seiko RTG 220U instrument using open platinum pans. Samples between 5 and 8 milligrams in weight were heated from 30° C. to 300° C. at 10° C./minute under an air purge at 200 milliliters/minute.
2. Fray Count: Yarn defect level was measured on-line using the Enka Tecnica FR-20 type Fraytec system. The fray counting sensor was mounted on the compaction panel between the commingling jet and the winding tension detector. A bending angle of greater than 2 degrees was maintained. The sensor was cleaned during every other doff to ensure the accurate measurement.
3. Breaking Strength: Breaking strength was determined according to ASTMD885 (1998). For each yarn tested, ten tests were conducted and the average of the ten tests was reported.
4. Wicking Cord Test Method: This test method covers determination of dip wicking ability on untreated or treated cords. A yarn or cord is vertically immersed in a container filled with dip. The dip permeability through fiber capillary in two minutes is then measured by tracking the vertical progress of the dyed dip.
The apparatus includes two ring stands for holding test cords, dip container of one inch diameter and one inch depth, and control motor (1/8 Hp with manual rpm control) to feed test yarn through apparatus.
All test specimens must be conditioned at least 24 hours at atmosphere of 70° F. and 65% relative humidity as directed in ASTM D1776.
For the test procedure, step 1 is to mix three drops of red dye well with dip solution. Step 2 is to pull the test cord through a sample holder in the order of a first ring stand, dip container, and a second ring stand to the control motor. Wind the cord on the pulley of the control motor. Finally, apply 20 gms pretension weight on the cord between the first ring stand and the ruler. Step 3 is to fill the dip container with the colored dip. Make sure dip level is at the top edge of the dip container, even with the “0” on the ruler. Step 4 is to turn on the motor and feed a section of yarn through the dip. Stop the motor and start the test. Step 5 is to allow dip to wick two minutes on the specimen. Measure and report position of colored dip as it climbs the sample. Repeat steps 4 and 5 for nine times per fiber. Calculate average and standard deviation of ten wicking reading.
The following examples are illustrative and not limiting.
COMPARATIVE A AND INVENTIVE EXAMPLE 1
Comparative A was an industrial yarn spin finish composition taught by commonly assigned U.S. Pat. No. 3,672,977 and comprised 30 weight percent coconut oil; 13 weight percent ethoxylated lauryl alcohol; 10 weight percent sodium petroleum sulfonate; 5 weight percent ethoxylated tallow amine; 2 weight percent sulfonated succinic ester; and 40 weight percent mineral oil.
For Inventive Example 1, commercially available component (a) having the formula
R 1 —(CO) x —O—(CH(R 2 )—CH 2 —O) y —(CO) z —R 3
as described in Table I below was used
TABLE I MW R 1 X R 2 Y Z R 3 950 C 4 0 50% H/50% CH 3 4-16 0 H
In an amount of 65 weight percent. In Table I, MW means molecular weight. Component (b) was a commercially available ethoxylated castor oil which contained components such as:
and was used in an amount of 25 weight percent. For component (c), silicone was used in an amount of 5 weight percent. For component (d), dipentaerythritol hexapelargonate was used in an amount of 5 weight percent.
In FIG. 1 , the thermogravimetric analysis for Inventive Example 1 (“IE1”) and Comparative A (“CA”) is plotted and shows that as temperature increases, less fuming occurs with Inventive Example 1.
In FIG. 2 , the fray count or quality is plotted as a function of the amount of spin finish on an industrial polyester yarn which was 1,000 denier and had 384 filaments. Above 600 fray is unacceptable quality and thus, at least 0.35 weight percent Comparative A (“CA”) spin finish was needed on the yarn. A yarn having Inventive Example 1 (“IE1”) spin finish has acceptable quality, in other words below 600 fray count, when the yarn has at least 0.35 weight percent Inventive Example 1 spin finish and unexpectedly when the yarn has less than 0.35 down to 0.15 weight percent Inventive Example 1 spin finish. Reduced finish levels are desirable for many end-use applications.
In FIG. 3 , the fray count or quality is plotted as a function of the maximum draw ratio on an industrial polyester yarn which was 1,000 denier and had 384 filaments for Comparative A (“CA”) and Inventive Example 1 (“IE1”).
Each spin finish was applied in an amount of 0.5 weight percent to industrial polyester yarn.
For FIG. 4 , a 1100 dtex dimensionally stable polyester yarn was cabled to a nominal twist of 470×470 tpm which is a standard construction for tire applications. The yarn was subjected to a state-of-the art direct cabler which operated at 9500 rpm. Three samples were cabled on two different machines to minimize any specific performance of a cabler. In FIG. 4 , Comparative A (“CA”) is set at 100% and Inventive Example 1 (“IE1”) is reported relative to Comparative A. Inventive Example 1 shows that the present spin finish on an industrial polyester yarn resulted in at least about 3% superior strength. Fiber strength is a major factor in the design of fiber composite systems such as those used in tires. Increased strength enhances performance but also allows consideration to be given to cost savings through material reduction.
In FIG. 5 , the wicking of Comparative A (“CA”) and Inventive Example 1 (“IE1”) were determined. This improved wicking leads to improved dip pickup which results in improved in-rubber performance.
INVENTIVE EXAMPLE 2
For Inventive Example 2, commercially available component (a) having the formula
R 1 —(CO) x —O—(CH(R 2 )—CH 2 —O) y —(CO) z —R 3
as described in Table 11 below was used
TABLE II MW R 1 X R 2 Y Z R 3 950 C 4 0 50% H/50% CH 3 4-16 0 H
In an amount of 5 weight percent. In Table 11, MW means molecular weight. Component (b) was pentaerythritol ester and was used in an amount of 85 weight percent. For component (c), silicone was used in an amount of 5 weight percent. For component (d), dipentaerythritol hexapelargonate was used in an amount of 5 weight percent. The spin finish was applied in an amount of 0.6 weight percent to industrial polyester yarn. The tenacity of the yarn was 9 grams/denier.
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A spin finish which enhances yarn processability and contributes to improved yarn performance. The spin finish is advantageous when compared with conventional spin finishes applied to industrial yarn because the present spin finish enhances yarn processability as evidenced by low forming, improved mechanical quality at lower amounts of spin finish per yarn, improved mechanical quality at higher draw ratios, and minimal depositing. It also improves yarn performance as evidenced by improved strength and wicking.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/421,517, filed Apr. 23, 2003 now U.S. Pat. No. 7,569,065, which is a divisional of U.S. patent application Ser. No. 09/596,160, filed Jun. 16, 2000 now U.S. Pat. No. 6,575,991, which claims the priority of U.S. Provisional Patent Application Ser. No. 60/139,580, filed Jun. 17, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an apparatus for the percutaneous positioning of a radiopaque marker for identifying the location of a lesion in a stereotactic biopsy procedure. More particularly, the invention relates to an introducer having a hollow cannula in combination with a movable stylet and a radiopaque marker disposed within the cannula and ejected from it by movement of the stylet.
2. Related Art
Tissue biopsies are commonly performed on many areas and organs of the body where it is desirable to ascertain whether or not the biopsied tissue is cancerous. Often, a lesion or other tissue to be biopsied is identified through use of an imaging technique such as a computerized axial tomography (CAT) scan, ultrasonography, and mammography.
One problem commonly encountered, especially in breast biopsies, is that the lesion is so small that the biopsy reduces its size to the extent that it is no longer visible by the imaging method employed. In such circumstances, it is desirable to place a radiopaque marker at the site of the biopsy to enable the medical practitioner subsequently to locate the lesion quickly and accurately in the event complete removal of the affected tissue is indicated. This problem is currently met by placing a radiopaque marker at the biopsy area by means of a cannula or similar device housing the marker.
More particularly, one of the markers heretofore in use is a staple-type clip. The clip is introduced through a large-diameter cannula, specifically one of 11 gauge.
Some practitioners employ an embolization coil as a marker. This requires them to find a cannula or hollow needle of a size to receive the coil and some means to force the coil through the needle, all the while trying to keep these components together and sterile.
Prior devices for marking a biopsy area have several other disadvantages. A significant disadvantage is that the marker is not always completely ejected from the cannula or can be drawn back into or toward the cannula by the vacuum created upon the withdrawal of the cannula, which results in the marker being moved from the intended site, leading to inaccurate identification of the location of the biopsy area. A second major disadvantage is that current markers have a tendency to migrate within the tissue, also causing error in determining the biopsy location.
SUMMARY OF THE INVENTION
The present invention provides a biopsy marking apparatus for the percutaneous placement of a marker at a biopsy site in a tissue mass to facilitate subsequent determination of the location of the biopsy site. The biopsy marking apparatus comprises an introducer having a handle to be grasped by a user, a cannula, a stylet, and a radiopaque marker. The cannula has a proximal end mounted to the handle and a distal end defining an insertion tip. The stylet is slidably received within the cannula for movement between a ready position in which a distal end of the stylet is spaced inwardly from the cannula tip to form a marker recess between the distal end of the stylet and the cannula tip, and an extended position in which the distal end of the stylet extends at least to the cannula tip to effectively fill the marker recess.
A plunger is movably mounted to the handle and operably engages the stylet, the plunger being movable between a first position and a second position for moving the stylet between the ready position and the extended position.
A latch is provided for fixing the stylet in the extended position to prevent retraction of the stylet from that position.
A radiopaque marker is disposed within the marker recess, whereby, when the plunger is moved between the first and second positions, the stylet is moved from the ready to the extended position to eject the radiopaque marker from the marker recess, and the latch fixes the stylet in the extended position to prevent the return of the marker to the marker recess.
The latch preferably comprises a detent on either the plunger or the handle and a catch on the other, the catch being receivable within the detent as the plunger is moved from the first to the second position.
In another aspect, the invention also provides a radiopaque marker having a marker body and an anchor extending away from the body for fixing the location of the radiopaque marker in a tissue mass by the tissue mass prolapsing about the anchor. Preferably, the body has an interior hollow portion forming an air trap to enhance the ultrasound characteristic of the radiopaque marker.
Other features and advantages of the invention will be apparent from the ensuing description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view of an introducer used to place a radiopaque marker at a biopsy location in accordance with the invention;
FIG. 2 is an enlarged sectional view of the area II of FIG. 1 , illustrating the position of a radiopaque marker within the introducer prior to ejection;
FIG. 3 is an enlarged sectional view of the area III of FIG. 1 , illustrating the arrangement of a handle, a plunger, and a stylet of the introducer;
FIG. 4 is a sectional view taken along line 4 - 4 of FIG. 1 and illustrating the introducer in a ready condition;
FIG. 5 is a sectional view taken along line 4 - 4 of FIG. 1 and illustrating the introducer in a discharged condition;
FIG. 6 is an enlarged view of a first embodiment of a radiopaque marker according to the invention;
FIG. 7 is an enlarged view of a second embodiment of a radiopaque marker according to the invention;
FIG. 8 is an enlarged view of a third embodiment of a radiopaque marker according to the invention;
FIG. 9 is an enlarged view of a fourth embodiment of a radiopaque marker according to the invention;
FIG. 10 is a partially broken away perspective view, greatly enlarged, of a fifth embodiment of a radiopaque marker according to the invention;
FIG. 11 is a plan view of the radiopaque marker of FIG. 10 ;
FIG. 12 is a greatly enlarged view of a sixth embodiment of a radiopaque marker according to the invention;
FIG. 13 is a greatly enlarged view of a seventh embodiment of a radiopaque marker according to the invention;
FIG. 14 is a greatly enlarged view of an eighth embodiment of a radiopaque marker according to the invention; and
FIG. 15 is a greatly enlarged view of a ninth embodiment of a radiopaque marker according to the invention.
DETAILED DESCRIPTION
FIGS. 1 to 4 illustrate a biopsy marking apparatus 10 according to the invention, which is capable of the percutaneous placement of a radiopaque marker at the location of a tissue biopsy. The biopsy marking apparatus 10 comprises an introducer 12 and a radiopaque marker 14 ( FIG. 2 ) contained within the introducer 12 . The introducer 12 includes a handle 16 having a hollow interior 18 . The handle 16 comprises a grip portion 20 from which extends a tapered nose portion 22 . The grip portion 20 defines a rear opening 24 that provides access to the hollow interior 18 . A pair of detents 26 are formed in the grip portion 20 near the rear opening 24 . Channels 28 are formed on the interior surface of the grip portion 20 and extend from the rear opening 24 to the detents 26 .
The nose portion 22 comprises a guide passage 30 extending from the tip of the nose portion 22 to the hollow interior 18 of the handle 16 . The guide passage 30 decreases in diameter inwardly from the tip of the nose portion to form a cannula seat 32 . Alternatively, the diameter of the guide passage 30 may be substantially equal to or slightly smaller than the outer diameter of a cannula 34 , which in any case is press-fit within the cannula seat 32 . As is customary, the cannula is formed with a hollow interior 36 and a sharpened tip 38 .
A stylet 40 comprising a shaft 42 and a base 44 is received within the hollow interior 18 of the handle 16 in a manner such that the shaft 42 extends through the guide passage 30 and into the cannula interior 36 and the stylet base lies within the hollow interior 18 .
A plunger 50 comprises a cylindrical body 52 from which extend a pair of catches 54 at diametrically opposed positions. The cylindrical body 52 is sized so that it is slidably received within the rear opening 24 of the handle 16 , where it is so oriented with respect to the handle that the catches 54 are aligned with the guide channels 28 .
It will be recognized that the foregoing construction provides a biopsy marking apparatus which may be preassembled as a unit and prepackaged, all under sterile conditions, thereby affording the practitioner substantially greater convenience and reliability. Such a construction also permits use of a narrower cannula, which may be of 14 gauge or smaller.
In operation, the introducer 12 begins in the ready condition shown in FIG. 4 . In this condition, the stylet shaft is received within the cannula but does not extend to the cannula tip 38 , thereby forming a marker recess 46 within the cannula 34 , the radiopaque marker 14 is disposed within the marker recess 46 , and the plunger 50 is in a position relative to the handle 20 in which the catches are outside the handle; that is, they are not received within the detents 26 . However, the plunger 50 is so oriented with respect to the handle that the catches 54 are aligned with the guide channels 28 .
With the introducer in the ready condition, the cannula is positioned so that its tip is at or near the location of a tissue mass where a biopsy has been taken. Preferably, the cannula tip is positioned by using imaging systems. The cannula tip 38 can be designed for enhanced visibility using common imaging systems, such as CAT scan, ultrasonography and mammography. Suitable cannula tips are disclosed in U.S. Pat. No. 5,490,521, issued Feb. 13, 1996 to R. E. Davis and G. L. McLellan, which is incorporated by reference. Ultrasound enhancement technology is also disclosed in U.S. Pat. No. 4,401,124, issued Aug. 30, 1983 to J. F. Guess, D. R. Dietz, and C. F. Hottinger; and U.S. Pat. No. 4,582,061, issued Apr. 15, 1986 to F. J. Fry.
Once the cannula is positioned at the desired location, the plunger 50 is moved from its first or ready condition as illustrated in FIGS. 1 to 4 to a second or discharged condition in which the catches 54 are received within the detents 26 to lock the plunger 50 in the discharged condition and the stylet shaft extends beyond the cannula tip 38 . The catches 50 and detents combine to function as a latch for locking the plunger in the discharged condition. As the plunger 50 is moved from the ready condition to the discharged condition, the plunger 50 drives the stylet base 44 forward to advance the stylet shaft 42 within the cannula interior 36 . As the stylet shaft 42 is advanced, the radiopaque marker 14 is ejected from the marker recess 46 through the cannula tip 38 and into the tissue at the biopsy location.
It is preferred that the stylet shaft 42 be sized in a manner such that when the plunger 50 is in the discharged condition the stylet shaft 42 extends beyond the cannula tip 38 to ensure the complete ejection of the radiopaque marker 14 from the marker recess 46 . The extension of the stylet shaft 42 beyond the cannula tip 38 also prevents the radiopaque marker 14 from being drawn back into the marker recess upon the removal of the introducer 12 from the tissue mass, which can occur as the tissue mass collapses and is drawn towards and into the cannula by the resilient nature of the tissue mass and the creation of a vacuum by the cannula as it is withdrawn from the tissue.
The rate at which the plunger 50 is moved from the ready condition to the discharged condition is preferably manually controlled by the user to control the rate at which the marker 14 is ejected into the tissue mass. Manual control of the ejection rate of the radiopaque marker provides the user with the ability to adjust the position of the cannula tip as the marker is being ejected and thereby permits additional control of the final location of the marker within the tissue mass. In other words, “on-the-fly” adjustment of the cannula tip during positioning of the marker 14 enables a more accurate placement of the marker.
The biopsy marking apparatus 12 may be placed in a safety condition (not shown) before packaging or use by rotationally orienting the plunger 50 with respect to the handle 16 so that the catches 54 are out of alignment with the guide channels 28 , whereby the plunger cannot be depressed or advanced within the handle. It will be apparent that the marking apparatus can be placed in the ready condition previously described simply by rotating the plunger relative to the handle until the catches 54 are aligned with the guide channels 28 .
It will also be apparent that the biopsy marking apparatus 10 may incorporate or be fitted with any one of several known trigger devices, some of them spring-loaded, for advancement of the plunger 50 . Such a trigger device is disclosed, for example, in U.S. Pat. No. 5,125,413, issued Jun. 30, 1992 to G. W. Baran.
It should be noted that as a variation of the foregoing procedure the cannula employed during the biopsy procedure might be left in place with its tip remaining at the site of the lesion. The introducer 12 of the present invention would then be directed to the site through the biopsy cannula or, alternatively, the marker 14 of the present invention would be introduced to the biopsy cannula and ejected from its tip into the tissue mass by fitting the biopsy cannula to the introducer 12 in place of the cannula 34 .
The radiopaque marker 14 used in combination with the introducer 12 to mark the location of the tissue biopsy should not only be readily visible using contemporary imaging techniques but it should not migrate within the tissue from the position in which it is initially placed. FIGS. 6 to 15 disclose various embodiments of radiopaque markers 14 that are highly visible using contemporary imaging techniques and are resistant to migration in the tissue.
FIG. 6 illustrates a first embodiment 60 of a radiopaque marker comprising a coil spring 62 from which extend radiopaque fibers 64 . The coil spring 62 is preferably made from platinum or any other material not rejected by the body. The coil spring 62 is wound to effectively form a hollow interior comprising one or more air pockets, which are highly visible using contemporary ultrasound imaging techniques. The radiopaque fibers 64 are preferably made from Dacron, which is also highly visible using current imaging techniques.
The radiopaque marker 60 is highly visible using any of the commonly employed contemporary imagining techniques because of the combination of reflective surfaces formed by the coils, the hollow interior and the air pockets of the coil spring 62 , as well as the radiopaque fibers 64 .
The coil spring 62 is pre-shaped prior to being loaded into the marker recess 46 so that it tends to form a circular shape as shown in FIG. 6 after it is ejected from the marker recess 46 . The circular shape tends to resist migration within the tissue.
FIG. 7 illustrates a second embodiment 70 of a radiopaque marker having a star-burst configuration comprising a core 72 with multiple fingers 74 extending from the core.
FIG. 8 illustrates a third embodiment 80 of a radiopaque marker that is similar to the star-burst marker 70 in that it comprises a core 82 from which extend three fingers 84 . Each of the fingers includes radiopaque fibers 86 , which are preferably made from Dacron or a similar material.
FIG. 9 illustrates a fourth embodiment 90 of a radiopaque marker having a generally Y-shaped configuration comprising an arm 92 from which extend diverging fingers 94 . The arm and fingers 92 , 94 are preferably made from a suitable resilient metal such that the fingers can be compressed towards each other and the entire radiopaque marker 90 stored within the marker recess 46 of the cannula. Upon ejection of the marker 90 from the marker recess 46 into the tissue mass, the fingers 94 will spring outwardly to provide the marker 90 with an effectively greater cross-sectional area.
In addition to providing the marker 90 with an effectively greater cross-sectional area, the tips of the fingers 94 , together with the free end of the arm 92 , effectively form points of contact with the surrounding tissue mass that help to anchor the marker 90 in its release condition to prevent migration through the tissue mass.
FIG. 10 illustrates a fifth embodiment 100 of a radiopaque marker having a wire-form body in a horseshoe-like configuration comprising a rounded bight portion 102 from which extend inwardly tapering legs 104 , each of which terminate in curved tips 106 . The entire marker 100 preferably has a circular cross section defining a hollow interior 108 . The hollow interior provides for the trapping of air within the marker 100 to improve the ultrasound characteristics of the marker 100 .
The curved bight portion 102 and legs 104 preferably lie in a common plane. However, the tips 106 extend away from the legs 104 and out of the common plane so that the tips 106 will better function as anchors for the tissue that prolapses about the tips 106 once the marker 100 is ejected from the marker recess 46 and the introducer 12 is withdrawn from the tissue mass.
FIG. 12 illustrates a sixth embodiment 110 of a radiopaque marker that is similar to the horseshoe-like fifth embodiment marker 100 in that it comprises a bight portion 112 from which extend legs 114 , which terminate in tips 116 . The legs 114 of the marker 110 are crossed relative to each other, unlike the legs of the marker 100 , providing the marker 110 with an effectively larger cross-sectional diameter. The tips 116 are oriented at approximately 90° relative to the legs 114 to form anchors. The marker 110 also has a hollow interior 118 for enhanced radiopaque characteristics.
Though, as illustrated in FIG. 12 , the tips 116 of the marker 110 are oriented at approximately 90° with respect to the legs 114 , it is within the scope of the invention for the tips 116 to extend at substantially any angle with respect to the legs 114 . The tips 116 also need not extend away from the legs in the same direction. For example, the tips 116 could extend in opposite directions from the legs 114 .
FIG. 13 illustrates a seventh embodiment 120 of a radiopaque marker having a generally helical configuration comprising multiple coils 122 of continuously decreasing radius. The helical marker 120 is preferably made from a radiopaque material and has a hollow interior 124 to enhance its radiopaque characteristics. The decreasing radius of the coils 122 provides the marker 120 with multiple anchor points created by the change in the effective cross-sectional diameter along the axis of the helix. In other words, since the effective cross-sectional diameter of each coil is different from the next and each coil is effectively spaced from adjacent coils at the same diametric location on the helix, the tissue surrounding the marker 120 can prolapse between the spaced coils and each coil effectively provides an anchor point against the tissue to hold the marker 120 in position and prevent its migration through the tissue mass.
FIG. 14 illustrates an eighth embodiment 130 of a radiopaque marker comprising a cylindrical body 132 in which are formed a series of axially spaced circumferential grooves 134 . The spaced grooves 134 form a series of ridges 136 therebetween on the outer surface of the cylindrical body 132 . The cylindrical body 132 preferably includes a hollow interior 138 .
The alternating and spaced ridges 136 and grooves 134 provide the marker 130 with a repeating diameter change along the longitudinal axis of the cylindrical body 132 . As with the helical marker 120 , the grooves 134 between the ridges 136 provide an area in which the tissue surrounding the marker 130 can prolapse thereby enveloping the ridges 136 , which function as anchors for preventing the migration of the marker 130 in the tissue mass.
FIG. 15 illustrates a ninth embodiment 140 of a radiopaque marker comprising a cylindrical body 142 having an axial series of circumferential grooves 144 whose intersections with adjacent grooves form ridges 146 . The cylindrical body 142 preferably includes a hollow interior 148 . An anchor 150 extends from the cylindrical body 142 . The anchor 150 comprises a plate 152 connected to the cylindrical body 142 by a wire 154 .
The grooves 144 and ridges 146 of the maker 140 provide anchors in the same manner as the grooves 134 and ridges 136 of the marker 130 . The anchor 150 further enhances the non-migrating characteristics of the marker 140 by permitting a large portion of the surrounding tissue mass to prolapse between the plate 150 and the cylindrical body 142 .
The fifth through the ninth embodiments all preferably have a wire-form body. The various wire-form body shapes can be formed by stamping the shape from metal stock or the bending of a wire.
It should be noted that virtually all of the embodiments of the radiopaque marker described as being hollow can be made without a hollow interior. Similarly, those without a hollow interior can be made with a hollow interior. The hollow interior improves the ultrasound characteristics of the particular marker beyond the inherent radiopaque and ultrasound characteristics attributable to the marker shape and material. In practice, the use of the hollow interior is limited more by manufacturing and cost considerations rather than by performance.
Also, the shape of each marker can be altered to improve or enhance its non-migrating characteristics by adding an express anchor such as that disclosed in connection with the marker 140 or by modifying the marker to provide more anchor points as may be compatible with the basic configuration of the marker.
The combination of the enhanced radiopaque characteristics of the markers and the enhanced non-migrating features result in markers that are superior in use for identifying biopsy location after completion of the biopsy. The ability to accurately locate the biopsy site greatly reduces the amount of tissue that must be removed in a subsequent surgical procedure if the biopsy is cancerous. Additionally, the marker further enhances the ability to use percutaneous methods for removing the entire lesion, reducing the trauma associated with more radical surgical techniques.
The radiopaque markers described and illustrated herein are smaller than the staple-type clip and embolization coil used heretofore, thereby permitting a cannula of 14 gauge or less.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.
PARTS LIST
10
biopsy marking apparatus
12
introducer
14
radiopaque marker
16
handle
18
hollow interior
20
grip portion
22
nose portion
24
rear opening
26
detents
28
guide channels
30
guide passage
32
cannula seat
34
cannula
36
cannula interior
38
cannula pointed tip
40
stylet
42
stylet shaft
44
stylet base
46
marker recess
48
50
plunger
52
cylindrical body
54
catch
56
58
60
radiopaque marker
62
coil spring
64
radiopaque fibers
66
68
70
second embodiment radiopaque marker
72
core
74
markers
76
78
80
third embodiment radiopaque maker
82
core
84
fingers
86
88
90
fourth embodiment radiopaque marker
92
arm
94
fingers
96
98
100
fifth embodiment radiopaque marker
102
curved bight portion
104
legs
106
tips
108
110
sixth embodiment radiopaque marker
112
curved bight portion
114
legs
116
tips
118
hollow interior
120
seventh embodiment radiopaque marker
122
coil
124
126
128
130
eighth embodiment radiopaque marker
132
cylindrical body
134
grooves
136
ridges
138
hollow interior
140
ninth embodiment radiopaque marker
142
cylindrical body
144
grooves
146
ridges
148
hollow interior
150
anchor
152
plate
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A biopsy marking apparatus for placing a radiopaque marker at the location of a percutaneous biopsy. The biopsy marking apparatus comprises an introducer in combination with a radiopaque marker. The introducer ejects the radiopaque marker at the location of the biopsy. The introducer is configured to completely eject the radiopaque marker and prevent it from being subsequently drawn into the introducer as the introducer is removed from the biopsied tissue mass. The radiopaque marker has enhanced radiopaque characteristics and enhanced non-migration characteristics.
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RELATED APPLICATIONS
This is a continuation-in-part application of international patent application PCT/EP97/01604, filed Mar. 29, 1997, which claims priority of German patent application 196 13 939.2 and which is fully incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a device for stabilizing a continuous paper web in a paper-making machine in the vicinity of a roll, to which the paper web is carried on a belt, comprising a box that is located upstream of the roll and extends along the side of the belt opposite the paper web, whose inside opens toward the belt and in which an underpressure is generated for sucking the paper web against the belt.
The present invention further relates to a method for stabilizing a paper web in a paper-making machine in the vicinity of a roll, to which the paper web is carried on a belt, wherein an underpressure is generated along the belt for sucking the paper web against the belt.
A device and a method of this kind for stabilizing a paper web are generally known (DE-A-44 02 105, DE-A-35 04 820).
In the case of high web running speeds, in particular when making paper grades of low basis weights, there is a risk of blisters forming as the paper web is transferred from a belt to a roll. This is so because the air necessarily entrained by the rapidly running paper web will be squeezed off in the nip between the belt, for example a felt, and the roll so that it has to escape laterally. If no additional counter-measures are taken this then results in a blister forming between the paper web and the belt before the point of entry into the nip (point of contact between the belt and the roll). The air enclosed in the blister must escape via the lateral edges of the paper web. The formation of such blisters is of course undesirable as it may lead to operational trouble and impair the paper quality.
The before mentioned DE-A-35 04 820 proposes for this purpose to generate an underpressure in the area preceding the transfer of the paper web to the roll, so as to suck the paper web against the belt in order to counteract the formation of blisters.
Further, it has been known from the before-mentioned DE-A-44 02 105 to expose a press felt, before its entry into the nip, to an underpressure over a first area of its path and to the action of steam over a following area, in order to de-water the press felt and, thus, to increase the dry content. In addition, the underpressure so produced counteracts the formation of blisters.
However, the known devices and methods are relatively complex and not easy to use in certain areas of a paper-making machine, i.e. such as press sections on the one hand and drying sections on the other hand.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a device and a method for stabilizing a paper web in the vicinity of a roll, which safely prevent the formation of blisters even in the case of rapidly running paper webs with low basis weights and which permit safe guiding of the web in the different areas of a paper-making machine to be ensured in an inexpensive way.
It is a further object of the invention to provide a device and a method which permit safe transfer of the paper web from one roll to another roll in a wet section, in particular in a wire section or in a press section of a paper-making machine, even at very high running speeds.
These and other objects are achieved in a device of the before-mentioned kind by the fact that a deflector surface is provided on the side of the box opposite the paper web, through which the air entrained by the belt is deflected to the outside and which communicates via a slit with the inner space of the box, which latter is open toward the belt.
The object of the invention is thus perfectly achieved.
According to the invention, the air entrained by the paper web and/or the belt is directly used to generate the underpressure within the box. This is achieved according to the invention by the fact that the deflector surface is used for deflecting the entrained air and passing it over a slit so as to produce an underpressure in the box. Thus, the underpressure needed to prevent blisters from forming is produced in the box, according to the invention, in a particularly simple way, without any need for a fan. Due to the particularly simple structure the device according to the invention can be used at numerous points of a paper-making machine, for example for transferring a paper web from a press felt to a guide roll or a suction guide roll and/or to a belt running about such a roll, or for transferring a paper web to a smooth press roll, a calander roll or to a drying cylinder in a drying section of a paper-making machine, or else for stabilizing the paper web as it is guided over a wire in the area of a wire drive roll.
According to an advantageous design of the invention, the deflector surface is curved toward the outside, relative to the belt, whereby a particularly efficient suction effect is achieved.
In a first embodiment of the invention, the suction slit is formed at the end of the deflector surface.
According to an alternative design of the invention it is, however, preferred to arrange the suction slit so that it interrupts the deflector surface, whereby an improved suction effect is achieved. It is especially advantageous in this connection if the suction slit is placed at the beginning of the deflector surface, as the air entrained by the belt has its highest speed in this area so that an especially high underpressure can be generated above the suction slit at this point.
According to a further embodiment of the invention, the paper web is transferred to the roll, while the belt is guided over a second roll.
With this design, the device according to the invention is employed with particular advantage in the area of a nip where the paper web is transferred from the belt to a first roll, with the effect that any formation of blisters, which is particularly critical in this area, is avoided by the device according to the invention in an especially simple and inexpensive way.
According to a further development of the invention, the inner space of the box is sealed off against the second roll.
One thereby achieves careful sealing between the deflector surface and the guide roll so that any pressure losses are minimized in order to ensure optimum effectiveness of the underpressure inside the box.
Alternatively, the object of the invention is achieved, in a device of the before-mentioned kind, by the fact that the box comprises a first and a second zone, the first zone being configured as an underpressure zone, for sucking the paper web against the belt, and the second zone being arranged downstream of the first zone and being designed as a pressure zone.
Although the first alternative of the invention is absolutely sufficient for most applications, this second alternative permits the paper web to be influenced very purposefully in order to avoid any formation of blisters, while at the same time the pressure zone that follows the underpressure zone facilitates the transfer of the paper web to the roll, making the transfer to the roll particularly safe. Thus, the paper web is sucked against the belt with sufficient safety in the zone of increased pressure before the roll, while at the same time the pressure zone provided downstream thereof makes the transfer to the roll particularly advantageous. This pressure-assisted transfer makes it possible in many cases to avoid the use of a suction roll and to permit instead the use of a simple roll. This leads to considerable cost savings.
According to a preferred further development of the invention, an air flow is generated in the box along the belt, essentially in the direction of movement of the belt, with a bottleneck being provided at the rear end of the box which acts to deflect the air flow toward the belt.
This arrangement provides a particularly simple way to guide the air inside the box.
Here again, a second roll may be arranged beside the roll, for guiding the belt, while the paper web is transferred from the belt to the first roll.
According to an advantageous further development of the invention, the box is sealed off from the belt by a sealing strip at its front delimiting surface, viewed in the direction of movement of the belt.
According to another advantageous further development of the invention, the box is sealed off by a sealing strip also against the second roll.
This feature provides an improved sealing effect between the box and the belt and/or the second roll.
As has been mentioned before, the first roll may be configured as guide roll or as suction guide roll, over which a press felt or a smooth felt is guided, and the second roll may be configured as a felt guide roll for guiding the belt from which the paper web is transferred to the other press felt, that latter belt being likewise configured as a press felt.
Further, the first roll may also be configured as press roll, as wire guide roll, as calander roll or as drying cylinder, to which the paper web is transferred from the belt.
With respect to the method of the invention, the object is further achieved, in a method of the before-mentioned kind, by the fact that an overpressure acting in the direction of the paper web is produced behind the underpressure zone, viewed in the direction of movement of the belt.
The invention thus on the one hand safely avoids any formation of blisters before the point of transfer of the paper web to the roll, while on the other hand the overpressure assists to transfer the paper web to the roll, with the advantages that have been described before.
In this context, an air flow, that is deflected in the direction of the belt, can be produced along the belt, substantially in the direction of movement of the belt.
It is thereby rendered possible to achieve a particularly simple air-guiding arrangement for the purpose of generating the underpressure and the overpressure.
According to an additional further development of that embodiment, air is blown off to the outside and in the direction of movement of the belt on both the guide and the drive ends of the belt.
This again has the effect to make the underpressure generation and/or the pressure generation in the different zones particularly efficient.
According to an alternative embodiment of the method according to the invention, the object of the invention is achieved, in a method of the before-mentioned kind, by the fact that the air flow entrained by the belt is deflected and utilized for generating an underpressure by means of which the paper web is sucked against the belt.
It is thus possible to produce the underpressure required to avoid the formation of blisters in an especially simple way, as the very air, that is entrained by the belt, is utilized thereby eliminating the need for a fan.
It is understood that the features mentioned above and those yet to be explained below can be used not only in the respective combinations indicated, but also in other combinations or in isolation, without leaving the context of the present invention.
SHORT DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention are evident from the description below of preferred exemplified embodiments, with reference to the drawings in which:
FIG. 1 shows a diagrammatic representation of a first embodiment of the invention, illustrating the area of a nip where the paper web is transferred from a belt to a first roll, while the belt is deflected by a second roll, with a compressed-air supply being provided for generating an underpressure;
FIG. 2 shows a diagrammatic representation of a second embodiment of the invention, likewise comprising a compressed-air supply in the area of a nip;
FIG. 3 shows a diagrammatic representation of a third embodiment of the invention, without a compressed-air supply in the area of a nip;
FIG. 4 shows a diagrammatic representation of a fourth embodiment of the invention, without a compressed-air supply in the area of a nip;
FIG. 5 shows a diagrammatic representation of a fifth embodiment of the invention, where the device according to the invention is arranged before a wire drive roll;
FIG. 6 shows a diagrammatic representation of a sixth embodiment of the invention, where the device according to the invention is arranged before the point of entry of the paper web into a press nip;
FIG. 7 shows a diagrammatic representation of another possible application of the invention, at the point of transfer to a smooth press roll; and
FIG. 8 shows a diagrammatic representation of another possible application of the invention, at the point of transfer of the paper web to a drying cylinder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a detail of a press section of a paper-making machine, where a paper web 18, being guided on a belt 20 configured as a press felt, is transferred from the belt 20 to a press felt 24 which latter runs about a roll 12 configured as a suction roll, from where it is transferred to a downstream press roll 16.
The belt 20 is guided over, and deflected by, a felt guide roll 14 arranged a short way downstream of the suction roll 12. In the area upstream of the two rolls 12, 14, a device 10 according to the invention is arranged below the belt 20 for stabilizing the paper web 18, the device 10 extending substantially in parallel to the belt 20 and over the full width of the paper web 18.
As a result of the high running speeds, air layers are necessarily entrained by the belt 20 and the press felt 24 with the result that an air flow 28 acting in the direction of movement 26 is produced above the paper web 18, and a parallel air flow 30, also acting in the direction of movement 26, is produced below the belt 20. In addition, a corresponding air flow 32, acting in the direction of movement of the press felt 24, is also produced at the surface of the press felt 24 that is guided over the roll 12.
As the belt 20, with the paper web 18 carried thereon, contacts the roll 12 in the so-called felt nip 13, the air flows 28 and 32 are squeezed off at that line of contact. In addition, an air layer produced between the paper web 18 and the belt 20 by relaxation of the belt and/or re-humidification of the paper web, is also entrained and squeezed off at the felt nip. In particular in the case of high running speeds and low basis weights, the air dammed up causes the paper web 18 to bulge out or to form a blister, as illustrated by the broken line 34 in FIG. 1. This means that the paper web 18 is slightly lifted off the belt 20, on which it is guided, before the felt nip 13 and comes to "float" on the cushion formed by the air flow 28, with the effect that part of the air can escape from the blister 34 laterally via the edges of the paper web 18.
Such formation of blisters is of course extremely undesirable as it increases the risk of failure and as it may under certain circumstances impair the paper quality.
The device 10 according to the invention serves to prevent such formation of blisters.
The device 10 comprises a closed box 11 which is arranged below the belt 20 and which extends parallel to the belt 20 and ends shortly before the surface of roll 14, with an air gap 37 on the order of roughly 20 mm being maintained with respect to the lower side of belt 20. At its front delimiting surface 41, viewed in the direction of movement 26, the box 11 is sealed off from the belt 20, i.e. against the press felt, by a sealing strip 40 which extends transversely to the direction of movement 26. With respect to roll 14 the box 11 is delimited by a limiting surface 43 which extends parallel to the surface of roll 14. The box 11 is sealed against roll 14 at its lower side by a further sealing strip 42.
Along air gap 37, which is formed between the surface of box 11 and the lower side of belt 20, air is blown by a blower 33a into the interior of box 11, as indicated by arrow 33. The air emerges via an outblow slit 35 with respect to the guide side and to the drive side and possibly into the direction of movement 26 against felt leading roll 14, as indicated by arrows 36. This leads to an underpressure within box 11 below belt 20, and consequently any formation of blisters before the felt nip 13 is prevented and an air flow in the direction of arrows 38 through belt 20 is formed.
A modification of the invention is shown in FIG. 2.
In this figure as well as in the following figures the same reference numerals are used for corresponding parts.
The device, indicated generally by reference numeral 10a, comprises a box 11, of roughly trapezoidal cross-section, that extends over the full width of the paper web and along the lower face of the belt 20, with an air gap 37 being maintained between the box and the lower surface of the belt 30. At its front delimiting surface 41, viewed in the direction of movement 26, the box 11 is again sealed off from the belt 20 by a sealing strip 40. However, in contrast to the design according to FIG. 1, the rear delimiting surface 43 of the box 11, facing the roll 14, is however arranged at a certain spacing from the surface of the roll 14 and is not sealed against the roll 14 by a seal. Consequently, there exists an air gap between the rear delimiting surface 43 of the box 11 and the surface of the roll 14. At the rear end of the box, facing the roll 14, the air gap 37 is narrowed by a bottleneck 44 with the result that the air flow is accelerated on its way through the bottleneck in the direction of arrows 46, and through the downstream zone B.
Air is blown off along the air gap 37 toward the drive end and toward the lead end and in the direction of movement 26 toward the roll 14, so that in the area below the belt 20 an air flow is produced from the underpressure zone A through the bottleneck 44 into the zone B, as indicated by arrows 46. In the zone B, following the bottleneck 44, between the box 11 and the roll 14, a zone of slight overpressure results since the air flowing in through the gap 44 dams up between the rear delimiting surface 43 of the box 11 and the roll 14 and escapes toward the bottom and at the same time through the belt 20 toward the top, as indicated by arrows 36, which assists to transfer the paper web 18 to the roll 12.
Another embodiment of the device according to the invention, somewhat simplified as compared with the embodiments described before, is illustrated in FIG. 3 and indicated generally by reference numeral 10b.
This device comprises again a box 11, extending below the belt 20, over the full width of the paper web and up to a short distance before the roll 14. At its front end, viewed in the direction of movement 26, the box 11 is sealed off against the belt 20 by a sealing strip 40.
In contrast to the embodiments described before, this embodiment does without the assistance of a fan; instead the air flow 30 at the lower surface of the belt 20 is used for producing an underpressure in the enclosed space between the box 11 and the belt 20. To this end, the air flow is deflected by a sealing strip 40, that extends over the full width of the paper web, from the bottom of the belt 20 in downward direction and along a curved deflector surface 48, as indicated by arrows. 51. On the bottom face of the box 11, there is provided a wall 50 that screens the roll 14 off against the air flow and that prevents any backflow of the air entrained by the roll 14. Thus, the air flow exiting toward the bottom, as indicated by 54, results in a diffuser effect that causes an underpressure to build up in a suction slit 52 formed between the lower end of the deflector surface 48 and the wall 50, so that a somewhat lower pressure, indicated by P 2 in FIG. 3, occurs in the enclosed space 39 of the box 11 defined by the bottom of the belt 20, the deflector surface 48 and the wall 14 and, at its end face, by the end sealing plates. Given the fact that a somewhat higher pressure, indicated by P 1 in FIG. 3, occurs in the area above the paper web 18, a pressure gradient P 2 -P 1 results with the effect that air flows in the direction of arrows 38 through the belt 20 and in downward direction and escapes from the box 11 through the suction slit 52 in downward direction, as indicated by arrow 54.
At its lead and end faces, the box 11 is sealed off against the belt 20 and the roll 14 by respective end sealing plates, with a minimal gap.
All in all, it is possible in this way to avoid the formation of blisters before the felt nip 13, and this even without the additional assistance of a fan.
A variant of the embodiment described before with reference to FIG. 3 is illustrated with reference to FIG. 4. In the case of that device, which is indicated generally by reference numeral 10c, the air flow 30 is again deflected by the sealing strip 40 from the bottom surface of the belt 20 in downward direction and is further deflected in downward direction by the downwardly curved deflector surface 48 that extends over the full width of the paper web, in order to generate an underpressure in the box 11.
In contrast to the embodiment described before with reference to FIG. 3, the suction slit is in this case provided not at the end of the deflector surface 48, but rather at the beginning of the deflector surface 48, immediately behind the sealing strip 40, by which the box 11 is sealed at its front end, in the direction of movement 26, against the belt 20. The end of the inner space 39 of the box facing the second roll 14 is sealed off by a wall 50 against the second roll 14, which latter can be inclined relative to the roll 14. Again, the box 11 has its end sealed on the lead and drive sides.
This altogether ensures efficient sealing of the inner space 39 against the outside and against the second roll 14, while the arrangement of the suction slit 52 at the beginning of the deflector surface 48 leads to an especially good suction effect. The suction slit 52, extending from the deflector surface 48 to the inside of the box, terminates by a delimiting surface 55 in the inner space 49 of the box, that extends initially roughly in parallel to the belt 20, and then approximately at a right angle away from the belt 20 and in downward direction, being then sealed off at its lower end against the second roll 14 by a wall strip 52. The deflector surface 48 and the delimiting surface 55 create an enclosed volume of substantially triangular cross-section that reduces the inner space 39 of the box 11, thereby considerably increasing the effect of the underpressure in the inner space 39.
Thus, it is possible, even without an additional fan, to achieve a good underpressure effect in the inner space 39 of the box which avoids any formation of blisters and ensures safe guiding of the strip.
It goes without saying that such a device for stabilizing the paper web can be provided not only in the area of a press section of a paper-making machine, as has been illustrated above with reference to FIGS. 1 to 4. Instead, such a device can be used in all contexts where a paper web has to be transferred from a belt to a roll.
This will be explained in more detail with reference to FIGS. 5 to 8.
FIG. 5 shows a detail of a paper-making machine in the area of transfer from a wire section 65 to a downstream press section 78.
In the wire section 65, the paper web 18, carried on the belt 20 designed as wire, is guided over the wire drive rolls 60, 21. Upstream of the wire drive roll 60, there is provided a device 10d according to the invention, which may have the same configuration as that shown in FIG. 4. The box 11 acts to suck the paper web 18 against the belt 20 so that the wire drive roll 60, over which the wire is guided, need not be configured as a suction roll, which in turn results in corresponding cost savings. Thereafter, the paper web 18 is removed from the wire in a manner known as such, by means of a take-over roll 64 in the form of a wire roll, and is guided between an upper felt 68 and a lower felt 70 through a first press nip formed between a shoe press with an upper shoe press roll 72 and a lower back-up roll 74. The upper felt 68 runs in the known manner about a felt guide roll 62 and the take-over roll 64 trough the press nip and is deflected, downstream of the press nip, by a felt guide roll 76. A felt guide roll 66 guides the lower felt 70 to the paper web 18 at a point a short way downstream of the take-over roll 64.
Another possible application of the invention is illustrated in FIG. 6. In this case, the device 10e according to the invention, the design of which may be identical to the device 10c according to FIG. 4, is arranged on the entry side of the paper web 18 into a press nip 85 that may be formed for example by a stand-alone shoe press 12, 14 with the shoe press roll arranged at the bottom.
The paper web 18 is taken over from a roll 80, which may be the central roll of the press section, by means of a take-over roll 82 and is then transferred to the belt 20, that is designed as lower felt and runs on felt guide rolls 84, 87. After having passed the press nip 85, the paper web 18 is taken off the roll 12 by a take-over roll 86 and is then transferred to a downstream drying section not shown in the drawing.
The roll 80 and the roll 12 are cleaned in the known manner by means of scrapers 88, 89.
Other generally possible applications of the invention are illustrated in FIGS. 7 and 8.
In FIG. 7, a roll 12 and a back-up roll 92 form together a press nip through which a press felt 98, if necessary, may be guided via felt guide rolls 94, 96.
A paper web is guided on the belt 20, configured as a press felt, over a front felt guide roll 90 and a rear felt guide roll 14 and is transferred from the belt 20 to the roll 12, which latter is configured as a smooth press roll. In the area of the felt nip 13, there is again provided a device according to the invention, which is indicated generally by reference numeral 10f and can be designed according to FIG. 1, FIG. 2, FIG. 3 or FIG. 4, as necessary under the particular circumstances. In any case, an underpressure is generated in the area of the felt nip 13, which acts to prevent any formation of blisters. If the device 10f is equipped with an active fan assist feature, a certain overpressure is additionally produced at the rear end of the device 10f, viewed in the running direction of the strip, to assist the transfer of the paper web to the roll 12.
The roll 12 may of course also consist of a roll of any other kind, such as a calander roll or a drying cylinder.
FIG. 8 illustrates the transfer of a paper web to a roll 12 designed as drying cylinder. In this case, the paper web is transferred from the belt 20 to a roll 12 of a drying section 104, which roll is in this case designed as a drying cylinder, and is then guided via a drying wire 100 guided over the roll 12 via a deflection roll 102.
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In the device disclosed, a paper web is carried on a belt and stabilized by an underpressure produced by a box opposite the roll, the paper web being sucked by the underpressure against the belt. Located in the box, immediately following the underpressure zone, may be a pressure zone which assists to transfer the paper web to the roll. In an alternative embodiment, a fan can be avoided. Instead the air entrained by the rapidly running belt is deflected by a wedge-shaped deflector and passed over a slit to generate an underpressure inside the box.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 62/050,286 filed on Sep. 15, 2014, which is hereby incorporated by reference herein in its entirety.
GOVERNMENT RIGHTS
[0002] This invention was made with government support under Contract No. FA8721-05-C-0002 awarded by the U.S. Air Force. The government has certain rights in this invention.
FIELD
[0003] The subject matter described herein relates generally to antennas and, more particularly, to wideband, multi-functional antennas that are capable of compact implementation.
BACKGROUND
[0004] In recent years, there has been an increasing demand for miniature multifunction antennas in both military and commercial applications. There has also been a demand for antennas and other radio frequency (RF) systems that can adapt to changing operational frequency band requirements. While software defined radio (SDR) technologies provide the desired flexibility in the receiver and processing systems, antennas are still largely designed as static devices. As a result, many RF systems include multiple antennas to service different applications or physically large antennas to provide a bandwidth wide enough to cover multiple applications with a single antenna. Both of these solutions require that a relatively large area be provided for antennas. As such, these solutions may not be adequate for use in many systems having limited available space (e.g., handheld devices, unmanned vehicles (aerial, terrestrial, and aquatic), body worn sensors, communication satellites, micro-satellites, avionics systems, wireless access points, wireless network interface devices, cellular base stations, and/or others). In addition, if a desired operating frequency band or other operational parameter later changes, these solutions may require an antenna re-design. As will be appreciated, such redesign efforts are both costly and time consuming.
[0005] There is a need for wideband, multi-function antenna structures and techniques that are capable of implementation in a relatively compact area. There is also a need for antenna structures and techniques that are capable of adapting to changing operational requirements.
SUMMARY
[0006] The present disclosure relates to miniature multifunctional antenna designs that are capable of achieving wide operational bandwidths from a relatively small antenna. The antennas utilize pixelated radiating structures that can be optimized for size reduction and bandwidth enhancement. In some embodiments, multi-level antennas are provided where one or more higher frequency pixelated radiating structures are implemented on one or more intermediate levels between a lower frequency pixelated radiating structure and a ground plane. Such multilevel structures are capable of providing wider instantaneous bandwidths than a single level antenna with little or no increase in physical size. In some embodiments, antennas are provided that can be reconfigured in the field for optimal operation in different frequency bands and/or different polarizations. Structures and techniques for controllably modifying a pixel topology of an antenna are also provided.
[0007] In accordance with one aspect of the concepts, systems, circuits, and techniques described herein, an antenna system comprises: a first pixelated radiating element on a first level; one or more second pixelated radiating elements on a second level, the second level being different from the first level; and a ground plane located below the first and second levels, the ground plane serving as a ground plane for radiating elements on both the first level and the second level, wherein the one or more second pixelated radiating elements fit within an outer boundary of the first pixelated radiating element projected onto the second level.
[0008] In one embodiment, the second level is between the first level and the ground plane; the first pixelated radiating element is operative in a first frequency range; and each second pixelated radiating element is operative in a second frequency range that is higher than the first frequency range.
[0009] In one embodiment, the antenna system further comprises a controller configured to multiplex feeds associated with the first and second pixelated radiating elements together to achieve a single wideband instantaneous bandwidth for the antenna system that is a combination of the first and second frequency ranges.
[0010] In one embodiment, the controller is configured to dynamically select a frequency mode for the antenna system from a group of frequency modes, wherein the group of frequency modes includes at least two of: a mode operative in the first frequency range, a mode operative in the second frequency range, and a mode operative in a wideband frequency range achieved by multiplexing feeds of the first and second pixelated radiating elements together.
[0011] In one embodiment, the antenna system further comprises one or more third pixelated radiating elements on a third level, the third level being between the second level and the ground plane, wherein each third pixelated radiating element is operative in a third frequency range that is higher than the second frequency range.
[0012] In one embodiment, the upper band edge of the first frequency range is approximately the same as the lower band edge of the second frequency range.
[0013] In one embodiment, the first pixelated radiating element is optimized to achieve small size and wide bandwidth; and the one or more second pixelated radiating elements are scaled versions of the first pixelated radiating element.
[0014] In one embodiment, the antenna system further comprises a third pixelated radiating element on the first level that is orthogonally oriented with respect to the first pixelated radiating element.
[0015] In one embodiment, the antenna system further comprises one or more fourth pixelated radiating elements on the second level, wherein each of the fourth pixelated radiating elements is orthogonally oriented with respect to a corresponding second pixelated radiating element.
[0016] In one embodiment, the antenna system further comprises a controller to select one of multiple polarization modes for the antenna system and to couple feeds of radiating elements on the first and second levels in a manner that supports the selected polarization mode, wherein the multiple polarization modes include at least two of: a vertical polarization mode, a horizontal polarization mode, a left hand circular polarization mode, and a right hand circular polarization mode.
[0017] In one embodiment, the first pixelated radiating element includes a plurality of adjustable pixels that can each be individually changed between multiple pixel states in response to one or more control signals; each of the second pixelated radiating elements includes a plurality of adjustable pixels that can each be individually changed between multiple pixel states in response to one or more control signals; and the antenna system further comprises a controller configured to: (a) provide control signals to the adjustable pixels of the first pixelated radiating element to modify a response of the first pixelated radiating element and (b) provide control signals to the adjustable pixels of the second pixelated radiating elements to modify responses of the second pixelated radiating elements.
[0018] In one embodiment, the controller is configured to adapt a pixel geometry of the first pixelated radiating element and a pixel geometry of the at least one second pixelated radiating element based on requirements of one or more applications currently being performed by the antenna, wherein the applications being performed can change with time.
[0019] In one embodiment, at least one of the pixelated radiating elements on the first and second levels includes one or more adjustable pixels having a conductive pixel element and a plurality of electronic switching devices coupled between the conductive pixel element and conductive pixel elements associated with adjacent adjustable pixels.
[0020] In one embodiment, at least one of the pixelated radiating elements on the first and second levels includes one or more adjustable pixels having a reservoir of a liquid conductive material coupled to a pixel chamber, wherein the adjustable pixel is activated by applying pressure to the reservoir to force the liquid conductive material into the pixel chamber.
[0021] In one embodiment, the controller is configured to adjust pixel geometries of pixelated radiating elements on the first and second levels to achieve optimized operation within a selected one of: a single narrow frequency band, multiple frequency bands, or a single wide frequency band.
[0022] In one embodiment, the antenna system further comprises: at least one sensor to measure a performance metric of the antenna; and a controller configured to determine new pixel geometries for the first and second pixelated radiating elements in the field based at least in part on readings of the at least one sensor.
[0023] In accordance with another aspect of the concepts, systems, circuits, and techniques described herein, an antenna system comprises: a first pixelated radiating element on a first level, the first pixelated radiating element having a plurality of adjustable pixels that can each be individually changed between multiple pixel states in response to one or more control signals; at least one second pixelated radiating element on a second level, the at least one second pixelated radiating element having a plurality of adjustable pixels that can each be individually changed between multiple pixel states in response to one or more control signals; and a ground plane located below the first and second levels, the ground plane serving as a ground plane for radiating elements on both the first level and the second level, the second level being located between the first level and the ground plane, wherein the at least one second pixelated radiating element fits within an outer boundary of the first pixelated radiating element projected onto the second level.
[0024] In one embodiment, the antenna system further comprises a controller configured to determine new pixel geometries for one or more of the first pixelated radiating element and the at least one second pixelated radiating element in the field to support optimized operation within one or more frequency ranges not currently supported by the antenna system.
[0025] In one embodiment, the antenna system further comprises a controller configured to: (a) identify a degraded response of one or more of the first and second pixelated radiating elements during antenna operation; and (b) determine a new pixel geometry for each radiating element having a degraded response to improve the response of the radiating element.
[0026] In one embodiment, the adjustable pixels of the first and second pixelated radiating elements include at least one adjustable pixel having a conductive pixel element and a plurality of electronic switching devices coupled between the conductive pixel element and conductive pixel elements associated with adjacent adjustable pixels.
[0027] In one embodiment, the adjustable pixels of the first and second pixelated radiating elements include at least one adjustable pixel having a reservoir of a liquid conductive material coupled to a pixel chamber, wherein the adjustable pixel is activated by applying pressure to the reservoir to force the liquid conductive material into the pixel chamber.
[0028] In one embodiment, the edges of the first and/or second pixelated radiating layers are shorted to the ground using shorting posts or a shorting plate or other shorting structure.
[0029] In one embodiment, a layer of artificially constructed material such as a metamaterial or magnetic composite is disposed below the second layer to achieve resonance at an even lower frequency.
[0030] In one embodiment, the edges of the first and/or second pixelated radiating layers are connected to shorting pins or shorting plates or other shorting structure(s) through resistors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The foregoing features may be more fully understood from the following description of the drawings in which:
[0032] FIG. 1 is a diagram illustrating an antenna aperture optimization technique that may be used in one or more embodiments;
[0033] FIGS. 2 and 3 illustrate an exemplary optimized pixelated bowtie antenna in accordance with an embodiment;
[0034] FIG. 4 is a plot of reflection coefficient versus frequency for the exemplary optimized antenna of FIGS. 2 and 3 ;
[0035] FIG. 5 is a diagram illustrating an exemplary multilevel optimized pixelated antenna in accordance with an embodiment;
[0036] FIG. 6 is a diagram illustrating an exemplary single level optimized pixelated antenna that is capable of providing multiple polarization modes in accordance with an embodiment;
[0037] FIGS. 7A and 7B are diagrams illustrating an exemplary switch-based reconfigurable pixelated antenna structure that may be used to provide real time reconfiguration in accordance with an embodiment;
[0038] FIGS. 8A and 8B are diagrams illustrating an exemplary liquid metal-based reconfigurable pixelated antenna structure that may be used to provide real time reconfiguration in accordance with an embodiment; and
[0039] FIG. 9 is a block diagram illustrating an exemplary wireless communication device having a reconfigurable antenna system in accordance with an embodiment.
DETAILED DESCRIPTION
[0040] In the description that follows, various features, concepts, and techniques are described in the context of a bowtie antenna above ground. It should be appreciated that these features, concepts, and techniques may also be used with other types of planar or conformal radiating structures and surfaces.
[0041] FIG. 1 is a diagram illustrating an antenna aperture optimization technique that may be used in one or more embodiments described herein. As shown, a conventional bowtie antenna 10 may include two triangular bowtie metallization regions 12 , 14 spaced above a ground plane 16 . The bowtie metallization regions 12 , 14 act as the radiating surfaces of the antenna. A dielectric layer 18 may separate the bowtie metallization regions 12 , 14 from the ground plane 16 . A radio frequency (RF) feed 20 may extend through the ground plane 16 to feed one of the bowtie regions (i.e., region 12 ) near a central portion of the bowtie. A shorting pin 22 may be coupled between the ground plane 16 and the other bowtie region 14 , also near the central portion of the bowtie. As part of an antenna aperture optimization technique, the bowtie regions 12 , 14 (i.e., the radiating surfaces) may be parameterized into a multitude of pixels 22 . That is, these radiating surfaces may be divided into a large number of small elements having known locations and shapes.
[0042] An optimization process may then be performed that is intended to determine an optimal state for each of the pixels 22 to achieve one or more predetermined design goals for the antenna (e.g., wide bandwidth with small antenna size, etc.). Each of the pixels may have two or more different states. In a binary pixel embodiment, for example, each pixel will have two possible states, one where the pixel includes metallization and another where it does not. The optimization process may be used to determine an overall pixel topology for the antenna that optimally or near optimally achieves the design goals of the antenna. Various different optimization strategies may be used to arrive at an optimized pixel topology. An optimized bowtie 24 is shown on the right in FIG. 1 .
[0043] In general, parameterizing a bowtie into N pixels produces p N different antenna geometries, where p is the number of topologies or states associated with each pixel. The topology of a pixel may be altered by varying the dimensions of the pixel (e.g., changing length and/or width) or by turning the pixel ON and OFF. For example, an antenna parameterized into 40 binary pixels (ON-OFF states) leads to 2 40 or over 1 trillion antenna geometries. Techniques may be used to identify an optimal or near optimal geometry for the antenna for achieving desired design goals. In at least one embodiment, a genetic algorithm is used to identify an optimal or near optimal geometry. Other optimization techniques may alternatively be used. In some embodiments, once an optimized pixel geometry has been decided upon, radiators having that optimized geometry may then be fabricated. However, in some embodiments, as will be described in greater detail, configurable pixelated antenna structures are provided that allow an optimized pixel geometry to be achieved in situ.
[0044] FIG. 2 is a diagram illustrating an assembled optimized pixelated bowtie antenna 30 . As shown, the antenna 30 includes first and second optimized pixelated bowtie metallization regions 32 , 34 spaced above a ground plane 36 . A feed 38 is coupled to the first optimized bowtie region 32 and a ground pin 40 is coupled to the second optimized bowtie region 34 near a central point of the antenna 30 . In addition, a plurality of shorting pins 42 are used to couple outer edges of the optimized bowtie regions 32 , 34 to the ground plane. Instead of shorting pins, a shorting wall or other shorting structure may also be used. FIG. 3 is a cross-sectional side view of the antenna 30 of FIG. 2 . As shown, the first and second optimized pixelated bowtie regions 32 , 34 may be implemented upon a first dielectric board material 44 and the ground plane 36 may be implemented upon a second dielectric board material 46 . A feed connector 48 may be used to feed the antenna 30 . Because dielectric boards are used to carry the bowtie members and the ground plane, an open space 50 is defined within the antenna 30 between the bowtie regions 32 , 34 and the ground plane 36 .
[0045] In at least one implementation, an optimized pixelated bowtie antenna similar to antenna 30 of FIGS. 2 and 3 was designed that is operative within a band extending from 1.2 GHz to 5.2 GHz. This corresponds to a bandwidth of 4.3:1 for an antenna that is less than ⅕ wavelength (λ/5) in size at 1.2 GHz. In this example, the operational band of the antenna is defined as the frequency band within which the reflection coefficient of the antenna is below −10 dB (i.e., the band edges are the frequencies at which the reflection coefficient transitions above −10 dB). FIG. 4 is a plot of reflection coefficient versus frequency for the exemplary optimized antenna described above.
[0046] In at least one embodiment, to achieve an even wider band of operation, a multilevel pixelated antenna approach is implemented in which one or more pixelated radiating surfaces are implemented within the outer boundaries of another pixelated antenna (e.g., in the open region between the radiating surface and the ground plane of the other antenna). FIG. 5 is a diagram illustrating an exemplary multilevel antenna 60 in accordance with an embodiment. As shown, the antenna 60 includes optimized pixelated bowtie radiating surfaces 62 , 64 on an upper level thereof with an underlying ground plane 66 as in the antenna 30 of FIG. 2 . However, the antenna 60 further includes an array of higher frequency pixelated bowtie radiators 68 on an intermediate level between the upper level and the ground plane 66 . The ground plane 66 may serve as a ground plane for radiators on both the upper level and the intermediate level.
[0047] In at least one implementation, the radiators 68 on the intermediate level can be a scaled version of the bowtie on the upper level. That is, for example, the antenna having bowtie radiating surfaces 62 , 64 , which is operative within a frequency range between 1 GHz and 5 GHz, can be scaled down by a factor of 4 to achieve bowtie radiators operative within a frequency range between 5 GHz and 20 GHz. Because the scaled down antenna is significantly smaller, multiple of these antennas may be implemented on the intermediate level of the larger antenna without increasing the overall size of the antenna. In some embodiments, however, only a single antenna is implemented on the intermediate level. In fact, any number of antennas may be implemented on the intermediate level in different implementations if space permits.
[0048] As described above, in some implementations, the radiator(s) on the intermediate level is a scaled version of the radiator on the upper level. However, in some embodiments, further refinement may be used to overcome, for example, mutual coupling effects between the two levels. For example, in one approach, an in situ re-optimization of the pixel geometry on each level may be performed to overcome mutual coupling and/or other effects between levels.
[0049] In some embodiments, a multi-level antenna design as shown in FIG. 5 may have multiple different modes of operation. For example, such an antenna may be operated within a single band mode or a multi-band mode. In multi-band mode, a controller may switch between the feeds of the different levels when operation within either the band associated with the upper level (1 GHz-5 GHz) or operation within the band associated with the intermediate level (5 GHz-20 GHz) is desired. In single band mode, a controller may multiplex the feeds from both levels together to create an instantaneous ultra-wideband response. For example, in the multi-level antenna 60 of FIG. 5 , diplexing the feeds from the two levels would produce an instantaneous bandwidth of 1 GHz to 20 GHz.
[0050] In the exemplary multi-level antenna 60 of FIG. 5 , two different levels are provided. This same approach can be extended to included three or more different levels within a single antenna. For example, in one possible implementation, the bowtie on the upper level of antenna 60 of FIG. 5 could be scaled up by a factor of four to achieve a larger antenna operative in the frequency range of 300 MHz to 1.2 GHz. Four antennas 60 of FIG. 5 could then be implemented below the new lower frequency radiator to achieve an overall bandwidth for the 3 level structure from 300 MHz to 20 GHz. The number of levels may be further increased to achieve even larger operational bandwidths. As described above, an in situ re-optimization may be performed for the 3 (or more) level antenna to overcome mutual coupling and/or other effects between levels. The total dimensions of a multi-level antenna system will typically be determined by the lowest frequency of operation. For example, in the two level embodiment of FIG. 5 , the lowest frequency is 1 GHz and the entire antenna fits in a box with dimensions less than 49 mm by 49 mm by 13 mm. This corresponds to roughly λ/5 by λ/5 by λ/23 at 1 GHz and represents a very small antenna in terms of size-bandwidth ratio.
[0051] In the multi-level antenna embodiments described above, all radiating surfaces are pixelated and optimized. In some other embodiments, however, multi-level antennas are provided that include one or more radiating surfaces that are not pixelated or optimized. For example, in the antenna 60 of FIG. 5 , instead of four optimized bowties 68 on the intermediate level, a single non-pixelated bowtie may be used. This single non-pixelated bowtie may, for example, have an operational frequency band with a lower band edge at 5 GHZ. Because of the higher frequency, the non-optimized element could still fit within the outer boundaries of the bowtie 62 , 64 on the upper level.
[0052] In the multi-level antenna embodiments described above, the radiators on the intermediate level(s) are the same type of radiator as the ones on the upper level (i.e., bowties). In some other embodiments, multi-level antennas are provided that use different types of radiators on the various levels. For example, a bowtie could be used on the upper level and one or more dipoles or patches could be used on an intermediate level. Other configurations are also possible.
[0053] In some embodiments, reconfigurable antennas are provided that are capable of switching between different polarizations during antenna operation. In this manner, the antennas can be used in systems that implement polarization diversity. FIG. 6 is a diagram illustrating an exemplary single level optimized pixelated antenna 80 that is capable of providing multiple polarization modes in accordance with an embodiment. As shown, the antenna 80 includes two bowtie radiators 82 , 84 arranged orthogonally to one another on a single metallization layer above a ground plane 86 . At any particular time, a controller may select either vertical, horizontal, or circular polarization for this antenna and use the corresponding antenna feeds to achieve transmission or reception. One bowtie can be used to achieve vertical polarization and the other can be used to achieve horizontal polarization. For circular polarization, the controller may combine the feeds of both bowties 82 , 84 using a 90 degree phase shift for one of the feeds (depending on whether right hand or left hand circular polarization is desired). In one approach, circular polarization may be achieved using a pair of 90 degree hybrids and corresponding switches. When right hand circular polarization is desired, one of the hybrids may be switched into the circuit and when left hand circular polarization is desired, the other hybrid may be switched into the circuit. Other hardware based techniques for achieving circular polarization may alternatively be used. Circular polarization may also be achieved using digital processing.
[0054] The polarization diversity approach illustrated in FIG. 6 may be extended to multi-level designs to create ultra-wideband antennas with polarization diversity. For example, one or more higher frequency intermediate levels may be added to the antenna 80 of FIG. 6 with each level having one or more multi-polarization radiating structures like the one shown (i.e., two orthogonal, pixelated, optimized bowties). Each level would then be capable of polarization diversity and a single wideband response could be achieved at any polarization. Again, any number of levels could be used to achieve a desired instantaneous bandwidth. Also, in situ optimization could be used to re-optimize the various levels to overcome mutual coupling and/or other inter-level effects.
[0055] In the embodiments described above, various antenna structures and technique are provided for achieving wide bandwidth operation from a relatively small antenna. It may not always be desirable, however, to operate over the full operational bandwidth of such an antenna. That is, in many applications, it may be preferable to operate over a narrower frequency band or multiple narrower bands. As described previously, in some embodiments, a multi-level antenna may be operated within either a single band mode or a multi-band mode. That is, the antenna may be operated using the bands associated with the various levels individually or it may multiplex the feeds together to form a single wide instantaneous bandwidth. In some embodiments, however, antennas are provided that are capable of being reconfigured and re-optimized in the field for use in different frequency band scenarios. To enable users to electronically reconfigure pixelated radiating surfaces in real time to produce one or more desired frequency responses, various reconfiguration structures/techniques have been developed.
[0056] FIGS. 7A and 7B are diagrams illustrating an exemplary switch-based reconfigurable pixelated antenna structure 90 that may be used to provide real time reconfiguration of pixelated radiating surfaces in accordance with an embodiment. As illustrated, the antenna structure 90 includes two orthogonal pixelated bowtie radiators 92 , 94 disposed above a ground plane 96 . However, instead of having static optimized pixelated radiating surfaces, the bowtie radiators 92 , 94 include a plurality of low-loss ultrawideband switching devices coupled between pixel elements that allow a wide variety of different pixel geometries to be achieved. In this manner, the antenna structure 90 may be reconfigured in the field for optimal operation in different desired frequency bands. If a relatively narrow frequency band is desired, the pixel geometry may be reconfigured to provide optimal performance within that narrow band. This may enable, for example, a better reflection coefficient to be achieved over the narrow band than would be available in this band if the antenna was optimized for a much wider bandwidth. The ability to switch from wideband to narrow band may be preferred (or even ideal) for operations in noisy environments among other things. If wider band operation is desired, the pixel geometry may be reconfigured to provide optimal performance over a wide bandwidth (such as in the antenna of FIG. 5 ).
[0057] FIG. 7B is a close up view of a portion 98 of bowtie radiator 92 of FIG. 7A . As shown, a plurality of switching devices 102 are provided to controllably interconnect a plurality of pixel elements 100 . The switching devices 102 can be individually turned on and off by a controller. The controller can thus achieve a wide variety of different pixel geometries by turning on different sub-groups of switching devices 102 . Any type of switching devices 102 may be used, including both transistors and diodes, provided they are capable of providing the switching speed and operational bandwidth required to support desired applications. In at least one embodiment, pneumatically actuated liquid metal switches are used for the switching devices 102 . Other types of devices that may be used include but are not limited to MEMS switches, transistors, pin diodes, high resistive silicone switches, varactors, and/or others. By isolating the pixels and interconnecting them with switching devices, the task of finding pixel configurations through computer simulation is reduced to finding switching configurations in real time that interconnect the appropriate pixels to create antenna geometries with desired electrical responses.
[0058] Although the antenna structure 90 of FIGS. 7A and 7B uses specific types of radiating elements and a specific number of pixel elements per radiating surface, it should be appreciated that these attributes are not intended to be limiting. That is, this approach to providing a reconfigurable antenna structure may be used with any type of planar or conformal radiating element. In addition, any number of pixels may be used in different implementations. The more pixels that are used in a particular implementation, the greater the number of pixel geometries that are available. However, a greater number of pixels may involve a larger amount of computational complexity to find optimal geometries. The features illustrated in FIGS. 7A and 7B may be extended to multi-level antennas to achieve an antenna that is reconfigurable on multiple different levels and over an extended bandwidth range.
[0059] FIGS. 8A and 8B illustrate another exemplary technique for achieving a reconfigurable pixelated antenna structure in accordance with an embodiment. In this technique, a liquid metal material is used to provide controllable pixels for a radiating surface of an antenna. As shown in FIG. 8A , a reservoir of liquid metal is provided in close proximity to a pixel chamber. The pixel is “activated” by applying pressure to the corresponding reservoir, thereby forcing the liquid metal into the pixel chamber, as shown in FIG. 8B . When the pixel is not part of a present pixel geometry, the liquid metal remains in the reservoir. Conductive interconnects may be provided between adjacent pixel chambers to provided electrical continuity between pixels that are currently active (i.e., filled with liquid metal). In at least one embodiment, galinstan is used as the liquid metal. Other liquid metals such as mercury and gallium/indium, conductive liquids or gel-based materials may alternatively be used. This approach may be used in single level and multi-level antennas and may be used with any type of planar or conformal radiating surface. This technique may also be used in multi-polarization antennas such as antenna 80 of FIG. 6 .
[0060] Either of the above-described approaches may be used to provide an antenna that is reconfigurable in the field to provide optimal operation within different desired frequency band scenarios. In some embodiments, antennas are provided that utilize both of these techniques. For example, in one embodiment, a multi-level antenna may be provided that uses a switch-based reconfiguration approach (as shown in FIGS. 7A and 7B ) on an upper level and a liquid metal approach (as shown in FIGS. 8A and 8B ) on one or more intermediate levels. Other combinations may also be made.
[0061] FIG. 9 is a block diagram illustrating an exemplary wireless communication device 110 having a reconfigurable antenna system in accordance with an embodiment. As illustrated, the wireless communication device 110 may include: a reconfigurable pixelated antenna system 112 , a wireless transceiver 114 , a controller 116 , and memory 118 . The reconfigurable pixelated antenna system 112 may include any of the reconfigurable antenna structures and variations described above, including both single level and multi-level antennas. The wireless transceiver 114 may include any device having transmit functionality for generating radio frequency (RF) signals for transmission from the device 110 via antenna 112 and receive functionality for processing signals received from an exterior wireless channel via antenna 112 . The controller 116 may be operative for, among other things, reconfiguring the reconfigurable pixelated antenna system 112 in real time or near real time to achieve one or more desired antenna responses. The controller 116 may include one or more digital processing devices to perform the control function. The digital processing device(s) may include one or more of, for example, a general purpose microprocessor, a digital signal processor (DSP), a reduced instruction set computer (RISC), a complex instruction set computer (CISC), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a programmable logic array (PLA), a microcontroller, an embedded controller, and/or others, including combinations of the above. Memory 118 is operative for storing one or more of: an operating system of controller 116 , one or more application programs of controller 116 , and/or user data for controller 116 . Memory 118 may include any type of device, or combination of devices, capable of storing digital data.
[0062] As described above, the controller 116 may be operative for reconfiguring the reconfigurable pixelated antenna system 112 in real time or near real time to achieve one or more desired antenna responses. The controller 116 may, for example, be capable of re-configuring the antenna system 112 to operate with different polarizations during different time periods. Likewise, the controller 116 may be capable of modifying the pixel geometry of one or more radiating surfaces of the antenna system 112 to optimize a frequency response of one or more corresponding antenna elements. For example, if the switch-based reconfiguration approach of FIGS. 7A and 7B is being used, the controller 116 may be programmed to activate appropriate switches to achieve one or more desired optimized pixel geometries. Similarly, if the liquid metal-based reconfiguration approach of FIGS. 8A and 8B is being used, the controller 116 may be programmed to apply pressure to certain liquid reservoirs of the antenna to achieve one or more desired optimized pixel geometries. If a multi-level antenna is being used, the controller 116 may be capable of independently re-configuring pixel geometries on different levels of the antenna.
[0063] In at least one embodiment, configuration data may be stored within memory 118 that corresponds to one or more different antenna pixel geometries that may be desired during operation of the communication device 110 . For example, one configuration file may include switching data (or liquid metal pixel activation data) for achieving a widest possible bandwidth in the antenna 112 . Other data files may be stored for achieving optimized narrower bandwidth operation. The controller 116 may first determine which antenna response is currently desired and then retrieve corresponding configuration data from memory 118 . The retrieved configuration data may then be used to configure the antenna 112 .
[0064] If a multi-level antenna is being used, the controller 116 may also be programmed to configure the antenna 112 to operate in either single band or multiband mode. As described previously, in multi-band mode, the controller 112 may switch between the feeds of the different levels when operation within either the band associated with the upper level or operation within the band associated with an intermediate level is desired. In single band mode, the controller 112 may multiplex the feeds from multiple levels together to create a wide instantaneous bandwidth.
[0065] In addition to the functions described above, the controller 116 may also provide control to the wireless transceiver 114 during operation of the wireless communication device 110 . For example, when a new application is initiated, the controller 116 may first reconfigure the antenna 112 to operate with the new application. When the reconfiguration is complete, the controller 116 may signal the transceiver 114 that transmission and/or reception can now commence for the new application. Alternatively, the controller 116 may instruct the transceiver 114 when to transmit and/or receive for the new application.
[0066] In some embodiments, the wireless communication device 110 may be capable of determining new pixel geometries and/or configuration data for the reconfigurable antenna 112 in the field to achieve new antenna responses. For example, in one embodiment, as shown in FIG. 9 , the wireless transceiver 114 may include an embedded voltage standing wave ratio (VSWR) sensor 120 for use in developing configuration data for antenna 112 . The VSWR sensor 120 may form a feedback control loop with the controller 116 for use in developing configuration data for the antenna 112 to achieve one or more desired responses. The controller 112 may iterate through, for example, a number of different pixel geometries for the antenna 112 and send corresponding configuration data to the antenna 112 . In each case, the controller 112 may cause the transceiver 114 to deliver one or more transmit signals (e.g., a series of signals having different frequencies, a single signal having a swept frequency, etc.) to the antenna 112 and corresponding VSWR values may be measured by the sensor 120 . The VSWR values may then be fed back to the controller 116 for use in selecting a pixel geometry to achieve the desired response. After the pixel geometry has been selected, the corresponding configuration data may be stored in the memory 118 . Any of a number of different optimization techniques may be used by controller 116 for quickly finding an optimized pixel geometry to provide a desired response. In at least one embodiment, a genetic algorithm is used to find a desired pixel geometry, although other techniques may alternatively be used.
[0067] The above-described technique for determining a new pixel geometry for a reconfigurable antenna may be used to, for example, optimize the antenna for use with a new or different application or frequency range. The technique may also, or alternatively, be used to provide a self-healing capability for the antenna for use in cases where one or more component failures have affected the antenna's ability to achieve one or more previously determined optimized responses. For example, one or more switch failures in an antenna may compromise the antenna's ability to achieve an optimal response across a wide bandwidth. A system having self-healing capability would be able to detect the defective condition and, in response, determine a new pixel configuration for the antenna for achieving the desired response. This self-healing capability can also be used to compensate for detuning effects other than component failures (e.g., component aging, effects caused by moisture absorption, etc.).
[0068] Although shown as part of the wireless transceiver 114 in FIG. 9 , it should be appreciated that the VSWR sensor 120 may alternatively be part of the antenna 112 or a separate sensor unit may be provided between the transceiver 114 and the antenna 112 . Other types of sensors may be used as an alternative to, or in addition to, the VSWR sensor 120 of FIG. 9 .
[0069] As used herein, the terms “optimal,” optimized,” and the like do not necessarily refer to the best possible configuration of an antenna to achieve a desired goal over all possible configurations, but can refer to the best configuration that was found during an optimization procedure given certain limits of the procedure. For example, there may be a time limit placed upon a search for an optimized pixel geometry to produce a particular response. In this case, an optimized or optimal pixel geometry may be a geometry that was found during the time limited search. In another optimization technique, an optimization procedure may continue until a predetermined performance level has been achieved. In this case, an optimal pixel geometry may be a final geometry which achieved the predetermined performance level. As stated previously, the number of possible pixel geometries in some implementations can be very large (e.g., p N ). It may be impossible to check every possible geometry to find the one that performs “best” at achieving a desired design goal.
[0070] Having described exemplary embodiments of the invention, it will now become apparent to one of ordinary skill in the art that other embodiments incorporating their concepts may also be used. The embodiments contained herein should not be limited to disclosed embodiments but rather should be limited only by the spirit and scope of the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.
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Miniature multifunctional antennas and related techniques are disclosed that are capable of wide bandwidth operation. In some embodiments, the antennas are capable of being reconfigured in the field for optimal performance in different frequency band configurations (e.g., a single wide instantaneous bandwidth, multiple smaller bands, etc.) and/or for purposes of self healing. In some embodiments, the antennas can be reconfigured in the field to achieve different polarizations (e.g., vertical, horizontal, circular). The antennas can be implemented in a very compact manner making them ideal for use in devices and platforms where size and weight are a concern.
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RELATED APPLICATIONS
The present application is related to the subject matter of the following applications: Ser. No. 09/363,464 (Docket No. AT9-98-945) entitled “Compressed String and Multiple Generation Engine” and filed Jul. 29, 1999; Ser. No. 09/263,667 (Docket No. AT9-98-525) entitled “An Instruction Buffer Arrangement for a Superscalar Processor” and filed Mar. 5, 1999; Ser. No. 09/345,161 (Docket No. AT9-98-939) entitled “Method and Apparatus for Modifying Instruction Operations in a Processor” and filed Jun. 29, 1999; and Ser. No. 09/363,463 (Docket No. AT9-98-948) entitled “XER Scoreboard Mechanism” and filed Jul. 29, 1999. The content of the above-referenced applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to data processing systems and in particular to a processor in a data processing system. More particularly, the present invention relates to scoreboarded special purpose registers on board the processor.
2. Description of the Related Art
Reduced instruction set computer (“RISC”) processors are employed in many data processing systems and are generally characterized by high throughput of instructions. RISC processors usually operate at a high clock frequency and because of the minimal instruction set do so very efficiently. In addition to high clock speed, processor efficiency is improved even more by the inclusion of multiple execution units allowing the execution of two, and sometimes more, instructions per clock cycle.
As used herein, “clock cycle” refers to an interval of time accorded to various stages of an instruction processing pipeline within the processor. Storage devices (e.g. registers and arrays) capture their values according to the clock cycle. The storage device then stores the value until the subsequent rising or falling edge of the clock signal, respectively.
Processors with the ability to execute multiple instructions per clock cycle are described as “superscalar.” Superscalar processors, such as the PowerPC™ family of processors available from IBM Corporation of Armonk, N.Y., provide simultaneous dispatch of multiple instructions. Included in the processor are an Instruction Cache (IC), an Instruction Dispatch Unit (IDU), an Execution Unit (EU), an Instruction Sequencer Unit (ISU) and a Completion Unit (CU). Generally, a superscalar, RISC processor is “pipelined,” meaning that a second instruction is waiting to enter the execution unit as soon as the previous instruction is finished.
Generally a pipeline comprises a plurality of pipeline stages. Each pipeline stage is configured to perform an operation assigned to that stage upon a value while other pipeline stages independently operate upon other values. When a value exits the pipeline, the function employed as the sum of the operations of each pipeline stage is complete. In a pipelined superscalar processor, instruction processing is usually accomplished in six stages—fetch, decode, dispatch, execute, writeback and completion stages.
The fetch stage is primarily responsible for fetching instructions from the instruction cache and determining the address of the next instruction to be fetched. The decode stage generally handles all time-critical instruction decoding for instructions in the instruction buffer. The dispatch stage is responsible for non-time-critical decoding of instructions supplied by the decode stage and for determining which of the instructions can be dispatched in the current cycle. A typical RISC instruction set (for PowerPC™) contains three broad categories of instructions: branch instructions (including specific branching instructions, system calls and Condition Register logical instructions); fixed point instructions and floating point instructions. Each group is executed by an appropriate function unit.
The execute stage executes the instruction selected in the dispatch stage, which may come from the reservation stations or from instructions arriving from dispatch. The completion stage maintains the correct architectural machine state by considering instructions residing in the completion buffer and utilizes information about the status of instructions provided by the execute stage. The write back stage is used to write back any information from the rename buffers that is not written back by the completion stage.
All pipelined instructions pass through an issue stage sequentially, but enter different pipeline stages so instructions may be stalled or out of order for proper execution. Utilizing scoreboard controls is a technique for resolving register access conflicts in a pipelined computer. Each potential dependency is recorded as a single bit, set when a register source operand is decoded and another single bit set when a register destination operand is decoded. The use of a register for fetching an operand is stalled if that register is indicated as the destination for a decoded but not yet executed instruction.
Scoreboard controls are often implemented because there are registers which are not renamed that could potentially be written to out of order or read from before they had been properly updated by a write operation. Also, register renaming may not be appropriate because of the complexity of the renaming scheme and the physical cost in processor area and timing of the rename hardware. In a microcode expansion unit, which uses data from various scoreboarded registers (such as the Integer Exception Register (XER) or Special Purpose Registers (SPR)), utilizing scoreboard controls prior to or during action by a microcode expansion unit is undesirable. It is undesirable to implement such a mechanism due to the complexity and potential timing impact on critical path circuitry.
X-form string instructions, which utilize the string count field of the XER to determine how many bytes are to be loaded or stored, require the XER to determine the count of generating instructions from microcode (Ucode). The string count field of the XER is not renamed and the instruction sequence generated by the Ucode unit is many pipe stages earlier. Because of this, the Ucode unit and the Instruction Sequencer Unit (ISU) must determine that no Internal Operation (IOP) that may trigger the ISU's XER scoreboard is in flight between the IDU and the ISU. Also, if the ISU's XER scoreboard is active, the IDU must be stalled. The Ucode generation for the string instruction must wait until the correct XER value is sent to the IDU or the registers that have not been renamed could be potentially written to out-of-order. If scoreboard controls are used in a microcode expansion unit the timing impact on critical path circuitry is significant.
It would be desirable therefore, to improve performance of microcode implementation of string instructions requiring count data in a superscalar processor without utilizing scoreboard controls prior to or during microcode expansion unit operation.
SUMMARY OF THE INVENTION
It is therefore one object of the present invention to provide a method and apparatus such that proper ordering of register reads and writes is enforced.
It is another object of the present invention to provide a method and system that will utilize an existing scoreboard function to stall the pipeline until an XER count is confirmed valid.
It is yet another object of the present invention to provide a method and apparatus that will test the existing scoreboard and maintain separation between testing and executing an instruction.
The foregoing objects are achieved as is now described. A dummy instruction, “mfXER” (move from integer exception register), is issued. An instruction sequencer unit (ISU) detects the mfXER instruction and stalls the pipeline until the scoreboard indicates the XER count is valid. No Operation—Internal Operations (NOP—IOPs) are inserted between write and read SPR IOPs to allow an ISU scoreboard mechanism to be activated before being tested by the read SPR IOP. A dummy read of the string count field or a predetermined scoreboarded SPR, is employed to read from a scoreboarded SPR. A predetermined number of dummy IOPs follow the initial dummy read to prevent the broadcast value of the string count field from being sampled. Further, a non-functional or “reserve from normal use” SPR, which may be written to and then read from, will implement the same function.
The above as well as additional objects, features, and advantages of the present invention will become apparent in the following detailed written description.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a block diagram of a processor and related portions of a data processing system by which a preferred embodiment of the present invention may be implemented;
FIG. 2 is a high-level block diagram of a superscalar processor in accordance with the present invention;
FIG. 3 illustrates a high-level flow diagram of a scoreboard state machine in accordance with the present invention;
FIG. 4 illustrates a high-level flow diagram of a method for a software based dispatch stall for scoreboard IOPs;
FIG. 5 depicts the state machine of FIG. 3 in an unknown state in accordance with a preferred embodiment of the present invention; and
FIG. 6 illustrates instruction flow in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the figures, and in particular with reference to FIG. 1, a block diagram of a processor and related portions of a data processing system in which a preferred embodiment of the present invention may be implemented, is depicted. Processor 100 is a single integrated circuit superscalar processor, such as the PowerPC™ processor available from IBM Corporation of Armonk, N.Y. Accordingly, processor 100 includes various units, registers, buffers, memories, and other sections, all of which are formed by integrated circuitry. Processor 100 also operates according to reduced instruction set computing (“RISC”) techniques.
Processor 100 includes level one (L 1 ) instruction and data caches (“I Cache” and “D Cache”) 102 and 104 , respectively, each having an associated memory management unit (“I MMU” and “D MMU”) 106 and 108 . As shown in FIG. 1, processor 100 is connected to system address bus 110 and to system data bus 112 via bus interface unit 114 . Instructions are retrieved from system memory (not shown) to processor 100 through bus interface unit 114 and are stored in instruction cache 102 , while data retrieved through bus interface unit 114 is stored in data cache 104 . A typical RISC instruction set (PowerPC™) contains three broad categories of instructions: branch instructions (including specific branching instructions, system calls and Condition Register logical instructions); fixed point instructions and floating point instructions. Each group is executed by an appropriate function unit. Instructions are fetched as needed from instruction cache 102 by instruction unit 116 , which includes instruction fetch logic, instruction branch prediction logic, an instruction queue and dispatch unit.
The dispatch unit within instruction unit 116 dispatches instructions as appropriate to execution units such as system unit 118 , integer unit 120 , floating point unit 122 , or load/store unit 124 . System unit 118 executes condition register logical, special register transfer, and other system instructions. Integer or “fixed-point” unit 120 performs add, subtract, multiply, divide, shift or rotate operations on integers, retrieving operands from and storing results in integer or general purpose registers (“GPR File”) 126 . Floating point unit 122 performs single precision and/or double precision multiply/add operations, retrieving operands from and storing results in floating point registers (“FPR File”) 128 .
Load/store unit 124 loads instruction operands from data cache 104 into integer registers 126 or floating point registers 128 as needed, and stores instructions' results when available from integer or floating point registers 126 or 128 into data cache 104 . Load and store queues 130 are utilized for these transfers from data cache 104 to and from integer or floating point registers 126 or 128 . Completion unit 132 , which includes reorder buffers, operates in conjunction with instruction unit 116 to support out-of-order instruction processing, and also operates in connection with rename buffers within integer and floating point registers 126 and 128 to avoid conflict for a specific register for instruction results. Common on-chip processor (COP) and joint test action group (JTAG) unit 134 provides a serial interface to the system for performing boundary scan interconnect tests.
The architecture depicted in FIG. 1 is provided solely for the purpose of illustrating and explaining the present invention, and is not meant to imply any architectural limitations. Those skilled in the art will recognize that many variations are possible. Processor 100 may include, for example, multiple integer and floating point execution units to increase processing throughput. All such variations are within the spirit and scope of the present invention.
Referring to FIG. 2, a block diagram of a superscalar processor in accordance with a preferred embodiment of the present invention, is depicted. To index instructions properly as instructions become wider in complex processors, it is important to optimize the translation from the complex instruction set with a large amount of implicit information to an explicit instruction set that does not require the use of architected registers. It is sometimes important to decompose or translate those instructions into two or more instructions that may not have a direct relationship to the original instruction to allow for faster execution of such instructions.
Processor 200 includes instruction fetch unit (IFU) 206 which provides signals to decode unit 204 which utilizes rename mapping structure 202 . Rename mapping structure 202 provides information directly to issue queues 211 - 217 . The issue queues 211 , 213 , 215 and 217 in turn feed execution units 210 , 212 a-b , 214 a-b , and 216 a-b.
Instruction cache 208 stores instructions received from IFU 206 . Data cache 230 receives data from execution units 210 - 216 . Level 2 (L2) cache 220 is utilized to store data and instructions from data cache 230 and instruction cache 208 . Processor 200 includes bus interface unit (BIU) 223 which passes information between L2 cache 220 and peripheral device interface 225 (i.e., memory, i/o device, mp).
In this embodiment, branch issue queue (BIQ) 211 provides information to condition register (CR) 218 or branch unit 210 . The floating point issue queue (FIQ) 213 provides information to floating point units (FPUs) 212 a and 212 b . Issue queue (IQ) 215 provides information to fixed point unit (FXU) 214 a and load/store unit (LSU) 216 . IQ 217 provides information to FXU 214 b and LSU 216 b . Although the issue queues are arranged in the above-identified manner, one of ordinary skill in the art readily recognizes, that the issue queues can be arranged in a different manner and that arrangement would be within the spirit and scope of the present invention.
Conditional register 218 provides and receives information from CR bus 201 . Floating point architectural registers (FPR) 220 provide and receive information from FPR bus 205 . General purpose registers (GPR) 224 and 226 provide and receive information from GPR bus 203 . Completion unit 207 provides information to rename mapping 202 via completion bus 209 .
Branch unit 210 provides and receives information via CR bus 201 utilizing, in a preferred embodiment, conditional registers 0-7 (CR 0-7). FPU 212 a and FPU 212 b provides information to CR 218 via CR bus 201 , utilizing in a preferred embodiment conditional register 1 CR1. FPU 212 a and 212 b also receive and provide information from and to FPR pool 220 via FPR bus 205 . FXU 214 a , FXU 214 b , LSU 216 a , LSU 216 b output results to CR 218 via CR bus 201 , utilizing in a preferred embodiment, conditional register 0 CR 0 . FXU 214 a , FXU 246 , LSU 216 a and LSU 216 b also receive and provide information from and to GPR pool 222 via GPR bus 203 . GPR pool 222 in a preferred embodiment is implemented utilizing a shadow GPR arrangement in which there are two GPRs 224 and 226 . All of the execution units 210 - 216 provide results to completion unit 207 via completion bus 209 .
Referring now to FIG. 3, a high-level flow diagram of a scoreboard state machine in accordance with the present invention, is illustrated. The state machine is shown as being reset into an unknown XER state 300 . The process moves to step 302 , which depicts a determination of whether a “move to XER” (mtXER) instruction is detected as being decoded. If no mtXER is detected as being decoded, the process repeats step 300 . If a mtXER instruction is detected as being decoded, the process moves to step 304 , which illustrates the state machine changing to XER busy state. The process then proceeds to step 306 , which depicts a determination of whether a “read from XER” (mfXER) is detected. If a mfXER is not detected, the process continues to step 304 and repeats. If a mfXER is detected the process instead passes to step 308 , which illustrates an X-form string being generated by the state machine. The state machine maintains XER busy state until a mfXER is detected and successfully dispatched. When a mfXER is detected and successfully dispatched the process proceeds to step 310 , which depicts the state machine transitioning to an idle state.
The process then passes to step 312 , which depicts a determination of whether a mtXER is detected. If a mtxer is detected, the process returns to step 304 and repeats. If a mtXER is not detected, the process instead passes to step 314 , which illustrates a determination of whether a mfXER is detected. If a mfXER is not detected, the process returns to step 304 and repeats. If a mfXER is detected, the process instead proceeds to step 314 , which depicts the state machine generating a short X-form string. The process continues to step 310 , which illustrates the state machine returning to an idle state. The process then passes to step 300 , where the state machine enters an unknown state.
Referring to FIG. 4, a high-level flow diagram of a method for a software based dispatch stall for scoreboard IOPs, is depicted. The process begins with step 400 , which depicts an operation, that utilizes a scoreboarded resource, being detected. The process then passes to step 402 , which illustrates a determination of whether the XER update is unknown or busy. If XER update is not unknown or not busy, the process passes to step 404 , which depicts the state machine of FIG. 3, generating a sequence of loads or stores for a string operation. If the XER update is busy, the process passes instead to step 406 , which illustrates generating a dummy read from the XER.
The process then passes to step 408 , which depicts dummy IOPs (NOPs) being added to delay completion of the string operation. Next, the process proceeds to step 404 , which illustrates generating a sequence of loads or stores for the string operation. The process then continues to step 410 , which depicts the generated string operations being executed.
Referring now to FIG. 5, the state machine of FIG. 3 shown is in an unknown state in accordance with a preferred embodiment of the present invention is illustrated. If the state machine is in an unknown scoreboard state 502 and a string operation (XER read) occurs, the internal code sequence will test (read) the XER (IOPs), insert (pad) dummy instructions (IOPs) and perform loads or stores. The state machine will also transition to SB_ACTIVE 504 (scoreboard active state) until the loads or stores are dispatched. At this point the state machine will transition to the scoreboard clear (SB_CLR) state. Subsequent XER read instructions will not require the test and pad IOPs until a flush or XER write instruction is detected.
FIG. 4 and FIG. 5 in combination illustrate the present invention. In summary, an operation that uses a scoreboarded resource is detected. A determination is made whether the XER register of the resource is busy and a state machine generates a sequence of loads and stores if the XER is not busy. If the XER is busy, the state machine generates a dummy read and dummy NOPs for padding the instruction stream, whereupon the state machine then generates the loads or stores. If the state machine in FIG. 5 is in an “unknown” scoreboard state and a string operation (XER read) is present, the resultant internal code sequence will test, pad the string with NOPs and perform the loads and stores. The state machine will also transition to the SB_ACTIVE (Scoreboard active) state until the loads and stores are dispatched. The state machine will then transition to the SB_CLR (scoreboard clear) state.
Referring now to FIG. 6, instruction flow in accordance with a preferred embodiment of the present invention, is depicted. The flow begins with fetcher 600 retrieving string instructions. The flow continues with the string instructions entering decode pipeline 602 . The string then enters the Instruction sequencer 604 which issues the string received from decode pipeline 602 . If the instruction will write the XER, the flow proceeds to set a scoreboard bit 610 . Concurrently, the instruction is sent to fixed point execution unit 606 which sends an XER string count to the XER register in dispatch unit 603 . As the string count is sent to the XER register, the scoreboard bit 610 is cleared.
NOP IOPs are inserted between the write and read SPR IOPs to allow the ISU scoreboard to be activated before being tested by the second read SPR IOP. A sequence which depends on valid SPR data:
mfspr
nop
nop
nop
mtspr
nop
nop
nop
nop
nop
nop
nop
nop
nop
nop
nop
mfspr
nop
nop
nop.
A non-functional or “reserve from normal use” SPR, which may be written to and then read from, will implement the same function as inserting the dummy operations (padding the sequence). A sequence that uses a “reserved” SPR address would utilize the following sequence:
mtspr
nop
nop
nop
nop
nop
nop
nop
nop
nop
nop
nop
mfspr
nop
nop
nop.
Utilizing an existing ISU scoreboard to confirm XER count, allows utilization of scoreboard controls in a microcode expansion unit without introducing timing problems in critical path circuitry. By issuing dummy instructions to predetermined registers, the pipeline is effectively stalled until a valid XER value is sent to the Instruction Dispatch Unit. X-form string instructions, utilizing the string count field of the XER to determine how many bytes are to be loaded or stored requires the XER to determine the count of generated instructions from microcode (Ucode).
It is important to note that those skilled in the art will appreciate that the mechanism of the present invention and/or aspects thereof are capable of being distributed in the form of a computer usable medium of instructions in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of computer usable media include: nonvolatile, hard-coded type media such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), recordable type media such as floppy disks, hard disk drives and CD-ROMs, and transmission type media such as digital and analog communication links.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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A dummy instruction is issued, followed by several groups of No Operations (NOPs). The instruction sequencer unit (ISU) detects the dummy instruction and stalls the pipeline until the scoreboard indicates the XER count is valid. After a read from a scoreboarded Special Purpose Register (SPR), No Operation—Internal Operations (NOP—IOPs) are inserted between write and read SPR IOPs to allow an ISU scoreboard mechanism to be activated before being tested by a read SPR IOP. A read-write-read sequence is utilized: a dummy read of the string count field from a scoreboarded SPR, writing that value back to the same SPR and then performing a read of the SPR once again. A predetermined number of dummy IOPs follow the initial dummy read to prevent the value of the string count field from being read too soon.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the art of dust collectors, which are adapted to separate solid particulate material from cleaned gas passing through a filter medium, and more particularly to an improved dust collector wherein cleaned gas is momentarily induced to flow back through the filter medium, countercurrent to the normal direction of flow during the filtration operation, to dislodge and remove solid material accumulating on one side of the filter medium.
2. Description of the Prior Art
Dust collectors having a filter medium operatively arranged to separate solid particulate material from cleaned gas passing therethrough, are known in the prior art, as representatively shown in my prior U.S. Pat. No. 3,864,108. In this prior patent, a plurality of filter bags were suspended in a dirty air chamber and a pulse of positively-pressurized cleaning gas, the velocity of which was further increased by passage through a venturi-like tube, was introduced into the bags to shock or puff accumulated solids collecting on the outer surface of the bags.
In U.S. Pat. No. 3,765,152, a jet of compressed air was passed through a venturi-tube to induce a reverse flow of cleaned air through the bags. However, this patent appears to provide a separate nozzle and venturi for each filter bag, and provides relatively complicated structure of considerable expense.
Additional details of other prior art structure may be shown in U.S. Pat. No. 3,368,328.
SUMMARY OF THE INVENTION
The present invention overcomes disadvantages in prior art structures by providing a unique improvement for a dust collector.
The improvement is particularly adapted for use in a dust collector having a dirty air chamber arranged to receive a flow of dirty air laden with suspended solid particulate material, a clean air chamber communicating with exhaust, and a plurality of filter bags operatively arranged to have their interior surfaces communicate with the dirty air chamber and operative to separate solid particulate material from cleaned air passing therethrough.
The improvement broadly includes an elongated venturi-like member arranged to separate a number of serviced filter bags from the dirty air chamber, this member having an entrance nozzle section, a throat section, and an exit nozzle section; a conduit arranged in the exit nozzle section and having a number of nozzles, such number preferably corresponding to the number of serviced filter bags, each of these nozzles being arranged proximate the open mouth of a filter bag and operative to discharge a pulse of high energy gas, such as compressed air, back through the various sections of the venturi-like member countercurrent to the normal flow of gas therethrough during the normal filtering operation; and supply means operatively arranged to supply a plurality of sequential pulses of such high energy gas to the conduit to be discharged through the nozzles to momentarily create a reduced pressure within the bags.
During the normal filtering operation, dirty air may pass through the venturi-like member to enter the filter bags, where solid particulate material is separated from cleaned air passing therethrough.
During the "reverse air" or bag cleaning operation, the discharged pulses of such high energy gas passing back through the venturi-like member momentarily create a reduced pressure within such serviced bags, which reduced pressure is lower than the pressure in the clean air chamber. Thus, the high energy pulses passing through the venturi-like member are operative to invert the normal positive pressure differential within the bags with respect to the clean gas chamber, and to induce cleaned air to flow back through the bags to dislodge and remove solid particulate material adhering to the inside surface of these serviced bags.
Accordingly, one general object of the present invention is to provide an improved dust collector having effective means for dislodging and removing solid particulate material collecting on the filter bag inner surfaces.
Another general object is to provide an improved dust collector wherein a number of filter bags may be serviced by a manifold venturi-like member.
Another object is to provide an improved design for a dust collector which is relatively uncomplicated in structure, relatively inexpensive to manufacture, and which affords the opportunity for compactness in size while simultaneously affording an effective bag cleaning operation.
These and other objects and advantages will become apparent from the foregoing and ongoing written specification, the drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a fragmentary transverse vertical sectional view of an improved dust collector, this view illustrating the dirty air chamber, the clean air chamber, and a row of filter bags operatively arranged to separate solid particulate material from cleaned gas passing therethrough, this view further showing a venturi-like member in central section, the conduit, and the supply means.
FIG. 2 is an enlarged fragmentary vertical sectional view thereof, taken generally on line 2--2 of FIG. 1, showing three adjacent venturi-like members arranged to service three adjacent rows of filter bags, the arrows in this view indicating the normal upward flow of dirty air into the filter bags.
FIG. 3 is a view generally similar to the view of FIG. 2, but illustrating the middle nozzles discharging a high energy pulse of compressed gas downwardly through the middle venturi-like member to momentarily invert the normal pressure differential and induce a reverse flow of cleaned gas back through the filter bags of the middle row to dislodge and remove accumulated solids.
FIG. 4 is a fragmentary perspective detail view of the left marginal end portion of one venturi-like member, with two filter bags removed for clarity of illustration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
At the outset, it should be clearly understood that like reference numerals are intended to identify the same elements and/or structure consistently throughout the several drawing figures, as such elements and/or structure may be further described or explained by the entire written specification of which this detailed description is an integral part.
Referring initially to FIG. 1, the present invention, of which the presently preferred embodiment is generally indicated at 10, is intended for use in a dust collector, of which one species is generally indicated at 11.
This particular species of dust collector includes an upper rectangular structure defined by a longitudinally-extending planar vertical left panel 12, a longitudinally-extending planar vertical right panel 13, a transversely-extending planar vertical back panel 14, and a transversely-extending planar vertical front panel (not shown); and a lower longitudinally-elongated hopper structure defined by a pair of longitudinally-extending downwardly and inwardly inclined planar left and right hopper panels 15, 16, respectively, having their upper divergent marginal end portions suitably secured to left and right upper panels 12, 13, respectively, extending the full length of the dust collector between the front and rear panels thereof, and having their lower convergent marginal end portions suitably secured to a longitudinally-extending trough 18 having a substantially U-shaped transverse cross-section. A longitudinally-elongated screw conveyor 19 is shown as being operatively arranged in trough 18, and has the front and rear marginal end portions (not shown) of its central shaft 20 suitably journalled on the front and rear panels of the dust collector. In the well known manner, a suitable means may be provided to rotate shaft 20 to cause the screw conveyor 19 to convey solid material accumulating in the bottom of the hopper structure, from the dust collector. The back panel 14 is shown further provided with an inlet opening 21 through which a flow of dirty air, containing suspended solid particulate material, may be supplied to the dirty air chamber, generally indicated at 22, of the dust collector.
This dust collector 11 is illustrated as further including a rectangular horizontal plate-like member 23 joining the four vertical panels of the dust collector and separating the lower dirty air chamber 22 from an upper clean air chamber, generally indicated at 24. This plate-like member is provided with a plurality of through holes, severally indicated at 25, which are arranged in a longitudinally-spaced series of transversely-extending rows, there being ten of such holes 25 in each such row of the illustrated dust collector. In the illustrated embodiment, the 10 filter bags of each row are arranged in two spaced banks of five each, the intermediate space 17 between these bags being available for use as a walkway for servicing the bags. Moreover, in this preferred embodiment, the longitudinal and transverse centerline spacing between adjacent holes 25 of the banks are equal to one another.
The dust collector 11 is depicted as further including a plurality of vertically-elongated substantially cylindrical filter bags, severally indicated by the general reference numeral 26, there being one filter bag for each of holes 25. Each of these filter bags 26 has its upper marginal end portion (not shown) suitably suspended or hung from the top (not shown) of the dust collector. The lower marginal end portion of each filter bag is suitably captured between an outer ring 28 and an inner ring 29 selectively attachable to the outer ring. Moreover, the outer peripheral surface of outer ring 28 is shown provided with an annular recess or groove 30 to enable the outer ring 28 to be snapped into a hole 25 such that the marginal portion of plate-like member 23 surrounding such hole will be received in groove 30, thereby retaining the lower marginal end portion of the filter bag in this engaged position with the plate-like member 23. Moreover, the operative side walls 31 of these filter bags are formed of a suitable gas-permeable medium, such as cloth or the like, and the cylindrical shape of wall 31 may be maintained by a plurality of vertically-spaced shape-retaining rings 32 suitably sewn into pockets formed in the wall 31.
Thus, during normal filtering operation of the dust collector, dirty air may enter dirty air chamber 22 through inlet opening 21 and rise upwardly to enter the interior of filter bags 26 through their open lower mouths. Thereafter, the gas-permeable filter medium operates to separate the suspended solid particulate material from cleaned gas passing through the filter bags to enter clean air chamber 24.
However, during such normal flow of air upwardly through the dust collector, it will be appreciated by those skilled in this art, that the separated solid particulate material will tend to collect or accumulate on the interior surfaces of the filter bags, thereby increasing the resistance of the filter medium to a normal flow of air therethrough. Over a period of time, such accumulated solids may form a significant cake on the interior surfaces of the filter bags, and may substantially reduce the operating efficiency of the dust collector.
To alleviate this problem, the present invention provides a simple and yet highly effective means for removing such accumulated solids from the interior surfaces of the filter bags, and which is believed to result in a more facile combination of structure than that heretofore known in the prior art.
To this end, the present invention 10 is shown as broadly including a plurality of venturi-like members, severally indicated at 33; a corresponding plurality of conduits, severally indicated at 34; and a corresponding plurality of supply means, severally indicated at 35.
Referring now to FIGS. 1, 2 and 4, each elongated venturi-like member 33 is shown as extending transversely of the dust collector from left panel 12 to right panel 13. As best shown in FIG. 2, and with reference to the normal upward flow of dirty gas, each venturi-like member 33 is configured to have, in cross-section, a lowermost entrance nozzle section 36, an intermediate throat section 38, and an uppermost exit nozzle section 39. Still referring principally to FIG. 2, the entrance nozzle section 36 is defined by a pair of elongated upwardly and inwardly inclined left and right planar walls 40, 41, respectively, which extend the full width of the dust collector from left panel 12 to right panel 13, with their divergent lowermost marginal end portions communicating with the dirty air chamber. The throat section 38 is defined by a pair of elongated left and right vertical planar walls 42, 43, respectively, also extending the full width of the dust collector, and having their lowermost marginal end portions suitably secured to the convergent upper marginal end portions of entrance nozzle section left and right walls 40, 41, respectively. The exit nozzle section 39 is defined by a pair of elongated upwardly and outwardly inclined left and right planar walls 44, 45, respectively, also extending the full width of the dust collector, and having their convergent lowermost marginal end portions suitably connected to the uppermost marginal end portions of throat section walls 42, 43, respectively. The divergent upper marginal end portion of each of exit nozzle section walls 44, 45 is shown suitably connected to the plate-like member 23 between adjacent rows of holes 25 by an elongated planar vertical common wall 46, which also extends the full width of the dust collector. Of course, in the commercial embodiment, spacers (not shown) may join the adjacent throat walls 42, 43 to maintain the desired spacing therebetween.
The various walls of the entrance nozzle, throat, and exit nozzle sections extend the full width of the dust collector from left panel 12 to right panel 13 so that each venturi-like member 33 may service the number of filter bags in a row. Thus, in the embodiment illustrated and described, each venturi-like member 33 is intended to service the ten filter bags in each row (FIG. 1), and one such venturi-like member is provided for each such row, this being fragmentarily illustrated in FIG. 2.
Adverting now to FIG. 1, a conduit 34 is provided in association with each venturi-like member 33. Each conduit 34 is shown as being an elongated pipe or tubular conduit which is arranged to penetrate left panel 12 and extend the full width of the dust collector. As best shown in FIG. 2, each conduit 34 is positioned between adjacent common walls 46, and is aligned with the transverse centerline of the holes 25 in a row. Moreover, each conduit is further provided with a number of discharge jets, severally indicated at 48, corresponding to the number of bags in each row. As may be best seen from a collective viewing of FIGS. 1 and 2, a jet 48 is provided on a conduit 34 vertically beneath each filter bag, and these jets are severally arranged to discharge a jet or pulse of a compressed gas, delivered by its associated conduit, downwardly into the exit nozzle and throat sections of its associated venturi-like member.
Adverting now to FIGS. 1 and 4, the supply means 35 is depicted as including a longitudinally-extending manifold pipe 49 having an electrically-operated solenoid valve 50 communicating manifold pipe 49 with each row of conduits 34. This manifold pipe 49 is connected to a suitable source (not shown) of pressurized gas, such as compressed air. Thus, the series of solenoid valves 50 may be sequentially operated to supply momentary pulses of compressed air to conduits 34 for discharge through jets 48 downwardly, this being countercurrent to the normal upward flow of gas through the dust collector.
The operation of the improved dust collector may be best understood with reference to FIGS. 2 and 3.
Referring now to FIG. 2, persons skilled in this art will readily appreciate that a positive pressure in the dirty air chamber relative to the pressure in the clean air chamber, will cause dirty gas containing suspended solid particulate material, to flow upwardly through venturi-like members 33 to enter the filter bags 25 where such solid particulate material will be separated from cleaned gas passing therethrough, such normal filtering flow being indicated by the direction of the schematic arrows in FIG. 2.
The bag cleaning operation is illustrated for the middle row of filter bags in FIG. 3. When the solenoid valve 50 of this middle row is operated, a pulse of compressed air will be discharged, by each of the nozzles 48 in this row, downwardly to pass through the venturi-like member. The effect of these discharged jets will be to reverse the normal upward flow of dirty gas through the venturi-like member, and to rapidly reduce the pressure within the row of serviced filter bags to a value lower than the pressure of the clean air chamber. By so inverting the normal pressure differential of the filter bags with respect to the clean gas chamber, clean air in the clean gas chamber will be induced to flow back through the filter medium to dislodge separated solid particulate material adhering to the inside surfaces of the bags, and to convey such dislodged material back through the venturi-like member to reenter the dirty air chamber. Moreover, while the normal pressure differential between the dirty and cleaned gas chambers may cause the filter bag walls to bow outwardly (FIG. 2), the pressure inversion caused by the reverse flow of the discharged pulses of compressed air causes the bag walls to snap inwardly (FIG. 3) to assist in dislodging such material from the bag walls.
Several significant advantages are afforded by use of the inventive dust collector herein disclosed. First, the structure is relatively simple, inexpensive to manufacture, and has no unnecessary moving parts within the dirty air chamber. Secondly, the bags of one row may be cleaned without interferring with the normal filtering operation of adjacent rows. Thirdly, this design allows a desirable minimum spacing between the filter bags, thereby affording the opportunity for compactness in dust collector size while preserving the capability for efficient dust collector operation.
Of course, persons skilled in this art will quickly appreciate that various changes or modifications may be made. Thus, while the preferred embodiment illustrates each venturi-like member as servicing ten bags, this number is not deemed critical and the number of serviced bags may be increased or decreased, as necessary. Similarly, while each of the entrance and exit walls is shown as converging at an imaginary acute included angle of from 75° to 85° (FIG. 3), persons skilled in this art will readily appreciate that such angles may be varied, as necessary. Moreover, a second supply pipe may be provided adjacent the right panel 13 and utilized in tandem with the illustrated supply means. It should be further understood that the size, configuration and spacing of the filter bags, and the particular shape and dimensions of the venturi-like members may be altered or modified, as necessary, to fit the design parameters, such as the normal pressure in the dirty air chamber, the normal pressure in the clean gas chamber, the pressure of the compressed gas, the length of the jet pulses, and the concentration of suspended solids.
Therefore, while the presently preferred embodiment of the present invention has been shown and described, persons skilled in this art will recognize that this illustrated embodiment constitutes only one particular species of the broad invention, which is generally defined in the following claims.
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A dust collector has a dirty air chamber arranged to receive a flow of dirty air containing suspended solid particulate material, a clean air chamber communicating with exhaust, and a plurality of filter bags arranged to have their interior surfaces communicate with the dirty air chamber and operative to separate solid particulate material from cleaned gas passing therethrough. The improvement includes an elongated venturi-like member arranged to service a number of such filter bags, and a conduit arranged to deliver high energy pulses of reverse air through the venturi-like member countercurrent to the normal flow of dirty gas therethrough. Such pulses of reverse air momentarily create a reduced pressure within the serviced filter bags, and induce cleaned gas to flow back through the serviced filter bags to dislodge and remove accumulated solid particulate material from the interior surfaces of such bags.
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BACKGROUND
[0001] The present invention relates to a detachable combination shoe-pedal assembly for use in cycling. More particularly, the invention relates to a pedal assembly that permits a cycling shoe-pedal assembly to operably engage and safely disengage the pedal crank arm of a bicycle or other pedal powered apparatus.
[0002] Many modern bicycles, including those intended for road racing, are designed to transfer and convert the linear forces applied by the cyclist into rotational motion of the crank arm and sprocket. In conventional bicycles, the forces generated by the cyclist are exerted through the pedal assembly in the vertical direction when the pedal is depressed by the rider's foot as well as lifted on the upstroke. A popular configurations for road racing is the clipless pedal system comprising a pedal with a receptacle adapted to receive a cleat mounted in the sole of a special cycling shoes. This cleat snaps into the pedal receptacle allowing the cyclist to connect a shoe directly to the pedal, and indirectly to the crank arms, with ease. The cyclist's foot then disengages the pedal system by rotating or displacing the shoe in a predefined manner or under the force of an accident, for example.
[0003] Although the clipless pedal system allows the operator's foot to quickly connect to and disconnect from the crank, the cleat and corresponding receptacle in prior art systems is located directly below the sole of the cycling shoe. The location of the cleat and receptacle below the cyclist foot detrimentally affect the performance in at least three ways: First, the prior art systems, which can be as much as an inch thick, reduce the ground clearance at the underside of the pedal, thereby reducing limiting the angle at which the bicycle may be simultaneously pedaled and turned. Second, the thickness of the cleat and receptacle system increases the riding height of the cyclist and the frame, thereby increasing aerodynamic drag and bicycle weight. Third, the force exerted by the foot of the cyclist is distributed over the relatively small area of the cleat which increases the pressure of the foot in immediate proximity to the cleat of the foot and causes discomfort to the cyclist.
[0004] U.S. Pat. Nos. 5,586,472 to Lin, 5,440,950 to Tranvoiz, and 5,315,896 to Stringer disclose detachable pedal assemblies in which a portion of the release mechanism is located in proximity to the crank arm. In each of these patents, the pedal is mounted either directly or indirectly into the crack through the spindle. The pedal remains rotatably affixed to the crank until a linear force co-parallel to the axis of the spindle is applied. Although these prior art pedal assemblies may be quickly attached to and removed from the crank arm, manual intervention is required without which the pedal cannot be engaged or disengaged. Moreoever, these pedal assemblies are designed to facilitate the assembly and disassembly of the pedal in connection with the storage and transportation of the bicycle. These pedal assemblies do not include means to attach a cycling shoe to the pedal and are, therefore, entirely unsuitable for road racing applications where it is necessary to both press down and lift up the pedal.
SUMMARY
[0005] The present invention overcomes the limitations of the prior art with a detachable pedal assembly in which the release mechanism is positioned adjacent to the axle that threadedly engages the bicycle pedal crank arm. Location of the release mechanism to the side of the pedal and away from the underside of the cyclist's foot allows (1) the rider to assume a lower riding position, thereby reducing the frame height and aerodynamic drag; (2) the bottom side of the pedal to be raised, thereby allowing for sharper turns of the bicycle; (3) the pedal to have a greater surface area, thereby reducing the pressure across the cyclist's foot; and (4) the rider visibility of the release mechanism during engagement, unlike prior art systems.
[0006] In one embodiment of the present invention, the detachable pedal assembly is comprised of an axle assembly, binding assembly, and connecting means. The axle assembly is comprised of an axle adapted to threadedly engage the bicycle pedal crank arm. The binding assembly is comprised of a pedal through which the cycling shoe applies force to drive the bicycle. The connecting means is comprised of a bearing and releasable coupling means, the connecting means being substantially interposed between the pedal crank arm and the binding assembly in the lateral direction. Although the bearing and releasable coupling means may be affixed to either the axle assembly or the binding assembly, it is important that the releasable coupling means rigidly hold the binding assembly to the axle assembly until a force equal to or greater than a predetermined force threshold is applied, at which point the release coupling means responds by automatically disengaging the binding assembly from the axle assembly. In this manner, a cyclist may exert force on the pedal assembly without disengaging the pedal crank arm unless the cyclist chooses to disengage the binding assembly from the axle assembly. In some embodiments, the shoe-pedal assembly may be automatically disengaged from the bicycle crank if the cyclist befalls adverse circumstances.
[0007] In some embodiments of the present invention are designed with offset between the pedal of the binding assembly and the axle assembly to position the ball of the cyclist's foot at the axis of the axle. Still other embodiments adapted primarily to bicycle road racing applications include shoe fastening means permitting the cycling shoe to be affixed to the pedal assembly, thereby allowing the cyclist to drive the bicycle by pushing against the pedal in the down stroke as well as pulling on the pedal during the upstroke. The shoe fastening means may be used in combination with a force-responsive locking means that determines the force necessary to release the binding assembly from the axle assembly.
[0008] The shoe-pedal assembly in preferred embodiments is made to engage and disengage the axle mounted on the bicycle pedal crank assembly in the vertical direction, while other embodiments permit the binding assembly to engage and disengage the axle in the other directions or manners. The binding assembly may be made to alternatively engage or disengage the axle by means of one or more forces including rotational forces or linear forces applied in the horizontal or vertical plain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is an exploded view of the detachable pedal assembly including the axle assembly, connecting means, and binding assembly of the present invention.
[0010] [0010]FIG. 2 is a cross-sectional view in a vertical plane through the axis of the axle in the preferred embodiment of the detachable pedal assembly.
[0011] [0011]FIG. 3 is an interior side view of the binding assembly of the preferred embodiment attached to the shoe.
[0012] [0012]FIG. 4 is a view of the underside of the binding assembly and axle assembly, attached to the shoe and mounted into the crank arm, of the preferred embodiment.
[0013] [0013]FIG. 5 is a front side view of the shoe with binding assembly, axle, and crank arm of the preferred embodiment in the locked position.
DETAILED DESCRIPTION
[0014] The present invention pertains to a detachable pedal assembly permitting a cycling shoe to operably engage and safely and efficiently disengage the pedal crank arm of a bicycle or other pedal powered apparatus. The pedal assembly effectively transmits the forces exerted by the cyclist's shoe to the pedal crank arm, allowing the cyclist to both push down on the pedal as well as lift up on it so long as the forces are within a predetermined range. For safety purposes, the cyclist's shoe-pedal assembly may be released from the pedal crank when the forces reach an unsafe level as in an accident or collision, for example.
[0015] The accompanying figures depict embodiments of the detachable pedal assembly of the present invention, and features and components thereof. With regard to means for fastening, mounting, attaching or connecting the components of the present invention to form the apparatus as a whole, unless specifically described otherwise, such means are intended to encompass conventional fasteners such as machine screws, machine threads, snap rings, hose clamps such as screw clamps and the like, rivets, nuts and bolts, toggles, pins and the like. Components may also be connected by friction fitting, or by welding or deformation, if appropriate. Unless specifically otherwise disclosed or taught, materials for making components of the present invention are selected from appropriate materials such as metal, metallic alloys, natural or synthetic fibers, plastics and the like, and appropriate manufacturing or production methods including casting, extruding, molding and machining may be used.
[0016] Any references to front and back, right and left, top and bottom, upper and lower, and horizontal and vertical are intended for convenience of description, not to limit the present invention or its components to any one positional or spatial orientation.
[0017] Referring to FIGS. 1 and 2, an exploded view and cross section of the detachable pedal assembly including the axle assembly, bearing, and binding assembly of the present invention are illustrated. The axle assembly 124 in this embodiment is comprised of an axle 102 , a bearing 103 , and an optional spacer 104 .
[0018] The axle 102 is comprised of a pedal crank connecting portion 109 and a bearing connecting portion 110 . The crank connecting portion 109 preferably includes a standard thread pattern adapted to securely engage the corresponding threads 107 of the crank arm 106 . The bearing connecting portion 110 is characterized by a diameter substantially equal to the diameter of the inner surface 114 of the bearing 103 such that the axle 102 and bearing 103 are securely affixed to one another after installation of the bearing 103 and during operation of the bicycle. After installation, the bearing 103 preferably abuts a retainer 111 which, in this embodiment, is a circularly symmetric lip used to prevent the bearing 103 from disengaging the axle 102 in the direction away from the crank arm 106 . The retainer 111 preferably includes two parallel planar faces 111 A that adapted to receive a wrench used to apply the torque necessary to engage and disengage the threads of the crank connecting portion 109 to the crank arm 106 . In other embodiments, the bearing connecting portion 110 and bearing 103 may include threads, set screws, permanent welds, bonding agents, or friction fitting to prevent the unintended separation of the bearing 103 from the axle 102 .
[0019] The bearing 103 represents any one of a number of alternative structures for providing a substantially friction free rotation of the binding assembly 101 relative to the axle 102 . In general, the bearing 103 includes an inner surface 114 and outer surface 113 that rotate relative to one another about the bearing axis that coincides in this embodiment with the axis of the axle 130 . The internal construction of bearings is well document and unnecessary for an understanding of the design, assembly and operation of the present invention.
[0020] In the preferred embodiment, the bearing 103 is a sealed thrust bearing capable of withstanding rotational forces about the axle axis 130 as well as torsional forces exerted by the binding assembly 101 discussed in more detail below. Although aircraft quality bearings are suitable, the bearing used in the present invention is subjected to relatively low speeds, typically on the order of 120 rpm in this embodiment. One skilled in the art will recognize that other standard bearings and custom bearings including various ball bearings, baring faces, and lubricants may be equally suitable with appropriate modification to the axle 102 and binding assembly 101 .
[0021] The detachable pedal assembly of the present invention may further include a spacer 104 in conjunction with the axle 102 in order to tailor the height of the axle 102 away from the pedal crank arm 106 . The thickness of the spacer 104 will, in general, depend on the particular preferences of the rider.
[0022] Also illustrated in FIG. 1 is the binding assembly 101 comprised of a releasable coupling means and a pedal. In the preferred embodiment, the releasable coupling means is a clasp or receptacle in the shape of an arcuate cup comprised of the first structure 115 , second structure 117 , and third structure 118 . The first, second, and third structures are designed with the precision and tolerance necessary to receive the bearing 103 and limit the relative movement of the binding assembly 101 and bearing 103 in non-vertical directions. In particular, the width between the first structure 115 and the second structure 117 must be substantially equal to the depth of the outer surface 113 of the bearing 103 in order avoid a loose fit that may reduce the ability of the binding assembly 101 to remain operatively engaged to the bearing 103 when upward force is applied to the binding assembly 101 .
[0023] The clasp should also be constructed of a substantially rigid material such as steel, titanium, aluminum, chromoly, or carbon fiber, for example, sufficient to withstand the static and dynamic forces exerted by a cyclist under stringent riding conditions. The clasp may further include portals 122 A, 122 B for allowing the egress of dirt from the interior side of the clasp and to permit visual alignment of the binding assembly 101 with the axle assembly 124 .
[0024] The binding assembly 101 further includes a pedal 120 for engaging the cycling shoe 140 and transferring the forces exerted by the cyclist to the axle 102 . In the preferred embodiment, the pedal 120 is comprised of a substantially flat plate rigidly affixed to the releasable coupling means, although the plate may assume alternative shapes necessary for adaptation to various cycling shoes. In some embodiments, the pedal 120 further includes shoe fastening means 121 for securing the cycling shoe 140 to the binding assembly 101 , as discussed below in more detail.
[0025] In some embodiments, the shoe fastening means may include a receptacle adapted to receive alternate forms of detachable pedal systems including the numerous clipless pedals on the market today.
[0026] The thickness of the pedal 120 will depend on the material selected but, in general, should be a thin as reasonably possible in order to increase the ground clearance with the bottom of the pedal 120 , important during high speed angled turning or maneuvering. The pedal 120 should be constructed of a substantially rigid material such as steel, titanium, aluminum, chromoly, or carbon fiber, for example, sufficient to withstand the static and dynamic forces exerted by a cyclist under stringent riding conditions.
[0027] An important feature of some embodiments of the present invention is the force-responsive locking means that firmly retains the binding assembly 101 engaged with the axle 102 until a predetermined force is exceeded. Once the predetermined force is exceeded, for example, where the cyclist dismounts the bicycle or is in an accident, the binding assembly 101 detaches or otherwise breaks-away from the axle 102 . The locking means is preferably designed to allow detachment the binding assembly 101 in a non-destructive manner, thus allowing the binding assembly 101 to later re-engage the axle 102 .
[0028] Still referring to FIGS. 1 and 2, the force-responsive locking means in the preferred embodiment is comprised of a detent device with a spring-load ball bearing 127 in the axle 102 that engages a corresponding recess 116 B in the binding assembly 101 . The ball bearing 127 is held in position by the retaining washer 131 on one side and the set screw 126 , spring 128 , and plate 129 on the other.
[0029] To engage the binding assembly 101 and axle assembly 124 in this embodiment, the cyclist lowers the binding assembly 101 on to the axle assembly 124 with the clasp vertically aligned with the bearing 103 . As the binding assembly 101 is lowered onto the axle 102 , the ball bearing 127 is guided by the race 116 A until the clasp fully engages the bearing 103 , at which point the ball bearing 127 seats into the recess 116 B. After being seated into the recess 116 B, the ball bearing 127 , under the force of the spring 128 , prevents the binding assembly 101 from being lifted off of the axle 102 during normal operating conditions. The force exerted by the spring may be adjusted as desired up to several hundred pounds using the set screw 126 that threadedly engages the axle within the recess 125 .
[0030] In this preferred embodiment, the binding assembly 101 is permitted to disengage the axle by means of a linear force applied in the vertical direction, the direction normal to the pedal surface 119 . One skilled in the art will recognize that alternative embodiments of the present invention may be adapted to permit detachment of a binding assembly if a linear or rotational force is applied in one or more different directions. The present invention would be equally applicable to an apparatus in which the cyclist disengaged his foot by applying a twisting force about the pedal or a linear force outward in the direction of the axle axis, for example.
[0031] Referring to FIG. 3, an interior side view of the binding assembly of the preferred embodiment is illustrated. The shape of the arcuate cup of the releasable coupling means is clearly visible, including the radial contour of the second structure 117 and third structure 118 . Located at the center of these concentric surfaces is the recess 116 B corresponding to the ball bearing 127 located on the axis 130 of the axle 102 . Leading to the recess 116 B is the race 116 A which approximately defines the direction that the binding assembly 101 is directed to engage and lock the axle assembly 124 .
[0032] Also illustrated in the preferred embodiment is the guide 115 A which assists the axle 102 into the arcuate cup. The guide 115 A is elevated above the surface 115 by a distance represented by the depth of the surface 115 B, which is substantially equal to the thickness of the retainer 111 .
[0033] Referring to FIG. 4, a view of the underside of the binding assembly and axle assembly when mounted into the pedal crank arm according to the preferred embodiment is illustrated. In the preferred embodiment, the pedal 120 has a width and length roughly corresponding to the ball of the cyclist's foot through which the energy is transferred during riding.
[0034] In some embodiments, the pedal 120 includes shoe fastening means for securing the cycling shoe to the binding assembly 101 . The shoe fastening means may comprise holes or slots 121 sized and positioned to receive screws or bolts capable of rigidly securing a cycling shoe to the binding assembly during cycling. Of course, the screws, bolts or equivalent means may be detached, thereby allowing the shoe or binding assembly to be replaced. The pedal 120 may further comprise float means permitting the cycling shoe to “float,” i.e., move in an angular and lateral direction relative to the pedal 120 to increase comfort and efficiency for the rider. The float means may be achieved in some embodiments a hinge, bearing, pivot, articulated joint, or equivalent means.
[0035] One skilled in the art will recognize the pedal 120 of the present invention also allows the cyclist to walk with the binding assembly 101 attached to the cycling shoe with minimal discomfort or damage to the binding assembly 101 . Unlike the prior art pedal assemblies, the cleat is not located underneath the rider's shoe where it would otherwise be subjected to the wear and tear that occurs when the rider walks on the cleats when dismounted from the bicycle. In some embodiments, the underside of the pedal 120 may further include a durable sole made or rubber or equivalent material for reducing wear of the pedal 120 and protectively concealing the screws or bolts that engage the cycling shoe.
[0036] [0036]FIG. 5 is a front side view of binding assembly, axle, and crank arm of the preferred embodiment in the locked position. As shown, the clasp receives a portion of the axle assembly 124 , in the preferred embodiment, thereby engaging the axle assembly 124 in a manner than supports the transfer of force from. the cyclist's foot to the crank arm 106 .
[0037] One skilled in the art will recognize that the advantage of interposing the detachable interface formed by the clasp and the axle assembly 124 between the rider's foot and the crank arm 106 , the height of the pedal surface 119 relative to the axle axis 13 O may be adjusted to improve the performance, efficiency, and performance of the cyclist. In particular, the offset position of the pedal surface 119 in the preferred embodiment is such that the axle axis 130 approximately coincides with the ball of the rider's foot. This configuration may be optimized according to biokinetics in a manner that was previously unavailable in prior art detachable pedal systems because of the thickness of the cleat system that occupied space below the pedal.
[0038] Although the above description contains many specifics, these should not be construed as limiting the scope of the invention, but rather as merely providing illustrations of some of the presently preferred embodiments of this invention.
[0039] Therefore, the invention has been disclosed by way of example and not limitation, and reference should be made to the following claims to determine the scope of the present invention.
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A detachable pedal assembly including an automatic release mechanism that is positioned approximately between the pedal and crank arm is disclosed. The detachable pedal assembly in one embodiment comprising an axle assembly including thrust bearing and threads to engage the crank, a binding assembly including a pedal to which the cyclist applies force and clasp that detachably receives the thrust bearing, and a force-sensitive locking means that holds the binding assembly in operational engagement to the axle assembly until a predetermined force is applied, at which time the binding assembly automatically releases the axle assembly to permit the cyclist to dismount or avoid injury in an accident. The position of the release mechanism to the side of the binding assembly permits the binding assembly to be offset from the axle axis, thereby improving increased riding efficiency, lower aerodynamic drag, and increased turning clearance.
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RELATED APPLICATIONS
This application relates to subject matter generally similar to other applications filed simultaneously by the same assignee, the applications being identified by German Patent Application Nos. P 39 34 738.9 and P 39 34 737.0, further Ser. No. 07/569,051, filed in the U.S. Patent and Trademark Office on Aug. 17, 1990.
BACKGROUND OF THE INVENTION
The invention is based on an apparatus having a control motor for intervention into a force transmission device, between an operating element and a control device that determines the output of a driving engine, as defined hereinafter.
For various closed-loop control tasks in driving engines, intervention into the force transmission device between the operating element, such as a gas pedal, and the control device, such as a throttle valve in an Otto engine or a control lever of a Diesel engine or the like, is necessary. One reason for an adjustment may for instance be to avoid slip between wheels of a motor vehicle that are driven by the driving engine and a road surface.
A known apparatus includes a first driver element connected to the operating element, a second driver element connected to the control device, a third driver element via which the control motor can act upon the control device, and a restoring spring that can actuate the third driver element counter to a reposed stop are combined in the region of the control device. If the control device is a throttle valve, then the aforementioned components are located directly on the intake tube of the auto engine. However, very cramped conditions often prevail in the region of the intake tube, making it difficult to create sufficient installation space for the known apparatus; that is, it is impossible to select an optimal disposition for the intake tube.
OBJECTS AND SUMMARY OF THE INVENTION
The apparatus according to the invention has an advantage over the prior art that with it, very favorable and flexible installation conditions are created.
The intermediate part connected to the second driver element by a force transmission means offers the special advantage that it enables an arbitrarily selectable spatial separation between the third driver element of the control device. As a result, the apparatus according to the invention can advantageously be used even in very cramped installation conditions in the region of the control device; that is, there is greater freedom in the disposition of the control device, because advantageously, the third driver element is not rigidly connected to the control device.
The disposition of the restoring spring in the final control element likewise advantageously increases the freedom in disposition of the control device.
The disposition of an actual-value transducer in the final control element simplifies detection of the control position in an advantageous manner, because the expenditure for control and electrical purposes is reduced.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of a preferred embodiment taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
The single figure of the drawing shows an exemplary embodiment of the invention in simplified form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The structure and operation of an apparatus according to the invention in an engine, in particular in a vehicle, having a control motor for intervention into a force transmission device 2 between an operating element 4, such as a gas pedal, and a control device 8 that determines the output of a driving engine 6, will now be described in further detail in terms of a preferred exemplary embodiment shown in the drawing.
The apparatus according to the drawing can be used in any machine including a driving engine 6, in which closed-loop control of the driving engine 6 is to be effected. The machine may either be mounted in stationary fashion or may for instance be a self-propelled machine or in other words a vehicle. Although not restricted solely to this, for the sake of simplicity it will be assumed in the description of the exemplary embodiment that the apparatus according to the invention is to be installed in a vehicle having an Otto engine.
The force transmission device 2 substantially includes a force transmission element 12, a first driver element 14, a second driver element 16 and a coupling spring 18.
The first driver element 14 is connected to the operating element 4 by the force transmission element 12, and the control device 8 is connected to the second driver element 16. The coupling spring 18 acts at one end on the first driver element 14 10 and at the other on the second driver element 16, in such a way that both driver elements 14, 16 are urged to execute a motion relative to one other until a first coupling stop 20 of the first driver element 14 comes to rest against a second coupling stop 22 of the second driver element 16.
The control device 8 is for instance a throttle valve 8 installed in an intake tube 24. Depending on the control position of the throttle valve 8, a flow, represented symbolically by arrows 26, for instance of a mixture flowing through the intake tube 24 to the driving engine 6 can be varied. In this way, the output of the driving engine 6 is controlled via the control position of the throttle valve 8. Actuation of the throttle valve 8 in the direction of an arrow 28 shown in the drawing represents an increase in the output of the driving engine 6, and actuation of the throttle valve 8 counter to the direction of the arrow 28 represents a reduction in the output of the driving engine 6. In the drawing, all the movable components are shown in such a way that their directions of motion extend parallel to the arrow 28, or in other words are either in or counter to the direction of the arrow 28. By means of the operating element 4, the control device 8 can be actuated via the force transmission device 2 in the direction of the arrow 28. The control device 8 can be actuated counter to the direction of the arrow 28 by a restoring spring 30 provided on the transmission device 2. The restoring spring 30 acts at one end on a wall 32 and on the other, on the first driver element 14. The restoring spring 30 acts on the first driver element 14 counter to the direction of the arrow 28. In addition to or instead of the restoring spring 30, some other restoring spring 34, shown in dashed lines, may also be provided. The restoring spring 34 likewise acts on one end on the wall 32, and on the other it acts on the second driver element 16 counter to the direction of the arrow 28. Depending on the actuation of the operating element 4, the two restoring springs 30, 34 can actuate the driver elements 14, 16 and the throttle valve 8 counter to the direction of the arrow 28, until one of these latter elements comes to rest on an adjustable idling.stop 36. In the exemplary embodiment, the first driver element 14 can be made to contact the idling stop 36.
The force of the coupling spring is is dimensioned such that without influenoe by a control element 40 on the force transmission device 2, the first coupling stop 20 of the first driver element 14 rests constantly on a second coupling stop 22 of the second driver element 16, and a control position of the operating element 4 can be transmitted to the control device 8 via the force transmission device 2.
Additionally, there is also the final control element 40. The final control element 40 substantially includes a control motor 42 having an operating member 44, a restoring spring 50, a third driver element 52, a repose stop 53, an intermediate part 54, and optionally a tension spring 56, an actual-value transducer 58 and/or an actual-value transducer 59.
The control motor 42 may be a rotary motor, for example, and the operative member 44 is a rotor shaft; alternatively, the control motor 42 may be a linear motor, such a hydraulic cylinder, and the operative member 44 in this case is a piston rod. The operative member 44 may be the rotor shaft of the control motor directly, for example, or a gear 64 can be interposed between the operative member 44 and an actual motor 62 of the control motor 42. In this latter case, the operative member 44 is an output shaft of the gear 64. The operative member 44 is connected to the third driver element 52.
The restoring spring 50 acts at one end on a housing 66 of the final control element 40 and at the other on the operative member 44, or on the third driver element 52, in the direction of the arrfow 28, with the tendency of actuating the third driver element 52 toward the repose stop 53. The third driver element 52 has a stop shoulder 68 and the intermediate part 54 on the other hand has a stop shoulder 69. Upon actuation of the third driver element 52 counter to the direction of the arrow 28, the stop shoulder 68 of the third driver element 52 can come to rest on the stop shoulder 69 of the intermediate part 54, depending on the control position of the intermediate part 54. If the third driver element 52 is actuated beyond this rest point counter to the direction of the arrow 28, then the intermediate part 54 is likewise carried along with the driver part 54 counter to the direction of the arrow 28.
The intermediate part 54 of the final control element 40 is connected to the second driver element 16 of the force transmission device 2 via a transmission means 72. The transmission means 72 may be a rod assembly, is a Bowden cable, a sheathed cable, or the like. If the transmission means 72 is a Bowden cable or a sheathed cable, for instance, then the tension spring 56 provided in the final control element 40 and acting on the intermediate part 54 counter to the direction of the arrow 28 assures a minimum tension in the transmission means 72; that is, the tension spring 56 prevents sagging of the sheathed cable, for instance. The tension spring 56 may be relatively weak, because it need merely compensate substantially for frictional forces. The tension spring 56 may also be dispensed with, depending on the embodiment of the transmission means 72.
With the aid of the actual-value transducer 58, a control position of the intermediate part 54 of the final control element 40, and thus at least indirectly a control position of the second driver element 16 and of the control device 8, can be detected. In the region of the control device 8, an actual-value transducer is already often provided for detecting a control position of the control device 8, for instance in order to regulate gasoline metering, but for electrical reasons it is poorly suited to detect the control position of the control device 8 for the sake of triggering the control motor 42. Since cramped installation conditions often prevail in the region of the control device 8, it is particularly favorable to dispose the actual-value transducer 58 in the region of the final control element 40. Since upon triggering of the control motor 42 the stops 68, 69 of the third driver element 52 and of the intermediate part 54 come to rest upon one other, the actual-value transducer 58 can also be replaced with the actual-value transducer 59. The actual-value transducer 59 detects a control position of the third driver element 52. For safety reasons, for instance, it may also be favorable to provide a plurality of actual-value transducers 58, 59.
In the apparatus according to the invention, a distinction can be made between two operating states. The first operating state is the unregulated operating state. In the first operating state, the control device 8 can be moved into any desired control position by the operating element 4 without influence by the final control element 40. In the first operating state, the third driver element 52 rests on the repose stop 53. Because of the transmission means 72 and because of the optionally present tension spring 56, the intermediate part 54 moves in the same direction as the second driver element 16 upon actuation of the operating element 4. Because there is a spacing between the two shoulder stops 68, 69 of the third driver element 52 and of the intermediate part 54, the shoulder stop 69 of the intermediate part 54 does not come to rest on the shoulder stop 68 of the third driver element 52 in the first operating state.
Upon actuation of the control device 8 by the operating element 4 in the direction of the arrow 28, the output produced by the driving engine 6 is increased. In this process it may happen that sensors, not shown, detect slip between driven wheels, not shown, and some road surface. The slip is highly undesirable. To avoid slip, the control motor 42 of the final control element 40 is triggered via electronics, not shown. In that case, the apparatus according to the invention operates in its second operating state, which can accordingly be called the regulated operating state. In the second operating state, the control motor 42 actuates the third driver element 52 counter to the arrow 28, and shoulder stop 68 of the third driver element 52 can come to rest on the shoulder stop 69 of the intermediate part 54. If the third driver element 52 is actuated beyond this counter to the direction of the arrow 28, then the intermediate part 52, and by it via the transmission element 72, the second driver element 16 and thus the control device 8 are all actuated counter to the direction of the arrow 28, or in other words in the direction of a reduced output of the driving engine 6. The control device 8 is actuated far enough counter to the direction of the arrow 28 that the sensors (not shown) do not detect inadmissibly high slip between the driven wheels and the road surface.
Depending on the embodiment, the transmission means 72 may be located very flexibly. The fact that the third driver element 52 with its shoulder stop 68 and the intermediate part 54 with its shoulder stop 69, as well as the restoring spring 50 and the repose stop 53, can all be disposed spatially independently of the intake tube 24 advantageously makes installation of the intake tube 24 and control device 8 considerably simpler. It is furthermore particularly advantageous to combine the third driver element 52, the intermediate part 54, the restoring spring 50 and repose stop 53, or at least some of these parts, with the control motor 42 in the final control element 40. The final control element 40 is preferably a compact unit, which can be disposed if needed with variable spacing with respect to the intake tube 24. The connection between the final control element 40 and the transmission device 2 is effected by the transmission means 72.
Compared with the other restoring spring 34, the restoring spring 30 has the advantage that the coupling spring 18 can be made weaker. Moreover, in the second operating state, the influence of the final control element 40 on the operating element 4 is weaker, and the force to be brought to bear by the final control element 40 in the second operating state is less. The tension spring 56 is advantageously selected to be weak enough that at most it can overcome a friction in the region of the intermediate part 54 and transmission means 72, but cannot exert any significant influence on the force transmission device 2 and in particular on the coupling spring 18.
The apparatus according to the invention has been described in terms of an exemplary embodiment having linear directions of motion parallel to the arrow 28. In another exemplary embodiment of the same apparatus according to the invention, at least some individual components do not move linearly but instead are pivotably supported. A motion in the direction of the arrow 28 then represents rotation in one direction, and a motion counter to the direction of the arrow 28 represents rotation in the opposite direction. Since the control device 8 is typically rotatably supported, it is a logical option to support the other components rotatably as well. 0 The foregoing relates to a preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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A control device of a driving engine which can be actuated purely mechanically, via a force transmission device or a control motor as needed, independently of a control position of the force transmission device in a direction of reduced output of the driving engine. The control device includes a restoring spring, a third driver element and a repose stop positioned away from the control device, in a final control element. The apparatus is particularly well-suited for motor vehicles equipped with traction control.
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BACKGROUND OF THE INVENTION
There are a great many machines in which a work piece is rotated to successive positions for performing machining operations, or in which the machine itself is rotated with respect to a stationary work piece to perform necessary operations. These include both metal working machines and wood working devices and possibly additional categories as well. Such machines are often provided with indexing means for specific divisions of a circle such as a quarter circle, an eighth circle, or more rarely, one-third circle, one-sixth circle, etc. No matter how many fixed indexing points are provided, the user of the device may find that he must improvise adjustments between the indexing positions. The provisions for indexing positions other than the fixed stops frequently lack precision and also lack secure holding power. In any case, a large number of such adjustments seriously slows a project. It is an object of my invention to provide an indexing mechanism which provides the utmost flexibility in the number of increments into which a circle may be divided, with great ease, accuracy, and security of adjustment.
I have located the following patents:
______________________________________3,054,333 3,362,295 3,443,4813,118,347 3,367,237 3,490,3363,251,592 3,380,322 3,507,1883,327,577 3,381,578 3,532,0093,336,823 3,412,644 3,532,0263,344,526 3,417,478 3,533,3283,548,712 3,866,309 3,975,8303,592,102 3,866,662 3,997,9773,661,050 3,887,202 4,008,9003,668,768 3,902,537 4,012,8433,668,772 3,938,816 4,027,3943,680,439 3,940,857 4,080,738______________________________________
None of these patents, so far as I am aware, discloses any system of indexing in which a circular indexing element is constructed of single standardized stop elements to form a circle of such elements of the required number which is then placed on a tapered body of rotation and secured there, with a stop adjustably placed in the plane of rotation of the circle of elements, so as to permit indexing to any number of increments in a circle including such awkwardly calculated increments as sevenths, seventeenths, or other numbers of segments, and yet changing quickly and conveniently to indexing to a different number of segments forming a complete rotation.
SUMMARY OF THE INVENTION
My invention consists of a tapered body of rotation, such as a cone, on which a circle of stop elements, preferably a roller chain, is secured in a circle by means of elements which fix the stop elements in a plane on that part of the body of rotation having the correct peripheral size, and stop means adjustable to lie in that plane to engage the stop elements and to have the correct angular relationship to a device such as a spindle or workpiece to which my indexing device is attached for rotation at a speed equal or proportional to the speed of rotation of the workpiece or spindle, so that the rotation may be prevented by engagement of the stop means between the stop elements in any reasonable integral number of increments forming a full circle. The range of adjustment is determined by the largest and smallest circumferences of the body of rotation and by the sizes of the stop elements. Roller chains are available in a variety of sizes, which adds to the flexibility of my invention.
My invention further includes a variety of fixtures to attach the stop elements to the body of rotation firmly and precisely and optical means of alignment using the hand wheel to support a layout of work positions.
DRAWINGS
FIG. 1 is a side elevational view of the device of my invention.
FIG. 2 is a top plan view of the device of my invention.
FIG. 3 is a cross-sectional view on line 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view on line 4--4 of FIG. 2.
FIG. 5 is a cross-sectional view similar to FIG. 3 but broken away at the ends and showing a modification of my device.
FIG. 6 is a top plan view of the device shown in FIG. 5 with the ends similarly broken away.
FIG. 7 is a top plan view with the ends broken away similar to FIG. 6 showing a means for installing a single stop.
DETAILED DESCRIPTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the best known embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. This invention is an indexing device. It may be used for maintenance and repair work, etc. Indexing is commonly done by means of dividing plates, worm gear drive devices, or through gears with ratios selected for particular jobs. This invention allows for an unusually wide variety of indexing positions with great accuracy and ease of adjustment and is thus particularly suitable for a rebuilder's tool although other uses will suggest themselves. It is portable and adaptable. In particular, the device of my invention allows easy division of a complete circle through which a work piece may be rotated into any integral number of stop positions as will be seen from the further detailed description of specific devices.
My device has a fixed base or frame 1 carrying bearings 3 for a shaft 5 to which is fixed a conical roller or tapered body of revolution 2 which preferably takes the form of a truncated cone throughout the major portion of its body. The largest and smallest diameters are selected to give a range of diameters adequate to accommodate the range of roller chains or other stop elements which will be described later. Preferably, the tapered body of rotation 2 is also provided at one end with a cylindrical portion around which brake band 10 extends so that cone or body 2 may be secured in an adjusted position by means additional to the stop that will be described to relieve the stop from vibrations or other forces exerted on the work piece.
At one end of shaft 5 is an adjusting wheel 29 which may be rotated manually to revolve tapered body 2 and a work piece. Preferably, shaft 5 is also bored and tapped for an axial screw 32 and washer 20 which may be used to secure a layout or template of the desired work positions to which the work piece is to be turned and base 1 is provided with an optical system such as magnifier 30 having a line with which the layout or template can be aligned for accurate positioning. Holes 33 may be provided in wheel 29 for torque bars to assist in moving a heavy work piece or large machine attached to shaft 5.
At the other end of shaft 5 is a flange 6 provided with attaching means such as cap screws 11 for attaching shaft 5 and flange 6 to a work piece, machine spindle, tail stock or work table, etc. If needed, shims 31 (FIG. 3) may be placed between bearings 3 and conical body of rotation 2 to remove any play.
As shown in FIGS. 1 through 6, a circle of stop elements is placed around tapered body of rotation 2. Preferably, the stop elements consist of the rollers or pins and the side plates of a roller chain 7. Roller chains are readily available with pins and side plates of various sizes and are adjustable in length simply by assembling the correct number of rollers or pins and connecting side plates in a well-known manner to form an endless chain of a circumference corresponding to any diameter of the tapered body of rotation or conical roller 2. The roller chain is not used to transmit power but is merely a convenient way of providing the needed circle of stop elements which take the form of the successive pins or rollers of the roller chain 7. The roller chain is installed about conical roller 2 in a plane at right angles to the axis of shaft 5 by any convenient means. The means selected may depend on the material used for conical roller or tapered body of revolution 2. In wood or composition material, the side plates of the chain may have portions nailed or screwed at 4 to secure the chain tightly about cone 2. If conical roller 2 is metal or some other materials chain 7 may be secured by fasteners in holes drilled and tapped in the cone, for instance cap screws, dowels, etc. On steel or ferrous materials it may be held magnetically, or with a body 2 of any material, clamps, anchor rods, push rods, glue, epoxy or welding may be used.
FIGS. 5 and 6 show a structure in which a means for supporting a circle of stop elements such as a roller chain includes an appropriate number of tapered members such as attachments or wedges 35 used to support the chain on a surface which is a portion of a cylinder with an adjoining radial surface holding the chain side plate 34 in the desired position. The tapered wedge 35 may itself be held in a variety of ways but one particularly flexible way is to secure brackets 38 by means of fasteners such as screw 39 to the tapered body of rotation 2. A screw 36 and nut 37 extend from bracket 38 toward wedge 35 and preferably into it. A lock nut 37 at the wedge and a lock nut 37 at the bracket 38 secure the adjustment of wedge 35.
Another means of holding a circle of stop elements such as roller chain 7 having side plates 34 in position, which may be used with the previously described method or separately, comprises a bracket 41 secured by fasteners such as screws 39 to tapered body of rotation 2. A hook 40 extends through a hole in bracket 41 along the surface of the tapered body 2 and is engaged at its end with side plate 34 of the roller chain or with an equivalent structure if other stop elements are used. An adjusting and locking nut 42 is used to apply tension to hook 40 to make roller chain 7 taut about body 2 in a plane perpendicular to the axis of shaft 5 and body 2. As may be seen from the above description, the means for supporting the circle of stop elements may take a variety of forms.
Once one has fixed the circle of stop elements such as roller chain 7 axially in a plane on the tapered body of rotation or roller cone 2 by appropriate supporting means it is necessary to provide a non-rotatable stop mechanism to engage the discreet connected stop elements such as the rollers of roller chain 7. Attached to fixed base or frame 1 and preferably extending parallel to conical roller 2 is a bar 9. The free end of bar 9 may be forked to receive a pin 8 in frame or base 1 (FIGS. 1 and 2) to keep the free end of bar 9 from moving in response to forces exerted to turn the shaft 5 but to permit it to move to carry the stop means radially away from the stop elements.
The other end of bar 9 is pivoted at 20 (FIG. 3) mounted on a block movable at right angles to the plane in which bar 9 pivots to make fine adjustments in the position of the stop mechanism. The block 24 that carries the pivot pin 20 is secured by bolts 25 extending through slots in block 24 to permit such movement. Mounted on base 1 is a hand wheel 28 having a knob 22 to turn a screw 27 extending into a threaded bore in block 24 (FIG. 4). Nut 25 and washer 26 may be used to hold block 24 in its adjusted position.
The mechanism described permits bar 9 to swing toward and away from the stop elements in a plane including the axis of shaft 5 so that as it approaches the stop elements mechanism attached to the bar is moving substantially radially of conical body 2. The exact position in which such movement takes place depends on the position of block 24 which therefore constitutes an adjusting means to move the stop mechanism a small distance in a direction peripheral to the body of rotation for fine adjustment. Bar 9 extends generally axially, and parallel to the tapered surface of the tapered body of rotation in its operative position. Pin or plunger 15 serves as a stop means and is engageable with any selected stop element to fix shaft 5 against rotation. Preferably, the stop pin 15 is pivoted by a pin 19 to release lever 17 which in turn is pivoted by a pin 21 to a block 12 movable along bar 9 in a direction generally parallel to the surface of body 2 to align stop pin 15 with a stop element such as a space between the rollers or pins of roller chain 7. (FIGS. 1 and 3). As shown in FIG. 7 it would be possible to provide stop elements 43 comprising bores in body 2 to receive a pin 15 on a bar 16 carried on bar 9 but this arrangement is less flexible.
Saddle or block 12 is secured by bolt or lock nut 13 to bar 9 when it is in its adjusted position. When plunger or stop pin 15 is in the position shown in FIG. 1 between the rollers of chain 7 it may be secured by a bolt or lock nut 14 against movement. Preferably, after everything is securely in place, brake 10 is engaged to prevent undue pressures from being exerted on stop pin 15 or on the means for supporting the circle of stop elements. Stop pin or plunger 15 is preferably shaped to enter the spaces in the roller chain to provide a secure reproducible stop position.
Preferably, release bar 17 is also provided with a pin or fulcrum 18 supporting a forked latch member 23 which may be engaged with block 12 as it is raised from the position shown in FIG. 3 to keep handle 17 from dropping while shaft 5 and body 2 are being rotated to index the work piece. It may simply be pushed by hand to allow release bar 17 to drop pin 15 radially into a space between one of the discreet connected stop elements of roller chain 7 after which bolt 14 is tightened and brake 10 is engaged. If desired, stop pin or plunger 15 may operate in a hole in block 12 which is radial to shaft 5 and the axis of cone 2. Bar 9 is long enough to allow block 12 to move to all positions above body 2 at which a roller chain 7 may be placed.
Thus it will be seen that my invention provides a machine indexing device in which an axially tapered body of rotation carries means for supporting a circle of stop elements and a plurality of discreet connected stop elements such as a roller chain secured tautly around the body of rotation at the appropriate diameter and over which is disposed a non-rotatable stop mechanism including a stop means engageable with a selected one of the stop elements to fix the tapered body of rotation and its shaft in any of as many stop positions as there are elements, the stop means being movable axially to overlie the appropriate diameter of the body of rotation and the stop mechanism being adjustable to a small degree peripherally for accuracy. Moreover, the hand wheel is provided with convenient means to hold a layout or template and with optical alignment means to use the layout or template directly to align the shaft and the attached part to be indexed.
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A fixture for indexing a work piece, a machine spindle, or the like permits indexing a single rotation of the work piece or other mechanism in any integral number of equal divisions. Stops for the divisions are made to suit the job by assembling a standard roller chain with as many pins and pin spaces as there are to be divisions and mounting the chain about a tapered body, preferably a cone. Fixtures hold the chain at the plane in which the periphery of the cone is the right diameter to receive the chain and other parts adjust the indexing stop to overlie the roller chain at that plane. Adjustments are provided to adjust the indexing stop peripherally of the cone a short distance in order to bring the indexing stop to the required rotational position. This adjustment may also be used to adjust the rotatable part a fraction of an indexing stop.
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FIELD OF THE INVENTION
[0001] The present invention relates to drilling subsea wells, and typically from a floating drilling rig. More particularly, this invention relates to a subsea riser disconnect equipment and techniques for sealingly connecting a lower riser extending downward into and fixed within a subsea well bore with an upper riser extending downward from the floating drilling rig, such that the upper riser may be disconnected from the fixed lower riser during adverse weather or other rig move-off conditions.
BACKGROUND OF THE INVENTION
[0002] Subsea wells are increasingly important to hydrocarbon recovery operations. Numerous land-based wells have been drilled, but the percentage of hydrocarbons recovered from land-based wells is steadily decreasing in some parts of the world. Jack-up rigs have been used offshore for decades to drill wells subsea to recover oil, but jack-up rigs are practically limited to drilling operations in relative shallow water of several hundred feet. As water depth increases other drilling rig options may be required to facilitate drilling and well completion operations. In addition to an increase in the number of off-shore wells being drilled, in more recent years an increasing number of wells are being drilled in deeper water and at increasing costs. Accordingly, drilling from offshore rigs, e.g., drilling ships, semi-submersibles, jack-ups, drilling barges or submersible rigs has significantly increased in recent years. The economics associated with drilling offshore remains, however, a primary reason why more wells are not drilled offshore. Particularly, in drilling exploratory wells where financial risk and commercial hydrocarbon uncertainty may severely impact the economics for drilling such wells, costs and may be more critical in determining whether any wells are drilled at all, and how many may be drilled.
[0003] The majority of offshore or marine drilling rigs utilize riser sections as the outermost tubular between the rig and the seafloor, with the riser sections typically being bolted, clamped, mechanically fixed by dog-type latch mechanisms or otherwise connected. Riser sections conventionally include hydraulic lines spaced outwardly of the assembled riser pipe for operating the blow out preventer (BOP) and subsea ram stack located above the mud line. During an emergency or in anticipation of adverse weather conditions, the subsea BOP may be closed and the rams hydraulically activated to seal off the well bore. Prior to closing the rams, the drill pipe may be threadably disconnected above or below the BOP stack utilizing a back off tool or back off method, or the drill pipe may be sheared by the shear ram assembly. In some applications, acoustically or electrically activated subsea accumulators have been used to replace the hydraulic lines which commonly are run along side the riser pipe. The subsea BOP stack assembly used during deep water drilling operations may contribute significantly to the cost of drilling a well and a substantial amount of expensive rig time may be expended running in and removing the riser pipe sections and related well control equipment.
[0004] The above disadvantages associated with drilling from floating drilling rigs have long been known. Accordingly, some drilling or operating companies may recommend “riser-less drilling” for certain deep water applications. A subsea pump may be provided to return the drilling fluid to the surface in a separate flow line. Riser-less drilling still has to contend with the high cost of the BOP stack and hydraulic operation of this equipment. Several wells have been successfully drilled from a floating drilling rig, while using a riser, wherein the BOP is placed on the drilling rig rather than subsea. To date, however, these wells practically are limited to geographic areas where and/or seasons when there is a reduced likelihood of adverse weather conditions which would require the floating drilling rig to relatively quickly disengage a portion of the riser, e.g., an upper riser from the lower riser. In these applications, however, elimination of the subsea BOP stack may result in significant cost savings when drilling a well. Further savings may be realized by using conventional threaded casing for a riser rather than flange-type riser pipe sections. Less area on the drilling vessel is required to store casing having the same nominal diameter as the riser pipe sections since conventional riser pipe sections include both flanges and hydraulic lines which are eliminated when using casing as the riser.
[0005] Typically, subsea BOP stacks are installed on the riser string. The BOP stack may be required to provide a subsea method of isolating a lower portion of the riser and well bore from the riser above the BOP stack. Stress in the riser typically includes the weight of the riser and the weight of the subsea BOP. Subsea BOP stacks may weigh in excess of 400,000 pounds. The weight of the BOP stack plus the weight of a riser sufficiently strong enough to deploy such stack and meet operational requirements necessitates that risers are inherently heavy pieces of equipment which may exert high levels of stress and strain on the drilling and on the riser sections. These effects may be even more pronounced in deep water applications. In deep water installations, installation of a typical riser system may require calm weather and well in excess of a week to install, and in excess of a week to retract. In addition to the subsea riser and BOP stack, electrical and hydraulic umbilical lines are typically deployed concurrently, to control and operate the BOP stack, choke and kill line valves, and hydraulic disconnects if present. Deployment and recovery of this equipment and the rig time involved all contribute significantly to well costs, as daily rental rates for semi-submersible drilling rigs may exceed $240,00 per day. Premature disconnection of a portion of the riser can likewise be expensive and time consuming, such as may be necessary in advance of hostile weather conditions, broken mooring chain or slipping mooring anchor.
[0006] If drill pipe is in a well bore and it becomes necessary to seal the interior of the well bore, pipe rams or shear rams in the BOP stack may be closed on the drill string to confine pressure and fluid within the well bore. In the event it becomes necessary to disconnect an upper portion of the drill pipe from a lower portion of the drill pipe, the drill pipe may be unthreaded at a tool joint, or cut with a chemical cutter or explosive charge. If pipe is stuck, the free point may be estimated by a free point calculation technique. Each of these disconnect methods requires time to determine free points, deploy appropriate tools on wire line, such as a “string shot,” a free-point tool, a chemical cutter or jet-shot explosive charge. Multiple attempts and re-calculations may be required. The process can be time consuming and frustrating and may still result disconnecting at an undesirable disconnect point. Reconnecting after disconnecting can be even more exasperating, time consuming and expensive, and even impossible.
[0007] Disadvantages of the prior art are overcome by the present invention. An improved method of drilling from a floating drilling rig is hereinafter disclosed. A subsea riser disconnect is provided for connecting and disconnecting a lower riser from an upper riser.
SUMMARY OF THE INVENTION
[0008] This invention provides means and equipment for relatively quickly, physically disconnecting a floating drilling rig from a subsea well in a manner that may be operationally and economically more efficient than prior art equipment and techniques. In the event hostile weather conditions, rig conditions or well conditions threaten the safety or operating capabilities of an offshore drilling rig or work over vessel, the rig or vessel may be disconnected and moved-out of harms way. The rig may later return to the well location and reconnect to the disconnected members. This invention provides means and equipment for installing a riser system and well control system which may provide for a more cost effective offshore drilling and/or work over operations than is available under prior art. Such improvements may reduce the costs to find, develop and produce hydrocarbons.
[0009] In one embodiment, this invention generally includes three primary components: a) a maritime or subsea riser disconnect for disconnecting and reconnecting an upper portion of the riser with a lower portion of the riser, b) a subsea riser valve for sealing off an interior of a well bore below the riser valve, and c) a drill pipe disconnect for disconnecting and reconnecting an upper portion of the drill pipe with a lower portion of the drill pipe.
[0000] Subsea Riser Disconnect
[0010] A preferred embodiment of a subsea riser disconnect includes an apparatus and means which disconnects an upper portion of the subsea riser from a lower portion of the riser, through axial movement of the upper riser relative to the lower riser. The upper riser and the lower riser may be collectively referred to as a riser system. The subsea riser disconnect may be positioned at substantially any point within the riser system, e.g., between the drilling rig and the mud line. The subsea riser is preferably accessible to either a remotely operated vehicle (ROV) or a diver, in order that a riser disconnect lockout device may be operated if needed. The subsea riser disconnect may facilitate placing the blow out preventer and well control stack (BOP) either on the rig or suspended from but relatively near the rig.
[0011] A preferred embodiment of a riser disconnect may include a male disconnect member secured to the lower end of the upper riser, and a female disconnect member secured to the upper end of the lower riser. The male disconnect member may include a seal mandrel and seal elements for providing a hydraulic seal between the male disconnect member and female disconnect member. The male disconnect member may also include a collet mechanism to facilitate latching and unlatching the male and female disconnect members. A lockout device may be included to prevent inadvertent actuation of the subsea riser disconnect, such as during initial installation of the riser disconnect and riser system. Manipulation of the lockout may be externally performed, such as by ROV, diver or otherwise.
[0012] The female riser disconnect member may include a seal bore receptacle for sealingly receiving the seal mandrel within the seal bore receptacle, and a circumferential collet groove may be included in an inner surface of the female riser disconnect for engaging collet dogs. A conical shaped entry guide may be included on an upper end of the lower riser disconnect member to guide the male disconnect member into the female disconnect member during subsea connection of the male and female disconnect member.
[0013] Manipulation of the riser disconnect latch may be performed by axial motion or reciprocation of the upper riser relative to the lower riser. (The terms “axial reciprocation, reciprocation, axial motion, axial, or similar variations of these terms, as used herein may be defined to be substantially synonymous, and include linear displacement of a first component relative to a second component, substantially along a common linear axis, in a first direction and/or second direction, but not necessarily consecutively in both directions during a single manipulation period.) The latching collet mechanism of the riser disconnect may be manipulated between the collet latch position and the collet unlatch position by alternately applying tension and releasing tension in the riser disconnect by the drilling rig.
[0014] In an initial installation, the riser latch mechanism, including the collet mechanism, may be positioned in the coIlet latch position. After the riser system is installed and cemented in position within the well bore, tension may be applied to the riser system at the riser disconnect to securely retain the latched engagement between the male and female disconnect members.
[0015] To disconnect the male and female disconnect members, such as in advance of an approaching storm, tension in the riser disconnect may be relaxed allowing the male disconnect member to move axially downward relative to the female disconnect member, thereby unlatching the collet mechanism. The upper riser may be subsequently raised, separated from and suspended above the lower riser. The rig may then be moved and/or the upper riser recovered to the rig.
[0016] To reconnect the riser disconnect, the male disconnect member may be guided by the entry guide into engagement with the female disconnect member and the collet mechanism re-latched. Tension may be applied and maintained in the riser system to retain the latched configuration during operations until it is desirable to again disconnect the riser disconnect system. Upon completion of well work operations, the female disconnect member with the male disconnect member (plus a subsea riser valve, if run) may be typically recovered together by normally cutting the riser below the mud line with either an explosive charge, a chemical cutter or a mechanical cutter.
[0017] If desired, the riser disconnect and lower riser may be drilled into position in the sea bed while the well bore for the lower riser is being drilled. This may be accomplished by a number of means, for example preferably by positioning the lower riser on the sea bed with a riser disconnect and portions of an upper riser attached or to be attached substantially during drilling operations, and running a string of drill pipe, a drill bit and/or an under reamer bit through the deployed riser assembly and rotating the riser string with the bit while drilling the lower riser into the seabed. Alternatively, the drill string may substantially swivel or rotate within the riser while the riser may not rotate or may rotate independently from the drill string, while drilling the lower riser into the sea bed for cementing and permanent placement of the lower nser. The drill bit and drill string may then be retrieved back to the rig. Those skilled in the art of well drilling operations will appreciate that there are a number of other means for drilling in the lower riser. An alternative embodiment for the riser disconnect provides non-rotational engagement grooves in order to rotate the riser with the drill string.
[0018] In an another alternative embodiment, the upper riser may include the female disconnect member and related components, while the lower riser provides the male disconnect member and related components. An alternative embodiment may also provide the seal members within the female member while the male seal member provides a substantially smooth sealing surface on a mandrel.
[0019] It is an object of the present embodiment to improve the economics of drilling, completion and work over operations from an offshore rig by providing a more economical method of equipment optimization and use. An embodiment provides apparatus and means for placing the wellhead and BOP system substantially on the rig. In a preferred installation, a riser system may be utilized which employs riser joint connections secured by means and apparatus other than by flanges and bolting, such as a threaded riser consisting of joints of well casing, or a groove locked connection. Such equipment usage and arrangement may also save a considerable amount of time in retracting and deploying the upper riser. In addition, a flex joint may be provided either above or below the riser disconnect to accommodate riser angular displacement.
[0020] It is also an object of this embodiment to provide apparatus and means to relatively quickly disconnect an upper riser from a lower riser to facilitate moving the rig out of harms way. This embodiment provides a riser disconnect system which may be actuated by merely reciprocating the upper riser relative to the lower riser.
[0021] It is further an objective of this embodiment to provide a riser disconnect apparatus which may be easily and reliably manipulated from the rig. Manipulation of the riser disconnect between the riser latch position and the riser unlatch position may be performed by simple axial reciprocation of the riser disconnect from the rig. Moving the BOP stack near the rig may also assist in economic riser deployment and recovery.
[0022] It is a feature of this preferred embodiment to provide a riser disconnect system which may be reconnected after disconnecting the male and female disconnect members. The riser disconnect system of this embodiment may be repeatedly connected and disconnected.
[0023] It is another feature of this embodiment that the riser disconnect may be manipulated between the connected and disconnected positions without subsurface hydraulic and/or electrical umbilical lines. Although such lines may optionally be employed for other purposes, the riser disconnect does not require them.
[0024] It is also a feature of this embodiment that the riser disconnect system may be locked in the riser latch or unlocked from the riser latch position. The riser system, including the riser disconnect may be installed while the riser disconnect is locked in the latched position, and after installation the riser disconnect may preferably remain unlocked, while riser tension maintains the disconnect in a latched configuration.
[0025] These advantages may enhance deep water operations by facilitating employment of an improved, more cost effective riser and drilling system which may save considerable time and costs. The subsea riser disconnect may provide for placing the BOP stack on or suspended just below the rig or drill ship, thereby effectively eliminating placing the BOP stack on the ocean floor. By minimizing the number of subsurface hydraulic and electric umbilical lines, connectors, and kill and choke lines, several days of rig time may be saved. The preferred drilling equipment configuration and alternative embodiments thereof, as disclosed herein, may be particularly applicable for drilling and completing exploratory or other wells where well costs are a key consideration and where the well may not be intended for production after well testing.
[0026] It is also a feature of this embodiment that the riser disconnect system may be employed with re-entry risers as well as drilling and completion risers. Although the preferred embodiment is illustrated generally in terms of use with a drilling riser installation, the concepts and apparatus for riser disconnect manipulation by axial reciprocation methods may be applied equally well to risers used in completion and re-entry operations following well completion.
[0000] Subsea Riser Valve
[0027] A preferred embodiment of a subsurface riser valve includes an apparatus and methods for sealing the interior of a well bore, below the riser valve, through axial movement of the riser above the riser valve (generally, the upper riser) relative to the riser below the riser valve (generally, the lower riser). The subsea riser valve may be positioned at substantially any point along a riser system, preferably below the riser disconnect such that the riser valve may be closed in conjunction with or prior to disconnection of a riser disconnect. The subsea riser valve may also provide a subsea method of well control, such that the BOP stack may be positioned on the rig.
[0028] A preferred embodiment of the subsurface riser valve provides for the riser valve as a distinct, stand-alone piece of equipment which may be employed separately or in combination with riser and/or drill pipe disconnect apparatus. The riser valve is preferably used in combination with the riser disconnect, such that the riser valve is positioned below the riser disconnect in order that the interior of a lower riser and well bore below the riser valve may be hydraulically isolated and confined. The lower end of a riser valve may be sealingly connected to the upper end of a lower riser, a well casing, a well head or other subsea component. The upper end of the subsea riser valve may be directly or indirectly secured to the lower end of the subsea riser disconnect.
[0029] The subsea riser valve includes a valve housing enclosing a valve sealing member, and a valve actuation mandrel telescopically extending from the upper portion of the riser valve. A linkage or connector may moveably connect the valve sealing member and the valve actuation mandrel. The riser valve may be biased closed and may be opened in response to axial tension in the riser system. A lockout device similar to the lockout device described on the riser disconnect above, may be included with the riser valve apparatus, to lock the riser valve in either the valve opened or valve closed positions.
[0030] The riser valve may be locked in the opened position during installation of the riser system to allow the riser to fill with fluid and to allow circulation of fluids or slurries through the string prior to applying tension in the valve system. When the riser valve and riser system are properly positioned, installed and cemented, tension may be exerted on the riser valve to maintain the valve sealing member in the valve opened position. Prior to closing the valve sealing member, components within the through bore of the riser valve may be removed from within the through bore of the riser valve, such that the valve sealing member may freely move between the valve closed and valve opened positions.
[0031] It is an objective of this embodiment to provide an apparatus and means for sealing the interior of a riser and well bore below the riser in response to axial motion of the upper riser string. To close an opened valve sealing member, axial tension in the riser system may be relaxed such that the weight of the riser and the resulting closing biasing force may close the riser valve, effectively sealing the well bore below the riser valve. To open the riser valve, axial tension may be applied to the upper riser and valve actuation mandrel sufficient to overcome the riser weight and closing bias force. The riser valve may be opened and closed repeatedly as needed during well operations.
[0032] It is an object of this embodiment that the riser valve may be used in conjunction with the riser disconnect to provide a mechanically actuated riser disconnect and well control system for connecting a drilling rig to a subsea well bore. Such mechanically actuated system may assist in facilitating placing the BOP stack and related well control equipment on or near the drilling rig. Such arrangement may significantly decrease well costs by eliminating hydraulic and/or electrical umbilical lines between subsea equipment and the rig. Concurrent and subsequent axial movement of the riser may also unlatch and disconnect the upper riser from the lower riser. The rig and upper riser may thereafter be removed from the situs of the well, while the subsea well control valve remains to contains well pressure and fluids within the well bore.
[0033] It is also an object of this embodiment to provide a subsea riser valve which may be manipulated between the opened and closed positions without hydraulic or electrical lines. Mechanical movement within the valve mechanism is provided by axial movement of the riser system, thereby effectively eliminating the need for hydraulic or electrical actuation of the valve sealing member.
[0034] It is a feature of this embodiment that the riser valve provide a full bore opening through bore. The preferred riser valve, including the valve sealing member may provide an ID that is not less than the minimum ID of either or both of the upper riser and lower riser.
[0035] It is another feature of this embodiment that the preferred riser valve may be provided as a separate, stand alone device, such that the riser valve may be used alone in a riser system, or a riser disconnect may be combined with a stand-alone riser valve and/or other separate devices. Alternatively, the riser valve may be integrated into a common housing with a riser disconnect apparatus. Both apparatus may be compatible for use as an integrated tool combining both the riser valve and the riser disconnect in a common housing or body, as both may be compatibly manipulated by axial tension applied at the drilling rig.
[0036] It is also a feature of this embodiment that the riser valve may be installed inverted from the preferred orientation described above, such that the valve actuation mandrel is connected to the lower riser, casing or well head. In either the preferred or an inverted embodiment, the riser valve may be manipulated with tension in the upper riser.
[0037] An additional feature of other embodiments of this invention is that the riser valve components may be varied such that the valve sealing member may be of a type other than a ball type sealing member, such as plug type rotational cylinder members, or gate type sealing members, or flapper type sealing members. Alternative embodiments for a riser valve may be configured for manipulating each of these types of sealing members from axial movement of the upper riser relative to the lower riser.
[0000] Drill Pipe Disconnect
[0038] Apparatus and method are disclosed for connecting and disconnecting an upper portion of a drill pipe string above a drill pipe disconnect apparatus from a lower portion of a drill pipe string below the disconnect apparatus. The drill pipe disconnect may be positioned at substantially any point along the drill string wherein it may be convenient or desirable to disconnect a portion of the drill pipe string from the remainder of the string. Such disconnection may be required in conjunction with disconnecting a subsea riser disconnect, and/or in conjunction with closing a subsea riser valve, such as may be desirable in advance of relocating the rig due to approaching threatening weather.
[0039] The drill pipe disconnect is preferably used in conjunction with the subsea riser disconnect and/or the subsea riser valve. Prior to closing a riser valve and/or disconnecting a riser disconnect, rather than pull the entire string of drill pipe above the riser valve, it may be prudent to temporarily abandon the portion of the drill pipe string which is below the riser valve and the drill pipe disconnect. In such event, the drill pipe disconnect may be disconnected at a point below the riser valve, and the upper disconnected portion of drill pipe pulled up to above the riser valve, such that the riser valve may be closed and the riser disconnect subsequently disconnected.
[0040] The drill pipe disconnect may be selectively operable to mechanically disconnect or connect the upper and lower portions of a drill pipe string, in response to movement of a latch mechanism, while also providing axial and rotational strength commensurate with the strength of the drill pipe in use. Non-rotational engagement components may be included within the drill pipe disconnect to carry rotational stresses in the drill string.
[0041] A preferred embodiment of a drill pipe disconnect apparatus may generally include a male drill pipe disconnect member and a female drill pipe disconnect member. The male disconnect member may include a collet mechanism to latch and unlatch the male and female disconnect members. A latch sleeve may be included, which is movable between a collet latch position and a collet unlatch position. When the latch sleeve is in the collet unlatch position, the male drill pipe disconnect member may be released from engagement with the female drill pipe disconnect member.
[0042] The male and female disconnect members of the drill pipe disconnect may be secured within a drill pipe string by connections provided on each end of the drill pipe disconnect. In a preferable embodiment, the upper end of the male disconnect may include a threaded box type tool joint, while the lower end of the female disconnect may include a threaded pin type tool joint.
[0043] A preferred method of operation for the drill pipe disconnect generally includes providing and operating a first assembly and a second assembly, which is a modification of the first assembly. The first assembly may typically be employed for an initial drill pipe disconnect installation. Thereafter, subsequent to disconnecting the drill pipe assembly and recovering the male drill pipe disconnect member to the rig, the second assembly may be installed. The second assembly is provided by substituting a male reconnect member for the male disconnect member, to reconnect the male reconnect member with the female disconnect member. Thereafter, if desired the male reconnect member and the female disconnect member may be re-unlatched from one another.
[0044] The first assembly for the drill pipe disconnect may be installed in a drill pipe string, such that the col let mechanism and latch sleeve are in the collet latch position. A shear pin may secure the position of the latch sleeve within a male disconnect housing, in the collet latched position. The string of drill pipe including the drill pipe disconnect may be repeatedly inserted into and withdrawn from a well bore as needed, such as when “tripping pipe,” with the drill pipe disconnect apparatus threadably secured within the drill string.
[0045] In the event it becomes desirable to disconnect the drill pipe disconnect and temporarily or permanently abandon a lower portion of drill pipe within the well bore, an unlatching ball or other closure device may be dropped through the upper portion of drill pipe, from the rig floor. The unlatching ball may sealingly seat on the unlatching seat such that hydraulic pressure may be applied to the drill string from the rig to cause the latch sleeve to shear the shear pin and move downward to a position where the collet dogs may unlatch from engagement with the female disconnect member. The male drill pipe disconnect member may then be telescopically withdrawn from the female disconnect member, and the male disconnect member and upper portion of drill pipe withdrawn to the rig.
[0046] To reconnect the male disconnect member with the female disconnect member, the male second assembly of the male disconnect member may be provided with a positionable latch sleeve that includes two unlatch grooves, shear pins that provide for two shearing actions, a latching seat and an extension tube on the latch sleeve. The male disconnect member may subsequently be engaged with the female disconnect member in the well bore. A latching ball may then be dropped through the drill pipe string for sealingly seating on a latching seat in the latch sleeve. The latching seat may be secured within the latch sleeve by shear pins. Hydraulic pressure may be applied within the drill string, sufficient to shear the double shear pins at a first shear point. The latch sleeve may then move downward from a collet unlatch position to a collet latch position, such that the male and female disconnect members are again securely latched together.
[0047] Hydraulic pressure within the drill string may be further increased to until the shear pins which secure the latch seat within the latch sleeve are sheared, allowing the latch seat and latching ball to be ejected downward from within the latch sleeve. The extension tube on the latch sleeve may receive or catch the ejected latch seat and latching ball. The extension tube may provide a plurality of ports to hydraulically interconnect the upper and lower portions of the interior of the drill pipe. A hydraulic conduit is thereby provided through the drill pipe through bore such that fluid may be circulated through the upper and lower portions of the drill pipe string. The latch seat and latching ball may remain within the extension tube. As an alternative, instead of shearing the latch seat pins and ejecting the latch seat and latching ball and receiving the latch seat and latching ball within the extension tube, the latch ball may be recovered to the surface. Fluid may be circulated down the drill pipe/casing annulus and back up through the drill bit and drill pipe to reverse flow the latching ball back to the surface of the rig.
[0048] In the preferred embodiment, to re-unlatch the male drill pipe disconnect from the female drill pipe disconnect, a re-unlatching ball may be dropped for sealingly seating on a re-unlatching seat. Hydraulic pressure applied within the drill pipe through bore may shear the double shear pins at a second point and allow the latch sleeve to move downward to a re-unlatch position, wherein the male disconnect member may be withdrawn from the female disconnect member and recovered to the rig. For subsequent re-engagement, the male disconnect member may be again re-dressed as described above for reconnection.
[0049] The drill pipe disconnect apparatus and/or method may be utilized in either an off-shore installation or a land based installation. In a land based installation, the drill pipe disconnect may provide for a disconnect point in the drill pipe string, such as may be desirable to provide above a geologic trouble spot or near a casing seat above an open hole section. It may be desirable to provide a convenient disconnect device at a point in the drill string where backing off or disconnecting otherwise may be difficult or impossible to achieve, particularly in deep wells or along long horizontal well bore sections.
[0050] It is an object of this embodiment to provide a method of operation and an apparatus for disconnecting an upper portion of a drill pipe string from a lower portion of the drill pipe string in a quick, reliable manner. The preferred disconnect method and apparatus disclosed herein facilitates providing a relatively simple and reliable disconnection point within a drill pipe string. Some of the components and mechanisms relied upon for operation of this embodiment are recognized as generally reliable mechanisms, such as a collet mechanism, shear pinned components, and ball and seat type hydraulic seals.
[0051] It is also an object of this embodiment to provide a drill pipe disconnect apparatus and method which may be manipulated without relying upon back-off tools, back-off methods, external manipulation devices or destruction of drill pipe to disconnect. This embodiment provides method and apparatus for disconnecting an upper section of a drill pipe string from a lower section of the drill pipe string by dropping a ball and applying hydraulic pressure to unlatch a latch mechanism. The drill pipe disconnect can also be actuated with a portion of the drill string off the bottom of the well bore. To disconnect the drill pipe disconnect mechanism with the drill string off bottom of the well bore, disconnection may only require that a higher pressure be applied to the interior of the drill pipe string above the dropped ball.
[0052] It is a feature of this embodiment that an apparatus and method are provided for reconnecting the upper and the lower drill pipe sections after they have been disconnected. In this embodiment the upper and lower drill pipe sections may be re-engaged and then re-latched by dropping a ball and applying hydraulic pressure to securely re-latch the upper and lower drill pipe sections.
[0053] It is also a feature of this embodiment that the re-latched drill pipe sections may subsequently be unlatched again, thereby facilitating repeated disconnects and reconnects as desired. The drill pipe reconnect and disconnect apparatus and methods are simple and reliable to operate and may save time and costs in disconnecting a drill pipe string at a pre-determined location.
[0054] It is yet another feature of this embodiment that the drill pipe disconnect may provide an apparatus and method for rotating the drill string. Non-rotational engagement members are provided which may provide rotational strength within the disconnect apparatus which is substantially equivalent to the strength of the drill pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIG. 1 is a simplified pictorial representation of a drilling rig, a riser assembly, a riser disconnect, a riser valve, a string of drill pipe, and a drill pipe disconnect in a drilling installation.
[0056] FIG. 1A is a pictorial illustration of a riser male disconnect member disconnected from a female riser disconnect member, with an upper portion of drill pipe disconnected from a lower portion of drill pipe.
[0057] FIG. 2 is a cross-sectional view of an upper portion of a riser disconnect assembly illustrated in cross-section.
[0058] FIG. 2A is a side view of a riser disconnect lockout as shown in FIG. 2 , in a locked orientation.
[0059] FIG. 3 is a cross-sectional view of lower portion of the riser disconnect assembly illustrated in FIG. 2 .
[0060] FIG. 3A is an enlarged view of a collet mechanism illustrating a collet mechanism in a latched position.
[0061] FIG. 4 is an enlarged half-section illustration of the riser disconnect collet mechanism generally illustrated in FIG. 3 .
[0062] FIG. 5 is a cross-sectional view of a riser disconnect lockout wherein the left half of FIG. 5 illustrates the lockout mechanism in the locked orientation and the right half of FIG. 5 illustrates the lockout mechanism in the unlocked orientation.
[0063] FIG. 5A is a side view of the riser disconnect lockout shown in FIG. 2 , in cross-section through the lockout pin illustrating retainers, grooves and stop dimples.
[0064] FIG. 6 is a cross-sectional top view of a riser valve assembly, illustrating a ball pivot and the ball linkage adapter.
[0065] FIG. 6A is a side view of a ball type sealing member shown in FIG. 6 , illustrating an engagement groove and engagement pin arrangement.
[0066] FIG. 7 is a cross-sectional view of a subsea riser valve assembly, with a valve ball in the opened position.
[0067] FIG. 8 is a cross-sectional top view of a subsea riser valve assembly illustrating a riser valve lockout device and a valve mandrel guide.
[0068] FIG. 9 is an enlarged half-sectional view of a subsea riser valve with a valve ball in a closed position.
[0069] FIG. 10 is a cross-sectional view of a drill pipe disconnect in the collet latched position initially installed, including an unlatching ball.
[0070] FIG. 11 is a cross-sectional view of the drill pipe disconnect illustrated in FIG. 10 , with the latch sleeve moved downward to the collet unlatch position.
[0071] FIG. 12 illustrates a lower end of a second assembly, a male reconnect member separated from the upper end of a female disconnect member, with the female disconnect member illustrating non-rotational engagement grooves.
[0072] FIG. 13 is a cross-sectional view of a drill pipe disconnect with the second assembly, a male reconnect member engaged with the female disconnect member, in the collet unlatch position with a latching ball seated.
[0073] FIG. 14 is an enlarged illustration of the disconnect shown in FIG. 13 , with the latch sleeve displaced downward in the collet latch position.
[0074] FIG. 15 is an enlarged illustration of a portion of the disconnect shown in FIG. 13 , with the latch ball and latch seat ejected into the latch sleeve extension.
[0075] FIG. 16 is a cross-sectional illustration of a drill pipe disconnect with a re-unlatching ball seated and the latch sleeve moved downward to the collet re-unlatch position.
[0076] FIG. 17 is a cross-sectional view of a drill pipe disconnect collet mechanism illustrating collet dogs engaged with a female disconnect member and illustrating the fingers connecting the latch mandrel with the collet engagement ring.
[0077] FIG. 18 is a cross-sectional view of a riser disconnect embodiment including a non-rotational key engagement head which is engaged with a non-rotational key.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0078] FIG. 1 illustrates a generalized, suitable application for a subsea riser disconnect, a subsea riser valve and a drill pipe disconnect according to the present invention. In one embodiment, this invention includes three principle assemblies, namely: 1) a subsea riser disconnect assembly 10 , 2) a subsea riser valve assembly 20 , and 3) a subsea drill pipe disconnect assembly 30 . Each of these three principle assemblies may be provided in a drilling installation, separate and apart from or in combination with any or both of the other principle assemblies, or primary components. As disclosed subsequently, safety mechanisms may be included within each principle assembly to prevent inadvertent operation of that assembly.
[0079] Each of these three primary components 10 , 20 , 30 may be employed individually or in conjunction with one or both of the other primary components. And each of these three components generally include a through bore extending through the component along a central axis 15 . The central axis 15 may substantially be common to each and all components. (It is understood and assumed throughout this disclosure, that all seals may be both hydraulic seals and pneumatic seals, notwithstanding the fact that a particular seal may be simply designated as a hydraulic seal or otherwise. It is also understood and assumed that all connections, secured components, attachments or otherwise joining of two or more components may effect a seal, unless designated otherwise. It is further understood and assumed that the terms drilling rig, rig, work over rig, and drill ship, semi-submersible and related terms may be used interchangeably and not in limitation.)
[0080] One or more portions of a preferred embodiment of a sub-sea riser disconnect assembly 10 are illustrated in FIGS. 1, 1A , 2 and 3 , for sealingly connecting a lower riser 28 extending downward from above the mud line ML through a seabed SB and into a subsea well bore WB with an upper riser 35 extending downward from a drilling rig DR to the lower subsea riser 28 . The drilling rig DR may include floating types of drilling rigs DR such as a drill ship and a semi-submersible rig. The position of the drilling rig DR is not fixed with respect to the location of the wellbore WB. The lower subsea riser 28 may be secured within the wellbore WB, e.g., by a cementing operation, such that the riser disconnect assembly 10 may be selectively activated to disengage and/or reengage a lower end 37 of the upper riser 35 from an upper end 19 of the lower riser 28 .
[0081] The subsea riser disconnect assembly 10 , the subsea valve assembly 20 , the drill pipe 36 , the drill pipe disconnect 30 and the wellbore WB may each include a through bore and a central axis 15 . Both the through bore and the central axis 15 may be substantially aligned along a common central axis 15 .
[0082] The riser disconnect assembly 10 includes a male disconnect member 12 , which may be secured to the lower end 37 of the upper riser 35 , and has a central axis aligned along the axis 15 . The riser disconnect assembly 10 also includes a female disconnect member 18 for axially receiving the male disconnect member 12 therein. The female disconnect member 18 may be secured to upper end 19 of the lower riser 28 . The riser disconnect assembly 10 may provide a full bore opening, such that the minimum ID of the through bore of the riser disconnect assembly 10 is equal to or greater than the ID of at least one of the upper 35 and lower 28 riser sections. Those skilled in the art will appreciate that a riser may generally be comprised of tubular components having a common through bore for providing a conduit that connects a drilling rig DR with a downhole DH portion of a well bore WB that typically extends below the lower end of the riser, where a portion of the lower end of the riser is secured within the seabed, below the mud line ML.
[0000] Riser Disconnect Male Member
[0083] As illustrated in FIGS. 1, 2 and 3 , a seal assembly 14 may provide a pneumatic seal in the connection between the outer surface of the male disconnect member 12 and a mating inner surface of the female disconnect member 18 . The male component of the seal assembly 14 includes an upper seal mandrel 42 , which may be connected to a lower end 19 of the upper riser 35 by a riser connector collar 41 . A lower end of the upper seal mandrel 42 may be connected to an upper end of a lower seal mandrel 56 . The lower end of the lower seal mandrel 56 in turn may be connected to a seal retainer 61 , which may be connected to latch mandrel 62 . The upper end of the latch mandrel 62 may be connected to the lower end of the seal retainer 61 , while the lower end of the latch mandrel 62 may generally include the lower end of the male disconnect member 12 . A commonly known latch J-slot groove 63 , as shown in FIG. 3 , may be included in the outer surface of the latch mandrel 62 , and may circumferentially surround the latch mandrel 62 , in either the pattern shown or another desired pattern.
[0084] One or more seal elements 54 , also commonly known as packing elements, may be positioned axially along the outer surface of the lower seal mandrel 56 , between the upper seal mandrel 42 and the seal retainer 61 . The seal elements 54 may circumferentially encompass the outer surface of the lower seal mandrel 56 and may include an alternating arrangement of a variety of seal materials in alternative embodiments. The seal elements 54 need not be axially continuous along the lower seal mandrel 56 , and may be positioned in sets, at axial intervals along the male component and female component. The female component of the seal assembly 14 may include a seal bore receptacle 58 for engaging the seal elements 54 . The female disconnect member 18 is discussed in detail below.
[0085] A riser interconnection device 40 may be included for releasably securing the male disconnect member 12 with the female disconnect member 18 . The riser interconnection device 40 may be actuatable in response to axial reciprocating movement of the upper riser 35 relative to the lower riser 28 from a connect position to a release position or from a release position to a connect position. This reciprocating movement may be effected by movement of the upper riser 35 at the drilling rig DR. In the release position, the male disconnect member 12 and the female disconnect member 18 may be uncoupled, thereby permitting mechanical separation of the upper riser 35 from the lower riser 28 , as discussed below.
[0086] Referring to FIGS. 1, 3 and 4 , the riser interconnection device 40 may include a collet mechanism 60 for releasably interconnecting the male disconnect member 12 with the female disconnect member 18 . Components of the collet mechanism 60 included in the male disconnect member 12 may include a collet latch sleeve 72 , a latch pin 74 and the collet locking sleeve 80 . The collet latch sleeve 72 may include a plurality of collet arms 76 , and each collet arm 76 may include a collet dog 78 for engaging a collet groove 82 . The collet groove 82 may be provided in the inner surface of a latch housing sleeve 84 of the female disconnect member 18 . The collet latch sleeve 72 , a plurality of collet arms 76 and corresponding plurality of latch dogs 78 may be circumferentially spaced about the external surface of the latch mandrel 62 for selectively interconnecting the plurality of collet dogs 78 with the collet groove 82 . The collet latch sleeve 72 , the plurality of collet arms 76 and the latch dogs 78 may be axially and rotationally moveable about the common central axis 15 , with respect to the latch mandrel 62 .
[0087] One or more latch pins 74 may be secured in the collet latch sleeve 72 . The latch pins 74 may protrude radially inward from the inner surface of the collet latch sleeve 72 toward the central axis 15 for a distance sufficient for the latch pins 74 to engage the latch J-slot groove 63 , in the outer surface of the latch mandrel 62 . The intrusion of latch pins 74 into the J-slot groove 63 may not exceed the depth of the latch J-slot groove 63 . The plurality of collet arms 76 and collet dogs 78 are preferably made integrally part of the collet latch sleeve 72 . The plurality of collet arms 76 and collet dogs 78 extend downward from the collet latch sleeve 72 . The collet locking sleeve 80 may be immovably secured to the lower end of the latch mandrel 62 , below the collet latch sleeve 72 .
[0088] A portion of the collet locking sleeve 80 may extend axially upward along the outer surface of the latch mandrel 62 for a sufficient distance such that, with the riser disconnect assembly 10 in the latched position, a tapered portion 81 of the collet locking sleeve 80 may be circumferentially positioned between an inner surface of the collet dogs 78 and an outer surface of the latch mandrel 62 . The tapered portion 81 of the collet locking sleeve 80 , which is between the inner surface of the collet dogs 78 and the outer surface of the latch mandrel 62 , may also be referred to as the collet engaging ring 81 . An outer surface of the collet engaging ring 81 includes the tapered surface which may taper upward to a circumferential upper edge. A load bearing shoulder at bottom of the collet dog 78 may be supported on load bearing shoulder at lower end of collet engaging ring 81 of collet locking sleeve 80 when the riser disconnect assembly 10 is in the latched position. A load bearing shoulder at top of the collet dog 78 may be supported on load bearing shoulder at upper end of a collet engagement groove 82 when riser disconnect assembly 10 is in the latched position.
[0000] Riser Disconnect Female Member
[0089] Referring to FIGS. 1, 2 , 3 and 4 , the lower riser 28 extends upward from the mud line ML, generally toward the drilling rig DR. The lower end of the lower riser 28 may be connected to a well casing 32 which extends through a seabed and into a subsea wellbore WB. The female disconnect member 18 may include the latch housing sleeve 84 , a seal bore receptacle 58 , and an entry guide 34 . The latch housing sleeve 84 may also include the female portion of the collet mechanism 60 , e.g., the collet groove 82 for coupling with the companion male components of the collet mechanism 60 . A casing end of the latch housing sleeve 84 may be attached to the upper end of a well casing 32 or other component. A latch end of the latch housing sleeve 84 may include a collet groove 82 circumferentially within the inner surface of the latch housing sleeve 84 for releasably receiving and securing the collet dogs 78 of the male disconnect member 12 .
[0090] The latch end of the latch housing sleeve 84 may be attached to the lower end of the seal bore receptacle 58 . An entry guide 34 may be secured to an upper end of the seal bore receptacle 58 , and may assist in aligning the male disconnect member 12 with the female disconnect member 18 during reconnection of the male disconnect member 12 and female disconnect member 18 . An entry guide retainer 52 may be used to secure the entry guide 34 to the seal bore receptacle 58 . The entry guide 34 may extend upward toward the water surface from the point of attachment to the female disconnect member 18 , with a frustoconically expanding circumference, thereby forming a generally cone shaped receptacle defined by surface 38 .
[0000] Riser Disconnect Lockout Mechanism
[0091] In addition to the latch mechanism and seal components, the riser disconnect assembly 10 may include a riser disconnect lockout 50 to prevent inadvertent or unintentional disengagement of the male disconnect member 12 from the female disconnect member 18 . The riser disconnect lockout 50 may typically be used in the locked configuration only during the initial connection, installation and cementing of the upper and lower riser assembly, when compressive forces may be experienced due to running, installing and cementing the casing 32 and/or the riser disconnect assembly 10 . The riser disconnect lockout 50 may otherwise normally remain in the unlocked position since the applied axial tensile forces in the upper riser 35 prevent disconnection of the male disconnect member and the female disconnect member. Referring to FIGS. 2, 2A , the riser disconnect lockout 50 may preferably be comprised of a shouldered pin and groove assembly. The riser disconnect lockout 50 preferably may be provided on the male disconnect member 12 , axially between the riser connector collar 41 and the lower seal mandrel 56 .
[0092] Referring to FIGS. 1, 2 , 2 A, 3 , 3 A, 4 , 5 , 5 A one or more lockout grooves 43 may be circumferentially provided on the outer surface of the upper seal mandrel 42 , each lockout groove to accommodate a lockout pin 46 . The one or more grooves 43 may each have a long axis which is aligned axially up and down along the upper riser 35 , substantially parallel with the central axis 15 . Each groove 43 includes a circular portion, at the lower end of the groove 43 , the circular portion having a diameter that is larger than the width of the groove 43 , as shown in FIGS. 2A and 5 . A riser disconnect lockout housing 48 may be circumferentially positioned on the external surface of the upper seal mandrel 42 , the riser disconnect lockout housing 48 being axially moveable along the central axis 15 , on the outer surface of the upper seal mandrel 42 .
[0093] A riser disconnect lockout pin 46 may be provided for each lockout groove 43 . Referring to FIGS. 2A, 5 , and 5 A, the riser disconnect lockout pin 46 may include a round shaped upset providing lockout upset shoulders 45 and having two opposing flat sides where opposing portions of the round shaped upset are removed to provide the flat sides, on an inner end of the riser disconnect lockout pin 46 , the rounded portion provided along a major axis between the rounded ends and having a length that is larger than the diameter of the pin 46 , and a minor axis between the two flat sides which is substantially equal to the diameter of the pin 46 . Each lockout pin 46 may extend from inside of the riser disconnect lockout housing 48 , through a pin port 51 and may be furnished with a square socket for engagement with an ROV operating wrench (not shown). The round shaped portion of the riser disconnect lockout pin 46 remains inside of the riser disconnect lockout housing 48 in the respective lockout groove 43 .
[0094] As illustrated in FIGS. 5, 5A , spring loaded and/or threaded or otherwise secured retainer pins 49 may be positioned within the riser disconnect lockout housing 48 to engage a retainer groove 53 in each lockout pin 46 to provide resistance to the pin 46 . Such configuration may thereby prevent inadvertent rotation of the pin 46 . In addition the retainer groove 53 may only be provided circumferentially around a portion of the outer surface of the lockout pin 46 , such as ninety degrees, in order to provide rotational stop positions to ensure proper rotational orientation of the lockout pin 46 . Stop dimples 88 , as shown in FIG. 5A , may be provided on a portion of the lockout pin 46 to ensure proper respective locked and unlocked lockout pin 46 orientation.
[0095] A lockout sleeve 44 may be concentrically disposed around a portion of the upper seal mandrel 42 . An upper end of the lockout sleeve 44 may engage the riser disconnect lockout housing 48 , and a lower end of the lockout sleeve 44 may engage the upper end of the seal bore receptacle 58 . The lockout sleeve 44 is axially moveable with respect to the upper seal mandrel 42 when lockout 50 is in the unlocked position.
[0096] An alternative embodiment for a riser disconnect may include an apparatus to facilitate rotating an upper riser, a riser disconnect and a lower riser, substantially in unison to drill the lower riser into position in the sea bed. A bit 39 or under reamer bit may be positioned near the lower end of the lower riser 28 . Referring to FIG. 18 , a tubular, generally female, non-rotational key engagement head 340 may be secured to a female riser disconnect member to receive and engage a non-rotational key member 346 . The non-rotational key member 346 may be secured to an outer surface of a mandrel, such as a lockout sleeve 344 , which may be concentrically disposed around an upper seal mandrel 342 . The female non-rotational key engagement head 340 may include a tapered upper surface, which may be referred to as an upper key guide surface 345 , to guide insertion of the male member into non-rotational engagement with the female disconnect member. An extension mandrel 359 may support the female non-rotational key engagement head 340 and may support an entry guide 334 . An upper end of a seal bore receptacle 358 may connect with the lower end of the extension mandrel 359 . An extension mandrel adapter ring 360 may connect the seal bore receptacle 358 and the extension mandrel 359 . Such embodiment may facilitate rotating a lower riser with an upper riser which may be connected by a riser disconnect 10 . The non-rotational key engagement head 340 and non-rotational key member 346 components, or variations thereof such components, may be employed for purposes other than drilling in the lower riser 28 , such as rotating the lower riser in preparation for and/or during cementing operations, or to rotationally manipulate the lower riser 28 and/or upper riser 35 .
[0000] Riser Disconnect, General Operation
[0097] Referring to FIGS. 1, 2 , 2 A, 3 , 3 A, 4 , 5 and 5 A, the riser disconnect assembly 10 , is generally operable by axial motion of the attached upper riser 35 relative to the lower riser 28 , using the drilling rig DR to effect axial motion or reciprocation. The male disconnect member 12 is latched into engagement with the female disconnect member prior to riser installation. When the riser disconnect assembly 10 is installed on a well as part of a riser assembly and in the connected and latched position, the upper riser 35 and lower riser 28 are normally under a tensile load, typically around one-hundred thousand pounds of force, between the drilling rig DR and the well casing 32 , that extends into the wellbore WB and is cemented therein. The tapered portion or collet engaging ring 81 is circumferentially spaced between the inside of the plurality of collet dogs 78 and the outer surface of the latch mandrel 62 , causing the collet dogs to be engaged in the collet groove 82 . The tensile load on the male disconnect member 12 is carried through the collet locking sleeve 80 into the collet dogs 78 as a compressive load, through engagement of the collet locking sleeve 80 with the collet dogs 78 . The compressive load in the collet dogs 78 is transferred to the female disconnect member 18 through the engagement of the collet dogs 78 with the collet groove 82 , the collet groove 82 being a component of the female disconnect member 18 . In such riser tensile load configuration, the latch pin 74 is in a latched position 66 within the latch J-slot groove 63 . A load bearing shoulder at bottom of the collet dog 78 may be supported on load bearing shoulder at lower end of collet engaging ring 81 of collet locking sleeve 80 when the riser disconnect assembly 10 is in the latched position. A load bearing shoulder at top of the collet dog 78 may be supported on load bearing shoulder at upper end of a collet engagement groove 82 when riser disconnect assembly 10 is in the latched position.
[0098] The load bearing lockout shoulders 45 of each riser disconnect lockout pin 46 are preferably normally positioned within the circular, lower portion of the respective lockout groove 43 and in a rotational orientation such that a long axis between the rounded end portions 47 of the lockout pin 46 may be axially aligned parallel to a long axis of the lockout groove 43 . In such orientation, the male disconnect member 12 may be unlatched from the female disconnect member 18 . Tensile load in the upper riser 35 may not act directly upon the riser disconnect lockout pin 46 . When in the locked orientation, the lockout pin 46 may prevent any compressive forces in the riser from inadvertently unlocking the riser disconnect assembly 10 , in that the load bearing shoulders 45 are not aligned to move along the lockout grooves 43 , as is otherwise required to disconnect the riser disconnect assembly 10 . The locked orientation may normally be used only in initial installation of the casing 32 , riser disconnect assembly 10 . Otherwise the lockout pin 46 will typically remain in the unlocked orientation.
[0099] When the riser disconnect lockout 50 is in the locked position, as illustrated in the left half of FIG. 5 , compressive forces in the upper riser 35 prohibit an unlocking axial movement of the upper riser 35 relative to the lower riser 18 . Compressive forces tending to axially move the upper riser 35 relative to the lower riser 28 , such as may be experienced during riser installation, will transfer from the upper seal mandrel 42 to the load bearing lockout shoulders 45 of the lockout pin 46 , and from the lockout pin 46 to the riser disconnect lockout housing 48 . When applying compressive forces substantially at the riser disconnect assembly 10 , the riser disconnect lockout housing 48 will compressingly engage an upper portion of the lockout sleeve 44 , which in turn will compressingly engage an upper portion of the seal bore receptacle 54 . The seal bore receptacle 54 is an immovable component of the lower riser 28 . If the lockout pin is in the unlocked orientation, axial movement of the upper riser 35 relative to the lower riser 28 will result, thereby permitting disconnecting the riser disconnect assembly 10 . If the lockout pin 46 is in the locked orientation, substantially no axial movement of the upper riser 35 relative to the lower riser 28 will result, thereby preventing inadvertent disconnecting of the riser disconnect assembly 10 . The lockout pin 46 is preferably in the locked orientation during running and installation of the casing 32 , the lower riser 28 and upper riser 35 . After cementing operations are complete and tension is applied to the riser disconnect assembly 10 , a remotely operated vehicle (ROV), diver or other means may be employed to orient the disconnect lockout pin 46 to the unlocked orientation. Well operations may normally be carried on with the riser disconnect lockout 50 in the unlocked orientation.
[0000] Riser Disconnect, Unlatching and Disconnecting Operation
[0100] In the embodiment illustrated in FIGS. 1, 2 , 2 A, 3 , 3 A, 4 , 5 and 5 A, to unlatch and disconnect the upper riser 35 from the lower riser 28 , the tensile load in the riser assembly may be relaxed and converted to a compressive load at the riser interconnection device 40 . If the lockout pin 46 is oriented in the locked position the riser disconnect lockout 50 must be unlocked, such as by ROV or diver, before the riser disconnect operation may be performed. The load bearing shoulders 45 of each riser disconnect lockout pin 46 , which are positioned within the circular, lower portion of the respective lockout groove 43 , may be rotated 90 degrees to a rotational orientation where the long axis portion of the lockout pin 46 providing the load bearing shoulders 47 , is aligned parallel to the long axis of each respective lockout groove 43 . When the riser disconnect lockout pin 46 is oriented in the unlocked position, axial downward displacement of the upper seal mandrel 42 relative to the lockout sleeve 44 is permitted, such that each lockout groove 43 in the upper seal mandrel 42 may axially move along the respective lockout pin 46 during the axial disconnect movement of the upper riser 35 .
[0101] As the upper riser 35 is axially moved downward, the male disconnect member 12 moves downward within the female disconnect member 18 . Such displacement results in relative movement of the latch J-slot groove downward along the latch pins 74 . As downward movement continues, the latch pins 74 move from the latched position 66 in the latch J-slot groove 63 to the collet disengage position 64 , and the collet latch sleeve 72 , the latch pin 74 , the plurality of collet arms 76 and the collet dogs 78 move axially and rotationally to the collet disengage position 64 . As the latch mandrel 62 and connected collet locking sleeve 80 move downward, the tapered portion or collet engaging ring 81 of the collet locking sleeve 80 is moved downward and out from between the collet dogs 78 and latch mandrel 62 . The collet dogs 78 may thereby move radially inward toward the latch mandrel 62 and out of engagement with the collet groove 82 . At that point, the male disconnect member 12 is unlatched from the female disconnect member 18 , but is not disconnected.
[0102] To disconnect the male disconnect member 12 from the female disconnect member 18 , an axial tensile force is applied by the drilling rig DR or other means, to the upper riser 35 . As the upper riser 35 moves upward relative to the lower riser 28 , the J-slot groove 63 in the latch mandrel 62 moves upward relative to latch pins 74 , from the collet disengage position 64 to the latch disconnect position 68 . Because the latch disconnect position 68 is relatively higher than the latch connect position 66 , the collet latch sleeve 72 and collet dogs 78 are prohibited from moving downward along the outer surface of the latch mandrel 62 sufficiently to permit the collet dogs 78 to engage the collet locking sleeve 80 . Thereby, during disconnection of the upper riser 35 from the lower riser, the collet dogs remain disengaged in the annulus between the outer surface of the latch mandrel 62 and the inner surface of the seal bore receptacle 58 . The components of the male disconnect member 12 , including the riser disconnect lockout 50 , the upper and lower seal mandrels 42 , 56 , the seal elements 54 , the riser interconnection device 40 and the collet mechanism 60 may be extracted from the seal bore receptacle 58 . The upper riser may be suspended from or removed to the drilling rig DR, leaving the lower riser in place on the well casing 32 .
[0000] Riser Disconnect, Re-Connecting and Latching Operation
[0103] In the embodiment illustrated in FIGS. 1, 2 , 2 A, 3 , 3 A, 4 , 5 and 5 A, to reconnect and latch the upper riser 35 to the lower riser 28 , the upper riser 35 may be lowered from the drilling rig DR toward the lower riser 28 . The male disconnect member 12 should be guided into and through the entry guide 34 , to compressively set in the female disconnect member 18 .
[0104] As the unlocked male disconnect member 12 is axially moved downward through the female disconnect member 18 , such displacement results in relative movement of the latch J-slot groove downward from the unlatched or disconnect position 68 , along the latch pins 74 . As downward movement continues, the latch pins 74 move from the unlatched or disconnect position 68 in the latch J-slot groove 63 to a top position 67 , resulting in the collet latch sleeve 72 , the latch pins 74 , the plurality of collet arms 76 and the collet dogs 78 moving axially and rotationally on the latch mandrel. As the latch mandrel 62 and connected collet locking sleeve 80 move downward, the collet dogs 78 will engage the collet groove 82 . The male disconnect member 12 may bottom out on an upset surface 87 in the latch housing sleeve 84 .
[0105] To re-latch the riser interconnection device 40 , tension may be applied to the upper riser 35 from the drilling rig DR, such that the upper riser 35 may begin to move upward relative to the lower riser 28 . As the latch mandrel 62 begins moving upward, the latch pins 74 remain alternatively axially immobile, due to the collet dogs 78 engaged within the collet groove 82 . The latch J-slot groove 63 will move upward relative to the latch pins 74 , repositioning the latch pins 74 from the top position 67 to one of the latch engaged positions 66 . As the latch pins 74 approach the latch engaged position 66 , the collet locking ring 81 may circumferentially slide between the inside of the collet dogs 78 and the outside of the latch mandrel 62 . The collet dogs 78 may thereby move radially outward toward the latch housing sleeve 84 , forcing the collet dogs 78 to fully engage the locking groove 82 . At that point, the male disconnect member 12 is securely reconnected and latched into the female disconnect member 18 . Tension is preferably sustained within the upper riser 35 from the drilling rig DR in order to maintain the riser interconnection properly in the latched position.
[0106] The riser disconnect lockout 50 typically remains in the unlocked orientation during drilling operations. In the event it is alternatively desired to lock the riser disconnect lock 50 , a remotely operated actuator, diver or other means are used to reorient the riser disconnect lockout pin 46 to a locked position. From the typically unlocked position, the load bearing shoulders 45 of each riser disconnect lockout pin 46 , which, (with the riser in tension) are normally positioned within the circular, lower portion of the respective lockout groove 43 , may be preferably rotated 90 degrees to a rotational orientation where the long axis of the round portion 47 of the lockout pin 46 which includes the load bearing shoulders 45 , is aligned perpendicular to the long axis of each respective lockout groove 43 . Such locked orientation of the lockout pins 46 prohibits axial downward displacement of the upper seal mandrel 42 relative to the lockout sleeve 44 , thereby locking the riser disconnect in a latched position.
[0107] Alternatively, the riser disconnect assembly 10 and lower riser 28 may be drilled into position in the sea bed while the well bore WB which is to accommodate insertion of the lower riser therein is being drilled. This may be accomplished by a number of means known within the industry. The lower riser 28 , upper riser 35 and the riser disconnect assembly 10 may be rotated substantially in unison, from the drilling rig DR. Additionally, rotating the lower riser 28 may be desirable in the event a ledge is encountered while installing the lower riser, wherein it may be desired to rotate the lower riser in order to assist insertion of the lower riser in a hole or well bore. An alternative embodiment of a riser disconnect assembly 10 for accomplishing such objectives is illustrated in FIG. 18 , and disclosed above.
[0108] Alternatively, depending upon water depth, the riser disconnect 10 , the lower riser 28 and/or the upper riser 35 , or a portion thereof as determined by water depth, may be positioned on the seabed. A string of drill pipe 36 , a drill bit 39 and/or an under reamer bit may be deployed through the positioned riser assembly and the drill string 36 may rotate the riser string along with the bit 39 while drilling the lower riser 28 into the seabed. Those-skilled in the art of well drilling operations will appreciate that there are a number of other means for drilling in the lower riser 28 .
[0109] In another alternative embodiment of the riser disconnect assembly 10 , the seal elements 54 may be positioned within one or more grooves in the inner wall of the seal bore receptacle 58 , as opposed to being carried upon the generally male component, the lower seal mandrel 56 . In such alternative configuration, the lower seal mandrel may then provide a generally smooth outer surface for insertion and sealing with the seal elements 54 .
[0110] Another alternative embodiment may include a riser flex joint (not shown) connected to the male or female component of the riser disconnect assembly 10 . The flex joint may be connected in the riser string between one of the riser connector collar 41 and one of the upper riser 35 and the lower riser 28 , or between the latch housing sleeve 84 and the other of the upper riser 35 and lower riser 28 , depending upon orientation of the riser disconnect assembly 10 .
[0111] As an alternative to use with floating drilling rigs DR, such as semi-submersibles and drill ships, the subsea riser disconnect may be used with other types of drilling rigs, such as submersibles, drilling barges orjack-up type drilling rigs. In the event the riser disconnect point is sufficiently far above the mud line, when the riser disconnect is disconnected, buoyancy cans (not shown) may be attached to the lower riser below the riser disconnect and above the mud line ML. Other alternative embodiments may provide for employing an embodiment of the riser disconnect assembly on production wells, development wells and wells other than exploratory or test wells.
[0000] Riser Valve Assembly
[0112] FIGS. 1, 6 , 6 A, 7 , 8 and 9 illustrate a suitable embodiment for a subsea riser valve assembly 20 according to the present embodiment. The subsea riser valve assembly 20 may be used as a stand alone device in a subsea riser installation or may be used in conjunction with the subsea riser disconnect assembly 10 . In an installation where the subsea riser valve assembly 20 is employed in conjunction with the subsea riser disconnect assembly 10 , the two components may be configured as a common component assembly, as generally illustrated in FIG. 1 , or preferably as two separate component assemblies, as generally illustrated in FIGS. 2, 3 , 7 and 9 . The riser valve assembly 20 may provide a full bore opening when the valve seal element is in the opened position, such that the minimum ID of the through bore of the riser valve assembly 20 is equal to or greater than the ID of one or both of the upper 35 and lower 28 riser. The riser valve assembly 20 may provide a method for isolating the lower riser 28 prior to disconnecting and removing the upper riser 35 from the lower riser 28 , and thereby closing in the well bore WB below the riser valve assembly 20 .
[0113] Those skilled in the are will appreciate that a riser valve 20 is generally a part of a riser system that includes an upper 35 and lower riser 28 , and that the riser valve may thereby include components generally having tubular properties, such as a through bore. Additionally, it may be appreciated that the riser valve 20 may include components which may be similar to components found in valves.
[0114] In an application wherein the riser valve assembly 20 is a distinctly separate component from the riser disconnect assembly 10 , the subsea riser valve assembly 20 may be preferably installed in an upper portion of the lower riser 28 . The lower riser 28 may be comprised of well casing 28 , which extends downward through a seabed and into the subsea wellbore WB where the lower riser is secured by cementing the lower riser 28 within the wellbore WB. The lower riser 28 may include or may be partially comprised of threaded well casing pipe 32 .
[0115] The subsea riser valve assembly 20 may include components for selectively closing off the through bore in the lower riser, thereby hydraulically isolating and enclosing the interior of the lower riser 28 and the wellbore WB below the lower riser 28 . FIG. 7 illustrates a cross-sectional view of a preferred embodiment for a subsea riser valve assembly 20 , with the riser valve assembly 20 in the opened position. FIG. 9 illustrates an enlarged half-section view of the riser valve, with the riser valve assembly 20 in the closed position. A preferred embodiment includes valve housing components 110 , 112 , 114 , and 134 , a valve sealing member 120 , a valve actuating mandrel 118 , and components 128 and 130 which connect the valve actuating mandrel 118 and the valve sealing member 120 . The subsea riser valve assembly 20 may be actuated between the valve opened position and the valve closed position by axial movement of the upper riser 35 relative to the lower riser 28 , by the drilling rig DR or by other means. The riser valve assembly 20 preferably is designed to fail closed such that tension on the riser assembly and the subsea riser valve assembly 20 is required to maintain the subsea riser valve in an opened position. Thus, under normal operating conditions, the subsea riser valve requires tensile force between the upper and lower ends of the riser valve assembly 20 . Releasing the tension or compressing the riser string at the riser valve assembly 20 may preferably result in closure of the riser valve assembly 20 .
[0116] Referring to FIGS. 1, 6 , 6 A, 7 , 8 and 9 , a preferred orientation for the subsea riser valve provides for installing the subsea riser valve assembly 20 with the valve actuating mandrel 118 connected to the upper riser 35 and with a lower valve housing 110 connected to the casing 32 extending below the mud line ML, with the casing 32 comprising a portion of the lower riser 28 . In such orientation, a lower end of a lower valve housing 110 may be secured, such as by threaded connection, to an upper end of a well bore casing 32 . A lower end of a central valve housing 112 may be secured, such as by threaded connection, to an upper end of the lower valve housing 110 . An upper valve housing 114 may be secured to an upper end of the central valve housing 112 , while a lower end of a valve mandrel housing 116 may be secured to an upper end of the upper valve housing 114 . A lower end of the valve actuating mandrel 118 may telescopically penetrate the upper end of the valve mandrel housing 116 and into an upper end of the upper valve housing 114 . An upper end of the valve actuating mandrel 118 may be secured to the lower end of the upper riser 35 .
[0117] The riser valve assembly 20 includes a valve sealing member 120 that may be actuated in response to movement of the valve actuating mandrel 118 . In a preferred embodiment, the valve sealing member 120 is a ball type sealing member, being rotatable about a ball axis 121 . Ball pivots 126 may extend along the ball axis 121 , from the generally spherically shaped valve sealing member 120 to maintain orientation during rotation of the sealing member 120 between a valve opened position and a valve closed position. The ball type sealing member 120 includes a through bore that provides a generally continuous through bore through the riser assembly and the riser valve assembly 20 , when the riser valve is in the valve opened position.
[0118] The valve sealing member 120 is generally positioned between the upper 114 and lower 110 valve housings, and within the central valve housing 112 . The valve sealing member may move rotationally on the ball pivots 126 , which in turn may be mounted within one or more ball mounts for supporting the ball pivots 126 during valve manipulation. The upper portion of the lower valve housing 110 may include a lower valve seat 122 to provide a hydraulic seal between the lower valve housing 110 and the valve sealing member 120 . An upper valve seat 124 may be included to provide a hydraulic seal between the upper valve housing 114 and the valve sealing member 120 . One or more seat engagement springs 141 may be provided to enhance the hydraulic seal between the valve sealing member 120 and the lower seat 122 . Wafer type corrugated springs, or other types of seal enhancement mechanism may be employed to effect seal enhancement.
[0119] The valve actuating member 118 may be connected with the valve sealing member 120 with a valve link pin 130 and a link pin adapter 128 . The valve actuating mandrel 118 may include an annular support ring 134 with a plurality of valve link sockets 137 , preferably two valve link sockets 137 , providing one on each side of the actuating member 118 . The each respective annular support ring 134 may move axially within one a respective mandrel guide groove 132 , within the inner surface of the valve mandrel housing 116 . The annular support rings 134 may be connected to an upper end of a valve link pin 130 . A retainer 136 may be provided on the upper end of each valve link pin 130 to secure the valve link pin 130 within the its respective valve link socket 137 . The valve link pin 130 may extend downward from the annular support ring 134 and penetrate the upper valve housing 114 through an upper valve housing passageway 117 , and extend below the upper valve housing 114 to connect with a link pin adapter 128 . The link pin adapter 128 may be moveably disposed within the central valve housing 112 to axially reciprocate along a link pin adapter passage 119 . The link pin adapter 128 may include a link pin adapter projection 131 to engage the valve seal member 120 in a seal member engagement groove 133 , as illustrated in FIG. 6A .
[0120] To prevent rotation of the valve actuating mandrel 118 relative to the mandrel housing 116 , one or more mandrel guides 146 may be positioned within corresponding grooves provided in both the outer surface of the valve actuating mandrel 118 and the inside surface of the valve mandrel housing 116 , as illustrated in FIGS. 7 and 8 . The mandrel guides may be secured to the mandrel housing 116 with mandrel guide retainers 140 for each respective mandrel guide 146 . The valve actuation mandrel 118 may axially reciprocate along the one or more relatively immovable mandrel guides 146 . A preferred embodiment provides two mandrel guides 146 and two mandrel guide retainers 140 .
[0121] In a preferred embodiment, the riser valve assembly 20 is designed to remain closed until sufficient tension may be applied to the riser valve assembly 20 to actuate the valve sealing member 120 to the opened position. During installation of the riser valve assembly 20 , the lack of sufficient tension may prevent the valve sealing member 120 from remaining in the valve opened position. To retain the riser valve in a valve opened position during riser installation, and at any time subsequent to installation, a riser valve lockout assembly 150 may be included. The riser valve lockout assembly 150 may be provided within the valve mandrel housing 116 to act upon the valve actuating mandrel 118 to prevent axial displacement of the valve actuating mandrel 118 relative to the mandrel housing 116 . The riser valve assembly 20 may be locked or may remain unlocked, when the valve sealing member 120 is in either t valve opened position or the valve closed position.
[0122] Referring to FIGS. 1, 7 , 8 and 9 , one or more valve lockout grooves 151 may be circumferentially provided on the outer surface of the mandrel housing 116 , each lockout groove 151 to accommodate a respective lockout device 153 . The combination of a lockout groove 151 plus a lockout device 153 may constitute a lockout assembly 150 . The one or more valve lockout grooves 151 may each have a long axis which is aligned axially up and down along the valve actuating mandrel 118 , substantially parallel with the central axis 15 . Each groove 151 includes a circular portion at the lower end of the groove 151 and at the upper end of the groove 151 , each circular portion having a diameter that is larger than the width of the groove 151 . The riser valve lockout device 153 is axially moveable along the central axis 15 , on the outer surface of the valve actuating mandrel 118 .
[0123] The riser lockout device 153 may include a lockout pin 148 , a lockout pin adapter 154 and a lockout pin connector bolt 152 connecting the lockout pin 148 and the lockout pin adapter 154 . The riser lockout pin 148 may be substantially round shaped with a pair of opposing flat sides, such that the round shoulders may provide a pair of upset shoulders 147 on the riser valve lockout pin 148 . The round ends of the lockout pin 148 may be axially located along a major linear axis through the lockout pin, the long axis having a length that is longer than the length of a minor axis which extends between the flat sides of the lockout pin 148 . The length of the minor axis may be substantially equal to the diameter of the lockout pin adapter 154 . Each valve lockout device 153 may extend from inside of a lockout groove 151 , outward through a pin port 157 in the valve mandrel housing 116 . The rounded end portion 147 of the riser valve lockout device 153 may remain inside of the groove 151 on the outer surface of the riser valve actuating mandrel 118 . In an unlocked orientation, the lockout pin adapter 154 may slide in lockout groove 151 , along a grooved but non-recessed portion 138 of the valve mandrel housing 116 .
[0124] As illustrated in FIG. 8 , and generally referring to the illustration depicted in FIG. 5A , spring loaded retainer pins 159 may be positioned within the riser valve mandrel housing 116 to engage a retainer groove 167 and/or stop dimple 88 on an outer surface of each lockout pin adapter 154 and may thereby prevent inadvertent rotation of the lockout device 153 and may assist the ROV, diver or other actuator in properly aligning the upset shoulders 147 on the lockout pin 148 with respect to the lockout groove 151 . The retainer groove 167 and/or stop dimple 88 may only be provided circumferentially around a portion of the outer surface of the lockout pin adapter 154 , such as substantially ninety degree portions of the lockout pin adapter 154 .
[0125] The riser valve lockout assembly 150 functions similar to the riser disconnect lockout disclosed above. As lockout pin 148 is rotated, such as by ROV or diver, within one of the upper or lower circular portions of the lockout groove 151 to the valve locked orientation, the upset shoulders 147 are oriented so as not to be axially moveable through the narrow portion of the lockout groove 151 . The resulting inability of the lockout device 153 to move axially along the lockout groove 151 provides the capability to lock the valve 20 in either a valve opened or valve closed position, depending upon whether the lockout device 153 is engaged in the upper or lower circular portion, respectively, of the lockout groove 151 . This assembly may provide the ability to install the riser valve assembly 20 in either a valve opened or a valve closed position.
[0126] In an alternative embodiment, a valve sealing member may be generally positioned within a valve housing which includes component variations from a valve housing discussed above that includes the upper 114 and lower 110 valve housings, and the central valve housing 112 . In an alternative embodiment, a central valve housing may be included as an integral portion of a lower valve housing or an upper valve housing.
[0000] Riser Valve Operation
[0127] The subsea riser valve assembly 20 is preferably an independent, stand-alone device which may be inter-connected with numerous other devices or related riser components, such as the riser disconnect, a riser flex joint, or other subsea equipment. The riser valve assembly 20 is preferably installed in tandem with the riser disconnect assembly 10 , such that the riser disconnect is positioned axially above the riser valve assembly 20 . Both assemblies, 10 , 20 , are generally inter-connnectably and operationally compatible, as both may be actuated through application and/or reduction of axial tensile force. FIG. 1 generally illustrates a preferred embodiment for a riser valve assembly 20 installation.
[0128] A subsea riser valve assembly 20 as illustrated in FIGS. 1, 6 , 7 , 8 and 9 , may be actuated through riser axial reciprocation at the drilling rig DR. The lower valve housing 110 of the riser valve assembly 20 may be connected to the upper end of a lower riser 28 . The lower riser 28 may be comprised of one or more joints of well casing pipe 32 of sufficient length that the lower riser 32 may be positioned within a well bore WB such that an upper portion of the lower riser 28 and the riser valve assembly 20 remain externally accessible above the mud line ML to an ROV, actuator or diver, e.g., to lock or unlock the valve lockout assembly 150 . The upper end of the valve actuating mandrel 118 may be directly or indirectly secured to the upper riser 35 , which extends substantially from the riser valve assembly 20 to the drilling rig DR.
[0129] The riser valve assembly 20 is preferably actuated to mechanically fail closed and to remain in the valve closed position, in the absence of a tensile force applied to the riser valve assembly 20 to maintain the riser valve assembly 20 in the opened position. During installation, the riser valve assembly 20 may be positioned in the valve opened orientation and the lockout device 153 rotated to the locked position, within the lower circular portion of the lockout groove 151 , to allow fluid to fill the upper 35 and lower 28 risers and to facilitate circulation of fluids, slurrys and/or cement through the upper and lower riser.
[0130] The lower riser 28 may be anchored within the well bore WB by placing cement in the annulus between the well bore WB and the outer surface of the well casing 32 . After the cement hardens, tension may be applied by the drilling rig DR, to the upper riser 35 , the riser disconnect assembly 10 , the riser valve assembly 20 and the portion of the lower riser 28 that is not cemented in the well bore WB. When tension is applied to the subsea riser valve assembly 20 , the valve lockout device may be rotated to the valve unlocked position. The riser lockout device 153 preferably remains rotationally oriented in the unlocked position during drilling and well work operations, such that the riser valve assembly 20 may be closed within a relatively short period of time by releasing tension in the upper riser 35 .
[0131] Referring to FIGS. 6, 6A , 7 , 8 and 9 , during riser valve assembly 20 closing operations, as tension is released in the upper riser 35 the weight of the upper riser 35 may provide an axially downward force acting upon an upper portion of the valve actuation mandrel 118 . The downward compressive forces acting upon the valve actuation mandrel 118 may cause the valve actuation mandrel 118 to telescopically move downward within the valve mandrel housing 116 and the upper valve housing 114 . Downward movement of the actuation mandrel 118 may be limited by interference between the top of the valve lockout groove 158 and the valve lockout device 153 .
[0132] The link pin adapter projection 131 on the link pin adapter 128 , which is secured to the lower end of the valve link pin 130 , is moveably engaged with the valve sealing member 120 . As the valve link pin 130 moves downward, the link pin adapter projection 131 may act generally tangentially upon the valve sealing member 120 to effect rotation of the valve sealing member 120 from an opened position to a closed position. The mere weight of components above the riser valve assembly 20 , in the absence of tension in the upper riser 35 , may provide a “fail closed” biasing effect to the sealing member 120 . In an alternative embodiment of a riser valve assembly 20 , a separate and/or additional biasing force may be provided, such as a spring, which may also contribute to closing the riser valve assembly 20 . The biasing effect in either the preferred or an alternative embodiment may serve to close the riser valve sealing member 120 on demand or in the event of loss of tensile force, and to maintain the riser valve assembly 20 in a closed position, such as when the upper riser 35 may be separated and removed from the riser valve assembly 20 .
[0133] To open a preferred embodiment of the riser valve assembly 20 , tensile force may be applied to the valve actuation mandrel 118 . As the valve actuation mandrel 118 is telescopically extended from within the upper valve housing 114 and the valve mandrel housing 116 , the link pin 130 and link pin adapter 128 , which connect the valve actuation mandrel 118 and the valve sealing member 120 , engage the valve sealing member 120 to cause the valve sealing member 120 to rotate from the valve closed position to the valve opened position. A lower valve seat 122 may form a hydraulic seal between the moveable valve sealing member 120 and the lower valve housing 110 . An upper valve seat 124 may form a hydraulic seal between the moveable valve sealing member 120 and the upper valve housing 114 . On O-ring seal 115 may provide a hydraulic seal between the lower end of valve actuation mandrel 118 and the upper valve housing 114 .
[0134] In an alternative embodiment of a riser valve assembly, the valve sealing member may be of a type other than a ball type sealing member, such as a gate type sealing member, a plug or cylinder type sealing member or a flapper type sealing member. These alternative type of sealing members may require variations and modifications on the linkage apparatuses required to effect valve manipulation between the valve opened position and the valve closed position, by axial motion or reciprocation of the valve actuation mandrel 118 .
[0135] In other alternative embodiments, the riser valve assembly 20 may be inverted from the preferred embodiment, such that the valve actuation mandrel 118 is secured to the well casing 32 and a valve body, such as the lower valve housing 110 , is secured to the upper riser 35 . Axial reciprocation of the upper riser 35 would nevertheless effect movement of the valve body relative to the valve actuation mandrel 118 , thereby effecting manipulation of the valve sealing member 120 between the valve opened position and the valve closed position.
[0136] An alternative embodiment for the subsea riser valve assembly 20 may integrate the subsea riser valve and subsea riser disconnect assembly 10 into a substantially single assembly which includes both components 10 , 20 . In such assembly, both the subsea riser disconnect assembly 10 and subsea riser valve assembly 20 may share common housing components.
[0137] As an alternative to positioning a subsea riser valve assembly 20 substantially adjacent and below a subsea riser disconnect assembly 10 , the subsea riser valve may be installed at any point in a riser assembly, including the lower riser 28 and the upper riser 35 , where it may be desirable to provide a valve for closing off an interior portion of a riser through bore.
[0000] Drill Pipe Disconnect
[0138] FIGS. 1 , and 10 through 17 illustrate suitable embodiment for a drill pipe disconnect 30 according to the present invention. The drill pipe disconnect 30 may be used offshore and onshore, along a string of drill pipe 36 used in drilling a subterranean well. In an offshore installation, the drill pipe disconnect may be employed in a drilling installation which also employs a riser disconnect assembly 10 and a subsea riser valve assembly 20 . In general, the drill pipe disconnect 30 provides a means for selectively disconnecting an upper portion of a drill pipe string 36 from a lower portion of the drill pipe string 36 , while leaving the lower portion of the drill pipe string 36 , e.g., within the well bore WB being drilled. The drill pipe disconnect 30 also generally includes an interconnection means which provides for rotating the drill pipe string 36 and for axially transmitting tension and compression in the drill pipe string 36 , through the drill pipe disconnect 30 .
[0139] The drill pipe disconnect 30 may be hydraulically or otherwise actuated between latched and unlatched positions. After disconnection of the drill pipe disconnect 30 , the drill pipe disconnect 30 may be reconnected, e.g., by hydraulic actuation of the latch mechanism.
[0140] In a preferred embodiment, a drill pipe disconnect 30 may be employed in a subsea installation and in conjunction with a subsea riser disconnect assembly 10 and a subsea riser valve assembly 20 . The drill pipe disconnect 30 may be secured within the drill pipe string 36 such that when a drill bit 39 or lower end of the drill pipe string 36 is on or near the bottom of the well bore WB, the drill pipe disconnect 30 may be positioned below the subsea riser valve assembly 20 and the riser disconnect assembly 10 . In such configuration, the drill pipe string 36 may be disconnected at the drill pipe disconnect 30 , and the upper portion of the drill pipe string 36 may be pulled above the subsea riser valve assembly 20 in order that the subsea riser valve assembly 20 may be closed, thereby sealingly isolating the well bore WB and the lower portion of the drill pipe string 36 within the well bore WB.
[0141] A preferred embodiment of the drill pipe disconnect 30 , as illustrated in FIGS. 10 through 17 , provides for male and female interconnection components. In addition, the preferred embodiment provides for a non-rotational engagement mechanism to facilitate rotational strength in the drill pipe disconnect 30 , and a collet mechanism for providing axial engagement and disengagement of the male and female interconnection components. The male interconnection component may generally be referred to as the male disconnect member 205 , while the female interconnection component may generally be referred to as the female disconnect member 215 . Each of the male disconnect member and female disconnect may include a through bore and a central axis 215 which may be a common to the disconnect members when the drill pipe disconnect 30 is connected.
[0142] The male disconnect member 205 may be secured to the lower end of an upper portion of drill pipe 236 . An upper end of an upper latch sleeve housing 210 may be secured to the lower end of the upper portion of drill pipe 236 . The lower end of the upper latch sleeve housing 210 may be secured to the upper end of a male drill pipe disconnect housing 212 . A lower end of the male drill pipe disconnect housing 212 may be secured to the upper end of a latch mandrel 222 . The lower end of the latch mandrel 222 may include a latch mandrel collet engaging ring 237 . (Referring to FIGS. 10 and 17 , the latch mandrel collet engagement ring 237 is preferably an integral portion of the latch mandrel 222 , which is distinguished with a separate component number ( 237 ) and name to assist in clarifying this disclosure.) A latch sleeve 216 may be moveably positioned within the through bore of the male disconnect member 205 . The outer surface of the latch sleeve may be moveably engaged with the inner surfaces of each of the upper latch sleeve housing 210 , the male drill pipe disconnect housing 212 , the latch mandrel 222 and the latch mandrel collet engaging ring 237 . The lower end of the latch sleeve 222 may axially extend below the lower end of the latch mandrel collet engaging ring 237 , such that the lower end of the latch sleeve 216 defines the lower end of the male disconnect member 205 .
[0143] A collet mechanism 230 may be included on the male disconnect member 205 for selectively securing and unsecuring the male disconnect member 205 with the female disconnect member 215 . The collet mechanism 230 includes a collet ring secured to and circumferentially encompassing a portion of the outer surface of the latch mandrel 222 . A plurality of collet fingers 231 may be spaced circumferentially around the latch mandrel 222 , with an upper end of each respective collet finger 231 secured to the collet ring 229 , and a lower end of each respective collet finger 231 secured to a respective collet dog 232 . The plurality of collet dogs 232 may be positioned near the lower end of the latch mandrel 222 , and extend inwardly through square windows 237 positioned in latch mandrel 222 to contact outer surface of latch sleeve 216 such that, in a latched position, the collet dogs 232 may engage the female disconnect member 215 in a collet engagement groove 239 .
[0144] A shear pin retainer ring 218 may be provided radially between the outer surface of the latch sleeve 216 and the inner surface of the male drill pipe disconnect housing 212 , and axially below the upper latch sleeve housing 210 and axially above the latch mandrel 222 . The shear pin retainer ring 218 may house one or more shear pins 220 which engage both the shear pin retainer ring 218 and the latch sleeve 216 for prohibiting the latch sleeve 216 from axial movement until the shear pins 220 are selectively sheared.
[0145] A collet unlatch groove 224 may circumferentially encompass the outer surface of the latch sleeve 216 , such that alignment of the collet unlatch groove 224 with the plurality of collet dogs 232 may provide for radially receiving the collet dogs 232 within the unlatch groove to provide for disconnection of the male disconnect member 205 and the female disconnect member 215 . An axial position of the latch sleeve 216 wherein the collet unlatch groove 224 on the latch sleeve 216 is aligned with the plurality of collet dogs 232 may generally be referred to as a collet unlatch position. When the collet unlatch groove 224 is not aligned with the collet dogs 232 , such that the collet dogs 232 are caused to engage the collet engagement groove 239 of the female disconnect member 215 by an the latch sleeve 216 , such axial position of the latch sleeve 216 may generally be referred to as a collet latch position.
[0146] When the male disconnect member 205 is engaged with the female disconnect member 215 , a male frustoconical surface 244 substantially on the lower end of the latch mandrel collet engaging ring 237 engages a companion female frustoconical surface 234 in the female disconnect member 215 . Engagement of the frustoconical surfaces 234 , 244 provides compressive load bearing shoulders between the male disconnect member 205 and the female disconnect member 215 . Downward axial movement thereafter of the latch sleeve 216 relative to the latch mandrel 222 effects manipulation of the drill pipe disconnect 30 between the collet latch position and the collet unlatch position. During movement of the latch sleeve 216 , the latch sleeve may telescopically and sealingly penetrate a lower portion of the through bore of the female drill pipe disconnect housing 228 axially below the female frustoconical surface 234 . The inner surface 245 of the lower portion of the through bore of the female drill pipe disconnect housing 228 which receives the latch sleeve 216 , in combination with seal 246 may provide a moveable hydraulic seal between the female disconnect housing 228 and the latch sleeve 216 .
[0147] An upper surface of the latch sleeve 216 may include an unlatching seat for sealing engagement with an unlatching ball 208 . Pressurized engagement of the unlatching ball 208 on the unlatching seat may permit shearing of the shear pins 220 and axial downward of movement of the latch sleeve 216 relative to the latch mandrel 222 .
[0148] The outer surface of the latch sleeve 216 may include a circumferential first shear pin retainer ring groove 260 having a first shear pin retainer upper stop surface 264 . The first shear pin retainer ring groove 260 may circumferentially accommodate the shear pin retainer ring 218 . The shear pin retainer ring 218 includes an upper retainer ring stop surface 262 . After shearing the shear pins 220 , axial downward movement of the latch sleeve 216 relative to the latch mandrel 222 , from the collet latch position to the collet unlatch position, is halted by interference between the upper retainer ring stop surface 262 and first shear pin retainer ring groove upper stop surface 264 . Such interference position of the latch sleeve 216 relative to the latch mandrel 222 may properly align the collet unlatch groove 224 with the collet dogs 232 , in the unlatch position, to permit disconnecting the male disconnect member 205 and the female disconnect member 215 .
[0149] The female disconnect member 215 may include a receptacle bore 241 for receiving the male disconnect member 205 . The collet engagement groove 239 may be positioned circumferentially in an inner wall of the receptacle bore 241 . A female non-rotational engagement member 227 , as illustrated in FIGS. 10 and 12 , may be included with the female disconnect member 215 for engaging a companion male non-rotational engagement member 226 , the male non-rotational engagement member 226 being a component secured to the male disconnect member 205 . The lower end of the female disconnect member 215 may be engaged with an upper end of the lower portion of drill pipe 240 .
[0150] Seals 246 , 247 , packing or other sealing devices may be included to provide hydraulic seals between the male disconnect member 205 , male reconnect member 225 and female disconnect member 215 , and between the latch sleeve 216 , 266 and the upper latch sleeve housing 210 . It will be apparent to one skilled in the art that a wide variety of seals and component variations are conceivable and may be applied to apparatus and embodiments of this invention. Consequently, not all seals may be illustrated and/or discussed in this disclosure.
[0000] Drill Pipe Disconnect Assembly Configured for Re-Connection and Re-Unlatching
[0151] In a preferred embodiment for the drill pipe disconnect 30 , when the drill pipe disconnect 30 has been disconnected and the male disconnect member 205 recovered to the drilling rig DR, before reconnecting the male disconnect member 205 with the female disconnect member 215 , the male disconnect member 205 may be replaced with a male reconnect member 225 . FIGS. 13, 14 , 15 and 16 illustrate a preferred embodiment for the redressed male reconnect member 225 . The redressed male reconnect member 225 generally includes similar components as the original male disconnect member 205 with the following modifications.
[0152] The male drill pipe disconnect housing 212 may be replaced with a male drill pipe disconnect housing 261 which provides ports for insertion of one or more shear pins which may be sheared at two positions on each shear pin (discussed below) or with two separate sets of shear pins. The original latch sleeve 216 is replaced with a latch sleeve 266 that provides an additional collet unlatching groove, referred to as a collet re-unlatching groove 274 , circumferentially on the outer surface of the latch sleeve 266 and axially above the original collet unlatch groove 224 . The radially raised circumferential surface between the collet unlatch groove 224 and the collet re-unlatch groove 274 may be referred to as the collet latch surface 263 . The latch sleeve 266 includes an additional groove 275 substantially adjacent the first shear pin retainer groove 260 , the additional groove being referred to as the second shear pin retainer groove 275 . The second shear pin retainer groove 275 may be located on the outer surface of the latch sleeve 266 , axially between a bottom surface of the shear pin retainer ring 268 and a latch mandrel upper stop surface 270 , and may circumferentially encompass the outer surface of the latch sleeve 266 . The second shear pin retainer groove 275 may permit movement of the latch sleeve 266 between a collet latch position and a collet re-unlatch position. The shear pin retainer ring 268 may include a port for providing two separate sets of shear pins or a set of double position shear pins 269 . The double position shear pin 269 may extend from a series of aligned ports, from the male drill pipe disconnect housing 261 through the shear pin retainer ring 268 , and into an annular groove in the outer surface of the latch sleeve 266 .
[0153] As illustrated in FIG. 13 , a latching seat 285 for sealingly seating a latching ball 286 thereon may be included near the lower end of the latching sleeve 266 , with the latching seat 285 secured to an inner surface of the latch sleeve 266 in the latch sleeve through bore, with the latching seat 285 secured by one or more latching seat shear pins 287 . When latching the male disconnect member 205 with the female disconnect member 215 , the latching ball 286 may sealing engage the latching seat 285 in order that the latch sleeve may axially move from a collet unlatch position to a collet latch position after shearing the first set or the portion of the double shear pin 269 extending through shear pin retainer 268 into the annular groove in the outer surface of the latch sleeve 266 . Shearing the one or more latching seat shear pins 287 may provide means for ejection of the latching seat 285 and latching ball 286 from within the latch sleeve 266 after movement of the latch sleeve 266 from the collet unlatch position to the collet latch position.
[0154] The upper end of a latch sleeve extension tube 280 may be secured to the lower end of the latch sleeve 266 to receive and retain the latching seat 285 and latching ball 286 after the latching seat 285 and latching ball 286 are sheared and ejected from within the latch sleeve 266 . A plurality of slots or ports 282 may be provided in the latch sleeve extension mandrel 280 to allow circulation of fluid within the through bore of the drill pipe string 36 . A ball and seat catcher 284 may be provided near the lower end of the latch sleeve extension tube 280 to catch and retain the ejected latching seat 285 and latching ball 286 within the latch sleeve extension tube 280 , as illustrated in FIG. 16 .
[0155] Alternatively, the latch sleeve 266 may be furnished with an integral non-shearing latching seat 266 and with no latch sleeve extension mandrel 280 . When employing this version of a latch sleeve, the latching ball 286 may be flowed to the surface by reverse circulating fluid after shifting the latching sleeve from the unlatch position to the re-latch position.
[0000] Drill Pipe Disconnect and Reconnect Operation
[0156] Referring to FIGS. 1 and 10 through 16 , in the preferred first embodiment for initial installation of the drill pipe disconnect 30 , the male disconnect member 205 and female disconnect member 215 may be connected as illustrated in FIG. 10 , excluding the unlatching ball 208 , and installed in a drill pipe string 36 . The latch sleeve 216 may be axially positioned such that the collet dogs 232 are engaged in the collet engagement groove 239 , thereby securing the male drill pipe disconnect member 205 with the female drill pipe disconnect member 215 . The axial position of the latch sleeve is secured by one or more shear pins 220 . The drill pipe disconnect 30 may be positioned at an axial point in the drill string from which it may be desirable to disconnect, such as below a subsurface riser disconnect assembly 10 , below a subsurface riser valve assembly 20 , or above a trouble spot in a wellbore where it may be desirable to disconnect an upper portion of the drill pipe 236 from a lower portion of the drill pipe 240 .
[0157] To disconnect the male disconnect member 205 from the female disconnect member 215 , the collet mechanism unlatches. Fluid may be circulated through the wellbore WB sufficiently to remove cuttings and other debris. The drill pipe disconnect may be manipulated with the drill pipe set off on bottom, or suspended off bottom in the wellbore by the upper portion of the drill string, thereby allowing the lower disconnected portion of drill pipe to fall subsequent to disconnection. In a preferred embodiment, an unlatching ball 208 may be dropped from the drilling rig DR, through the through bore of the upper portion of drill pipe 236 to sealingly seat on the unlatching seat 209 , on a substantially top surface of the latch sleeve 216 . Pressure may be applied by the drilling rig DR to the through bore of the upper portion of drill pipe 236 to a first release pressure which creates sufficient axial force upon the latch sleeve 216 to shear pins 220 between male drill pipe disconnect housing 212 and latch sleeve 216 to axially move the latch sleeve downward from a collet latch position to a collet unlatch position. In the collet unlatch position, the plurality of collet dogs 232 may move radially inward within the circumferential collet unlatch groove 224 , thereby allowing the male disconnect member 205 to be telescopically removed from the female disconnect member 215 .
[0158] The upper portion of drill pipe 236 may then be recovered to the drilling rig while leaving the lower portion of drill pipe 240 within the well bore WB. To avoid pulling a “wet string,” a drain groove 213 may be provided in the upper portion of the upper latch sleeve housing 210 and one or more drain ports 211 may be provided in the upper portion of the latch sleeve 216 to allow fluid in the upper portion of drill pipe 236 to drain while the upper portion of drill pipe 236 is being removed to the drilling rig DR.
[0159] In a subsea installation, a subsea riser valve may be closed above the female disconnect member 215 in order to confine pres sure and fluid with the wellbore WB. In addition, a subsea riser disconnect assembly 10 may be disconnected such that the upper riser 35 may be recovered to the drilling rig DR or the rig may be moved with the upper riser suspended below the drilling rig DR.
[0160] To reconnect the upper portion of drill pipe 236 with the lower portion of drill pipe 240 , the male disconnect member 205 may be replaced or redressed with male reconnect member 225 as described previously. The replaced male reconnect member 225 may be telescopically inserted into the female disconnect member 215 , as illustrated in FIG. 13 , excluding the latching ball 286 . During such insertion, the collet dogs 232 may be recessed into the collet unlatch groove 224 on an outer surface of the latch sleeve 266 . The latch sleeve 216 in the male reconnect member 225 may be properly, axially positioned in the unlatch configuration by engagement of upper surface 273 on the outer surface of the latch sleeve 216 and a lower surface of the shear pin retainer 268 . During the telescopic insertion of the male reconnect member 225 into the female disconnect member 215 , the male non-rotational engagement member 226 may telescopically engage the female non-rotational engagement member 227 to facilitate unitary rotation of the drill pipe string 236 , 240 .
[0161] To latch the male reconnect member 225 with the female disconnect member 215 , a latching ball 286 or other closure device, may be dropped or otherwise deployed from the drilling rig DR, through the through bore of the upper portion of drill pipe 236 to sealingly seat on the latching seat 285 . Pressure may be applied to the fluid in the through bore of the upper portion of drill pipe 236 , upon the latching ball 286 and latching seat 285 , to a latching pressure. The latching pressure is sufficient to shear a first shear position on the double position shear pin 269 or first set of separate shear pins, between the latch sleeve and shear pin retainer ring 268 . When the first shear position on the double shear position shear pin 269 shears, or the first set of separate shear pins shears, the latch sleeve 266 may axially move downward from the collet unlatch position to the collet latch position. Downward movement of the latch sleeve 266 may be arrested when the first shear pin retainer groove upper stop surface 264 interferes with or engages the upper retainer ring stop surface 262 .
[0162] At such axial position of the latch sleeve, the collet latch surface 263 on the outer surface of the latch sleeve 266 may engage an inward portion of each collet dog 232 , causing each collet dog 232 to remain positioned radially outward and engage the collet unlatch groove 224 . The collet dog stop surface 233 engages the collet dogs 232 to prohibit axial separation of the male reconnect member 225 and the female disconnect member 215 , and the load bearing shoulder at the bottom of collet dogs 232 may engage a load bearing upper side of the collet engagement ring 237 portion of the latch mandrel 222 , thereby securing the male reconnect member 225 with the female disconnect member 215 .
[0163] After latching the collet mechanism 230 , pressure in the upper drill pipe 236 through bore may be further increased from the latching pressure to a ball and seat ejection pressure. The ball and seat ejection pressure may be sufficient to cause the axial downward force upon the latching ball 286 and latching seat 285 to shear the latching seat shear pin 287 . When the latching seat shear pin 287 is sheared, the latching seat 285 and latching ball 286 may move axially downward through the through bore in the lower portion of the latch sleeve 266 , out of the lower end of the latch sleeve 266 , through an upper portion of the latch sleeve extension tube 280 and into a lower portion of the latch sleeve extension tube 280 . The ejected latching ball 286 and latching seat 285 may be caught within the lower portion of the latch sleeve extension tube 280 and retained therein by the ball and seat catcher 284 . One or more ports 282 through the latch sleeve extension tube 280 may permit transmission of fluid through the drill pipe 36 and drill pipe disconnect 30 through bore, to a bit or other tool on the lower end of the drill pipe 36 . As an alternative to shearing the latching seat 285 and latching ball 286 and ejecting the same into latch sleeve extension tube 280 , the ball 286 may be recovered to the surface by other means, such as reverse circulating fluid or with tools, prior to shearing the seat 285 .
[0164] Such configuration thereby represents the normal operating configuration for a preferred embodiment of the drill pipe disconnect 30 , after reconnection of the male reconnect member 225 with the female disconnect member 215 .
[0165] To disconnect the drill pipe disconnect 30 a second time, as illustrated in FIG. 16 , a re-unlatching ball may be dropped through the through bore in the upper portion of drill pipe 236 for sealingly seating on the re-unlatching seat 259 , the re-unlatching seat positioned substantially on an upper surface of the latch sleeve 266 . Pressure may be applied in the through bore of the upper portion of drill pipe 236 to a re-unlatching pressure. The re-unlatching pressure may be sufficient to cause the axial downward force on the re-unlatching seat 259 and re-unlatching ball 258 to shear the second set of separate shear pins or the double shear position shear pin at the second shear position. When the second separate set of shear pins or the double shear position shear pin 269 is sheared at the second shear position, the latch sleeve may move axially downward from a collet latch position to a collet re-unlatch position. In the collet re-unlatch position, the collet dogs 232 may be aligned with the collet re-unlatch groove 274 such that the collet dogs may move radially inward toward the latch sleeve 266 and partially recess in the collet re-unlatch groove 224 . Downward movement of the latch sleeve may be arrested by engagement of the lower retainer ring stop surface 271 with the latch mandrel upper stop surface 270 . The male reconnect member 225 may be telescopically withdrawn from the female disconnect member by axial tensile force at the drilling rig DR, permitting recovery of the upper portion of drill pipe 236 to the drilling rig DR.
[0166] Alternative embodiments for the drill pipe disconnect may provide components and means for manipulating components similar to the latch sleeve 216 or 266 other than balls and seats, and hydraulic pressure, such as by mandrel or bars on wire line, or other wireline conveyed tools. Recovery of balls or other manipulating devices may be employed to avoid leaving a ball in the drill pipe disconnect during well drilling or operations, or when pulling the upper portion of drill pipe 236 after disconnecting, to avoid recovering a “wet string.” An alternative embodiment functions by dropping a retrievable device to seal on one or more of the seats for manipulation of the latch sleeve 216 , 266 , which may thereafter be retrieved on wireline to avoid leaving a latching ball in the drill pipe disconnect 30 . A dart or standing valve may alternatively be dropped in lieu of a ball. An embodiment may include means for recovering the latching ball after manipulation of the latch sleeve 266 , such as with a magnet or by reversing fluid flow to retrieve the ball in a catcher or basket for ball retrieval.
[0167] The drill pipe disconnect 30 may be manipulated between latched and unlatched positions, with the drill pipe string 36 set off on bottom of the well bore WB. Also, the drill pipe disconnect 30 may be manipulated between latched and unlatched positions with the drill pipe suspended off of bottom of the well bore WB, in the well bore WB. The weight of the drill pipe suspended below the disconnect may merely require additional hydraulic pressure to disconnect when the drill pipe is suspended off bottom of the well bore WB.
[0168] In alternative embodiments for the drill pipe disconnect 30 , the collet mechanism may be replaced with a different mechanical or hydraulic latch mechanism, such as a grapple type mechanism. Also, the male disconnect member 205 , 225 and female disconnect member 215 may be inverted such that the male disconnect 205 , 225 may be secured to the lower portion of drill pipe 240 and the female disconnect member 215 may be secured to the upper portion of drill pipe 236 . Alternative embodiments may also be assembled with components which interconnect by means other than generally male and female interconnecting components.
[0169] The drill pipe disconnect 30 is generally applicable to drilling wells both onshore and off-shore. In addition, although the drill pipe disconnect device is generally referred to herein as a drill pipe disconnect, this device may also be employed with drill pipe used in work over operations, with a “work string” that is generally tubular. The drill pipe disconnect may be positioned below a BOP stack to facilitate disconnecting the drill pipe at a location in the drill string which may be relatively close to the rig, such that subsequently, blind rams may be closed, thereby sealing the interior of the well bore below the BOP stack. Such time saving option may be desirable in a well control situation. Such action may also minimize the amount of pipe that must be tripped out of the well to the rig floor.
[0170] The drill pipe disconnect device may be alternatively adapted for use in setting liners or other downhole tubular members wherein it may be desirable to reliably disconnect an upper portion of tubulars from a lower portion of tubulars to leave the lower portion of tubulars within the wellbore.
[0171] The disconnect device as disclosed herein may also be usefully employed as a safety device for drilling in high risk environments where the risk of sticking pipe, collapsing a well bore, key-seating the drill pipe in the well bore or other drilling hazard risks losing a lower portion of the pipe in the hole. In such instances, this device may be positioned within the tubular string such that the disconnect device may remain above the hazard point to provide a quick and reliable disconnect point uphole from the hazardous well bore region.
[0172] Non-rotational engagement may be alternatively provided by components other than male and female engaging components, such as interlocking keys, dogs or otherwise. Where male and female non-rotational components engaged, the male component may be secured to either the upper portion of drill pipe or to the lower portion of drill pipe, with the female non-rotational engagement component secured to the other of the upper and lower portion of drill pipe.
[0173] The drill pipe disconnect may provide the ability to further extend an “extended reach” well bore beyond the point at which all of a drill pipe string may be recovered to the rig by tensional force. In such instance where an open-hole completion may be economically feasible, a lower portion of the drill pipe string may be abandoned within a lower section of the well bore, and the upper portion of the drill string recovered.
[0174] An alternative embodiment of the drill pipe disconnect may provide for manipulating a latch sleeve by a mechanism other than hydraulically with balls and seats. A latch sleeve may be manipulated by a standing valve, dart or rod that may sealingly engage a seat for hydraulic manipulation of the latch sleeve. Such standing valve, dart or rod may be recoverable on wireline or otherwise, such as reverse pumping the component out of the drill pipe string. A weight bar or rod may engage a load bearing shoulder with sufficient mass weight force to manipulate the latch sleeve. Alternative embodiments may eliminate the latch sleeve altogether and provide for a collet or other latch and unlatch mechanism which does not require a latch sleeve component to effect engagement of the upper and lower disconnect members.
[0175] An embodiment of a drill pipe disconnect may be provided which eliminates the latch seat, latch ball and extension tube, thereby providing an open through bore, through the disconnect tool. Such open through bore may provide access for tools, instruments and materials which would not other wise pass through the ports in the extension tube, to pass through the disconnect device to the lower portion of drill pipe.
[0176] Shear pins may be eliminated in favor of other retainer and release components. The drill pipe disconnect may be configured for manipulation between latch and unlatch positions by a combination of axial, rotational and hydraulic forces. Alternative embodiments may also be configured which provide for replacement of each double shear pin with two separate shear pins.
[0177] The embodiments described herein and other embodiments of this invention are disclosed in an absence of hydraulic lines between these embodiments and a drilling rig. It is a significant benefit of this invention that hydraulic lines between the rig and downhole assemblies may be omitted. It may be appreciated by one skilled in the art that hydraulic lines may alternatively be provided for various uses or applications, including the disclosed assemblies or embodiments, or with other components or assemblies employed in conjunction with these embodiments. For example, an application for concurrently employing hydraulic lines in conjunction with employment of one or more of the disclosed assemblies may be elected in a shallow water installation, or to provide additional manipulating force to a riser valve sealing member to shear drill pipe. Hydraulic lines are not intended for preclusion from use, however, the disclosed embodiments may provide a more attractive alternative which permits excluding hydraulic lines.
[0178] It may be appreciated that various changes to the details of the illustrated embodiments, methods and systems disclosed herein may be made without departing from the spirit of the invention. While preferred embodiments of the present invention have been described and illustrated in detail, it is apparent that still further modifications and adaptations of the preferred and alternative embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, which is set forth in the following claims.
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A subsea riser disconnect assembly 10 may be actuated from a drilling rig DR by axial movement of an upper riser 35 relative to a lower riser 28 , for disconnecting the upper riser 35 from the lower riser 28 . A subsea riser valve assembly 20 may be actuated from the drilling rig DR by axial movement of the upper riser 35 relative to the lower riser 28 , for sealing an interior portion of the lower riser 28 and well bore WB below the subsea riser valve assembly 20 . A drill pipe disconnect 30 may be actuated from a drilling rig DR, either onshore or offshore, for disconnecting an upper portion of drill pipe 236 from a lower portion of drill pipe 240 . The drill pipe disconnect 30 may be actuatable by hydraulic and/or mechanical forces applied to the drill pipe disconnect 30 from the drilling rig DR. The drill pipe disconnect 30 may be compatible for use with or without the subsea riser disconnect assembly 10 and/or the subsea riser valve assembly 20 . The component assemblies of this invention may improve the efficiency and lower the cost of recovering hydrocarbons by reducing drilling costs and time requirements. Also, the ability to relatively quickly disconnect a floating rig from a well may enhance the safety of persons and equipment facing hostile weather conditions or other emergency situations.
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BACKGROUND OF THE INVENTION
The invention was made in the course of, or under, a contract with the U.S. Energy Research and Development Administration.
The present invention relates to an improvement over the U.S. Pat. No. 3,662,589, issued May 16, 1972, and No. 3,776,026, issued Dec. 4, 1973 to Laszlo Adler, et al, both entitled "Ultrasonic Flaw Determination by Spectral Analysis", and both having a common assignee with the present application.
The above patents relate to a nondestructive method for determining the size and orientation of a randomly oriented flaw within a material sample comprising the steps of generating an ultrasonic pulse having a wide frequency spectrum by a transducer, receiving with the same transducer (or another transducer) ultrasonic signals reflected from any flaw in said sample in close proximity to said transducer, analyzing the frequency spectrum of the reflected signals to determine a first average frequency interval between points of maxima in the reflected spectrum, recording said first average frequency interval, displacing the transducer a first selected angle in a first plane from its first position with respect to the sample and then repeating the above steps to determine a second average frequency interval between points of maxima in the second reflected spectrum, recording said second average frequency interval, displacing the transducer a second selected angle in a second plane and from said first position with respect to said sample and then repeating the above steps to determine a third average frequency interval between points of maxima in the third reflected spectrum, recording said third average frequency interval, and finally utilizing the recorded average frequency intervals obtained for all positions of said transducer for determining the size and orientation of the flaw in said sample.
The above patented method, however, has been found to give erroneous results when inspecting welds, particularly in thick sections of stainless steel and like materials useful for nuclear reactor systems. Frequently, the size and location, as obtained by the above method, are found to be substantially in error when compared to destructive analysis. Thus, the ultrasonic inspection with the above prior art appeared to be non-applicable to the inspection of thick welds in pipe, plate, and other configurations.
In the prior research, materials under study were isotropic or were assumed to be so. Under such conditions, ultrasound velocities are substantially uniform in any direction of propagation. In recent work, however, it has been found that weld metal is anisotropic, i.e., nonisotropic, and thus there is a slowing down of the ultrasound in certain directions of propagation through a sample of such material. This is deemed to create the erroneous results obtained heretofore.
Thus, there exists a need for determining the true and/or actual velocity of sound propagation through any given nonisotropic sample material at the angle of transducer orientation, and applying such a velocity correction to the above method to thus provide a more accurate determination of the flaw size and its location. The present invention was conceived to meet this need in a manner to be described hereinbelow.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a means and/or a method for determining the actual velocity of sound propagation through any given nonisotropic sample material at the angle of transducer orientation such that a more accurate determination of the flaw size and its location can be made.
The above object has been accomplished in the present invention by providing a means and/or method for accurately determining various ultrasound velocities through a sample as a function of respective orientations such that a desired or selected one of such velocities can then be utilized for correctly determining the size of any flaw and the orientation of such a flaw in a sample material in a manner to be described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing illustrating apparatus for measuring ultrasound velocity propagation in samples;
FIG. 2 is an isometric drawing showing sample orientations in weldment;
FIGS. 3a, 3b, and 3c are an assembly of polar plots showing the variation of ultrasonic velocity as a function of orientation in one of the major planes illustrated in FIG. 2 for an Inconel 82 weldment;
FIGS. 4a, 4b, and 4c are an assembly of polar plots showing the variations of ultrasonic velocity as a function of orientation in another of the major planes illustrated in FIG. 2 for an Inconel 82 weldment;
FIGS. 5a, 5b, and 5c are an assembly of polar plots showing the variation of ultrasonic velocity as a function of orientation in still another of the major planes illustrated in FIG. 2 for an Inconel 82 weldment; and
FIG. 6 is a reconstructed three dimensional plot of the interference reflected spectrum of a weld containing a flaw showing the effect of angle of orientation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the U.S. Pat. Nos. 3,662,589 and 3,776,026, referred to above, the principal equation used in the spectral analysis for flaws is: ##EQU1## d = diameter of reflector (flaw) v = velocity of sound in the material,
Δf = average frequency interval between points of maxima in reflected spectrum, and
θ 1 ,θ 2 = angles at which Δf is obtained.
Since it has been determined that the ultrasound velocities through anisotropic material, such as weld metal, are not uniform in all directions of propagation, as discussed hereinabove, and since such a variation of ultrasound velocity as a function of polar orientation will have a significant effect upon the determination of flaw size and orientation when ultrasonic spectral analysis is used for detecting the flaw, a means and method for accurately determining the ultrasound velocity (the value v in the above equation) in such an anisotropic material as a function or orientation will now be discussed.
Referring now to FIG. 1, a system is illustrated for the determination of ultrasound velocities through a sample as a function of orientation. A sample 10, in this instance a cylinder, is mounted from a goniometer 11, whereby the sample 10 is adapted to be slowly rotated about its axis while maintained within a sound-coupling liquid 12, such as water. Also disposed in the liquid 12 is an ultrasound transmitter 13 and a receiver 14. The transmitter 13 and receiver 14 are adjustable by means of tubes 15, 16, respectively, and by manipulators 17, 18, respectively, so as to be aligned with the sample 10 for through transmission measurements. The receiver 14 or the transmitter 13 is adapted to be moved to other locations to obtain ultrasonic velocities. Electrical lead 19 supplies the transmitter 13 while lead 20 carries signals from the receiver 14 to monitoring and recording equipment, not shown.
The manner of obtaining samples of a weldment for use in equipment such as shown in FIG. 1, is illustrated in FIG. 2 of the drawings. One cylindrical sample 21 is obtained having its axis along the No. 1 axis, i.e., across the width of the weld 22 from the base material 23 to the base material 24. Another cylindrical sample 25 is prepared having its axis along the weld 22 on the No. 2 axis. A third cylindrical sample 26 is obtained having its axis through the weld 22 on the No. 3 axis. A cubical (or rectangular) sample 27 may be prepared having faces perpendicular to the above-mentioned, mutually-perpendicular axes and is useful for calibration purposes.
Typical data for the samples in FIG. 2, when examined with the apparatus of FIG. 1, are depicted in the polar plots of FIGS. 3a-3c, 4a-4c, and 5a-5c. These are from an Inconel 82 weldment. The plots of FIGS. 3a-3c represent data that would be generated using a cylindrical sample such as sample 26 of FIG. 2. The longitudinal data of FIG. 3a is obtained by through-transmission directly across a diameter of the sample; the polar plot of FIG. 3b is the signal derived by the shear wave polarized in the 1-2 plane of FIG. 2; and the third polar plot of FIG. 3c is the shear wave polarized along the No. 3 axis. Similarly, the plots of FIGS. 4a-4c are representative of a cylinder such as sample 25 of FIG. 2, and the plots of FIGS. 5a-5c are representative of a cylinder like sample 21. The points on the plots are actual data (in the shear plots, the data actually came from a cube such as sample 27), while the solid lines are derived from calculations. A sample taken through the thickness of the weld (like sample 26) exhibited little variation of ultrasound velocity as a function of polar angle. However, the other samples exhibited changes in velocity of up to 30%. This clearly demonstrates that the weld material is anisotropic even though the base material itself is essentially isotropic. It should be noted that variations up to 40% have been measured in other anisotropic materials.
The most common analysis of welds uses a 45° polarized shear wave. As may be seen in FIG. 4b and 5b, this angle correlates with the maximum variation in the propagation velocity and thus the greatest error caused by anisotropy.
The effect of a varying velocity of sound is illustrated in FIG. 6 of the drawings. In this pseudo-3D computer generated plot, the spectrum in the foreground is that which would be obtained by spectral analysis from a 0.25 inch diameter circular flaw in type 308 stainless steel if the velocity was that of the base metal. The spectrum in the background is the true distribution when account is taken of the anisotropy; i.e., the distribution that would be measured. This demonstrates the necessity of correcting for velocity variations in the welds.
Accordingly, before welds in a particular base material are to be analyzed for flaws by the spectral analysis method, the values of propagation velocity must be obtained. This is accomplished through the use of representative samples as described above. The velocity plots from the samples are then used to determine the proper value of velocity to be used in the calculation of flaw size and its orientation using the methods described in the above-mentioned prior art patents. The data from a set of samples for a specific material may then be used for subsequent welds of that material.
In addition to welds, other materials have been found to be anisotropic. For example, cast metals generally exhibit anisotropy. Also, some graphite structures are known to be anisotropic. Accordingly, a proper set of velocity propagation plots would be required in order to utilize ultrasonic spectral analysis for flaws in such structured materials.
Initial testing of the improved spectral analysis method utilizing the proper velocity in the calculations for flaw identification yielded data in good agreement with findings by destructive analysis. However, without the application of a proper value of velocity, flaws in thick objects are often indicated which are not found when physical inspections are made.
This invention has been described by way of illustration rather than by limitation and it should be apparent that it is equally applicable in fields other than those described.
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The anisotropic nature of a material is determined by measuring the velocity of an ultrasonic longitudinal wave and a pair of perpendicular ultrasonic shear waves through a sample of the material each at a plurality of different angles in three planes orthogonal to each other. The determined anisotropic nature is used as a correction factor in a spectral analyzing system of flaw determination.
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REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 09/738,080, filed Dec. 15, 2000, and which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to the field of polymerizable materials, specifically including polymerizable materials used in the practice of dentistry, such as sealants. According to the invention, a barrier material is used to mask flavor of the polymerizable material, and/or to impart flavor and aroma, and to prevent oxygen from being exposed to the polymerizable material during polymerization, thereby preventing oxygen from inhibiting polymerization of the material.
BACKGROUND
[0003] Polymerizable materials and related procedures are central ideas in dentistry. Polymerizable adhesives are used in orthodontic treatments to adhere brackets to tooth enamel. Polymerizable resin-based materials such as pit and fissure sealants are bonded to tooth enamel (e.g., a vital tooth, while the tooth is in the patient's mouth) to provide a coating that protects the enamel from decay. Adhesives may be used to secure a tooth filling material at its margins, to enamel and dentin, and reduce or eliminate the penetration of microbial agents across these margins. Adhesive materials may also be used to restore teeth in a number of ways. When a minor restoration or repair is required, e.g., as when a tooth is missing an incisal edge, a polymerizable material can be bonded to the surface of the tooth to replace the lost tooth matter. Adhesive materials are also used where a greater amount of oral rehabilitation is required, as in the cementing of inlays, crowns and bridges, and in aesthetic dentistry, where veneers can be cemented on an enamel facing of a tooth to mask a defect or discoloration.
[0004] Pit and fissure sealants are adhesive dental materials used to prevent tooth decay. Pits and fissures are sites on teeth that my be difficult to clean, with the risk of plaque stagnation and consequent possible onset of decay (caries). Pit and fissure caries may account for up to 90% of the total caries experience in some child populations (Combe, E C, Burke F J T & Douglas W H, 1999, Dental Biomaterials, p. 165 Boston: Kluwer Academic Publishers). Accordingly, the concept of sealing pits and fissures with resin applied to an etched enamel surface, known as fissure sealing, was developed in the 1960s, after the introduction of the acid-etch technique in 1955 (Buonocore M G, 1955, Journal of Dental Research, 34: 849-853). Such treatment is of benefit to patients at risk of occlusal caries, because the sealant will protect the susceptible pits and fissures from plaque accumulation and substrates that may be metabolized into destructive acids.
[0005] Of course, dental procedures benefit from patient comfort and patient cooperation during treatment. This can be difficult considering that many polymerizable materials that must be placed in the mouth, such as sealants, have a disagreeable taste or odor. There is always a need to improve comfort and cooperation of patients during treatment, for example by finding new ways of eliminating disagreeable tastes and odors of such materials. Also, it is necessarily a continuing goal to identify and use dental materials and procedures that are safe and biocompatible.
[0006] Adhesive materials such as sealants commonly include polymerizable dental materials that cure or harden by chemical polymerization reactions. Another problem with some such polymerizable materials is that their reactions can be inhibited by oxygen. Oxygen is known to react with free radicals of free-radically-polymerizable dental materials to give peroxide radicals of low reactivity, and which can unite to an oxygen-containing polymer (Combe E C, in Concise Encyclopedia of Medical and Dental Materials, Editor: Williams D, p. 10 Oxford: Pergamon Press). This inhibits polymerization.
[0007] A result of oxygen inhibition can be the formation of a layer at the surface of the polymerized dental material that is not fully polymerized (referred to as an “oxygen-inhibited layer” because oxygen has inhibited some of the desired polymerization reaction). The oxygen-inhibited layer, having not been completely reacted, contains unreacted or not-fully-reacted components.
[0008] In dentistry, an incompletely-polymerized surface of a dental material can have undesirable consequences. For example, the taste of unpolymerized materials can be objectionable, especially to children. Also, there can be health concerns, including the risk of patient exposure to unreacted chemicals of polymerizable dental materials. Some such chemicals can exhibit in-vitro cytotoxicity and allergenic potential. One chemical often used in dental sealants, bis-DMA (bisphenol A dimethacrylate), is said to react with salivary esterases to form bisphenol A, which is known to be an estrogen-mimicking agent (Rueggeberg, F A, Dlugokinski M & Ergle J W, 1999, Journal of the American Dental Association, 130: 1751-1757).
[0009] Dental practitioners have attempted to minimize exposure of patients to unreacted chemicals from dental sealants. See, e.g., Rueggeberg, F. A., D.D.S., et al., “Minimizing Patients' Exposure to Uncured Components in a Dental Sealant,” JADA, Vol. 130, 1751 (December 1999). Rueggeberg et al, for example, found that treatments of cured dental materials with mechanical action and a mild abrasive yielded a reduction in uncured resin components.
[0010] There exists a need for methods of reducing dental patients' exposure to unreacted components of dental materials. Also, there is room for improving patient comfort and cooperation in dental procedures involving polymerizable dental materials.
SUMMARY
[0011] The invention relates to materials and methods involving polymerizable dental materials. The materials and methods can reduce or eliminate issues relating to the typically disagreeable taste of polymerizable dental materials. This is accomplished by the use of a barrier material preferably having desirable flavor and/or aroma, each of which can improve patient comfort and cooperation, with the aroma also having potential psychological benefits. The materials and methods also improve polymerization of the dental materials by preventing oxygen from inhibiting polymerization at the material surface. Improved polymerization provides the further benefits of reducing the amount of unpolymerized materials remaining in the mouth, which further eliminates disagreeable taste and also improves the strength of the polymerized material surface and simplifies procedures relating to application of the material in the mouth.
[0012] According to the invention, a barrier material is used to cover a polymerizable dental material placed in the mouth. Preferably, the barrier material can comprise an oil such as an essential oil. Preferred polymerizable dental materials include sealants, e.g., pit and fissure sealants. The barrier material covers up the taste of the polymerizable dental material and optionally provides its own desirable flavor and aroma, all of which add to patient comfort and cooperation during the procedure. At the same time, the barrier material prevents oxygen from reaching the polymerizable dental material where the oxygen would inhibit polymerization. This reduces the inhibitory effect that the oxygen would have on polymerization of the dental material and ultimately reduces the amount of unpolymerized material that will remain at the surface of the dental material, which can in turn reduce a patient's exposure to uncured materials.
[0013] An advantage of the invention is that the barrier material can be designed to allow for easy removal of the barrier material by rinsing, particularly if the barrier material contains an oil. Overall, the method is an improvement over past methods used for removing uncured polymerizable components from the mouth, such as by application of air or water from a syringe spray, the use of wet or dry cotton rolls, manual use of pumice with a cotton pellet, or the use of pumice in conjunction with a prophy cup in a dental hand-piece. See generally, Rueggeberg et al.
[0014] The methods can be used to prevent oxygen inhibition of any polymerizable dental material, but can be specifically useful with oral adhesives and pit and fissure sealant.
[0015] An aspect of the invention relates to a method of applying a polymerizable dental sealant to a tooth. The method includes applying a barrier material to the sealant and polymerizing the sealant. Preferred barrier materials include an oil, e.g., an essential oil.
[0016] Another aspect of the invention relates to a method of applying a polymerizable dental material to a tooth. The method includes applying a barrier material comprising an essential oil to the polymerizable dental material, then polymerizing the polymerizable material.
[0017] Yet another aspect of the invention relates to a method of applying a polymerizable dental sealant to a tooth. The method includes preparing a tooth surface using an etchant, applying a polymerizable dental sealant to the etched surface, applying a barrier material to an exposed surface of the sealant, and polymerizing the sealant.
[0018] Yet another aspect of the invention relates to a method of preventing tooth decay. The method includes applying a polymerizable pit and fissure sealant to the tooth, applying a liquid barrier material to the sealant, the barrier material comprising an oil, and polymerizing the sealant.
[0019] Yet a further aspect of the invention relates to a method of curing a polymerizable dental material. The method includes reducing the amount of oxygen contacting the polymerizable dental material by providing a barrier material comprising an essential oil on the polymerizable dental material.
[0020] Yet a further aspect of the invention relates to a composition comprising a polymerizable dental material applied to a tooth, and a barrier material comprising an essential oil disposed on a surface of the polymerizable dental material.
DETAILED DESCRIPTION
[0021] Polymerizable dental materials include materials used to repair, replace, protect, or otherwise complement the surface of a tooth. Such materials include, for example, sealants, adhesives, composites, restoratives, and the like, which are well known in the dentistry arts.
[0022] The chemistry of the polymerizable dental material can be any chemistry, but the invention can be especially useful in combination with polymerizable dental materials whose cure can be inhibited by exposure to oxygen, especially free-radically polymerizable materials. Examples of such dental materials include materials commonly referred to as “resins,” “resin composites,” and “compomers.”
[0023] Generally speaking, resins and resin composites are materials that typically cure or harden by free-radical addition polymerization activated by chemicals or more usually by radiation, commonly visible light. The term “resin” generally refers to the polymerizable component of a composition (alone or with other materials) while “resin composite” refers to the resin in combination with a filler material. Thus, resins and resin composites may contain inert inorganic fillers (silica, barium glass, zirconia/silica glass are some examples) to modify properties. These types of materials adhere micromechanically to tooth enamel, especially after acid etching, and bond to dentin via application of an acid conditioner followed by a primer and/or adhesive, after which a combination of micromechanical and interdiffusion bonding occurs. Many different types of resins and resin composites are commercially available, and typically vary in the type, concentration, and properties of the filler. Representative examples of commercially available resin composites include, but are not limited to, Revolution (Kerr Corporation, Orange, Calif.); Silux (3M, St Paul, Minn.); HRV Herculite (Kerr Corporation, Orange Calif.); Restorative Z100 (3M, St Paul, Minn.); and Alert (Pentron Inc, Wallingford, Conn.).
[0024] Glass ionomers may optionally be included in a polymerizable composition, in combination with a polymerizable resin. Glass ionomers, sometimes referred to as polyalkenoate cements, set and/or harden via an acid-base reaction wherein an acidic polymer or copolymer aqueous solution reacts with an ion-leachable glass. Glass ionomers are well known in the dental arts, and include, for example, poly(acrylic acid) and related copolymers which can react with a fluoroaluminosilicate glass (FAS) to give a product including a core containing unreacted FAS surrounded by the acid-base reaction products. Such materials are commercially available, for example from Ketac-Cem Radiopaque (Espe America, Inc, Norristown Pa.).
[0025] Polymerizable compositions that include a glass-ionomer are sometimes referred to as “resin-modified glass-ionomers” and can be used in situations where properties intermediate between those of resins and glass-ionomers are desired. Resin-modified glass-ionomers set and harden via a combination of an acid-base reaction and a free-radical polymerization reaction, which may be activated chemically and by radiation, e.g., visible light. Resin-modified glass-ionomers are well-known and commercially available. One representative example of a commercially available resin-modified glass-ionomer composition is GC Fuji II LC Improved (GC America Inc, Alsip, Ill.).
[0026] Compomers are another class of polymerizable dental materials that can be advantageously used where properties intermediate between those of resins or resin composites and glass-ionomers are desired. Compomers are polyacid-modified resin composites that polymerize via a free-radical polymerization mechanism. Compomers are well-known and commercially available. One example of a commercially available compomer includes is Compoglass® (Ivoclar North America Inc, Amherst, N.Y.).
[0027] The specific chemistry of the polymerizable dental material can preferably be any chemistry whose polymerization would be inhibited by oxygen. Many sealants include a mixture of monomers, usually including acrylates, e.g., di(meth)acrylates (as used herein, the term “(meth)acrylate” refers to both acrylates and methacrylates). Specific examples of dimethacrylates used in sealant formulations include Bis-GMA (Bisphenol A glycidyl methacrylate, often referred to as “Bowen's resin”), Bis-DMA, TEGDMA (triethylene glycol dimethacrylate), and UDMA (urethane dimethacrylate). Inert inorganic filler can be included to modify the appearance and/or mechanical properties of the sealant. Some products claim to contain fluoride-containing components.
[0028] Pit and fissure sealants may be classified according to their setting mechanism. According to standard specifications (ANSI/ADA Specification No. 39-1992; ISO 6874:1988; British Standard Specification BS 7180:1989) there are two types of materials. Type 1 materials include a chemical setting mechanism, meaning that they contain a chemical activator. Type 2 materials are described as “external-energy-cured,” meaning they cure upon application of an external source of energy such as visible light of an appropriate wavelength and intensity. Type 2 materials are often referred to as visible-light cure (VLC) materials. Both types of sealant set (i.e., polymerize) essentially by free-radical addition polymerization.
[0029] Examples of commercially available sealants include Concise™ White Sealant, available as Type 1 or a Type 2 material (3M Company, St. Paul, Minn.), FluoroShield™ (Type 2, Dentsply/Caulk, Milford, Del.), Helioseal® (Type 2, Ivoclar/Vivadent, Buffalo, N.Y.), Prisma-Shield® (Type 2, Dentsply/Caulk, Milford, Del.), Sealite™ (Type 2, Kerr USA, Romulus, Mich.) and Seal-Rite™ (Type 2, Pulpdent, Watertown, Mass.).
[0030] According to the invention, a barrier material is applied to the polymerizable dental material prior to polymerization, e.g., after the material has been placed in the mouth. The barrier material can cover or mask the taste of the polymerizable dental material. The barrier material can also impart its own desirable flavor and aroma into the process, allowing for improved patient comfort and cooperation; in this regard the barrier material can impart the flavor and odor of an essential oil and can optionally and preferably act as a vehicle for incorporating additional flavor or aroma such as by an added flavoring. Moreover, the barrier material can act as a barrier to prevent oxygen from contacting the polymerizable dental material, providing improved polymerization of the polymerizable material. As noted above, polymerization of polymerizable materials can be inhibited by oxygen. According to the invention, the barrier material is placed on a surface of the material to prevent oxygen from contacting the material where the oxygen would inhibit polymerization.
[0031] Because the barrier material is being used in dentistry environments, a number of features are important. The barrier material should be biocompatible, consisting of materials acceptable for oral use. When the barrier material is used with a radiation-curable dental material, the barrier material should be able to transmit such radiation. This is true, for example, when using the invention with Type 2 sealant materials where light must reach the sealant to activate polymerization. A barrier material should preferably form a continuous film over the polymerizable dental material. The barrier material should be chemically compatible with the polymerizable dental material and not cause chemical degradation. This of course will depend on the composition of the polymerizable dental material. The barrier material should be of a character that will at least cover up or mask a flavor of the polymerizable dental material, or ideally have a flavor and aroma that is tasteful. And, the barrier material should be convenient to apply to a tooth in a patient's mount.
[0032] The barrier material can preferably be a liquid comprising or based on an oil. Preferred oils include essential oils, for example soybean oil, safflower oil, sesame oil, olive oil, sunflower oil, canola oil, walnut oil, peanut oil, orange oil, eucalyptus oil, cod liver oil, castor oil, or a combination of two or more of these oils. Essential oils are suitable for use as a barrier material because many exhibit one or more properties including suitable flavor and/or liquidity for ease of application, chemical inertness, film-forming capability, and transparency to electromagnetic radiation. Also, essential oils are known to be compatible with resin based filling materials (see generally Applicants' U.S. patent application Ser. Nos. 09/427,876, 09/427,943, the disclosures of which are incorporated herein by reference).
[0033] An essential oil may be used by itself as the barrier material, a mixture of essential oils may be used, or an essential oil may be used with other ingredients (e.g., flavoring agents) included in amounts that do not unduly hinder the ability of the barrier material to cover a flavor or odor of the polymerizable dental material or to reduce the amount of oxygen reaching the polymerizable dental material.
[0034] Those with an understanding of polymerizable dental materials will understand that materials other than essential oils, for example other types of oils, may also be used in a barrier material, singly or in combination with essential oils or other materials. For example, liquids such as glycerol and propylene glycol can be used in combination with an essential oil. A flavor included in a barrier material may be any of a variety of desirable flavors, for example cherry, strawberry, blueberry, watermelon, lemon, lime, raspberry, apple, grape, cranberry, coconut, banana, tangerine, pineapple, bubble gum, almond, hazelnut, chocolate, etc.
[0035] The barrier material is applied to a surface of a polymerizable dental material, preferably by first placing the polymerizable dental material in the mouth, particularly at a tooth, and then applying the barrier material. Next, the polymerizable dental material can be polymerized. The polymerizable dental material is typically applied to a tooth after some preparation of the tooth, as is appropriate for the specific dental procedure and material being used. This can include cleaning and often some application of a primer or other treatment to promote adhesion. The polymerizable dental material is then applied to the prepared surface, as needed. Following placement of the polymerizable dental material, the barrier material is applied to the exposed surface of the dental material, and the dental material is then polymerized by appropriate means. The barrier material covers or masks the flavor of the dental material, and also reduces the amount of oxygen contacting the polymerizable dental material, preferably to entirely prevent environmental oxygen from contacting the dental material. The barrier material is applied to the polymerizable dental material in any fashion that will accomplish this, preferably in a fashion that will result in a continuous coating (e.g., a film) of barrier material over the surface of the polymerizable dental material. Examples of methods of applying the barrier material to a polymerizable composition include dropping, spreading, spraying, or brushing the barrier material onto the polymerizable dental material
[0036] Specifically with respect to sealants, application of a sealant involves preparation of the tooth by first cleaning and drying a tooth surface. An etchant, usually based on phosphoric acid, is applied to the surface, e.g., a fissure, for typically 15 seconds, and the surface is washed to remove etching debris and thoroughly dried. The sealant is applied to the etched surface. According to the invention, a barrier material is applied to the exposed surface of the sealant, preferably in an amount and manner to form a continuous film over the sealant. The sealant is then polymerized. Optionally the barrier material can be washed away by rinsing with water.
EXAMPLE
[0037] A Type 2 fissure sealant (Helisoseal®, Ivoclar/Vivadent, Buffalo, N.Y.) was used in this study, tested by the method of Section 6.6 of ANSI/ADA Specification No. 39-1992). A drop of the sealant was placed on a microscope slide and covered with a glass cover slip to give an approximately round mass of sealant, with an edge of the material exposed to air and the two flat surfaces covered by glass. Polymerization was activated using a dental VLC unit (Caulk “The Max” Model 106, Caulk/Dentsply, Milford Del.) with output 470-480 nm wavelength and minimum intensity of 450 mW/square centimeter. The light was applied for 10 seconds. On examining the disc of material, visually, using a microscope, an oxygen inhibited zone was detected.
[0038] The above experiment was repeated, except that olive oil was placed on the drop of material before the application of the cover slip. When the cover slip was applied, the oil flowed and formed a barrier to air at the circumference of the material. Following polymerization as above, no oxygen inhibited zone could be detected microscopically.
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Described are methods of improving cure of polymerizable dental materials by preventing oxygen inhibition; preferred embodiments relate to methods wherein the dental compositions comprises a polymerizable sealant and the barrier material comprises an essential oil.
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BACKGROUND OF THE INVENTION
The present invention is concerned with certain 6-biphenylylalkenoic acids and esters having pharmaceutical utility, especially for inhibiting blood platelet aggregation.
Biphenylylalkenoic acids where the alkenoic acid moiety has four or less carbon atoms are known (see e.g. European Patent Application No. 20230, German No. 2,205,732, RD No. 189,021, Belgian No. 840,354, Belgian No. 825,643). These compounds are generally taught to have anti-inflammatory activity. 2-(4-biphenylyl)-4-hexenoic acid of the formula ##STR2## is disclosed in Morand et al., J. Pharm. Sci. 53, 504-507 (1964); and is taught to inhibit cholesterol synthesis.
A class of biphenylylakenoic acids have been discovered. These hexenoic acids are useful as anti-inflammatory agents, as blood platelet aggregation inhibitors and to prevent bronchoconstriction.
SUMMARY OF THE INVENTION
Biphenylylhexenoic acids and esters of the formula: ##STR3## and their use as pharmaceuticals.
DETAILED DESCRIPTION OF THE INVENTION
The invention is embodied in compounds having the formula ##STR4## wherein R is H or C 1 -C 4 alkyl, C 1 -C 4 alkoxy or hydroxy,
R 1 is H or C 1 -C 4 alkyl, C 1 -C 4 alkoxy or hydroxy,
R 2 is
(i) hydrogen,
(ii) C 1 -C 6 alkyl, ##STR5## wherein R 3 is C 1 -C 6 alkyl or aryl (as defined in U.S. Pat. No. 4,342,693) or
(iv) ##STR6## wherein n is 0, 1, 2, or 3;
m is 0, 1, 2, or 3;
R 4 and R 5 are individually H or alkyl of 1 to 3 carbon atoms and;
R 6 is selected from the group consisting of
(A) a monocyclic or bicyclic heterocyclic radical containing from 3 to 12 nuclear carbon atoms and 1 or 2 nuclear hetero atoms selected from N and S with at least one being N, and with each ring in the said heterocyclic radical containing 5 to 6 members and
(B) the radical X 1 --R 7
wherein X 1 is --O--, --S-- or --NH-- and R 7 contains up to 21 carbon atoms and is (1) a hydrocarbon radical or (2) an acyl radical of an organic acyclic or monocyclic carboxylic acid containing not more than 1 hetero atom in the ring,
Y is H, halo, hydroxy, C 1 -C 4 alkoxy or azido,
X is H, halo, hydroxy, C 1 -C 4 alkoxy or azido, and
Z is 3, 5 or 7,
and pharmaceutically acceptable salts thereof. A preferred definition of Z is 3.
The formula I compounds exist as geometrical isomers by virtue of the alkene double bond. Thus, formula I includes mixtures of these isomers as well as the individual isomers. The isomers are conventionally designated as e.g. cis and trans.
The pharmaceutically acceptable salts are salts of the formula I acids with suitable bases, exemplified by the ammonium salts, the alkali metal salts e.g., sodium, potassium, the alkaline earth metal salts e.g. Ca, Mg and salts with amines such as lysine, morpholine, piperazine and the like.
Identification and introduction of the formula II ester group is taught in U.S. Pat. No. 4,342,693 whose disclosure, to the extent necessary, is incorporated herein by reference. A preferred method for preparing a formula II group ester is by treating the lithium or silver salt of the formula I acid with the bromo derivative: ##STR7## in a suitable reaction medium. Methyl t-butyl and phenyl are preferred R 3 definitions.
Identification and introduction of the formula III ester group is taught in U.S. Pat. No. 3,983,138 and U.S. Pat. No. 3,988,341 and, to the extent necessary, these disclosures are incorporated herein by reference. Preferred formula III ester groups are those where R 6 is (i) X 1 --R 7 where X 1 is O, S or NH and R 7 is hydrocarbyl or non-heterocyclic acyl or (ii) glutarimido, nicotinamido, phthalimido, naphthalimido, acetamido, maleimido or succinimido.
More preferred formula III ester groups are those having the formula: --CH 2 --R 8 , --CH(CH 3 )--R 8 or --(CH 2 ) 2 --R 8 where R 8 is ##STR8##
The C 1 -C 4 alkyl group substituents are exemplified by CH 3 , t-butyl, isopropyl and the like. The C 1 -C 6 alkyl group substituents are exemplified by CH 3 , n-hexyl, sec.-butyl and the like. The halo substituent is Cl, Br, or F.
The C 1 -C 4 alkoxy groups are exemplified by methoxy, ethoxy, isopropoxy, t-butoxy and the like.
Preferred compounds are those of formula I where R 2 is H. A more preferred group of compounds is formula I where R 2 is H and R/R 1 are independently selected from H and CH 3 .
Another more preferred group of compounds is formula I where R, R 1 and R 2 are all H and Z is 3. A most preferred compound is formula I where X, Y, R, R 1 and R 2 are all H and Z is 3.
The compounds of Formula I are useful as pharmaceuticals.
Representative compounds inhibit bronchoconstriction induced by leukotrienes (LTD 4 ) or arachidonic acid--and in the latter instance, show no inhibition of the concomitant fall in blood pressure due to inhibition of synthesis prostaglandin I 2 and F 2 . Thus, the present compounds are considered to have thromboxane synthetase (TS) enzyme and cyclooxygenase (CO) enzyme inhibiting properties. A discussion of the metabolic cycle involving these enzymes is found in U.S. Pat. No. 4,233,778.
By virtue of the pharmacological activities of the formula I compounds, they are useful e.g. as anti-inflammatory agents, as cardiovascular agents, e.g., to treat and prevent blood platelet aggregation and to treat asthma.
For use as blood platelet aggregation inhibitors the present compounds are administered either orally or parenterally in daily dosages ranging fr m 5 mg. to 500 mg.
For use as anti-inflammatory agents, the present compounds are administered orally or parenterally in daily dosages ranging from 10 mg. to 1,500 mg.
For use in treating asthma, the present compounds are administered orally, parenterally or by insufflation. The oral or parenteral daily dosage will range from 50 mg. to 1,500 mg. Administration by insufflation e.g., spray, will be in metered doses ranging from 50 to about 1000 mcg, administered as needed.
Appropriate dosage forms will be used. Suitable oral dosage forms are tablets, elixirs, solutions, emulsions, capsules and the like. Suitable parenteral dosage forms are solutions, emulsions and the like. Suitable insufflation dosage forms are sprays, aerosols, and the like. The dosage forms are prepared using conventional procedures and, where required, pharmacologically acceptable diluents, carriers and the like.
The compounds of formula I can be prepared by any convenient method.
One such process involves the reaction of a biphenylyl aldehyde with a triphenyl phosphine alkanoic acid adduct in the presence of a coupling agent such as BuLi/hexamethyl disilazane or K 2 CO 3 /18-Crown-6, as illustrated by the following equation: ##STR9##
This reaction is generally carried out in a suitable solvent such as tetrahydrofuran or a like aprotic solvent at below 0° C. and preferably about -50° to -80° C.
Another process for preparing compounds of Formula I is by dehydrating an appropriate hydroxy derivative, as illustrated by the following equation: ##STR10##
Any conventional dehydrating agent can be used for example p-toluenesulfonic acid (p-TsOH) and the like. Generally, the reaction is carried out in a liquid reaction medium such as an inert aromatic hydrocarbon.
The formula C precursor is prepared from the correspondlng ketone derivative as illustrated by the following equations. ##STR11##
For preparing formula E, conventional reducing agents/reaction conditions are used. Conventional Grignard reactants/conditions are used to prepare formula F.
The preparation of precursor D involves conventional Friedel Crafts coupling of a biphenyl with an appropriate acyl halide as illustrated by the following equation: ##STR12##
Esters of Formula I are prepared from the free acid (where R 2 is H) using conventional esterification procedures e.g. diazomethane in a suitable solvent, or an alcohol with an acid catalyst.
A third process for preparing compounds of Formula I, in particular those with the cis configuration of the double bond in the hexenoic acid chain, involves the selective reduction of an appropriate biphenylyl hexynoic acid, as illustrated by the following equation: ##STR13## A typical reduction was effected using Lindlar catalyst at a pressure of 10-60 psi H 2 in an alcohol solvent such as methanol or ethanol.
The appropriate alkynoic acid G is prepared by a series of steps involving alkylation of appropriately substituted biphenylyl acetylene J, catalyzed by a strong base such as a BuLi in an ether solvent such as THF, with a tetrahydropyranyl protected bromo propanol K, as illustrated by the following equation: ##STR14## The protected alcohol L is converted directly or sequentially to the nitrile H using conventional procedures, and the nitrile is then hydrolyzed to obtain G, as illustrated by the following equation: ##STR15##
The G compound may also be prepared by reacting J with an appropriate terminally substituted carboxylic acid such as 4-bromobutanoic acid or equivalent.
A fourth process for the preparation of biphenyl alkynoic acids involves the following new procedure.
A Vilsmeir reaction is performed on an appropriate phenyl ketone using the known phosphorous oxychloride/dimethyl formamide method. The chloro-formyl derivative N so formed is oxidized using the common oxidizer sodium chlorate in aqueous buffer pH3-6 and the so formed chloro-acid P is decarboxylated e.g., in the presence of a Cu powder and a basic solvent like quinoline at a temperature between 100° and 160° C. yielding the intermediate alkynoic acid G. This intermediate G can then be converted as described above to the Formula I compound. ##STR16##
The following examples illustrate the preparation of compounds of Formula I. All temperatures are in °C.
A. WITTIG APPROACHES TO 6-BIPHENYLYLHEX-5-ENOIC ACIDS
EXAMPLE 1
6-(4'-Biphenylyl)hex-5-enoic Acids
Six grams biphenylcarboxaldehyde, 10.23 g 5-carboxypentyl triphenylphosphorane bromide, 5.8 g anhydrous K 2 CO 3 and 130 mg 18-Crown-6 were suspended in 240 mL dry tetrahydrofuran. The mixture was heated and stirred at reflux for 7 days, diluted with 200 mL H 2 O, extracted with EtOAc (5×200 mL). The EtOAc extract was dried (Na 2 SO 4 ) and concentrated, the residue was taken up in methanol (200 mL) treated with 1 equivalent BF 3 .OEt 2 and the methyl esters of the cis and trans acids separated by chromatography (yield 59%). The esters were hydrolyzed upon dissolving in MeOH (100 mL) and treatment with 1N NaOH (50 mL). Acidification resulted in precipitation of the corresponding acids cis-6-(4'-biphenyl)hex-5-enoic acid, m.p. 107°-109° and trans-6-(4'-biphenylyl)hex-5-enoic acid, m.p. 116°-118°.
EXAMPLE 2
6-(4"-Fluoro-4'-biphenylyl)hex-5-enoic Acids
Six grams 4'-fluoro-4-biphenylyl carboxaldehyde, 10.2 g 5-carboxypentyl triphenyl phosphorane bromide, and 5.8 g anhydrous K 2 CO 3 , 130 mg 18-crown-6 were suspended in anhydrous THF and refluxed for 7 days. The solution was diluted with 200 mL H 2 O, and extracted with EtOAc (5×100 mL). The dried organic phases were concentrated and methylated as in Example 1 with BF 3 .OEt 2 in methanol. Separation of the cis and trans isomers was effected by HPLC, yield 45%. Hydrolysis was achieved using NaOH (1N) in methanol followed by acidification to precipitate the products, cis-6-(4'-fluoro-4-biphenylyl)hex-5-enoic acid m.p. 115°-116° and trans-6-(4'-fluoro-4-biphenylyl)hex-5-enoic acid m.p. 128°-130°.
B. FRIEDEL-CRAFTS ACYLATION TO 6-KETO-6-(4'-BIPHENYLYLHEXANOIC ACIDS
Example 3
6-(4'-Biphenylyl)-6-keto-hexanoic acid 2
Seventeen grams biphenyl was added at 0° to a solution containing tetrachloroethane (250 mL), AlCl 3 (28.4 g) and methyl-5-chloroformyl pentanoate (20 g). After 10 minutes, the reaction was poured onto ice and filtered to yield 30.3 g, (94%) methyl-6-(4'-biphenylyl)-6-keto hexanoate. The acid 2 was recovered by hydrolysis of the ester with NaOH (1N) followed by acidification, m.p. 161°-162° (lit 159°-160°).
EXAMPLE 4
6-(4"-Fluoro-4'-biphenylyl)-6-keto hexenoic acid 3
Two grams 4'-fluorobiphenylyl was added to a solution containing 2.0 g methyl-5-(chloroformyl)pentanoate, 3.0 g AlCl 3 and 200 mL methylene chloride. After 15 minutes stirring at 0°, the solution was kept at 15°-20° for 16 hours. The reaction was poured into ice and the product 3 was filtered and recrystallized from MeOH (2.0 g 55%). Hydrolysis was achieved by stirring the ester with 20 mL 1N NaOH in 50 mL methanol. Acidification precipitated the product 3, m.p. 182°-184°.
EXAMPLE 5
6-[4"-Methoxy-(4'-biphenyl)]-6-keto Hexanoic Acid 4
Two grams 4'-methoxybiphenyl was added to a solution containing 200 mL dichloroethane, 2.0 g methyl-5-(chloroformyl)pentanoate and 3.0 g AlCl 3 at -10° C. The reaction was stirred at -10° for 15 minutes poured onto ice and the product precipitated. Hydrolysis in 1N NaOH, followed by acidification, precipitated the acid 4 in 67% yield m.p. 184°-186°. Other 6-ketonexanoic acids prepared using the process illustrated in Example 5 were 6-[4"-methyl-(4'-biphenyl)] 6-keto hexanoic acid, m.p. 143°-145°, 6-[4"-carboxyl-(4'-biphenyl)]-6-keto hexanoic acid, m.p. 270° (decomp.) and 6-[4"-hydroxy(4'-biphenyl)]-6-keto hexanoic acid, m.p. 116°-119°.
C. GENERAL PROCEDURE FOR GRIGNARD CONVERSION OF 6-KETO BIPHENYLYL HEXANOIC ACIDS
EXAMPLE 6
The esters, methyl-6-(4"-fluoro-4'-biphenylyl)-6-keto hexanoate, methyl-6-(4'-biphenylyl)-6-keto hexanoate, methyl-6-(4"-methoxy 4'-biphenylyl)-6-keto hexanoate and methyl-6-(4"-methyl-4'-biphenylyl)-6-keto hexanoate, were respectively dissolved in toluene at -40°. A molar equivalent of the respective Grignard reagent was added (methyl or ethyl magnesium bromide) in THF (3M) dropwise. THe reaction mixtures were stirred at RT overnight. The organic phases were then diluted with EtOAc (2×V) and extracted with H 2 O. The organic phase was dried (Na 2 SO 4 ) and concentrated. Products were isolated by chromatography on silica gel (EtOAc/hexane 3:7). Hydrolysis to the free acid was achieved by treating the esters from the above Grignard reactions with methanol (5% w/v) and adding 5 equivalents of 0.1N NaOH. Acidification resulted in precipitation. The following products were thus obtained and characterized: 6-(4'-biphenylyl)-6-hydroxy hexanoic acid, m.p. 77°-80°; 6-(4"-fluoro-4'-biphenylyl)-6-methyl-6-hydroxy hexanoic acid, m.p. 48°-52°; 6-(4"-methyl-4'-biphenylyl)-6 -methyl-6-hydrous hexanoic acid, m.p. 86°-88°.
The following products may be prepared using the processes described in Example 6: 6-(4"-methoxy-4'-biphenylyl)-6-methyl-6-hydroxy hexanoic acid and 6-(4"-fluoro-4'-biphenylyl)-6-ethyl-6-hydroxy hexanoic acid.
GENERAL PROCEDURE FOR REDUCTION OF SUBSTITUTED 6-KETO-6-(4'-BIPHENYL)HEXANOIC ACID ESTERS
Example 7
Forty grams 6-keto-6-(4'-biphenylyl)hexanoate methyl ester was dissolved in 370 mL MeOH. NaBH 4 5.1 g was added portionwise at room temperature. The reaction was complete after 10 minutes. H 2 O was added (100 mL) and the solution concentrated to 200. The solution was extracted by CH 2 Cl 2 to (3×200 mL). Purification was achieved by chromatography on silica gel.
Hydrolysis to the acid was achieved by treatment with 1N NaOH (30 mL) in MeOH (50 mL) and precipitation of the product with HCl. The following hexanoic acid products were thus obtained: 6-hydroxy-6-(4'-biphenylyl)hexanoic acid m.p. 260°; 6-hydroxy-6-(4"-fluorobiphenylyl)hexanoic acid, m.p. 175°-178°. Other products which may be obtained using the processes described in claim 7 are
6-hydroxy-6-(4'-hydroxybiphenylyl)hexanoic acid;
6-hydroxy-6-(4'-carboxybiphenylyl)hexanoic acid;
6-hydroxy-6-(4'-carbomethoxybiphenylyl)hexanoic acid.
E. GENERAL PROCEDURE FOR DEHYDRATION OF 6-HYDROXY-6-(4'-BIPHENYLYL)HEXANOIC ACIDS
EXAMPLE 8
The esters of 4"-substituted, 2'-substituted or 2',4"-disubstituted 6-hydroxy-6-(4'-biphenylyl)hexanoic acid (5 g) were dissolved in toluene (150 mL). Then 0.6 g p-toluene sulphonic acid was added. The solution was heated to reflux for 10 minutes. After evaporation to near dryness, water was added (25 mL) and the solution extracted with ethyl acetate. The product was purified by chromatography on silica gel and hydrolysis of the ester was achieved with 1N NaOH (50 mL) in MeOH 50 mL. Acidification (1N HCl) precipitated the product acid. The following hexenoic acids were thus prepared: trans-6-(4'-biphenylyl)hex-5-enoic acid, m.p. 129°-130°; trans-6-(4"-fluoro-4'-biphenylyl)hex-5-enoic acid, m.p. 128°-130°; trans-6-(4"-methoxy-4'-biphenylyl)hex-5-enoic acid, m.p. 111°-120°; trans-6-(4"-carboxy-4'-biphenylyl)hex-5-enoic acid, m.p. 196°-201°. The process of Example 8 may also be used to prepare products such as 6-[4"-methyl(4'-biphenylyl)]-hex-5-enoic acid and 6-[4"-methyl-2'-fluoro-4'-biphenylyl)]hex-5-enoic acid.
F. GENERAL PROCEDURE FOR DEHYDRATION OF 6-ALKYL-6-HYDROXY-6-(4'-BIPHENYLYL)HEXANOIC ACIDS
EXAMPLE 9
The esters of 6-alkyl-6-hydroxy-(4'-biphenylyl)hexanoic acid were dissolved (10 g) in toluene 200 mL and 1.1 g p-toluene sulphonic acid was added. The solution was heated to reflux for 10 minutes. After evaporation to dryness, addition of water (25 mL) and extraction of the aqueous with ethyl acetate, (5×50 mL) separation of the cis and trans isomers was achieved by high performance liquid chromatography on silica gel. Hydrolysis was achieved with 1N NaOH in MeOH. Acidification precipitated the product hexenoic acids. The following-6-(4'-biphenylyl)hept-6-enoic acid, m.p. 178°-180°; cis-6-(4'-biphenylyl)hept-6-enoic acid, m.p. 154°-156°; trans-6-(4"-fluoro-4'-biphenylyl)hept-6-enoic acid, m.p. 102°-105° and cis-6-(4"-fluoro-4'biphenylyl)hept-6-enoic acid, m.p. 132°-135°.
Analogous octenoic acids (where Z is 5 in Formula I) and decenoic acids (where Z is 7 in Formula I) are also prepared using appropriate starting materials in the Example 8 or 9 processes.
G. PROCEDURE FOR THE PREPARATION OF 6-(4'-BIPHENYL)-HEX-5-YNOIC ACID 10
EXAMPLE 10
Biphenyl acetylene 5.6 g was dissolved in THF (150 mL) at -78° C. One equivalent n-BuLi was added over one hour. The reaction was allowed to reach room temperature for one hour. 1-Iodo-3-O-tetrahydropyranylpropan-3-ol was added, (one equivalent). The reaction was refluxed for 24 hours. The product 1-O-tetrahydropyranyl-6-(4'biphenylyl)-pent-5-yn-1-ol, (oil C: 82.47, H: 7.55) was isolated by addition of water and extraction with ethyl acetate. The product (1 g) was dried (60° 10 -3 mmHg), dissolved in CH 2 Cl 2 (50 mL) and Ph 3 P.Br 2 (1.95 g) was added, after stirring for 15 minutes at room temperature NaCN (0.54 g) in 20 mL DMSO was added. The mixture was heated at 45° for 16 hours. The intermediate 1-cyano-6-(4'-biphenylyl)pent-5-yne m.p. 60°-61° C.: 88.13, H: 6.16, N: 5.71 was isolated by addition of water and extraction with EtOAc-hydrolysis to the title acid 10 was achieved by refluxing the nitrile in 10 mL (2 N NaOH in 50 mL ethanol) followed by acidification with 6 N HCl. The product 10 was filtered off and dried, 70% yield. m.p. 95°-96°.
H. PROCEDURE FOR THE PREPARATION OF 6-(4'-BIPHENYL) HEX-5-YNOIC ACID
EXAMPLE 11
(Step A) 6-4'-biphenylyl-6-chloro-5-formyl-hex-5-enoic acid methyl ester
6-(4'-Biphenylyl)-6-keto-hexanoic acid (5 g) methyl ester was dissolved in DMF (30 mL) and the solution added to a solution of POCl 3 (1 mL) in DMF (5 mL) cooled to 0° C. The reaction was stirred for 15 minutes at 0° C., warmed to room temperature for 2 hours. Water was added. The product was extracted with EtOAc. Chromatography on silica gel isolated the desired 6-(4'-biphenylyl)-6-chloro-5-formyl-hex-5-enoic acid methyl ester, 800 mg, which was identified NMR and IR spectra.
(Step B) 6-(4'-biphenylyl)-6-chloro-5-carboxy-hex-5-enoic acid methyl ester 12
6-(4'-Biphenylyl)-6-chloro-5-formyl-hex-5-enoic acid methyl ester (1 g) was dissolved in t-BuOH (75 mL). A solution of NaClO 2 (2.42 g) and NaH 2 PO 4 (2.42 g) in 25 mL H 2 O was added dropwise. The solution was stirred for 16 hours. The methanol was removed in vacuo. The solution was acidified (3N HCl) and the product ester 12 extracted with EtOAc. 1 g, 95%. NMR and IR spectra of 12 were obtained.
(STEP C) 6-(4'-biphenylyl)hex-5-ynoic acid 13
6-(4'-Biphenylyl)-6-chloro-5-carboxy-hex-5-enoic acid methyl ester (500 mg) was dissolved in 2 mL quinoline. Eighty-eight milligrams Cu powder was added and the solution heated at 140° for 4 hours. The solution was diluted with citric acid (20% aqueous) and extracted with ethyl acetate. After drying (Na 2 SO 4 ) and concentration the product was isolated by chromatography and hydrolyzed by treatment in methanol (10 mL) with 0.1 N NaOH (5 mL). Acidification precipitated the product 13 (100 mg), m.p. 95°-96°.
C: 81.81; H: 6.06; calc. C: 81.74; H: 6.18; observed.
Corresponding octenoic and decenoic acids are prepared using appropriate starting materials in the Example 11 process.
Claims to the invention follow.
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Substituted phenylalkenoic acids and esters of the formula: ##STR1## having useful pharmaceutical activity are disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a collapsible work horse having first and second pairs of legs pivotally mounted to a support beam to move from an extended or working position to a storage and/or transporting, e.g., collapsed, position, and a locking arrangement to lock the legs in the extended position and, more particularly, to a collapsible work horse having the legs secured in the extended position by a plunger mounted in each of the legs and biased into a hole in the support beam. The invention further relates to a work station having one or more work horses for supporting a shaping tool and for supporting the pieces to be shaped.
[0003] 2. Discussion of the Technical Problems
[0004] In general, work horses, also known as sawhorses or trestles, include a first pair of legs secured to one side of a support beam and a second pair of legs secured to an opposite side of the support beam. The legs can be fixedly secured to the support beam using fasteners, e.g. but not limited to, nails, screws, and/or nut and bolt arrangements, or detachably secured to the support beam using clamps. In general, the clamps include a pair of elongated members pivotally mounted together such that moving one end of the members away from one another moves the opposite ends of the members toward one another against the support beam. In another arrangement, the legs are secured by pivotally attaching the legs to the support beam as taught in U.S. Pat. No. 3,951,233 (hereinafter also referred to as “Patent '233”).
[0005] Although the presently available work horse designs are acceptable for their intended use, they have drawbacks. More particularly, work horses that have the legs and support beam fixedly secured together are usually moved and/or stored in the assembled state, which results in wasted unused space. The work horses that have the legs detachably secured to the support beam reduces the amount of unused space required for storage but requires disassembling the work horse, keeping track of the disassembled parts, and assembling the parts to use the work horse.
[0006] The collapsible work horse of Patent '233 eliminates many of the problems discussed above; however, the work horse of Patent '233 has limitations. More particularly, the extended legs of the work horse disclosed in Patent '233 are maintained in the extended position by a constant frictional force applied to the pivot point of the legs. The frictional force is applied by tightening the bolt at the pivot point. For a detailed discussion of the arrangement to maintain the legs in the extended position, reference can be made to Patent '233.
[0007] As can be appreciated, tightening bolts to secure the legs in the extended position requires the use of the tool to tighten the bolts to secure the legs in the extended position and to loosen the bolts to move the legs to the collapsed position. It can be appreciated by those skilled in the art that it would be advantageous to provide a work horse that has legs that can be moved between the extended position and the collapsed position and does not have the drawbacks and/or limitations of the presently available work horses.
SUMMARY OF THE INVENTION
[0008] This invention relates to a collapsible work horse having, among other things, a support member having a first surface and an opposite second surface; a first pair of legs, with each leg of the first pair having a first end and an opposite second end, with the first end of the first pair of legs pivotally mounted at a pivot point to the first surface of the support member; and a second pair of legs, each leg of the second pair having a first end and an opposite second end, with the first end of the second pair of legs pivotally mounted at a pivot point to the second surface of the supporting beam. The legs of the first pair of legs and the legs of the second pair of legs are in spaced relationship to one another to move the legs between an extended position and a collapsed position. The legs are maintained in the extended position by a two-part locking arrangement. The first part of a locking arrangement is mounted to each of the first end of the legs adjacent the pivot point of its respective leg, and the second part of the locking arrangement mounted to the support member, wherein with the legs in the extended position, the first and second parts of the locking arrangement engage one another to secure the leg in the extended position.
[0009] In one non-limiting embodiment of the invention, the first part of the locking arrangement includes a spring-biased plunger, and the second part of the locking arrangement includes a hole to receive the first end of the plunger. When the leg is in the extended position, the end portion of the plunger is biased into the hole.
[0010] In still another non-limiting embodiment of the invention, each of the legs of the first and second pairs of legs includes a first surface and an opposite second surface, with the first surface at the first end of the leg in facing relationship to portions of the support member, the plunger includes a second opposite end and a shoulder or stop member fixed between the first and second ends of the plunger. The first part of the locking arrangement further includes a housing having a first open end at the first side of the leg and an opposite second open end at the second surface of the leg, with the first and second openings smaller than the shoulder to capture the shoulder in the housing. The first end of the plunger is biased to extend out of the first end of the housing and the second end of the plunger extends out of the second end of the housing. A spring is mounted on the plunger between the second end of the housing and the shoulder or stop member of the plunger. In this manner, moving the second end of the plunger out of the housing compresses the spring, and releasing the second end of the plunger moves the shoulder toward, and the first end of the plunger out of, the first end of the housing under the biasing action of the spring.
[0011] This invention further relates to a tool support that can be used with a work horse, for example but not limited to, the collapsible work horse of the invention. In one non-limiting embodiment of the tool support of the invention, the tool support includes a support platform having a first major surface and an opposite second major surface, and a first and second vise arrangement mounted on the second major surface of the platform in spaced relationship to one another. The second major surface of the support platform is mounted on the support member, with the first and second vise arrangements engaging sides of the support member.
[0012] In another non-limiting embodiment of the tool support of the invention, at least one of the first and second vise arrangements includes a guide shaft mounted to the support platform in spaced relationship to the second surface of the support platform. A first jaw member is slidably mounted on the guide shaft and a detachably securing arrangement mounting the first jaw member, wherein with the detachably securing arrangement in a non-engaged position, the first jaw member can move along the guide shaft, and with the detachably securing arrangement in an engaged position, the first jaw member is secured in a position on the guide shaft. A second jaw member is movably mounted on the guide shaft and driven by a screw drive mounted on the shaft and operatively connected to the second jaw member. The screw drive moves the second jaw member toward the first jaw member to engage the sides of the first support member and to move the second jaw member away from the first jaw member.
[0013] The invention still further relates to a work piece support that can be used with a work horse, for example but not limited to, the collapsible work horse of the invention. In one non-limiting embodiment, the work piece support includes an engaging cover plate member mounted over an end of the support beam of the work horse. The cover plate member has a top plate, a first side, an opposite second side, a third side between the first and second sides, and a first lock screw passing through one of the first and second sides of the cover plate member to engage the support beam of the work horse. A shaft receiving hole is provided on the third side of the engaging cover plate member, with a second lock screw passing through a wall of the shaft receiving hole. A cylindrical support is rotatably mounted on one end of a shaft, with the body of the shaft passing through the shaft receiving hole. The cylindrical support is in a fixed position above the support member of the work horse by the second lock engaging the shaft of the work piece support.
[0014] In another non-limiting embodiment of the invention, the support platform of the tool support has a cut out adjacent a side of the support platform of the tool support, and the tool support and the work piece support in a storage position includes the shaft of the cylindrical support positioned between the first and second sides of the engaging cover plate member and biased against one of the first and second sides of the plate member by the first lock screw, and the engaging cover plate member secured between the first and second jaw members of the work piece support between the first and second jaw members.
[0015] The invention further relates to a work station having a first material shaping position and one or more support positions. The shaping position includes the tool support of the invention mounted on a first work horse, e.g., the collapsible work horse of the invention, and a shaping tool secured on the tool support. The support positions each include a work piece support of the invention mounted on a second work horse, e.g., the collapsible work horse of the invention. A support board has one end attached to the shaping tool and the other end supported at the support positions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Further advantages and details of the invention will be explained in more detail with reference to the exemplary embodiment illustrated in the schematic figures, in which like reference numbers identify like parts throughout.
[0017] FIG. 1 is an elevated front view of a non-limiting embodiment of a collapsible work horse of the invention;
[0018] FIG. 2 is an isometric end view of the collapsible work horse shown in FIG. 1 ;
[0019] FIG. 3 is an isometric end view of a vertical support member of the collapsible work horse shown in FIG. 1 ;
[0020] FIG. 4 is an elevated front view of the collapsible work horse shown in FIG. 1 in the collapsed condition for storage and/or transportation in accordance with the teachings of the invention;
[0021] FIG. 5 is an elevated side view of a leg of the collapsible work horse of the invention;
[0022] FIG. 6 is an elevated front view of the leg shown in FIG. 5 ;
[0023] FIG. 7 is a view taken along lines 7 - 7 of FIG. 1 and having portions removed for purposes of clarity;
[0024] FIG. 8 is an isometric front view having portions removed for purposes of clarity of a work station incorporating features of the invention and including a non-limiting embodiment of the collapsible work horse of the invention;
[0025] FIG. 9 is an isometric bottom view of a non-limiting embodiment of a tool supporting platform of the invention;
[0026] FIG. 10 is a view taken along lines 10 - 10 of FIG. 8 and having portions of the shaping tool removed for purposes of clarity;
[0027] FIG. 11 is an isometric fragmented view of a non-limiting embodiment of a support member of the invention supporting a board; and
[0028] FIG. 12 is an elevated plan view showing the tool support of FIG. 9 and the support member of FIG. 11 in a storage and/or transportation arrangement in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Before discussing several non-limiting embodiments of the invention, it is understood that the invention is not limited in its application to the details of the particular non-limiting embodiments shown and discussed herein since the invention is capable of other embodiments. Further, the terminology used herein to discuss the invention is for the purpose of description and is not of limitation. Still further, unless indicated otherwise, in the following discussion like numbers refer to like elements.
[0030] As used herein, spatial or directional terms, such as “inner”, “outer”, “left”, “right”, “up”, “down”, “horizontal”, “vertical”, and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Further, all numbers expressing dimensions, physical characteristics, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims can vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, e.g., 1 to 6.7, or 3.2 to 8.1, or 5.5 to 10.
[0031] With reference to FIGS. 1 and 2 as needed, a work or saw horse 20 of the invention includes a support or cross beam 22 , legs 24 and 25 mounted in spaced relationship to one another on side 27 of the support beam 22 , and legs 29 and 30 mounted in spaced relationship to one another on opposite side 32 of the support beam 22 . The invention is not limited to any particular design of the support beam 22 ; however, it should have sufficient structural strength to support the desired load. In one non-limiting embodiment of the invention, the support beam 22 had a T-shaped cross section, clearly shown in FIG. 2 . Horizontal support member 34 of the beam 22 was made of wood having a thickness of 1 inch, a width of 3.5 inches, and a length of 46 inches. Vertical support member 42 of the beam 22 was made of wood having a thickness of 1 inch and a length of 46 inches. The width of the vertical support member 42 varied in width across its length to provide access to centrally located elongated opening or cut out 44 when the legs 24 , 25 , 29 , and 30 are moved to the storage and/or transport position, e.g., the collapsed position, discussed in detail below. In this non-limiting embodiment of the invention, the vertical support member 42 had a width at ends 46 and 48 of 3.5 inches, a uniformly increasing width for a length of 19 inches from each of the ends 46 and 48 toward the center of the vertical support member 42 , and a center portion having a length of 8 inches and a width of 5 inches.
[0032] In the following discussion, the sides 27 and 32 of the support beam 22 to which the legs 24 , 25 and 29 , 30 , respectively, are secured in accordance to the teachings of the invention are the sides 27 and 32 of the vertical member 42 . With reference to FIG. 3 , each of the sides 27 and 32 of the vertical member 42 has a pair of cut outs 52 , 53 and 55 , 56 , respectively, to receive a wedge member 58 (wedge member 58 only shown in cut out 56 ). The wedge members 58 provide an angle to the legs 24 , 25 and 29 , 30 in relationship to the support beam 22 when the legs 24 , 25 and 29 , 30 are extended, e.g., the work horse 20 is in the work position, as shown in FIG. 2 . In the non-limiting embodiment of the invention under discussion, the cut outs 52 , 53 and 55 , 56 had a width of 3.5 inches, a depth of 3/16 inch, and extend from top side 60 to bottom side 62 of the vertical support member 42 . The wedge members 58 had a width and length of 3.5 inches, a thickness at one end, e.g., end 64 , of 1⅜ inches and a thickness at the opposite end, e.g., end 66 of 3/16 inch. The wedge members 58 were secured in their respective cut out 52 , 53 and 55 , 56 by wood screws, with the smaller end 64 of the wedge members 58 adjacent to, or level with, the top side 60 of the vertical member 42 .
[0033] As can be appreciated, the invention is not limited to the shape of the cut outs 52 , 53 and 55 , 56 for receiving the wedge members 58 . Further, the invention is not limited to the dimensions of the wedge members 58 . For example and not limiting to the invention, the end 66 of the wedge members 58 can be increased relative to the end 64 of the wedge members 58 to increase the spaced distance between the legs 24 and 29 , and 25 and 30 , and the end 66 of the wedge members 58 can be decreased relative to the end 64 of the wedge members 58 to decrease the spaced distance between the legs 24 and 29 , and 25 and 30 (see FIG. 2 ). Further, the invention is not limited to having cut outs 52 , 53 and 55 , 56 in the vertical support member 42 to contain the wedge members 58 , and the invention contemplates the sides 27 and 32 of the vertical member 42 without the cut outs, and the wedge members 58 mounted on such surfaces. Still further, the invention is not limited to the technique used to secure the wedge members 58 to the vertical member 42 , e.g., the wedge members 58 can be secured to the vertical member 42 by fasteners of the type discussed above and/or by adhesives.
[0034] The horizontal and vertical support members 34 and 42 , respectively, can be joined together in any convenient manner. With reference to FIG. 2 , in the non-limiting embodiment of the invention under discussion, a channel 70 (see also FIG. 10 ) centrally located between sides 72 and 74 is provided, e.g., cut into bottom surface 76 of the horizontal support member 34 . The channel 70 had a depth of 3/16 inch and a width of 1 inch. The top side 60 of the vertical support member 42 was secured in the channel 70 by screws 78 passing through top surface 80 of the horizontal support member 34 into the top side 60 of the vertical support member 42 (see FIGS. 2 and 3 ). In the instance when the horizontal support member 34 is made of wood, two relief grooves 82 are imposed into the top surface 80 of the horizontal support member 34 (see FIGS. 2 and 10 ) to reduce warpage of the horizontal support member 34 . As can be appreciated, the invention is not limited to the manner in which the vertical and horizontal members are joined together and any joining technique known in the art can be used in the practice of the invention.
[0035] Each of the legs 24 , 25 and 29 , 30 has one end 84 mounted to a respective one of the wedge members 58 (one of the wedge members 58 shown in FIG. 3 ) by a shaft 86 (see FIGS. 1 and 4 ) such that each of the legs are secured to their respective one of the wedge members 58 for rotational or pivotal movement about their respective shaft 86 to move between the extended or work position (shown in FIG. 1 ) to a collapsed position (shown in FIG. 4 ) for transporting and/or storing the work horse 20 in a manner discussed in detail below. As is appreciated, the invention is not limited to the manner in which the ends 84 of the legs 24 , 25 and 29 , 30 are secured to their respective one of the wedge members 58 which are secured to the vertical support member 42 , as discussed above, and any fastening arrangement can be used. In the non-limiting embodiment of the invention under discussion, the shaft 86 was a screw and washer arrangement used to secure the ends 84 of the legs 24 , 25 and 29 , 30 to its respective one of the wedge members 58 for pivotal or rotational movement around the screw.
[0036] Although not limiting to the invention and as can be appreciated from FIGS. 2 and 4 , the legs 25 and 30 are pivoted around the shaft 86 in a counter-clockwise direction to move the legs 25 and 30 from the extended position as shown in FIG. 2 to the collapsed position shown in FIG. 4 , and the legs 25 and 30 are pivoted around the shaft 86 in a clockwise direction to move the legs 25 and 30 from the collapsed position to the extended position. The legs 24 and 29 are pivoted around the shaft 86 in a clockwise direction to move the legs 24 and 29 from the extended position as shown in FIG. 2 to the collapsed position shown in FIG. 4 , and the legs 24 and 29 are pivoted around the shaft 86 in a counter-clockwise direction to move the legs 24 and 29 from the collapsed position to the extended position.
[0037] In the following discussion, reference will be made to the leg 25 , with the understanding that the discussion is applicable to the legs 24 , 29 , and 30 , unless indicated otherwise. With reference to FIGS. 5 and 6 , in the non-limiting embodiment of the invention under discussion, the leg 25 had a thickness of 1.00 inch as measured between surfaces 90 and 92 of the leg 25 ( FIG. 5 ). End 88 of the leg 25 had a width of 1.25 inches as measured between sides 94 and 96 of the leg 25 , and the end 84 had a width of 3 11/16 inches as measured between the sides 94 and 96 . The leg 25 had a length of 32.25 inches as measured between the ends 84 and 88 along the side 96 of the leg 25 . The side 94 of the leg 25 slopes toward the side 96 , and the sides 94 and 96 do not slope toward one another for nesting of the legs when the work horse 20 is in the collapsed position, as shown in FIG. 4 .
[0038] In the following discussion, the leg 25 will be discussed with the understanding that the discussion is applicable to the leg 30 , unless indicated otherwise, and the reverse of the discussion is applicable to the legs 24 and 29 , unless indicated otherwise, because, as discussed above, the legs 25 and 30 move in an opposite clockwise direction when moving from the extended position to the collapsed position and from the collapsed position to the extended position.
[0039] The ends 84 and 88 of the leg 25 each form an angle A between the sides 94 and 96 , as shown in FIG. 6 , such that the distance between the ends 84 of the legs 24 and 25 on the side 27 of the vertical support member 42 (see FIG. 2 ) increases as the distance from the vertical member 42 increases, and the distance between the ends 84 of the legs 29 and 30 on the side 32 of the vertical support beam 42 increases as the distance from the vertical member 42 increases, for stability of the work horse 20 when the legs are extended and the work horse 20 is in the upright or work position. In the non-limiting embodiment of the invention under discussion, the angle was 12 degrees. The ends 84 and 88 of the leg 25 between the surfaces 90 and 92 each beveled to have an angle B, as shown in FIG. 5 , such that the distance between legs 24 and 29 , and between the legs 25 and 30 , increases as the distance from the vertical support member 42 increases for stability of the work horse 20 when the legs are extended and the work horse 20 is in the upright or work position. In the non-limiting embodiment of the work horse under discussion, the angle B was 20 degrees.
[0040] In the non-limiting embodiment of the invention under discussion, hole 98 extends through the surfaces 90 and 92 to receive the screw 78 about which the leg 25 rotates. The hole 98 is on a center to side 94 spacing of 13/16 inch, and on a center to end 84 spacing of 1⅞ inches as measured between an imaginary line 100 extending through the center of the hole 98 and parallel to straight portion 102 of the end 84 at the surface 90 of the leg 25 . Corner 104 of the leg 25 between the end 84 and the side 94 is rounded as shown in FIG. 6 to move the rounded corner 104 under the horizontal beam 34 (see FIG. 2 ) as the leg 25 is rotated about the screw 78 . In the non-limiting embodiment of the invention under discussion, the rounded corner 104 of the leg 25 had a radius of 1⅞ inches.
[0041] As can be appreciated, the ends 84 of the legs 24 , 25 , 29 and 30 are shaped, e.g., corner 104 rounded, to provide for rotation of the legs between the work position ( Fig. 2 ) and the collapsed position ( FIG. 4 ). With reference to FIGS. 1 and 2 and as mentioned above, the legs 25 and 30 move in a clockwise direction opposite to the clockwise direction of the legs 24 and 29 when moving from the work position to the collapsed position. As is appreciated by those skilled in the art, the particulars relating to the rounded corner 104 at the end 84 of the legs 25 and 30 discussed above are opposite to the particulars relating to the rounded corner at the end 84 of the legs 24 and 29 because they move in an opposite direction to the legs 25 and 30 when the legs are moved to the same position.
[0042] As can be appreciated, the invention is not limited to any synchronized movement among the legs 24 , 25 , 29 , and 30 , e.g., the movement of the legs 25 and 30 in a counter-clockwise direction, and the movement of the legs 24 and 29 in the clockwise direction, to move into the work position. However, in the preferred embodiment of the invention, the legs 25 and 30 move in a direction opposite to the direction of the legs 24 and 29 when moving the legs to the same position so that the work horse 20 of the invention can be collapsed into a convenient carrying and storage arrangement, e.g., as shown in FIG. 4 .
[0043] In another embodiment of the invention, the legs 24 , 25 , 29 , and 30 are secured in the work position by a leg lock assembly 110 . In the non-limiting embodiment of the invention under discussion, the leg lock assembly 110 is a spring-biased plunger 110 mounted in hole 112 in the wedge member 58 (the hole 112 clearly shown in FIG. 7 ). With continued reference to FIG. 7 , the spring-biased plunger 110 includes a cylindrical housing 114 having a flanged end 116 mounted in the hole 117 , with the flanged end 116 flush with the surface 90 of the leg 25 facing the wedge member 58 , as shown in FIG. 7 . The flanged end 116 has an opening 118 having a diameter less than inside diameter of the housing 114 . A plunger 120 has an engaging end 122 sized to fit into the opening 118 of the flanged end 116 , and a shoulder 124 spaced from the engaging end 122 of the plunger 120 sized to fit within the housing 114 and not pass through the opening 118 in the flanged end 116 . A retainer nut 126 having external threads (not shown) is threaded into opposite end 128 of the housing 114 having internal threads (not shown) at the end 128 . The retainer nut 126 has an opening 130 sized to pass end 132 of the plunger 120 . A coil spring 134 was mounted on the plunger 120 between the retainer nut 126 and the shoulder 124 of the plunger 120 . The biasing force of the spring 134 acts on the shoulder 124 of the plunger 120 to bias the engaging end 122 of the plunger 120 out of the housing 114 into the hole 112 in the wedge member 58 . The end 132 of the plunger 120 extends out of the retainer nut 126 and has a knob 136 secured thereto for ease of moving the engaging end 122 of the plunger 120 into the housing 114 against the biasing action of the spring 134 .
[0044] With the legs 24 , 25 , 29 , and 30 of the work horse 20 in the extended position, the work horse 20 is in the work position (see FIG. 1 ) and the engaging end 122 of the plunger 120 of the leg lock attachment assembly 110 of each leg 24 , 25 , 29 , and 30 is biased by the spring 134 into the hole 112 of the wedge member 58 (see FIG. 7 ) to lock the legs in the extended position. To move the legs to the collapsed position shown in FIG. 4 , the knob 136 of the leg lock attachment assembly 110 of the legs 24 , 25 , 29 , and 30 is moved away from the wedge member 58 to move the engaging end 122 of the plunger 120 out of the hole 112 in the wedge member 58 against the biasing force of the spring 134 . With the engaging end 122 of the plunger 120 out of the hole 112 in the wedge member 58 , the leg is rotated into the collapsed position. The procedure is repeated for each of the legs. In the instance when the leg lock attachment assembly 110 is positioned on its respective one of the legs to have the engaging end 122 of the plunger 120 remain in contact with its respective one of the wedge members 58 , the leg is moved from the collapsed position to the work position, and the biasing action of the spring 134 moves the engaging end 122 of the plunger 120 into the hole 112 in the wedge member 58 when they are aligned with one another. In the instance when the leg lock attachment assembly 110 is positioned on its respective one of the legs to have the engaging end 122 of the plunger 120 clear its respective wedge member 58 , the biasing action of the spring 134 moves the engaging end 122 of the plunger 120 out of the housing 114 when the engaging end 122 clears the wedge member 58 . In this instance, as the leg is moved to the work position, the knob 136 is moved away from the leg to move the engaging end 122 of the plunger 120 into the housing 114 until the engaging end 122 clears its respective one of the wedge members 58 . Thereafter, the knob 136 is released to move the engaging end 122 under the biasing action of the spring 134 against the wedge member 58 , and the biasing action of the spring 134 moves the engaging end 122 of the plunger 120 into the hole 112 in the wedge member 58 when they are aligned with one another. The above is repeated for each of the legs to lock the legs in the work position.
[0045] As can be appreciated, the invention contemplates a work horse having more than two legs, e.g., having 3, 4 or more legs, on each side of the vertical support member 42 , and having the same or a different number of legs on the sides of the vertical support member 42 . Further, as can be appreciated, the invention is not limited to the material of the work horse and the work horse can be made of any material that can support the expected load to be supported by the work horse. Materials that can be used in the practice of the invention to make the work horse of the invention include but are not limited to metal, wood, plastic, pressed wood, metal and/or fiber glass reinforced plastic. In the instance when the work horse is made of wood, the relief grooves 82 (see FIGS. 2 and 10 ) are provided on the top surface 80 of the horizontal support member 34 to reduce warpage of the wood.
[0046] With reference to FIG. 8 , there is shown a work station 150 incorporating features of the invention which include but are not limited to a plurality of work horses 20 of the type discussed above. As can be appreciated, the work station 150 is not limited to using the work horse 20 of the invention and any type of work horse can be used. The work station 150 shown in FIG. 8 includes a shaping station 152 , a work piece support position 154 on the right side, and a work piece support position 156 on the left side of the shaping station 152 . In one non-limiting embodiment of the invention, the shaping station 152 includes a working tool 158 securely mounted on a tool support or tool supporting member 160 securely mounted on a work horse 20 in a manner discussed below. The working tool 158 is not limiting to the invention and can be any type of tool for shaping or joining materials, e.g. and not limiting to the invention, a drilling machine, a punching machine, a welding machine, or cutting machine. The working tool 158 can be motor and/or hand operated. In one non-limiting embodiment of the invention, the working tool 158 was a motor driven radial miter saw. In the following discussion, the working tool will be referred to as miter saw, however, as is appreciated, the invention is not limited thereto.
[0047] With reference to FIG. 9 , the tool supporting member 160 has an elongated cut out 162 adjacent one side, e.g., side 164 , of the tool supporting member 160 for ease of carrying the tool supporting member 160 , and has a plurality of spaced holes 166 which are aligned with mounting holes (not shown) in base 168 of the miter saw 158 (see FIG. 10 ). The tool supporting member 160 can be made of any structurally stable material. In the practice of a non-limiting embodiment of the invention, the table 160 was made of 0.75 inch thick plywood. Securing arrangements, e.g. and not limiting to the invention, nut and bolt members 170 (see FIG. 10 ) are used to secure the miter saw 158 to upper surface 172 of the tool supporting member 160 . Mounted on opposite or lower surface 174 of the tool supporting member 160 is a pair of clamps 176 and 178 to secure the tool supporting member 160 to the horizontal member 34 of the work horse 20 (see FIG. 10 ).
[0048] The invention is not limited to the type of clamps 176 and 178 used to secure the tool supporting member 160 to the work horse 20 . In the non-limiting embodiment of the invention under discussion, the clamps 176 and 178 each included a guide shaft or pipe 182 mounted to, and spaced from, the lower surface 174 of the tool support 160 and spaced from one another. The clamp 176 will be discussed with the understanding that the discussion, unless indicated otherwise, is applicable to the clamp 178 . The guide shaft 182 of the clamp 176 was mounted on posts 184 to space the guide shaft 182 from the lower surface 174 of the tool support 160 . The guide shaft 182 was secured against the posts 184 and the posts 184 secured against the lower surface 174 of the tool support 160 by a machine screw (not shown) passing through the upper surface 172 of the tool support 160 , through the posts 184 and threaded into the guide shaft 182 . A jaw clamp 186 is mounted on the pipe 182 to slide between the posts 184 . A threaded drive shaft 188 passes through an internally-threaded passageway 190 of collar 191 secured to end 192 of the guide shaft 182 with end 193 of the threaded drive shaft 188 rotatably mounted to the jaw clamp 186 , and a handle 194 secured to opposite end of the threaded drive shaft 188 . With this arrangement, rotating the handle 194 in a first direction moves the jaw clamp 186 away from the end 192 of the guide shaft 182 and rotating the handle 194 in the opposite direction moves the jaw clamp 186 toward the end 192 of the guide shaft 182 .
[0049] A lockable jaw clamp 196 is mounted on the guide shaft 182 adjacent opposite end 198 of the guide shaft 182 to slide toward and away from the end 198 of the guide shaft 182 . The lockable jaw clamp 196 is moved to a predetermined location on the guide shaft 182 and secured in position in any convenient manner, e.g., by a screw passing through the jaw clamp 196 to engage the guide shaft 182 , by a spring-biased engaging member, or by an off center wheel rotated to engage the guide shaft 182 . With this arrangement, the tool support 160 can be set on the work horse 20 to have a more equal weight distribution of the working tool 158 mounted on the tool support 160 .
[0050] As is appreciated by those skilled in the art, cutting an end of corner molding requires support for long pieces of corner molding, e.g., pieces having a length of 12 feet. In this embodiment of the invention, a 2 inch by 12 inch by 16 feet piece of lumber designated by the number 200 (see FIGS. 8 and 10 ) was used to support the corner molding (not shown). An angle iron 202 was secured to each of the opposite sides of the base 168 of the working tool 158 , and an end of each of the pieces of lumber 200 was secured to one of the angle irons 202 . The other end of the pieces of lumber 200 was supported at its respective one of the work piece support positions 154 and 156 by a roller support assembly or work piece support 210 mounted on the work horse 20 . In the following discussion, the roller support assembly 210 of the work piece support position 154 will be discussed with the understanding that the discussion, unless indicated otherwise, is applicable to the roller assembly 210 of the support position 156 .
[0051] The roller support 210 includes a base 212 that fits over an end of the horizontal member 34 of the work horse 20 and is secured thereto by rotating a threaded shaft 214 having an end passing through a threaded hole in the base 212 . As can be appreciated, the invention is not limited to the structure or design of the base 212 . In a non-limiting embodiment of the invention, the base was made by welding 4 pieces of angle irons together to form a base having three sides and an open end. A hole was drilled through one of the sides and a nut welded over the hole to receive a threaded shaft, e.g., the shaft 214 . To prevent the end of the shaft 214 from cutting into the horizontal member 34 of the work horse 20 , the end of the shaft 214 contacting the horizontal member 34 can have an enlarged end (not shown). Mounted on end 216 of the base 212 is a shaft retaining assembly 220 to receive shaft 222 of the roller assembly 224 and to secure the shaft 222 in the shaft retaining assembly 220 , with the roller assembly 224 in a fixed elevated position.
[0052] The construction of the shaft retaining assembly 220 is not limiting to the invention. In the non-limiting embodiment of the invention under discussion, the shaft retaining assembly 220 was made by welding a section of pipe to the end 216 of the base 212 and providing a threaded hole in the section of the pipe to receive a screw 226 to engage the shaft 222 of the roller assembly 224 . The roller assembly 224 further included a U-shaped member 228 mounted on the shaft 222 and having a roller 230 rotatably mounted in legs 232 of the U-shaped member 228 .
[0053] In another non-limiting embodiment of the invention, the roller support assembly 210 and the tool support 160 can be mounted on the same work horse.
[0054] In another non-limiting embodiment of the invention, the tool support 160 and the roller support assembly 210 can be packed together for storage or transportation. More particularly and with reference to FIGS. 11 and 12 as needed, the roller assembly 224 is removed from the shaft retaining assembly 220 and placed in the base 212 of the roller support assembly 210 . A block of wood 236 is positioned between the shaft 222 of the roller assembly 224 and the threaded shaft 214 in the base 212 . The threaded shaft 214 is rotated to move the block of wood 236 against the shaft 222 to secure the shaft 222 in the base 212 of the roller support assembly 210 . The base 212 of one of the roller support assemblies 210 is placed between the jaw clamps 186 and 196 of one of the clamps 176 and 178 , and the other one of the roller support assemblies 210 is placed between the jaw clamps 186 and 196 of the other one of the clamps 176 and 178 , and the jaws moved toward one another to capture the bases 212 between the jaw clamps. The tool support 160 and the roller support assemblies 210 can now be moved by engaging the cut out 162 in the tool support 160 .
[0055] Based on the description of the embodiments of the invention, it can be appreciated that this invention is not limited to the particular embodiments disclosed but it is intended to cover modifications that are within the spirit and scope of the invention, as defined by the appended claims.
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A collapsible work horse has legs pivotally mounted to opposing surfaces of a support beam. The legs are secured in the extended position by a two-part locking arrangement. In one non-limiting embodiment of the invention, a first part of a locking arrangement is mounted to each of the first ends of the legs adjacent the pivot point of its respective leg, and a second part of the locking arrangement is mounted to the supporting member. When the legs are in the extended position, the first and second parts of the locking arrangement engage one another to securely fix the legs in the extended position. In another non-limiting embodiment of the invention, a plurality of work horses are assembled with a tool support and work piece supports to provide a work station. The tool support and work piece supports are designed to be fixable in a compact storage arrangement.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cleaning compositions which will replace cleaning agents containing an organic solvent including flon and the like.
2. Description of the Related Art
In manufacturing various parts such as metal parts, plated and coated parts, and electronic and semiconductor parts, flon containing solvents such as flon 113, and organic solvents such as trichloroethane, trichlorethylene, tetrachloroethylene, and carbon tetrachloride are widely used as cleaning agents for eliminating oil stains and the like.
The above organic solvent containing cleaning agents are also used as dewatering cleaning agents after having washed various parts with water in order to avoid the following problems that are associated with direct drying of water present on an object to be cleaned:
(1) Heating (100° C. or more) which entails energy loss;
(2) Reducing in productivity due to time taken in drying;
(3) Likely deformation of the object to be cleaned due to heating (thermal expansion that exceeds the tolerance); and
(4) Increase in space for installing a cleaning system including a cooler and a heat shielding unit.
The term "dewatering cleaning agent" is used herein to denote a cleaning agent into which an object to be cleaned, which has been washed with water, is immersed or with which the object is rinsed by shower thereby to have water present on the object substituted by itself and then vaporized by air at room temperature or heated to 60° C. or less so that the object can be dried.
However, ever since it has been found that the destruction of the ozone layer by discharge of flon affects seriously the human body and the ecological system, the use of flons such as flon 12 and flon 113 whose ozone destruction coefficients are high is on the gradual decline on a global scale for an eventual total ban.
Stricter regulations are imposed also on chlorine containing organic solvents such as trichloroethylene and tetrachloroethylene which are presumed to induce soil and underwater contaminations and the like.
Flons whose ozone destruction coefficients are lower than the currently used flon containing solvents are being developed, some of which are under fabrication on a commercial basis. However, these new developments are not so welcome because they still are destroyers of the ozone layer.
What gradually attracts attention as a replacement for the above organic solvents is a surfactant-based water system cleaning agent which is free from environmental destruction and contamination. However, cleaning agents containing only surfactants are not satisfactory in penetrability, thereby not cleaning, e.g., stains penetrated into narrow portions and medium to high viscous, persistently sticky oil stains.
Japanese Patent Publication No. 50463/1988 discloses a method of cleaning woven materials by using silicone containing compounds. According to the disclosure, a liquid cleaning composition containing an effective amount of cyclic siloxane having 4 to 6 silicon atoms is used. However, the liquid cleaning compositions including the above silicone containing compound are not suitable for use not only in general industrial products due to their being specifically prepared for woven materials, but also in systems using water (hereinafter referred to as "water system") due to their being based on a single cyclic siloxane or the mixture of a cyclic siloxane and an organic solvent. Further, such compositions are not so dispersive in water that the addition of a surfactant thereto does not assist in blending them homogeneously, thereby causing phase separation immediately. Thus, they are not adapted for use as water system cleaning agents.
On the other hand, Japanese Patent Laid Open No. 56203/1978 recites an aerosol aqueous cleaning composition containing a chain polydimethylsiloxane having 2 to 3 silicon atoms in a single molucular. Since its content is limited to about 0.02 to 0.1 wt. %, no such advantage as improving the cleaning property of water system cleaning compositions is disclosed.
Under such circumstances, the development of high-performance water system cleaning agents free from environmental problems is strongly called for.
In the meantime, the use of lower alcohols such as isopropyl alcohol is under study for a new development that can replace the above-mentioned organic solvents for dewatering. However, isopropyl alcohol has a flash point of 11.7° C., which is lower than room temperature, and this involves some danger of fires under ordinary handling conditions. In addition, isopropyl alcohol is highly compatible with water, so that the initial dewatering property is ensured, but its repetitive use causes dissolved water to be present again. As a result its dewatering property will be impaired on a long-term basis. To refine isopropyl alcohol for reuse by removing water from the water containing isopropyl alcohol, a tremendous equipment investment is required. That isopropyl alcohol is toxin to the human body is another factor that tends to keep it from using.
The use of hydrocarbon and higher alcohols which have higher flash points than room temperature allows a comparatively easy removal of water, but their low volatility prevents drying themselves at low temperatures, e.g., 60° C. or less, thereby making them unsuitable for applications to dewatering cleaning agents.
Therefore, an object of the invention is to provide water system cleaning compositions which have cleaning capability equivalent to that of organic solvent containing cleaning agents including such as flon and which are stable as water system cleaning agents and free from environmental destruction and contamination.
Another object of the invention is to provide dewatering compositions which have the substituting and drying properties equivalent to those of organic solvent containing dewatering cleaning agents, which have few risks of fires and which are free from environmental destruction.
SUMMARY OF THE INVENTION
A cleaning agent composition of the invention comprises at least one low molecular weight polyorganosiloxane selected from the group consisting of straight chain polydiorganosiloxane represented by a general formula: ##STR3## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and 1 is an integer from 0 to 5), and cyclic polydiorganosiloxane represented by a general formula: ##STR4## (wherein R 1 is an organic group of single valence substituted by the same of different group of unsubstituted, and m is an integer from 3 to 7).
Each of such low molecular weight polyorganosiloxanes exhibits powerful penetrability to stains and satisfactory substituting property with water alone, making itself a feature component of the invention. Reference character R 1 in formulas (I) and (II) denotes a substituted or unsubstituted organic group of single valence including: a single-valence unsubstituted hydrocarbon group such as an alkyl group such as a methyl group, an ethyl group, a propyl group, and a butyl group and a phenyl group; and a single-valence substituted hydrocarbon group such as a trifluoromethyl group. As the R 1 which is placed at an end of formula (I), an amino group, an amide group, an acrylic acid ester group, and a mercaptan group are typical organic groups; however, the methyl group is most preferable from the viewpoint of stability, and maintainability of volatility, and the like.
The cleaning compositions of the invention may roughly be classified into two groups: a water system cleaning agent and a dewatering cleaning agent.
For use as a water system cleaning agent, suitable low molecular weight polyorganosiloxanes include: octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane and mixtures thereof, each having a cyclic structure; and octamethyltrisiloxane and decamethyltetrasiloxane, each having a straight chain structure, from the viewpoint of penetrability and cleaning capability. In regions where the water system cleaning composition has a strong alkaline property from the viewpoint of stability of polysiloxane, the low molecular weight polyorganosiloxane having a straight chain structure which is represented by formula (I) is preferable.
For use as a dewatering cleaning agent, low molecular weight polyorganosiloxanes having a cyclic structure are preferable from the viewpoint of substituting property with water and penetrability and the like, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, and mixtures thereof are more preferable.
A case in which the cleaning compositions of the invention are used as water system cleaning agents will now be described.
Although the low molecular weight polyorganosiloxanes represented by formulas (I) and (II) exhibit powerful penetrability to stains, each composition is not compatible with water singly nor is it soluble and stably dispersive in water so that it is likely to have phase separation in water. That is, it is proposed to use them in combination with polyoxyalkylene group containing polyorganosiloxane having in a single molecule at least one siloxy unit represented by a general formula: ##STR5## (wherein R 2 is an alkyl or phenyl group and A is a polyoxyalkylene group). As a result of such use in combination, the low molecular weight polyorganosiloxanes, providing stable dispersion in water, exhibit strong penetrability to stains. In addition, the use of a surfactant in combination with the compositions may improve their cleaning property.
Thus, preferable compositions for a water system cleaning agent of the invention contain the low molecular weight polyorganosiloxane represented by formula (I) or (II); the polyoxyalkylene group containing polyorganosiloxane having at least one siloxy unit represented by formula (III) in a single molecular; a surfactant; and water.
The polyoxyalkylene group containing polyorganosiloxane exhibits affinity for water owing to its polyoxyalkylene group bonded with the silicon atom, thus not only being a component for a stable water system dispersed solution or aqueous solution but also acting as an agent for eliminating stains by penetrating into the interface between the stains and a substrate which is made of, e.g., a metal and which has the stains deposited thereon, and as an antifoaming agent as well.
Such a polyoxyalkylene group containing polyorganosiloxane can be prepared by hydrosilyl group containing polyorganosiloxane and a polyoxyalkylene compound having an unsaturated group at the end to interact with each other for addition under the presence of a platinum containing catalyzer.
An example of the polyoxyalkylene group denoted by reference character A in formula (III) is, e.g., a single-valence group represented by the formula:
--R.sup.3 --(--O--R.sup.4 --).sub.n --OR.sup.5 (IV)
(wherein R 3 is a two-valance group selected from the group consisting of an alkylene group having from 1 to 8 carbon atoms, a β-hydroxypropyleneoxyalkylene group and a polymethylene oxyalkyelene group, both having from 4 to 11 carbon atoms; R 4 is an alkylene group having from 2 to 4 carbon atoms; R 5 is an end group selected from a hydrogen atom and a single-valence organic group; and n is a positive integer).
Siloxane that forms a main component of the polyoxyalkylene group containing polyorganosiloxane is not particularly limited. The organic group that is to be bonded with the silicon atom of the siloxane is basically a methyl group, but may also contain a single-valence hydrocarbon group such as an ethyl group, a propyl group, a butyl group, a phenyl group, or a single-valence substituted hydrocarbon group such as a trifluoromethyl group as long as the advantages of the invention can remain harmless therefrom.
Also, the molecular weight of the siloxane is not particularly limited nor is that of a single polyoxyalkylene group. Although they are large values, the addition of a surfactant thereto and the like allows the composition to be made sufficiently water soluble or stably water dispersive. However, it is practically preferable to limit the molecular weight of the single polyoxyalkylene group in the order of 100 to 5000. For a polyoxyalkylene chain, it is preferable to adjust its oxyethylene component to 40 mol % or more in the total polyoxyalkylene.
While the amount of the polyoxyalkylene group is not particularly limited, it is more preferable to limit it within 5 mol % or more of the total organic groups bonded with silicon atoms of the polyorganosiloxane from the standpoint of system stability.
Exemplary polyoxyalkylene group containing polyorganosiloxanes include:
a chain polysiloxane represented by the formula: ##STR6## (wherein p, q, r, and s are positive integers); and a cyclic polysiloxane represented by the formula: ##STR7## (wherein t, u, and v are positive integers).
The surfactant serves as a component for dissolving, emulsifying, and stabilizing the stains removed by the low molecular weight polyorganosiloxanes or polyoxyalkylene group containing polyorganosiloxanes.
Such surfactants can be classified by the activation chemical structure into the following types: cationic, anionic, nonionic, amphoteric, and combined types. The invention may be applied to all the above types of surfactants. However, to obtain the advantage from their combination with the polyoxyalkylene group containing polyorganosiloxane, it is preferable to use anionic, nonionic, or amphoteric surfactants. Particularly, the use of the polyoxyalkylene group containing polyorganosiloxane in combination with either anionic/nonionic surfactants or amphoteric/nonionic surfactants provides a remarkable synergetic effect in improving the cleaning property and penetrability of the low molecular weight polyorganosiloxanes or the polyoxyalkylene group containing polyorganosiloxanes.
Exemplary suitable surfactants to be applied to the invention include: anionic surfactants such as polyoxyalkylene alkylether sulfonates and phosphoric esters; nonionic surfactants such as polyalcohol fatty acid esters, polyoxyalkylene fatty acid esters, and polyoxyalkylene alkylethers; amphoteric surfactants such as imidazolin derivatives; and cationic surfactants such as alkylamine salts, alkyl quaternary ammonium salts. In addition thereto, terpene containing compounds which are rarely present in the form of a single substance and extracted from natural substances as well as higher fatty acid esters may also be applied. It is also possible to use synthetic compounds in which part of the chemical structure of each compound is substituted by a fluorine or silicon atom.
While the composition ratio of the above-mentioned quaternary water system cleaning agent is not particularly limited, it is preferable to blend 10 to 1000 parts by weight of a surfactant to 100 parts by weight of the polyoxyalkylene group containing polyorganosiloxane, and 1000 parts by weight or less of the low molecular weight polyorganosiloxane to 100 parts by weight of a total combination of the above surfactant(s) and the polyoxyalkylene containing polyorganosiloxane. Too small an amount of the surfactant reduces the cleaning capability, while too large an amount impairs the penetratbility. Too large an amount of the low molecular weight polyorganosiloxane not only makes the system difficult to disperse but also reduces stability as a water system composition. A preferable fraction of the surfactant is 30 to 700 parts by weight, or, more preferably, 50 to 300 parts by weight, to 100 parts by weight of the polyoxyalkylene group containing polyorganosiloxane. A more preferable fraction of the low molecular weight polyorganosiloxane is between 10 and 1000 part by weight. While the fraction of water in the quaternary water system cleaning agent is not particularly limited either, it is preferable to have water 40 wt. % or more or, more preferably, 70 to 99.5 wt. % to the total composition from a stability viewpoint.
By the way, the polyoxyalkylene group containing polyorganosiloxane having in a single molecule at least one siloxy unit represented by formula (III) penetrates, as described above, into the interface between the stains and the substrate made of, e.g., a metal to which the stains adhere to "peel off" the stains. Thus, even a tertiary composition consisting of the polyoxyalkylene group containing polyorganosiloxane, a surfactant, and water may serve as a viable water system cleaning agent. In this case, the fractions of the quaternary water system cleaning agent will apply to the tertiary composition.
The fractions of the tertiary or quaternary water system cleaning agents may be so designed that the value to be obtained by a canvas method at room temperature for evaluating penetrability will be 15 or less, 10 or less, or 5 or less. For the evaluation, the canvas method specified as a fiber/textile test method by Japanese Industrial Standards (JIS) is adopted. Since the cleaning property of these water system cleaning agents depends on the pH value of the solution itself, it is desirable to adjust the pH value to the alkali region. The pH value is more preferably be between 8 to 14.
The tertiary or quaternary cleaning agents can be prepared easily by blending and stirring the above-mentioned polyoxyalkylene group containing polyorganosiloxane, a surfactant, water, or further the low molecular weight polyorganosiloxane represented by formula (I) or (II), where necessary. The use of a known dispersing device will help obtain a water system cleaning agent with ease.
The water system cleaning agents such as described above may have additives to be applied to ordinary water-soluble cleaning agents such as pH modifiers, adsorbents, solid particles, synthetic builders, rust preventives, and antistatic agents mixed as cleaning assistants or post-cleaning added-value improving agents and the like, depending on the property, amount, adhering state, cleaning condition, and the like of a stain. Such an addition may play an important part depending on their application.
The water system cleaning agents of the invention may be applied to metals, ceramics, plastics, and the like. More specifically, they may be applied to metallic parts, surface treated parts, electronic and semiconductor parts, electric and precision machinery parts, optical parts, glass and ceramic parts, and the like. An exemplary general-purpose cleaning process usually involves cleaning of any of the above-described parts by such a process as ultrasonic process, mechanical stirring and spraying, and thereafter, washing by water (preferably by pure water or ion-exchanged water), and is dewatered by drying the part with heated air or a like process. The cleaning composition in which the stain separated from the part is present is treated by, e.g., separating the stain through a filter or the like and thereafter by being subjected to a general waste water treatment process, thereby allowing the composition to be unhazardous and pollution-free easily.
According to the water system cleaning agent of the invention, the powerful penetrating property of the low molecular weight polyorganosiloxane represented by formula (I) or (II) for the interface between the stains and the substrate as well as the cleaning capability of the surfactant(s) to the stains provides a cleaning performance equivalent to that of the conventionally used flon containing cleaning agents. The use of the polyoxyalkylene group containing polyorganosiloxane in combination with the water system cleaning agents of the invention allows satisfactory dispersing property in water. In addition, when applied as a tertiary composition consisting of the polyoxyalkylene group containing polyorganosiloxane, the surfactant, and water, the cleaning agent of the invention exhibits excellent cleaning property by the penetrating capability of the polyoxyalkylene group containing polyorganosiloxane with respect to the stain. Being a water system agent, it will bring no risk of environmental destruction and pollution. Thus, it can be said from the above that the water system cleaning agent of the invention can be an attractive replacement for cleaning agents based on organic solvents containing flon and other substances which have considered hazardous.
A case in which a cleaning composition of the invention is used as a dewatering cleaning agent will now be described.
Here, the term "dewatering agent" is only so named after "water," which is a typical liquid capable of being substituted by the low molecular weight polyorganosiloxanes, and the cleaning compositions of the invention may also be used as "liquid removing" agents in substituting and cleaning liquids other than water. The applicable liquids may be those which are insoluble or difficult to be dissolved in the low molecular weight polyorganosiloxanes and whose surface tensions are larger than those of the low molecular weight polyorganosiloxanes. The "water" to be cleaned may include liquids using water as a dispersion medium such as mixtures of water and alcohols and liquids in which various substances are dissolved.
The low molecular weight polyorganosiloxane represented by formula (I) or (II) can be, as described previously, substituted by water alone, thus allowing itself to be easily vaporized and dried by hot air below 60° C.
Such a dewatering cleaning agent may consist substantially of the low molecular weight polyorganosiloxane and with it a satisfactory effect can be obtained. However, its cleaning and dewatering properties and the like will be further improved by forming it into a composition having the low molecular weight polyorganosiloxane mixed with a surfactant and/or a hydrophilic solvent.
The above-mentioned surfactants contribute to improving particularly the cleaning and dewatering property, and suitable surfactants to be applied to the invention include: anionic surfactants such as polyoxyalkylene alkylether sulfonates and phosphoric esters; nonionic surfactants such as polyalcohol fatty acid esters, polyoxyalkylene fatty acid esters, and polyoxyalkylene alkylethers; amphoteric surfactants such as imidazolin derivatives; and cationic surfactants such as alkylamine salts, alkyl quaternary ammonium salts. In addition thereto, terpene containing compounds which are rarely present in the form of a single substance and extracted from natural substances as well as higher fatty acid esters may also be applied. It is also possible to use synthetic compounds in which part of the chemical structure of each compound is substituted by a fluorine or silicon atom. However, it is more preferable to use nonionic surfactants if the effect as a dewatering cleaning agent used in combination with the low molecular weight polyorganosiloxane is to be further improved.
While the composition ratio of the surfactant is not particularly limited, it is desirable to have 20 parts by weight or less, or, more preferably, 3 parts by weight or less, of the surfactant to 100 parts by weight of low molecular weight polyorganosiloxane.
A suitable hydrophilic solvent may be one compatible with the low molecular weight polyorganosiloxanes, and more particularly, one whose flash point is 40° C. or more from the practical viewpoint. The hydrophilic solvent contributes to improving substituting property by water.
Suitable hydrophilic solvents include: polyalcohols and their derivatives such as ethylene glycol monomethyl ethers, ethylene glycol monoethyl ethers, ethylene glycol monopropyl ethers, ethylene glycol monobutyl ethers, ethylene glycol monobutyl ether acetates, diethylene glycol monobutyl ethers. Particularly preferable are diethylene glycol monobutyl ethers from the viewpoint of its compatibility with the low molecular weight polyorganosiloxanes and safety to the human body and the like. Since these compounds exhibit improved properties when coexisting with the low molecular weight polyorganosiloxanes, a composition only using this combination may allow substitution by water and drying.
While the composition ratio of the hydrophilic solvent is not particularly limited, it is preferable to have 100 parts by weight or less or, more preferably, 50 parts by weight or less of the hydrophilic solvent mixed with 100 parts by weight of the low molecular weight polyorganosiloxane.
The dewatering cleaning agents of the invention may be applied to metals, ceramics, plastics, and the like. More specifically, they may be applied to metallic parts, surface treated parts, electronic and semiconductor parts, electric and precision machinery parts, optical parts, glass and ceramic parts, and the like. An exemplary general-purpose cleaning process usually involves immersing of any of the above-described parts or spraying a dewatering cleaning agent of the invention onto the part to substitute it by water and drying by blowing hot air and the like. The immersing and spraying processes may be accompanied by an ultrasonic process and mechanical stirring.
The dewatering cleaning agents of the invention, exhibiting a powerful dewatering property, can not only provide cleaning and water-substituting effects equivalent to those of conventional cleaning agents containing flon and the like but also allow various materials to be stably cleaned with their low eroding action. In addition, containing no element halogen such as chlorine and bromine in general, the dewatering cleaning agents of the invention have few risk of destroying or polluting the environment. Thus, it can be said that the dewatering cleaning agents of the invention will be a viable replacement for the conventional organic solvent containing dewatering cleaning agents such as flon, which have been imposing the environmental problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an exemplary construction of a cleaning system using a dewatering cleaning agent of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described with reference to examples in which a cleaning composition of the invention is applied to water system cleaning agents.
Example 1
Two kinds (A1 and A2) of polyoxyalkylene group containing polyorganosiloxane, each represented by formula (V) and (VI), were prepared. ##STR8##
Then, the polyoxyalkylene denatured silicone (A1) represented by formula (V), polyoxyalkylene denatured silicone (A2) represented by formula (VI), sodium laurate (B1) and polyoxyethylene octylphenyl ether (B2) (20 moles of polyoxyethylene), both serving as surfactants, and water were weighed so that their ratio by weight will be 5:5:4:4:82. Thereafter, these components were charged into a homogenizing mixer for blending to obtain a water system cleaning composition P1.
Example 2
The polyoxyalkylene group containing polyorganosiloxane (A1), the sodium laurate (B1) and polyoxyethylene octylphenyl ether (B2), both serving as surfactants, and water were weighed so that they satisfy the composition ratio specified in Table 1. Then, a water system cleaning composition P2 was obtained as in Example 1.
Examples 3 to 5
The polyoxyalkylene group containing polyorganosiloxanes (A1) and (A2), dioctyl sodium sulfosuccinate (B3) that serves as a surfactant in addition to the surfactants (B1) and (B2), octamethyl tetrasiloxane (D1) and octamethyl trisiloxane (D2), both as low molecular weight polyorganosiloxanes, and water were selectively mixed to prepare water system cleaning compositions P3 to P5 having composition ratios specified in Table 1 in the same manner as that in Example 1.
Comparative examples 1 to 3
Three kinds of water system cleaning compositions were prepared in a manner similar to that of each of the above examples except that no polyoxyalkylene group containing polyorganosiloxane was mixed.
The properties as a cleaning agent were evaluated as to the water system cleaning compositions of Examples 1 to 5 and Comparative examples 1 to 3 by the following methods. The result is also shown in Table 1.
(1) Penetration test
Measurements were made based on the JIS-specified canvas method. The smaller value means better penetrating property; i.e., the composition is more effective in cleaning smaller parts.
(2) Cleaning property test
A sample is prepared by applying a spindle oil over a steel strip and baking it at 135° C. for 48 hours. The property is evaluated by the time spent for cleaning the oil baked on the sample (by ultrasonic cleaning). The smaller the value is, the better the cleaning property becomes.
(3) Stability test
Each composition was contained in a transparent bottle of 200 ml sealed thereafter and then heated at 50° C. for 6 hours. After being gradually cooled from 50° to 25° C., its appearance in the bottle is observed.
TABLE 1______________________________________ Comparative Examples examples 1 2 3 4 5 1 2 3______________________________________Composition ratio (wt. %)Polyoxyalkylene A1 5 0.5 1.0 -- 10 -- -- --Denatured silicone A2 5 -- -- 1.0 -- -- -- --Surfactant B1 4 0.8 0.3 0.3 4 1.2 0.8 0.8 B2 4 0.7 0.4 0.5 -- 0.8 0.7 0.7 B3 -- -- -- -- 0.5 -- 0.5 --Water 82 98 98 98 82 98 98 98Low molecular weight D1 -- -- -- 0.2 3.5 -- -- 0.5polyorganosiloxane D2 -- -- 0.3 -- -- -- -- --Evaluation resultPenetrability (Canvas 7 8 4 3 2 25 22 18method, in second)Cleaning property 14 14 12 11 7 22 23 17(in minute)Stability ST ST ST ST ST ST ST SEP______________________________________ Note: ST: stable SEP: separated
As is apparent from the result shown in Table 1, the water system cleaning agent of the invention exhibits excellent cleaning capability and penetrability, attesting to its availability as a replacement for the conventional solvent based cleaning agents containing flon and the like. With its stability, it is considered a highly practical product. In contradistinction thereto, the water system cleaning agents according to Comparative examples were satisfactory neither in cleaning capability nor in penetrability.
An exemplary process employed to clean a specific part using a water system cleaning agent of the invention will now be described.
Example 6
In fabricating a liquid crystal device, a liquid crystal cell is evacuated to a high vacuum degree and a liquid crystal material is sealed in a device. In this case, the evacuation is carried out by a high performance diffusion vacuum pump. Since the diffused oil enters into the vacuum system in the form of mist, the pump must be cleaned often to remove the oil.
In this example, the water system cleaning agent of the invention was used in lieu of a conventional triethane cleaning agent.
A pump part made of a stainless steel SUS304 and a Ni-plated stainless steel SUS304 material having an adhesion of Silicon Oil F-4 (trademark of Shinetsu Chemical) as a diffusion oil was cleaned.
The composition ratio of the used water system cleaning agent is as shown below.
That is, in 80 wt. % of ion-exchanged water being sufficiently stirred at ambient temperature, 6 wt. % of the polyoxyalkylene group containing polyorganosiloxane having the following chemical structure was gradually added to obtain an achromatic translucent homogenous solution. ##STR9##
On the other hand, as a surfactant, a mixture of 8 wt. % of special nonionic Adecanol B-4001 (trademark of Asahi Electrochemical) and 6 wt. % of anionic TWA-2023 (trademark of Ipposha Oil and Grease) of sulfuric acid ester PURLONIC structure was added to the above water/siloxane solution.
After diluting the water system cleaning agent thus obtained was diluted by ion-exchanged water at an arbitrary ratio, Silicone Oil F-4 was cleaned using the diluted cleaning agents. As a result, the pump part was satisfactorily cleaned: through immersion by stirring for 1 minute in a 1/10 diluted cleaning agent at ambient temperature; through immersion by oscillating for 1 minute in a 1/30 diluted cleaning agent at 40° C. or through 1 minute ultrasonic cleaning at 20° C. in the same cleaning agent; and through 1 minute ultrasonic cleaning in a 1/50 diluted cleaning agent at 50° C., respectively.
For comparison, the pump part was similarly cleaned with compositions containing only surfactant(s) and no polyoxyalkylene group containing polyorganosiloxane. Silicone Oil was not removed sufficiently with 10 or more minute immersion ultrasonic cleaning in a 1/10 diluted composition at ambient temperature. To remove Silicone Oil with this composition, it took more than 5 minutes at 65° C. or more.
It is understood from this data that the cleaning agent that incorporates the polyoxyalkylene group containing polyorganosiloxane of the invention exhibits an outstanding cleaning property.
Example 7
The polyoxyalkylene group containing polyorganosiloxanes and the low molecular weight polyorganosiloxanes of the invention contribute to significantly improve the cleaning capability of commercially available water-soluble cleaning agents.
An aqueous solution of Chemiclean MS-109 (trademark of Sanyo Kasei Kogyo), which is a surfactant containing, low foaming, rust preventive cleaning agent, is typically used to clean mechanical and metallic parts. Blending 3 wt. % of the polyoxyalkylene denatured silicon (A1) represented by formula (V) in Example 1, 5 wt. % of cyclic hexamethylcyclotrisiloxane, 17 wt. % of ion-exchanged water with 65 wt. % of the above aqueous solution, a new cleaning composition was prepared.
This new cleaning composition was 1/20 diluted by ion-exchanged water and its cleaning property was evaluated by the following method. The result is shown in Table 2. For comparison, the evaluation result of 1/20 diluted Chemiclean MS-109 was also shown.
Test Method
(1) Cleaning test--1
The following contaminants were applied to a degreased aluminum plate (AC-4A) by immersing, dried by blowing, and immersed while stirred (400 rpm) in respective cleaning agents (1/20 diluted) for 15 seconds to 1 minute. Then, after immersed in water, the aluminum plate was dried by blowing. Each contaminant was transferred on white paper through an adhesive tape for reflectance measurement by a colorimeter thereby to calculate the cleaning rate.
Contaminant:
______________________________________Spindle oil 78%Fatty acid ester 15%Chlorinated paraffin 5%Carbon black 2%______________________________________
Cleaning rate (%)=Rw-Rs/Ro-Rs
Ro: Reflectance of the original white paper
Rs: Reflectance of the standard contaminated plate
Rw: Reflectance of the contaminated plate after cleaned
(2) Cleaning test--2
A contaminant was prepared by adding 2% of carbon black to a water-soluble machining oil (emulsive), and the test was performed in a manner similar to that of Cleaning test--1. Its cleaning rate was similarly calculated.
TABLE 2______________________________________ Immersion time Cleaning rate (%) (second) Invention MS-109______________________________________Cleaning test - 1 15 72.4 59.0 30 86.5 65.2 60 100.0 67.8Cleaning test - 2 15 81.7 58.0 30 93.8 71.0______________________________________
Similar tests were conducted on EP-680 (trademark of E.P. Japan) which is a commercially available supereffective cleaning solution and water system cleaning agent; Banrise D-20 (trademark of Joban Chemical Industries) which is an emulsive degreased cleaning agent; and Hikari Ace (trademark of Shoko Trade) which is a powerful special cleaning agent. As a result, these cleaning agents, when used in combination of the polyoxyalkylene group containing polyorganosiloxane and the low molecular weight polyorganosiloxane of the invention, exhibited a significantly improved cleaning property.
Example 8
The water system cleaning agent of the invention exhibits remarkable effect on cleaning of fluxes used in mounting electronic parts on printed boards. The flux comes roughly in two types: rosin containing and water-soluble. A specific example of cleaning rosin containing fluxes, which is said to be a difficult task, will now be described.
As a step prior to soldering a part on a printed board, a WW rosin ester was put on a part and immersed in a solder bath at 230° to 250° C. and then the part was mounted. It was observed that the flux was completely removed when the printed board was shower-rinsed for 35° C. for 45 seconds using a water system cleaning agent described below.
The water system cleaning composition used here is prepared by blending 2 wt. % of the polyoxyalkylene group containing polyorganosiloxane represented by formula (VII), 3 wt. % of Senkanol FM (trademark of Nippon Senka), which is an amphoteric surfactant, 5 wt. % of Nikkol CMT-30 (trademark of Nippon Surfactant), which is a sodium-N-COCOIL methyl taurine containing nonionic surfactant, and adding ion-exchanged water to prepare 100 wt. % of the composition. ##STR10##
When acceleration aging tests which guarantees US MIL-F-14256C standard, surface insulation resistance tests, ion residual tests and the like were conducted on the above composition which was 1/10 diluted by ion-exchanged water, the results were satisfactory.
Examples in which cleaning compositions of the invention were applied to dewatering cleaning agents will now be described.
Examples 9 to 17
Octamethyltrisiloxane (El), octamethylcyclotetrasiloxane (E2), and decamethylcyclopentasiloxane (E3) were prepared as low molecular weight polyorganosiloxanes; polyoxyethylene oleyl ether (F1) (P.O.E =6 moles), and polyoxyethylene octylphenyl ether (F2) (P.O.E =10 moles) as surfactants; and diethylene glycol monobutyl ether (G1) as a hydrophilic solvent were prepared.
These components were selected and blended so that the composition ratio shown in Table 3 were satisfied to obtain respective dewatering cleaning agents.
Comparative examples 4 to 8
Flon 113, methylene chloride, isopropyl alcohol, and ethanol were prepared as conventional dewatering cleaning agents to obtain 5 types of dewatering cleaning agents whose composition ratios were as shown in Table 3.
The properties of Examples 9 to 17 and Comparative examples 4 to 8 were evaluated by the following methods. The result is also shown in Table 3.
(1) Dewatering property
Various pieces (a stainless steel strip, a ceramic piece, a polycarbonate piece, a Ni-plated steel strip) were immersed in each dewatering cleaning agent after washed by water. In examples 13 to 15, each piece was then rinsed by the low molecular weight polyorganosiloxane blended to prepare each dewatering cleaning agent. Thereafter, each piece was dried in an oven at 50° C. The water marks (a stain by impurities dissolved in water) after drying each piece was observed visibly and by a scanning electron microscope and evaluated in accordance with the following criteria.
XX: Not evaluable due to erosion of the piece during dewatering.
X: Water marks were visibly observed.
∘: No water marks were visibly observed.
⊚: No water marks whose size is 50 μm or more were observed by the scanning electron microscope.
(2) Continuous dewatering property
A continuous dewatering test with a frequency of 50 times were conducted on a stainless steel strip and the appearance of the strip was evaluated in a manner similar to that of item (1).
(3) Drying property
The stainless steel strip was immersed in each dewatering cleaning agent and dried in the oven at 50° C. During the drying process, the strip was touched by a finger to see the drying condition every 5 minutes and the time required for drying was recorded on a 5-minute basis.
TABLE 3__________________________________________________________________________ Examples Comparative examples 9 10 11 12 13 14 15 16 17 4 5 6 7 8__________________________________________________________________________Composition ratio(Parts by weight)Low molecular weight E1 100 -- -- 50 100 -- -- -- -- -- -- -- -- --polyorganosiloxane E2 -- 100 50 50 -- 100 100 100 -- 50 -- -- -- -- E3 -- -- 50 -- -- -- -- -- 100 -- -- -- -- --Surfactant F1 -- -- -- -- 0.3 0.3 -- -- -- -- -- -- -- -- F2 -- -- -- -- -- -- 0.2 -- -- -- -- -- -- --Hydrophilic solvent C1 -- -- -- -- -- -- -- 10 20 -- -- -- -- --Methylene chloride -- -- -- -- -- -- -- -- -- 50 100 -- -- --Freon 113 -- -- -- -- -- -- -- -- -- -- -- 100 96 --Ethanol -- -- -- -- -- -- -- -- -- -- -- -- 4 --Isopropyl alcohol -- -- -- -- -- -- -- -- -- -- -- -- -- 100Dewatering propertyStainless steel ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ◯ ◯ ⊚ ⊚ ⊚Ceramics ◯ ◯ ◯ ◯ ⊚ ⊚ ⊚ ⊚ ⊚ X X ◯ ⊚ ⊚Polycarbonate ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ XX XX ⊚ ⊚ XX*Ni plated strip ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ XX XX ⊚ ⊚ ⊚Continuous dewatering ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ◯ ◯ ⊚ ⊚ ⊚propertyDrying property 10 5 10 10 10 5 5 10 15 5 5 <5 <5 <5(50° C. in oven in minute)__________________________________________________________________________ Note: *Solvent cracks occurred.
As is apparent from the result shown in Table 3, the dewatering cleaning agents of the invention, exhibiting satisfactory dewatering property, can be a viable substitute for organic solvent containing flon and the like based cleaning agents.
Dewatering cleaning agents containing methylene chloride or isopropyl alcohol (Comparative examples 4 and 5) rust and erode metal films and plastics. In contradistinction thereto, the dewatering cleaning agents of the invention are stable to metal films and plastics and exhibit satisfactory dewatering property even to ceramics which have large surface roughness values, thereby ensuring their reliability when applied to parts including metal, plated, electronic, semiconductor, plastic, and ceramic parts. The dewatering cleaning agent containing isopropyl alcohol permitted water to be dissolved therein, thereby causing water to present on the part again.
Moreover, it is understood that mixing of surfactants and hydrophilic solvents with the dewatering cleaning agents of the invention improved the dewatering property, thereby attesting to their industrial applicability.
An exemplary cleaning system using a dewatering cleaning agent of the invention will now be described with reference to FIG. 1.
A cleaning system shown in FIG. 1 consists roughly of a cleaning/water-substituting process A and a rinsing/dewatering process B.
The cleaning/water-substituting process A, which is the first process involves a first cleaning vessel 1 and a second cleaning vessel 2, each serving both as a separator through sedimentation and a separator through overflow, and a dewatering vessel 3. The first and second cleaning vessels 1 and 2 communicate with each other through a drain line 2a and an overflow line 2b. The first and second cleaning vessels 1 and 2 are operated together with ultrasonic, oscillating, mechanical stirring, cleaning agent heating, and brushing processes and the like, if necessary.
The first and second cleaning vessels 1 and 2 respectively contain a cleaning agent D1 composed of a low molecular weight polyorganosiloxane and a surfactant, which is one of the dewatering cleaning agents of the invention. The surfactant containing cleaning agent D1 may be so prepared that its specific gravity is smaller than that of water and larger than that of an oily stain. Therefore, water Y introduced by an object to be cleaned X is separated by being sedimentated at the bottom of the surfactant containing cleaning agent D1 that has been charged in the first and second cleaning vessels 1 and 2. If an oily stain Z is present on the object X, the oily stain Z is separated by floating upward in the surfactant containing cleaning agent D1 in the first and second cleaning vessels 1 and 2.
The water Y separated by being sedimentated in the second cleaning vessel 2 is intermittently discharged to the first cleaning vessel 1 through a drain line 2a while the water Y separated by being sedimentated in the first cleaning vessel 1 is intermittently discharged to a cleaning agent recycling mechanism C (described later) through a drain line 4. A drain line 3a connected to the drainage vessel 3 is also connected to the cleaning agent recycling mechanism C.
The oily stain Z separated by floating in the first and second vessels 1 and 2 is discharged outside while continuously overflown through an overflow line 5 connected to the first cleaning vessel 1.
The surfactant containing cleaning agent D1 charged in the first and second cleaning vessels 1 and 2 is continuously circulated through a filter 6 that serves to remove solid particles, H 2 O particles, undissolved substances, and the like contained in the cleaning agent D1.
The rinsing/dewatering process B, which is the second process, involves a third cleaning vessel 7 and a shower rinse vessel 8. Below the shower rinse vessel 8 is a buffer tank 9 that communicates with the third cleaning vessel 7 through a drain line 9a and an overflow line 9b. The third cleaning vessel 7 is also operated together with ultrasonic, oscillating, mechanical stirring, cleaning agent heating, and brushing processes and the like, if necessary.
The third cleaning vessel 7 contains a cleaning agent D2 consisting only of a silicone composition identical to the low molecular weight polyorganosiloxane used in the first process A. The cleaning agent D2 may be so prepared that its specific gravity is smaller than that of water and larger than that of an oily stain. Therefore, as in the first process A, water Y is separated by being sedimentated at the bottom of the cleaning agent D2 and the oily stain Z is separated by floating upward in the cleaning agent D2.
The water Y separated by being sedimentated in the third cleaning vessel 7 is intermittently discharged to the cleaning agent recycling mechanism C through a drain line 10 while the oily stain Z separated by floating in the third cleaning vessel 7 is discharged outside through an overflow line 11.
The cleaning agent D2 charged in the third cleaning vessel 7 is continuously circulated through a filter 12 that serves to remove solid particles, H 2 O particles, undissolved substances, and the like contained in the cleaning agent D2.
The object to be cleaned X undergoes the first process A and then the second process B, cleaned and dewatered, and then dried by a fan forced drier (not shown) to complete the cleaning process.
The cleaning agent used in the cleaning system is subjected to the following recycling process.
As described above, the drain lines 4, 3a, 10 of the first, second, and third cleaning vessels 1, 2, and 7, and the dewatering vessel 3 are connected to the cleaning agent recycling mechanism C. The cleaning agent D1 or D2 contained in each cleaning vessel is constantly cleaned by the filters 6 and 12. However, when heavily contaminated, the cleaning agent is introduced to the cleaning agent recycling mechanism C through drain lines 4 and 10 by a conveyer pump 13 for fractional distillation. The cleaning agent D1 deposited in the dewatering vessel 3 is also supplied intermittently to the cleaning agent recycling mechanism C.
At the cleaning agent recycling mechanism C, the introduced cleaning agent is separated into liquid components and solid components by a filter 14, and only the liquid components are forwarded to a distiller 15 with the solid components being destroyed. The distiller 15 separates various components, water, oily stains in the cleaning agent utilizing the difference in their boiling points. Water and the like that remain in the distiller 15 are further separated by a decanter 16.
Since the cleaning agent D1 is an agent having a surfactant added to the cleaning agent D2 that contains only the low molecular weight polyorganosiloxane, the low molecular weight polyorganosiloxane, i.e., the cleaning agent D2, can be extracted from both cleaning agents D1 and D2, thereby allowing the cleaning agent D2 to be recycled. The components other than the recycled cleaning agent D2, i.e., the surfactant, water, and the like will be destroyed.
The recycled cleaning agent D2 is forwarded to a mixer 18 from which the cleaning agent D1 is supplied to the shower rinse vessel 8, the third cleaning vessel 7, or the second cleaning vessel 2 through a line 17.
In the shower rinse vessel 8, a shower rinsing process is conducted using only the recycled cleaning agent D2 or a cleaning agent D2 newly introduced through a cleaning agent supply line 19, both being free from impurities.
The mixer 18 mixes the recycled or new cleaning agent D2 with the surfactant newly supplied from a surfactant supply line 20 to prepare a new cleaning agent D1. The new cleaning agent D1 is supplied to the second cleaning vessel 2, if necessary.
With the cleaning system of such construction as described above, the dewatering cleaning agents of the invention can be used efficiently and effectively enjoying the advantage of excellent cleaning properties.
Industrial Applicability
As described in the foregoing pages, the cleaning compositions of the invention, when used as water system cleaning agents, exhibit a cleaning effect equivalent to that of conventional flon containing cleaning agents and an excellent stability as a water system with no risk of enviromental destruction and pollution, thereby making a viable replacement for the organic solvent based cleaning agents including flon and the like which have environmental disadvantages. In addition, the cleaning compositions of the invention, when used as dewatering cleaning agents, provide a powerful dewatering property with no risk of environmental destruction and pollution, thereby serving a viable replacement for the organic solvent based dewatering cleaning agents including flon and the like which have environmental disadvantages.
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A cleaning composition comprising at least one low molecular weight polyorganosiloxane selected from the group consisting of straight chain polydiorganosiloxane represented by a general formula: ##STR1## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and 1 is an integer from 0 to 5), and cyclic polydiorganosiloxane represented by a general formula: ##STR2## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and m is an integer from 3 to 7). To use it as a water system cleaning agent, polyoxyalkylene group containing polyorganosiloxane, a surfactant, and water are additionally mixed. Accordingly, a cleaning effect free from environmental destruction and contamination, equivalent to flon containing cleaning agents, and satisfactorily stable in terms of dispersion as a water system cleaning agent can be obtained. In addition, to use as a dewatering cleaning agent, the low molecular weight polyorganosiloxane is additionally mixed alone or with a surfactant and/or a hydrophilic solvent. Accordingly, cleaning and water substituting properties equivalent to flon containing dewatering cleaning agents and environmental safety can be obtained.
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BACKGROUND
1. Field of the Invention
This invention relates generally to devices for drawing cable or rope, and more particularly to power hoists for raising and lowering scaffolds and the like along a cable or a wire rope.
2. Prior art
(a) General history: The basic patent in this area is U.S. Pat. No. 3,231,240, which issued in 1966 to Ichinosuke Naito. It describes the concepts of using a chain-like member to press the cable into a peripheral groove in a driven sheave to obtain traction between the cable and the sheave, and applying the weight of the load to tension the chain-like member so that the traction on the cable is proportional to the load. The Naito patent was directed to stretching or moving the cable through the apparatus, with the tacit assumption that the apparatus was stationary.
Naito's invention, essentially the first generation of devices of its kind, made it possible to reliably tension and move cable of any length, without need of a drum on which to wind and store the cable. The improvement in bulk and weight were significant.
Many applications of this basic invention have since been developed. One line of such applications is the development of hoists for the movable scaffolds used in constructing and maintaining many kinds of structures, such as ships, bridges, dams and--most frequently--the exteriors of tall buildings. Such a scaffold moves up and down along cables or wire ropes that are anchored to the top of the particular structure. Generally unchanged are the basic principles of drawing the cable through the apparatus and pressing the cable into a peripheral sheave groove proportionally to the load. Here, however, what is stationary is the cable, and what moves is the apparatus--the hoist mechanism, a motor to power it, and of course the scaffold and its cargo and crew.
Among the patents directed to application of the Naito principles to scaffold hoists are U.S. Pat. No. 3,944,185, which issued in 1976 to Michael Evans, and U.S. Pat. No. 4,139,178, which issued in 1979 to Wilburn Hippach. The Evans patent introduced several features aimed at this specialized application--in particular, a secondary sheave used for at least three distinct purposes. One of these purposes was to tension the traction chain from both ends rather than only one end. Another purpose was to act as the driving end of a gear train to develop a mechanical output signal indicative of cable speed, for use in an automatic overspeed braking system. Yet another purpose was to help guide the unloaded end of the cable out of the apparatus.
Hippach provided further refinements directed to the reliability (particularly reliability under extreme operating conditions) and the convenience in use of the apparatus. The Hippach patent describes subtle features of the overspeed-brake gear train, designed to ensure smooth operation of the mechanism under extremely high accelerations; and also describes what could be called spring-preloading of the secondary sheave, to facilitate automatic reeving or "threading" of the cable through the apparatus.
Thus these patents may be regarded as the second generation of cable-drawing equipment developments, in the scaffold-hoist field. They were directed to producing optimum performance in terms of reliability and convenience.
Modern users of industrial equipment, however, demand more than this. The present age is extremely conscious of the usage of energy, particularly nonrenewable energy sources. The modern age is also extremely conscious of the usage of materials, particularly metals.
It has therefore become a matter of paramount concern to all manufacturers, and certainly to manufacturers of scaffold hoists, that apparatus be efficient in terms of energy usage, and that its construction use no more material than need be--while remaining just as reliable and convenient as before.
(b) Hoist weight considerations: Such concerns of course render it undesirable to construct hoists that are relatively heavy. Past hoists have not been greatly overweight, of course, and they have been the state of the art.
Still, under the modern conditions outlined above they may not have been optimum, both because of the relatively large amounts of metal that must go into their construction and because of the continuing costs of hoisting their own weight--to the extent of whatever "excess" weight they may have.
(c) Multiple-cable-size considerations--efficiency: Perhaps less plain, but equally significant in terms of energy and materials efficiency, is the undesirability of making several different models of hoists for use with cables of different sizes. It has been a standard practice in the hoist industry to make either different models, or models with different modules, for use with cables of different sizes.
The use of cables of different sizes arises from the various loads which scaffolds must carry, and to some extent from variety in the local safety statutes with which users must comply, and also from the special circumstances and preferences of users. Thus it is neither possible nor particularly desirable to eliminate nonuniformity of cable sizes in use.
Yet there are many inefficiencies in the practice of manufacturing different hoists for the different cable sizes. Such inefficiencies extend through warehousing, spare-parts maintenance, billing and bookkeeping systems, and communications complexity all along the distribution chain from manufacturer to user. In addition, for a user who wishes to use cables of different sizes within his own operations, for different scaffolding purposes, the expense and inconvenience of having to own more than one hoist model or module are particularly salient.
(d) Multiple-cable-size considerations--reliability of performance: For such a user the problems arising from ownership of different hoist equipment can also pose a procedural problem: constant vigilance must be exercised when personnel have been using one cable size and switch to another, to be sure that the right hoist has been selected for use with that other cable size--or, even more insidiously, to be sure that the right cable-size-dependent module has been selected.
Interestingly enough, the area in which cable-size-dependent modules have most prominently been introduced is the area of overspeed brakes. The practice of providing different brake components for use with different cables is particularly unfortunate in view of the fact that overspeed brakes, by their nature, are not actually placed into service until an overspeed condition (i.e., emergency) occurs.
Generally speaking, if a hoist being used with a cable of small diameter has attached to it a brake designed for use with a cable of large diameter, the hoist will operate to drive the scaffold up and down the cable; there is nothing inherent in the mismatch, but only the user's watchfulness, to prevent the user from proceeding--but generally if an emergency arises the brake will not work at all. In some cases the same problem is present when using a large-diameter cable and a brake designed for a small-diameter cable.
(e) Power-transmission systems: In another field, the field of mechanical power-transmission devices, certain basic developments have arisen which have never been used in hoists. U.S. Pat. No. 4,194,415, which issued in 1980 to Frank Kennington and Panayotis Dimitracopoulos, describes a "quadrant drive" system.
This system provides mechanical motion transmission with a large mechanical advantage, using extremely lightweight construction by comparison with conventional gear trains. Yet the quadrant drive has all the load-bearing and torque-transmitting capability of the heavier conventional gearing.
The quadrant drive accomplishes this by using an eccentric gear-like input drive wheel that drives a multiplicity of small drive pins at the periphery of the wheel. The drive pins are constrained to follow an ovoid path, about half of which path follows the teeth on the eccentric wheel (so that the drive pins are engaged with the teeth on the eccentric wheel), and the other half of which path is spaced away from those gears. The pins are simultaneously constrained to move in radial slots--or to bear against other drive-pin-engaging elements--in another wheel or plate.
Some manufacturers have introduced devices related to the quadrant drive, such as the Graham Company's "circulute reducer". The principal developer of the quadrant drive has been the Swiss firm Plummettaz S. A.
In some quadrant-drive devices the pins are always engaged with this second plate, and in others they are engaged with this second plate at least whenever they are on that part of their path which follows the teeth on the eccentric wheel. Moreover, as already mentioned, they are about half the time engaged with the eccentric wheel; thus the driving load is at all times borne by about half the pins, and by about half the teeth of the eccentric drive wheel, and by about half the radial slots (or other drive-pin-engaging elements) of the driven plate--rather than by only two or three gear teeth.
The result is a great improvement in torque-to-weight ratio, since a much more lightweight construction may be used to obtain the same load-bearing and torque-transmitting capability.
By their nature, however, quadrant (or circulute) drives are relatively bulky, and somewhat cumbersome to use in portable equipment--particularly equipment, such as scaffold hoists, in which space is at a distinct premium. If others in the hoist industry have taken note of the quadrant drive (and we have no indication that such an event has occurred) perhaps they may have been deterred by the seeming awkwardness of mating the lightweight--but somewhat cumbersome--quadrant drive to the traditionally and ideally compact scaffold hoist.
At least two other complications tend to teach away from the concept of using quadrant or circulute drives in scaffold hoists. First, such drives provide a mechanical advantage ratio that is--while relatively high for a single stage--somewhat limited in comparison with an entire conventional gear train. Typical single-stage commercial units have ratios no higher than sixty or seventy to one. Of course two-stage units (two quadrant drives connected in series) produce extremely high reduction ratios, as large as the square of the ratio produced by highest-ratio single-stage units--some 5000 to one. Two-stage units, however, would be all the more bulky and awkward, and for scaffold-hoist applications would lose a great deal of the torque-to-weight ratio advantage of the single-stage units.
Second, the mechanical advantage of a quadrant drive is not readily modified; that is to say, the drive has a mechanical advantage that is quite firmly built into the device. (In a conventional gearbox, by contrast, changing two spur gears at one end of the train or the other can provide desirable refinements of the overall reduction for particular applications.) Thus, even if quadrant drives were available with high enough single-stage reductions for scaffold hoists, their use in such applications would require hoist manufacturers (and some users) to stock and service a variety of drives with various reductions, to satisfy the gearing requirements of different hoist applications.
(f) Summary: The foregoing comments show that there has been a need in the scaffold-hoist industry for a third generation of hoists, substantially lighter in weight than those of the second generation but just as convenient and reliable, and capable of accommodating any of several different cable sizes without change of hoist--or hoist components. This need arises from considerations of energy and materials efficiency, and efficiency in general, and also from considerations of reliability in use.
These comments also show that the quadrant or circulute drive has some tantalizing benefits for the scaffold-hoist industry, but that certain inherent characteristics and certain commercial characteristics of the quadrant drive have seemed to make it incompatible with the requirements of such hoists.
SUMMARY OF THE INVENTION
The present invention is directed to a third generation of scaffold-hoist equipment. It provides an efficient, lightweight hoist, which therefore requires considerably less power to operate, and less manpower to move around when on the ground. It nevertheless has all the torque of previous models and is just as sturdy.
Moreover, this invention makes it possible for just one hoist model to be used for three or even more different cable diameters, an improvement which produces very significant economies in construction, warehousing, distribution and maintenance, as well as giving users more options for the use of their equipment.
The hoist of this invention has a housing in which and to which the other components are mounted.
This hoist also has a power transmission mechanism, which includes a case, an output drive shaft an input drive shaft, and some means of speed reduction connected between the input and output drive shafts. The output drive shaft, when driven, rotates relative to the case.
In accordance with the present invention, however, the output shaft is secured to the hoist housing, so that in use the case of the transmission mechanism rotates relative to the hoist housing. Furthermore, the hoist of this invention also has a cable-driving sheave that is secured to and rotated by the case of the transmission mechanism.
Since the sheave and the case must both be of relatively large diameter, in comparison with the input and output drive shafts of the quadrant drive, fixing the sheave to the case of the quadrant drive is a particularly beneficial arrangement. With this arrangement it is not necessary to provide a hub for the sheave, or to provide spokes or an intermediate annular portion between a hub and the periphery of the sheave. It is only necessary to provide the peripheral portion of the sheave--the outer grooved portion which drives the cable--as this outer portion can be bolted directly to the rotary case of the transmission mechanism.
Yet at the same time the output shaft of the transmission mechanism, or more accurately its two output shafts at its two ends, are readily mounted to the housing of the hoist, to effect a very firm attachment. Preferably both output shafts are positioned in mating apertures in the housing so that the transmission mechanism is held at both ends, but for simplicity and economy only one shaft is secured against rotation relative to the housing. One of the output shafts is concentric with the transmission-mechanism input drive shaft; advantageously it is this particular output-drive-shaft section that is secured against rotation relative to the corresponding housing wall.
It is advantageous to use a quadrant drive as the transmission mechanism in this system. The quadrant drive provides a combination of relatively lightweight construction and full torque-handling capability that is favorable for use in scaffold hoists. Moreover, the mounting system already described--in which the output shaft or shafts are secured to the hoist housing while the transmission-mechanism case rotates, carrying the sheave--tends to overcome the slight awkwardness of the quadrant drive in the context of a scaffold hoist.
Drive means are also included for applying torque to the input drive shaft of the transmission mechanism. These drive means include a motor (not necessarily electrical).
If the transmission mechanism is a quadrant drive, the drive means also preferably include a conventional speed-reduction mechanism mounted to the housing and transmitting such torque from the motor to the input shaft of the quadrant drive. This speed reducer advantageously is made up of a pair of spur gears, supplying roughly a two-to-one mechanical advantage--or, better yet a pair of spur gears that can be factory selected to supply approximately a two-to-one mechanical advantage or to supply other values of mechanical advantage appropriate for variant versions of the system.
This concept of using a hybrid power train (quadrant drive for sixty-to-one reduction, and conventional gearing for two-to-one additional reduction) has several advantages. It permits use of a standard commercial quadrant-drive model. It also adds only very slight additional weight in the single added gear stage, so that even though the torque-to-weight ratio of the two-to-one reducer is not as favorable as that in the quadrant drive, the overall detrimental impact is negligible. It also provides a part of the overall reduction mechanism in which fine-tuning of the total mechanical advantage can be selected to suit the particular application at hand--merely by selecting and installing any of various standard commercial gear pairs.
It should be noted that if a user mistakenly uses a hoist that has a gear pair that is inappropriate for the load, in greatest likelihood the scaffold will merely (1) operate too slowly, if the gearing is too high, or (2) not raise the load, if the gearing is too low. Either of these results will presumably be self-correcting, in the sense of calling the user's attention to the error.
(In the worst circumstances that are at all likely, a user might use a hoist with gearing ratio high enough to permit raising the load, but so low as to lug the motor. If the user does not observe that the scaffold is moving slowly and that the motor is overheating, conceivably this condition could result in burning out the motor. If this occurs, and the motor-overload section of the control circuit fails too, one end of the scaffold might fall quickly enough to actuate the overspeed brake. Even this worst-case possibility, though plainly to be avoided, does not in itself pose the kind of intense hazard discussed earlier in regard to variable overspeed-brake modules.)
The cable-driving sheave has a tapered groove defined in its periphery. A cable in use is pressed into this groove, with force proportional to the load on the cable, to such a depth that the frictional force between the cable and the walls of the groove is sufficient to ensure adequate traction for the load.
The total depth of this groove is made sufficient to accommodate any of a selected multiplicity of cable diameters, by seating of the cables at a corresponding multiplicity of positions relative to the total groove depth. In other words, cables of different diameters seat at different depths in the groove. (In previous hoists, sheaves were provided with tapered grooves, and the groove depth was sufficient to accommodate the range of forces required for a single cable size; this condition remains in the present invention, but the depth must be even greater because of the need to seat small-diameter cables in a narrow region nearer the bottom of the groove, and large-diameter cables in a wide region nearer the top of the groove.)
The hoist of the present invention also has some means for guiding cables into the groove of the sheave. These guiding means are fixed relative to the hoist housing, and may take the form of an entry aperture in the top of the housing, together with suitable contouring of the housing interior. More elaborate provisions, such as a diverter block, may be made if desired.
In addition the hoist of the present invention has some means for supporting at least one end of a scaffold or like load. These means are coupled to the housing, but the coupling may be either direct or indirect. For example, the scaffold-supporting means may be in essence a hook firmly attached to the base of the hoist housing, for attachment of the scaffold; in this case, to press the cable into the groove of the sheave with a force proportional to the load on the cable, some separate arrangement must be provided for determining the tension on the cable.
Alternatively the scaffold-supporting means are coupled to the hoist housing indirectly--through the intermediary of the mechanism which presses the cable into the groove of the sheave. In this way the weight of the scaffold, equipment and personnel are applied directly to that latter mechanism, and a simpler overall configuration results. This alternative will be illustrated and described in some detail, below.
As to the mechanism which presses the cable into the groove, the hoist of the present invention also includes a chain-like member that is disposed around a certain portion of the circumference of the sheave. This chain-like member is connected--in one of the manners described above--to be tensioned by whatever weight is suspended from the scaffold-supporting means, and is adapted to press the cable into the groove of the sheave.
The chain-like member has a multiplicity of rollers that are disposed in a sequence around the portion of the sheave circumference just mentioned. Each roller is enlarged in diameter at its center to extend into the groove of the sheave--and diminished in diameter at its ends to clear the extreme periphery of the sheave, when any of the selected multiplicity of cable diameters is in use. That is to say, each roller has a large enough diameter at its center, and a small enough diameter at its ends, that it can engage and effectively compress into the tapered groove even the smallest-diameter cable (of those for which the apparatus is intended), seated near the bottom of the groove, while clearing the outer rim of the sheave.
The chain-like member also has a multipicity of side bars, with holes defined in their ends for journalling of the ends of the rollers and for connecting adjacent rollers together. The combination of rollers and side bars thus in fact connects the adjacent rollers in a continuous configuration to function analogously to a chain--that is, to sustain tension applied to the two ends of the chain-like element. Each side bar is disposed axially outboard of the sheave, at one side or other of the sheave, to axially clear both the periphery and the side of the sheave.
The side bars advantageously extend radially inward, from the periphery of the sheave toward the center of the sheave, and thereby capture the sheave closely between them. This construction opposes any tendency for the chain-like member to ride axially off the sheave, and also opposes any tendency for the cable, even if it is damaged, to escape from the sheave. The advantages of this construction are considered particularly useful under adverse circumstances, such as severe accelerations or other violent stresses acting upon the mechanism.
The best system known for applying the weight of the scaffold and its load to tension the chain-like member makes use of two levers in series. The system also has some means for securing one end of the chain-like member to the housing. The first lever is rotatably fixed to the housing and secured to the other end of the chain-like member. The second lever, also rotatably fixed to the housing, has the scaffold-supporting means depending from it and is pivotally secured to the first lever. Thus in this case the coupling of the scaffold-supporting means to the housing is indirect, via the chain-like member.
With this configuration, the weight suspended from the scaffold-supporting means is applied to the second lever, and thereby to the first lever, and thereby in turn to the chain-like member. The weight and the two levers thus apply tension to the chain-like member in proportion to the magnitude of the weight, the constant of proportionality being determined by the relative dimensions of the lever arms.
Furthermore, the operation of this system and the overall performance of the hoist as well as its compactness can be optimized by arranging the housing features and the levers as follows. The housing should have a cable-entry point that is substantially aligned along a plumb line tangent with the periphery of the sheave. The housing also provides a route for the cable which passes from the entry point downward into tangential engagement with the sheave, and remains in engagement around substantially three-quarters of the circumference of the sheave to a point generally above the center of the sheave. The chain-like member is secured to the housing at a point very nearly above the center of the sheave.
The first lever is secured to the chain-like member at a point approximately halfway--following along the periphery of the sheave--between the bottom of the sheave and the tangent point of the plumb line with the periphery of the sheave. The chain-like member, consequently, engages the cable around generally five-eighths of the circumference of the sheave, to press the cable into the sheave groove along this entire distance. The second lever is pivotally secured to the first lever at a point that is at most only very slightly outboard, relative to the sheave, from the plumb line mentioned earlier. The other linkage points are all inboard from the outboard pivot point just mentioned. This geometry satisfies the desired condition that the scaffold-supporting means be suspended at a point substantially along the plumb line from the entry point, without necessitating extension of the mechanism significantly outboard from that plumb line.
The hoist of the present invention also has a resettable overspeed brake that is mounted to the hoist housing. The brake has some means for sensing the cable speed. These sensing means are adapted and disposed to respond to the velocity of the cable relative to the housing, and to provide an actuating signal. This signal may be mechanical, or electrical, or may take other forms. The brake also has an automatic trigger that is mounted to the housing, and is positioned and adapted to be actuated by the signal from the cable-speed sensing means.
The brake also has a cam that is rotatably mounted to the housing. This cam is provided with some means for spring-loading it into a cocked position out of contact with the cable. These spring-loading means are anchored against the housing. The cam is adapted to be released by the trigger, to rotate into contact with the cable.
The cam has a range of diameters sufficient to accommodate any of the selected multiplicity of cable diameters.
In use, when the overspeed mechanism actuates the trigger, the trigger allows the cam to be rotated by the spring-loading means into a position in which the cam jams the cable against a backup block. The cam has a range radii sufficient not only to provide the necessary wedging or jamming action against the cable, but also sufficient to provide such action for any of the cable sizes of interest.
Thus, as with the extended depth of the sheave groove, the innovation in this area may be seen as extending the range of dimensions from that required for operation with a single cable size to that required to accommodate multiple cable sizes. The cam acts upon cables of different sizes identically, except that the cam rotates further to engage smaller cables, and rotates less far to engage larger cables.
In other words, the rotary cam jams a cable of any of the sizes for which the device is intended, at correspondingly various rotary positions of the cam, or cam angles.
The previously mentioned backup block--which keeps the cable from retreating from the cam--slides away from the cable at an angle during resetting, to facilitate unjamming the cable by moderate force. It is spring-loaded in the opposite direction, to ensure that if the overspeed trigger operates the backup block will be close enough to the cable to back up the cable and thereby promote the jamming action of the cam.
Using the principles outlined above, a single apparatus could be economically constructed to accommodate a great many different cable sizes with excellent performance. Based on the cable sizes currently in popular use for scaffold hoists, however, it is considered preferable to provide a hoist according to the present invention that is capable of use with three standard metric cable diameters--eight, nine, and ten millimeters. For all practical purposes, eight- and ten-millimeter cables are equivalent to five-sixteenths- and three-eighths-inch cables, these being standard cable diameters in the U.S. (formerly Imperial) system of measure.
Of course the hoist of our invention operates equally as well with cables having any diameter between eight and ten millimeters, but such cables are rarely encountered.
All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the appended drawings, of which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of the exterior of a scaffold hoist that is a preferred embodiment of the invention.
FIG. 2 is an end elevation of the same embodiment.
FIG. 3 is an exploded isometric view of the power-transmission system of the embodiment of FIGS. 1 and 2.
FIG. 3 a is a block diagram, also including some electrical details, showing the mechanical and electrical connections to a primary-brake system that is a part of that same embodiment.
FIG. 4 is an elevation showing the traction system of the embodiment of FIGS. 1 and 2.
FIG. 5 is a plan view of the chain-like member used in the FIG. 4 traction system, but here shown extended. (To preserve a reasonable drawing scale, only the three rollers at each end of the chain-like member, along with their associated side bars, are illustrated; the intermediate rollers and side bars are omitted.)
FIGS. 6 through 8 are elevations, partly in section, showing the detailed engagement of the traction system of FIG. 4 with cables of three different sizes, respectively.
FIG. 9 is an elevation, partly broken away, showing an overspeed braking system used in the embodiment of FIGS. 1 and 2, from the right side (as viewed in FIG. 1).
FIG. 10 is a similar elevation showing the FIG. 9 braking system from the left side (as viewed in FIG. 1) --that is, from the same viewpoint from which FIG. 2 is taken.
FIG. 11 is a detailed view of part of the overspeed braking system, taken along the line 11--11 in FIG. 10, looking down.
FIG. 12 is another detailed view of part of the overspeed braking system, taken along the line 12--12 in FIG. 10, looking up (at a slight angle to the vertical).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. GENERAL ORIENTATION
As seen in FIG. 1, the present invention provides a scaffold hoist that includes a housing having two sections --a leftward housing section 11 and a rightward housing section 12--which enclose most of the power-transmission and traction portions of the hoist. A stirrup or hook 13 hangs below the leftward housing section 11 for attachment of the scaffold (or other like load).
Attached to the left side of the leftward housing section 11 is a preliminary speed-reducer section 14, which is part of the drive means of the hoist. Attached to the left of the preliminary speed-reducer 14 is a motor 15, which may be electrical, pneumatic or even hydraulic. The end grille 17 provides needed ventilation if the motor 15 is electrical.
Conveniently secured to the casing of the motor 15 is an electrical control box 16, on which is mounted in turn an "up/off/down" power switch 16' for controlling the motor.
A primary brake assembly 21 is secured to the rightward hoist-housing section 12. This brake is controlled by the "up/off/down" power switch, in reverse parallel with the motor 15--so that the primary brake is on whenever the apparatus is not set to power upward or downward along the cable 25.
Mounted to the top of the housing sections 11 and 12, near their front panels, is an automatic overspeed brake assembly 24. At the top of this assembly is a port 26 for entry of the cable 25 along which the hoist is to operate. The top of this cable 25 must be secured to the structure which is to be built or maintained by use of the scaffold. A manual actuator for the brake appears at 151.
A second overspeed brake assembly 24a is recommended, though the hoist can be built and used without it. The second brake assembly 24a accepts an independent cable 25a that is not normally loaded, but serves--with the second brake assembly 24a--only as a backup in case the main cable 25 or the first overspeed brake assembly 24 fails.
2. POWER-TRANSMISSION SYSTEM
FIG. 3 illustrates the power-transmission system (except for the motor 15) of the preferred embodiment of FIGS. 1 and 2.
This description focuses first upon those parts of the power-transmission system that are essentially independent of the type of speed-reducing mechanism used. FIG. 3 shows the leftward and rightward sections 11 and 12 of the hoist housing, just as shown in FIGS. 1 and 2. Formed in these housing sections 11 and 12 are apertures 36 and 37, respectively. These apertures receive the output drive shaft sections 31 and 35, respectively, of the speed-reducing mechanism.
Aperture 36 is internally splined, to mate with the external splines 32 of the corresponding output drive shaft section 31. In this way the output drive shaft section 31 is secured against rotation relative to the hoist housing. As will be seen, the two output drive shaft sections are fixed angularly relative to each other; consequently, holding just one output drive shaft section 31 suffices to prevent both sections 31 and 35 from rotating relative to the housing.
The case of the speed-reducing mechanism is in two half-case sections 41 and 43, with an intermediate section 84. These three parts are fastened to each other and to the sheave 51, as by bolts 46--which pass through the clearance holes 44 in the rightward half-case section 43, the further holes 45 in the intermediate portion 84, and the further holes 42 in the leftward half-case section 41; and thread into the tapped holes 52 in the sheave 51.
In operation, torque from the motor 15 (FIGS. 1 and 2) is applied to the input shaft 71. Due to the operation of the speed-reducing mechanism, corresponding torque is generated between the case 41-84-43 and the output drive shaft sections 31 and 35. Since the output shaft sections 31 and 35, as already explained, are kept from turning relative to the hoist housing 11-12, the case 41-84-43 rotates within the housing 11-12. The sheave 51, being bolted to the speed-reducer case 41-84-43, rotates with that case.
The sheave in turn drives the cable 25 (FIGS. 1 and 2), by means of traction between the cable and the internal walls of a tapered peripheral groove 53 in the sheave, as will be explained in detail below.
The input shaft 71 has an extension 72 which protrudes through the aperture 37 in the rightward housing section 12, into engagement with the primary brake assembly 21 (FIG. 1). The action of the primary brake assembly 21--to hold the hoist at a particular position along the cable--is thus achieved by holding the input-shaft extension 72, and thereby the entire speed-reducing mechanism and the sheave 51.
FIG. 3a illustrates the general principle of the primary brake 21a, which as shown is mechanically connected to the input-shaft extension 72. The motor 15, the input shaft 71, the transmission 40, and the part 81 of the input shaft that is within the transmission 40 are all shown schematically in FIG. 3a.
A brake-actuating spring (or "actuating spring means") 21b is mechanically linked at 21c to the primary brake 21a, in such a way that when the electrical power is interrupted the spring 21b forcibly applies the brake 21a to immobilize the input drive shaft extension 72--and thereby the entire mechanism, including the sheave and cable. This condition obtains when there is no electrical power at the input, or when the switch 16' is set to its "stop" position.
When electrical power is available at the input to the system, and the operator sets the switch 16' to its "up" or "down" position, one pole of the switch 16' transmits the electricity to the motor 15 via its corresponding "up" or "down" terminal (and, in one case or the other, via a phase-reversing capacitor 15'). The motor 15 then delivers torque to the input drive shaft 71. The shaft 71 transmits this torque to the transmission 40, and thereby to the sheave and cable.
It will be noted, however, that there is a second pole of the switch 16', in parallel with the pole which energizes the motor 15. Simultaneously this other pole of the switch 16' transmits electricity to the brake-suppression mechanism (or "powered means for overcoming the spring means") 21d, and that mechanism disengages the primary brake 21a by means of a mechanical linkage at 21e. (As will be clear from FIG. 32, if preferred the brake-suppression mechanism 21d may be made to operate upon the brake-actuating spring 21b rather than operating upon the primary brake 21a.)
This system works to ensure that whenever the motor 15 is not turned on, to power the hoist up or down the cable, the primary brake 21a is applied to hold the hoist firmly at its then position along the cable. The system is fail-safe in the sense that proper application of the brake is independent of the availability of electrical power. When the motor 15 is turned on, the brake 21a is released.
Depending upon the type of speed-reducing mechanism used, the motor 15 may mount directly to the left side of the leftward housing section 11, or (as illustrated in FIGS. 1 and 3) to a mounting flange 14a (FIG. 3) which forms part of a preliminary reducer section 14 (FIG. 1). In either case the input drive shaft 71 (FIG. 3) must be suitably coupled to the motor.
Now when the main speed-reducing mechanism is a quadrant drive, or one of its variants such as a circulute drive, it is desirable to provide a preliminary reducer section such as that shown in FIG. 3: leftward gearbox section 14a, rightward gearbox section 14b, conventional spur gears 63 and 64, and input and output shafts 62 and 65. The rightward gearbox section 14b is fastened--as by stud, nut and washer combinations 91--to the outside of the leftward housing section 11. The two gearbox sections 14a and 14b are held together as by bolts 92.
The input shaft 62 extends through the leftward gearbox section 14a--which as mentioned also serves as mounting flange for the motor 15. The output shaft 65 extends through a bushing 66 formed in the rightward gearbox section, and through the large splined aperture 36 that is formed in the leftward housing section 11.
Connection between the preliminary-reducer output shaft 65 and the main-speed-reducing-mechanism input drive shaft 71 is provided by a hexagonal coupler 67, which rides in mating hexagonal sockets in the respective ends of the two shafts 65 and 71.
The preliminary reducer section compensates for the fact that single-stage quadrant and circulute drives are impractical or at least currently unavailable in reduction ratios exceeding about seventy to one. The preliminary reducer also permits customizing the apparatus to particular applications by selection of the reducing spur gears as a pair--to maintain the necessary spacing between the input and output shafts 62 and 65, while varying the tooth ratio on the spur gears 63 and 64.
Nominally, spur gears 63 and 64 are selected to provide a two-to-one reduction, and the main reducing mechanism provides a sixty-to-one reduction, for an overall ratio of 120 to one.
As to the quadrant or circulute drive itself, the input shaft 71 is made integral with an eccentric shaft 81. This eccentric shaft acts through rollers (not shown) against the internal circular-cylindrical surface of a roller-bearing race 93. This race 93 forms the central hub of a sprocket wheel 82 that has peripheral teeth 94. By virtue of riding on the eccentric shaft 81, the sprocket 82 revolves around the centerline 95 of the mechanism.
The intermediate casing portion 84 mentioned earlier is actually a functional part of the speed-reducing mechanism--a capture gear, having internal teeth 96 for receiving and holding a multiplicity of drive pins 83. Since the capture gear is bolted to the casing sections 41 and 43, the drive pins 83 are fixed relative to the casing 41-84-43 of the quadrant drive. As the sprocket 82 revolves about the mechanism centerline 95, its external teeth 94 engage whichever of the drive pins 83 are held in the internal teeth 96 of the capture gear 84 at an angle corresponding to the revolution angle of the sprocket 82.
For example, when the sprocket 82 is directly above the centerline 95, its upper teeth engage those drive pins that are held in the capture gear teeth directly above the centerline 95--and a certain number of drive pins to both sides of that position, approaching as many as one-third to one-half of all the pins, for favorable designs. (As previously mentioned, this multiple engagement spreads the torque over many more teeth of the sprocket and capture gear than the two or three teeth that bear the load in conventional gearing systems.) When the sprocket 82 is below the centerline 95, its teeth 94 engage those drive pins 83 that are held in the teeth 96 of the capture gear 84 below the centerline, and so forth.
By virtue of this engagement between the sprocket 82 and (via the drive pins 83) the case-integral capture gear 96, the sprocket 82 is prevented from spinning freely on the eccentric shaft 81. The sprocket 82 in fact is constrained to rotate systematically relative to the capture gear 84--by exactly as many tooth spacings per revolution of the eccentric shaft 81 as the difference between the number of teeth 94 on the sprocket 82 and the number of teeth 96 inside the capture gear 84.
The speed-reduction ratio of the mechanism is equal to this difference (a measure of the change in angular position of the sprocket 82 per rotation of the eccentric shaft) divided by the total number of teeth on the sprocket 82 (a measure, in compatible units, of the change in angular position of the eccentric shaft 81 per rotation of the eccentric shaft).
For example, if there are sixty teeth 94 on the sprocket 82 and sixty-one teeth 96 on the capture gear 84, the difference is thus made equal to one, and the quotient is one divided by sixty: the angular velocity of the output drive shafts 31 and 35 is one-sixtieth the angular velocity of the input drive shaft 71, and the mechanical advantage is sixty to one. These principles of operation of the quadrant drive may be further understood from the earlier-mentioned patent to Kennington and Dimitracopoulos.
In the particular embodiment illustrated in FIG. 3, the rotation of the sprocket 82 is transmitted to the output drive shafts 31 and 35 by means of twelve "axle" pins 86. These pins 86 ride within the bushings 85 in the sprocket 82 and extend into the holes 87 and 88 in "torque reactors" 33 and 34, respectively, at the two sides (axially) of the sprocket 82. The holes 87 and 88, and the ends of the axle pins 86, are mutually sized to accommodate the eccentric motion of the sprocket while maintaining driving engagement between the axle pins 86 and the interior surfaces of the holes 87 and 88.
In this way the rotational motion of the sprocket is transmitted to the torque reactors 33 and 34, and these elements are respectively integral with the output drive shafts 31 and 35. Consequently the sprocket motion is transmitted to the output drive shafts 31 and 35. The output drive shafts 31 and 35 ride within large ball bearings 73, which are fitted into recesses in the casing sections 41 and 43 respectively.
To reduce vibration, two counterweights 89 are fixed to the input shaft 71 and its extension 72, respectively, at the two sides (axially) of tne eccentric shaft 81--which is to say, one on each side (axially) of the sprocket 82. These two very compact counterweights 89 are weighted and angularly positioned to counterbalance the eccentric motion of the sprocket 85 and axle pins 86.
3. TRACTION SYSTEM
FIGS. 4 through 8 illustrate the traction system used in the preferred embodiment of FIGS. 1 and 2. In particular FIG. 4 is an elevation looking toward the inside wall of the leftward housing section 11, from the right (as shown in FIG. 1). Prominent in this drawing is the sheave 51, with its peripheral surface 54, tapped mounting holes 52, and inner circular hole 56. The inside wall 11 is visible at the periphery of the drawing, and also at the center of the drawing by virtue of the central hole 56 in the sheave 51.
In this inside wall 11 there appears--through the hole 56 in the sheave--the internally splined aperture 36 that was discussed above in relation to FIG. 3. Through this aperture, in turn, may be seen the outside wall of the gearbox section 14b, the preliminary-reducer output shaft 65 (running in bushing 66 in the gearbox section 14b), and the hexagonal coupler 67 received in a hexagonal socket in the end of the output shaft 65--all of which were also shown in FIG. 3 and discussed in relation to that drawing.
Entering from above right in the illustration is a cable 25 (shown also in FIGS. 1 and 2), following a plumb line 106 that is generally tangent to the sheave periphery 54, though slightly inward radially from the extreme periphery. This cable follows a path around roughly three-quarters of the sheave circumference, to a point just below a post 101 that is fixed in the inside wall 11.
In a very general way the cable continues as toward 25' to follow the sheave periphery 54. As will be understood shortly, however, in the area 25' to the right of the post 101 the cable is neither under tension nor pressed against the sheave, whereas it is tensioned in the first 270 degrees (roughly) of its path around the sheave, and it is pressed against the sheave in the last 225 degrees (roughly) of those 270 degrees.
Pivotally secured to the post 101 is one end of a chain-like member 112a through 112k, also shown in FIG. 5, which wraps around the sheave 51. This chain-like member is made up of two kinds of side bars--on each side eleven inside bars 112a, 112b, . . . 112j and 112k, and ten outside bars 113a, 113b, . . . 113i and 113j --and twenty rollers 141a through 142j (see FIG. 5), with corresponding bushings 114a through 115j. The bushings 114a through 115j act as pins to hold the side bars together in the sequence illustrated.
The rollers 141a, 141b, . . . 141i, 141j, and 142a, 142b, . . . 142i, 142j all act to press the cable 25-25' into the peripheral groove 53 (FIGS. 3, 6, 7 and 8) of the sheave. By friction between the groove wall 53 and the sides of the cable, the sheave obtains traction on the cable.
As seen in FIG. 5, the first traction roller 141a rides on a bushing 114a; as seen from FIG. 4, this bushing is above and just to the right of the center 57 of the sheave. The last traction roller 142j (FIG. 5) rides on a bushing 115j, which is (FIG. 4) approximately halfway along the circumference of the sheave between the tangent point to the plumb line 106 and the lowermost point of the sheave. Thus the traction rollers extend around roughly five-eighths of the circumference of the sheave, or approximately 225 degrees, as previously mentioned.
These figures represent almost the same "wrap" angle obtained through the use of the auxiliary sheave introduced by Evans, but with a far simpler mechanism. The mechanism is in fact only slightly more elaborate than that of the basic Naito patent, but wraps traction rollers around fifty percent more of the sheave circumference than the Naito design.
The same benefits may be seen even more clearly in terms of the number of rollers. The present invention provides twenty such rollers, which is the same as the Evans device and twice as many as the Naito device.
The key to these advantages resides in the specific geometry of the linkage 121-122-123-124-13, which applies the weight of the load to tension the chain-like member 112a-112k. To tension this chain-like member it is necessary to pull the final link 112k rightward (as drawn in FIG. 4); however, to keep the entire mechanism from canting into an unfavorable orientation it is also necessary to align the hook or stirrup 13 (FIGS. 1, 2 and 4) along the plumb line 106 directly below the cable entry point. These two constraints tend to be in conflict.
Prior devices following the Naito design have let the second of these constraints control--meaning that the final link in the chain-like member has been placed well to the left of the plumb line, to leave enough room for a lever arm between the final link and the plumb line. The Evans principle resolved this conflict by deflecting the cable substantially and in a relatively elaborate way, and by providing a relatively elaborate mechanism.
The present invention accommodates both constraints with a relatively simple mechanism--by using a dual-lever linkage to, in effect, fold the motion over upon itself so that the final link 112k itself can extend almost to the plumb line 106. The first lever in the linkage is 121-122; this lever is pivoted about a post 103 that is secured in the housing wall 11. One arm 121 of this first lever is connected by a pin 117 to the final link 112k; another arm 122, at the other end of the lever, is connected by another pin 125 to the second lever 123-124.
The second lever 123-124 is pivoted about a post 104 that is secured in the housing wall 11. The full length of the second lever 123-124 is used as one lever arm, between the fulcrum post 104 and the pin 125 that connects the two levers together; and the partial length 124 serves as another lever arm, between the fulcrum post 104 and another pin 126, which supports the scaffold stirrup 13.
The interlever linking pin 125 is journalled in the end of one lever arm 123 of the second lever 123-124, but rides in an elongate slot 131 in the arm 122 of the first lever 121-122. The use of a slot 131 rather than a circular hole accommodates the need for a variable effective lever arm 122--that is, an arm of length that is different for different positions of the lever arms. Different positions of the lever arms result from (1) the use of different cable diameters, as will be seen from the following discussion, and from (2) different scaffold loads, and hence different amounts of tension on the chain-like member.
The stirrup 13 similarly is provided with an elongate slot 132 for the linking pin 126 to the second lever, to allow for some forcible upward motion of the scaffold without drastic loss of tension and traction at the cable.
To hold the chain-like member nominally in position when there is no weight on the stirrup 13, the final link 112k is lightly tensioned in the direction indicated by the arrow 102 in the drawing; this tension is applied by a spring 105, with an anchor point (not shown) on the housing.
Also retaining the chain-like member in position under various unstable conditions--as, for instance, when the cable is snapped or whipped by externally generated forces, or when the scaffold falls abruptly, actuating the overspeed brake--are radially inward extensions 116a through 116k of the corresponding inner links 112a through 112k. These radially inward extensions 116a through 116k, extending toward the center 57 of the sheave, ride rather closely at the sides (axially) of the sheave.
They make it very unlikely that high accelerations of the equipment--or even breaking or "birdcaging" of the cable--will disrupt the engagement of the chain-like member with the sheave, or will lead to escape of the cable from the cable path formed between the sheave and the chain-like member. This feature is particularly important when the equipment is used with large-diameter cables, which, as will be seen, tend to ride very high in the groove 53 of the sheave and thus to place the innermost surfaces of the traction rollers 141a, etc., well outside the groove 53 of the sheave.
To prevent the loose segment 25' of the cable from chafing against the tensioned vertical segment 25 of the cable, the loose segment 25' is passed over a guide 55--forward of the tensioned segment 25--to an exit aperture 11" in the rear wall 11' of the leftward housing section 11.
FIGS. 6 through 8 illustrate the way in which the traction system of the present invention accommodates cables of different diameters. The sheave 51 appears in section at the bottom of each of the three drawings, and a typical traction roller 141--with ends 118 turned down to a smaller diameter--appears at the top. The bushing 114 is shown in each drawing, extending through the center of the roller 141 and into the inner side bar 112. The radially inward extensions 116 of the inner side bar 112 are also shown. (The outer side bar 113 and the rivet-like enlargement of the bushing 114 on the outside of the outer side bar 113, however, are omitted.)
FIG. 6 illustrates these components in use with a cable 25a of the largest diameter which the device can accommodate. The cable cross-section is literally wedged into the groove. In other words, by the principle of the inclined plane, the tension in the chain-like member is multiplied by a mechanical advantage related to the taper angle of the groove 53, to produce extremely high pressure between the cable and the groove (when the tension on the chain-like member is high). The cable is flattened slightly at areas of contact with the tapered groove 53--one such contact area at each side of the sheave's central plane. The result is extremely effective traction.
These contact areas extend very nearly to the periphery 54 of the groove--but not quite. If the cable were to touch the "corner" between the groove 53 and the peripheral surface 54, the resulting truncation of the contact area would cause at least partial loss of traction. Moreover, the resulting abrupt pressure discontinuity would generate damaging stresses within the cable. The traction roller 141 is entirely outside the groove, but as mentioned above the skirts or radially inward extensions 116 of the side bar 116 ride along the two sides (axially) of the sheave 51, keeping the chain-like member in place and preventing escape of the cable 25a even in event of relatively violent mechanical disruptions.
FIG. 7 illustrates the same components in use with a cable 25b of diameter generally central to the range of diameters that is of interest. The cable is here well within, and the traction roller 141 slightly within, the groove 53. By virtue of being turned down to smaller diameter than the roller 141 cable-contact surface, however, the end portions 118 of the roller are well separated outwardly (radially) from the sheave periphery 54.
FIG. 8 illustrates the same components in use with a cable 25c of the smallest diameter for which the equipment is intended. Here the cable approaches the bottom of the groove--but it is crucial that it not actually bottom out, since the "wedging" deformation of the cable described above, and necessary to produce the high tractive force mentioned above, would then be absent.
It would not suffice to merely press the cable into the bottom of the groove, with the available tension of the chain-like member but without the mechanical advantage provided by the wedging action along the tapered sides of the groove. In short, if the cable were allowed to bottom out, the proportionality between scaffold load and tractive force would be defeated--and traction would likely fail, and the cable would slip in the sheave.
The turned-down ends 118 of the roller here come quite close to the periphery 54 of the sheave, but do not touch. This too is crucial, since if the roller ends 118 did touch the outer surface 54 of the sheave the force available to wedge the cable 25c into the groove 53 would drop very sharply. Again, the load/traction proportionality would be destroyed, traction would likely fail, and the cable would slide through the mechanism.
The two-diameter roller geometry described here is an important part of the solution which the present invention provides to the conflicting requirements posed by multiple cable diameters. Such multiple requirements necessitate providing a sheave groove that is wide at the top (for large-diameter cables), narrow at the bottom (for small-diameter cables), and deep (to obtain both width regions in a single groove)--and into which the engaging part of the roller must penetrate, to reach the small-diameter cables near the bottom of the groove.
As previously mentioned, the three cable diameters represented by FIGS. 6 through 8 are eight, nine and ten millimeters respectively--the first and last of these sizes corresponding closely to five-sixteenths and three-eighths of an inch. The sheave groove found to be effective in this context is 0.45 inch deep, with a radius of 0.10 inch at the bottom and the opposing groove walls at thirty degrees to one another (i.e., the half-angle is fifteen degrees).
At the extreme periphery of the sheave the groove is 0.424 inch wide. The overall width of the sheave is 0.709 inch--a dimension that has some importance, since it has been found to provide satisfactory side-wall thickness (0.14 inch at the periphery) and therefore strength to withstand the wedging forces discussed above.
Earlier sheaves, used for nine-millimeter cables in devices of the Evans-Hippach type, had overall width of only about 0.65 inch, and had grooves 0.15 inch shallower, or only about 0.30 inch deep.
4. OVERSPEED BRAKE SYSTEM
This part of the invention is illustrated in FIGS. 9 through 12. The front cover 22, side covers 23 and 24, entry port 26, and manual brake actuator 151 shown in FIGS. 1 and 2 all appear in FIGS. 9 through 11 as well.
The operating components of the overspeed brake assembly are mounted to a generally planar vertical wall or frame, which is disposed roughly midway between the left and right covers 24 and 23. The components on the left side of the wall (FIGS. 10 through 12) are those which directly engage the cable--some to sense the cable velocity, and others to brake or jam the cable.
The components on the right side of the wall (FIG. 9) are those whose functions are intermediate to the sensing and braking functions--namely, testing of the sensed velocity against a calibrated standard, and automatic application of the brake if the velocity fails the test (that is, if the testing indicates that the velocity is excessive).
The cable enters the automatic overspeed brake assembly through an entry bushing 26 (FIG. 10), and passes just out of grazing contact with the backup block 214 (FIGS. 10 and 11). In particular the cable passes just out of grazing contact with the bottom of the groove 215 at the rear (to the left in FIG. 10) of the backup block 214. The cable then passes into engagement with the idler wheel 212, which is rotationally mounted to the wall 236 and which helps hold the cable in proper alignment, just barely out of grazing contact with the bottom of the groove 215.
Next the cable engages the speed-sensing wheel 161, entering its groove 163. This wheel 161 too is mounted for rotation in the wall 236, by means of a bolt 162 which rides in a bushing formed in or fitted into the wall. The wheel 161 is pinned as at 211 to the bolt 162, so that the wheel and bolt must rotate together. The cable exits through the lower port 237, to enter the traction mechanism at 25 (FIG. 4).
The relative alignment of the entry port 26, idler 212, speed-sensing wheel 161, lower port 237, and sheave periphery 54 (FIG. 4) is such that the cable must deflect slightly forward (to the right in FIG. 10) to pass the speed-sensing wheel 161. By means of this geometry a fraction of the weight of the scaffold is applied to press the cable toward (but not to) the bottom 163 of the groove in the speed-sensing wheel 161. The traction principles here are very generally similar to those described in connection with the drive sheave. As will be seen, however, there is very little resistance to rotation of the speed-sensing wheel 161; consequently, while the traction here must be positive, it need not be very high.
Juxtaposed to the speed-sensing wheel 161 is a guide wheel 201. The purpose of this wheel 201 is to aid in guiding the cable into engagement with the speed-sensing wheel 161 and through the lower port 237 when there is no load on the hoist--and to aid in retaining the cable in engagement with the speed-sensing wheel 161 under that condition. The guide wheel is mounted, by a pin 202 and circlip 206, for rotation to an arm 203--which arm is in turn mounted by a bolt 204 for rotation relative to the wall 236. The arm is biased by a spring 205 to swing the guide wheel 201 toward the speed-sensing wheel 161.
When a cable is in place in the mechanism, whatever longitudinal motion it may have is transmitted to the speed-sensing wheel 161 and thereby to the bolt 162. Also pinned or keyed to this same bolt 162, but at the other side of the wall 236, is a turntable 165 (FIG. 9). Mounted to this turntable are four weights 166, each pivoted to the turntable at a respective bolt axis 167. The four weights 166 are arranged symmetrically about the center of the turntable 165, and the opposed pairs of weights are interconnected by calibrated springs 168.
When a cable in the mechanism rotates the speed-sensing wheel 161, bolt 162 and turntable 165, centrifugal force tends to move the weights 166 outward from the center of the turntable. This tendency is opposed by the springs 168, so that the positions of the weights relative to the center of the turntable depend upon the ratio of cable speed to the spring constants of the springs 168. The spring constants are chosen so that in an overspeed condition will the weights swing outward far enough to reach the tip 174 of a trigger 171 (FIG. 9), just above the turntable 165.
The trigger 171 is mounted to the wall 236 for rotation about pivot bolt 172, and is biased in a clockwise direction by a spring 173. While the lower end of the trigger 171 terminates in the tip 174, just mentioned, the upper end 175 is formed into a hook or ratchet arm for engagement with a mating ledge or hook 183 formed in a brake actuator 181. The actuator 181 is a generally disc-shaped member, mounted for rotation relative to the wall 236 by means of a bolt 182 which rides in a bushing in the wall 236, and a nut 184 that holds the actuator 181 in place axially. The actuator 181 is keyed or pinned to the bolt 182, and like the trigger 171 is biased in a clockwise direction by a heavy spring 185.
If the cable is moving upward relative to the apparatus--a condition corresponding to descent of the apparatus along the cable--the speed-sensing wheel 161 rotates counterclockwise (as seen in FIG. 10), driving the turntable clockwise (as seen in FIG. 9). When the turntable is operating in this direction and the weights swing outward far enough to reach the tip 174 of the trigger 171, the weights force the tip 174 rightward (in FIG. 9), tending to rotate the trigger 171 counterclockwise against its spring 173, and against the frictional force between the trigger hook 175 and the actuator-disc hook 183.
Once the weights engage the trigger tip 174, the full weight of the hoist load is applied--through the traction of the cable against the speed-sensing wheel 161--to overcome the effects of the spring 173 and the friction between the hooks 175 and 183. All of this chain of events takes only a small fraction of a second. In response the trigger immediately snaps counterclockwise, releasing the actuator disc 181. The latter also immediately rotates, but clockwise, under the influence of its driving spring 185, to apply the brake.
Thus the mechanism as shown in FIGS. 9 and 10 is in a "cocked" condition.
In addition to applying the brake (as will be described in detail below), the actuator disc 181 acts through an arm 186 to release the control button 191 of a switch 194, which is mounted by an "L" bracket 192-193 to the wall 236. The bracket consists of one portion 193 that is screwed flat against the wall 236, and another portion 192 that stands out at right angles to the wall 236. The switch 194 is mounted to the latter portion 192.
The switch 194 is normally open, but when the mechanism is cocked as illustrated the arm 186 of the actuator 181 depresses the switch control button 191, supplying a switch closure to the control electronics in the electronics compartment 16 (FIGS. 1 and 2). This switch closure signifies that the overspeed brake is not applied. When the trigger 171 snaps counterclockwise and the actuator disc 181 clockwise, the switch button 191 is released and the switch opens, signifying that the overspeed brake is applied. The electronics include a relay or like logic circuit that locks out operation of the motor 15 when the switch closure is absent--to avoid operating the motor against the brake.
In the event that an operator of the hoist wishes to apply the brake when there is no overspeed condition, the operator may do so by pressing the manual actuator button 151. The actuator button 151 is secured to a shaft 152 (FIG. 9), which passes through a bushing in the front wall 22 of the brake assembly and through one leg 154 of an "L" bracket 154-155 (similar to the bracket 192-193 described earlier).
Fixed to the shaft 152 is a stop ring 152', which prevents the shaft from escaping through the front wall 22. The stop ring 152' also serves as an anchor point for a spring 153 that surrounds the shaft between the inside of the front wall 22 and the bracket leg 154. This spring biases the shaft forwardly--so that the actuator button 151 moves away from the front wall 22, toward the operator, and so that the inward end of the shaft clears the trigger 171.
When the operator presses the actuator button 151, the button moves the shaft 152 inwardly against the action of the spring 153 and into engagement with the trigger, forcing the trigger counterclockwise. The result is to release the actuator disc 181, as previously described, and thereby to apply the brake.
When the actuator disc 181 operates clockwise (as seen in FIG. 9), it rotates the bolt 182. This bolt extends through the wall 236 to the left side of the apparatus (FIG. 10), where it is pinned to a cam 231. The cam thus rotates counterclockwise (as seen in FIG. 10), as indicated by the arrow 232, into engagement with the cable. A backup block 214 (FIGS. 10 and 11) is provided to avoid the cable's simply retreating from the cam. The cam 231 and backup block 214 both are grooved--at 235 and 215 respectively--to avoid the cable's escaping sideward (that is, axially) off the side of the cam.
The cam 231 is of variable radius, being tapered gradually from a relatively small radius in the region 234a closest to the cable, through an intermediate radius in the region 234b that is centrally located along the cam surface, to a relatively large radius in the region 234c that is furthest from the cable.
This gradual increase of radius serves a dual function:
First, when the cam swings into engagement with the cable, the cable is very nearly tangential to the cam and just grazes the cam; the cam surface is angled at an extremely shallow angle relative to the cable. Thus the spring 185 (FIG. 9) is acting through a very large mechanical advantage, provided by the inclined-plane principle, to advance the cam against whatever resisting force may be present. At least in the case of manual actuation of the brake when the scaffold is stationary, the force of friction between cam and cable provides such a resisting force.
If the cable is moving upwardly (that is, in the same direction as the cam surface), then once the cam has moved into frictional engagement with the cable, the cable helps to pull the cam further along its rotary path, and thus further into frictional engagement. Eventually the cam swings so far toward the backup block, squeezing the cable between cam and block, that friction overcomes the momentum of the apparatus and stops the cable. This generally occurs within about two inches of cable travel.
(Once the cam has jammed or pinched the cable in this way, the pinched portion of the cable should not be relied upon. The cable must be repaired, if possible, or preferably discarded.)
As to the second function of the tapered cam surface, by use of a taper that extends far enough it is possible to provide a first region 234a along the cam surface for engagement with large-diameter cables such as 25a in FIG. 6, a second region 234b for engagement with intermediate-diameter cables such as 25b in FIG. 7, and a third region 234c for engagement with small-diameter cables such as 25c in FIG. 8.
The mechanism is thus rendered essentially indifferent, within the design limits, to the diameter of the cable in use. The only difference is in the time required for the cam to swing far enough for the pertinent segment of the cam surface to engage the cable, and this difference is made insignificant by proper choice of the cam driving spring 185.
After the overspeed brake has gone into operation, and after the scaffold and hoist have been secured and the traction (or other) failure which occasioned actuation of the brake has been corrected, it is desirable to release the jammed cable from the brake mechanism. Because of the very high forces that operate in jamming the cabling against the backup block 214, resetting the mechanism would expectably require comparable forces. Normally however, wrenches or other tools with very long lever arms are not available under field operating conditions. As a part of the present invention it has been recognized that some provision is highly desirable for resetting the mechanism with only moderate force.
This provision in the present invention is made by mounting the backup block 214 for sliding motion along the angled path 225 formed by the interface between the backup block 215 and a fixed block 221. This sliding motion--along the line of motion indicated by arrows 224 (FIG. 10) --is also guided by an angled slot 226, which is formed in a cover plate 223 (FIGS. 10 and 11). Both the interface path 225 and the slot 226 are angled in such a way that (1) the backup block 214 is closest to the cam 231 when the block is at the top of its sliding motion, and (2) the block 214 is furthest from the cam 231 when the block is at the bottom of its sliding motion.
The slot 226 is engaged by a guide pin 216, which passes through the backup clock 214 into the stationary block 236 behind the backup lock 214, and which also extends outward through the slot 226. The backup block is biased upward by a spring 217 which operates against the guide pin 216. Hence, when the apparatus is in its cocked condition as illustrated, the block 214 is spring-loaded upward, with its guide pin 216 pressed against the top end of the slot 226, and the block is thus in its position that is closest to the cam 231. When the brake is applied, the block 214 tends to be pulled upward by the cam, so that the guide pin 216 is pulled harder against the top end of the slot 226; thus the block remains in its position that is closest to the cam, and there is no decrease in efficacy of the jamming action of the cam against the cable.
When the cable is no longer under load and it is time to release the brake, however, this normally can be accomplished by means of the handle 182' (FIGS. 1 and 2), which extends through the wall 24 of the brake housing to engage the hexagontal head of the bolt 182 (FIG. 10).
If the cable has been jammed with unusually great force, the leverage provided by the handle 182' may be insufficient to release the brake. In such cases the brake can be released with the aid of an ordinary wrench applied to the hexagonal head of the bolt 182 (FIG. 10)--possibly using a relatively modest lever arm to aid the wrench. The bolt 182 and cam 231 are rotated clockwise (counter to the direction indicated by the arrow 232), tending to slide the backup block 215 downward against the action of the spring 217. As the backup block 215 moves downward it retreats from the cam, by virtue of the angled interface 225, slot 226, and thus motional path 224. This retreating action immediately and significantly decreases the normal force between the cam, cable and block, and in turn decreases the associated frictional force, so that the cable can be easily disengaged.
5. CONCLUSION
It is to be understood that all of the foregoing detailed descriptions are by way of example only, and not to be taken as limiting the scope of the invention--which is expressed only in the appended claims.
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This scaffold hoist uses a transmission mechanism whose output shafts are fastened to the hoist housing, and whose case rotates, carrying a sheave which impels the mechanism along the cable. The transmission mechanism is advantageously a quadrant drive for extremely high torque-to-weight ratio.
The sheave has a peripheral groove, tapered and deep enough to seat a cable having any of three different diameters, at different depths in the groove.
The cable wraps around three-quarters of the sheave. Around five-eighths of the sheave, a chain presses the cable into the groove. The chain rollers enter the groove deeply enough to engage even the smallest-diameter cables of interest, while clearing the sheave periphery. The chain side bars ride along the sides of the sheave, holding the chain and cable in position.
A resettable overspeed brake uses a rotary cam that jams a cable of any of the three sizes, at correspondingly various cam angles. The cam is cocked out of contact with the cable, and immediately spring-driven against the cable when triggered by a centrifugal sensor. A backup block--which keeps the cable from retreating from the cam--slides away from the cable at an angle during resetting, to facilitate unjamming the cable by moderate force.
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RELATED APPLICATIONS
[0001] This application claims priority to Taiwan Application Serial Number 98100535, filed Jan. 8, 2009, which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an imprint process, and more particularly to an imprint process of a thermosetting material.
BACKGROUND OF THE INVENTION
[0003] A thermosetting material, such as polyimide (PI), is a material with high heat resistance, a great mechanical property, a superior optical property and a low dielectric constant, so that the thermosetting material has been widely applied in flexible printed circuit (FPC) boards, electronic packages, optical waveguides, alignment films of liquid crystal displays (LCD) and microfluidic devices. In the application, the thermosetting material typically needs to be patterned by a pattern definition technology to form the desired pattern structure for use.
[0004] Several technologies, such as laser machining technology, conventional photolithography technology, new photolithography technology, and nano-imprint technology including, for example soft imprint technology and hot-embossing technology, have been developed to pattern the thermosetting material. When the laser machining technology patterns the thermosetting material, the laser directly irradiates the thermosetting material layer through a mask to remove a portion of the thermosetting material layer to complete the thermosetting material pattern structures. However, when the laser machining technology patterns the thermosetting material, irradiation of many laser shots is required, so that the process is time-consuming and consumes large amounts of laser energy, thereby increasing the cost. Moreover, due to the size of the laser beam and the optical diffraction limit, the laser machining technology cannot produce the pattern with too small size, such as the thermosetting material pattern structures with the nanometer scale.
[0005] When the conventional photolithography technology is used to pattern a thermosetting material layer, a photoresist layer is firstly coated on the thermosetting material layer, the photoresist layer is patterned by the exposure and development technology, and then the thermosetting material layer is etched with tile patterned photoresist layer as the etching mask to complete the thermosetting material pattern structures. However, due to the wavelength limit of the exposure light source, the feature size of the thermosetting material pattern strictures produced by the conventional photolithography technology has a limit, so that the pattern structures with a smaller size cannot be produced.
[0006] When the new photolithography technology is used to pattern the thermosetting material, a photosensitive thermosetting material is needed, the bonding link in parts of directions of the thermosetting material is destroyed by directly using the light source, such as deep ultraviolet, and the exposed thermosetting material layer is developed to complete the pattern structures of the thermosetting material. However, the surface roughness of the thermosetting material pattern structure formed by the new photolithography technology is poor, there still exists many issues in the positive tone and negative tone photosensitive thermosetting materials, such as that the adjustment of the ingredients of the material is difficult, and the control of the process parameters and the machining precision of the thermosetting material is difficult to result in the poor fidelity and the reliability of pattern transferring. In addition, similarly, due to the wavelength limit of the exposure light source, the new photolithography technology cannot produce the thermosetting material pattern structures with a smaller size. Furthermore, the negative tone photosensitive thermosetting material is swelling after the developing process, so that the fidelity of the pattern transferring is further decreased.
[0007] When the soft nanoimprint technology is used to pattern the thermosetting material, such as polyimide, and the imprint mold is pressed into the liquid poly(amic acid) (PAA) that has not been heated to form the solid polyimide, it is easy for bubbles to form between the pattern structures of the imprint mold and the liquid poly(amic acid) after heating, and these bubbles are formed on the surface of the polyimide. Therefore, the surface of the pattern structures of the thermosetting material formed by the soft nanoimprint technology has many holes, so that the surface roughness of the thermosetting material pattern structures is poor, and the mechanical strength of the thermosetting material pattern structures is reduced. Moreover, when the liquid poly(amic acid) is heated to solidify the liquid poly(amic acid) to form the polyimide before the mold is removed, the solvent of the poly(amic acid) is evaporated, so that the volume of the thermosetting material pattern structures is decreased to lower the fidelity of the pattern transferring.
[0008] When the hot embossing nanoimprint technology is used to pattern the thermosetting material, the imprint temperature needs to be raised to more than the glass transition temperature (Tg) 300° C. of the thermosetting material. In addition, due to the heat, the remaining thermal stress, the expansion and the shrink effects occur on the mold and the substrate simultaneously, thereby seriously affecting the substrate material and the size of the thermosetting material pattern structures to reduce the reliability of the pattern transferring.
SUMMARY OF THE INVENTION
[0009] Therefore, one objective of the present invention is to provide an imprint process of a thermosetting material, which can accurately transfer a pattern on an imprint mold to a thermosetting material layer, thereby effectively increasing the accuracy and the reliability of the pattern transferred to the thermosetting material layer.
[0010] Another objective of the present invention is to provide an imprint process of a thermosetting material, which can successively define the pattern of the thermosetting material with low thermal budget and under relatively lower temperatures compared with the hot embossing nanoimprint process, thereby reducing the process cost and preventing the feature size of the transferred pattern of the thermosetting material from being distorted. Furthermore, the remaining thermal stress formed on the substrate and the thermosetting material layer due to high temperature can be decreased, and the substrate and the thermosetting material layer can be prevented from being damaged.
[0011] According to the aforementioned objectives, the present invention provides an imprint process of a thermosetting material, comprising: providing a mold including a pattern structure, wherein the pattern structure comprises a plurality of convex portions and a plurality of concave portions; forming a transferred material layer on the convex portions and the concave portions; providing a substrate, wherein a surface of the substrate is covered with a thermosetting material layer and a sacrificial layer in sequence; performing an imprint step to transfer the transferred material layer on the convex portions onto a first portion of the sacrificial layer and to expose a second portion of the sacrificial layer; dry etching the second portion of the sacrificial layer and a second portion of the underlying thermosetting material layer to remain the first portion of the sacrificial layer and a first portion of the underlying thermosetting material layer by using the transferred material layer as a mask; and performing a wet stripping step by using a stripper to completely etch the first portion of the sacrificial layer and to lift off the overlying transferred material layer, wherein the stripper has a first etching rate and a second etching rate to the thermosetting material layer and the sacrificial layer respectively, and a ratio of the second etching rate to the first etching rate is greater than or equal to 30.
[0012] According to a preferred embodiment of the present invention, the material of the sacrificial layer may be PMMA 950K A6 provided by MicroChem Corp., Newton, Mass., U.S.A. or photoresist S1818 provided by Shipley Company, L.L.C., Marlborough, Mass., U.S.A., the stripper may be acetone, such as TAIMAX acetone provided by Taiwan Maxwave Co., Ltd.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing aspects and many of the attendant advantages of this invention are more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0014] FIGS. 1A through 1H are schematic flow diagrams showing an imprint process of a thermosetting material in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] FIGS. 1A through 1H are schematic flow diagrams showing an imprint process of a thermosetting material in accordance with a preferred embodiment of the present invention. In an exemplary embodiment, when the imprint process of a thermosetting material is performed, a mold 100 may be provided to perform the imprint process. A pattern structure 104 is set in a surface 102 of the mold 100 , wherein the pattern structure 104 comprises a plurality of concave portions 108 and a plurality of convex portions 106 . The feature size of the pattern structure 104 may be micrometer scale or nanometer scale. Next, such as shown in FIG. 1A , an anti-stick layer 110 is selectively formed to cover the pattern structure 104 of the mold 100 by, for example, a thermal evaporation method, wherein the anti-stick layer 110 includes two portions 110 a and 110 b, the portion 110 a of the anti-stick layer 110 covers on bottoms of the concave portions 108 of the pattern structure 104 , and the portion 110 b of the anti-stick layer 110 covers on top surfaces of the convex portions 106 of the pattern structure 104 . In another exemplary embodiment, when the material of the mold 100 itself has an anti-stick property, such as ethylene tetrafluoroethylene [—(C2H4-C2F4)-] provided by DuPont Company, the anti-stick layer 110 does not need to be formed additionally.
[0016] Next, such as shown in FIG. 1B , a transferred material layer 112 is formed on the anti-stick layer 110 by using, for example a thermal evaporation method, an e-beam evaporation method, a chemical vapor deposition method or a physical vapor deposition method cooperating with a typical pattern definition technique, wherein the transferred material layer 112 also includes portions 112 a and 112 b, the portions 112 a of the transferred material layer 112 are located on the portion 110 a of the anti-stick layer 110 within the concave portions 108 of the pattern structure 104 , and the portions 112 b of the transferred material layer 112 are located on the portion 111 b of the anti-stick layer 110 on the top surfaces of the convex portions 106 of the pattern structure 104 . In another exemplary embodiment, when the material of the mold 100 itself has an anti-stick property and the anti-stick layer 110 is not formed, the transferred material layer 112 directly covers the pattern structure 104 of the mold 100 , wherein the portions 112 a of the transferred material layer 112 are directly located on die bottoms of the concave portions 108 of the pattern structure 104 , and the portions 112 b of the transferred material layer 112 are directly located on the top surfaces of the convex portions 106 of the pattern structure 104 . The material of the transferred material layer 112 may be metal, oxide or a dielectric material. In one embodiment, the material of the transferred material layer 112 may be chromium (Cr). In another embodiment, the material of the transferred material layer 112 may be a dielectric material and oxide, such as silicon dioxide (SiO 2 ). By disposing the anti-stick layer 110 or adopting the mold 100 having an anti-stick property, the portions 112 b of the transferred material layer 112 on the convex portions 106 of the mold 100 can be successively separated from the convex portions 106 of the mold 100 .
[0017] Simultaneously, a substrate 114 desired to be imprinted is provided, wherein the substrate 114 is preferably composed of a material that can resist the etching of the stripper 130 (referring to FIG. 1G ). The material of the substrate 114 may be, for example, silicon wafer, glass, quartz or metal. A thermosetting material layer 118 is formed to cover a surface 116 of the substrate 114 by, for example, a physical vapor deposition method, a chemical vapor deposition method or a coating method. In some embodiments, the material of the thermosetting material layer 118 may be, for example, polyimide or polyethersulfone (PES), wherein each polyimide and polyethersulfone is a material having a high glass transition temperature. In an exemplary embodiment, the material of the thermosetting material layer 118 may be RN-1349 polyimide provided by Nissan Chemical Industries. Next, the thermosetting material layer 118 may be baked to dry the solvent in the thermosetting material layer 118 . Then, such as shown in FIG. 1C , a sacrificial layer 120 is formed to cover the thermosetting material layer 118 by, for example, a deposition method or a coating method. In an exemplary embodiment, the material of the sacrificial layer 120 may be polymethylmethacrylate (PMMA) or photoresist S1818 provided by Shipley Company, L.L.C., Marlborough, Mass., U.S.A. The material of the sacrificial layer 120 also may be PMMA 950K A6 provided by MicroChem Corp., Newton, Mass., U.S.A. The choice of the materials of the thermosetting material layer 118 and the sacrificial layer 120 is in relation to the stripper 130 (referring to FIG. 1G ), wherein the stripper 130 has two different etching rates to the thermosetting material layer 118 and the sacrificial layer 120 respectively, and the etching rate of the stripper 130 to the sacrificial layer 120 is much larger than that of the stripper 130 to the thermosetting material layer 118 . Therefore, when the sacrificial layer 120 is completely removed by the stripper 130 , the thermosetting material layer 118 may hardly be etched by the stripper 130 and is kept. In an exemplary embodiment, the ratio of the etching rate of the stripper 130 to the sacrificial layer 120 to the etching rate of the stripper 130 to the thermosetting material layer 118 may be preferably larger than or equal to 30, more preferably be larger than or equal to 40, and further more preferably be larger than or equal to 50.
[0018] Next, referring to FIG. 1D , an imprint step is performed, wherein the surface 102 of the mold 100 is oppositely pressed on the surface 116 of the substrate 114 to press the portions 112 b of the transferred material layer 112 on the convex portions 106 of the pattern structure 104 of the mold 100 on the liquid status of the sacrificial layer 120 on the substrate 114 and contact with the sacrificial layer 120 . After the portions 112 b of the transferred material layer 112 on the mold 100 are pressed on the sacrificial layer 120 on the substrate 114 , the sacrificial layer 120 is baked at substantially 95° C. in substantially five minutes to dry the sacrificial layer 120 . After the temperature is lowered to room temperature, the mold 100 is removed from the sacrificial layer 120 . At this time, the convex portions 106 of the pattern structure 104 of the mold 100 are covered with the anti-stick layer 110 to make the anti-stick layer 110 be located between the surface 102 of the mold 100 and the transferred material layer 112 , or the mold 100 itself has an anti-stick property, so that the portions 112 b of the transferred material layer 112 on the convex portions 106 of the pattern structure 104 of the mold 100 can be successfully separated from the mold 100 to transfer to the surface of the sacrificial layer 120 to complete the imprint step. After the imprint step is completed, the portions 112 b of the transferred material layer 112 are only transferred to a first portion 122 of the sacrificial material layer 120 , and a second portion 124 of the sacrificial layer 120 is exposed, such as shown in FIG. 1E .
[0019] Next, referring to FIG. 1F , the second portion 124 of the sacrificial layer 120 uncovered by the portions 112 b of the transferred material layer 112 and the portion of the thermosetting material layer 118 underlying the second portion 124 are removed until a portion of the surface 116 of the substrate 114 underlying the second portion 124 of the sacrificial layer 120 is exposed, and the first portion 122 of the sacrificial layer 120 and a first portion 126 of the thermosetting material layer 118 underlying the first portion 122 are maintained. In another embodiment, according to the difference of the applications of the products, the removal step may only remove the second portion 124 of the sacrificial layer 120 and a portion of the thermosetting material layer 118 underlying the second portion 124 of the sacrificial layer 120 to keep the first portion 122 of the sacrificial layer 120 , the other portion of the thermosetting material layer 118 underlying the second portion 124 of the sacrificial layer 120 , and the first portion 126 of the thermosetting material layer 118 underlying the first portion 122 . Accordingly, the surface 116 of the substrate 114 underlying the second portion 124 of the sacrificial layer 120 is not exposed. In a preferred embodiment, in the removal of a portion of the sacrificial layer 120 and a portion of the thermosetting material layer 118 , an etching method, such as a dry etching method, may be adopted, and the portions 112 b of the transferred material layer 112 on the first portion 122 of the sacrificial layer 120 may be used as the etching mask to etch and remove the portion of the sacrificial layer 120 and the portion of the thermosetting material layer 118 . The dry etching method may be, for example, a reactive ion etching (RIE) technique or an inductively coupled plasma (ICP) ion etching technique. In some embodiments, when the dry etching method, such as the reactive ion etching method or the inductively coupled plasma ion etching method, is used to perform the etching of the sacrificial layer 120 and the thermosetting material layer 118 , oxygen may be used as the main reactive gas. For example, oxygen, or oxygen and argon of specially designated ratio may be used as the etching reactive gas. In the present exemplary embodiment, the adjacent portions 112 b of the transferred material layer 112 pressed on the first portion 122 of the sacrificial layer 120 have a pitch 134 .
[0020] According to the experiment discovery, the photosensitive photoresist material is used as the etching mask to pattern the thermosetting material layer in the conventional photolithography technique, and the photoresist layer swells due to that the photoresist layer absorbing a portion of the developer during the development process, so that the volume of the photoresist layer is expanded. Therefore, when the photoresist layer with the expanded volume is used as the etching mask to etch the pattern of the underlying material layer, the feature size of the formed pattern structure of the material layer is distorted. However, in a preferred embodiment of the present invention, the portions 112 b of the transferred material layer 112 on the first portion 122 of the sacrificial layer 120 are used as the etching mask without using the photoresist layer as the etching mask, and the transferred material layer 112 does not experience the exposing and developing process, so that the transferred material layer 112 will not swell due to the developer. Therefore, by using the transferred material layer 112 as the dry etching mask, it can ensure that the pattern structures of the etched sacrificial layer 120 and the thermosetting material layer 118 are not distorted to greatly increase the fidelity of the achieved pattern structures of the sacrificial layer 120 and the thermosetting material layer 1118 .
[0021] Then, referring to FIG. 1G , a stripping tank 128 that can resist the etching of the stripper 130 is provided, wherein the stripping tank 128 is filled with the stripper 130 for the wet stripping step. Next, the substrate 114 , and the portions 112 b of the transferred material layer 112 , the first portion 122 of the sacrificial layer 120 and the first portion 126 of the thermosetting material layer 118 on the substrate 114 are entirely immersed in the stripper 130 in the stripping tank 128 to use the stripper 130 to completely etch and remove the first portion 122 of the sacrificial layer 120 and to lift off the portions 112 b of the transferred material layer 112 on the first portion 122 of the sacrificial layer 122 while the thermosetting material layer 118 may hardly be etched by the stripper 130 . Therefore, the etching rate of the stripper 130 to the first portion 122 of the sacrificial layer 120 must be far larger than that of the stripper 130 to the first portion 126 of the thermosetting material layer 118 . In one embodiment, the ratio of the etching rate of the stripper 130 to the sacrificial layer 120 to the etching rate of the stripper 130 to the thermosetting material layer 118 may be, for example, larger than or equal to 30, more preferably be larger than or equal to 40, and further more preferably be larger than or equal to 50.
[0022] In a preferred embodiment, the thermosetting material layer 118 may be composed of, for example, RN-1349 polyimide provided by Nissan Chemical Industries, the sacrificial layer 120 may be composed of, for example, PMMA, such as PMMA 950K A6 provided by MicroChem Corp., Newton, Mass., U.S.A., and the stripper 130 may be composed of TAIMAX acetone provided by Taiwan Maxwave Co., Ltd. In another preferred embodiment, the thermosetting material layer 118 may be RN-1349 polyimide provided by Nissan Chemical Industries, the sacrificial layer 120 may be photoresist S1818 provided by Shipley Company, L.L.C., Marlborough, Mass., U.S.A., and the stripper 130 may be acetone, such as TAIMAX acetone provided by Taiwan Maxwave Co., Ltd. After the etching of the first portion 122 of the sacrificial layer 120 is completed, the substrate 114 and the first portion 126 of the thermosetting material layer 118 on the substrate 114 are removed from the stripping tank 128 and are rinsed with the deionized water, and then a heating and baking treatment is performed to bake under substantially 100° C. for substantially three minutes. The first portion 126 of the thermosetting material layer 118 remained on the substrate 114 is the pattern structure 132 with the desired pattern, and the pattern of the pattern structure 132 are completely and reliably transferred from the pattern of the pattern stricture 104 of the mold 100 .
[0023] The etching rate of the stripper 130 to the thermosetting material layer 118 is very small, and the etching rate of the stripper 130 to the sacrificial layer 120 is much larger than that of the stripper 130 to the thermosetting material layer 118 , so that the sacrificial layer 120 can be completely etched by the stripper 130 in a very short time. Therefore, when the sacrificial layer 120 has been completely removed by the stripper 130 , the first portion 126 of the thermosetting material layer 118 is hardly etched by the stripper 130 and is almost retained entirely, so as to precisely and exactly transfer the pattern of the pattern structure 104 of the mold 100 to the thermosetting material layer 118 to obtain the pattern structure 132 with the desired pattern. Accordingly, the pattern of the imprint mold 100 can be reliably transferred to the thermosetting material layer 118 with low thermal budget. Therefore, the fidelity and the reliability of the pattern transferred from the mold 100 to the thermosetting material layer 118 can be increased, and the process cost can be greatly reduced due to the decrease of the thermal budget.
[0024] According to the aforementioned embodiments of the present invention, one advantage of the present invention is that an imprint process of a thermosetting material of the present invention can accurately transfer a pattern on an imprint mold to a thermosetting material layer, thereby effectively increasing the accuracy and the reliability of the pattern transferred to the thermosetting material layer. Furthermore, the imprint process can be completed under the relatively lower temperature compared with the hot embossing nanoimprint process, so that the remaining thermal stress formed on the substrate and the thermosetting material layer due to high temperature can be decreased, and the substrate and the thermosetting material layer can be prevented from being damaged.
[0025] According to the aforementioned embodiments of the present invention, another advantage of the present invention is that an imprint process of a thermosetting material of the present invention can successively define the pattern of the thermosetting material with low thermal budget, thereby reducing the process cost and preventing the feature size of the transferred pattern of the thermosetting material from being distorted.
[0026] As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrated of the present invention rather than limiting of the present invention. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure.
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An imprint process of a thermosetting material is described, comprising: providing a mold including pattern structures, wherein convex portions and concave portions of the pattern structures are covered with a transferred material layer; providing a substrate, wherein a thermosetting material layer and a sacrificial layer cover the substrate in sequence; performing an imprint step to transfer the transferred material layer on the convex portions onto a first portion of the sacrificial layer; etching a second portion of the sacrificial layer and the underlying thermosetting material layer by using the transferred material layer as a mask; and performing a wet stripping step by using a stripper to completely etch the sacrificial layer and the overlying transferred material layer, wherein the stripper has a first etching rate and a second etching rate to the thermosetting material layer and the sacrificial layer respectively, and a ratio of the second etching rate to the first etching rate is greater than or equal to 30.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. § 119, of German Patent Application DE 10 2007 029 211.4, filed Jun. 25, 2007; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a print control strip to be applied to printing material during a multicolor printing operation. The print control strip includes multiple measuring fields which are associated with an ink zone on the printing material. The present invention also relates to a method of measuring the print control strip and to a method of controlling the metering of ink in offset printing presses based on color measurements on the print control strip.
[0003] The quality of a printing operation is measured by evaluating to what extent the printed products conform to the original. A high degree of conformity between the colors of the printed product and the original is an important aspect of print quality. The operator may evaluate the quality of the printed products by visual inspection. In that case, the inspection is subjective and depends on the person who makes the inspection. In order to provide a more objective approach to quality control, color measuring devices have been developed, which measure the printed products in colorimetric or densitometric terms. In most cases, however, it is not the entire printed image that is being measured, because that would require a plurality of measuring locations and would thus be a very time-consuming process. Instead, it is common to use the color measuring devices to measure what are known as print control strips. Those print control strips are located outside the printed image in the lateral region of the printing material. They may even be measured in the printing press through the use of integrated color measuring devices because only a limited number of color measurements need to be taken on the print control strips, making precise measurements possible even at the high printing speeds of approximately 18,000 sheets per hour, which are common in modern offset printing presses. Such a print control strip is known from German Published, Non-Prosecuted Patent Application DE 36 43 721 A1, corresponding to U.S. Pat. No. 4,947,746. Such a print control strip for controlling the printing process includes several color fields of different color and structure disposed in a row and distributed in a manner corresponding to the ink zones of the ink fountain in an offset printing press. The printing colors that are used in the printing process are in general included as solid-tone and halftone fields in the print control strip. The print control strip described in German Published, Non-Prosecuted Patent Application DE 36 43 721 A1, corresponding to U.S. Pat. No. 4,947,746, has alternating solid-tone fields and continuous-tone fields for each color and single-color screen fields for each color. The print control strip described in German Published, Non-Prosecuted Patent Application DE 36 43 721 A1, corresponding to U.S. Pat. No. 4,947,746, includes a gray measuring field on each border between two ink zones. However, an optimum control of the color according to those few gray measuring fields is impossible.
SUMMARY OF THE INVENTION
[0004] It is accordingly an object of the present invention to provide a print control strip, a measuring method and a method of metering ink, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and which provide improved ink control on the basis of gray measuring fields.
[0005] With the foregoing and other objects in view there is provided, in accordance with the invention, a print control strip to be applied during a multicolor printing operation to printing material having ink zones. The print control strip comprises multiple measuring fields associated with an ink zone on the printing material. The measuring fields associated with one ink zone include at least two gray measuring fields.
[0006] With the objects of the invention in view, there is also provided a method of controlling metering of ink in offset printing presses having printing units, at least one ink metering device in each printing unit, and a control unit. The method comprises measuring a measuring strip including a plurality of gray measuring fields within an ink zone on a printed product, with a color measuring device, feeding measured gray values to the control unit for controlling the metering of the ink in the printing units, and calculating nominal values for controlling the metering of the ink in the printing units with the control unit and transmitting the nominal values to the printing units.
[0007] With the objects of the invention in view, there is furthermore provided a method of measuring fields in print control strips on printing material. The method comprises providing the measuring fields in at least two rows in the print control strips, providing each measuring field at least once in each row of the print control strips, measuring the measuring fields with a measuring device to provide measured values, and subjecting the measured values, during the measuring step, to a plausibility check in a control unit connected to the measuring device.
[0008] In accordance with the present invention, print control strips which contain several measuring fields associated with an ink zone on the printing material are printed onto the printing material in the printing press. In order to improve the control based on gray measuring fields, the measuring fields associated with one ink zone include at least two gray measuring fields. Thus, it is possible to obtain multiple measured gray values for each ink zone, with each gray measuring field being composed of the colors cyan, magenta, and yellow. Multiple gray levels can be determined in each ink zone by providing several gray measuring fields per ink zone. The gray values which have been measured in densitometric or calorimetric terms by the color measuring device may then be fed to the control unit of the printing press. The control unit may then compare the measured gray values to measured color values of the original. If there are unacceptable deviations, the control unit may calculate a correcting variable to control the ink metering device in the printing units of the printing press. If the printing units include zonal ink metering devices, the present invention provides multiple measured gray values for control purposes. This increases the accuracy of the ink metering in the ink zones. In addition to the gray measuring fields, the print control strip may include the usual color measuring fields such as the solid tones of cyan, magenta and yellow, as well as black and potential special or spot colors. Furthermore, the individual colors may also be available as halftone fields between zero and 100 percent.
[0009] In accordance with another particularly advantageous feature of the invention, the measuring fields associated with one ink zone may include three gray measuring fields. The more gray measuring fields that are present, the more accurately the ink may be metered in each ink zone. In particular, due to the provision of three gray measuring fields in 25% continuous tone, 50% continuous tone, and 75% continuous tone for the three basic process colors cyan, magenta and yellow, particularly accurate color measurement and ink control are possible. Thus, it is possible to provide accurate ink control even for highly complicated print jobs.
[0010] In accordance with a further feature of the invention, the measuring fields may be disposed in at least two parallel rows. The print control strips that have been known heretofore are formed of one row of measuring fields, which are repeated to match the number of ink zones. Due to the configuration of the color measuring fields in two or more rows, the color measuring fields are redundant in each ink zone. Thus, the operator receives more information for the color measurement and ink control in each ink zone. The redundant information in each ink zone also provides a possibility to realize the presence of measuring errors resulting from printing problems such as ghosting, hickeys, or the accumulation of powder during the printing process in the printing press. Thus, color measurement and ink control or metering become more reliable.
[0011] In accordance with an added feature of the invention, each measuring field of the first row is present at least once in each of the other rows. In this case, the color measuring device measures two measuring fields of the same type in each ink zone. Thus, a twofold color measurement for each measuring field in each ink zone is possible. The control unit of the printing press may then evaluate the measured values which have been obtained in this way in terms of plausibility. If the measured values of identical measuring fields in one ink zone differ beyond an acceptable tolerance, the assumption is that there are printing problems in that particular ink zone which make the measured values inconclusive. In this case, the control unit assumes that the values are implausible, and the ink metering device for the relevant ink zone may instead be controlled on the basis of the measured values of an adjacent ink zone. The measured values of the adjacent zones may at least be used to determine to what extent the measured values in the ink zone which have been established as erroneous need to be corrected.
[0012] In accordance with an additional feature of the invention, which improves the conclusiveness of the measured values, the order of the measuring fields in the rows is different. This avoids local printing problems such as hickeys or powder accumulation in locally limited specific areas on a measuring field affecting all measuring fields of the same type in an ink zone. Due to the different order of the measuring fields, measuring fields of the same type in one ink zone are disposed at different locations, a fact which means that printing problems which are locally limited do not cause all measuring fields of the same type to be considered useless. Through the use of the measured values for the adjacent measuring fields, the control unit of the printing press may be able to decide which of the measuring fields of the same type in the ink zone in question most probably is the correct measuring field. In this context, it is sufficient for measuring fields of the same type to be present only once in each ink zone. Due to the configuration in two or more rows, the redundancy required for reliable color measurement is ensured without requiring the multiple-row print control strip to have too many measuring fields per ink zone. Since the width of the ink zone is given and invariable, an unnecessarily high number of measuring fields per ink zone leads to correspondingly small measuring fields which make an accurate color measurement more difficult.
[0013] In accordance with yet another feature of the invention, only one gray measuring field is present in each ink zone, but the advantages of a print control strip which has two or more rows is still exploited. In this case, the gray measurements will be less accurate than if several gray measuring fields were present, but the improvement of the reliability of the measurement due to the redundancy of the measuring fields in the multi-row print control strip is advantageous even if the multi-row print control strip does not have more than one gray measuring field.
[0014] In accordance with a concomitant feature of the invention, the evaluation of the gray measuring fields through the use of the computer may be influenced through an input device before the measurement of the gray measuring fields is taken through the use of a color measuring device. If more gray measuring fields are provided in each ink zone, the evaluation thereof may be adapted to the specific conditions of the print job. Thus, knowing the specific conditions of the print job, the operator may select gray measuring fields in a job-specific way on the control unit of the printing press through the use of a user interface and input devices such as a keyboard, mouse, or touch screen. For example, the operator may select to control the ink only based on the 25% continuous tone or based on the 50% continuous tones and 75% continuous tones of the gray measuring fields. If mostly 25% continuous tones are present in a gray area in a printed image, the best possible control result for the metering of the ink is achieved if the individual ink zones are controlled on the basis of the measured gray values of the 25% continuous-tone gray measuring field. In this case the control suggestions for 50% continuous tone and 75% continuous tone gray measuring fields should be suppressed. Thus, measuring all gray measuring fields with the same weighting, the control quality compared to a control based on average color values would be considerably improved. However, the default settings for the ink control in the computer may be that the measured gray values are introduced in the control of the ink-metering printing units as an average value. A job-specific ink control based on the selected gray measuring fields is only implemented when the operator expresses his or her wish to do so by the appropriate inputs on the control computer through a suitable input menu. This provides more options to the operator to adapt ink control to the specific conditions of a print job without losing the advantages of a default control based on averaging the measured gray values.
[0015] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0016] Although the invention is illustrated and described herein as embodied in an improved print control strip for color measurement on printing material, a measuring method and a method of metering ink, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0017] 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 SEVERAL VIEWS OF THE DRAWING
[0018] FIG. 1 is a diagrammatic, partly perspective and partly elevational view of a closed ink control loop formed of a color measuring device, a control unit and an ink metering device in a printing press;
[0019] FIG. 2 is a top-plan view of a double-row ink control strip including multiple gray measuring fields in one ink zone; and
[0020] FIG. 3 is a top-plan view of a double-row ink control strip with redundant measuring fields in one ink zone.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen an ink control loop which includes a color measuring device 1 , a control unit 4 and an ink metering device in printing units 10 of a printing press 7 . The aforementioned devices 1 , 4 , 7 are connected to each other through electronic communication lines. The color measuring device 1 shown in FIG. 1 is a standalone color measuring device which includes a measurement table 2 for receiving printed products 3 . Instead of such a standalone ink measuring device 1 , an inline ink measuring device, which is integrated into the printing press 7 , may be used to measure the printed products 3 in the printing press 7 , preferably at the outlet of the last printing unit 10 . The standalone ink measuring device 1 shown in FIG. 1 includes a measuring bar which is movable across the printed product 3 in the longitudinal direction, and an ink measuring head 8 which is movable across the printed product 3 in the transverse direction to measure each point on the printed product 3 in colorimetric terms. As can be seen in FIG. 1 , a print control strip 13 is present next to the printed image on the printed product 3 . This print control strip 13 is located in the lateral region of the printed product 3 . In order to shorten the measuring process, only the measuring fields of the print control strip 13 need to be scanned by the color measuring device 1 . Measured values established by the color measuring device 1 are then fed to the control unit 4 , which may be a standalone computer or an integral part of a control unit of the printing press 7 . The control unit 4 compares the measured color values to predetermined measured values of the original. For this purpose, the original may have been stored in the control unit 4 in digitized form, or the control unit 4 may be given the opportunity to access relevant data in a prepress department. If the control unit 4 realizes deviations beyond a certain tolerance between the data of the original and the measured values, the established deviations are converted into control values for the metering device in the printing units 10 of the offset printing press 7 . The control values which have been calculated in this way are then transmitted to the printing press 7 , where they are translated into corresponding modifications, for example, of an ink zone opening in ink-zone inking units in the printing units 10 . In this way, the control loop between the color measuring device 1 and the printing press 7 is closed. For display and input purposes, the control unit 4 includes a screen 5 and input devices such as a mouse 11 and a keyboard 6 for the operator to influence the control loop of the ink metering device. Thus, the operator may use the mouse 11 or keyboard 6 to select the way to evaluate the print control strip 13 in the control unit 4 . For example, the operator may decide whether to evaluate all measuring fields of the print control strip or to evaluate only specific measuring fields which are relevant for the current print job.
[0022] FIGS. 2 and 3 illustrate an enlarged view of the print control strip 13 provided on the printed product 3 . What is shown is a section of the lateral region of the printed product 3 . The print control strip 13 is shown in FIGS. 2 and 3 for one ink zone 9 . This ink zone 9 repeats itself in a direction transversal to a direction of transport BT of the printed product across the entire width of the printed product 3 . In the 102 sheet format, 32 ink zones 9 are usually present adjacent each other in one row. There may be gaps or additional measuring fields for register control, for example, between the individual ink zones 9 . Thus, the print control strip 13 is not exclusively limited to color measurement, but may be used for other control loops as well. The print control strip 13 shown in FIG. 2 has several gray measuring fields CMY in each ink zone 9 . These gray measuring fields CMY are in different tones. The gray measuring fields CMY in FIG. 2 are embodied as 25% continuous tone, 50% continuous tone, and 75% continuous tone in each ink zone 9 . The gray measuring fields CMY are only present in the upper row, which also includes the color black B and special or spot colors X, Z, U, V. The lower row likewise includes the special or spot colors X, Z, U, V and the color black B as well as the colors cyan C, magenta M and yellow Y instead of the gray measuring fields CMY. All of the measuring fields can be scanned by the color measuring device 1 , which can then transmit the measured values to the control unit 4 for ink control purposes. The color values that have been measured in this way will then be used to control the ink metering devices in the printing units 10 of the offset printing press 7 .
[0023] The print control strip 13 shown in FIG. 3 likewise includes two rows. Each measuring field present in one ink zone 9 is provided twice. Thus, the color black B, the colors cyan C, magenta M and yellow Y as well as the spot colors X, Z, U, V are present both in the upper row and in the lower row of the print control strip 13 . Furthermore, the order of the measuring fields of one ink zone 9 in the upper row and in the lower row is different so that measuring fields of the same type are not directly above each other. If a measuring field is not to be evaluated due to printing problems, the redundant measuring field can be evaluated correctly in the case of locally limited printing errors by carrying out a plausibility check in the control unit 4 for the different color values which have been measured for the same measuring field. Measured values of neighboring ink zones 9 may be considered in the plausibility check. Of course, it is possible to integrate the gray measuring fields CMY which are known from FIG. 2 in the print control strip of FIG. 3 , for example by replacing the spot colors X, Z, U, V by gray measuring fields CMY if no spot colors are being used. However, if spot colors are used nevertheless, the number of the measuring fields for one ink zone needs to be increased in a corresponding way. This, however, would reduce the size of the measuring fields due to the predetermined width of the ink zone 9 . Since the measuring fields in FIG. 3 are redundant due to the two-row configuration, the reduction in size of the measuring fields does not cause the same deteriorations as in the known one-row structure of a print control strip 13 . Moreover, in the case of only slight deviations between measuring fields of the same type in the top and lower row of the print control strip 13 , the measured values can be averaged in the control unit 4 and the average value may be used to calculate the control values in the ink metering devices of the printing units 10 of the offset printing press. Thus, it is possible to avoid slight differences caused, for example, by ghosting.
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A print control strip to be applied to printing material during a multicolor printing process, includes multiple measuring fields associated with one ink zone on the printing material. The measuring fields, which are associated with one ink zone, include at least two gray measuring fields. A method of measuring fields in print control strips on printing material with a measuring device and a control unit connected thereto, and a method of controlling metering of ink in offset printing presses including at least one ink metering device in each printing unit and a control unit, are also provided.
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RELATED APPLICATIONS
The following applications contain subject matter related to the subject matter of the present application.
1. "Dual Mode LMS Nonlinear Data Echo Canceller" filed on even date herewith for Walter Y. Chen and Richard A. Haddad and bearing Ser. No. 438,598, now U.S. Pat. No. 4,977,591; and
2. "Noise Reduction Filter" filed on even date herewith for Walter Y. Chen and Richard A. Haddad and bearing Ser. No. 438,610.
The above-identified applications are assigned to the assignee hereof.
FIELD OF THE INVENTION
The present invention relates to a channel equalizer for improving the performance of data transmission over a regular telephone voice channel.
BACKGROUND OF THE INVENTION
The regular telephone voice channel has been used for digital data transmission since the early 1960's. The digital data is modulated onto a sine wave carrier signal whose frequency is within the voice band for transmission. The digital data is demodulated off the carrier signal after passing through the telephone channel. The device used to modulate digital data onto a carrier or demodulate digital data from a carrier is known as a modem. Three basic modulation techniques used by such modems are Amplitude Modulation, Frequency Modulation or Frequency Shift Keying, and Phase Modulation or Phase Shift Keying.
A regular telephone voice channel has a pass band from about 300 Hz to about 3300 Hz . However, the telephone voice channel is characterized by amplitude and phase deterioration at both the low and high frequency ends of this frequency band. The deterioration introduced by the telephone channel may make it difficult to confidently make a decision at a receiver as to the original transmitting value of a received signal. Accordingly, it is desirable to compensate for the undesirable frequency response characteristics of the voice telephone channel, so that an approximately flat frequency response is achieved across the voice pass band.
With some primary channel compensation techniques, such as compromise equalization, a regular telephone voice channel can transmit digital data at 1200 bits per second in full duplex, meaning two-way transmission at the same time.
A compromise equalizer is a transversal digital filter whose frequency response is the inverse of that of the average telephone channel. The use of the compromise equalizer in a modem brings a telephone voice channel one step closer to the desired flat voice band frequency response. However, since the frequency response of a particular telephone channel can differ very much from the average and varies with time, the compensation provided by the compromise equalizer is very limited.
The demand for higher transmission rates and the advancement of signal processing technology have led to the application of adaptive channel equalization. Adaptive channel equalization typically involves use of a digital filter with adaptive filter coefficients--i.e. a digital filter whose coefficients vary in time. An adaptive channel equalizer sets up its filter coefficients to model the inverse frequency response of a particular voice telephone channel at the beginning of a transmission session according to set of predetermined training data and keeps track of any channel variation thereafter by adaptively changing its filter coefficients. The adaptive channel equalizer's filter coefficients are set up according to each different individual telephone channel and any necessary changes are made continuously along with the variations of the particular telephone channel. Thus, the compensation provided by the adaptive channel equalizer is quite good. The adaptive channel equalizer has become a major component of high speed modems whose transmission rate is 2400 bits per second or higher.
The most commonly used adaptive signal processing algorithm for setting up filter coefficients and for keeping track of channel variations is the adaptive Least Mean Square (LMS) algorithm. The application of the LMS algorithm to the channel equalization problem is disclosed in R. W. Lucky, "Automatic Equalization for Digital Communication," Bell System Tech.J., Vol. 44, pp. 547-588, April 1965. Based on the error between known training data and a received signal formed by transmitting the training data via a particular telephone channel, the LMS algorithm sets up filter coefficients according to an approximate gradient one small quantity at a time, so as to make the error as small as possible. The adaptive channel equalizer employing the LMS algorithm sufficiently reduces the error introduced into transmitted data by the telephone channel so that a confident decision can be made about the original transmitting value of a received signal. A significant advantage of using the LMS algorithm for channel equalization is that the LMS algorithm requires a relatively small amount of computation and can be easily implemented using a VLSI chip.
Thus, the use of an adaptive LMS channel equalizer can significantly increase usable channel capacity and make the high speed modem a reality. However, the initial convergence speed of an adaptive LMS channel is slow and the minimum Mean Square Error (MSE) is high for higher speed modems. With a conventional LMS adaptive channel equalizer, one has to trade a large MSE for a fast convergence time.
An important component of the MSE of a conventional LMS adaptive channel equalizer is the channel additive noise. The conventional LMS adaptive channel equalizer only identifies and tracks channel parameters but pays no attention to noise filtering.
Alternative adaptive signal processing algorithms for better channel equalization have been proposed: see e.g., J. M. Cioffi, "Fast Transversal Filter Applications for Communications Applications," Ph.D. Dissertation, Stanford University, 1984; B. Mulgrew and C. F. N. Cowan, "An Adaptive Kalman Equalizer: Structure and Performance," IEEE Tran. on Acoust., Speech. SIgnal Processing, Vol. ASSP-35, No. 12, pp. 1727-1735, December 1987; C. A. Belfior and J. H. Park, "Decision Feedback Equalization," Proc. IEEE, Vol. 67,(8), pp. 1143-1156, August 1979. However, these equalizers all require more computation power than the conventional LMS channel equalizer. The rapid convergence provided by the algorithms utilized in these equalizers is only required in the startup period when the filter coefficients are being set up. Once the filter coefficients characteristic of the inverse frequency response of a particular telephone channel are identified, the required speed to track the slowly time varying channel is much slower. Hence, the computation power of many fast algorithms is wasted in normal operation.
In view of the foregoing, it as an object of the present invention to provide an adaptive channel equalizer which overcomes the shortcomings of the conventional LMS channel equalizer, which is structurally simple, and which requires a minimum of computation power. More particularly, it is an object of the present invention to provide an adaptive channel equalizer which not only adaptively estimates the inverse frequency response of a particular telephone channel, but also smooths received data to reduce the effects of channel additive noise so as to achieve a smaller minimum mean square error or a faster convergence time.
SUMMARY OF THE INVENTION
The present invention is directed to a dual mode LMS channel equalizer. The inventive dual mode channel equalizer uses the same simple LMS algorithm as is used in the conventional LMS channel equalizer described above. However, the inventive channel equalizer not only identifies and tracks telephone channel parameters--i.e. filter coefficients characteristic of the inverse frequency response of the channel--but also smooths the received data signal to mitigate the effects of channel additive noise. Because the effective noise level in the received data is reduced by the smoothing process a better set of channel parameters is identified. The improved performance can be translated into either a smaller squared estimation error or a faster initial convergence speed.
Because the variation in time of the channel parameters is relatively slow, both the channel parameter identification task and the data smoothing task share the same simple LMS algorithm in the channel equalizer of the present invention. Hence, in comparison to the conventional LMS adaptive channel equalizer, the inventive dual mode LMS adaptive channel equalizer provides a significant performance improvement with little additional cost.
In real time operation, the inventive channel equalizer first performs the channel identification task in a training period. Thereafter, the same LMS algorithm is switched to smooth the received data signal, while intermittently, the LMS algorithm is switched back to track the slowly changing channel parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG 1 schematically illustrates a conventional telephone voice channel used for data transmission.
FIG. 2 schematically illustrates a conventional LMS adaptive channel equalizer for use in the telephone voice channel of FIG 1.
FIG. 3 schematically illustrates the task to be performed by the inventive dual mode LMS channel equalizer.
FIG. 4 schematically illustrates a dual mode LMS channel equalizer in accordance with a illustrative embodiment of the present invention.
FIG. 5 compares the performance of a conventional LMS adaptive channel equalizer and the inventive dual mode LMS channel equalizer.
DETAILED DESCRIPTION OF THE INVENTION
The Detailed Description of the Invention is divided into the following subsections. Subsection A describes a conventional LMS adaptive channel equalizer. Subsection B describes the inventive dual mode LMS channel equalizer. Subsection C compares the performance of the conventional LMS adaptive channel equalizer and the inventive dual mode LMS channel equalizer.
A. Conventional LMS Adaptive Channel Equalizer
A system 10 used for the transmission of digital data via a telephone voice channel is illustrated in FIG. 1. The signal to be transmitted is represented by X(k). where k=0,1,2 . . . represents the discrete time variable. The signal X(k) is modulated onto a sine wave carrier by the transmitter 12 which illustratively forms part of a modem (not shown).
The signal X(k) is then transmitted via a voice telephone channel represented in FIG. 1 by the box 14. The channel impulse response (i.e. frequency response to an impulse driving signal) at the time k may be represented by the vector ##EQU1##
In addition, the signal X(k) is degraded by additive channel noise v(k). In FIG. 1, the noise generation is represented by the box 16.
Thus, the signal Z(k) which arrives at the channel equalizer 18 is degraded in two ways. One source of degradation results from the slowly changing impulse response H k of the channel 14 and another source of degradation is the additive channel noise V(k).
It is the role of the channel equalizer 18 to process the arriving signal values Z(k) so that a confident decision can be made at the receiver 20 as to the original transmitted signal values X(k).
The conventional LMS adaptive channel equalizer processes the arriving signal Z(k) to compensate for the time variable frequency response of the channel, but does not compensate for the channel additive noise V(k).
The impulse response of the channel equalizer at the time k is represented by the vector ##EQU2## The vector C k is an estimate of the inverse channel impulse response. The values C 1 ,k. . . C n ,k may be viewed as the filter coefficients of an adaptive digital filter comprising the channel equalizer 18.
The conventional adaptive channel equalizer utilizes the following LMS algorithm to estimate C k+1 :
C.sub.k+1 =C.sub.k +μZ.sub.k (X(k)-Z.sub.k.sup.T C.sub.k) (3)
where Z k is a received signal vector made up of the current and previous n-1 received signal values, i.e. ##EQU3## Normally the values X(k) are not available to the channel equalizer which executes the algorithm of Eq(3). To the contrary, in normal operation it is the role of the channel equalizer to provide as an output the values X(k) based on the received signal values Z(k).
During a training period the vector C k is set up using known training X(k)'s. After the channel equalizer converges to a minimum mean square error using the training X(k)'s, the channel equalizer switches to normal operation wherein the values X(k) are not available.
To reconstruct the originally transmitted X(k)'s from the actually received Z(k)'s, the virtual match function is utilized. First, the quantity
C.sub.k.sup.T Z.sub.k =Z.sub.k.sup.T C.sub.k (6)
is formed. This operation compensates for the effect of the channel frequency response on the received signals Z(k). During an iteration k, to obtain a value X(k) from a quantity C k T ·Z k , a decision block which stores all possible values of X(k) is utilized. For any given iteration, k, of the algorithm of Equation 3, X(k) is taken as the value stored in the decision block which is closest to C k T Z k .
FIG. 2 schematically illustrates a conventional LMS adaptive channel equalizer 18. The inputs to the channel equalizer are the received signal values Z(k). The outputs from the channel equalizer are the originally transmitted values X(k). The channel equalizer 18 as shown in FIG. 2 comprises one shift register 30 and one non-shift register 32. The shift register 30 stores the values comprising the received signal vector Z k . The non-shift register 32 stores the filter coefficients which make up the estimated inverse channel impulse response C k . To obtain the value X(k) during the k th iteration, the multiplier 36 is used to form the quantity C k T Z k . This quantity is then transmitted to the decision block 40 which performs the virtual match function described above to obtain a signal value X(k). The estimated inverse channel impulse response is then updated, i.e. the quantity C k+1 is then formed, by first using the subtraction unit 42 to form the error quantity X(k)-C k T Z k . This error quantity is then multiplied by the adaptation step size μ using the unit 44 and multiplied by the vector quantity Z k using the multiplier unit 46. The resulting vector quantity μZ k (X(k)-C k T Z k ) is then added to C k to form C k+1 .
The performance of a channel equalizer, such as the conventional LMS adaptive channel equalizer described above, is usually judged according to its mean square error (MSE). The mean square error level is given by
ξ.sub.k =E[X(k)-C.sub.k.sup.T Z.sub.k ].sup.2 (7)
where E[x] is the expectation value of x. Thus the MSE depends on the difference between the original transmitted signal value X(k) and the signal value obtained by compensating the received signal for the frequency response of the channel as indicated by C k T Z k .
The mean square error of an adaptive LMS channel equalizer decreases as the number of iterations, k, increases, until a minimum MSE level is reached. As indicated above, the conventional adaptive LMS channel equalizer's MSE level is usually brought down to the minimum during the startup or training period. The minimum MSE level is related to the tap length n of the channel equalizer and the adaptation step size μ. A large minimum MSE is expected if the tap length of the channel equalizer is not long enough to cover the inverse channel impulse response which generally is a finite impulse response. A large step size μ also causes a high MSE level, provided that μ is still small enough to make the LMS algorithm stable. The step size μ will also affect the initial convergence time, i.e. the number of iterations required to bring the MSE down to its minimum.
Thus, as indicated above, the use of a conventional LMS adaptive channel equalizer can significantly increase the capacity of a telephone voice channel for digital data transmission and make the high speed modem a reality. However, at least in part because the conventional LMS adaptive channel equalizer fails to treat the channel additive noise V(k), the conventional LMS equalizer has a high MSE for high speed modems and a slow convergence speed.
B. Dual Mode LMS Channel Equalizer
As indicated above, the present invention is a channel equalizer which utilizes the LMS algorithm to both smooth the received signal Z(k) to mitigate the effects of channel additive noise V(k) and to estimate the inverse channel impulse response.
In principal, it is desirable for the channel equalizer to perform the operations illustrated in FIG. 3, where the Z(k)'s are the received signal values with additive channel noise, the Y(k)'s represent the smoothed received signal and the C i ,k 's represent the inverse channel impulse response.
In particular, as shown in FIG. 3
Y(k)=Z(k)-V(k) (8)
and
X(k)=ΣC.sub.i,k Y(k-i+1) (9)
Thus, a two-step process is used to obtain the value X(k) for each such iteration k. First, the subtraction units 52 are used to subtract the channel additive noise values v(k),v(k-1) . . . v(k-1+1) from the received signal values Z(k), Z(k-1) . . . Z(k-n+1), to obtain the smoothed signal values Y(k),Y(k-1) . . . Y(k-n+1) (It should be noted that in FIG. 3, the boxes 50 represent unit delays.) The values Y(k),Y(k-1) . . . Y(k-n+1) may be viewed as forming a smoothed signal vector Yk.
After, the smoothed signal vector Yk is obtained by subtracting the channel additive noise, it is then necessary to compensate for the frequency response of the channel. The inverse channel impulse response is represented by the filter coefficients c 1 ,k, C 2 ,k . . . C n ,k which form the vector C k . To obtain the value X(k) the multipliers 54 and summation unit 56 are used to perform the operation ##EQU4##
In reality, however, neither the channel additive noise signal values V(k) nor the time variable inverse channel impulse response C k are known. Thus, the present invention utilizes the LMS algorithm to obtain an estimate C k for the vector C k . In addition, the present invention utilizes the LMS algorithm to estimate the smoothed received signal vector Y k . More particularly, the present invention utilizes a prior prediction or estimate Y k/k-1 and the LMS algorithm to form an updated estimate Y k/k . (Note that the notation Y k/k-1 means a prediction or estimate of Y k made during the (k-1)th iteration of the LMS algorithm). In short the channel equalizer of the present invention is known as a dual mode LMS channel equalizer because the LMS algorithm performs two roles: it serves to smooth the receive data signal to mitigate the effects of the additive channel noise (i.e. estimate the vector Y k ) and estimate the inverse channel impulse response (i.e. estimate the vector C k ).
The operation of the dual mode LMS channel equalizer of the present invention is divided into a startup training phase and a dual mode phase.
The operation for the startup phase is the same as that of a conventional LMS channel equalizer. The channel equalizer obtains an estimate C k of the inverse channel impulse response C k by executing the following expression based on known training X(k)'s.
C.sub.k+1 =C.sub.k +μZ.sub.k (X(k)-Z.sub.k.sup.T C.sub.k) (11)
with the initial value C o =0.
As indicated above, ##EQU5##
The vector Z k may also be written as ##EQU6## The purpose of the shift matrix F and the matrix G is to construct a new received signal vector Z k from the previous received signal vector Z k-1 and the new received signal value Z(k).
When k=n c , after the inverse channel response has been estimated and the channel equalizer reaches an MSE level determined by the channel additive noise, the dual mode channel equalizer begins to operate in the dual mode phase.
In the dual mode phase, the channel equalizer normally executes the following smoothed received signal vector estimation operation while allowing the estimated inverse channel impulse response to remain unchanged:
Y.sub.k+1/k+1 =Y.sub.k+1/k +βC.sub.k (X(k)-C.sub.k.sup.T Y.sub.k+1/k) (16)
C.sub.k+1 =C.sub.k (18)
Y.sub.k+1/k =FY.sub.k/k +GZ(k) (18)
In equation (16), the virtual match function is used to obtain X(k) from C k T Y k+1/k .
When k equals a multiple of M in the dual mode phase, the echo canceller updates the estimated inverse channel impulse response by executing the following expressions:
C.sub.k+1 =C.sub.k +μY.sub.k/k (X(k)-Y.sub.k/k.sup.T C.sub.k) (19)
Y.sub.k+1/k+1 =FY.sub.k/k +GZ(k) (20)
Generally, M should be small enough such that the adaptive channel tracking process can catch up with any slow channel variation. In addition, M should not be too small such that the received data signal smoothing operation can still be properly carried out even though the operation is skipped once every M th cycle. Typically, M is on the order of the tap length n of the channel equalizer. Illustratively, the tap length is n=11.
FIG. 4 schematically illustrates a circuit implementation of a dual mode LMS channel equalizer 18'. The inputs to the channel equalizer 18' are the received signal values Z(k) on line 80. The outputs of the channel equalizer 18' on line 82 are the reconstructed original transmitted signal values X(k).
The channel equalizer 18' contains one shift register 84 and one non-shift register 86. The received signal values Z(k) enter the shift register 84 on line 80.
The channel equalizer 18' of FIG. 4 also contains a switch mechanism 90. When the switch mechanism 90 is in the position b, the channel equalizer performs the inverse channel impulse response estimation task. When the switch mechanism 90 is in the position a, the smoothed received signal vector estimation task is performed.
During the training period, when the operation of equation (11) is carried out, the switch mechanism 90 is in position b and the received signal vector Z k is stored in the shift register 84. Known training values of the signal X(k) are supplied (rather than using the decision unit 92 to reconstruct values of X(k) using the virtual match function). The multiplier unit 94, the subtraction unit 96, the scaler-multiplier 98, and the multiplier unit 100 are used to carry out the operation of equation (11) to obtain a primary estimate of the inverse channel impulse response C k . The unit 98 supplies the adaptation step size μ.
As indicated above, when k=n c the channel equalizer switches operation to the dual mode phase. Normally, during the dual mode phase, the switch mechanism 90 is in position a and the smoothed received signal vector estimation task is performed. In this case the shift register 84 stores the estimated smoothed received signal vector Y k/k . The values Z k) enter the shift register 84 at the left hand side thereof and the values Z(k) are shifted one position to the right during each iteration while being smoothed to form the vector Y k/k using the operation of equation (16). The operation of equation (16) is carried out using the multiplier unit 94, the subtraction unit 96, the scaler-multiplier unit 99 and the multiplier unit 101. The scaler multiplier unit 99 supplies the adaptation step size β. During the dual mode phase, when the iteration number k is a multiple of M, the switch mechanism 90 switches to position b to update the inverse channel frequency response by carrying out the operation of equation (19).
C. Performance Comparison
In comparison to a conventional LMS adaptive channel equalizer, the inventive dual mode LMS channel equalizer can be used to achieve either a smaller minimum MSE or a faster convergence time.
For example, consider an illustrative simulated transmission channel whose signal-to-noise ratio is 20 dB. With an adaptation step size μ set equal to 0.075, the conventional LMS adaptive channel equalizer achieves a minimum MSE level of approximately 10 -2 . A dual mode channel equalizer with the same value for μ and with a value of β (the adaptation step size for the signal smoothing task) set equal to 0.5, achieves a minimum MSE level of about 10 -2 .4. This minimum MSE level could be achieved using the conventional LMS channel adaptive channel equalizer only in a system with a signal-to-noise ratio of 25 dB. Thus, the inventive dual mode channel equalizer achieves a 5 dB signal-to-noise improvement.
In the foregoing example, the dual mode adaptive channel equalizer was used to achieve a smaller minimum MSE level. Alternatively, by using a larger value for μ, the dual mode LMS channel equalizer can be used to achieve a faster convergence time. Consider an illustrative simulated transmission channel with a signal-to-noise ratio of 30 dB. The conventional LMS channel equalizer with an adaptation step size μ of 0.025 has a residual squared error of 10 -3 .3 and converges in about 400 iterations. In contrast, the inventive dual mode channel equalizer with an adaptation step size μ set equal to 0.075 and a signal smoothing adaptation step size μ set equal to 0.3, achieves a residual squared error of 10 -3 .4 but requires only 150 iterations to converge.
FIG. 5 illustrates the performance of conventional LMS adaptive channel equalizer and the performance of the inventive dual mode channel equalizer for a model AT&T telephone channel (see e.g., K. Abend and B. D. Fritchman, "Statistical Detection for Communication Channels With Intersymbol Interference," Proc. IEEE, Vol. 158, pp. 779-785) with a signal-to-noise ratio of 20 dB. In FIG. 5, the abscissa plots the number of iterations and the ordinate plots the mean square error on a logarithmic scale.
Curve 300 plots the mean square error of a conventional LMS channel equalizer with an adaptation step size μ set equal to 0.075 as a function of the number of iterations. The channel equalizer converges to a minimum mean square error of 10 -1 .7 in about 200 iterations. Curve 400 plots the mean square error of a dual mode channel equalizer with μ=0.075 and β=0.3 as a function of the number of iterations. The startup or training phase and the dual mode phase are indicated in FIG. 5. As indicated in FIG. 5, the startup or training phase is about 200 iterations. The mean square error during the dual mode phase is about 10 -2 .2 which is significantly lower than the mean square error of the conventional LMS adaptive channel equalizer.
CONCLUSION
A dual mode channel equalizer for improving the transmission of digital data over the regular telephone voice channel has been disclosed. The dual mode channel equalizer uses an LMS algorithm to smooth a received data signal to compensate for additive channel noise and to estimate the inverse channel impulse response to compensate for the frequency response of the channel.
Finally, the above-described embodiments of the invention are intended to be illustrative only. Numerous alternative embodiments may be devised by those skilled in the art without departing from the spirit and scope of the following claims.
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A dual mode LMS channel equalizer is disclosed. The inventive channel equalizer utilizes an LMS algorithm to both identify channel parameters and to smooth the received data signal to mitigate the effects of channel additive noise. In real time operation, the inventive equalizer first identifies the channel parameters in a training period. Thereafter, the same LMS algorithm is switched to smooth the received data signal, while intermittently, the LMS algorithm is switched back to track the slowly changing channel parameters. In comparison with the conventional LMS adaptive channel equalizer, the inventive dual mode channel equalizer achieves a significant performance improvement at little additional cost.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image scanning apparatus, an image forming apparatus, and an image scanning method, and, more particularly to an image scanning apparatus, an image forming apparatus, and an image scanning method that use a contact-type sensor.
2. Description of the Related Art
An image scanning apparatus such as a scanner and an image forming apparatus such as a copying machine include optical systems for scanning an original. The optical systems can be classified into a “reduction optical system” and a “contact optical system” (a CIS system: Contact Image Sensor).
The “reduction optical system” is a system for, while returning reflected light from an original many times with a mirror, leading the reflected light to a condenser lens and reading a reflection signal from the original with a sensor provided in a position apart from the original. Compared with the “contact optical system”, the “reduction optical system” has an advantage that a large depth of field can be secured. However, since an optical path length from the original to the sensor is large, in general, a physical length of the “reduction optical system” is large.
On the other hand, the “contact optical system” is a system for arranging a sensor under an original to be in contact with the original. The “contact optical system” has a disadvantage that a depth of field is small but has an advantage that a physical size thereof is small.
An original obtained by partially sticking two or more originals together (hereinafter referred to as stuck original) is included in originals to be scanned by the scanner or the copying machine. Since such a stuck original has a step in a stuck portion, the portion of the step may form a shade (hereinafter referred to as original shade) and appear as a black line in image data scanned.
In the case of the “reduction optical system”, since it is possible to irradiate direct light from a light source and reflected light from a mirror on the step of the stuck portion from different directions, an influence of the original shade is relatively small.
On the other hand, since the “contact system optical system” is a form in which a mirror is not provided, there is a problem in that, when an original is irradiated by one light source from a direction obliquely below the original, an influence of the original shade of the stuck portion is large.
In order to solve this problem, in the “contact system optical system”, a method of providing two light sources on the left and the right across a contact-type sensor and irradiating a step portion of an original from left and right two directions obliquely below the original to prevent occurrence of an original shade is considered.
However, since this method is a form in which two light sources are used, there is a problem in that power consumption increases.
SUMMARY OF THE INVENTION
The invention has been devised in view of the circumstances and it is an object of the invention to provide an image scanning apparatus and an image forming apparatus, which include contact optical systems, and an image scanning method that can reduce power consumption while preventing occurrence of an original shade of a stuck original.
In order to attain the object, an image scanning apparatus according to an aspect of the invention includes: a sensor disposed under an original stand, on which an original is placed, to be in close contact with the original stand; a first light source that irradiates light on a scanning area of the original from a direction obliquely below the original; and a second light source that is disposed in a position opposite to the first light source across the sensor and irradiates light on the scanning area of the original from a direction obliquely below the original opposite to a direction of the light irradiated from the first light source. When the original is not a stuck original, the first light source is turned on and, when the original is a stuck original, the first light source and the second light source are turned on.
In order to attain the object, an image forming apparatus according to another aspect of the invention includes: a scanner unit; an image processing unit that applies various kinds of image processing to image data generated by the scanner unit; and an image forming unit that prints the image data subjected to the image processing on recording paper. The scanner unit includes: a sensor disposed under an original stand, on which an original is placed, to be in close contact with the original stand; a first light source that irradiates light on a scanning area of the original from a direction obliquely below the original; and a second light source that is disposed in a position opposite to the first light source across the sensor and irradiates light on the scanning area of the original from a direction obliquely below the original opposite to a direction of the light irradiated from the first light source. When the original is not a stuck original, the first light source is turned on and, when the original is a stuck original, the first light source and the second light source are turned on.
In order to attain the object, an image scanning method according to still another aspect of the invention includes the steps of: scanning an original using a sensor disposed under an original stand, on which the original is placed, to be in close contact with the original stand; irradiating light on a scanning area of the original from a direction obliquely below the original using a first light source; and irradiating light on the scanning area of the original from a direction obliquely below the original opposite to a direction of the light irradiated from the first light source using a second light source that is disposed in a position opposite to the first light source across the sensor. When the original is not a stuck original, the first light source is turned on and, when the original is a stuck original, the first light source and the second light source are turned on.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a diagram showing an example of structures of an image scanning apparatus and an image forming apparatus according to an embodiment of the invention;
FIG. 2 is a diagram showing an example of a structure of a CIS unit according to the embodiment;
FIGS. 3A and 3B are diagrams schematically showing a state of an original shade that occurs when a stuck original is scanned only by a main lamp;
FIGS. 4A and 4B are diagrams schematically showing a state in which occurrence of an original shade can be reduced when a stuck original is scanned by both a main lamp and an auxiliary lamp;
FIG. 5 is a flowchart showing an example of an operation, in particular, a lighting control method for a main lamp and an auxiliary lamp according to a first embodiment;
FIG. 6 is a flowchart showing an example of an operation, in particular, a lighting control method for a main lamp and an auxiliary lamp according to a second embodiment;
FIGS. 7A and 7B are diagrams for explaining characteristics of a stuck original used to automatically determine whether an original is a stuck original; and
FIG. 8 is a diagram for explaining a lighting control method for a main lamp and an auxiliary lamp in the case in which an ADF is used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of an image scanning apparatus, an image forming apparatus, and an image scanning method according to the invention will be hereinafter explained with reference to the drawings.
(1) Structure of the Image Forming Apparatus
FIG. 1 is a diagram showing an example of a structure of an image forming apparatus 1 according to an embodiment of the invention.
The image forming apparatus 1 includes an image scanning apparatus 2 (a scanner unit 2 ), an image processing unit 3 , an image forming unit 4 , a paper feeding unit 5 , a paper discharging unit 6 , a control unit 7 , and an operation unit 8 .
The image scanning apparatus 2 has an original glass stand 25 on which an original 100 is placed. A contact-type sensor (CIS) unit 20 is provided under the original glass stand 25 to be in close contact with the original glass stand 25 .
As indicated by an arrow in the figure, the CIS unit 20 scans the original 100 while moving in a sub-scanning direction from a leading end to a trailing end of the original 100 placed on the original glass stand 25 and outputs image data scanned to the image processing unit 3 .
An original bumping plate 26 is provided for positioning of the original 100 at a front end of the original glass stand 25 . A white reference plate 27 is provided below the original bumping plate 26 . The white reference plate 27 is used as a reference reflection plate in correcting non-uniformity and the like of an amount of light of a light source and sensitivity of a sensor (shading correction) with respect to a main scanning direction (a depth direction perpendicular to the sub-scanning direction).
The image data outputted from the CIS unit 20 is subjected to various kinds of image processing such as shading correction, color conversion processing, space filtering processing, and tone correction processing in the image processing unit 3 .
The image data subjected to the image processing is inputted to the image forming unit 4 . The image forming unit 4 exposes and develops the image data to form a toner image, for example, on a photosensitive drum (not shown) according to an electrophotographic process or the like.
On the other hand, recording paper supplied from the paper feeding unit 5 is conveyed to the image forming unit 4 . In the image forming unit 4 , the toner image is transferred onto the recording paper from the photosensitive drum and fixed on the recording paper. An image is printed on the recording paper. The recording paper having the image printed thereon is discharged to the outside from the paper discharging unit 6 .
The control unit 7 includes a CPU and the like and performs control for the entire image forming apparatus 1 . The operation unit 8 is connected to the control unit 7 . The operation unit 8 is also called a control panel and includes a liquid crystal display and a touch panel or various switches.
(2) Structure of the CIS Unit
FIG. 2 is a diagram showing an example of a structure of the CIS unit 20 . The CIS unit 20 includes two exposure lamps, namely, a main lamp (a first light source) 21 and an auxiliary lamp (a second light source) 24 .
The main lamp 21 includes, for example, a light guide tube extending in the main scanning direction and three LEDs of red, green, and blue provided at one end of the light guide tube. Light radiated from the LEDs is deflected while propagating through the light guide tube and uniformly irradiates the original in the main scanning direction.
It is possible to output image data of R, G, and B with respect to a color original by moving the CIS unit 20 in the sub-scanning direction while sequentially switching the three LEDs of red, green, and blue.
On the other hand, the auxiliary lamp 24 is, for example, a light source constituted by an LED linear array of YG (Yellow-Green). As described later, in scanning a stuck original, occurrence of an original shade of the stuck original is prevented by irradiating the original from a direction different from a direction of the main lamp 21 .
The CIS unit 20 further includes a self-focusing lens 22 and a CCD sensor (a sensor) 23 .
The self-focusing lens is a lens also called a selfocs lens. The self-focusing lens 22 is constituted by arranging cylindrical lens units in an array shape in the main scanning direction.
The main lamp 21 and the auxiliary lamp 24 are arranged below the original glass stand (an original stand) 25 across this self-focusing lens 22 .
Reflected light from an original placed on the original glass stand 25 is made incident on the self-focusing lens 22 via a glass of the original glass stand 25 , condensed on the self-focusing lens 22 , and focused on the CCD sensor 23 .
FIG. 2 shows a state in which the usual original 100 (an original that is not a stuck original) is scanned. In this case, light is radiated only from the main lamp 21 .
On the other hand, FIGS. 3A and 3B are diagrams schematically showing a state of an original shade 101 that occurs when a stuck original 100 a is scanned.
The stuck original 100 a is, as shown in FIG. 3A , obtained by sticking a partial original 100 b on recording paper. This is a form frequently used, for example, when one original is created by cutting and sticking plural originals and when an original is corrected.
In the stuck original 100 a , a step is formed in a portion at an edge of the partial original 100 b . Therefore, when the original is scanned only by the main lamp 21 , the step portion forms a shade to cause the original shade 101 .
FIG. 3B is a diagram schematically showing a state in which the original shade 101 occurs in a formed image as a black line on a line.
FIGS. 4A and 4B are diagrams showing a state in which the auxiliary lamp 24 is turned on in addition to the main lamp 21 in order to prevent the occurrence of such an original shade 101 .
Irradiated light from the auxiliary lamp 24 is irradiated on the stuck original 100 a from a direction obliquely below the stuck original 100 a different from a direction of the main lamp 21 to prevent a shade from being caused by the step in the edge portion of the partial original 100 b . As a result, as shown in FIG. 4B , it is possible to form a clear image without the original shade 101 even in the edge portion of the partial original 100 b.
(3) Operations (First Embodiment)
FIG. 5 is a flowchart for explaining an example of operations of the image forming apparatus 1 according to this embodiment (including operations of the image scanning apparatus 2 ), in particular, operations according to lighting control for the main lamp 21 and the auxiliary lamp 24 .
First, a user determines, for example, visually whether an original to be scanned by the image forming apparatus 1 is the stuck original 100 a (step ST 1 ).
When the original is the stuck original 100 a , the user operates the operation unit 8 and sets the image forming apparatus 1 in a “stuck original mode” (step ST 2 ). The “stuck original mode” set is stored in, for example, an original determining unit 70 of the control unit 7 .
The user depresses a start key provided in the operation unit 8 (step ST 3 ). Scanning of the original is started under the control by the control unit 7 (step ST 4 ).
The original determining unit 70 of the control unit 7 determines whether a set mode is the “stuck original mode” (step ST 5 ). When the set mode is the “stuck original mode”, the original determining unit 70 simultaneously turns on the two exposure lamps, the main lamp 21 and the auxiliary lamp 24 (step ST 7 ) and performs scanning of the original (step ST 8 ).
As a result, as shown in FIGS. 4A and 4B , it is possible to form a clear image that does not cause the original shade 101 in the stuck portion even in the stuck original 100 a.
On the other hand, when the set mode is not the “stuck original mode”, the original determining unit 70 turns on only the main lamp 21 (step ST 6 ) and performs scanning of the original (step ST 8 ).
When the original is not the stuck original 100 a , it is unlikely that the original shade 101 occurs. It is possible to form a clear image by turning on only the main lamp 21 . It is possible to save wasteful power consumption by turning off the auxiliary lamp 24 .
When the scanning of the original ends (step ST 9 ), in the case of the “stuck original mode”, the original determining unit 70 turns off both the main lamp 21 and the auxiliary lamp 24 . When the set mode is not the “stuck original mode”, the original determining unit 70 turns off only the main lamp 21 (step ST 10 ).
(4) Operations (Second Embodiment)
The form shown in FIG. 5 is a form in which the user determines whether an original to be scanned is the stuck original 100 a and operates the operation unit 8 on the basis of the determination to set a mode to the “stuck original mode”.
On the other hand, a second embodiment is a form in which the image forming apparatus 1 (or the image scanning apparatus 2 ) determines whether an original to be scanned is the stuck original 100 a and automatically sets a mode to the “stuck original mode”.
FIG. 6 is a flowchart showing an example of operations of the image forming apparatus 1 (or the image scanning apparatus 2 ) according to the second embodiment.
A user depresses a start key in order to start scanning of an original (step ST 11 ).
In the second embodiment, first, preliminary scanning is performed according to the depression of the start key (step ST 12 ). Since the scanning is performed by turning on only the main lamp 21 , power consumption is relatively small.
For example, the original determining unit 70 provided in the control unit 7 determines whether an original scanned is the stuck original 100 a on the basis of image data obtained by the preliminary scanning (step ST 13 ).
FIGS. 7A and 7B are diagrams schematically showing characteristics of the original shade 101 that occurs when an original is the stuck original 100 a . Thickness of the partial original 100 b stuck is usually limited to a certain range. Therefore, width W of the original shade 101 appearing in image data is usually limited to a certain range as well.
In addition, it is less likely that density of the original shade 101 changes at random within the width W of the original shade. The original shade 101 has a characteristic that the density usually changes monotonously. By adopting these characteristics found in the original shape in the stuck portion as determination criteria, it is possible to determine whether the original scanned by the preliminary scanning is the stuck original 100 a.
The original determining unit 70 of the control unit 7 sets the “usual mode” or the “stuck original mode” on the basis of a result of the determination (steps ST 14 and ST 15 ).
In the case of the “stuck original mode” (Yes in step ST 16 ), the original determining unit 70 turns on both the main lamp 21 and the auxiliary lamp 24 (step ST 18 ). In the case of the “usual mode” (No in step ST 16 ), the original determining unit 70 turns on only the main lamp 21 (step ST 17 ).
In this lighting state, the original determining unit 70 performs main scanning (step ST 19 ). When the scanning of the original ends (step ST 20 ), in the case of the “stuck original mode”, the original determining unit 70 turns off both the main lamp 21 and the auxiliary lamp 24 . When a mode is not the “stuck original mode”, the original determining unit 70 turns off only the main lamp 21 (step ST 21 ).
In the second embodiment, since the preliminary scanning is required, longer time is taken for scanning. However, time and labor for visual determination of a state of an original by the user and time and labor for manual setting of the “stuck original mode” are saved.
As scanning of an original, there is a form of scanning by an automatic document feeder (ADF) other than the form of placing an original on an original stand and scanning the original.
FIG. 8 is a diagram schematically showing an example of an original scanning method using the ADF. Usually, a frequency of scanning the stuck original 100 a using the ADF is not so high.
However, even if a user scans the stuck original 100 a using the ADF, as shown in FIG. 8 , when the stuck original 100 a is scanned by the CIS unit 20 , the stuck original 100 a is scanned in a slightly curved state. Therefore, occurrence of the original shade 101 due to the step of the stuck portion is reduced compared with the case in which the stuck original 100 a is placed flat on the original glass stand 25 .
Thus, in this embodiment, in scanning an original using the ADF, the form of turning on only the main lamp 21 is adopted with priority given to a reduction in power consumption. Then, if the original shade 101 is conspicuous in an image formed, the form may be changed to the form of turning on both the main lamp 21 and the auxiliary lamp 24 according to operation of the operation unit 8 .
The invention is not limited to the embodiments themselves. At a stage of carrying out the invention, it is possible to embody the invention by modifying the components without departing from the spirit of the invention. It is possible to form various inventions according to appropriate combinations of the plural components disclosed in the embodiments. For example, several components may be deleted from all the components disclosed in the embodiments. Moreover, the components in the different embodiments may be appropriately combined.
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An image forming apparatus according to the invention includes: a sensor disposed under an original stand, on which an original is placed, to be in close contact with the original stand; a first light source that irradiates light on a scanning area of the original from a direction obliquely below the original; and a second light source that is disposed in a position opposite to the first light source across the sensor and irradiates light from a direction obliquely below the original opposite to a direction of the light irradiated from the first light source. When the original is not a stuck original, the first light is turned on and, when the original is a stuck original, the first light source and the second light source are turned on. According to the image forming apparatus according to the invention, it is possible to reduce power consumption while preventing occurrence of an original shade of a stuck original in a contact-type optical system.
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BACKGROUND
[0001] Optical micro-electro-mechanical system (MEMS) devices are often integrated into a silicon substrate using semiconductor processing techniques and then sealed under a glass cover to protect the device from environmental damage while still allowing light to reach the device. A Fabry Perot filter light receptor spectrophotometer, for example, uses solid state light sensors and Fabry Perot filters integrated into a silicon substrate. Some of the components in such spectrophotometers are very delicate, making them particularly susceptible to damage from the higher temperatures and contaminants present in conventional MEMS sealing/packaging processes.
DRAWINGS
[0002] FIG. 1 is a plan view illustrating an optical micro device package according to one embodiment of the disclosure.
[0003] FIG. 2 is a section view taken along the line 2 - 2 in FIG. 1 .
[0004] FIG. 3 is a plan view illustrating a micro device wafer assembly according to one embodiment of the disclosure.
[0005] FIG. 4 is a detail view of a portion of the wafer assembly shown in FIG. 3 .
[0006] FIGS. 5-10 are section views illustrating one embodiment of a sequence of steps for processing a wafer assembly to form individual micro device packages such as the one shown in FIGS. 1 and 2 .
[0007] FIGS. 11-15 are section views illustrating another embodiment of a sequence of steps for processing a wafer assembly to form individual micro device packages such as the one shown in FIGS. 1 and 2 .
DESCRIPTION
[0008] Embodiments of the present invention were developed in an effort to improve MEMS packaging for Fabry Perot filter light receptor spectrophotometers. Embodiments of the invention, however, are not limited to Fabry Perot filter light receptor spectrophotometer MEMS packaging but may be used in for packaging spectrophotometers in general as well as other types of optical MEMS devices. Hence, the following description should not be construed to limit the scope of the invention, which is defined in the claims that follow the description.
[0009] FIG. 1 is a plan view illustrating a micro device package 10 according to one embodiment of the disclosure. FIG. 2 is a section view taken along the line 2 - 2 in FIG. 1 . Referring to FIGS. 1 and 2 , device package 10 includes a glass or other suitable transparent cover 12 , a substrate 14 and an optical micro device 16 integrated into substrate 14 . Micro device 16 represents generally one or more optical devices that include a solid state light sensor, such as a Fabry Perot filter light receptor spectrophotometer for example. Cover 12 may also include a coating 18 on one or both surfaces 20 , 22 to filter some wavelengths, to deter reflection (an “anti-reflection” coating), and/or to otherwise alter the characteristics of transparent cover 12 . In a package 10 for Fabry Perot filter light receptor spectrophotometer device 16 , for example, cover 12 typically will include anti-reflective coatings 18 .
[0010] “Transparent” means the property of transmitting electromagnetic radiation along at least that part of the spectrum that includes wavelengths of infrared, visible and/or ultra-violet light. The nature or degree of transparency for cover 12 may vary according to the characteristics of optical device 16 . For example, for an optical micro device 16 used to modulate color in a digital projector or to measure color in a Fabry Perot filter light receptor spectrophotometer, cover 12 will be transparent at least to visible light but need not be transparent to infrared and ultraviolet light. In another example, for an optical micro device 16 used to generate, modulate or detect light in the infrared range, cover 12 will be transparent at least to infrared light but need not be transparent to visible and ultraviolet light.
[0011] A primary surface 20 on cover 12 is affixed to a primary surface 24 on substrate 14 by a spacer 26 that surrounds micro device 16 . Micro device 16 is enclosed within a cavity 28 defined by cover 12 , substrate 14 and spacer 26 . Electrical contact pads 30 are positioned along an exposed periphery 31 of substrate 14 for making electrical contact to micro device 16 through a circuit structure (not shown) integrated into substrate 14 . In the embodiment shown, coating 18 forms cover primary surface 20 at spacer 26 and a layer 32 forms substrate primary surface 24 at spacer 26 . Layer 32 represents generally, for example, a layer of silicon dioxide, silicon nitride, or silicon carbide, a polymeric passivation layer, or metal traces, or a combination of any such elements, that may be exposed along substrate surface 24 .
[0012] As described in more detail below, spacer 26 is formed from an SU- 8 photoresist (commercially available from Microchem Corp.) or another suitable light sensitive, photo definable adhesive material that is fully curable at lower temperatures. SU-8 photoresists are epoxy based negative resists fully curable at temperatures under 300° C. that will adhere to and seal a variety of materials commonly used in micro device fabrication and packaging. Although spacer 26 is shown bonding together surface coating 18 on cover 12 and a layer 32 on substrate 14 , other configurations are possible. For example, an SU-8 or other suitable light sensitive adhesive material spacer 26 could be used to bond a glass or other transparent cover 12 directly to the surface of a silicon substrate 14 .
[0013] With continued reference to FIGS. 1 and 2 , in one example embodiment for a spectrophotometer MEMS device 16 , a gap 33 of 20 μm-50 μm should be maintained between cover 12 and device 16 for proper device performance. Thus, in this embodiment, spacer 26 should be 20 μm-50 μm thick. In addition, to facilitate the wafer scale fabrication process described below, an SU-8 spacer 26 can be comparatively narrow, as little as 50 μm for example, and still maintain adequate bonding. In the embodiment shown in FIG. 1 , the width W x of spacer 26 in the X direction ( FIG. 1 ) is larger where there are no contact pads and the width W y of spacer 26 is smaller in the Y direction ( FIG. 1 ) near contact pads 30 . The width of spacer 26 for any particular application may vary from that shown depending, for example, on the bond strength needed to meet process and reliability requirements for the application, the type of light sensitive adhesive used, and any limitations in the fabrication process. SU-8 photoresists and other such photo-definable adhesives are particularly advantageous for spectrophotometer packaging because the thickness and width of spacer 26 and its alignment to the underlying structure may be precisely defined. In addition, the techniques for processing these adhesive materials is comparatively clean, thus reducing the risk that debris or other contaminants will damage the delicate components in optical device 16 or alter the transparency characteristics of cover 12 .
[0014] FIG. 3 is a plan view illustrating an in-process optical micro device wafer assembly 34 containing individual in-process device packages 36 . FIG. 4 is a detail view of a portion of the wafer assembly 34 shown in FIG. 3 . FIGS. 5-10 are section views illustrating one embodiment of a sequence of steps for fabricating wafer assembly 34 and singulating the individual device packages 36 from wafer assembly 34 to form packages 10 shown in FIGS. 1 and 2 . FIGS. 5-7 , 9 and 10 are taken along the X-X section line shown in FIG. 4 . FIG. 8 is taken along the Y-Y section line shown in FIG. 4 . Conventional techniques well known to those skilled in the art of semiconductor processing may be used to form the structures described below. Thus, the details of those techniques are not included in the description except where it may be desirable to a better understanding of the innovative aspects of an embodiment to describe a specific technique or processing parameter.
[0015] Referring first to FIG. 5 , a layer of SU-8 or other suitable light sensitive adhesive material 38 is formed on a substrate wafer 40 to the desired thickness of spacers 26 . Substrate wafer 40 represents a fully processed, or near fully processed, wafer that includes optical MEMS devices 16 , contact pads 30 and any other operational components that may be integrated into the substrate. As shown in FIG. 6 , layer 38 is selectively removed in the desired pattern of spacers 26 surrounding devices 16 . (The pattern of spacer 26 is best seen in the plan views of FIGS. 1 and 4 .) A glass or other suitable transparent cover wafer 42 is aligned with and bonded to substrate wafer 40 at spacers 26 as shown in FIG. 7 using, for example, a conventional wafer bonder. Cover wafer 42 represents a fully processed, or near fully processed, wafer that includes any anti-reflective and/or filter coatings 18 . Although a coating 18 on the exposed outer surface 22 of cover wafer 42 may be formed after bonding, it is expected that any such coating 18 will usually be formed prior to alignment with and bonding to substrate wafer 40 .
[0016] An SU-8 photoresist used for spacers 26 , for example, will cure fully at a temperatures in the range of 100° C.-200° C., thus avoiding the higher temperatures needed to seal the glass covers used in a conventional ceramic optical MEMS device package. The lower bonding temperature protects anti-reflective coatings 18 on cover 12 , which can delaminate at higher temperatures, and reduces the risk of damage to device 16 and other components in substrate wafer 40 from the material stresses induced by high temperature bonding. It is expected that SU-8 and other negative photoresists will be desirable for most optical MEMS packaging applications due to low curing temperatures, excellent adhesive qualities, and precise structural alignment/definition characteristics. However, other suitable light sensitive, photo definable adhesives fully curable at temperatures less than 300° C. may be used. For example, IJ5000™ (commercially available from E. I. DuPont Company) and other such polymeric adhesives used as a so-called “barrier” layer in inkjet printheads may also be suitable for spacers 26 .
[0017] Referring now to the section view of FIG. 8 (which corresponds to the Y-Y section line in FIG. 4 ), individual device packages 36 are singulated from wafer assembly 34 by first sawing or otherwise cutting wafer assembly 34 between packages 36 in the X direction ( FIG. 4 ), as indicated by saw cut arrows 44 in FIG. 8 . Referring to FIG. 9 , cover wafer 42 is cut through to gap 33 in the Y direction ( FIG. 4 ) to expose contact pads 30 , as indicated by saw cut arrows 46 in FIG. 9 . Rotating the saw blade up, away from substrate wafer 40 helps minimize the risk of damage to bond pads 30 during cutting. With an upward rotating saw blade, it is expected that a gap 33 as small as 5 μm will provide sufficient clearance to the saw blade so that pre-trenching transparent cover wafer 42 at the cut locations is not required. In FIG. 10 , a second cut is made in the Y direction between rows of contact pads 30 , as indicated by saw cut arrows 48 in FIG. 10 , to complete the singulation of individual packages 36 , thus forming each individual package 10 described above with reference to FIGS. 1 and 2 . Other singulation sequences may be used. For example, it may be desirable in some applications to expose contact pads 30 first, and then cut in the X and Y directions to singulate individual die packages 36 from wafer assembly 34 .
[0018] In an alternative embodiment shown in FIGS. 11-15 , a layer of SU-8 or other suitable light sensitive adhesive material is formed on substrate wafer 40 (layer 38 in FIG. 11 ) and on cover wafer 42 (layer 50 in FIG. 13 ). The combined thickness of layers 38 and 50 corresponds to the desired thickness of spacers 26 . Layers 38 and 50 are selectively removed in the pattern of spacers 26 surrounding devices 16 , as shown in FIGS. 12 and 14 , respectively. The two wafers 40 and 42 are then bonded together as shown in FIG. 15 . Singulation may proceed as described above with reference to FIGS. 8-10 . Each adhesive layer 38 and 50 need not be the same thickness or formed from the same adhesive material (although, of course, different adhesive materials must be compatible). For example, it may be desirable in some packaging sequences for some optical devices 16 to form only a thin film of a transparent adhesive material on cover wafer 42 and proceed with bonding under vacuum without first having to remove any of the transparent adhesive film.
[0019] “A” or “an” in the claims means one or more when introducing an element of the claim. For example, “a solid state light sensor” in claim 1 means on or more solid state light sensors. “And/or” in the claims means one or the other or both.
[0020] As noted at the beginning of this Description, the exemplary embodiments shown in the figures and described above illustrate but do not limit the invention. Other forms, details, and embodiments may be made and implemented. Therefore, the foregoing description should not be construed to limit the scope of the invention, which is defined in the following claims.
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In one embodiment, a method for making an optical micro device package includes: providing a substrate wafer having a plurality of solid state light sensors integrate therein; providing a transparent cover wafer coated with a material that alters the transparency characteristics of the cover wafer; forming a layer of light sensitive, photo definable adhesive material on the substrate wafer; selectively removing part of the layer of adhesive material in a pattern for a plurality of adhesive spacers between the substrate wafer and the cover wafer with each spacer surrounding a corresponding one of the light sensors; bonding the substrate wafer and the cover wafer together at the spacers to form a wafer assembly in which each spacer surrounds and seals a corresponding one of the light sensors within a cavity bounded by a spacer and the two wafers; and singulating individual device packages from the wafer assembly.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electronic balance, and more particularly to an electronic balance utilizing as a balancing force an electromagnetic force which is automatically controlled so as to be balanced against a weight to be measured.
2. Prior Art
In general, known electronic balances have a force equilibrating unit comprising an electromagnetic coil and a magnetic circuit to provide a static magnetic field, the electromagnetic coil being mechanically connected with a weight-receiving tray and supported movably in a vertical direction in said static magnetic field. The electromagnetic coil, supplied with an electric current, produces an electromagnetic force to oppose a weight placed on the weight-receiving tray. The weight value is given by the current which makes the electromagnetic force just balanced against the weight to be measured.
In relation to this type of balances the present patent applicant has already filed an electronic balance in which the electromagnetic coil is supplied with an "alternating" pulse current, namely, a pulse current whose pulse polarity is alternating. The frequency of the pulse is chosen sufficiently high so that the balance may be prevented from possible mechanical vibrations. The electromagnetic force opposing the weight is regulated by automatically controlling the duty factor of the pulse current, with the amplitude and frequency kept constant. The average current, which determines the electromagnetic force, depends on the duty factor of the pulse. The use of an "alternating" pulse current is to keep the Joule heat generation by the coil always constant irrespective of the average value of the pulse current. There are also disclosed some other kinds of electronic balance in which a "non-alternating" pulse current is used. In any way, the most important problem involved in an electronic balance in which a pulse current is used is to measure the duty factor of the pulse so precisely as to comply with a resolving power required for the balance. The duty factor of a pulse current is, in general, measured with a clock signal whose frequency is sufficiently higher than that of the pulse. In principle, therefore, the resolving power can be increased to any degree by increasing the frequency of the clock. In practice, however, there are some technological and economic difficulties and disadvantages in increasing the clock frequency on a large scale. In case of a balance using a 1 kHz-pulse current a 1 MHz-clock gives a resolving power of the order of only 10 -3 . If, as is often the case with a precision balance, a resolving power of the order of 10 -6 is needed, a 1 GHz-clock must be used. The use of such a high frequency clock in a balance is apparently unpractical in both technological and economic aspects. Although there have been proposed, of course, some contrivances for measuring the duty factor, they also have many disadvantages, particularly in relation to the requirements for the measuring speed and precision.
SUMMARY OF THE INVENTION
The present invention aims at solving the above mentioned problems involved in measuring the duty factor of the pulse current flowing through the electromagnetically weight-balancing coil, and it is an object of the present invention to provide an improved electronic balance which gives a precise value of measurement without incorporating such a very high frequency clock as is mentioned above.
Another object of the invention is to enable such an improved electronic balance to give a precise value of measurement in a short time.
A further object of the invention is to enable such an improved electronic balance to be manufactured in a simple construction and at low cost.
Other objects and advantages of the present invention will become apparent from the detailed description of the invention given hereinafter in conjunction with the embodiments and appended drawings.
To accomplish the above mentioned objects the electronic balance based on the present invention is, in brief, provided with two weight-balancing systems: a coarse balancing system and a fine balancing system. The coarse balancing system comprises an electromagnetic coil whose attainable maximum force reaches the maximum scalable weight of the balance, a pulse current supplyer to the coil, and a pulse current duty factor controller which coarsely regulates the duty factor of the pulse according to a relatively rough digital signal. The value of the digital signal changes in accordance with a predetermined program until the tray loaded with a weight to be measured is brought to a coarsely balanced position within a predetermined range. The fine balancing system also contains an electromagnetic coil, which gives the tray a fine balancing in accordance with an output from a tray displacement detector provided to detect the displacement of the tray. The current flowing through this coil is digitalized, and then added to said digital signal concerned with the duty factor regulation in the coarse balancing system, to give the precise result of weight measurement.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a block diagram of a first embodiment of the invention.
FIG. 2 shows a block diagram of a second embodiment of the invention.
Fig. 3 shows a block diagram of a third embodiment of the invention.
FIG. 4 shows the currents flowing through the electromagnetic coils in the embodiment shown in FIG. 1.
FIG. 5 shows the currents flowing through the electromagnetic coils in the embodiments shown in FIGS. 2 and 3.
FIG. 6 shows a block diagram of a fourth embodiment of the invention.
FIG. 7 shows a block diagram of a fifth embodiment of the invention.
FIG. 8 shows the current in the electromagnetic coil in the embodiments shown in FIGS. 6 and 7.
FIG. 9 is a flow chart illustrating the function of the embodiment shown in FIG. 1.
FIGS. 10, 11, 12 and 13 are flow charts illustrating different ways of determining the presetting signal in the embodiment shown in FIG. 1.
FIG. 14 shows a partial block diagram of a further modified embodiment of the invention.
FIG. 15 is a flow chart illustrating the function of the embodiment shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 which shows a block diagram of a first embodiment of the present invention, a force equilibrating unit 1A contains two electromagnetic coils 2 and 3, and a tray displacement detector 1 shown in the vicinity of a weight receiving tray 1B. The unit 1A is devised so that a weight loaded to the tray 1B may be balanced coarsely in the first place by the force produced by the coil 2 and then balanced precisely by that produced by the coil 3. The coils 2 and 3, wound on the same bobbin and mechanically connected with the tray, are designed to be movable freely in a vertical direction in a static magnetic field provided by a permanent magnet assembly (not shown in the figure). The electromagnetic coil 2, a change-over switch 8, a constant-current supply 9 and a presettable up-and-down counter 10 constitute a coarse balancing system. The current outputted from the constant-current supply 9 is converted to an "alternating" pulse current by the change-over swtich 8 which is driven by the digital output from the presettable up-and-down counter 10. The coil 2 is thus supplied with an alternating pulse current. In the figure the change-over switch 8 is illustrated only schematically, but it is really made up of any of known electronic change-over switching circuits. On the other hand the displacement detector 1, a displacement signal amplifier 4, a PID controller 5, a power amplifier 6, the electromagnetic coil 3 and a resistor R constitute a fine balancing system. The coarse balancing system covers the whole weighing range of the balance coarsely, whereas the fine balancing system covers only a limited range but precisely.
On receiving on the tray 1B a weight to be measured the tray displacement detector 1 outputs a tray displacement signal to the PID controller 5 through the displacement signal amplifier 4. This signal causes the PID controller 5 to develop a current in the system to make the coil 3 produce a force opposing the weight. If the weight is small so as to be overcome by a current within the maximum value that the PID controller 5 can control, the balance comes to be precisely balanced only by the fine balancing system. The resistor R develops a voltage which corresponds to the balancing current flowing through the coil 3. This voltage is converted to a digital signal by an A-D converter 7, and then outputted therefrom toward a weight value indicator 15 through an adder 14 without any value added to the digital signal in the present case. In case the weight overwhelms the control capacity of the PID controller 5, a saturation signal is inputted to a memory 16 from the A-D converter 7. On receiving the saturation signal the memory 16 outputs a presetting signal to the presettable up-and-down counter 10 in accordance with a predetermined program stored in the memory 16. With the presetting signal inputted the counter 10 starts counting the clock signal sent from a clock 11, and outputs a first switching signal when it completes counting the clock signal up to the number determined by the presetting signal. The counter 10 is further devised also to output a second switching signal when reset by the reset signal from a monostable multivibrator 13, which is driven at a frequency made reduced from that of the clock 11 through a frequency divider 12. The change-over switch 8, driven by these first and second switching signals, alternates the direction of the current to be supplied to the coil 2, so that the coil 2 is supplied with an alternating pulse current. The frequency of the pulse, determined by the reset signal, is equal to the frequency of the monostable multivibrator 13, while the duty factor is determined by the counted number of the clock pulses. The presetting signal to determine the number of the clock pulses to be counted is successively renewed in accordance with the program prepared in the memory 16 until the duty factor comes to make the average of the pulse current give the coil 2 a force balancing with the weight. Once the coarse balancing is thus attained positioning the weight-receiving tray 1B at a coarsely balanced point, the PID controller 5 becomes free from saturation, and the fine balancing system again starts functioning. Then the coil 3 is controlled finely and the tray 1B is positioned at a precisely balanced point. At the adder 14 the output from the A-D converter 7 is added to the presetting signal outputted from the memory 16. The output of the adder 14 is displayed at a displayer 15 as a precisely measured weight value.
FIG. 9 shows a flow chart explaining the performance of the abovedescribed first embodiment. It is judged at Step 91 if the fine balancing system is saturated. lf the system is judged not to be saturated, at Step 92 the adder 14 takes in a fine balancing value W 2 obtained by the fine balancing system, namely the output from the A-D converter 7. Step 92 is followed by Step 93 at which the adder 14 adds the value W 2 to a value W 1 given by the coarse balancing system, namely the presetting signal sent from the memory 16. A tare is subtracted from the sum W=W 1 +W 2 at Step 94, and then a final measured weight is displayed at the displayer 15 (Step 95). On the other hand, if at Step 91 the fine balancing system is judged to be saturated, the presetting signal is renewed at Step 96 according to the program. At Step 98 it is judged if the coarse balancing system normally produces a balancing force. If the system is judged working normally, Step 98 is followed again by Step 91. This process is repeated until Step 91 judges the fine balancing system made free from saturation.
In the process described above there are considered four kinds of process of renewing the presetting signal. Theses are explained by the partial flow charts shown in FIGS. 10, 11, 12 and 13. The partial flow charts correspond to a part defined between the points A and B in FIG. 9.
FIG. 10 shows the first way of renewing the presetting signal. If the fine balancing system is judged to be saturated on the positive side, the presetting signal W 1 is replaced by W 1 +1 (Step 97A). If the system is saturated in the negative side the presetting signal W 1 is replaced by W 1 -1 (Step 97B). In each case it is judged at Step 97C or 97D if the renewed value makes the coarse balancing system produce a force less than the maximum controlling force of the fine balancing system. The process is repeated until Step 91 (FIG. 10) judges the fine balancing system made free from saturation.
FIG. 11 shows the second way of renewing the presetting signal. If the fine balancing system is judged to be saturated on either the positive side or the negative side, the presetting signal W 1 is replaced by W 1 +N or W 1 -N, respectively, where N is a predetermined integer larger than unity. In repetition of the process if the saturation polarity of the fine balancing system changes to the opposite (negative or positive respectively) sign, a value of unity is, respectively, subtracted from or added to the presetting signal.
FIG. 12 shows the third way of renewing the presetting signal. An integer N to be added to or subtracted from the presetting value W 1 is initially predetermined at a value equal to the decimal number corresponding to the number of bits of the presettable counter 10.
In the repetional process of renewing the presetting signal, the integer N is successively reduced by half until the fine balancing system is judged saturated either on the positive side or the nagative side. This way enables the whole balancing system to be settled in the shortest time.
FIG. 13 shows the fourth way of renewing the presetting signal. In this example, a comparator 27 shown with a dotted line in FIG. 1 also is put into action. As is shown by the flow chart, the presetting signal is increased or decreased by N pulses when not only the fine balancing system but also the comparator 27 is saturated, and increased or decreased by one pulse when only the fine balancing system is saturated. In this case a set level of the comparator 27 is made larger than N times the saturation input of the fine balancing system so that, when the comparator 27 comes to output a non-saturated signal, the fine balancing system still remains saturated. Therefore, the presetting signal changes toward a final value with the changing direction kept unchanged.
A second embodiment of the invention is shown in FIG. 2. In this embodiment the fine balancing system comprises a tray displacement detector 1, a displacement signal amplifier 4, a PID controller 5, a voltage-pulse width converter 26, a constant-current supply 9A, a switching circuit 7 and an electromagnetic coil 3. In such a construction of the fine balancing system, the coil 3 also is supplied with a pulse current through the switching circuit 17 which, driven by the pulse from the voltage-pulse width converter 26, outputs a pulse current whose average value is controlled by the PID controller 5. The output of the fine balancing system is inputted to the same adder 14 as is used in FIG. 1 through an AND gate 25 and a counter 18. FIG. 5 shows the currents flowing through the coil 3 and the coil 2 in the coarse balancing system.
A third embodiment of the invention is shown in FIG. 3. This embodiment has a distinct feature in determining the presetting signal through a coarsely balancing action of the balance. Switches S 1 and S 2 change the balance either to a coarse balancing action or to the fine balancing action. With the switches S 1 and S 2 turned to COARSE the coarse balancing system in this embodiment is constituted with an electromagnetic coil 2, a change-over switch 8, a constant-current supply 9, a tray displacement detector 1, a displacement signal amplifier 4, a PID controller 5, a voltage-pulse width converter 26, an AND gate 25 and a counter 18. A coarsely measured weight value is memoried in a latch 19. The fine balancing system of this embodiment (with the switches S 1 and S 2 turned to FINE) is the same as the constitution of said second embodiment shown in FIG. 2. FIG. 15 shows a program stored in the memory 16 of this embodiment. After an initial condition being set, the fine balancing system is put into action in the first place at Step 101. If at Step 102 a measured value W 2 is judged to be within the maximum controllable range of the system, this value alone gives a final measured weight at Step 104. If at Step 102 the measured value W 2 is judged overflowing the maximum controllable range, Step 102 is followed by Step 103 at which the coarse balancing system is put into action. A measured value W 1 is memoried in the latch 19, and the weighing process returns to Step 102, at which it is judged if the value measured by the fine balancing system comes into the maximum controllable range of it. If the value is within the range, this value W 2 is added to the value W 1 to give a total measured weight W=W 2 +W 1 (Step 105). The wave form of the current through the finely balancing coil 3 is the same as that shown in FIG. 5.
A fourth embodiment of the invention is shown in FIG. 6. This embodiment has one electromagnetic coil 2A, which is commonly used for both the fine balancing system and the coarse balancing system. The coil 2A being commonly used this embodiment comprises a voltage-current converter 20. FIG. 8 shows a current flowing through the coil 2A, in which the dotted line means an current increase within the maximum controllable range of the fine balancing system.
A fifth embodiment of the invention is shown in FIG. 7. This embodiment is constructed by combining said third embodiment shown in FIG. 3 with said fourth embodiment shown in FIG. 6. With switches S 1 and S 2 turned to COARSE the coarse balancing system is put into action, and with them turned to FINE the fine balancing system is put into action.
Further, all the embodiments described above can be modified by using a non-alternating pulse current in the coarse balancing system. In this case it is necessary to provide any suitable countermeasure to overcome the Joule heat variations which arise in the electromagnetic coil depending on the weight value to be measured.
Finally, a further embodiment is described, in which the pulse current in the coarse balancing system is controlled not by the duty factor but by the frequency with the amplitude and duty factor kept constant. In this case the presetting signal, which determine the frequency of the pulse and not the duty factor, has discrete values, for example, with an interval of 1 Hz in a range between 1 kHz and 3 kHz. The electromagnetic coil, supplied with such a pulse current, produces the electromagnetic force corresponding to the presetting signal, as is the case with the embodiment in which the duty factor is controlled. FIG. 14 shows a partial construction of the frequency controlling part. A frequency synthesizer 21 is constructed with a PPL (phase locked loop), and produces a frequency corresponding to the presetting signal. A monostable multivibrator 22 produces a pulse signal with a constant width in response to the frequency. According to the pulse an electronic switch 23 changes the current supplied by a constant-current supply 9 to a pulse current.
The present invention, as is made clear, dissolves many disadvantages and difficulties involved in the prior art of improving a resolving power and measuring speed of electronic balances in which a pulse current is used to produce a balancing force. It should be, therefore, understood that there may be some other changes and modifications which a person skilled in the art can make within the spirit of the present invention, since the explanation described above in conjunction with the embodiments are only by means of examples.
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An electronic balance whose force equilibrating unit consists of a coarse balancing system and a fine balancing system to obtain a precise value of weight measurement in a short time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention lies in the field of amusement games and, more particularly, in the area of tag games involving the use of projected light. Players of this game project visible images on a gaming surface and seek to "tag" each others' projected image by causing the images to overlap.
2. Description of the Prior Art
To date there exist numerous examples of games which project light at targets. The advent of such games brought about simulated tests of marksmanship at the early game arcades. The prior art discloses games which project light at a moving or stationary physical target wherein the target includes either an optical detector or means to reflect the projected light back to the projection device for detection. Two games cited make use of projected light images as targets but do not achieve the goals of the presently disclosed game.
Games which project light pulses at physical targets which have photodetectors include U.S. Pat. Nos. 2,309,614, 2,404,653, and 2,710,754; these make use of a single light gun. U.S. Pat. Nos. 2,629,598, 4,192,507, and 4,232,865 have provision for multiple guns with a single target. U.S. Pat. Nos. 4,192,722 and 4,545,583 equip each opponent with a target and gun.
U.S. Pat. No. 3,655,192 is a single gun game which uses a passive, reflective target for hit detection by the gun. Recently, Worlds of Wonder has produced the game, LAZER TAG™, which provides each player with an infrared light-emitting pistol and a vest. The vest carries an infrared light sensor worn on the chest to detect and annunciate a hit by an opponent. U.S. Pat. No. 4,322,080 is an image-projecting amusement device which includes a target in the form of the stationary image of a racetrack or obstacle course projected on a screen. The image of a moving object under player control is projected on the target racetrack image. The moving object projector controlled by the player has an optical receiver mounted with it which images the projected object as it is being projected on the racetrack/obstacle course. This receiver can sense changes in light level reflected from the screen at the position of the projected object indicative of violation of the track boundary or encounter of an obstacle. This game does not allow players to compete via the independent projection of images.
Ideal Toy Corporation marketed a game entitled ELECTRONIC 2-MAN SKEET™ which made use of a projector unit to create a moving target image on a wall. Players used rifles containing narrow field of view optical receivers which when appropriately aimed at the target image would detect it and score a hit. Although this game does allow scoring competition between players, the immediate opponent is constrained to be an automatic target. The game allows only two players and unlike the present invention, the players do not project visible images. Such images provide the visual feedback necessary if a player chooses not to aim along his line of sight or if he is chasing an extremely dynamic target image which requires coordination of wide field vision with wrist action. Nitendo Incorporated has introduced the Nitendo Entertainment System which uses a single gun incorporating an optical receiver to detect target images produced on a television screen. These images are generated by video game cartridges which are played on a console connected to the television. Again, this game does not make use of player-projected images and confines the playing space to that of the television screen.
Pertinent areas of classification for the present invention are believed to comprise U.S. Class 273, Subclasses 310, 311, 312, 358, and U.S. Class 446, Subclasses 175 and 219.
That art which is known to the inventors does not include a tag game wherein players independently project visible images onto a gaming surface with the goal of causing their overlap or superposition and wherein such overlap is detected as a tag by the game hardware.
SUMMARY OF INVENTION
This invention provides a light tag game of the type described initially. The game devices project visible images which make possible player aim improvement and the high speed game action associated with video arcades but with little playing space limitation. The portability of the game allows it to be played indoors or outside. The game devices can automatically annuniciate and score game points.
According to one of two chief device embodiments for the present invention players each use a handheld optical transceiver which has a narrow receiver field of view that is coincident with the field of visible light which the transceiver projects to form an image on a gaming surface. Detection of fluctuation in the visible light in this field of view indicates an opponent image has overlapped the initial image (i.e., a tag has occurred). The use of this approach requires only that the gaming surface be relatively flat and uniform in color.
A second embodiment includes in each transceiver a source of infrared light modulated at a frequency characteristic of that unit which is projected along the same path as the visible light. In lieu of a visible light detector, the receiver portion of the transceiver uses an infrared detector with tone decoders to detect frequencies of opponent infrared light images which may enter the field of view of the receiver.
A basic feature of this embodiment is robust operation on any non-specular gaming surface (irregular or flat) in the presence of room lighting and other noise sources.
Further embodiments of the game device are subsidiary to the tag detection means and involve variations in the optical component geometry within the transceiver. In another embodiment of the game, means are provided for projecting automatic targets. This is accomplished by a transceiver which has an electrically or mechanically controlled beam steering mirror. The control of this mirror induces random translation of target image and/or images across the playing surface. These images may be caused to blink on and off as well.
A gaming maze embodiment makes use of a transceiver which can project target images in the form of mazes. A slide projector version would use any of a large number of maze slides. The objective of this game version would be time limited transit or chase of an opponent through the maze without player image overlap with the maze boundaries.
The aforementioned use of infrared signal decoders in each transceiver also makes possible a game embodiment wherein a master game control transmitter communicates game controls to each transceiver via wide area coverage infrared light. It is also considered that the transceivers may likewise communicate with the game control or other transceivers.
The most basic version of this game invention would use small handheld flashlight units with contained scoring means. With only incremental cost the more elaborate embodiments can add automated targets or microprocessor control to the game.
Versions of this invention are explained in detail below with reference to the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial diagram of the general game concept;
FIG. 2 is an embodiment of the game transceiver which uses a beamsplitter to separate transmitted and received energy paths;
FIG. 3 is a transceiver geometry which collocates the transmitter and detector;
FIG. 4 is a transceiver geometry which allows the transmitter and detector to be located coaxially on a single optical axis;
FIG. 5 is a transceiver geometry which places the detector and transmitter on separate optical axes that intersect at the target plane;
FIG. 6 is an electronic schematic of a receiver circuit which detects a target image by variation of light intensity in the receiver aperture;
FIG. 7 is an embodiment of the receiver portion of a game transceiver which detects target images on the basis of color;
FIG. 8A is an embodiment of the transceiver which projects and detects modulated infrared light;
FIG. 8B is a depiction of the placement geometry of the transmission and detection elements for the transceiver version which uses infrared light;
FIG. 9A is a schematic of a transceiver embodiment which uses a single infrared light-emitting diode as both a transmitter and detector of light;
FIG. 9B is a waveform diagram which details the timing of modulation applied to the infrared diodes;
FIG. 10 is a pictorial diagram of an implementation of an automatic target generator;
FIG. 11 is a pictorial diagram of a maze projection version of the game;
FIG. 12 is a pictorial diagram of a version of the game which allows master game control signals to be transmitted to each transceiver via infrared light.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an illustration of the light tag game depicts the general concept. Optical transceivers 1 and 2 nominally a few inches in diameter and several inches long are held by each player. Each transceiver projects light along its respective beam path 3 or 4 to form a focused image 5 or 6 on the distant gaming surface 7. The transceivers are capable of detecting image overlap 8 which constitutes a "tag." The light from each player's transceiver could be a different color or form a different shape image for ease of distinguishing the identity of projected images.
The optical transceiver can be reduced to practice in either of two major embodiments. The first of these exploits detection of changes in visible light signals; a second approach involves auxiliary projection and detection of modulated infrared light with the projected visible light serving solely as a visual cue for players. FIGS. 2, 3, 4, and 5 portray the various transceiver geometries that may be used with the aforementioned approaches. FIG. 2 depicts a transceiver in which a beamsplitter separates transmit and receive functions. The power supply 11 energizes the illuminating light source 12 which projects light through an aperture 13 which shapes the projected light 14. This projected light passes through the beamsplitter 16 and is focused by a lens 17 to form an image 22 on a distant diffuse reflecting surface 23. Light 21 from an opponent transceiver which reflects from the surface 23 and falls within the field of view 18 of the depicted transceiver will travel back through the lens 17 and will be partially reflected from beamsplitter 16 along an optical path 15 to the receiver detector 19. The detector provides signals to the processing electronics 20 which sets the threshold for detecting light from an opponent's transceiver within its field of view (thereby constituting a tag). The electronics 20 will reject signals due to light source 12 and will annunciate a tag by audio-visual output.
FIG. 3 provides a geometry whereby the transmitting light and detector are essentially collocated. a power supply 31 energizes a light source 32 which projects light through shaping aperture 35 along path 36 through a focusing lens 37 which creates an image 40 on a distant surface 39. The light 41 from an opponent transceiver within the system field of view will travel along path 38, through lens 37, via path 36 to the detector 33 which is collocated with the light source 32 in a common assembly 34. The detected light signal is fed to processing electronics 42 which will score and annunciate a tag.
A coaxial arrangement of transmitter light and detector is shown in FIG. 4. A power supply 51 energizes light source 52 which projects light through shaping aperture 53 along path 54 through focusing lens 55. The resulting focused image 58 appears on the distance surface 57. Opponent light 59 within the field of view travels back along path 56 through lens 55. A portion of this received light is collected by a small lens 61 for focus on detector 62. Received signals are then processed by the electronics 63. The sizes of the detector 62 and lens 61 are small enough to avoid significant obscuration of the projected beam path 54.
Total separation of the transmit and receive beampaths is the distinction of FIG. 5. The power supply 71 energizes light source 72 which projects light through shaping aperture 73 along path 74 through transmit lens 75. This lens projects thee light along path 76 to create a focused image 78 at surface 77. The receiver can image opponent light on this region of the surface by accepting light along path 79 through receiver lens 80. The receiver light is brought along path 81 to the detector 82 which delivers detection signals to processing and annunciation electronics 83.
An optical detection technique which requires sensing changes in the visible light level within the receiver field of view is explained with reference to the receiver schematic of FIG. 6. An opponent's projected image 92 is shown entering the receiver field of view 91 on the gaming surface. Light from the opponent image is focused by lens 93 on a photodiode 94 as is light from the projected image of the transmitter (not shown) associated with their receiver. The detected signals are amplified by amplifiers 95, 97, and 99 but are AC-coupled through capacitors 96 and 98 so that only transient or time-varying signals can be passed. In this way the constant signal due to the light transmitted by a given device will be rejected by its own receiver and the transient signal due to an opponent image transiting the receiver field of view will be detected. A threshold for such detection is established by the voltage comparator 100. The digital output of the comparator which is indicative of a tag feeds the annunciation and scoring electronics 101.
A variation of this detection approach is shown in FIG. 7. An opponent image 116 of a particular color different than that associated with the depicted transceiver is shown traversing the receiver field of view 115. The opponent light is imaged by lens 114 and focused along path 113 through a color filter 112 which admits only the opponent coloration of light to detector 111. The detector feeds signals to processing electronics 110.
An alternate optical detection technique is shown in FIG. 8A. A visible light source 121, an infrared light source 122, and an infrared detector 123 are shown collocated in assembly 124. A power supply 120 continuously energizes the visible light source 121. An oscillator 132 operating at a fixed frequency modulates the intensity of an infrared light-emitting diode by toggling a voltage-controlled switch 131 connecting the diode 122 to power 120. The continuous visible and modulated infrared light are both projected through shaping aperture 136 along path 125 through focusing lens 126 to form both a visible and infrared image 129 on surface 128. The corresponding visible and infrared light from an opponent 130 which is in the receiver field of view will traverse path 127 through lens 126 and be focused on the infrared detector 123. The opponent infrared light will be modulated at a frequency different from oscillator 132 but a frequency which will be detected by the tone decoder 134 subsequent to passage through amplifier 133. Scoring electronics 135 will annunciate a tag.
FIG. 8B shows a geometry for collocating the infrared diode 140, visible light 141, and infrared detector 142 for use with a common lens 143.
The use of a single infrared diode to provide both transmit and receive functions is shown in FIG. 9A. Transceiver A, 160, and transceiver B, 165, are shown with overlapping fields of view 150 and 162. The visible light sources are not depicted. Discussion of function of the infrared system is directed to transceiver A, 160. Infrared light is both projected from and received through lens 151. Oscillator 1, 153, causes the infrared diode to toggle between transmit and detection modes of operation by alternating its switch connection 155 to transmit power or receiver amplification. Oscillator 2, 154, serves to amplitude modulate the infrared diode via the voltage-controlled switch 156 connection to the power 157 when switch 155 is in the transmit position. When switch 155 is in the receive or detection position, the received modulated signal is boosted in amplifier 158 and detected in the tone decoder 159. Annunciation and scoring occur in the score electronics 161. Tone decoder 159 in transceiver A, 160, will detect the frequency of oscillator 4, 164, in transceiver B, 165, and the complimentary decoder 166 of transceiver B, 165, will detect the frequency of oscillator 2, 154, of transceiver A, 160.
FIG. 9B provides a timing diagram for oscillators 153, 154, 163, and 164. Periods T1, T2, T3, and T4 are the waveform periods associated with oscillators 153, 154, 163, and 164, and respectively. Period T represents the minimum image encounter time associated with a tag. The relative duration of the these periods is chosen to insure tag detection within the alloted receive mode time windows (during portions of the waveforms where transmit pulses are absent).
FIG. 10 shows an automatic target generator. One of the aforementioned transceivers 176 can project and receive light through focusing lens 175. The optical path 174 introduces the light to a tilt mirror 171 which is caused to rotate about a horizontal axis mount 172 by motor 178. Motor 180 via drive wheel 179 and platform 177 causes the mirror 171 to also rotate about its vertical axis. The trajectory of the image 170 which is reflected from the mirror 171 to a distant surface is determined by the speed controls 173 for both motors.
A maze projection device is shown in FIG. 11. A maze image 190 is projected on a gaming surface by projector 19. Transceivers 193, 194 have means of detecting when their projected images 191, 192 have violated maze boundaries. Characteristic infrared modulation associated with the maze image could be used to detect such boundary violation.
FIG. 12 depicts a master game control unit 204 which floods the gaming surface 201 with infrared light 200 which is modulated with game control information. This light 200 will always be within the transceiver fields of view 202, 203, and can be detected in order to alter transceiver characteristics.
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A light projection tag game requires the overlap of player projected images on a gaming surface. Each player is provided with an optical transceiver which has a receiver with a narrow field of view that is geometrically coincident with the light beam projected from the transceiver. Each player's transceiver can detect when an opponent's image which is also projected on the gaming surface enters this field of view thereby achieving a tag. Receiver methods use either signal transients or infrared modulation. Various embodiments include automatic targets, automatic game control and projected gaming mazes.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention relates to a pressure monitoring apparatus, in particular for a compressor, with at least one pressure transducer for recording the pressure within a certain volume, with at least one nonreturn valve and with at least one shutoff valve for blocking of the nonreturn valve, the shutoff valve and the nonreturn valve each being located in a flow path through which a medium can flow between the volume being monitored and the pressure transducer.
Description of Related Art
[0002] Pressure monitoring apparatus are known from the prior art and are often used. In many, technical domains for example pure gases are required which are sold as a product or are used in industrial installations for other purposes. Such technical gases, for example cooling gases, are routed in a continuous circuit in order on the one hand to enable economical operation of an industrial installation and on the other to make the gases available at the decisive points in the process. To enable transport of the gases or liquids, they are generally conveyed using compressors or pumps. In doing so in particular gases can be contaminated by lubricants or other substances. In order to reduce contamination, generally membrane compressors or membrane pumps are therefore used to convey these gases.
[0003] Membrane compressors work similarly to piston compressors, but with a separating membrane between the gas side and the oil side. On the gas side there are gas intake and pressure valves. On the oil side there are cylinders and pistons, as in a piston compressor. When the piston is retracted, it displaces a certain volume in the oil space. The resulting pressure rise acts on the membrane which is being deflected. The deflection of the membrane in the direction of the gas side in turn compresses the gas on the gas side and the gas is expelled by the pressure valves. When the piston is being extended a reverse process is triggered. Due to the oil pressure which drops when the piston is being lowered in the direction of the piston, therefore in the direction of the oil side, the membrane is deflected, as a result of which the gas expands on the gas side and further gas is intaken by the gas intake valves.
[0004] Membrane compressors are in any case more sensitive than piston compressors since the so-called leakage of the piston must be compensated by continuous injection of oil via a secondary oil circuit. The exact amount of leakage can be determined, if at all, only at a disproportionate high cost. Still the amount of oil on the oil side must be so great that the oil pressure at top dead center of the piston is always greater than the pressure on the gas side in this state. If this is not the case, unperturbed operation of the membrane compressor cannot be ensured. In the worst case the membrane or the compressor can be damaged.
[0005] For this reason various oil pressure monitoring systems or oil pressure measurement methods have been developed. A process is known from practice in which a pressure transmitter is located on the oil side of a membrane compressor, the pressure transmitter being connected to a programmable control (SPS). When the pressure is acquired it is important that the pressure which has been reached at maximum for one piston stroke is recorded since the latter is decisive for the correct manner of operation of the compressor. Since the time which one piston stroke requires is very short, for example only roughly 200-300 ms, the control must be able to process the pressure currently acquired from the pressure transmitter within very short time intervals of a few ms. Consequently in the process known from the prior art the disadvantage is that a high-speed pressure transmitter and a very fast SPS must be used; this is reflected in a high cost for this system.
[0006] Moreover, German Patent DE 101 38 674 B4 and corresponding U.S. Pat. No. 6,767,189 B2 shows a process for avoiding damage cases of membrane compressors in which both on the oil side of the membrane head and also in the gas pressure line on the gas exit side of the membrane head there are electronic pressure transducers. The pressure transducers are connected to an electronic evaluation system, the signals of the two electronic pressure transducers being brought into a relation to one another. When a certain minimum relation is not reached, signalling is induced to avoid a possible damage case. In this process prompt evaluation of the signals is necessary in order to determine the maximum pressure caused by the piston stroke within the discrete time intervals in which the measurement is being taken.
SUMMARY OF THE INVENTION
[0007] The object of this invention is therefore to devise a pressure monitoring apparatus and a process for operation of a compressor with a pressure monitoring apparatus which delivers exact measured values and which can be still economically implemented.
[0008] The object is achieved in the pressure monitoring apparatus in accordance with the invention in that there are at least two nonreturn valves each of which is located anti-parallel in a respective flow path, one nonreturn valve blocking in the flow direction from the volume to the pressure transducer and the other nonreturn valve blocking in the flow direction from the pressure transducer to the volume. Moreover, there are at least two shutoff valves, each of which blocking a respective one of the flow paths. The arrangement of the nonreturn and shutoff valves in accordance with the invention makes it possible to alternatively acquire the maximum generated pressure of one piston stroke or the minimum pressure. Both the oil pressure and the gas pressure rise when the piston is retracted into the oil space. The pressure transducer is located preferably on the oil side, in particular for a membrane compressor. In a piston compressor, however, an arrangement of the pressure transducer on the gas side is also possible and effective, as a result of which the compressor valves can be monitored. A measurement with two pressure transducers, one at a time both on the gas and also on the oil side is likewise conceivable, but not necessary.
[0009] The pressure transducer thus acquires the maximum pressure because the nonreturn valve blocks in the flow direction from the pressure transducer to the volume. This means the nonreturn valve is opened as long as the pressure in the volume is higher than the pressure downstream of the nonreturn valve in the first flow path. With the shutoff valve opened in this flow path, consequently also the pressure in the flow path rises when the pressure rises in the monitored volume. Here, the shutoff valve in the second flow path is closed. When the pressure drops again due to the oscillating movement of the piston, the pressure in the flow path downstream of the shutoff valve is higher than in the volume. The shutoff valve thus automatically blocks the flow path between the volume and the pressure transducer due to the pressure difference. The second flow path is closed by the second shutoff valve. In this way the pressure transducer records only the maximum pressure and changes the value only when the pressure in the monitored volume, for example, the oil space, becomes greater than the value which was measured last.
[0010] In order to be able to take another measurement of the maximum pressure without the maximum pressure which was acquired last by the pressure transducer having to be exceeded, the flow path for measuring the maximum pressure must be blocked with the assigned shutoff valve, the shutoff valve of the other flow path being opened. If the pressure in the opened other flow path upstream of the shutoff valve on the side of the pressure transducer is higher than the pressure in the volume, the second shutoff valve of the second flow path which is located anti-parallel to the shutoff valve in the first flow path opens so that pressure equalization takes place. The pressure which has been measured by the pressure transducer drops in doing so until the minimum pressure of the piston stroke is reached. In this way the minimum pressure in the volume is thus measured. When the pressure rises again in the volume, the nonreturn valve of the second flow path blocks this second flow path. Furthermore the shutoff valve in the first flow path is opened again and the shutoff valve in the second flow path is closed so that again the maximum pressure in the volume is being measured. In this way, consequently the flow paths are alternately relieved and pressurized, and both the maximum and also the minimum pressure can be acquired.
[0011] One advantage of this invention is that a high-speed and thus expensive SPS and a high-speed pressure transducer can be omitted since it is not necessary to take a prompt continuous measurement, but rather either the maximum and ultimately also relevant pressure or the minimum pressure is determined. Even for very short time intervals of a few hundred ms, in which one piston stroke is executed, there is thus no danger of missing the maximum pressure caused by one piston stroke.
[0012] The arrangement of the shutoff valves in the respective flow paths can be made differently. In one configuration of the pressure monitoring apparatus, it is provided that the shutoff valves are each located in the flow direction from the volume to the pressure transducer upstream of the assigned nonreturn valve. In another configuration, it is conversely provided that the shutoff valves are each located in the flow direction from the volume to the pressure transducer downstream of the assigned nonreturn valve. It would also be conceivable for one shutoff valve to be located upstream of a nonreturn valve while the other shutoff valve is located downstream of the other nonreturn valve. The shutoff valves need simply be suitable for blocking of the flow path from the volume to the pressure receiver or from the pressure receiver to the volume.
[0013] It is advantageously provided that the shutoff valves are implemented by a 3/2 way valve. The 3/2 way valve simplifies the switching possibilities of the flow path. In this way, it is possible to automatically block only the first flow path or only the second flow path. Appropriately, at least one flow path at a time is consequently opened so that measurements can be taken. The option of opening two flow paths would lead to the pressure transducer continuously receiving signals, since both a pressure increase, and also a pressure reduction are possible when the two flow paths are opened. Moreover, the use of a 3/2 way valve also leads to the pressure monitoring apparatus being able to have altogether a relatively small installation volume.
[0014] For easier operation of the pressure monitoring apparatus, there is a pressure display apparatus which displays the values which have been measured by the pressure transducer. The pressure display apparatus can preferably be a visual indication, for example, a display, so that the current pressure value can be promptly and easily read off on site. In addition, however, an acoustic indication is possible with which in addition a warning signal is delivered when a boundary value is reached.
[0015] Another advantageous configuration of the invention calls for there to be a programmable control for control and/or adjustment of the pressure monitoring apparatus. In this way, the shutoff valves or the 3/2 way valve can be automatically opened and blocked and other actions for predetermined events can be programmed. The SPS need not have an especially short processing time since a measurement of the maximum and of the minimum pressure at an interval of a few seconds is generally sufficient.
[0016] The initially named object in a process for operating a compressor with a pressure monitoring apparatus in accordance with the invention is achieved in that the shutoff valves are activated in defined intervals, one shutoff valve at a time being opened and the other shutoff valve being blocked so that in the flow direction from the volume to the pressure transducer the maximum pressure in the volume and in the flow direction from the pressure transducer to the volume the minimum pressure are acquired by the pressure transducer. The maximum and the minimum pressure can be measured in almost any time intervals and the measurement is in particular independent of the time which one piston stroke requires. Within this time which is generally only a few 100 ms, the pressure passes through both a maximum and also a minimum. The measurements of the maximum and minimum pressure can however be taken at much longer intervals of for example some few seconds. Longer time intervals are also conceivable to save resources.
[0017] In order to enable economical operation of piston and membrane compressors, characteristics are generally recorded from compressors and also from pumps, which characteristics yield a relationship between physical quantities which are relevant to operation, such as for example the delivery amount and the pressure. One compressor operates ideally in the region of the respective characteristic, i.e. at a certain delivery amount with the optimum pressure provided for this purpose. If the pressure deviates too dramatically from the ideal value, this can be due to a fault or damage of the compressor. According to one configuration of the process it is therefore provided that when a respectively defined boundary value of the maximum pressure is exceeded or undershot an optical and/or acoustic signal is output. The acoustic signal can be implemented for example by a warning tone. Signal lamps are also possible for an optical warning. A display is likewise conceivable on which fault reports can be output. Furthermore, relaying and processing of the measured signals in a process control system are possible.
[0018] Another configuration of the invention calls for an optical and/or acoustic signal to be output when a respectively defined boundary value of the minimum pressure is exceeded or undershot. Exactly as in the warning of the maximum pressure being exceeded or undershot a warning for the minimum pressure being exceeded or undershot can also be output. The warnings can be the same or can differ from one another so that a user directly recognizes which type of fault is present.
[0019] One possible change in current operation of the compressor can also already be recognized before a boundary value is exceeded or undershot. For this purpose, in another configuration of the process it is provided that the characteristic of the acquired values of the maximum pressure and/or the characteristic of the acquired values of the minimum pressure is determined. By observing the characteristic of the respective pressures, therefore of the maximum pressure and/or the minimum pressure, a trend of the pressure characteristic can be recognized. If the maximum pressure, for example, rises too dramatically with time or the minimum pressure drops too dramatically with time, corresponding countermeasures can be taken by a technician. A continuous drop of the oil pressure is generally a sign of wear of the compressor components, in particular of the oil overflow valve or of the compensation pump. A rapid drop of the oil pressure can in turn be a sign of an operating problem or a defect. When faulty behavior is recognized by the trend recognition, the compressor can thus be already ramped down in good time, and in this way, if necessary, a serious defect or destruction of a part can be prevented.
[0020] In order to increase the accuracy of the measurements and in particular of the trend recognition, in one advantageous configuration of the process as claimed in the invention it is provided that in a deviation of the given pressure characteristics of the maximum pressure and/or of the minimum pressure the defined intervals in which the shutoff valves are each opened and blocked are adjusted. Stipulated pressure characteristics are defined as an ideal characteristic of the pressure. When a compressor is started up the pressure is first built up gradually until the desired pressure is reached. The maximum oil pressure rises dramatically during the start-up of a membrane compressor, while the pressure peak and pressure minimum in current operation should not fluctuate too much. If the pressure minimum and/or the pressure maximum rises or falls too dramatically with time, this can be due to a fault in the operating installation or a compressor fault. In this case it can be a good idea to shorten the interval of the measurements in order to be able to react more quickly to critical pressure values being reached. A technician can conclude from this that there is a fault in the installation or on the compressor. He can thus react before damage to the compressor or the entire installation occurs.
[0021] In particular, there is a host of possibilities for configuring and developing the pressure monitoring apparatus and the process in accordance with the invention for operation of a membrane compressor. For this purpose reference is made to the following description of exemplary embodiments in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows a schematic of a pressure monitoring apparatus known from the prior art,
[0023] FIG. 2 shows a schematic of a first exemplary embodiment of a pressure monitoring apparatus in accordance with the invention,
[0024] FIG. 3 shows a schematic of another exemplary embodiment of a pressure monitoring apparatus in accordance with the invention,
[0025] FIG. 4 shows a schematic of an exemplary embodiment of a pressure monitoring apparatus with a 3/2 way valve in accordance with the invention. and
[0026] FIG. 5 shows a simplified representation of the sequence of a measurement of the maximum and of the minimum pressure in accordance with the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 is a schematic representation of a pressure monitoring apparatus 1 known from the prior art. The illustrated pressure monitoring apparatus 1 can be used to monitor the pressure in a membrane compressor 2 with an oil side A and a gas side B separated by a membrane. For this purpose, there is a pressure transducer 3 which measures the pressure in the volume 4 on the oil side A of the membrane compressor 2 . Between the volume 4 and the pressure transducer 3 , there are a nonreturn valve 5 and a shutoff valve 6 in the flow path 7 from the volume 4 to the pressure transducer 3 . Downstream of the shutoff valve 6 in the direction toward the pressure transducer 3 is a branch 8 in which there is another shutoff valve 9 .
[0028] The nonreturn valve 5 blocks flow in the direction from the pressure transducer 3 to the volume 4 , i.e., the nonreturn valve 5 opens in the direction from the volume 4 to the pressure transducer 3 . As long as the pressure in the volume 4 is greater than the pressure in the flow path 7 downstream of the nonreturn valve 5 , a medium which is flowing through the flow path 7 can flow from the volume 4 to the pressure transducer 3 . This increases the pressure in the flow path 7 and thus also the pressure which is measured by the pressure transducer 3 . The pressure transducer 3 thus does not continuously measure the pressure characteristic which prevails in the volume and which arises due to the oscillating movement of the piston, but only the maximum pressure, the pressure which has been measured by the pressure transducer 3 only changing when the pressure in the volume A and thus also in the flow path 7 continues to increase. If the pressure in the volume A decreases so that it is less than the pressure in the flow path 7 downstream of the nonreturn valve 5 , then the nonreturn valve 5 blocks the flow path 7 and the pressure measured by the pressure transducer 3 remains constant at the pressure maximum which was measured last.
[0029] In order to be able to take a new measurement, in a first step the shutoff valve 6 is closed. In this way, the flow path 7 downstream of the shutoff valve 6 is blocked, the pressure furthermore remaining constant at the pressure maximum which was measured last. If at this point the further shutoff valve 9 is opened, the medium located in the flow path 7 can flow out through the branch 8 . In the flow path 7 , ambient pressure which is also being measured by the pressure transducer 3 then prevails so that it no longer measures the previous maximum value. Then, the two valves 6 and 9 are actuated in the reverse sequence, specifically first the shutoff valve 9 in the branch 8 is closed and then the shutoff valve 6 in the flow path 7 is opened again. In this way, the flow path 7 is opened again and the medium can flow from the volume 4 in the membrane compressor 2 to the pressure transducer 3 , as a result of which the pressure which has been measured by the pressure transducer 3 increases when the pressure rises in the volume 4 .
[0030] FIG. 2 shows a first exemplary embodiment of a pressure monitoring apparatus 1 in accordance with the invention. Similarly to the pressure monitoring apparatus 1 which is shown in FIG. 1 and which is known from the prior art, a pressure transducer 3 is connected to the volume 4 , specifically the oil side A, of a membrane compressor 2 . In a first flow path 7 , there are a nonreturn valve 5 and a shutoff valve 6 , the shutoff valve 6 blocking in the flow direction from the pressure transducer 3 to the volume 4 so that the maximum pressure can be measured with the pressure transducer 3 . In addition, in the pressure monitoring apparatus 1 shown in FIG. 2 there are another nonreturn valve 10 and another shutoff valve 11 in a second flow path 12 which is parallel to the first flow path 7 , The nonreturn valve 10 in the second flow path 12 is located anti-parallel to the nonreturn valve 5 in the first flow path 7 so that the nonreturn valve 10 blocks in the flow direction from the volume 4 to the pressure transducer 3 .
[0031] The shutoff valves 6 and 11 are used to block the flow paths 7 and 12 so that one flow path 7 or 12 at a time is always open. If the first flow path 7 is opened, medium can flow from the volume 4 to the pressure transducer 3 , as a result of which the pressure transducer 3 can measure the maximum pressure in the volume 4 since the medium downstream of the nonreturn valve 5 cannot flow back through the flow path 7 in the direction of the volume 3 . This path is blocked by the nonreturn valve 5 . If the second flow path 12 is opened, while the first flow path 7 is blocked by the shutoff valve 6 , medium can flow back from the pressure transducer 3 to the volume 4 as long as the pressure in the volume 4 is less than the pressure prevailing on the pressure transducer 3 above the nonreturn valve 10 . In this way, the pressure in the flow path 12 can decrease when the pressure in the volume 4 decreases. When the pressure in the volume 4 has reached its minimum, this pressure is measured by the pressure transducer 3 . If the pressure in the volume 4 rises again due to the oscillating movement of the membrane compressor 2 , the nonreturn valve 10 blocks the flow path 12 and the pressure measured by the pressure transducer 3 downstream of the nonreturn valve 10 remains constant at the minimum value which was measured last.
[0032] In this way, both the maximum pressure and also the minimum pressure which depending on the position of the piston 13 of the membrane compressor 2 prevails in the volume 4 can be measured by alternating actuation of the two shutoff valves 6 , 11 . Continuous measurement of the pressure in the volume 4 is not necessary since the respective maximum value or minimum value prevails on the pressure transducer 3 due to the two nonreturn valves 5 , 10 . The values measured by the pressure transducer 3 only change when the maximum value which was measured last has been exceeded or the minimum value which was measured last has been undershot, and thus, a new maximum value or a new minimum value is recorded. The two nonreturn valves 5 , 10 thus act as a type of peak value storage.
[0033] FIG. 3 shows one exemplary embodiment of a pressure monitoring apparatus 1 similarly to the pressure monitoring apparatus 1 shown in FIG. 2 . In this case however, the pressure is measured not on the oil side A, but on the gas side B. Moreover, the nonreturn valves 5 , 10 are located upstream of the shutoff valves 6 , 11 in the direction from the volume 4 , therefore the gas side B of the membrane compressor 2 , to the pressure transducer 3 . The valves can be located in the respective flow paths 7 , 12 in any sequence relative to one another as long as the individual flow paths 7 , 12 can be blocked independently of one another.
[0034] FIG. 4 shows a similar exemplary embodiment of a pressure monitoring apparatus 1 similar to the pressure monitoring apparatus 1 shown in FIG. 3 , but like the FIG. 2 embodiment, the pressure transducer 3 here measures the pressure in the volume 4 on the oil side A of the membrane compressor 2 . Instead of the two separate shutoff valves 6 and 11 , in the pressure monitoring apparatus 1 , a 3/2 way valve 14 is used by which the two flow paths 7 , 12 can be reciprocally blocked and opened. In this way, the size of the pressure monitoring apparatus 1 can be reduced. Moreover, a programmable control 15 can be connected to the pressure transducer 3 . In this way, the sequence of the measurement of the pressure and of the maximum and the minimum pressure can be automated. In particular, in this way, the intervals in which the 3/2 way valve is switched over can be changed or set. Furthermore a pressure display apparatus 16 , for example a display, can be connected to the pressure transducer 3 , so that the current pressure value can be easily read off on site.
[0035] FIG. 5 shows a simplified representation of the sequence of a measurement of the minimum and of the maximum pressure with a pressure monitoring apparatus according to FIG. 2 . In step 101 , the shutoff valve 6 is opened and in step 102 the shutoff valve 11 is closed. In this way, the first flow path 7 is opened so that, in step 103 , the pressure transducer 3 measures the pressure in the volume 4 which ultimately corresponds to the maximum pressure which prevails in the volume 4 . The measurement can be taken essentially over any time interval, but a measurement in the range of a few seconds being preferred. In step 104 , the shutoff valve 6 is closed, as a result of which the flow path 6 is blocked and in step 105 the shutoff valve 11 is opened so that the flow path 12 is cleared. In this way, in step 106 , the minimum pressure can be measured with the pressure transducer 3 when the pressure in the volume 4 is reduced again.
[0036] In any time intervals, steps 101 to 106 can be repeated. When a measurement is automated by a programmable control 15 , other functions can be introduced. Thus, for certain boundary values of the maximum pressure or of the minimum pressure, warnings can be output or when the boundary values are exceeded or undershot and the intervals 103 and 106 in which the measurements are taken can be shortened or prolonged. In this way, it is possible to react to changes of the pressure which are measured by the pressure transducer 3 in the monitored volume 4 which do not correspond to the expected pressure characteristic, as a result of which a defect can be recognized in time.
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A pressure monitoring apparatus for a membrane compressor, with at least one pressure transducer for recording the pressure within a certain volume, with at least one nonreturn valve and with at least one shutoff valve, for blocking of the nonreturn valve, the shutoff valve and the nonreturn valve each being located in a flow path through which a medium can flow between the volume and the pressure transducer. A pressure monitoring unit delivers exact measured values and which can be economically implemented is achieved by there being at least two nonreturn valves which are located anti-parallel in respective flow paths, the first nonreturn valve blocking in the flow direction from the volume to the pressure transducer and the second nonreturn valve blocking in the flow direction from the pressure transducer to the volume, and by there being at least two shutoff valves for blocking a respective flow path.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims priority from U.S. Provisional Patent Application Ser. No. 61/325,612 filed on Apr. 19, 2010, the entirety of which is expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to food processing vats and, more particularly, to vents that are used with food processing vats.
2. Discussion of the Related Art
Vents that are mounted to food processing vats are known in the food processing industries. Such vents fluidly connect an inside space within the vat to the ambient.
Clean-in-place systems for use with food processing vats are also known in the food processing industries. Such clean-in-place systems automatically spray cleaning fluid, in liquid form, inside of food processing vats.
SUMMARY OF THE INVENTION
The inventors have recognized that in typical food processing vats, the clean-in-place systems have been primarily designed to clean the inside walls of the vat and large mechanicals that are housed in the vat, such as agitator shafts, while other parts of the overall vat systems have not been cleaned with these clean-in-place systems. The inventors have also recognized that in typical food processing vats, vents must be manually cleaned by technicians and, at times, require removal of the vents for thorough cleaning, which can be substantially time consuming. The inventors have further recognized that typical vents have side walls with relatively small surface areas upon which to condense out water or other condensate from the vapor or vented fluid that flows out of the vat. The present invention contemplates a vent for a food processing vat that addresses these and other problems and drawbacks of the prior art.
In accordance with an aspect of the invention, a food processing vat system is provided with a vent that is attached to a vat and fluidly connects an inside space of the vat to the ambient so as to maintain a pressure within the vat at an ambient pressure and/or to direct a vented fluid that flows out of the vat to the ambient. A nozzle that is configured to convey a cleaning fluid through it is mounted to at least one of the vent and the vat, and may be mounted in a generally fixed position. The nozzle has an opening that is positioned with respect to the vent so that the nozzle directs the cleaning fluid into the vent while the vent remains attached to the vat. This allows the vent to be cleaned in place, without requiring manual cleaning by a technician.
In accordance with another aspect of the invention, the nozzle is positioned inside of the vent. The vent may define a vent body having an upper edge and the nozzle may be positioned below the upper edge of the vent body. The vent may include a lid, and the vent may further include a nozzle tube that extends through the lid and holds the nozzle inside of the vent. This may also allow the vent to be cleaned in place, without requiring manual cleaning by a technician.
In accordance with another aspect of the invention, the vent defines a vent body and a lid that is positioned with respect to the vent body such that (i) vented fluid that flows out of the vat can flow between the vent body and the lid so that the vented fluid can exit the vent, and (ii) cleaning fluid that is delivered out of the nozzle cannot flow between the vent body and the lid so that the cleaning fluid remains in the vent body or flows into the vat. The lid may include a lid lower portion that longitudinally overlaps at least part of an upper end of the vent body and is transversely spaced from the upper end of the vent body. A lid upper portion may be spaced from the upper end of the vent body. The lid may be maintained by spring clips in such a position with respect to the vent body. This may allow the vented fluid that flows out of the vat to be directed to the ambient while maintaining any cleaning fluid that is sprayed in the vent to remain in the vent or flow into the vat.
In accordance with another aspect of the invention, the vent further includes a collar that is positioned with respect to the nozzle and the lid so that the cleaning fluid that is delivered out of the nozzle is deflected by the collar to prevent the cleaning fluid from exiting the vent. The collar may be connected to and extend downwardly from a lower surface of the lid, spaced radially inside of an outer perimeter of the lid. The vent body may include a tube that is housed concentrically inside of a canister, and the collar may be concentrically aligned between the tube and container. This may allow the collar to deflect cleaning fluid that is delivered from the nozzle so that the cleaning fluid remains in the vent body or flows into the vat, without spraying outside of the vent.
In accordance with another aspect of the invention, the vent is removably attached to the vat. The vent may be attached to the vat with a clamp that holds a pair of flanges that are provided at respective ends of the vent tube, and a vat tube that is fixed to the vat. This may permit quick removal of the vent from the vat for occasional servicing and maintenance.
In accordance with another aspect of the invention, the vent tube extends between the vat or vat tube and the lid of the vent, directing the vented fluid from the vat to the vent. A lower portion of the vent tube may extend beyond the canister and define a solid side wall. An upper portion of the vent tube may be provided within the canister and may have a perforated side wall. The openings or perforations of the perforated side wall may be configured to diffuse streams of the cleaning fluid that is delivered by the nozzle, so that the cleaning fluid is spread out and applied to substantially an entire inner surface(s) area of the vent. This may allow a nozzle to be used near the walls of the vent while delivering cleaning fluid across substantially the entire walls of the vent.
In accordance with another aspect of the invention, the canister extends concentrically around the vent tube so as to define an annular passage between the vent tube and the canister and through which the vented fluid can flow. The canister may further include a lower wall that extends generally radially toward and connects to the vent tube. The lower wall of the canister may connect to the vent tube at a location on the vent tube that generally defines a division line between the solid side wall of the vent tube and the perforated side wall of the vent tube. This may allow the cleaning fluid to be diffused through the perforated side wall of the vent tube, spreading out its application through the vent, while retaining the cleaning fluid within the vent or allowing it to flow into the vat.
According to another aspect of the invention, the canister lower wall is slanted so that different depths of the annular passage are defined at different locations about a periphery of the vent tube. The slanted lower wall may extend angularly with respect to the canister side wall so that corresponding portions of the slanted lower wall, vent tube, and canister side wall define a collection chamber that can collect condensate that condenses out of the vented fluid. The collection chamber may also collect the cleaning fluid that remains in the vent and does not flow into the vat. The vent may include a drain that extends through the canister side wall at a location that corresponds to a deepest portion of the annular passage. This may allow removal of condensate, including water and non-water materials that may be suspended in the vented fluid, the cleaning fluid, and/or other substances that may collect in the collection chamber to be removed from the vent.
Various other features, objects, and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
FIG. 1 is an isometric view from above and in front of a vat system incorporating a clean-in-place vent in accordance with the present invention;
FIG. 2 is an isometric view from above and in back of the vat system of FIG. 1 ;
FIG. 3 is a top plan view of the vat system of FIG. 1 ;
FIG. 4 is a front elevation view of the vat system of FIG. 1 ;
FIG. 5 is a sectional view of the vent of the vat system of FIG. 1 , taken at line 5 - 5 of FIG. 4 ; and
FIG. 6 is a sectional view of the vent of the vat system of FIG. 1 , taken at line 6 - 6 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a vat system 5 that can be used for processing food and related products (collectively referred to as “vat contents”) by mechanically manipulating and heating or cooling the vat contents, depending on the particular food or related product being processed. In a representative application, the vat system 5 may be used in the production of cheese, although it is understood that the vat system 5 may be used in processing other types of food products. The vat system 5 includes a vat 7 that has an agitation system 40 which performs the mechanical manipulation tasks by rotating a pair of shafts upon which blade assemblies are mounted, and a zoned heat transfer system 50 to perform heating and/or cooling to provide zoned temperature control to the vat 7 .
Vat 7 defines an enclosure having a top wall 10 , a bottom wall 11 , and side walls 14 , 15 , all of which extend longitudinally between a pair of end walls 18 and 19 . The walls 10 , 11 , 14 , 15 , 18 , 19 are multilayered, having an outer jacket 20 and an inner shell 25 that are spaced from each other. Insulation and various components of the zoned heat transfer system 50 are housed between the jacket 20 and shell 25 . The shell 25 is the innermost structure of the vat 7 , so that its inner surface surrounds and defines an outer periphery of a void or inside space 8 within the vat 7 . A lower part of the inside space 8 resembles two horizontal parallel cylinders that transversely intersect each other, being defined by a lower portion of the shell 25 that has a pair of arcuate depressions which extend along the length of the vat 7 , on opposing sides of a longitudinally extending raised middle segment. From the lower portion of the shell 25 , opposing side portions extend in an outwardly bowed manner, arching away from each other in a transverse direction of the vat 7 . An upper portion of the shell 25 arcs gradually between side portions of the shell 25 and defines an upper perimeter of the inside space 8 of vat 7 .
Referring now to FIGS. 1-4 , operation of the zoned heat transfer system 50 alters the temperature of the inside space 8 of vat 7 , which correspondingly changes a volume of the gases within the inside space 8 of vat 7 . Vent 60 allows the vat 7 to breathe, accommodating the changing volume of gases without changing a pressure within the vat 7 so as to keep the pressure of the inside space 8 of the vat at the ambient pressure.
Referring now to FIGS. 5 and 6 , vent 60 includes a vent body 62 that is defined by a vent tube 70 and a container or canister 80 , and a lid 100 that sits over the vent body 62 . A nozzle 90 that sprays a cleaning fluid, which may be in a liquid form, is positioned with respect to the vent tube 70 , canister 80 , and lid 100 so that the cleaning fluid that exits the nozzle 90 either remains in the vent 60 or flows into the vat 7 , described in greater detail elsewhere herein.
Still referring to FIGS. 5 and 6 , in this embodiment, the vent 60 is attached to the vat 7 by coupling the vent tube 70 to a vat tube 55 . Vat tube 55 is connected at its bottom end to the top wall 10 of the vat 7 . A flange 56 is connected to the top end of the vat tube 55 . Flange 56 sits below a cooperating flange 71 that is connected to the bottom of vent tube 70 , and a seal 58 sits between the flanges 56 , 71 of the vat and vent tubes 55 , 70 , respectively. A lower surface of flange 56 and an upper surface of flange 71 are angled toward each other. Correspondingly, a cross-sectional profile shape of the flanges 56 , 71 together is wedge-shaped, tapering down from a thicker portion adjacent the vat and vent tubes 55 , 70 , respectively, to a thinner portion that is radially furthest from the vat and vent tubes 55 , 70 , respectively. A clamp 57 ( FIG. 5 ) fits around and engages both of the flanges 56 , 71 and pushes them toward each other to compress the seal 58 to provide a liquid-tight joint between the vat and vent tubes 55 , 70 , respectively. Removal of the clamp 57 from the flanges 56 , 71 allows the vent 60 to be detached from the vat 7 by lifting the vent away from the vat tube 55 .
Still referring to FIGS. 5 and 6 , in this embodiment, a lower portion 72 of the vent tube 70 extends upwardly from the flange 71 , toward the canister 80 . Lower portion 72 has a solid side wall 73 which ensures that the vented fluid flows in a generally longitudinal direction through the lower portion 72 , without escaping the confines of the lower portion 72 of the vent tube 70 .
An upper portion 75 of the vent tube 70 connects to and extends upwardly from the lower portion 72 . The upper portion 75 in this embodiment has a length that is over half of the overall length of the vent tube 70 , the upper portion 75 being about four times longer than the lower portion 72 . In another embodiment, the upper portion 75 may be about two times longer than the lower portion 72 . A side wall 76 of upper portion 75 is perforated with openings 77 that extend entirely through the thickness of the side wall 76 and that are spaced at substantially equal distances from each other to provide a matrix or array of openings 77 that define the perforation(s).
The perforated side wall 76 of the upper portion 75 of the vent tube 70 allows the vented fluid that flows out of the lower portion 72 to flow in both a generally longitudinal direction through the upper portion 75 and also in a generally radial direction out of the openings 77 . In so doing, a portion of the vented fluid flows through the entire length of the upper portion 75 and exits out of the vent tube 70 through an opening defined at an upper perimeter edge of the upper portion 75 with its further longitudinal flow being impeded by the overlying lid 100 . The rest of the vented fluid diffuses and radially flows through the openings 77 of the perforated side wall, with its further radially directed flow being impeded by the canister 80 .
Still referring to FIGS. 5 and 6 , canister 80 includes a solid side wall 81 that extends concentrically around the vent tube 70 , so as to define an annular passage 78 between the vent tube 70 and the canister 80 . The annular passage 78 provides a path through which the vented fluid flows in a longitudinal direction while exiting the vent 60 , after flowing in the radial direction into the annular passage 78 from the vent tube 70 . A diameter of the flow path through the vent 60 which is defined by the solid side wall segments that radially restrict flow through the vent 60 , namely, the side walls 73 and 81 , has a step-change increase in which the relatively smaller diameter of the side wall 73 of the vent tube lower portion 72 increases to a relatively larger diameter of the side wall 81 of the canister 80 . Such diameter increase occurs generally at a lower wall 82 of the canister 80 .
Lower wall 82 of the canister 80 has an annular perimeter shape and extends radially between the vent tube 70 and canister side wall 81 . Lower wall 82 connects the canister side wall 81 to the vent tube 70 at a location that generally defines a division line between the solid and perforated side walls 73 , 76 , respectively, of the upper and lower portions 72 , 75 , respectively, of the vent tube 70 .
In this embodiment, the canister lower wall 82 is slanted, extending angularly with respect to the tube and canister side walls 73 , 76 , 81 . This provides the annular passage 78 with different depths at different locations about the perimeter of the vent tube 70 . A collection chamber 85 is defined by a space between respective portions of the slanted lower wall 82 , vent tube 70 , and canister side wall 81 that can collect condensate that condenses out of the vented fluid and/or cleaning fluid that is delivered out of nozzle 90 .
The particular volume of condensate, cleaning fluid, or other liquid that the collection chamber 85 holds is determined at least in part by (i) the width of the lower wall 82 and thus the radial distance between the vent tube 70 and canister 80 , and (ii) the particular location of the division line between the solid and perforated side walls 73 , 76 , respectively, of the upper and lower portions 72 , 75 , respectively, of the vent tube 70 and thus a maximum height at which contents in the collection chamber 85 can be held and over which the contents will spill through the openings 77 of the perforated side wall 76 and run down the inside of vent tube 70 and into the vat 7 . In this embodiment, the diameter of the canister 80 is about 25 percent larger than the diameter of the vent tube 70 , although it is understood that any other satisfactory differential may be employed. Also in this embodiment, the division line between the solid and perforated side walls 73 , 76 , respectively, of the upper and lower portions 72 , 75 , respectively, of the vent tube 70 extends orthogonally with respect to a longitudinal axis of the vent tube 70 , whereby the division line is not slanted like the orientation of the canister lower wall 82 . In another embodiment, the division line between the solid and perforated side walls 73 , 76 , respectively, of the upper and lower portions 72 , 75 , respectively, of the vent tube 70 may extend parallel to the canister lower wall 82 .
Still referring to FIGS. 5 and 6 , regardless of the particular location of the division line between the solid and perforated side walls 73 , 76 , respectively, of the upper and lower portions 72 , 75 , respectively, of the vent tube 70 , the collection chamber 85 includes a drain 87 that extends though the canister side wall 81 . The drain 87 of this embodiment is provided at a location upon the canister side wall 81 that corresponds to a deepest portion of the annular passage 78 and thus at the bottom of the collection chamber 85 . The drain 87 allows removal of condensate, including liquid and non-liquid materials that may be suspended in the vented fluid, the cleaning fluid, and/or other substances that may collect in the collection chamber 85 , to be removed from the vent 60 . Still referring to FIGS. 5 and 6 , the cleaning fluid that may collect in the collection chamber 85 is that which is delivered from nozzle 90 during a clean-in-place procedure. Nozzle 90 is positioned with respect to the vat system 5 so that its opening(s) 91 directs cleaning fluid into the vent 60 while the vent remains attached to the vat 7 . FIG. 6 shows another nozzle 90 that is mounted to the top wall 10 of the vat and has openings 91 provided about its outer surface so as to direct cleaning fluid in multiple directions, so that some of the cleaning fluid may enter the bottom opening of the vat tube 55 and may deflect into the vent 60 .
Still referring to FIGS. 5 and 6 , in this embodiment, toward the top of the vent 60 , one of the nozzles 90 that can spray cleaning fluid is mounted fully inside of the vent 60 . This nozzle 90 is positioned below an upper edge of the vent body 62 and is substantially aligned with a longitudinal axis of the vent 60 and thus concentrically inside of the perforated side wall 76 of the upper portion 75 of vent tube 70 . With the nozzle 90 mounted in this position with respect to the perforated side wall 76 , the discrete streams of cleaning fluid leaving the openings 91 can be split into more streams that deflect in different directions while being sprayed through the openings 77 of the perforated side wall 76 , diffusing the cleaning fluid and spreading out its application through the vent 60 .
Referring now to FIG. 6 , in this embodiment, the nozzle 90 is mounted to and suspended from the lid 100 with a nozzle tube 92 . The nozzle tube 92 extends through a flange that is raised above the rest of the lid 100 with a tube segment that extends above and below the lid 100 . An end of the nozzle tube 92 that is outside of the vent 60 has a flange that couples to a corresponding flange of a cleaning fluid supply line 95 , allowing such flanges to be uncoupled from each other to separate the nozzle tube 92 from the cleaning fluid supply line 95 while leaving the nozzle tube 92 connected to the lid 100 . The cleaning fluid supply line 95 is connected to a known clean-in-place system (including suitable plumbing components, hardware components, and controls) that is configured to deliver cleaning fluid for automatically spraying down predetermined surfaces within the vat system 5 .
Referring again to FIGS. 5 and 6 , the lid 100 is dished out, presenting a convex upper surface and a concave lower surface, with a lower lip 102 provided at a lower portion 105 of the lid 100 and extending downwardly from its outer perimeter. The lid 100 is positioned with respect to the vent body 62 such that (i) vented fluid that flows out of the vat 7 can flow between the vent body 62 and the lid 100 so that the vented fluid can exit the vent 60 , and (ii) cleaning fluid that is delivered out of the nozzle 90 cannot flow between the vent body 62 and the lid 100 so that the cleaning fluid remains in the vent body 62 or flows into the vat 7 . The lip 102 of the lower portion 105 longitudinally overlaps at least part of an upper end of the vent body 62 and is transversely spaced from the upper end of the vent body 62 . A lid upper portion 110 is spaced longitudinally from the upper end of the vent body 62 .
The lid 100 of this embodiment is maintained in this overlying and longitudinally and radially-spaced relationship with respect to the vent body 62 by spring clips 120 . In this embodiment, the spring clips 120 are connected to and extend upwardly from an upper edge of the vent tube 70 . Spring clips 120 are bent and generally L-shaped and have an upright segment that aligns with the vent tube 70 and a horizontal segment that engages an inner circumferential surface of a collar 125 .
Still referring to FIGS. 5 and 6 , collar 125 is connected to and extends down from a lower surface of the lid 100 and is spaced radially inside of an outer perimeter of the lid 100 . The collar 125 is positioned concentrically between the vent tube 70 and canister 80 when viewed from a top plan view. In this embodiment, the collar 125 extends downwardly from the lid 100 to a height along the vent 60 at which upper edges of the vent tube 70 and canister 80 are provided. In another embodiment, the collar 125 extends relatively further down, between the vent tube 70 and canister 80 , and thus into the annular passage 78 . Regardless of how far the collar 125 extends from the lid 100 in any particular embodiment, the collar 125 is positioned with respect to the nozzle 90 and the lid 100 so that some of the cleaning fluid that is delivered out of the nozzle 90 is deflected by the collar 125 into the annular passage 78 , preventing such cleaning fluid from exiting the vent 60 . The collar 125 thus cooperates with the upper end of vent tube 70 and the upper end of canister 80 to define a serpentine path between the interior of the vent tube 70 and the exterior of canister 80 , which allows passage of air into and out of vat 7 and also functions to ensure that cleaning fluid from nozzle 90 does not escape from vent 60 other than through collection chamber 85 at the lower end of annular passage 78 .
Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
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A food processing vat is provided with a vent that can be automatically cleaned in place, without requiring manual cleaning by a technician or removal of the vent from the vat. A nozzle is mounted to at least one of the vent and the vat and has an opening(s) that is posited with respect to the vent to direct cleaning fluid into the vent. The vent may include a canister that concentrically surrounds at least a portion of a vent tube that is fluidly connected to the vat, which collects cleaning fluid and/or condensate from gas that enters or exits the vat.
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This application is a divisional application of U.S. Ser. No. 12/064,715, filed Feb. 25, 2008, now pending. This application claims the benefit of priority to France Application No: 05/08.845, filed Aug. 26, 2005.
FIELD OF THE INVENTION
The invention relates to the field of distributor trays intended to supply chemical reactors functioning in gas and liquid co-current down-flow mode with gas and liquid.
Such reactors are encountered in the refining field, more particularly in the selective hydrogenation of various oil cuts, and more generally in hydrotreatments which require high pressure hydrogen streams operating with heavy liquid feeds which may contain impurities constituted by plugging solid particles.
In some cases, the liquid feed contains impurities which may be deposited on the catalytic bed itself and over time may reduce the interstitial volume of that catalytic bed.
Plugging feeds which may be cited include mixtures of hydrocarbons containing 3 to 50 carbon atoms, preferably 5 to 30 carbon atoms, which may contain a non-negligible proportion of unsaturated or polyunsaturated acetylenic or dienic compounds or a combination of those various compounds, the total proportion of unsaturated compounds possibly being up to 90% by weight in the feed. A representative example of feeds which are of relevance to the present invention is pyrolysis gasoline, “pyrolysis” designating a thermal cracking process which is well known to the skilled person.
A description of that type of process and the corresponding products can be found in the work entitled “Raffinage et Génie Chimique” [Refining and Chemical Engineering] by P Wuithier, Editions Technip, page 708.
The present invention allows for limiting the deposition of plugging particles in the catalytic bed.
It thus contributes to keeping the bed homogeneous as regards the void fraction and thus the flow quality, and it allows also for limiting the increase in pressure drop.
When a blockage occurs in a catalytic bed, the pressure drop in the flow through the reactor is observed to rise very rapidly.
The pressure drop may become such that the operator is obliged to shut down the reactor and replace all or part of the catalyst, which clearly considerably reduces the run times of the process.
Blockage of part of the catalytic bed may be due to a number of mechanisms.
Directly, the presence of particles in the feed stream may cause a blockage by deposition of said particles in the catalytic bed, this deposition effectively reducing the void fraction.
Indirectly, the formation of a layer of products derived from chemical reactions, typically coke, but possibly other solid products derived from the impurities present in the feed, which products are deposited at the surface of the catalyst grains, may also contribute to reducing the void fraction of the bed.
Further, the plugging particles may be deposited in the bed in a more or less random manner and result in heterogeneities in the distribution of the void fraction of that bed which result in the creation of preferred pathways.
Such preferred pathways are major problems from the hydrodynamic viewpoint as they can substantially perturb the homogeneity of flow of the phases in the bed and may contribute to heterogeneities in the progress of the chemical reaction, as well as thermal considerations.
EXAMINATION OF THE PRIOR ART
U.S. Pat. No. 3,702,238 proposes a system of conduits provided with calibrated breakage disks which are intended to deflect part of the flow of reagents when the catalytic bed becomes plugged. The increase in pressure ruptures the breakage disk and allows the feed to flow through the conduits.
The instantaneous effect of deflecting part of the flow through the conduits is a large reduction in the pressure drop. The inlet to the conduits is located upstream or downstream of a distributor tray, but no system is provided for deflecting the liquid flow and the gas flow in a controlled or independent manner.
No re-distribution device is provided in this case to homogenize the flow at the outlet from the conduits. This device also suffers from the disadvantage of being sensitive to sudden pressure variations.
U.S. Pat. No. 3,607,000 and FR-A-7513027 propose systems composed of filter baskets placed upstream or at the head of the catalytic bed to collect impurities transported by the flow of reagents. In this case, a non-negligible volume of the bed is occupied by said baskets which do not actually prevent fouling of the fractions of the bed located between the baskets. Further, for gas/liquid flow applications, the system cannot control a homogeneous distribution of the gas/liquid flow between the baskets and downstream of the baskets.
In the article by T H Lindstrom et al in Hydrocarbon Processing, February 2003 (pages 49-51), a system of external filters is described, but that system does not overcome all types of blockage and the cost of that solution is very high.
U.S. Pat. No. 4,313,908 or EP-A2-0 050 505 describe devices which can reduce the increase in the pressure drop in the catalytic bed by deflecting part of the flow through tubes. A series of tubes forming a short-circuit pass through the catalytic bed. The inlet to those tubes is located downstream of a distributor tray and the outlet from those tubes opens above the inlet to the catalytic bed at various levels, The system can thus independently deflect the gas and liquid flows provided that a liquid level is established upstream of the bed. The device described in the cited patents cannot control the ratio between the liquid flow and the gas flow deflected into the tubes composing said system. The gas will be deflected from start-up of the reactor and the liquid will only be deflected when a sufficient liquid level has been established above the bed because of fouling.
Further, there is no fluid distribution effect at the outlet from the devices described in the two cited patents, necessitating the downstream provision of a distributor tray or an equivalent system. In the case of the present invention, the distribution function is incorporated into the filtration system to form a single device.
The more recent patent application WO-A1-03/000401 describes a device using tubes forming a short-circuit coupled with chambers also forming a short-circuit and acting to capture any impurities contained in the feed. That device does not include an effective system for re-distribution of gas/liquid effluents at the outlet from said chambers when the system is used in gas/liquid flow mode.
The tray of the invention in U.S. Pat. No. 3,958,952 is constituted by a series of filtration units each being constituted by alternating concentric chambers, one empty and the other occupied by “filtration bodies” which are not described in detail.
In such a system, the filtration function is completely separate from the mixing and distribution function, while in the device of the present invention, there is genuine synergy between the filtration bed and the mixing chimneys, as will be explained below.
In fact, the filtration bed directly integrated with the tray has a secondary function of stabilizing the gas/liquid interface located above the tray, and thus contributes to a uniform supply of liquid to the mixing and distribution chimneys which form an integral part of said tray.
U.S. Pat. No. 4,229,418 describes a tray system comprising filtration elements, but the term “filtration” in the context of that patent means permeability with respect to the process fluids and impermeability with respect to the catalyst particles, while in the context of the present invention, the term “filtration” means the capacity to retain plugging particles contained in the feed.
Finally, the device described in the present invention is remarkably compact, in contrast to that of the prior art, and thus means that more catalyst can be used in a given volume of reactor, thereby increasing its efficiency.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 represents a diagram of a filtering distributor tray of the invention, said tray being placed upstream of a catalytic bed supplied with a feed having a gas portion and a liquid portion.
FIG. 2 shows curves of the change, as a function of time, in the quantity of deposited impurities (curve A), of the pressure drop through a catalytic bed without a filtration bed (curve B) and of the pressure drop through a catalytic bed with a tray of the invention, i.e. provided with a filtration bed.
BRIEF DESCRIPTION OF THE INVENTION
The device described in the present invention can trap plugging particles contained in the liquid flow constituting part of the feed for a reactor functioning in gas and liquid down-flow co-current mode by means of a specific distributor tray comprising a filtration medium.
The present invention consists of a device which can simultaneously distribute the gas phase and the liquid phase supplying a fixed bed reactor functioning with a down-flowing co-current of said phases, while ensuring a filtration function for impurities contained in the liquid phase constituting a portion of the feed to be treated.
More precisely, the device of the invention is a device for filtering and distributing a gas phase and a liquid phase constituting the supply to a reactor comprising at least one fixed catalyst bed, functioning in a gas and liquid down-flow co-current mode, the liquid phase generally being charged with plugging particles, said device comprising a tray located upstream of the catalytic bed, said tray being constituted by a substantially horizontal base plane which is linked to the walls of the reactor and to which substantially vertical chimneys are fixed which are open at their upper end to admit gas and at their lower end to evacuate the gas-liquid mixture for supplying the downstream catalytic bed, said chimneys being perforated over a certain fraction of their height by a continuous lateral slot or lateral orifices for the admission of liquid, said tray supporting a filtration bed surrounding the chimneys and said filtration bed being constituted by at least one layer of particles with a size which is less than or equal to the size of the particles of the catalytic bed.
Said filtration bed, which forms part of the distributor tray, is generally composed of a plurality of layers of particles of different sizes.
The particles composing the various layers of the filtration bed are generally inert and usually formed from silica or alumina, or any other ceramic substance.
In certain cases however, it may be advantageous for at least one layer of the filtration bed to be composed of particles which are active in the sense of the chemical reaction which takes place on the catalytic bed located downstream of the filtering distributor tray. In this case, the active particles are preferably composed of an identical catalyst or one belonging to the same family as the catalyst in the catalytic bed.
In a further variation of the device of the invention, the filtration bed is composed of a packing structured with a porosity in the range between 35% to 50% (0.35 to 0.50).
To prevent blockage of the lateral orifices of the chimneys or the lateral slot, each chimney is generally separated from the filtration bed which surrounds it by means of a screen with a sufficiently fine mesh, i.e. a mesh size which is lower than that of the particles of the filtration bed. In this case, the distance separating the chimney from the filtration bed is generally in the range from 5 mm to 20 mm.
The filtration and distribution device of the invention is thus a filtering distributor tray with a base plane supporting the chimneys and the filtration bed which is preferably provided with orifices, with an orifice density of more than 100 orifices per m 2 section of reactor.
The filtration and distribution device of the present invention can significantly extend the service life of the catalyst. In general, periodic replacement of the filtration bed is carried out with a periodicity of at least 6 months.
The filtration and distribution device of the invention is particularly advantageous for use in hydrotreatment reactors, selective hydrogenation reactors or in the conversion of residues or hydrocarbon cuts with an initial boiling point of more than 250° C.
DETAILED DESCRIPTION OF THE INVENTION
The device of the present invention is composed of a distributor tray comprising a substantially horizontal base plane which is integral with the walls of the reactor, on which are fixed a set of substantially vertical chimneys provided with an upper opening and a lower opening and perforated with lateral orifices distributed all along their vertical walls.
The gas portion of the supply penetrates into the inside of the chimneys essentially via the upper opening, and the liquid portion of the supply penetrates into the inside of the chimneys essentially via the lateral orifices. The term “essentially” means that at least 50%, preferably at least 80% of the gas and liquid respectively penetrate into the inside of the chimneys via the upper opening and via the lateral orifices.
The gas and liquid are mixed inside the chimneys and the resulting mixture leaves the chimneys via the lower opening.
The lateral orifices may form a continuous slot extending over the major portion of the height of the chimneys. The remainder of the text will refer to lateral orifices, but this will encompass the case of a continuous slot.
The distributor tray supports a filtration bed constituted by at least one granular solid acting as a filter, said solid granular bed surrounding each of the chimneys over a fraction of their height.
The chimneys are generally higher than the level of the filtration bed by a height (H′) of at least 30 mm, preferably more than 35 mm, or even more than 40 mm.
The filtration bed may comprise a plurality of layers of particles of any shape.
The size of the particles constituting each layer of the filtration bed reduces from the top to the bottom of the filtration bed.
The particles of the lower (or the lowest) layer has a mean size which is preferably smaller than the size of the particles of catalyst constituting the catalytic bed located downstream of the distributor tray.
In general, the size of the particles in each layer varies between 1 and 30 mm, preferably between 1 and 20 mm.
In a variation of the filtration and distribution device of the invention, the filtration bed is composed of at least two layers of solid particles, the size of the particles of a given layer being smaller than that of the particles of the immediately superior layer.
In a particular variation of the device of the invention, the size of the particles of the upper layer of the filtration bed is in the range from 5 mm to 30 mm, and the size of the particles of the lower layer is in the range from 2 mm to 10 mm.
Purely by illustration, and without constituting any limitation, a filtration bed of the device of the invention may be constituted by:
an upper layer representing 25% of the total height of the filtration bed and composed of particles with a size which is greater (preferably by at least 10%) than that of the catalyst grains; an intermediate layer representing 25% of the total height of the filtration bed, and composed of particles with a size approximately equal to that of the catalyst grains; a lower layer representing 50% of the total height of the filtration bed and composed of particles with a size lower (preferably by at least 10%) than that of the catalyst grains.
The particles forming the filtration bed may have any shape, for example spherical or cylindrical, with or without void in the interior. They are generally inert, but may possibly be catalytic. In the latter case, the active particles of the filtration bed are generally constituted by a catalyst from the same family as the catalyst used in the catalytic bed located downstream of the filtration bed.
The filtration bed may also be constituted by packing elements offering a large capture surface for impurities while offering a high void fraction.
Examples of such packing elements which may be cited are inert particles composed of titanium and alumina with a cylindrical 20 mm diameter shape, in which cylindrical channels are formed.
Examples of active particles which may be cited are 10 mm diameter beads containing nickel-molybdenum or cobalt-molybdenum as well as alumina.
An example of a composition of a filtration bed using a plurality of layers is given in the detailed example following the present description.
For the majority of industrial reactors, the total height of the filtration bed is in general in the range from 200 to 1500 mm, preferably in the range from 300 to 600 mm.
The lateral orifices extend over the major portion of the height of the chimneys, but the lowest of them is preferably located at a minimum height (h) with respect to the base plane of the tray, which is preferably 50 mm above the base plane of said tray, or even 60 mm above. The “base plane of the tray” is the plane which is linked to the walls of the reactor and supporting the filtration bed.
The orifices are preferably stepped over the whole height of the chimney to the maximum height (h′) which is preferably 20 mm above the upper surface of the filtration bed, or even 15 mm above.
The minimum and maximum stepped heights of the lateral orifices may also apply in the case in which a continuous slot is used.
The internal diameter of the chimneys is generally in the range from 10 mm to 150 mm, and preferably in the range from 25 mm to 80 mm.
In one preferred implementation of the invention, a separation zone surrounding each chimney avoids direct contact of the filter with the chimneys to prevent the lateral orifices or the lateral slot of the chimneys from being obscured by the solid particles or the packing elements constituting the filtration bed.
In this case, the distance separating the chimney from the filtration bed is generally in the range from 5 mm to 20 mm.
The filtration bed plugs slowly over time, starting with the lower layers, and an interface is effectively created between the lower plugged portion and the upper non-plugged portion.
The liquid passes through the filtration bed over its upper non plugged portion and penetrates through the chimneys via the lateral orifices.
The gas phase is primarily introduced into the inside of the chimneys via their upper opening.
A greater or lesser portion of the gas is also introduced via the lateral orifices of the chimneys or via the lateral slot.
The upper opening of the chimneys is generally located at a height H′ above the filtration bed and is generally protected by a cap or any equivalent form which is aimed for preventing the direct introduction of liquid via said upper opening of the chimneys.
The liquid introduced via the lateral orifices or the lateral slot thus mix with the gas phase inside the chimney and the resulting mixture is evacuated from the chimneys via the lower opening then is distributed to the catalytic bed located downstream of the distributor tray.
In the remainder of the text, we shall term the ensemble of the device constituted by the distributor tray, the chimneys, and the filtration bed supported by said distributor tray the “filtering distributor tray”.
The device of the present invention is thus composed of a filtering distributor tray linked to the internal cylindrical wall of the reactor and located above the catalytic bed.
When the reactor includes a plurality of distinct catalytic beds, each of these catalytic beds may be supplied with a filtering distributor tray of the invention.
In this case, the gas phase and the liquid phase supplying a given filtering distributor tray are constituted by effluents from the catalytic bed located immediately above it, to which may optionally be added a fluid introduced between two catalytic beds which in the case of hydrogenation or hydrotreatment reactions is usually a cooling fluid.
The filtering distributor tray may also be pierced through its horizontal base plane by holes of any shape so that the overall porosity due to these holes can produce a minimum height of liquid on the tray, termed the liquid trap. A filtering distributor tray without holes through its base plane will function, however, and is included within the scope of the invention.
The filtering distributor tray also supports chimneys which act to mix the gas and liquid and to route the resulting mixture towards the catalytic bed located in the zone downstream of the tray.
The density of these chimneys is in the range from 10 to 150 per m 2 section of catalytic bed, preferably in the range from 30 to 100 per m 2 section of catalytic bed.
All of the chimneys are provided with lateral orifices located at different levels stepped all the way along the vertical wall of the chimneys or a continuous longitudinal slot, allowing the liquid phase to pass inside said chimneys regardless of the level of plugging in the filtration bed.
The shape of these lateral orifices or of the lateral slot is studied to adjust it according to the variation in the liquid flow rate during the operational cycle, as will be explained below.
In the case of a lateral slot, the shape of said slot may be rectangular or triangular with the point of the triangle directed upwards or downwards.
Any shape of slot is possible as long as the conditions regarding the height of the slot are satisfied. It preferably should commence at a height (h′) of at least 50 mm above the base plane of the tray and preferably extend to a height (h) of at least 20 mm above the upper level of the filtration bed.
The distribution function of the gas/liquid flow is maintained as plugging progresses since the whole set of the chimneys is always used and the liquid flow rate remains approximately identical between the chimneys, this latter being essentially conditioned by the liquid level established on the tray. Thus, the importance of establishing and maintaining a certain liquid level above the base plane of the filtration tray will be appreciated.
Further, the existence of the filtration bed contributes to stabilizing this liquid level by accommodating fluctuations in the interface between the gas and the liquid.
Thus, the liquid distribution remains under control throughout the service life of the filtration bed and the progressive use of the lateral orifices or the lateral slots distributed along the whole length of the chimneys allows the filtration bed to be used until it is completely saturated, without the pressure gradient increasing which would mean that the unit would have to be shut down.
A detailed description of the device of the invention is presented with the aid of FIG. 1 which concerns an embodiment in which the filtering distributor tray is constituted by a base plane 11 supporting a granular filtration bed 2 comprising three layers in the case of FIG. 1 .
It will be recalled that a larger number of layers is perfectly possible and still falls within the scope of the present invention.
The filtering distributor tray is located in the upper portion of a reactor supplied with a gas (G) and liquid (L) in a down-flow co-current flow.
The filtering distributor tray is located upstream of a catalytic bed 10 in which a catalytic reaction occurs which employs the gas (G) and liquid (L) phases introduced at the head of the reactor.
The filtering distributor tray is constituted by a base plane 11 on which chimneys 3 provided with lateral openings 4 , are fixed.
In the case of FIG. 1 , the lateral openings 4 are constituted by longitudinal slots which are rectangular in shape, but they may equally be constituted by a slot with a non rectangular shape, for example triangular, or by a series of orifices of any shape distributed at different levels over the entire height of the chimneys 3 .
The density of the chimneys 3 is in the range from 10 to 150 per m 2 , preferably in the range from 30 to 100 per m 2 . The distribution of chimneys 3 over the base plane 11 is regular and may be in a square or triangular pattern.
The shape of particles constituting the filtration bed 2 is defined so as to develop a large area facilitating the deposition of impurities while maintaining a sufficient pore volume to capture the maximum amount of impurities and increase the service life of the filter.
At the start of the cycle, a liquid level is established above the base plane 11 and the liquid flow is distributed over the whole section of the reactor through the orifices 12 located on the base plane of the tray 11 .
It will be recalled that a base plane without an orifice is also possible and is encompassed in the scope of the invention, but preferably the base plane is provided with orifices, and in this case the density of the orifices located on the base plane of the tray 11 is, generally, at least equal to 100 orifices per m 2 .
As the filtration bed 2 becomes plugged, the liquid level above the tray 11 increases and a portion of the liquid starts to flow through the rectangular slot 4 of the chimneys 3 .
As plugging proceeds, the liquid level above the base plane of the tray 11 rises.
When the filtration bed is completely plugged, liquid flows through the lateral slot 4 into its portion located above the upper level of the filtration bed 2 .
In all cases, gas flows through the chimneys 3 and is principally introduced via the upper openings 6 , optionally provided with caps 7 to prevent liquid from being introduced via said upper openings 6 .
A circular screen 8 surrounds the chimneys 3 to leave a void volume between the chimneys 3 and the filtration bed 2 , so that the particles of the filtration bed 2 do not obstruct the lateral slot 4 located along the chimneys 3 .
The mesh size of this screen 8 will thus be smaller than the minimum diameter of the particles of the filtration bed 2 of the distributor tray.
EXAMPLE
The following example derives from a simulation using a kinetic equation for the deposition of particles which corresponds to a linear deposition as a function of time.
The reactor had a diameter of 1 meter and a total height of 5 meters including the distributor tray and the catalytic bed. The catalytic bed was composed of particles of a traditional catalyst to carry out selective hydrogenation. It was a catalyst containing Ni deposited on an alumina support.
The particle size of the catalyst forming the catalyst bed located downstream of the distributor tray was 2 mm.
The reactor was supplied with a liquid portion and a gas portion.
The liquid was constituted by a pyrolysis gasoline with a boiling point range in the range from 50° C. to 280° C. with a mean boiling point of 120° C. under standard conditions. The gas phase was composed of 90 mole % hydrogen, the remainder being essentially methane.
The filtering distributor tray had 7 chimneys with a diameter of 50 mm and a height of 650 mm, each chimney being provided with a rectangular longitudinal slot with dimensions of 400 mm (height of slot) by 5 mm (width of slot).
The lower end of the slot began at h=50 mm above the base plane of the tray. The filtration bed was composed of 4 layers of the same thickness denoted 1, 2, 3, 4 from bottom to top. The particles were inert alumina particles sold by AXENS society.
The size characteristics of the particles and the porosity of each layer are given in Table I below.
TABLE I
Properties of particles
Particle type
Diameter (mm)
Initial porosity of layer
1 st filtration tray layer
1.0
0.39
2 nd filtration tray layer
1.5
0.41
3 rd filtration tray layer
2.0
0.41
4 th filtration tray layer
2.5
0.43
Catalyst bed
2.0
0.41
The properties of the gas and liquid under the operating conditions of the reactor are given in Table II below:
TABLE II
Properties of fluids
Density of liquid (kg/m 3 )
710
Density of gas (kg/m 3 )
15
Dynamic viscosity of liquid (Pa · s)
0.00085
Dynamic viscosity of gas (Pa · s)
0.00002
Superficial velocity of liquid (m/s)
0.0062
Superficial velocity of gas (m/s)
0.1000
Surface tension (N/m)
0.01
FIG. 2 shows the change with time:
of the quantity of impurities deposited on the filtration bed represented by curve (A). This curve was obtained using a kinetic deposition equation; the pressure drop measured through the catalytic bed in the absence of a filtration bed, represented by curve (B); the pressure drop measured through the catalytic bed in the presence of the filtration bed of the invention, represented by curve (C).
Curve (B) and (C) are approximately parallel, shifted with respect to time.
This time shift corresponds to gradual plugging of the filtration bed.
The plugging period extends from time t 0 to time tf, which corresponds to saturation of the filtration bed marked by the flat part of the curve (A).
At time tf, curve (A) reached its flattened portion and beyond time tf, impurities contained in the liquid feed were no longer retained by the filtration bed.
with the tray without a filtration bed (prior art), the pressure drop through the catalytic bed increases sharply from time tb to a limiting value of the pressure drop which is allowable by the reactor; with the filtration tray with its filtration bed according to the present invention, the pressure drop through the catalytic bed increases sharply from time to which is clearly shifted with respect to time tb. This tc-tb shift quantified the improvement provided by the tray of the invention since during the whole supplemental period corresponding to tc-tb, the pressure drop through the catalytic bed is practically constant, and remains the same as its value at the start of the cycle, t 0 .
The tray of the invention can thus extend the service life by a period equivalent to tc-tb.
In the present case, said extension is 80% compared with the cycle time with a distributor tray without a filtration bed.
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The device described in the present invention can trap plugging particles contained in the liquid feed supplying a reactor functioning in gas and liquid co-current down-flow mode using a specific distributor tray comprising a filtration medium. The present device is of particular application to the selective hydrogenation of feeds containing acetylenic and dienic compounds.
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FIELD
[0001] The field is work vehicles. More particularly, the field is engines and engine compartments for agricultural work vehicles.
BACKGROUND
[0002] Agricultural work vehicles travel through agricultural fields planting, cultivating, treating and harvesting crops. These vehicles are often surrounded by clouds of light combustible matter, such as leaves, dust, chaff, and the like.
[0003] This light combustible matter will accumulate in areas with stagnant air flow, often settling out and coating surfaces of high temperature objects such as exhaust pipes, turbochargers, diesel particulate filters, and the like. It is a concern that this accumulated light material will combust when otherwise cool surfaces are periodically cycled to extremely hot temperatures, such as a diesel particulate filter experiences during its regeneration process.
[0004] There are many prior art arrangements that enclose an engine block and associated components. These can be seen in U.S. Pat. No. 4,324,208, U.S. Pat. No. 4,610,326, U.S. Pat. No. 4,891,940, U.S. Pat. No. 7,523,726, U.S. Pat. No. 2,250,382, U.S. Pat. No. 4,241,702, U.S. Pat. No. 3,949,726, and GB 1,397,476.
[0005] These arrangements, however, are not directed to the problem of solving the accumulation of light combustible particles on exhaust gas aftertreatment devices such as diesel particulate filters. Instead, they are directed to ways of soundproofing engines, air cooling engines, cooling of mufflers, and the like.
[0006] Some prior art arrangements are directed to the problem of combustible particles accumulating on diesel particulate filters or other hot exhaust gas conduits. These have proposed directing a flow of air (both clean and dirty) either continuously or intermittently across surfaces on which the particles may accumulate to either prevent the accumulation of light combustible particles or to periodically blow the light combustible particles off the surfaces. These prior art arrangements use the kinetic energy of air and therefore require nozzles located close to all of the surfaces on which particles might accumulate and a relatively large fan to supply air at a sufficient velocity.
[0007] Both of these cleaning arrangements do not prevent light combustible materials from reaching the hot surfaces. Instead they deflect the light combustible material before it settles, or blow it off the surfaces before the surfaces are heated up sufficient to ignite the light particles.
[0008] These cleaning arrangements are typically employed in vehicles in which a large volume of air is directed through an engine coolant heat exchanger and then through the engine compartment, across the surface of the engine and the other hot surfaces. Engine coolant heat exchangers typically require a large supply of air passing therethrough to extract sufficient heat from the engine coolant.
[0009] A further problem with these cleaning arrangements is that so much air must pass through the engine coolant heat exchangers in order for them to work that it is impossible to filter the air sufficiently to remove all of the light combustible material. Much of the light combustible material is dust, and therefore would require filtering at a micron level in order to prevent its accumulation on surfaces inside the engine compartment.
[0010] What is needed, therefore, is an improved method for preventing light combustible matter from accumulating on hot surfaces in the engine enclosure of an agricultural vehicle. What is also needed is a method that will not require extremely fine filtering of large quantities of engine cooling air and the attendant cleaning and replacement of filter elements.
[0011] It is an object of this invention to provide such a system.
SUMMARY
[0012] In one arrangement, a vehicle configured to work in an agricultural field has an internal combustion engine that is disposed inside an engine enclosure in the form of a box. The engine enclosure defines an air inlet. A source of air is coupled to the air inlet and generates an air flow into the engine enclosure. The source of air produces a slight positive pressure in the engine enclosure. The source of air maintains the air pressure in the engine enclosure slightly higher than the air pressure of the ambient environment surrounding the engine enclosure. The pressure produced by the source of air prevents dust and debris from entering the engine enclosure.
[0013] In another arrangement, an engine enclosure for an internal combustion engine is provided that comprises a plurality of walls surrounding the internal combustion engine, wherein the walls define an air inlet opening into a space between the internal combustion engine and the plurality of walls, and the fan coupled to the air inlet to provide air under pressure to the space between the internal combustion engine and the plurality of walls, and to maintain the air in the space at a pressure above the air pressure outside the plurality of walls.
[0014] The engine enclosure may further comprise a combustion air conduit coupled to the internal combustion engine to supply the internal combustion engine with air for internal combustion, wherein at least a portion of said combustion air conduit is disposed inside the engine enclosure.
[0015] The combustion air conduit may extend through a wall of the plurality of walls.
[0016] An end of the combustion air conduit may be disposed outside of the engine enclosure to receive ambient air from the environment outside of the engine enclosure and to conduct the ambient air through the wall of the plurality of walls and into the internal combustion engine.
[0017] The fan may be disposed to receive ambient air from outside the engine enclosure and to convey the ambient air into the air inlet.
[0018] An air filter may be disposed between the fan and the ambient environment to filter ambient air before it is conveyed into the air inlet.
[0019] The engine enclosure may further comprise a heat exchanger disposed outside of the engine enclosure, and configured to receive ambient air from the ambient environment outside of the engine compartment, to transfer heat to the ambient air and to transmit now-heated ambient air back into the ambient environment outside of the engine compartment.
[0020] The engine enclosure may further comprise a first engine coolant conduit coupled to and extending between the internal combustion engine and the heat exchanger to conduct hot engine coolant from the engine to the heat exchanger for cooling, and a second engine coolant conduit coupled to and extending between the internal combustion engine and the heat exchanger to conduct engine coolant from the heat exchanger back to the engine after cooling.
[0021] The first engine coolant conduit and the second engine coolant conduit may extend through a wall of the engine enclosure.
[0022] The engine enclosure may further comprise a PTO gearbox disposed inside the plurality of walls that is coupled to the internal combustion engine to be driven thereby.
[0023] The engine enclosure may further comprise an output driveshaft coupled to and driven by the PTO gearbox.
[0024] The output driveshaft may extend through a wall of the plurality of walls.
[0025] The output driveshaft may be coupled to and may drive a driven machine disposed outside of the plurality of walls.
[0026] The engine enclosure may further comprise an air vent extending from a wall of the plurality of walls and configured to communicate air from inside the engine enclosure to the ambient atmosphere outside of the engine enclosure thereby preventing overpressure of the engine enclosure.
[0027] The plurality of walls may enclose a turbocharger that is coupled to the engine to pressurize combustion air for the engine.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 is a schematic diagram of an engine enclosure in accordance with the present invention.
[0029] FIG. 2 is a schematic diagram of an alternative engine enclosure in accordance with the present invention.
DETAILED DESCRIPTION
[0030] Referring to FIG. 1 , an engine enclosure 100 surrounds an internal combustion engine 102 that is coupled to a gearbox 104 . A turbocharger 106 is driven by exhaust gas leaving an exhaust manifold 108 of the internal combustion engine 102 . The exhaust gas passes through an exhaust gas aftertreatment device 110 and thence through a conduit 112 that passes through a wall 114 of the engine enclosure 100 . Turbocharger 106 sucks air into a combustion air conduit 116 , pressurizes it, and transmits it through a combustion air outlet 118 into the internal combustion engine 102 . An air inlet 120 is provided in a wall of the engine enclosure 100 to receive air pressurized by a fan 122 . Fan 122 has an air inlet that is coupled to and receives air from an air filter 124 . The air filter 124 is coupled to and receives air from a cyclone separator 126 . The cyclone separator 126 has a debris outlet 128 that receives debris, dust, and other solid particles from the cyclone separator 126 . The cyclone separator 126 has an intake air inlet 130 that receives air from the ambient atmosphere. An air vent 132 is provided in a wall of the engine enclosure 100 to permit excess air inside the engine enclosure 100 to escape the engine enclosure 100 thereby preventing overpressure of the engine enclosure 100 .
[0031] Referring to an alternative arrangement shown in FIG. 2 , an engine enclosure 200 surrounds an internal combustion engine 202 that is coupled to a gearbox 204 . An exhaust gas aftertreatment device 206 is coupled to internal combustion engine 202 to receive exhaust gas therefrom. The exhaust gas aftertreatment device 206 is internally configured to treat the exhaust gas to reduce the atmospheric contaminants entrained therein. A typical exhaust gas aftertreatment device 206 is a diesel particulate filter, which cycles from cool to extremely hot when it is regenerated. An exhaust gas outlet 208 extends from the exhaust gas aftertreatment device 206 through a wall 210 of the engine enclosure 200 . Aperture 212 and aperture 214 are provided in wall 216 and wall 218 , respectively, of the engine enclosure 200 . Aperture 212 and aperture 214 surround output drive shaft 220 and output drive shaft 222 , respectively. The output drive shaft 220 and the output drive shaft 222 extend from the gearbox 204 . The output drive shaft 220 and the output drive shaft 222 extend through the wall 216 and the wall 218 and are coupled to the driven machine 224 and the driven machine 226 , respectively to communicate power from the gearbox 204 to the driven machine 224 and the driven machine 226 . The driven machine 224 and the driven machine 226 are disposed outside of the engine enclosure 200 . A combustion air conduit 228 for the internal combustion engine 202 extends through a wall 230 of engine enclosure 200 . The combustion air conduit 228 is coupled to and receives air from and air filter 232 that is disposed outside of the engine enclosure 200 . The air filter 232 has an air inlet 234 that receives air from the ambient environment outside the engine enclosure 200 . A fan 236 is coupled to an air inlet 238 disposed in the wall 210 of the engine enclosure 200 . The fan 236 is disposed outside of the engine enclosure 200 . The inlet of the fan 236 is connected to an air filter 240 . The air filter 240 has an air inlet 242 that is open to receive air from the ambient environment outside the engine enclosure 200 .
[0032] A first engine coolant conduit 244 is coupled to the internal combustion engine 202 to receive hot engine coolant therefrom and to conduct the hot engine coolant from the internal combustion engine 202 through the wall 210 of the engine enclosure 200 , and to a heat exchanger 246 for cooling engine coolant. A fan 248 is driven by a motor 250 and is disposed to move ambient air 254 through the heat exchanger 246 thereby cooling the hot engine coolant. The now-cool engine coolant is conveyed from the heat exchanger 246 into a second engine coolant conduit 252 which is coupled to the heat exchanger 246 . The second engine coolant conduit 252 is disposed to convey the cool engine coolant back to the internal combustion engine 202 . The second engine coolant conduit 252 passes through the wall 210 of the engine enclosure 200 . As in the example of FIG. 1 , an air vent 256 is provided in the wall 218 of the engine enclosure 200 to permit excess air inside the engine enclosure 200 to be released into the ambient environment, thereby preventing overpressure of the engine enclosure 200 .
[0033] The heat exchanger 246 is disposed outside of the engine enclosure 200 such that the ambient air 254 is drawn from the ambient environment surrounding the engine enclosure 200 , passes through the heat exchanger 246 , and is returned to the ambient environment surrounding the engine enclosure 200 without passing into or out of the engine enclosure 200 . In this way, the large quantities of air necessary for cooling the hot engine coolant need not be filtered in order to remove the large quantities of debris as is necessary in the traditional arrangement. In the traditional arrangement, as described above, air passing through the heat exchanger 246 for cooling engine coolant is then passed over and around the engine and other hot surfaces such as surfaces of the internal combustion engine 202 , the exhaust gas aftertreatment device 206 , and the exhaust gas outlet 208 .
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An engine enclosure ( 100, 200 ) for an agricultural work vehicle has a plurality of walls ( 114, 210, 216, 218, 230 ) that surround an internal combustion engine ( 102, 202 ) and a fan ( 122, 236 ) coupled to an air inlet ( 120, 238 ) in the plurality of walls for maintaining the inside of the engine enclosure ( 100, 200 ) at a pressure slightly higher than atmospheric pressure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to metal oxide doped cerium oxides and a method for the preparation thereof. Further, the present invention relates to a resin composition or a cosmetic composition in which said metal oxide doped cerium oxides or a complex composed of said metal oxide solid doped cerium oxides and an oxide are blended.
2. Description of the Prior Art
As is well known, ultra violet ray causes degradation of plastic resins, and many kinds of countermeasure are carried out to protect the degradation. As one of the countermeasure method, it is widely practiced that a plastic resin is admixed with an ultraviolet shielding agent including an organic ultra violet ray absorbing agent or an inorganic ultraviolet ray scattering agent. And by admixing these agents in plastic resin, the adverse influence of ultra violet ray is reduced. As the organic ultra violet ray absorbing agent, salicylic acid type compound, benizophenon type compound, benzotriazol type compound or cyanoacrylate type compound can be mentioned, however, recently, the lack of heat resistance, lack of durability to weather or the safety of decomposed chemicals of it are becoming serious problems. To solve these problems, fine particles of titanium dioxide or fine particles of zinc oxide which are the inorganic ultra violet ray scattering agent are developed, however, the lack of dispersability of these agents is a problem and the catalytic activity of these agent are becoming a new problem. Recently, especially regarding titanium dioxide, it is pointed out that the generation of singlet oxygen by photo catalyst function of it causes new problem.
Ultraviolet ray has an adverse influence also on living bodies. Namely, it is well-known that the so called UV-B ultraviolet ray in the wavelength range of 280 to 320 nm causes cutaneous inflammations such as erythemas blister and the like while the so called UV-A ultraviolet ray in the wavelength range 320 to 400 nm causes tanning of skin by the accelerated formation of melanin. As the countermeasure method against above mentioned adverse influences of the ultraviolet ray, many kinds of sunscreen cosmetic compositions have been developed hereto before. The ultraviolet shielding agents contained in conventional sunscreen cosmetic compositions can be grossly classified into two types including an ultraviolet absorbing agent such as cinnamic acid type, benzophenon type or dibenzoylmethane type and an ultraviolet scattering agent such as zinc oxide or titanium dioxide. However, above mentioned ultraviolet absorbing agents have several problems, such as low absorptivity of ultraviolet ray and safety when the admixing amount in a cosmetic composition is too high. Further, in a case of conventional ultraviolet scattering agent, since it is impossible to improve the transparency even if the (dispersibility of particles is improved, the admixing use of it not only causes the deterioration of feeling when the cosmetic composition is applied but also the skin look becomes unnatural. Recently, the use of cerium compound as an ultraviolet scattering agent has been proposed, for example, in Japanese Patent Laid Open Publication 6-145645 or Japanese Patent Laid Open Publication 7-207151. However, since cerium oxide has strong catalytic activity, it has a problem that accelerates the oxidation decomposition of resin or oil and causes color change and generates offensive odor when admixed in cosmetic compound or resin. Thereupon, the development, of new cerium compound which has a function as the ultraviolet scattering agent and does not have catalytic activity has been desired. And in Japanese Patent Laid Open Publication 9-118610, silica-cerium oxide composite particle is proposed, however, the reduction of catalytic activity of said silica-cerium oxide composite particle is almost accomplished but the ability for ultraviolet ray shielding is not sufficient.
OBJECT OF THE INVENTION
The present invention is carried out concerning above mentioned circumstance, whose object is to provide metal oxide doped cerium oxides with strong ultraviolet ray shielding ability, lower catalytic activity and with excellent transparency. Further, the other object of this invention is to provide a composite composition of said metal oxide doped cerium oxides coated with metal oxide. Furthermore, the other object of this invention is to provide a resin composition or a cosmetic composition to which said metal oxide doped cerium oxides or a composite thereof is admixed with.
BRIEF SUMMARY OF THE INVENTION
That is, the present invention is the metal oxide doped cerium oxides composed of cerium oxide in which metal ion having larger ion radius than that of tetravalent cerium ion (Ce 4+ ) and/or lower valence metal ion than Ce 4+ are doped. As the concrete example of a metal ion used in this doping, Ca 2+ , Y 3+ , La 3+ , Nd 3+ , Eu 3+ , Tb 3+ , Sm 3+ , Mg 2+ , Sr 2+ , Ba 2+ , Ce 3+ and the like can be mentioned. The desirable cerium oxide concentration in said metal oxide solid doped cerium oxide is 40 to 98 molar %. Further, when the color index of said metal oxide doped cerium oxide is estimated by L*, a* and b* space, the desirable region of L* is larger than 80, the desirable region of a* is smaller than 4 by absolute value and desirable region of b* is smaller than 10 by absolute value, further the desirable average particle size is ultra fine particle of 2 to 4 nm.
Further the metal oxide doped cerium oxides of this invention can be prepared by following steps. That is, prepare the metal oxide doped cerium oxide at the temperature lower than 60° C. and in the condition of pH higher than 5 by reacting aqueous solution of cerium salt, aqueous solution of metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ and alkali, then by adding oxidizing agent in it at the temperature lower than 60° C. Furthermore the metal oxide doped cerium oxide of this invention can be prepared by adding and mixing aqueous solution of cerium salt, aqueous solution of metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ , alkali and oxidizing agent simultaneously at the temperature lower than 60° C. and in the condition of pH higher than 5.
The present invention also relates to a composite composition of said metal oxide doped cerium oxides coated by one or more kinds of oxide selected from the group composed of silicon oxide, zirconium oxide, aluminium oxide, iron oxide and titanium dioxide. Further, the present invention relates to the resin composition to which said metal oxide doped cerium oxide or the composite composition thereof is blended. Still further, the present invention relates to the cosmetic composition to which said metal oxide doped cerium oxide or the composite composition thereof is blended. The surface treated metal oxide doped cerium oxides or the composite composition thereof can be blended to the cosmetic composition. And, said cosmetic composition can contain an ultraviolet ray absorbing agent, and/or an ultraviolet ray scattering agent. As the desirable example of said ultraviolet ray absorbing agent, one or more kinds of compound selected from the group composed of oxybenzone, octyl metoxycinnamate and 4tertbutyl-4′-methoxy dibenzoylmethane can be mentioned, and the desirable contents of the ultraviolet ray absorbing agent is 0.1 to 40% by weight. As the desirable example of said ultraviolet ray scattering agent, titanium dioxide and/or zinc oxide can be mentioned, and the desirable contents of the ultraviolet ray scattering agent is 0.1 to 50% by weight. Above mentioned cosmetic composition is suited to be used as a sunscreen cosmetic composition.
The metal oxide doped cerium oxide of this invention is the cerium oxide in which metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ are doped. By doping said metal ion, the catalytic activity of cerium oxide can be reduced Further, by doping said metal ion, the transparency of cerium oxide is improved and the ultraviolet ray shielding effect can be improved. As the concrete example of metal ion which has larger ion radius than Ce 4+ (ion radius of Ce 4+ is 0.097 nm), Ca 2+ , La 3+ , Nd 3+ , Eu 3+ , Tb 3+ , Sm 3+ , and Ce 3+ can be mentioned. As the concrete example of metal ion which has lower valence than Ce 4+ , Y 3+ , Mg 2+ , Sr 2+ and Ba 2+ can be mentioned besides above mentioned metal ions. These metal ions can be used alone or together with. In addition, the desirable concentration of metal oxide doped cerium oxide is 40 to 98 molar %.
The metal oxide doped cerium oxide of this invention can be prepared by following steps. That is, prepare metal hydroxide doped cerium hydroxide, for example, at the temperature lower than 60° C. and in the condition of pH higher than 5, by reacting aqueous solution of cerium salt, aqueous solution of metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ and alkali, then add oxidizing agent in it maintaining the temperature lower than 60° C. The obtained reacted product is rinsed by water, filtered, and dried or calcined then pulverized. Thus the metal oxide doped cerium oxide can be obtained. As the concrete example for the preparation of said solid solution of cerium hydroxide and metal hydroxide following methods can be mentioned. That is, (1) the method to add aqueous solution of cerium salt and aqueous solution of salt of metal to be solid solved simultaneously into a container in which alkaline solution is contained, or (2) the method to add aqueous solution of cerium salt, alkaline solution and aqueous solution of salt of metal to be solid solved simultaneously into a container in which water is contained.
Furthermore the metal oxide doped cerium oxide of this invention can be prepared by adding and mixing aqueous solution of cerium salt, aqueous solution of metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ , alkali and oxidizing agent simultaneously. For instance, at the temperature lower than 60° C. and in the condition of pH higher than 5, aqueous solution of cerium salt, aqueous solution of salt of metal to be solid solved, alkaline solution and hydrogen peroxide which is an oxidizing agent are added simultaneously into a container in which water is contained. The obtained reacted product, is rinsed by water and filtered, dried or calcined then pulverized, thus the fine particles of metal oxide doped cerium oxide can be prepared.
Aqueous solution of cerium salt which is used in above mentioned reaction, can be prepared by solving e.g. cerium carbonate in aqueous solution of hydrochloric acid or nitric acid, or by solving cerium chloride, cerium nitrate, cerium sulfate or cerium acetate in water. As alkali, aqueous solution of alkali metal hydroxide such as sodium hydroxide or potassium hydroxide, or aqueous solution of ammonia can be used. Further, as the salt of metal to be doped, for example, chloride, salt, of nitric acid, salt of sulfuric acid or salt of acetic acid can be mentioned. As the oxidizing agent, hydrogen peroxide, hypochlorous acid, sodium hypoclilorite, potassium hypochlorite, calcium hypochlorite and ozone can be used. In above mentioned methods, the doping is carried out in aqueous solution, however not limited with these examples.
In any kind of above mentioned reacting method, nano-size particles of metal oxide doped cerium oxide having 2-4 nm average diameter can be obtained by keeping the temperature of solution lower than 60° C., desirably lower than 40° C. and by rising pH higher than 5 during the adding process of oxidizing agent. Such kind of fine pulverized particles of metal oxide doped cerium oxide have a superior transparency at visible ray range and have an excellent dispersability, further, have a good ultraviolet ray shielding effect.
Further, in any kind of above mentioned reacting method, the yellowish tendency of metal oxide doped cerium oxide can be moderated and the white particles are obtained. And when the color index is estimated by L*, a* and b* space, the metal oxide doped cerium oxide whose L* is larger than 80, a* is smaller than 4 by absolute value and b* is smaller than 10 by absolute value can be obtained. In this invention, the term of L*, a* and b* space is regulated by CIE1976L* a* b* color space which is authorized by CIE (Commission Internationale de Enluminure) on 1976. This color space is a coordinate having axis of L*, a* and b* which are regulated by following numerical formulae.
L*= 116( Y/Y 0 ) ⅓ −16
a*= 500[( X/X 0 ) ⅓ −( Y/Y 0 ) ⅓ ]
b*= 200[( Y/Y 0 ) ⅓ −( Z/Z 0 ) ⅓ ]
(wherein, X/X 0 , Y/Y 0 , Z/Z 0 >0.008856, X,Y and Z indicate 3 stimulate values of object color, X 0 , Y 0 and Z 0 indicate 3 stimulate values of color source which illuminates the object, and standardized to Y 0 =100).
In the present invention, color index estimated by L*, a* and b* space is settled to L*≧80, |a*|≦4, |b*|≦10. And each L*, a* and b* value are measured by color difference meter (product of Nihon Denshoku Kogyo).
Said metal oxide doped cerium oxide of this invention can be used as the composite form, namely coated with oxide (hereinafter said composite can be expressed as “oxide coated metal oxide doped cerium oxide”). As the oxide to be used for the preparation of said oxide coated metal oxide doped cerium oxide, one or more kinds of compound selected from the group composed of silicon oxide, zirconium oxide, aluminum oxide, iron oxide and titanium dioxide. By the use of composite of metal oxide doped cerium oxide which is coated with oxide, the catalytic activity can be more weakened and the dispersability can be improved.
The oxide coated metal oxide doped cerium oxide can be prepared by the further treatment of metal oxide doped cerium oxide prepared by the use of afore mentioned starting materials and by afore mentioned method with said oxide. For example, aqueous solution of cerium salt, aqueous solution of salt of metal to be doped (e.g. salt of calcium) and aqueous solution of alkali are added into water which is kept at the temperature lower than 60° C. and higher than pH 9, then calcium hydroxide doped cerium hydroxide can be obtained. An oxidizing agent such as hydrogen peroxide is further added to generate calcium oxide doped cerium oxide. Then heated to the temperature higher than 80° C. and keeping pH higher than 9, aqueous solution of sodium silicate and aqueous solution of mineral acid such as hydrochloric acid, nitric acid or sulfuric acid are added to coat silicon oxide over calcium oxide doped cerium oxide, and rinsed by water, filtrated, dried, calcined and pulverized. Thus the silicon oxide coated calcium oxide doped cerium oxide can be obtained. In this case, desirable amount, of sodium silicate to be added is 2 to 60% by weight, to coat subject of solid solution as SiO 2 . Also in this case, by keeping pH of solution under 8 at the finishing point of oxidation, the yellowish tendency of oxide coated metal oxide doped cerium oxide can be weakened and improve the color index, and the metal oxide doped cerium oxide whose L* value is bigger than 80, absolute value of a* is smaller than 4 and absolute value of b* is smaller than 10 when color index is estimated by L* a* and b* space can be obtained. Further, by keeping pH of solution higher than 5 during oxidizing agent adding process, ultra fine particles of silicon oxide coated calcium oxide doped cerium oxide whose average particle diameter is 2 to 4 nm can be obtained.
BRIEF ILLUSTRATION OF THE DRAWING
FIG. 1 is the graph which shows the light transmittance of the metal oxide doped cerium oxide of this invention.
FIG. 2 is the graph which shows the catalytic activity of the metal oxide doped cerium oxide of this invention.
FIG. 3 is the graph which shows the light transmittance of the soft polyvinyl chloride sheet containing the metal oxide doped cerium oxide of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The metal oxide doped cerium oxide of this invention has an excellent ultraviolet ray shielding effect. FIG. 1 shows the results of measurement, of the light transmittance as a function of wavelength of the metal oxide doped cerium oxide obtained by above mentioned method. The light transmittance is measured according to the following method. That is, each specimen is added to and dispersed in 6 ml of clear lacquer in such an amount that the content thereof is 3.0% by weight by using a Hoover muller (rotating at 50 revolutions×2) and mixed. The obtained solution is coated on a transparent quartz board by 30 μm thickness and the light transmittance is measured by a spectrophtometer (UV-2200, product of Shimadzu Seisakusho Co., Ltd.).
In FIG. 1,
specimen (1) contains no additives,
specimen (2) is high purity pulverized cerium oxide particles (average particle size is 10 μm) on market,
specimen (3) is europium oxide doped cerium oxide of this invention whose molar ratio of Ce 4+ and Eu 3+ is 7:3, and
specimen (4) is calcium oxide doped cerium oxide of this invention whose molar ratio Ce 4+ and Ca 2+ is 8:2.
As clearly understood from FIG. 1, europium oxide doped cerium oxide particles (3) and calcium oxide doped cerium oxide particles (4) of this invention are superior to high purity cerium oxide particles (2) on market at the ultraviolet ray shielding effect in the wavelength range of 250 to 400 nm, further at the transparency in the visible wavelength of 400 to 800 nm.
FIG. 2 shows the estimation results of catalytic activity of metal oxide doped cerium oxide obtained by above mentioned method measured by RANSHIMAT method which is a kind of CDM (Contactometric Determination Method). As the CDM apparatus, Model E679 (product of Metrom Co.) is used. 0.5 g of specimen and 5 g of caster oil (product of Ito Seiyu Co.) are mixed together, poured into a sealed container placed in a thermostat set up to 130° C. for 10 hours. Air is introduced with bubbling by 20 liter/hour flow rate to the caster oil. Air of head space is introduced to the water contained in a separated flask, and the change of electro conductivity of trapped water caused by volatile decomposition of caster oil is detected by measuring cell. The degree of change of electric conductivity by lapse of time is regarded as the intensity of catalytic activity. The same specimen used at the measurement of light transmittance is used.
As clearly understood from FIG. 2, the europium oxide doped cerium oxide particles (3) and the calcium oxide doped cerium oxide particles (4) of this invention have smaller tendency to promote the oxidation and decomposition of caster oil compared with the high purity cerium oxide particles (2) on market, and it is obvious that; the catalytic activity of (2) and (3) is remarkably reduced.
A resin composition and a cosmetic composition of this invention are illustrated as follows. In general, a resin composition degrades by the absorption of ultraviolet ray of sun light. As the countermeasure method against the degradation by ultraviolet ray, the metal oxide doped cerium oxide is blended to the resin composition. Thus, the resistance to light is improved and the decomposition by light can be prevented or reduced. Further, the light decomposition of the contents which is covered by a transparent resin composition by ultraviolet ray can be prevented or reduced. When the catalytic activity of metal oxide doped cerium oxide of this invention is compared with that of cerium oxide, it is remarkably weaker, therefore, the oxidizing decomposition of resin composition caused by cerium oxide can be reduced. The resin composition of this invention indicates a molded product of synthetic resin such as polyvinylchloride, polypropylene, polyethylene, polyamide, polyester or polycarbonate, or natural resin, or a coating in which said resins are blended.
A cosmetic composition of this invention is illustrated as follows. The cosmetic composition of this invention exhibits excellent transparency and high sunscreening effect by virtue of the inventive metal oxide doped cerium oxide particles containing therein. Because the catalytic activity of the metal oxide doped cerium oxide of this invention is remarkably weaker than that of cerium oxide, the decomposition of blended component in cosmetic compound such as oil caused by cerium oxide can be reduced. As a concrete example of the formulation type of the inventive cosmetic composition, a skin care cosmetic composition such as milk lotion, skin lotion and the like, a make up cosmetic composition such as foundation or lipstick and a hair care cosmetic composition can be mentioned, desirably a sunscreening cosmetic composition can be mentioned. The amount of the metal oxide doped cerium oxide to be blended in a cosmetic composition is not limited, however, the desirable amount is 1 to 70% by weight.
It is optional that the metal oxide doped cerium oxide or an oxide coated metal oxide doped cerium oxide composite particles are subjected to a surface treatment before being incorporated in a cosmetic composition. As the concrete example for the surface treatment method, a treatment by ordinary type oil and fat, a metal soap, silicone, dialkyl phosphoric acid, perfluoroalkyl group containing compound, amino acid, lecithin or collagen, can be mentioned.
The sunscreening effect exhibited by the inventive cosmetic composition can be further enhanced by containing the composition with other well known ultraviolet ray absorbers and/or ultraviolet ray scattering agents in combination with the metal oxide doped cerium oxide particles. The ultraviolet ray absorbing agent suitable for the purpose includes oxybenzone, octyl methoxycinnamate, 4-tert-butyl-4′-metahoxydibenzoylmethane and the like either singly or as a combination of two kinds or more according to need. The containing amount thereof is, though not particularly limitative, usually in the range from 0.1 to 40% by weight of the composition. The ultraviolet ray scattering agent used for the above mentioned purpose is preferably a fine powder of titanium dioxide or zinc oxide, more preferably, having an average particle diameter not exceeding 0.05 μm. The containing amount thereof is desirably in the range from 0.1 to 50% by weight.
Any conventional cosmetic ingredients can be used together with the cosmetic compositions. Typical examples of such ingredients are cosmetic powder, surface active agents, oil, polymeric compounds, aesthetic ingredients, moisturizing agents, coloring agents, preservatives, perfumery and so on each in a limited amount not to decrease the advantages obtained by the invention.
The effect of this invention is illustrated as follows. The catalytic activity of metal oxide doped cerium oxide of this invention is reduced by doping metal oxide in cerium oxide, the transparency in the visible range is good and the effect to shield the ultraviolet ray at A-range and the ultraviolet ray at B-range is increased. And, the resin composition or the cosmetic composition in which said metal oxide doped cerium oxide particles are blended have an excellent transparency and ultraviolet ray shielding effect. A resin or a cosmetic in which conventional cerium oxide is blended has a tendency that the contained oil or blended components are easily oxidized and decomposed by the catalytic activity of contained cerium oxide, on the contrary, since the catalytic activity of metal oxide doped cerium oxide of this invention is reduced, said defect can not be observed and has an excellent stability for aging. A complex of metal oxide doped cerium oxide whose surface is coated with oxide, can further reduce and weaken the catalytic activity and can improve the dispersability.
EXAMPLES
The present invention will be understood more readily with reference to the Example and the Comparative Examples, however, these are only intended to illustrate the invention and not be construed to limit the scope of the invention.
Example 1
Europium Oxide Doped Cerium Oxide Particles
342 g of cerium chloride (CeCl 3 ) is dissolved in water and 3 liter of cerium chloride aqueous solution is prepared. 155 g of europium chloride (EuCl 3 ) is dissolved in water and 3 liter of europium chloride aqueous solution is prepared. Further 237 g of sodium hydroxide (NaOH) is dissolved in water and 12 liter of sodium hydroxide aqueous solution is prepared. Furthermore, 118 g of 30 wt % hydrogen peroxide is dissolved in water and 3 liter of hydrogen peroxide aqueous solution is prepared. 12 liter of sodium hydroxide aqueous solution is heated to 30-40° C. and said cerium chloride aqueous solution and europium chloride aqueous solution are added simultaneously by constant stirring maintaining pH of reacting solution higher than 11 and temperature of the solution lower than 40° C. After adding continue the stirring for 30 minutes, maintain the temperature of reacting solution at 60° C., then aqueous solution of hydrogen peroxide is added. After the adding, continue the constant stirring for 30. minutes, then the reacted product is rinsed by water, filtered and dried, thus the europium oxide doped cerium oxide particles whose molar ratio of Ce 4+ and Eu 3+ is 7:3 is obtained.
Example 2
White Colored Calcium Oxide Doped Cerium Oxide Particles
390 g of cerium chloride (CeCl 3 ) is dissolved in water and 3 liter of cerium chloride aqueous solution is prepared. 45 g of calcium chloride (CaCl 2 ) is dissolved in water and 3 liter of aqueous solution of calcium chloride is prepared. Further 237 g of sodium hydroxide (NaOH) is dissolved in water and 8 liter of sodium hydroxide aqueous solution is prepared. Furthermore, 118 g of 30 wt % hydrogen peroxide is dissolved in water and 3 liter of hydrogen peroxide aqueous solution is prepared. To 8 liter of water heated to 30-40° C., said cerium chloride aqueous solution, calcium chloride aqueous solution and sodium hydroxide aqueous solution are added simultaneously by constant siring maintaining pH of reacting solution 9-11 and temperature of the solution lower than 40° C. After the reaction, add hydrochloric acid so as to adjust pH of reacting solution to 5-7 and the temperature of solution to 60° C., the aqueous solution of hydrogen peroxide is added. The reacted product is rinsed by water, filtered and dried, thus the calcium oxide doped cerium oxide particles whose molar ratio of Ce 4+ and Ca 2+ is 8:2 is obtained.
The color index of obtained solid solution is L* value; 94.0, a* value; −1.6 and b* value; 6.2.
20 g of obtained powder is press molded on pan of 6 cm and L*, a* and b* values are measured by a color difference meter (product of Nihon Denshoku Kogyo).
Example 3
Ultra Fine Particles of Calcium Oxide Doped Cerium Oxide
390 g of cerium chloride (CeCl 3 ) is dissolved in water and 3 liter of cerium chloride aqueous solution is prepared. 45 g of calcium chloride (CaCl 2 ) is dissolved in water and 3 liter of aqueous solution of calcium chloride is prepared. Further 237 g of sodium hydroxide (NaOH) is dissolved in water and 3 liter of sodium hydroxide aqueous solution is prepared. Furthermore, 118 g of 30 wt % hydrogen peroxide is dissolved in water and 3 liter of hydrogen peroxide aqueous solution is prepared. To 8 liter of water heated to 30-40° C., said cerium chloride aqueous solution, calcium chloride aqueous solution and sodium hydroxide aqueous solution are added simultaneously by constant stirring maintaining pH of reacting solution 9-11 and temperature of the solution lower than 40° C. After the reaction, the reacted product is rinsed by water, filtrated and dried, thus the calcium oxide doped cerium oxide whose molar ratio of Ce 4+ and Ca 2+ is 8:2 is obtained.
The average particle diameter of metal oxide is 2.8 nm. The diameter of particle is measured by a transmission electron microscope (product of JEOL Co., Ltd.). Namely, diameter of 100 particles are measured by naked eyes of inspector and averaged.
Example 4
Composite of Silicon Oxide Coated Calcium Oxide Doped Cerium Oxide
562 g of sodium silicate solution (content of SiO 2 is 28.5 wt %) is dissolved in water and 2 liter of sodium silicate solution is prepared. 75.8 g of 95 wt % sulfuric acid is diluted with water and 2 liter of diluted sulfuric acid is prepared. The aqueous solution containing calcium oxide doped cerium oxide obtained in Example 2 is heated to the temperature higher than 80° C. with constant stirring, aqueous solution of sodium silicate and diluted sulfuric acid are added simultaneously as to maintain pH of reacting solution higher than 9. After the adding of both solution, the solution is continued to stir for another 30 minutes and adjusted pH of reacting solution to 7-8 by adding diluted sulfuric acid. The reacted product is rinsed by water, filtered, dried and pulverized, thus the 30 wt % SiO 2 coated calcium oxide doped cerium oxide (silicon oxide coated calcium oxide doped cerium oxide) is obtained.
Example 5
0.05 and 1 wt % of the white calcium oxide doped cerium oxide particles obtained in Example 2 are blended to plasticized polyvinyl chloride resin. The polyvinyl chloride resin without doped particles and the two resin composition blended with said both amounts of particles are each shaped into a sheet having a thickness of 0.24 mm by using hot calendering rollers. Each of thus prepared sheets are subjected to the measurement of the transmittance on a spectrophotometer (UV-2200, product of Shimadziu Seisakusho Co., Ltd.). Results illustrated in FIG. 3 are obtained.
Specimen a is a sheet with no additives,
Specimen b is a sheet containing 0.5 wt. % of calcium oxide doped cerium oxide.
Specimen c is a sheet containing 1.0 wt % of calcium oxide doped cerium oxide.
It is clearly understood from FIG. 3, that the calcium oxide doped cerium oxide of this invention can improve the shielding effect in the range of ultraviolet ray by the higher blending ratio, however it maintains good transparency in the range of visible ray.
Example 6
Four kinds of cream foundation of following recipe are prepared containing metal oxide doped cerium oxide or composite of silicon oxide coated calcium oxide doped cerium oxide obtained from Example 1 to Example 4.
Recipe
wt %
(1)
stearic acid
5.0
(2)
oleophilic glyceryl monostearate
2.5
(3)
cetanol
1.5
(4)
isopropylene glycol monolaurate
2.5
(5)
liquid parafin
8.0
(6)
isopropyl myristate
7.0
(7)
propyl paraben
0.1
(8)
purified water
47.3
(9)
triethanolamine
1.2
(10)
sorbitol
3.0
(11)
methyl paraben
0.2
(12)
titanium dioxide
8.0
(13)
kaolin
5.0
(14)
doped particles obtained from
3.0
Example 1, 2, 3 or 4
(15)
bentonite
1.0
(16)
red iron oxide
2.5
(17)
yellow iron oxide
2.0
(18)
black iron oxide
0.2
Method for Preparation
(a) Ingredients (12) to (14)and (16) to (18) are blended together.
(b) Ingredient (15) is admixed with (8) heated at 80° C. to effect full swelling, then ingredients (9) to (11) are added and dissolved therein. To the mixture, the prepared mixture (a) is added and dissolved at 80° C. (water phase).
(c) Ingredients (1) to (7) are mixed together and dissolved at 80° C. (oily phase).
(d) To the prepared (water phase), the prepared (oily phase) is added and emulsified. After that, cooled down to 35° C. under constant stirring.
The cream foundations obtained as above, exhibit excellent transparency of coated layer along with good spreadability and an excellent sunscreening effect.
Example 7
150 g of the ultra fine particles of calcium oxide doped cerium oxide obtained in Example 3 and 200 g of purified water are taken into a flask and are mixed together with heating to 70° C. to prepare an aqueous slurry. Further, an aqueous emulsion obtained from 6 g of diethanolamine salt of perfluoroalkyl phosphoric acid ester (Asahiguard AG 530, a product of Asahi Glass Co., Ltd.) and 150 g of purified water are admixed and emulsified. The obtained emulsion is added gradually into said slurry and followed by continuous stirring for 1 hour. After acidification, the aqueous dispersion is rinsed with water, filtered, dried then 154 g of fluorinated calcium oxide doped cerium oxide fine particles are obtained (hereinafter shortened to fluorinated doped particle).
Example 8
150 g of the white calcium oxide doped cerium oxide obtained in Example 2 and 200 g of isopropanol are taken into a flask and are mixed together with heating to 70° C. to prepare an aqueous slurry, then 3 g of methyl hydrogen polysiloxan (product of Shin-Etsu Chemical Co., Ltd.) is added and mixed for 1 hour. And followed by removal of isopropyl alcohol by heating and vacuuming to give 152 g of silicone treated white calcium oxide doped cerium oxide (hereinafter, shortened to silicone treated doped particle).
Example 9
A sunscreen milk lotion is prepared by using fluorinated doped particles obtained in Example 7 according to the following recipe and preparing method.
Recipe
wt %
(1)
fluorinated doped particles
10.0
(2)
microcrystalline wax
1.0
(3)
beeswax
2.0
(4)
squalane
10.0
(5)
dimethicone (10 cSt)
10.0
(6)
decamethyl cyclopentasiloxane
10.0
(7)
sorbitan sesquioleate
4.0
(8)
polyoxyethylene-methylpolysiloxane
1.0
copolymer
(9)
oxybenzone
0.1
(10)
1,3-buthyleneglycol
9.0
(11)
preservative
q.s.
(12)
purified water
balance
(13)
perfume
q.s.
Method for Preparation
(a) Ingredients (2) to (9) are melted together by heat, and ingredient (1) is added and heated to 70° C.
(b) Ingredients (10) to (12) are mixed together by heating up to 70° C., and obtained mixture is added to (a) and emulsified.
(c) After (b) is cooled clown, ingredient (13) is added and mixed, thus the sunscreen milk lotion is obtained.
Comparative Example 1
A sunscreen milk lotion is prepared by same recipe and same method to Example 9 except using a high purity cerium oxide particles (average particle size is 10 μm) on the market instead of ingredient (1).
When the sunscreen milk lotion of Comparative Example 1 is applied on human skin, it exhibits a pale-white color and white powderiness not to give a natural feeling of cosmetic finish. On the contrary, the sunscreen milk lotion of Example 9 which relates to this invention exhibits a transparent and good cosmetic finish along with an excellent sunscreen effect and preservability.
Example 10
A powder foundation is prepared by using silicone treated solid doped particles obtained in Example 8 according to the following recipe and preparing method.
Recipe
wt %
(1)
silicone treated talc
20.0
(2)
silicone treated mica
balance
(3)
silicone treated titanium dioxide
12.0
(4)
silicone treated red iron oxide
1.0
(5)
silicone treated yellow
3.0
iron oxide
(6)
silicone treated black iron oxide
3.0
(7)
silicone treated doped particles
20.0
(8)
silicone treated zinc oxide
1.0
(9)
squalane
5.0
(10)
glyceryl tri-2-ethylhexanoate
2.0
(11)
white vaseline
1.0
(12)
preservative
q.s.
(13)
perfume
q.s.
Method for Preparation
(a) Ingredients (1) to (8) are blended together by a Henschel mixer.
(b) Ingredients (9) to (11) are heated and blended together and ingredients (12) and (13) are added.
(c) The obtained mixture in (b) is pulverized into a powder, molded by pressing and a powder foundation is obtained.
Comparative Example 2
A powder foundation is prepared by same recipe and same method to Example 10 except using a high purity cerium oxide particles (average particle size is 10 μm) on the market instead of ingredient (7).
When the powder foundation of Comparative Example 2 is applied on human skin, it exhibits a pale-white color and white powderiness not to give a natural feeling of cosmetic finish. On the contrary, the powder foundation of Example 10 which relates to this invention exhibits a transparent and good cosmetic finish along with an excellent sunscreen effect and preservability.
Example 11
A lipstick is prepared by using fine particles of calcium oxide doped cerium oxide obtained in Example 3 according to the following recipe and preparing method.
Recipe
wt %
(1)
ethylene-propylene copolymer
9.0
(2)
microcrystalline wax
5.0
(3)
candelilla wax
3.0
(4)
ceresin wax
3.0
(5)
lanolin
10.0
(6)
caster oil
20.0
(7)
hexyldecyl 2-ethylhexanoate
26.9
(8)
D & C Red No. 6
2.0
(9)
D & C Red No. 7
1.0
(10)
D & C Orange No. 5
0.1
(11)
fine particles of calcium
20.0
oxide doped cerium oxide
Method for Preparation
(a) Ingredients (8) to (11) are blended together and added to a part of ingredient (6), then are mixed and dispersed by a mixing roller.
(b) Ingredients (1) to (5), remaining part of the ingredient (6) and (7) are heated and blended together, then prepared (a) is added and further mixed homogeneously.
(c) A container for lipstick is filled with the molten mixture of (b) and cooled clown rapidly, thus a lipstick is obtained.
Comparative Example 3
A powder foundation is prepared by same recipe and same method to Example 11 except using a fine particles of titanium dioxide instead of ingredient (11).
When the lipstick of Comparative Example 3 is applied on human lips, it exhibits a pale-white color and not give a natural and healthy feeling on lip. On the contrary, the lip stick of Example 11 which relates to this invention exhibits a transparent with healthy coloration along with an excellent sunscreen effect, and preservability.
Example 12
A pressed powder is prepared by using europium oxide doped cerium oxide obtained in Example 1 according to the following recipe and preparing method.
Recipe
wt %
(1)
europium oxide doped cerium oxide
50.0
(2)
talc
30.0
(3)
sericite
6.0
(4)
kaolin
balance
(5)
titanium dioxide
3.0
(6)
zinc myristate
2.0
(7)
red iron oxide
0.2
(8)
yellow iron oxide
0.8
(9)
squalane
2.0
(10)
octyl methoxycinnamate
2.0
(11)
preservative
q.s.
(12)
perfume
q.s.
Method for Preparation
(a) Ingredients (1) to (8) are blended together.
(b) Ingredients (9) to (12) are blended together and added to (a) and mixed homogeneously.
(c) The obtained mixture (b) is pulverized into a powder, molded by pressing and a pressed powder is obtained.
Comparative Example 4
A pressed powder is prepared by same recipe and same method to Example 12 except using fine particles of titanium dioxide instead of ingredient (1).
When the pressed powder of Comparative Example 4 is applied on human skin, it exhibits a pale-white color and white powderiness not to give a natural feeling of cosmetic finish. On the contrary, the pressed powder of Example 12 which relates to this invention exhibits a transparent and good cosmetic finish along with an excellent sunscreen effect and preservability.
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The present invention relates to the metal oxide doped cerium oxide which has an excellent ultraviolet ray shielding effect and a transparency and whose catalytic activity is reduced. More in detail, relates to the metal oxide doped cerium oxide composed of cerium oxide in which metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ , such as Ca 2+ , Y 3+ , La 3+ , Nd 3+ , Eu 3+ , Tb 3+ , Sm 3+ , Mg 2+ , Sr 2+ , Ba 2+ , Ce 3+ and so on are doped. Said metal oxide doped cerium oxide can be prepared at the temperature lower than 60° C. and in the condition of pH higher than 5 by reacting aqueous solution of cerium salt, aqueous solution of metal ion having larger ion radius than that of Ce 4+ and/or lower valence metal ion than Ce 4+ and alkali, then adding oxidizing agent. Further, said metal oxide doped cerium oxide can be blended to resin composition or cosmetic composition and can display and ultraviolet shielding effect without spoiling transparency at visible ray region.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a no-draw press section for a paper machine and a method of pressing a web in such a press section.
More particularly, the present invention relates to a no-draw press section in which a paper web leaving the wire section of the paper machine is supported by a first felt fabric and is conducted between two felt fabrics through a first double felted press nip which is defined by two press rolls having recessed surfaces and in which dewatering from the paper web takes place through both web surfaces. The press section includes a plain surface roll against which at least two single felted press nips are defined, the first of which is located at a given distance from the first double felted press nip. The first felt fabric also serves as a pressing fabric in the first single felted press nip. The paper web travels between the first double felted press nip and the first single felted press nip carried by the first felt fabric and separates therefrom after passing through the first single felted press nip whereupon the web adheres to the surface of the plain surface roll and is transferred on that surface to the second single felted press nip, the latter being provided with its own felt fabric.
The starting point in the development of the press section of the present invention comprises the "Sym-Press" press section manufactured by Valmet Oy of Finland in view of the several years of experience obtained in the operation thereof.
The construction of a "Sym-Press" press section is disclosed in Finnish publication print No. 50651 and U.S. Pat. No. 4,209,361. Generally, the "Sym-Press" press section constitutes a compact, so-called fully closed press section in which a paper web coming from the forming wire of the paper machine is conducted between two felts through a first press nip which is defined between two rolls including recessed surface rolls and/or suction rolls, so that dewatering of the paper web takes place through both of its surfaces. The press section includes a plain surface roll which is provided with at least one doctor device. A second press nip is defined by the plain surface roll and the second of the two rolls defining the first press nip whereby dewatering takes place in the second press nip through the surface of the paper web which faces the second roll of the first press nip. At least one additional press nip is defined between the plain surface central roll which has a larger diameter than that of the other press rolls of the press section and a recessed surface roll, a felt being passed through such additional press nip, the latter being located on a side of the central plain surface roll which is substantially opposite to the location of the second press nip.
Reference is made to U.S. Pat. No. 4,257,844 as well as to articles published in the following magazines "Das Papier" Heft 1 pages 33-44, 1981 and "Norsk Skogindustri" No. 3, page 80, 1974, with respect to the state of the art relating to the present invention.
A modification of the "Sym-Press" press section described above is described in the last mentioned publications. In such modification the suction roll of the "Sym-Press" does not define a press nip with the plain surface central roll, a first double-felted press nip of the press section being arranged in connection with this suction roll or preceding it and in which dewatering the web takes place in two directions. A recessed surface press roll is substituted for a suction roll of the "Sym-Press" and defines a second press nip of the press section in conjunction with the plain surface central roll. The third press nip is formed against the plain surface central roll on a side thereof which is substantially opposite to the second press nip.
It has been necessary to use a suction roll either as a press roll or as a roll on which the web is carried by a pick-up felt to change the direction of the felt run upwardly towards the second nip. The use of a suction roll or other equivalent suction device has several considerable disadvantages discussed in detail below.
More particularly, the perforations of a suction roll may leave a marking on the paper web which detracts from the appearance of the paper and may affect the surface characteristics of the paper as well. Suction rolls are expensive, each requiring an individual drive motor and associated control system. It is well known that the operation of suction rolls generate significant noise levels and, furthermore, large quantities of air are consumed due to the fact that not only does the air which passes through the web and felt enter the suction system but, additionally, the air which arrives in the suction zone of the suction roll in the shell perforations in each revolution must also enter into the suction system. Additionally, the sealing of the suction box of the suction roll causes many difficulties in practice.
As is well known, a suction roll comprises a rotating perforated cylindrical shell and a stationary suction box situated within the shell which faces and sealingly engages by means of sealing elements the inner side of the cylindrical shell. The suction box generally extends axially from one end of the shell to the other end and has a suction width of about 100-500 mm. The suction box is connected to a suction system so that a flow of air is obtained through the shell perforations on that area thereof which is in communication with the suction box while the roll is rotating. As noted above, suction rolls are expensive components of a paper machine resulting from the fact that the drilling of the shell is a difficult task, among other reasons. The perforations reduce the strength of the shell and, therefore, special metal alloys must be used in the construction of the roll shell and the latter must have a relatively large thickness, all contributing to high material costs.
The amount of air carried in the shell perforations into the suction zone and which therefore enter the suction system has been found to be unexpectedly great in modern high speed paper machines. It follows that the higher the speed of the paper machine, the greater will be the proportion of "hole air" which enters the suction system together with the drying air. This proportion is even further increased by the fact that with increasing machine speeds, the roll shells must be of even greater thickness to provide increased strength, it being understood that the amount of "hole air" is proportional to the thickness of the roll shell.
As also pointed out above, another drawback encountered in the operation of suction rolls is the generation of high noise levels which can cause severe health risks for the operators if certain measures are not taken to avoid such noise. The generation of such high noise levels results from the fact that the perforations formed in the suction roll shell act as whistles. In other words, as the perforations which are subjected to the vacuum in the suction zone travel beyond the suction zone, the same are abruptly filled with air thereby causing a loud whistling noise having a basic frequency equivalent to the acoustical resonating frequency of the hole. The whistle system constituted by the multitude of roll perforations often creates a noise whose level exceeds the pain limit of the human ear. Although attempts have been made to attenuate this noise level by various arrangements, such as by employing a suitable drilling pattern for the perforations, a satisfactory attenuation of this noise has not been achieved in practice.
Another disadvantage in the use of suction rolls is that it is often desirable to provide deflection compensation, especially when such suction rolls are utilized as press rolls. However, the provision of such deflection compensation is not possible as a rule since the suction roll shell is perforated and/or due to the fact that the interior of the roll is occupied by the suction box to such an extent that it is not possible to accommodate conventional deflection compensation apparatus in the roll interior.
Further pertaining to the state of the art relating to the present invention, reference is made to U.S. Pat. No. 4,192,711 in which a method is disclosed for detaching a paper web from a forming wire and conducting it in a so-called closed, no-draw conduction to the press section and for accomplishing a dewatering pressing process. The method disclosed in this patent basically comprises the following steps in sequence:
(a) a felt is conducted onto the web lying on the forming wire, which felt is conducted over the suction slot or slots of a transfer suction box, the web being subjected to a suction effect and the direction of the run of the felt and of the web lying thereon deviated with respect to the run of the forming wire;
(b) the web carried by the felt is conducted around a grooved and/or perforated roll located within the loop of that felt over a substantially large sector on which the web is subjected to an external steam treatment by which the web (and possibly the felt underneath the web) on the roll is heated, the web being supported externally during its change of direction on the roll;
(c) the heated web is then conducted on the felt into the first press nip in which the web is pressed between a recessed surface roll and a plain surface roll for the purpose of dewatering; and
(d) after detachment from the felt, the web is conducted onto the surface of the plain surface roll.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide new and improved press apparatus and methods wherein no suction rolls or at least no suction press rolls are required.
Another object of the present invention is to provide new and improved press apparatus and methods in a paper machine in which the web can be conducted to and through the press section in a reliable manner in a no-draw conduction without the risk of web breakage.
Still another object of the present invention is to provide new and improved press apparatus and methods which maintain the advantageous features of the "Sym-Press" press section.
A further object of the present invention is to provide new and improved press apparatus and methods wherein the noise level generated during operation is reduced.
A still further object of the present invention is to provide new and improved press apparatus and methods which further those objects presented in U.S. Pat. No. 4,192,711.
Briefly, in accordance with the present invention, these and other objects are attained by providing press apparatus and methods wherein the press section operates only with non-suction rolls and wherein a first double felted press nip is defined between two rolls having a solid shell and a recessed surface.
A first or upper felt fabric which supports the paper web leaving the wire section of the paper machine is guided with the web supported thereby over a first sector of the first recessed surface roll whereby the direction thereof is changed so as to be directed generally upwardly prior to the first double felted press nip, the magnitude of the first sector being in the range of about 30° to 150°.
A second or lower felt fabric which also passes through the first double felted press nip is guided over a second sector of the first recessed surface roll which comprises at least a substantial portion of the first sector of the first recessed surface roll to provide external support for the web over the second sector. The second or lower felt fabric is separated from the web substantially immediately after the first double felted press nip.
It will be understood that the term "press felt fabric" as used in the instant application refers to all felt-like products made of artificial or natural fibers and which are conventionally used in paper machines and particularly in their press sections, to either improve the dewatering from the web or for carrying the web from one treatment location to another.
DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:
FIG. 1 is a schematic elevation view of one embodiment of the press apparatus of the present invention;
FIG. 2 is a view similar to FIG. 1 illustrating a second embodiment of the present invention;
FIG. 3 is a section view taken along line III--III of FIG. 1; and
FIG. 4 is a schematic detail view illustrating the geometry of the rolls and fabrics in the first double felted press nip of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters designate identical or corresponding parts throughout the several views, in both of the embodiments illustrated in FIGS. 1 and 2, a web W entering the press section is formed on a wire 10 from which web W is detached at point P located on a downwardly sloping run of the wire between rolls 11 and 12 and is transferred by means of a suction sector 24 α of a pick-up roll 24 onto a first or upper fabric felt 20. In addition to serving as a pick-up fabric, the first fabric felt 20 operates as a press felt in a first press nip N 1 and in a second press nip N 2 of the press section.
After passing through the first press nip N 1 , the first fabric 20 is directed generally upwardly on a run R and the web W supported thereby is transferred to the second nip N 2 . The first felt fabric 20 also passes through the second nip N 2 and functions as a press fabric therein. The second nip N 2 is defined between a plain surface central roll 40 and a press roll 41 having a recessed surface. The plain surface central roll 40 preferably has a larger radius than that of the other press rolls and may, for example, constitute a granite roll. In this connection, the use of a granite roll is advantageous in that the adhesion of the web to the surface of the roll 40 will be stronger than the adhesion of the web to the fabric 20 while at the same time the web can be easily detached from the surface of the granite roll utilizing the speed differential as the web is transferred from the press section to the drying section of the paper machine. A third press nip N 3 is defined by a press roll 43 having a recessed surface and the central roll 40. The roll 43 is provided with a separate fabric loop 44. The guide rolls for the fabric loop 44 are indicated by reference numeral 49 and the felt conditioning means therefore by reference numeral 49'. The guide rolls of the first felt fabric 20 are indicated by reference numeral 21 and corresponding felt conditioning means by reference numeral 23.
The first press nip N 1 is defined between press rolls 25 and 32 and constitutes a double felted nip, i.e., two felt fabrics passed therethrough. The first felt fabric 20 serves as an upper felt while a felt fabric 30 operates as a lower felt which is guided by rolls 31 and 33. The guide rolls of the lower felt fabric 30 which are situated below the floor level T are indicated by reference numeral 33 and the corresponding felt conditioning means by reference numeral 34.
One of the important features of the present invention, among others, is that there is no need for expensive suction rolls or other equivalent suction devices in the dewatering press nips. This is accomplished by defining the first press nip N 1 between two recessed surface press rolls 25 and 32. The nip N 1 is double felted and the web W enters the nip adhered to the lower surface of the first felt fabric 20. The second fabric in nip N 1 is the second felt 30 or other equivalent fabric enclosing the press roll 32.
The plain surface central roll 40 is mounted by means of bearings fixed in the frame structure 100 of the paper machine. A downwardly open sector 40' substantially opposite to the nips N 2 and N 3 is provided with a doctor device 50 as shown in FIG. 1. In case of web breakage during operation, the paper web is guided by the doctor device 50 into a broke pulper (not shown) which is situated below the press section.
The paper web W is detached from the surface of the plain surface central roll 40 by utilizing the speed differential between the press section and the dryer section and is guided by the guide roll 52 which conducts the web W into the drying section of the paper machine. A lead-in cylinder 53 is illustrated in FIGS. 1 and 2 as are drying cylinders 56 of the dryer section. A single fabric web conduction system comprising a fabric 55 guided by guide rolls 54 can be advantageously utilized in the dryer section.
The frame 100 of the paper machine is indicated by reference numeral 100 in FIGS. 1-3. Intermediate frame members 110, known per se, are provided in the frame 100 and in the vertical columns 100a (FIG. 3) thereof, which intermediate members can be detached to facilitate changing of the felt fabrics 20 and 30.
Referring to FIG. 3, a sectional view of one part of the frame 100 of the press section is illustrated comprising beams 120 and 121 which are supported at one of their ends by cantilever extensions 120' and 121'. Such support is accomplished by means of rods 122 and horizontal beams 123. Of vertical columns 100a and 100b, the latter constitute the drive side of the press section. Side beams 125 are located on both sides of the paper machine below the floor level T.
The press section of the present invention described above constitutes an improvement on the so-called "Sym-Press" press section described above. As is known, the "Sym-Press" press section is a compact one in which the nips between each pair of rolls form a continuous series and in which there is only a single press suction roll. The press section according to the present invention accomplishes a no-draw conduction of the web but is not as compact in the same sense as the "Sym-Press" press section. It is noted that neither one of the press rolls defining the first double felted nip N 1 is in contact with any rolls defining the second nip N 2 . However, the press section of the present invention can be considered to constitute a compact press construction since the space requirements, especially in the horizontal direction, are not substantially greater than those required by a conventional "Sym-Press" press section.
In conventional press sections according to the prior art discussed above, the roll corresponding to the roll 25 of the present invention has generally been constituted by a suction roll which, by means of its suction sector, retains the web attached to a felt corresponding to the felt fabric 20 as the direction of run of the same changes.
Referring now to FIG. 4, the particular parameters defining the geometry of the first double felted press nip N 1 are illustrated. It is important to note that as the first felt fabric 20 and the web W supported thereby change the direction of their run on the press roll 25 over a sector α 1 , the web is subjected on this sector to a centrifugal force which tends to detach the web W from the fabric 20. However, according to the present invention, the use of a suction roll has been avoided by guiding the second felt fabric 30 over a second sector α 2 of the press roll 25, the second sector α 2 comprising at least a substantial portion of the first sector α 1 . Thus, the second felt fabric 30 which passes through the first nip N 1 follows and supports the web W carried on the fabric 20 over a sector α 2 within the sector α 1 . As seen in FIG. 4, the fabric 20 and the web supported thereby are conducted in the nip N 1 substantially at right angles to the plane N-N which passes through the axes of rolls 25 and 32. In other words, the fabric 20 and web W supported thereby depart from the first double felted press nip N 1 tangentially with respect to rolls 25 and 32 forming the same. After the nip N 1 , the second felt fabric 30 wraps the press roll 32 over a sector α 4 . As illustrated in FIG. 2, the angle α 1 constituting the change of direction undergone by the first felt fabric 20 and web W supported thereby can be relatively small whereby the height of the press section is also correspondingly small. A consequence of this construction, however, is that the length of the press section may become somewhat longer than that of the embodiment illustrated in FIG. 1 wherein the change of direction undergone by the first felt fabric and web supported thereby is larger.
The embodiments of the press section illustrated in FIGS. 1 and 2 differ in several respects. Thus, firstly, in the embodiment illustrated in FIG. 1, the plane N-N which passes through the axes of press rolls 25 and 32 is substantially horizontal and the run R of the first felt fabric 20 between the nips N 1 and N 2 is substantially vertical so that the angle α 1 illustrated in FIG. 4 is slightly larger than 90° with respect to the horizontal plane H-H.
In practice, the angle α 1 may have a magnitude of about 150°. According to the embodiment of FIG. 1, the second felt fabric 30 guides and supports the web W lying on the fabric 20 substantially over the entire sector α 1 so that as seen in FIG. 4, the angle α 3 =0. As will be apparent from the geometry indicated in FIG. 4, the angle α 3 =α 1 -α 2 . Thus, the change of direction in the run of the web W which is supported by the fabric 20 at the press roll 25 according to the invention is accomplished between felt fabrics 20 and 30 so that any risk of detachment of the web W from the fabric 20 under centrifugal force is eliminated. In the embodiment illustrated in FIG. 1, the angle α 4 shown in FIG. 4 is very small due to the location of the guide roll 31. Again referring to FIG. 4, the angle α 5 =90°-α 1 .
On the other hand, in the embodiment of the invention illustrated in FIG. 2, the angle α 1 is about 45° and under some circumstances the angle α 1 may be as small as about 30°.
Referring to FIG. 2, the second press nip N 2 forms a central angle β 2 with the horizontal through the axis of the central roll 40. The angle β 2 preferably has a magnitude of about 45°. The third nip press nip N 3 is located at an angle β 1 from the second nip N 2 . In the embodiment of FIG. 2, the angle β 1 is about 90°. In the embodiment of FIG. 1, the nip N 2 is located substantially in a horizontal plane which passes through the rotational axis of the central roll 40 while the nip N 3 is spaced from the nip N 2 by an angle β 1 . In the embodiment of FIG. 1, the angle β 1 is about 120°.
The embodiments of the invention illustrated in FIGS. 1 and 2 essentially represent the extremes in the construction of the invention with respect to the magnitude of the angle β 1 which is important from the point of view of the invention. Thus, the embodiment illustrated in FIG. 1 is advantageous in that the press section requires relatively little space in the horizontal direction while the height of the press section is relatively great since the distance L between the first and second nips is substantially vertical. Although the angle α 1 which represents the extent of the change of direction of the web run is relatively large in the embodiment of FIG. 1, no substantial difficulties are presented even though suction rolls are not utilized since the second or lower felt fabric 30 provides external support for the web W while the same runs on the fabric 20.
The angles α 1 . . . α 5 can be chosen within the scope of the invention in a manner such that the transfer and pressing of the web is optimized. It is again pointed out that the press rolls 25, 32, 40, 41 and 43 each comprise a non-suction roll. More particularly, the rolls 25 and 32 can constitute rolls having a recessed surface, i.e., either grooved or blind drilled or the like. The recessed nature of rolls 25 and 32 is indicated by reference numerals 25' and 32', respectively. One or both of the rolls 25 and 32 can, if necessary, constitute a roll provided with a soft covering such, for example, as rubber. Preferably, the roll 25 has a soft covering while the roll 32 constitutes a hard roll so that in this manner a sufficient width in the running direction of the web W is accomplished in the nip N 1 . Of course, the time during which the web dwells in the nip under pressure is proportional to the width of the nip. The nip width can also be increased utilizing a felt having sufficient compressibility. The press rolls 41 and 43 may also constitute recessed surface rolls such, for example, as grooved or blind drilled rolls. Additionally, rolls 41 and 43 preferably are provided with deflection compensation and controlling apparatus. In this connection, the rolls 25 and 32 may, if necessary, be provided with deflection compensation or deflection controlling apparatus.
The manner in which the felt fabrics 20 and 30 are guided after the nip N 1 , i.e., the magnitude of the angle α 4 in FIG. 4, depends, for example, on the rewetting tendency of the web W. This phenomenon can be minimized through suitable guidance of the run of the fabrics 20 and 30 after the nip N 1 .
A steam box 51 is illustrated in FIG. 2 which is situated on the run of the fabric 20 between nips N 1 and N 2 and which faces the web W. By means of the steam box 51, the temperature of the web can be raised in order to improve dewatering in the nips N 2 and N 3 . As to the construction, operation and effect of the steam box 51, reference is made to U.S. Pat. No. 4,163,688.
As seen in FIGS. 1 and 2, the web W is detached from the wire 10 at a point P by means of a pick-up suction roll 24 having a suction zone 24α. If it is desired to provide that the entire wet end of the paper machine be formed of non-suction rolls to thereby minimize to the greatest extent possible the suction energy required and noise levels generated, the suction roll 24 can be replaced by a transfer suction box, such as the type disclosed in the above-mentioned U.S. Pat. No. 4,192,711.
From the above, it is seen that by suitably choosing the angle α 1 through which the fabric 20 and web W supported thereon changes direction, it is possible to effectively determine the amount of space required for the press section in both vertical and horizontal directions. The magnitude of the angle α 1 also determines the height at which the second press nip N 2 is located with respect to the central roll 40, i.e., the angle β 2 seen in FIG. 2. The embodiment of the invention illustrated in FIG. 1 is advantageous in that the angle β 1 can be relatively large so that the arcuate distance between the nips N 2 and N 3 can be quite large. Thus, the angle β 1 may be about 180° which constitutes the most advantageous construction when the loading directed on the granite central roll 40 is considered. The embodiment according to FIG. 1 in which α 1 is greater than 90° and the run of felt 20 and web W supported thereby is guided somewhat obliquely backwardly with respect to the main direction of the web run is also favorable in that it is possible, if necessary, to provide three or more press nips with the central roll 40 while still providing the downwardly facing open sector 40' for the central roll 40 with sufficient space to accommodate a doctor device 50 for cleaning the roll surface for directing the broke downwardly in the case of web breakage.
In the embodiments of FIGS. 1 and 2, the press rolls 25 and 40 are mounted in fixed bearing supports. The central plain surface roll 40 is illustrated as being supported by structure located beneath the same. However, it is understood that this roll may also be supported from above by means of bearing supports fixed to the frame. The rolls 32, 41 and 43 are supported by rods provided with loading devices known per se in order to provide a suitable linear nip pressure in the nips N 1 , N 2 and N 3 . For example, rods 45 and 47 which are fixed to the framework 100 by means of joint pins 46 and 48, respectively, constitutes such supporting means.
It is known in the art that a web will always adhere in a single felted nip to the surface of the smooth press roll and in a double felted nip on the surface of that felt which is smoother, absent the effect of suction which may act in the press nip or an unclean felt.
An important consideration in the present invention is to assure that a situation does not occur wherein the web W will not follow the upper fabric felt 20 and therefore not pass into the second nip N 2 but become attached onto the lower felt fabric 30 of the first nip N 1 , such as due to the possibility that the lower felt fabric 30 is dirty. In order to eliminate this possibility, all felts and fabrics and particularly the lower fabric 30 must be provided with effective cleaning and felt conditioning devices known per se.
Furthermore, in order to assure a safe conduction of the web W from the first nip N 1 to the second press nip N 2 , it is necessary to closely consider the quality and type of the felts and fabrics 20 and 30 which are utilized. In this connection, primary consideration must be paid to the manner in which the felts and fabrics are manufactured, i.e., to the particular textile technology.
In order to obtain the object of the invention, the pick-up felt 20 belonging to the press section and operating in the first press nip N 1 as an upper felt fabric must have two basic characteristics. Firstly, the surface of this upper felt fabric 20 must be considerably smoother than the surface of the second or lower fabric 30 present in the first nip. Secondly, the upper fabric felt 20 must be especially compressible and particularly elastic so that when the felt 20 is released from the pressure between the rolls of the first nip N 1 , the same expands relatively strongly so that its yarn structure becomes relatively open. The consequence of this action is that a slight suction effect is created which contributes to the attachment of the web W onto the felt fabric 20 in addition to the adhesive forces created by the smooth surface of the fabric 20. By means of the structure and characteristics of such a felt fabric 20, it is possible to assure the adherence of the web W to the upper felt fabric 20 after the first nip N 1 and a reliable transfer of the web W to the second nip N 2 .
To accentuate the effect of the above characteristics of the pick-up fabric felt 20, the second or lower fabric felt 30 present in the first nip N 1 must be relatively hard and have a coarse surface while also having an open structure so as to possess sufficient capability to receive water in the pressing process.
Obviously, numerous modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the claims appended hereto, the invention may be practiced otherwise than as specifically disclosed herein.
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A press section in a paper machine includes a first double felted press nip defined by first and second rolls through which first upper and second lower felt fabrics pass and at least two single felted press nips defined with a plain surface roll, the first felt fabric passing through a first one of the single felted press nips. The press section includes only non-suction rolls, the first and second rolls defining the first double felted press nip each having a solid shell and recessed surface. The first felt fabric supports the web leaving the wire section and is guided over a first sector of the first recessed surface roll wherein the direction thereof is changed so as to be directed generally upwardly prior to the first double felted press nip. The second lower felt fabric which passes through the first double felted press nip is guided over a second sector of the first recessed surface roll which comprises at least a substantial portion of the first sector thereof to provide external support for the web. The second felt fabric is separated from the web substantially immediately after the first double felted press nip whereupon the first felt fabric and web supported thereby is conducted to and passes through the first single felted press nip, the web then detaching from the first felt fabric and adhering to the surface of the plain surface roll for subsequent passage through the second single felted press nip.
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This application claims the benefit of PCT/US01/14795 filed May 8, 2001, which claims the benefit of U.S. Provisional Application 60/211,498 filed Jun. 14, 2000; the entire contents of each of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention provides inhibitors of the enzyme 15-lipoxygenase, pharmaceutical compositions comprising said inhibitors, and methods of treating diseases responsive to inhibition of 15-lipoxygenase.
BACKGROUND OF THE INVENTION
Hypercholesterolemia can induce monocytes to migrate into the arterial wall and mature into foam cells or tissue macrophages that accumulate fatty material, including cholesterol esters. For example, continued creation of foam cells thickens the inner lining of medium and large arteries, thereby forming atherosclerotic plaques or lesions containing cholesterol, smooth muscle cells, and connective tissue cells. Affected arteries lose elasticity and become narrowed or obstructed by the plaques. These events are the hallmark of the disease atherosclerosis. Furthermore, atherosclerotic plaques may collect calcium, become brittle, and even rupture, triggering the formation of a blood clot or thrombus capable of occluding an artery and causing a stroke or a heart attack. In addition to atherosclerosis, hypercholesterolemia plays a role in peripheral vascular diseases of small arteries, veins, and lymphatics. Thus, hypercholesterolemia may also affect the arms, legs, kidneys, and other vital organs in addition to the heart and brain.
Cholesterol is transported in blood in particles called lipoproteins, which include low-density lipoproteins (LDL). Lipoproteins also contain cholesterol and are necessary for foam cell formation.
Lipoxygenases are enzymes that catalyze the oxidation of polyunsaturated fatty acids and esters thereof, including those found in low-density lipoproteins. For example, the enzyme 15-lipoxygenase (15-LO) oxidizes esterified polyenoic fatty acids. 15-LO has been implicated in inflammatory disorders and in the origin and recruitment of foam cells. In addition to modifying lipoproteins involved in the formation of foam cells, 15-LO also mediates an inflammatory reaction in the atherosclerotic lesion In human monocytes, 15-LO is induced by the cytokine IL-4.
Inhibitors of 15-LO are therefore useful to prevent and treat diseases with an inflammatory component such as asthma, psoriasis, osteoarthritis, rheumatoid arthritis, colorectal cancer, and atherosclerosis. For example, it has been shown that treatment with an inhibitor of 15-LO suppressed atherogenesis, or the production of atheroma, a fatty degeneration of the arterial wall, in rabbits fed a high-fat diet
A chief object of this invention is to provide new 1,2,4-trisubstituted benzenes that are potent inhibitors of 15-LO.
SUMMARY OF THE INVENTION
The invention provides 1,2,4-trisubstituted benzenes, compositions of matter containing said benzenes, and methods for treating diseases related to the 15-LO cascade using such compounds or compositions. The invention provides compounds of Formula I:
wherein:
R is OH, O—C 1 -C 4 alkyl, or halo; X is R 1 , OR 1 , SR 1 , NHR 1 , or NR 1 R 2 , wherein R 1 and R 2 are independenty selected from C 1 -C 12 alkyl C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, benzyl, C 3 -C 7 cycloalkyl, C 2 -C 6 heteroaryl, C 2 -C 6 heteroalkyl, and phenyl, wherein the alkyl alkenyl, alkynyl, heterocyclic radical, benzyl, and phenyl groups are optionally substituted with from 1 to 5 substituents independently selected from halo, NHR 3 , CF 3 , C 1 -C 6 alkyl, OR 4 , CO 2 R 3 , NO 2 , and SR 3 , wherein R 3 and R 4 are independently H or C 1 -C 6 alkyl; W and V are independently SO 2 or C═O, provided that when W is SO 2 , —V— can further be a covalent bond and X can further be hydrogen; R 5 is H, C 1 -C 6 alkyl, or benzyl, wherein benzyl is optionally substituted with R 1 , wherein R 1 is as defined above, or R 5 is a pharmaceutically acceptable cation; Y is NR 6 or O, wherein R 6 is H or C 1 -C 6 alkyl; Z is 2-indolyl, 3-indolyl, 2-benzimidazolyl, 2-benzoxazolyl, C(O)N(H)Ph, or N(H)C(O)Ph, which are optionally substituted with from 1 to 4 substituents independently selected from C 1 -C 6 alkyl, fluoro, chloro, bromo, iodo, nitro, NHR 7 , NR 7 R 8 , and OR 7 , wherein R 7 and R 8 are independently H or C 1 -C 6 alkyl; wherein each hydrocarbyl or heterocyclic radical above is optionally substituted with from 1 to 3 substituents independently selected from halo, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 6 alkenyl, C 1 -C 6 alkynyl, phenyl, hydroxyl, amino, (amino)sulfonyl, N-acetyl, O-acetyl, C 1 -C 6 thioalkyl, C 1 -C 6 alkoxy, COOH, COO(C 1 -C 6 allyl), SO 3 Na, SO 3 H, SO 2 NH 2 , cyano, CH 2 NH 2 , acetyl, di(C 1 -C 6 alkyl)amino, and nitro, wherein the alkyl, cycloalkyl, alkenyl, alkynyl, and phenyl substituents may be optionally substituted with from 1 to 3 substituents independently selected from halo, C 1 -C 6 alkyl, hydroxyl, amino, and nitro; and pharmaceutically acceptable salts thereof.
Preferred are compounds of Formula II
and pharmaceutically acceptable salts thereof, wherein X′ is OR 1 , SR 1 , NHR 1 , or NR 1 R 2 , and R 1 , R 2 , R, Z, Y, and R 5 are as defined above.
Also preferred are compounds of Formula III
and pharmaceutically acceptable salts thereof, wherein R, Z, Y, and R 5 are as defined above.
Preferred are compounds of Formula IV
and pharmaceutically acceptable salts thereof, wherein R 1 , R, Z, Y, and R 5 are as defined above.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein R is H or methyl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein R is methyl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is as defined above for Formula I and is optionally substituted with from 1 to 4 substituents independently selected from fluoro, chloro, and methyl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is as defined above for Formula I and is substituted with from 1 to 3 substituents, wherein the substituents are as defined above for Formula I.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is as defined above for Formula I and is substituted with from 1 to 3 substituents independently selected from fluoro, chloro, bromo, and iodo.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is C(O)N(H)Ph.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is C(O)N(H)Ph substituted with at least 1 fluoro.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is C(O)N(H)Ph substituted with at least 2 fluoro groups.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is C(O)N(O)Ph substituted with at least 2 fluoro groups, wherein the said at least 2 fluoro groups are bonded to adjacent carbon atoms.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is (3,4-difluorophenyl)amino-carbonyl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z comprises 2-indolyl optionally substituted with from 1 to 4 substituents independently selected from fluoro, chloro, and methyl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein Z is 5,6-difluoro-indol-2-yl.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein R 5 is H.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein R 5 is a cation selected from an alkali earth metal cation, an alkaline earth metal cation, ammonium, and choline.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein R 5 is sodium cation, potassium cation, choline, or hemi calcium cation.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein W is SO 2 .
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein X is R 1 , OR 1 , SR 1 , NHR 1 , or NR 1 R 2 wherein R 1 and R 2 are independently selected from C 1 -C 8 alkyl C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, benzyl, C 3 -C 6 cycloalkyl, C 2 -C 6 heterocyclic radical, and phenyl, wherein the alkyl, alkenyl, alkynyl, heterocyclic radical, benzyl, and phenyl groups are optionally substituted with from 1 to 3 independently selected substituents, wherein the substituents are as defined above for Formula I.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein X is R 1 , OR 1 , NHR 1 , or NR 1 R 2 wherein R 1 and R 2 are independently selected from C 2 -C 5 alkyl, C 2 -C 5 alkenyl, C 2 -C 5 alkynyl, benzyl, and phenyl, wherein the alkyl, alkenyl, alkynyl, benzyl, and phenyl groups are optionally substituted with from 1 to 3 independently selected substituents, wherein the substituents are as defined above for Formula I.
Preferred is a compound of Formula I, and pharmaceutically acceptable salts thereof, wherein X is phenylamino, phenoxy, alkoxy, alkylamino, dialkylamino, or (carboxy)alkoxy.
Preferred compounds of the present invention are selected from the group consisting of:
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, dodecyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(4-morpholinyl)ethyl ester;
Carbamic acid, [[(5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 3-(dimethylamino) propyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(1-pyrrolidinyl)ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(dimethylamino)ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-phenylethyl ester, monopotassium salt;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(2-thienyl)ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(ethylsulfonyl)ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 3-bromopropyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-[[(phenylmethoxy)carbonyl]amino] ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-ethoxyphenyl]amino]-sulfonyl]-, 2-(3-thienyl)ethyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, octyl ester;
Carbamic acid, [[[(5-(5,6-difluoro-1H-indol-2-yl)2-methoxyphenyl]-amino]sulfonyl]-methyl-, 3-phenylmethoxy)propyl ester;
Carbamic acid, [[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-(phenylmethyl)-, 3-(phenylmethoxy)propyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-2-(dimethylamino)ethyl ester, monohydrochloride;
Acetic acid, [[[[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-amino]carbonyl]oxy]-, phenylmethyl ester;
Benzamide, 3-[[[[[(3,5-dichlorophenyl)amino]carbonyl]amino]-sulfonyl]-amino]-N-(3,4-difluorophenyl)-4-methoxy-;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)-carbonyl]amino]-sulfonyl]amino]-;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, ethyl ester;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)-amino]-sulfonyl]amino]carbonyl]amino]-;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, butyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, 2-methylpropyl ester;
Carbamic acid, [[(5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 2-methylpropyl ester;
Urea, N-(3,5-dichlorophenyl)-]-N′-[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, ethyl ester;
Carbamic acid, [[[5-(1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, ethyl ester;
Urea, N-(4-chlorophenyl)-N′-[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-;
Urea, N-[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-N′-(4-methylphenyl)-;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-methyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-heptyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-pentyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-(2E)-3-phenyl-2-propenyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, (2E)-3-phenyl-2-propenyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-2-(1-methylethoxy)ethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]-, 2-(1-methylethoxy)ethyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, phenylmethyl ester,
Sulfamide, N-[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-N′-methyl-;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[(methylamino)-sulfonyl]amino]-;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 3-(4-pyridinyl)propyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-2-phenylethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 2-phenylethyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, phenylmethyl ester,
Acetic acid, [[[[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl[-amino]carbonyl]oxy]-, methyl ester,
Acetic acid, [[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]amino]carbonyl]oxy]-, methyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-3-hydroxypropyl ester;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 3-hydroxypropyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, 2-ethoxyethyl ester,
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-ethoxyethyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-3-(phenylmethoxy)propyl ester,
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 3-(phenylmethoxy)propyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-hexyl ester,
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, hexyl ester;
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, 1,1-dimethylethyl ester;
Sulfamide, [5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-;
Benzamide, 3-[(aminosulfonyl)amino]-N-(3,4-difluorophenyl)-4-methoxy-;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 2-(1,3-dihydro-1,3-dioxo-2H-isoindol-2-yl) ethyl ester;
Benzamide, N-(3,4-difluorophenyl)-3-[[[[(dimethylamino)sulfonyl]-amino]carbonyl]-amino]-4-methoxy-;
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 1,1-dimethylethyl ester;
Benzamide, N-(3,4-difluorophenyl)-3-[[[[[[4-(1,1-dimethylethyl)phenyl]-amino]carbonyl]amino]sulfonyl]amino]-4-methoxy-;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(3-nitrophenyl)-amino]-carbonyl]amino]sulfonyl]amino]-;
Benzamide, 3-[[[[[(3-chlorophenyl)amino]carbonyl]amino]sulfonyl]-amino]-N-(3,4-difluorophenyl)-4-methoxy-;
Benzamide, 3-[[[[[[3,5-bis(trifluoromethyl)phenyl]amino]-carbonyl]amino]sulfonyl]-amino]-N-(3,4-difluorophenyl)-4-methoxy-;
Benzamide, 3-[[[[[(4-aminophenyl)amino]carbonyl]amino]-sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-, mono(trifluoroacetate);
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[[3-(trifluoromethyl)phenyl]-amino]carbonyl]-amino]sulfonyl]amino]-;
Benzoic acid, 4-[[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]amino]carbonyl]amino]-;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)-amino]-carbonyl]amino]sulfonyl]amino]-;
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)-carbonyl]-amino]sulfonyl]amino]-;
Benzamide, 3-[[[[[(4-chlorophenyl)amino]carbonyl]amino]sulfonyl]-amino]-N-(3,4-difluorophenyl)-4-methoxy-; and
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]methyl-, ethyl ester.
The invention also provides pharmaceutical compositions, comprising compounds of Formula I, and pharmaceutically acceptable salts thereof, in admixture with a pharmaceutically acceptable carrier, diluent, or excipient. Preferred compositions comprise a compound of Formulas II through IV with a pharmaceutically acceptable carrier.
The compounds of Formula I and their pharmaceutically acceptable salts are useful for treating diseases responsive to inhibition of 15-LO, including atherosclerosis, diseases involving chemotaxis of monocytes, inflammation, stroke, coronary artery disease, asthma, arthritis, including osteoarthritis and rheumatoid arthritis, colorectal cancer, and psoriasis. Thus, the invention also provides methods for treating mammals with diseases relating to the 15-LO cascade. These methods are for treating, preventing, or ameliorating the related condition or disease. These methods include the following.
A method for inhibiting 15-LO, said method comprising administering to a patient in need of 15-lipoxygenase inhibition a pharmaceutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing atherosclerosis, said method comprising administering to a patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for inhibiting the chemotaxis of monocytes, said method comprising administering to a patient in need of inhibition of monocytic migration a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing inflammation, said method comprising administering to patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing stroke, said method comprising administering to a patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing coronary artery disease, said method comprising administering to a patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing asthma, said method comprising administering to patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing arthritis, said method comprising administering to patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing colorectal cancer, said method comprising administering to a patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
A method for treating or preventing psoriasis, said method comprising administering to a patient at risk or in need of such treatment a therapeutically-effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
Other aspects and features of the invention will be apparent from the disclosure, examples, and claims set forth below.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides compounds of Formula I, compositions containing the compounds, methods of making the compounds, and methods of using the compounds to treat diseases responsive to inhibition of 15-LO. Other features of the invention, and preferred embodiments thereof, will become apparent from the examples and claims below.
A. Terms
Certain terms used herein are defined below and by their usage throughout this disclosure.
Alkyl groups include aliphatic (i.e., hydrocarbon radicals containing hydrogen and carbon atoms) with a free valence. Alkyl groups are understood to include straight chain and branched structures. Preferred alkyl groups have from 1 to 6 carbon atoms. Examples of typical alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, n-butyl isobutyl, t-butyl, pentyl, isopentyl, 2,3-dimethylpropyl, hexyl, 2,3-dimethyl hexyl, 1,1-dimethylpentyl, heptyl, and octyl. Cycloalkyl groups are C 3 -C 8 cyclic structures, examples of which include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cyclooctyl.
Alkyl and cycloalkyl groups can be substituted with 1, 2, 3 or more substituents which are independently selected from halo (fluoro, chloro, bromo, or iodo), hydroxy, amino, alkoxy, alkylamino, dialkylamino, cycloalkyl, aryl, aryloxy, arylalkyloxy, heterocyclic radical, (heterocyclic radical)oxy, (amino)sulfonyl, N-acetyl, O-acetyl, C 1 -C 4 thioalkyl, C 1 -C 4 alkoxy, COOR 6 , SO 3 Na, SO 3 H, SO 2 NH 2 , cyano, CH 2 NH 2 , acetyl, trifluoromethyl, and nitro. Specific examples include COOH, thiomethyl, methoxy, ethoxy, dimethylamino, ethylmethylamino, diethylamino, and chloro. Other examples include fluoromethyl, hydroxyethyl, 2,3-dihydroxyethyl, (2- or 3-furanyl)methyl, cyclopropylmethyl, methylcyclopropyl, benzyloxyethyl, (3-pyridinyl)methyl, (2- or 3-furanyl)methyl, (2-thienyl)ethyl, hydroxypropyl, aminocyclohexyl, 2-dimethyl-aminobutyl, methoxymethyl, 2-ethoxycyclopentyl, N-pyridinylethyl, diethylaminoethyl, and cyclobutylmethyl.
Alkenyl groups are analogous to alkyl groups, but have at least one double-bond (two adjacent sp 2 carbon atoms). Depending on the placement of a double-bond and substituents, if any, the geometry of the double-bond may be entgegen (E), zusammen (Z), cis, or trans. Similarly, alkynyl groups have at least one triple-bond (two adjacent sp carbon atoms). Unsaturated alkenyl or alkenyl groups may have one or more double- or triple-bonds, respectively, or a mixture thereof; like alkyl groups, they may be straight chain or branched, and they may be substituted as described above and throughout the disclosure. Examples of alkenyls, alkynyls, and substituted forms include cis-2-butenyl, trans-2-butenyl, 3-butynyl, 3-phenyl-2-propynyl, 3-(2′-fluorophenyl)-2-propynyl, 3-methyl(5-phenyl)-4-pentynyl, 2-hydroxy-2-propynyl, 2-methyl-2-propynyl, 2-propenyl, 4hydroxy-3-butynyl, 3-(3-fluorophenyl)-2-propynyl, and 2-methyl-2-propenyl.
The foregoing groups are referred to collectively as “hydrocarbyl” groups. More general forms of substituted hydrocarbyls include hydroxyalkyl, hydroxyalkenyl, hydroxyalkynyl, hydroxycycloalkyl, hydroxyaryl, and corresponding forms for the prefixes amino-, halo- (e.g., fluoro-, chloro-, or bromo-), nitro-, alkyl-, phenyl-, cycloalkyl- and so on, or combinations of substituents. According to Formula I, therefore, substituted alkyls include hydroxyalkyl, aminoalkyl, nitroalkyl, haloalkyl, alkylalkyl (branched alkyls, such as methylpentyl), (cycloalkyl)alkyl, phenylalkyl, alkoxy, alkylaminoalkyl, dialkylaminoalkyl, arylalkyl, aryloxyalkyl, arylalkyloxyalkyl, (heterocyclic radical)alkyl, and (heterocyclic radical)oxyalkyl and so on. Where R 1 is phenyl, for example, R 1 thus includes 3-halo-4-hydroxyphenyl, 3-(fluoro or chloro)-4-nitrophenyl 3,4-dichlorophenyl, 3,5-dichlorophenyl, 3,5-difluorophenyl, 3-hydroxy-4-nitrophenyl, 4-hydroxy-3-nitrophenyl, 3-chlorophenyl, 4-chlorophenyl, 2-fluorophenyl, 3-fluorophenyl, 4-fluorophenyl, 3,4-difluorophenyl, 2,3-difluorophenyl-2,4-difluorophenyl, 3-trifluoromethylphenyl, 4-trifluoromethylphenyl, 3-aminophenyl, 4-aminophenyl, 3,5-dimethylphenyl, 3-methylphenyl, 4-methylphenyl, 3-nitrophenyl, 4-nitrophenyl, 3-nitro-4-chlorophenyl, 3-cyanophenyl, 4-cyanophenyl, 3-methyleneaminophenyl, 4-methyleneaminophenyl, 3-hydroxyphenyl, 4-hydroxyphenyl, 3,4-dihydroxyphenyl, 4chloro-3-trifluoromethylphenyl, 3-carbomethoxyphenyl, 4-carbomethoxyphenyl, bis(3,5-trifluoromethyl)phenyl, 4-t-butylphenyl, 4-n-butylphenyl, 4-isopropylphenyl, 3-acetylphenyl, 4-sulfonic acid (e.g., sodium salt), 3-carboxyphenyl, 4carboxyphenyl, 3-methoxyphenyl, 4-methoxyphenyl, 3,4-dimethoxyphenyl, 4-acetamidophenyl, 3-amino-4-halophenyl, 3-alkoxy-4-halophenyl, 3-halo-4-alkylaminophenyl, 4-(N,N-dimethylamino)phenyl, 3-cycloalkylphenyl, 3(3′,5′-dihalophenyl)-4-nitrophenyl, 4-aryloxyphenyl, arylalkyloxyphenyl, heterocyclic radical phenyl, (heterocyclic radical)oxy, 4-sulfamoylphenyl (or 4-aminosulfonylphenyl), 3-(alkylcarbonyloxy)phenyl such as 3-acetylphenyl, and 3-(C 1 -C 4 thioalkyl)phenyl. It also follow that where Z includes a phenyl, such as Z=NH(CO)Ph, the phenyl can be similarly substituted.
Similarly, the invention features analogous examples of substituted R where R is a heterocyclic radical. Heterocyclic radicals, which include but are not limited to heteroaryls, include cyclic and bicyclic ring moieties having between 1 and 4 heteroatoms selected independently from O, S, and N, and having from 2 to 11 carbon atoms. The rings may be aromatic or nonaromatic, with sp 2 or sp 3 carbon atoms. Examples include: furyl, oxazolyl, isoxazolyl, thienyl, thiophenyl, thiazolyl, pyrrolyl, imidazolyl, triazolyl such as 1,3,4-triazolyl, tetrazolyl, thiazolyl, oxazolyl, xanthenyl, pyronyl, pyridyl, pyrimidyl, triazinyl, pyrazinyl, pyridazinyl, indolyl, and pyrazolyl. Further examples of heterocyclic radicals include piperidyl, quinolyl, isothiazolyl, piperidinyl, morpholinyl, piperazinyl, tetrahydrofuryl, tetrahydropyrrolyl, pyrrolidinyl, octahydroindolyl, octahydrobenzothiofuranyl, and octahydrobenzofuranyl. Particularly preferred heterocyclic radicals include 2-pyridyl, 3-pyridyl, 4pyridyl, 3-picolinyl, 2-thienyl, 3-thienyl, 2-furyl, 3-furyl, dansyl, 8-quinoyl, 2-acetamido-4-thiazole, and imidazolyl. These may be substituted with one or more substituents such as halo, C 1 -C 4 alkoxy, COOR 6 , SO 3 Na, SO 3 H, SO 2 NH 2 , cyano, CH 2 NH 2 , acetyl, trifluoromethyl. Examples of substituted heterocyclic radicals include chloropyranyl, methylthienyl, fluoropyridyl, amino-1-,4-benzisoxazinyl, nitroisoquinolinyl, and hydroxyindolyl. Heterocyclic radicals can be bonded through a carbon atom or a heteroatom.
The term “patient” means a mammal such as a human or a domestic animal such as a dog, cat, horse, bovine, porcine, and sheep.
The term “effective amount” means that quantity of a compound of Formula I that inhibits the 15-LO enzyme in a patient to an extent that results in prevention or treatment of an inflammatory condition or otherwise benefits a patient by virtue of having endogenous 15-LO enzymes inhibited.
The term “halo” includes fluoro, chloro, bromo, and iodo.
The term “amino” means NH 2 .
The term “alkylamino” means an alkyl group as defined above bonded through an —NH— group.
The term “dialkylamino” means two alkyl groups, each bonded through an —N— group.
The phrase “pharmaceutically acceptable cation” means an alkali or alkaline earth metal cation or a protonated organic amine.
B. Compounds
The invention provides compounds of Formula I and pharmaceutically acceptable salts thereof. Also provided are hydrates and solvated forms thereof; masked or protected forms; and racemic mixtures, or enantiomerically or optically pure forms (at least 90%, and preferably 95%, 98% or greater purity).
Pharmaceutically acceptable salts include carboxylate salts (e.g., C 1 -C 8 alkyl, cycloalkyl, aryl, heteroaryl, or heterocyclic) and amino acid addition salts which are within a reasonable benefit/risk ratio, pharmacologically effective, and suitable for contact with the tissues of patients without undue toxicity, irritation, or allergic response. Representative salts include hydrobromide, hydrochloride, sulfate, bisulfate, nitrate, acetate, oxalate, valerate, oleate, palmitate, stearate, laurate, borate, benzoate, lactate, phosphate, tosylate, citrate, maleate, fumarate, succinate, tartrate, naphthylate, mesylate, glucoheptonate, lactiobionate, and laurylsulfonate. These may include alkali metal and alkali earth cations such as sodium, potassium, calcium, and magnesium, as well as nontoxic ammonium, quaternary ammonium, and amine cations such as tetramethyl ammonium, methylamine, trimethylamine, and ethylamine. See, for example, S. M. Berge, et al., “Pharmaceutical Salts,” J. Pharm. Sci., 1977;66:1-19, which is incorporated herein by reference.
C. Synthesis
The compounds of the present invention can be synthesized according to the synthetic routes outlined in Schemes 1-4. Scheme 1 illustrates the preparation of compounds of the present invention of Formula Ia, which is a compound of Formula I wherein W is SO 2 , V is C═O, R 5 is hydrogen, X is OR 1 , SR 1 , NHR 1 , or NR 1 R 2 , and R 1 , R 2 , R, Z, and Y are as defined above for Formula I. In Scheme 1, chlorosulfonylisocyanate of formula (1) (CSI), is reacted with either an alcohol, thiol, or amine of formula H—X′, wherein X′ is OR 1 , SR 1 , or NHR 1 or NR 1 R 2 , respectively, wherein R 1 and R 2 are as defined above, in a nonprotic solvent such as methylene chloride, which can contain, but does not require, an amine such as, for example, an organic tertiary amine or pyridine, to give a chlorosulfonamide of formula (2). The chlorosulfonamide of formula (2) is then further reacted with an alcohol or amine of formula (3) wherein Y′ is OH or NH 2 , in an organic solvent such as methylene chloride with an amine base such as triethyl amine or pyridine to give a compound of Formula Ia.
Scheme 2 illustrates the preparation of a compound of the present invention of Formula Ib, which is a compound of Formula I wherein W is SO 2 , V is C═O, X is OR 1 , SR 1 , NHR 1 , or NR 1 R 2 , and R 1 , R 2 , R, Z, Y, and R 5 are as defined above for Formula I. Scheme 2 further illustrates the preparation of a compound of the present invention of Formula Ic, which is a compound of Formula I wherein W is SO 2 , —V— is a covalent bond, X is hydrogen, and R, Z, Y, and R 5 are as defined above for Formula I. In Scheme 2, a compound of Formula Ia is reacted with an organic base, such as 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), in a nonprotic solvent, such as methylene chloride, and alkylated with an alkyl halide of formula R 5 -L, wherein L is chloro, bromo, or iodo, to give a compound of Formula Ib. A compound of Formula Ib, wherein X′ is OR 1 , wherein R 1 is an acid labile group such as, for example, tert-butyl or a hydrogenolysis labile group such as benzyl, can further be converted to a compound of Formula Ic by acid-catalyzed cleavage or hydrogenolysis. For example, when R 1 is tert-butyl, the reaction can be carried out by treating a compound of Formula Ib wherein X′ is OR 1 , with hydrogen chloride gas or trifluoroacetic acid (TFA) in a solvent such as methylene chloride. Alternatively, when R 1 is benzyl, the reaction can be carried out by treating a compound of Formula Ib wherein X′ is OR 1 , with hydrogen gas in the presence of a suitable hydrogenation catalyst such as palladium (0) tetrakis(triphenyl)-phosphine in a suitable solvent such as ethanol, tetrahydrofuran (THF), or acetic acid.
Compounds of the present invention of Formula Id, which is a compound of Formula I wherein —V— is a covalent bond, W is SO 2 , X is R 1 , and R, Z, Y, and R 5 are as defined above for Formula I, can be synthesized according to the method illustrate in Scheme 3. In Scheme 3, a compound of formula (3), wherein Y′ is OH or NH 2 , is allowed to react with a sulfamylchloride of formula (4), wherein R 1 and R 5 are as defined above for Formula I, in an organic solvent such as acetonitrile with or without an organic base to give a compound of Formula Id.
Amines of formula (3), wherein Y′ is NH 2 in Schemes 1 and 3 can be synthesized according to the methods described in WO 99/32433, which is hereby incorporated by reference. In particular, the procedure of Example 15 of WO 99/32433 may be used. Additional amines of formula (3), wherein Y′ is NH 2 , R is methoxy, and Z is optionally substituted indol-2-yl wherein the substituents are as defined above for Z in Formula I, can be synthesized according to the method illustrated in Scheme 4. In Scheme 4, a phenylacetic acid of formula (5) is converted to an acid chloride with a chlorinating reagent such as thionyl chloride or oxalyl chloride, which is then reacted with anisole in the presence of a Friedel-Crafts catalyst such as aluminum chloride to give a ketone of formula (6). The ketone of formula (6) is then subjected to dinitration using a nitrating reagent such as fuming nitric acid in acetic acid to give a compound of formula (7). The compound of formula (7) is then reduced using a reducing agent such as lithium aluminum hydride or hydrogen and a heavy metal catalyst such as Raney Ni, to give an intermediate di-amine, which undergoes an intermolecular cyclization to give an amino-indole of formula (8), which is the amine of formula (3) described immediately above wherein R′ is the substituents described above for Z of Formula I.
Further guidance and exemplification regarding the synthesis of the compounds of the present invention is provided in the chemical synthetic Examples 1 through 69 below.
The invention also includes disclosed compounds having one or more functional groups (e.g., hydroxyl, amino, or carboxyl) which may be masked by a protecting group so as to avoid unwanted side reactions. Some of these masked or protected compounds are pharmaceutically acceptable; others will be useful as intermediates. The use of protecting groups is fully described by Greene and Wuts in “Protecting Groups in Organic Synthesis” (John Wiley & Sons, 2 nd ed.).
Disclosed compounds which are masked or protected may be prodrugs, compounds metabolized or otherwise transformed in vivo to yield a disclosed compound, e.g., transiently during metabolism. This transformation may be a hydrolysis or oxidation which results from contact with a bodily fluid such as blood, or the action of acids, or liver, gastrointestinal, or other enzymes.
The invention is further described in the working examples described below. The examples are provided for illustration only, and are not to be construed as limiting the invention in any respect As shown by Examples 1 and 25 described below, compounds of Formulas Ia and Ib may be prepared by reaction of a penultimate reactive sulfonyl-carbamic acid ester derivative such as a chlorosulfonamide of formula (2) or a trialkylamino sulfonyl carbamic acid ester, which is a zwitterionic compound wherein the chloro of the compound of formula (2) has been replaced by a trialkylammonium group and the nitrogen of the carbamic acid ester has been deprotonated. These reactive sulfonyl-carbamic acid ester derivatives may optionally be prepared in situ or isolated and purified before reaction with an amine of formula (3) wherein Y′ is NH 2 .
D. EXAMPLES
Example 1
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, Dodecyl Ester
In methylene chloride (40 mL) was stirred chlorosulfonyl isocyanate (CSI) (1.56 g, 11 mmol). To this solution was added dodecanol (1.86 g, 10 mmol), in parts. The solution was stirred for 15 minutes. To this solution was added triethylamine (1.5 g, 15 mmol), and the mixture stirred an additional 15 minutes. To this was added 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (2.33 g, 8.5 mmol), and the mixture stirred at room temperature for 24 hours. The mixture was washed with water (2×100 mL), and the organic phase dried over magnesium sulfate. The solvents were evaporated at reduced pressure to give a foam. The foam was dissolved in fresh methylene chloride (40 mL), and the solution was treated with 1N hydrochloric acid (40 mL). The resulting mixture was vigorously stirred for 20 minutes and then filtered to collect the solid. The solid was stirred into acetonitrile (40 mL) and filtered to collect the solid. The solid was then washed with a mixture of water:acetonitrile (1:1) (10 mL) and dried at 65° C. to give 0.495 g of pure carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, dodecyl ester. 1 HNMR (DMSO-d 6 ) δ 0.80-0.84 (t, 3H), 1.14-1.21 (m, 18H), 1.4-1.55 (m, 2H), 3.78 (s, 3H), 4.00-4.05 (m, 2H), 6.75 (s, 1H), 7.12-7.18 (m, 1H), 7.23-7.31 (m, 1H), 7.41-7.48 (m, 1H), 7.60-7.70 (m, 2H), 9.25 (s, 1H), 11.40 (s, 1H), 11.61 (s, 1H) ppm Microanalysis: C 28 H 37 F 2 N 3 O 5 S; calculated: C=59.45; H=6.59; N=7.43. found: C=59.46; H=6.81; N=7.32. MS: M + +1=566 Da.
Example 2
Carbamic Acid, [[[5[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]-, 2-(4morpholinyl)ethyl ester
The title compound was synthesized in the same manner as Example 1 using 2-morpholinylethanol (1.30 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.270 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(4-morpholinyl)ethyl ester. 1 HNMR (DMSO-d 6 ) δ 2.6-2.75 (m, 4H), 2.75-2.85 (m, 2H), 3.55-3.61 (m, 4H), 3.84 (s, 3H), 4.12-4.23 (m, 2H), 7.12-7.15 (d, 1H), 7.36-7.44 (m, 1H), 7.50-7.53 (m, 1H), 7.72-7.75 (m, 1H), 7.88-7.94 (m, 2H), 8.6-8.8 (br. s, 1H), 10.29 (s, 1H) ppm. Microanalysis: C 21 H 24 F 2 N 4 O 7 S.0.22 H 2 O; calculated: C=45.51; H=5.17; N=10.11. found: C=45.69; H=5.01; N=10.03. MS: M + +1=515.3 Da.
Example 3
Carbamic Acid, [[(5-[[(3,4-diflu rophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(dimethylamino)propyl Ester
The title compound was synthesized in the same manner as Example 1 using 2-dimethylaminopropanol (1.03 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.505 g of pure carbamic acid, [[(5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 3-(dimethylamino) propyl ester. 1 HNMR (DMSO-d 6 ) δ 1.76-1.83 (m, 2H), 2.68 (s, 6H), 2.95-2.99 (m, 2H), 3.80-3.83 (m, 2H), 3.85 (s, 3H), 7.02-7.05 (d, 1H), 7.36-7.43 (m, 1H), 7.50-7.53 (m, 2H), 7.60-7.70 (br. S, 1H), 7.87-7.93 (m, 1H), 7.99-8.00 (m, 1H), 10.25 (s, 1H) ppm. Microanalysis: C 20 H 24 F 2 N 4 O 6 S0.25H 2 O; calculated: C=48.92; H=5.03; N=11.41. found: C=48.85; H=4.84; N=11.41. MS: M + +1=487.3 Da.
Example 4
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-suffonyl]-, 2-(1-pyrrolidinyl)ethyl ester
The title compound was synthesized in the same manner as Example 1 using 2-pyrrolidinylethanol (1.15 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.305 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, 2-(1-pyrrolidinyl)ethyl ester. 1 HNMR (DMSO-d 6 ) δ 1.79-1.9 (m, 1H), 3.11-3.38 (m, 6H), 3.86 (s, 3H), 4.00-4.05 (m, 2H), 7.03-7.05 (d, 1H), 7.36-7.43 (m, 1H), 7.50-7.65 (m, 3H), 7.87-7.93 (m, 1H), 8.00 (s, 1H), 10.26 (s, 1H) ppm Microanalysis: C 21 H 24 F 2 N 4 O 6 S.1.0H 2 O; calculated: C=48.83; H=5.07; N=10.85. found: C=49.13; H=4.90; N=10.72. MS: M + +1=499.3 Da.
Example 5
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(dimethylamino)ethyl ester
The title compound was synthesied in the same manner as Example 1 using 2dimethylaminoethanol (0.89 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluorophenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.499 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(dimethylamino)ethyl ester. 1 HNMR (DMSO-d 6 ) δ 2.68 (s, 6H), 3.17-3.32 (m, 2H), 3.87 (s, 3H), 4.05-4.10 (m, 2H), 7.04-7.06 (d, 1H), 7.36-7.50 (m, 1H), 7.52-7.58 (m, 2H), 7.55-7.65 (br. s, 1H), 7.88-7.93 (m, 1H), 8.00 (s, 1H), 10.26 (s, 1H) ppm. Microanalysis: C 19 H 22 F 2 N 4 O 6 S.0.4H 2 O; calculated: C=47.57; H=4.79; N=11.68. found: C=47.75; H=4.62; N=11.51. MS + +1=473.3 Da.
Example 6
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-phenylethyl Ester, Monopotassium Salt
To carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-phenylethyl ester (480 mg, 0.949 mmol) in acetonitrile (40 mL) was added KOH (1.90 mL of a 0.498N solution) in methanol. The mixture was stirred at room temperature for 15 minutes and evaporated in vacuo. The residue was triturated with ether (25 mL) and filtered to collect the solid which was dried at 65° C. in vacuo for 3 hours. This gave 0.490 g of the pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-phenylethyl ester, monopotassium salt. 1 HNMR (DMSO-d 6 ) δ 2.67-2.71 (m, 2H), 3.83 (s, 3H), 3.86-3.90 (m, 2H), 6.99-7.02 (d, 1H), 7.10-7.25 (m, 5H), 7.35-7.55 (m, 2H), 7.64 (s, 1H), 7.82-7.93 (m, 1H), 8.00 (s, 1H), 10.23 (s, 1H) ppm. Microanalysis: C 23 H 20 F 2 N 4 O 6 SK. 0.5H 2 O; calculated: C=49.99; H=3.83; N=7.60. found: C=49.71; H=3.82; N=7.65. MS: M + +1=506.2 Da.
Example 7
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(2-thienyl)ethyl ester
The title compound was synthesized in the same manner as Example 1 using 2-(2-hydroxyethyl)thiophene (1.28 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.955 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(2-thienyl)ethyl ester. 1 HNMR (DMSO-6) δ 3.07-3.10 (m, 2H), 3.79 (s, 3H), 4.22-4.26 (m, 2H), 6.88-6.92 (m, 2H), 7.16-7.18 (d, 1H), 7.30-7.31 (m, 1H), 7.36-7.44 (m, 1H), 7.50-7.53 (m, 1H), 7.85-7.93 (m, 3H), 9.44 (s, 1H), 10.32 (s, 1H), 11.50 (s, 1H) ppm. Microanalysis: C 21 H 19 F 2 N 3 O 6 S 2 .0.1H 2 O; calculated: C=49.13; H=3.77; N=8.19; found: C=48.87; H=3.91; N=8.10. MS: M + +1=512.2 Da.
Example 8
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(ethylsulfonyl)ethyl ester
The title compound was synthesized in the same manner as Example 1 using 2-ethanesulfonyletanol (1.38 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol), to give 2.05 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(ethylsulfonyl)ethyl ester. 1 HNMR (DMSO-d 6 ) δ 1.13-1.17 (m, 3H), 3.08-3.13 (m, 2H), 3.40-3.50 (m, 2H), 3.84 (s, 3H), 4.38-4.41 (m, 2H), 7.19-7.21 (d, 1H), 7.37-7.51 (m, 2H), 7.89-7.94 (m, 3H), 9.60 (s, 1H), 10.33 (s, 1H), 11.59 (s, 1H) ppm. Microanalysis: C 19 H 21 F 2 N 3 O 8 S 2 .0.15H 2 O; calculated: C=43.53; H=4.10; N=8.02; found: C=43.50; H=4.09; N=8.01. MS: M + +1=522.2 Da.
Example 9
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-bromopropyl ester
The title compound was synthesized in the same manner as Example 1 using 3-bromopropanol (1.39 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.495 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-bromopropyl ester. 1 HNMR (DMSO-d 6 ) δ 2.06-2.13 (m, 2H), 3.51-3.54 (m, 2H), 3.84 (s, 3H), 4.14-4.17 (m, 2H), 7.18-7.21 (d, 1H), 7.37-7.53 (m, 2H), 7.86-7.94 (m, 3H), 9.53 (s, 1H), 10.32 (s, 1H), 11.40 (s, 1H) ppm. Microanalysis: C 18 H 18 F 2 BrN 3 O 6 S; calculated: C=41.39; H=3.47; N=8.04. found: C=41.60; H=3.44; N=7.99. MS: M + +1=524.2 Da.
Example 10
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-[[(phenylmethoxy)carbonyl]amino]ethyl ester
The title compound was synthesized in the same manner as Example 1 using (2-hydroxyethyl)carbamic acid benzylester (1.95 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.639 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-[[(phenylmethoxy)carbonyl]amino]ethyl ester. 1 HNMR (DMSO-d 6 ) δ 3.26-3.33 (m, 2H), 3.81 (s, 3H), 4.07-4.09 (m, 2H), 4.98 (s, 2H), 7.16-7.18 (d, 1H), 7.28-7.44 (m, 7H), 7.50-7.53 (m, 1H), 7.86-7.94 (m, 3H), 9.45 (s, 1H), 10.32 (s, 1H), 11.40 (s, 1H) ppm. Microanalysis: C 25 H 24 F 2 N 4 O 8 S. 0.2 H 2 O; calculated: C=51.53; H=4.22; N=9.62. found: C=51.15; H=4.08; N=9.51. MS: M + +1=579.3 Da.
Example 11
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(3-thienyl)ethyl ester
The title compound was synthesized in the same manner as Example 1 using 3-(2-hydroxyethyl)thiophene (1.28 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.95 g, 7.0 mmol) to give 0.360 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(3-thienyl)ethyl ester. 1 HNMR (DMSO-d 6 ) δ 2.87-2.91 (m, 2H), 3.80 (s, 3H), 4.22-4.25 (m, 2H), 7.01-7.02 (d, 1H), 7.17-7.20 (m, 2H), 7.37-7.44 (m, 2H), 7.51-7.57 (m, 1H), 7.87-7.95 (m, 3H), 9.45 (s, 1H), 10.33 (s, 1H), 11.46 (s, 1H) ppm. Microanalysis: C 21 H 19 F 2 N 3 O 6 S 2 ; calculated: C=49.31; H=3.74; N=8.21. found: C=48.91; H=3.76; N=8.09. MS: M + +1=512.2 Da.
Example 12
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-octyl ester
The title compound was synthesized in the same manner as Example 1 using n-octanol (1.30 g, 10.0 mmol), CSI (1.56 g, 11.0 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (2.33 g, 8.5 mmol) to give 0.935 g of pure carbamic acid, [[[5-(5,6-difluoro-1-H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-octyl ester. 1 HNMR (DMSO-d 6 ) δ 0.77-0.81 (m, 3H), 1.14-1.25 (m, 10H), 1.47-1.55 (m, 2H), 3.78 (s, 3H), 4.00-4.04 (m, 2H), 6.72 (s, 1H), 7.12-7.14 (d, 1H), 7.25-7.30 (m, 1H), 7.74-7.46 (m, 1H), 7.61-7.67 (m, 2H), 9.27 (s, 1H), 11.38 (s, 1H), 11.62 (s, 1H) ppm. Microanalysis: C 24 H 29 F 2 N 3 O 5 S; calculated: C=56.57; H=5.74; N=8.25. found: C=56.17; H=5.56; N=8.22. MS: M + +1=510.3 Da.
Example 13
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]methyl-, 3(phenylmethoxy)propyl ester
To carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-3-(phenylmethoxy)propyl ester (0.70 g, 1.28 mmol) in THF (12 mL) was added sequentially, DBU (0.198 g, 1.3 mmol), and then methyl iodide (0.185 g, 1.3 mmol). The mixture stirred overnight at room temperature. The solution was diluted with methylene chloride (75 mL) and washed with water (75 mL). The organic phase dried over magnesium sulfate and then evaporated in vacuo to give the crude compound. This was purified by flash chromatography over silica gel (9:1, methylene chloride:ethyl acetate). The appropriate factions were combined and evaporated in vacuo to give 0.380 g of pure carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]methyl-, 3-(phenylmethoxy)propyl ester. 1 HNMR (DMSO-d 6 ) δ 1.78-1.87 (m, 2H), 2.97 (s, 3H), 3.38-3.48 (m, 2H), 3.76 (s, 3H), 4.15-4.18 (m, 2H), 4.36 (s, 2H), 6.75 (s, 1H), 7.12-7.14 (d, 1H), 7.20-7.35 (m, 6H), 7.42-7.47 (m, 1H), 7.68-7.75 (m, 2H), 9.69 (s, 1H), 11.67 (s, 1H) ppm. Microanalysis: C 27 H 27 F 2 N 3 O 6 S; calculated: C=57.95; H=4.86; N=7.53. found: C=57.99; H=4.94; N=7.33. MS: M + +1=560.3 Da.
Example 14
Carbamic Acid, [[(5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-(phenylmethyl), 3-(phenylmethoxy)propyl ester
The title compound was synthesized in the same manner as Example 13 using carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-3-(phenylmethoxy)propyl ester (0.640 g, 1.17 mmol), benzyl bromide (0.205 g, 1.2 mmol), and DBU (0.183 g, 1.2 mmol) to give 0.215 g of pure carbamic acid, [[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]phenylmethyl)-, 3-(phenylmethoxy)propyl ester. 1 HNMR (DMSO-d 6 ) δ 1.81-1.85 (m, 2H), 3.35-3.39 (m, 2H), 3.71 (s, 3H), 4.19-4.22 (m, 2H), 4.33 (s, 2H), 4.60 (s, 2H), 6.74 (s, 1H), 7.06-7.33 (m, 12H), 7.42-7.47 (m, 1H), 7.67-7.71 (m, 2H), 9.75 (s, 1H), 11.66 (s, 1H) ppm. Microanalysis: C 33 H 31 F 2 N 3 O 6 S; calculated: C=62.35; H=4.92; N=6.61. found: C=62.26; H=5.00; N=6.27. MS: M + +1=636.3 Da.
Example 15
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-2-(dimethylamino)ethyl ester, Monohydrochloride
The title compound was synthesized in the same manner as Example 1 using 2-dimethylaminoethanol (0.802 g, 9.0 mmol), CSI (1.27 g, 9.0 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.91 g, 7.0 mmol) to give 0.395 g of pure carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-2-(dimethylamino)ethyl ester, monohydrochloride. 1 HNMR DMSO-d 6 ) δ 2.71 (s, 6H), 3.20-3.40 (m, 2H), 3.80 (s, 3H), 420-4.35 (br. s, 2H), 6.66 (s, 1H), 7.08-7.10 (d, 1H), 7.26-7.30 (m, 1H), 7.44-7.52 (m, 2H), 7.77 (s, 1H), 11.63 (s, 1H) ppm. Microanalysis: C 20 H 22 F 2 N 4 O 5 S.0.25HCl.0.25 H 2 O; calculated: C=48.45; H=4.78; N=11.30. found: C=48.30; H=4.65; N=11.08. MS: M + +1=469.3 Da.
Example 16
Acetic Acid, [[[[[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]amino]carbonyl]oxy]-, phenylmethyl ester
The title compound was synthesized in the same manner as Example 1 using benzyl-2-hydroxyacetate (1.50 g, 9.0 mmol), CSI (1.27 g, 9.0 mmol), and 5(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.91 g, 7.0 mmol) to give 1.2 g of pure acetic acid, [[[[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]amino]carbonyl]oxy]-, phenylmethyl ester. 1 HNMR (DMSO-d 6 ) δ 3.75 (s, 3H), 4.77 (s, 2H), 5.16 (s, 2H), 6.76 (s, 1H), 7.12-7.14 (m, 1H), 7.26-7.33 (m, 6H), 7.42-7.47 (m, 1H), 7.64-7.7 (m, 2H), 9.51 (s, 1H), 11.61 (s, 1H), 11.77 (s, 1H) ppm. Microanalysis: C 25 H 21 F 2 N 3 O 7 S; calculated: C=55.04; H=3.88; N=7.70. found: C=54.73; H=3.82; N=7.55. MS: M + +1=546.2 Da.
Example 17
Benzamide, 3-[[[[[(3,5-dichlorophenyl)amino]-carbonyl]amino]sulfonyl]-amino]-N-(3,4-difluorophenyl)-4-methoxy
The title compound was synthesized in the same manner as Example 1 using 3,5-dichloroaniline (1.0 g, 6.2 mmol), CSI (0.64 mL, 4.4 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.24 g, 7.0 mmol) to give 0.05 g of pure benzamide, 3-[[[[[(3,5-dichlorophenyl)amino]-carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-. Microanalysis: C 21 H 16 Cl 2 F 2 N 4 O 5 S; calculated: C=46.25; H=2.96; N=10.27; found: C=46.30; H=3.32; N=9.93. MS: M + +1=544.9 Da.
Example 18
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)carbonyl]-amino]sulfonyl]amino]
The title compound was synthesized in the same manner as Example 1 using aniline (0.59 g, 6.4 mmol), CSI (0.67 mL, 7.7 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.19 g, 4.3 mmol) to give 0.17 g of pure benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)carbonyl]amino]sulfonyl]amino]-. Microanalysis: C 21 H 18 F 2 N 4 O 5 S; calculated: C=52.94; H=3.81; N=11.76. found: C=52.70; H=4.04; N=11.51. MS: M + +1=477 Da.
Example 19
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, Ethyl Ester
The title compound was synthesized in the same manner as Example 1 using ethanol (0.52 g, 11.3 mmol), CSI (1.08 mL, 12.4 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.1 g, 4.0 mmol) to give 0.65 g of pure carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, ethyl ester. Microanalysis: C 17 H 17 F 2 N 3 O 6 S; calculated: C=47.55; H=3.99; N=9.79. found: C=47.66; H=3.88; N=9.42. MS: M + +1=430 Da.
Example 20
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)-amino]sulfonyl]amino]carbonyl]amino]
3-Amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (3.0 g, 10.8 mmol) was dissolved in 200 mL dichloromethane and added dropwise to a solution of CSI (1.15 mL, 12.9 mmol) in 50 mL of dichloromethane at 0° C. The resulting white suspension was stirred for 1 hour and then filtered to give 2.94 g of a chlorosulfonyl urea intermediate. This intermediate (1.4 g, 3.5 mmol) was added in portions to a solution of p-anisidine (0.43 g, 3.5 mmol) in 50 mL acetone with triethylamine (1.94 mL, 13.9 mmol). The resulting mixture was stirred for 16 hours at room temperature. The reaction mixture was concentrated in vacuo, and the residue was partitioned between ethyl acetate and 1 M HCl. The ethyl acetate layer was dried over magnesium sulfate, filtered, and concentrated to give a pale pink oily solid. Recrystallization from dichloromethane gave 0.55 g of pure benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)amino]-sulfonyl]amino]carbonyl]amino]-. Microanalysis: C 22 H 20 F 2 N 4 O 6 S; calculated: C=52.17; H=3.98; N=11.06. found: C=52.20; H=4.06; N=10.98. MS: M + +1=507 Da.
Example 21
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, Butyl Ester
To a cold solution of chlorosulfonylisocyanate (3.1 g, 0.022 mol) in dichloromethane (20 mL) was added dropwise a solution of n-butanol (1.5 g, 0.020 mol) in dichloromethane (5 mL). The solution gradually warmed to room temperature and was stirred overnight. The solvent was concentrated in vacuo leaving a viscous liquid. The crude product was triturated with hexane/ethyl acetate (4:1) and concentrated to give the sulfamoyl chloride intermediate as a white solid. The solid was suspended in hexane and collected by filtration. Yield: 3.4 g, (87%) of chlorosulfonyl-carbamic acid, n-butyl ester, which was used without further characterization.
A solution of the chlorosulfonyl carbamic acid, n-butyl ester (3.4 g, 0.018 mol) in benzene (25 mL) was added dropwise at room temperature to a stirred solution of triethylamine (4.5 g, 0.044 mol) in benzene (25 mL). The reaction mixture was stirred overnight, filtered, and the filtrate was concentrated in vacuo to give a viscous liquid. A portion of the liquid obtained (0.5 g, 1.78 mmol) was diluted with benzene (50 mL) and treated with 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (0.48 g, 1.78 mmol) in one portion. The reaction mixture was stirred at room temperature overnight, at which time it was diluted with aqueous HCl (25 mL) and ethyl acetate (50 mL). The organic phase was separated and washed with brine, dried (MgSO 4 ), and concentrated. The resulting residue was recrystallization from hexane/ethyl acetate to give 0.12 g (15%) of carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl)-amino]sulfonyl]-, butyl ester. Mp 193-194° C.; 1 HNMR (CDCl 3 /DMSO-d 6 ) δ 11.1 (s, 1H), 9.3 ((s, 1H), 7.9 (s, 1H), 7.7-7.6 (m, 3H), 7.3 (m, 1H), 7.1 (m, 1H), 6.9 (d, 1H), 3.9 (s, 3H), 3.8 (d, 2H), 1.8 (m, 1H), 0.8 (m, 6H) ppm. Microanalysis: C 19 H 22 F 2 N 3 O 6 S; calculated: C=49.78; H=4.84; N=9.17. found: C=49.88; H=4.53; N=9.16. MS:M + +1=457 Da.
Example 22
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, 2-methylpropyl ester
The title compound was synthesized in the same manner as Example 1 using isobutanol (1.5 g 0.020 mol) to give 0.15 g (18%) of pure carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, 2-methylpropyl ester, which was isolated as a cream colored solid. Mp 187-189° C.; 1 HNMR (CDCl 3 /DMSO-d 6 ) δ 11.0 (s, 1H), 10.4 (s, 1H), 7.7 (s, 1H), 7.6 (s, 1H), 7.4 (d, 1H), 7.3 (m, 1H), 7.1, (m, 1H), 6.9 (d, 1H), 6.6 (s, 1H), 3.8 (s, 3H), 3.78 (d, 2H), 1.8, (m, 1H), 0.7 (d, 6H) ppm. Microanalysis: C 20 H 21 F 2 N 3 O 5 S; calculated: C=52.97; H=4.67; N=9.27. found: C=52.64; H=4.57; N=9.10. MS: M + +1=453 Da.
Example 23
Carbamic Acid, [[(5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-methylpropyl ester
The title compound was prepared by replacing 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine with 3-amino-N-(2,4-difluorophenyl)-4-methoxy-benzamide (0.49 g, 1.78 mmol) in the procedure used in Example 22 to give 0.17 g (21%) of pure carbamic acid, [[(5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-methylpropyl ester as a white powder. Mp 188-190° C.; 1 HNMR (CDCl 3 /DMSO-d 6 ) δ 10.9 (s, 1H), 10.3 (s, 1H), 7.7 (s, 1H), 7.6 (s, 1H), 7.4 (d, 1H), 7.3 (m, 1H), 7.1 (m, 1H), 6.9 (d, 1H), 6.6 (s, 1H), 4.1 (t, 2H), 3.9 (s, 3H), 1.5 (m, 2H), 1.2 (m, 2H), 0.8 (t, 3H) ppm. Microanalysis: C 20 H 21 F 2 N 3 O 5 S.0.38H 2 O; calculated: C=52.19; H=4.76; N=9.13. found: C=52.18; H=4.80; N=8.96. MS: M + +1=457 Da.
Example 24
Urea, N-(3,5-dichlorophenyl)-]-N′-[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]
Urea, N-(3,5-dichlorophenyl)-]-N′-[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl] was synthesized in the same manner as Example 1 using 3,5-dichloroaniline (2.0 g, 12.3 mmol), CSI (1.28 mL, 14.8 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.3 mmol); Microanalysis: C 22 H 16 Cl 2 F 2 N 4 O 4 S.2.0H 2 O; calculated: C=45.77; H=3.49; N=9.70. found: C=45.79; H=3.08; N=9.68. MS: M + =541 Da.
Example 25
Carbamic Acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, ethyl ester
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, ethyl ester was synthesized in the same manner as Example 1 using 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (0.5 g, 1.8 mmol) and Et 3 NSO 2 NCO 2 Et (0.46 g, 1.8 mmol); Microanalysis: C 18 H 17 F 2 N 3 O 5 S.C 4 H 8 O 2 ; calculated: C=51.46; H=4.91; N=8.18; found: C=51.86; H=4.57; N=8.58. MS: M + +1=426.1 Da.
Example 26
Carbamic Acid, [[[5-(IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, Ethyl Ester
Carbamic acid, [[[5-(IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, ethyl ester was synthesized in the same manner as Example 1 using 5-(1H-indol-2-yl)-2-methoxy-phenylamine (0.87 g, 3.64 mmol) and Et 3 NSO 2 NCO 2 Et (0.92 g, 3.64 mmol); Microanalysis: C 18 H 19 N 3 O 5 S; calculated: C=55.52; H=4.92; N=10.79. found: C=55.30; H=5.04; N=10.39. MS: M + +1=390.1 Da.
Example 27
Urea, N-(4-chlor phenyl)-N′-[[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]
Urea, N-(4-chlorophenyl)-N′-[[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl] was synthesized in the same manner as Example 1 using 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (0.41 g, 1.5 mmol) and (4-chlorophenyl)NHCONHSO 2 Cl (0.4 g, 1.5 mmol); Microanalysis: C 22 H 17 Cl 2 F 2 N 4 O 4 S.0.5 H 2 O; calculated: C=52.19; H=4.76; N=9.13. found: C=52.18; H=4.80; N=8.96. MS: M + +1=507 Da.
Example 28
Urea, N-[[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-N′-(4-methylphenyl)
Urea, N-[[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-N′-(4-methylphenyl) was synthesized in the same manner as Example 1 using 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (0.33 g, 1.2 mmol) and (4-methylphenyl)NHCONHSO 2 Cl (0.3 g, 1.2 mmol); Microanalysis: C 23 H 20 F 2 N 4 O 4 S.1.75 H 2 O; calculated: C=53.33; H=4.57; N=10.82. found: C=53.41; H=4.16; N=10.42. MS: M + +1=487 Da.
Example 29
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-methyl ester
Carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-methyl ester was synthesized in the same manner as Example 1 using 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine and Et 3 NSO 2 NCO 2 Me; Microanalysis: C 20 H 21 F 2 N 3 O 5 S.0.38 H 2 O; calculated: C=52.19; H=4.76; N=9.13. found: C=52.18; H=4.80; N=8.96. MS: M + +1=457 Da.
Example 30
Carbamic Acid, [[[5-(5,6-difluoro-IH-indo-2-yl)2-methoxyphenyl]amino]-sulfonyl]-heptyl ester
The title compound was synthesized as in Example 1 using heptyl alcohol (1.3 mL, 8.9 mmol), CSI (0.85 mL, 9.8 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (2.4 g, 8.9 mmol) to give 2.9 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-heptyl ester. Microanalysis: C 23 H 27 F 2 N 3 O 5 S; calculated: C=55.75; H=5.49; N=8.48; found: C=55.64; H=5.61; N=8.41. MS: M + +1=496 Da. Mp 178-180° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.63 (s, 1H), 11.38 (s, 1H), 9.27 (s, 1H), 7.67 (d, J=1.9 Hz, 1H), 7.62 (d, J=8.7 Hz, 1H), 7.49-7.44 (m, 1H), 7.30-7.26 (m, 1H), 7.13 (d, J=8.4 Hz, 1H), 6.72 (s, 1H), 4.02 (t, J=6.5 Hz, 2H), 3.78 (s, 3H), 1.17-1.13 (m, 10H), 0.78 (t, J=6.5 Hz, 3H).
Example 31
Carbamic Acid, [[[5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-pentyl ester
The title compound was synthesized as in Example 1 using pentyl alcohol (0.97 mL, 8.9 mmol), CSI (0.85 mL, 9.8 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (2.4 g, 8.9 mmol), to give 2.9 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl)-pentyl ester. Microanalysis: C 21 H 23 F 2 N 3 O 5 S; calculated: C=53.95; H=4.96; N=8.99; found: C=53.86; H=5.06; N=8.95. MS: M + +1=468 Da. Mp 182-184° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.63 (s, 1H), 11.38 (s, 1H), 9.27 (s, 1H), 7.68 (s, 1H), 7.62 (d, J=8.4 Hz, 1H), 7.49-7.44 (m, 1H), 7.30-7.26 (m, 1H), 7.14 (d, J=8.7 Hz, 1H), 6.72 (s, 1H), 4.03 (t, J=6.8 Hz, 2H), 3.78 (s, 3H), 1.20-1.13 (m, 6H), 0.78 (t, J=6.5 Hz, 3H).
Example 32
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-(2E)-3-phenyl-2-propenyl ester
The title compound was synthesized as in Example 1 using cinnamyl alcohol (0.99 g, 7.3 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.51 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-(2E)-3-phenyl-2-propenyl ester. Microanalysis: C 25 H 21 F 2 N 3 O 5 S; calculated: C=58.47; H=4.12; N=8.18. found: C=58.59; H=4.09; N=8.20. MS: M + +1=514 Da. Mp 149-152° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.66 (s, 1H), 11.51 (s, 1H), 9.44 (s, 1H), 7.71 (s, 1H), 7.66-7.64 (m, 1H), 7.46-7.13 (m, 8H), 6.75-6.65 (m, 2H), 6.37-6.30 (m, 1H), 4.77 (d, J=6.1 Hz, 2H), 3.78 (s, 3H).
Example 33
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, (2E)-3-phenyl-2-propenyl ester
The title compound was synthesized as in Example 1 using cinnamyl alcohol (0.99 g, 7.3 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluorophenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.55 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, (2E)-3-phenyl-2-propenyl ester. Microanalysis: C 24 H 21 F 2 N 3 O 6 S.0.18 C 6 H 16 NCl; calculated: C=55.55; H=4.44; N=8.21; found: C=55.32; H=4.16; N=8.30. MS: M + −1=516 Da. Mp 159-163° C. 1 HMR (400 MHz, DMSO) δ 11.49 (s, 1H), 10.34 (s, 1H), 9.53 (s, 1H), 7.93-7.87 (m, 3H), 7.54-7.16 (m, 8H), 6.70-6.66 (m, 1H), 6.38-6.31 (m, 1H), 4.76-4.75 (d, J=5.8 Hz, 2H), 3.82 (s, 3H).
Example 34
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-2(1-methylethoxy)ethyl Ester
The title compound was synthesized as in Example 1 using 2-isopropoxyethanol (0.47 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.67 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-2-(1-methylethoxy)ethyl ester. Microanalysis: C 21 H 23 F 2 N 3 O 6 S.0.3 C 6 H 16 NCl.0.41H 2 O; calculated: C=51.46; H=5.42; N=8.69. found: C=51.45; H=5.18; N=8.85. MS: M + +1=484 Da. Mp 158-163° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.64 (s, 1H), 11.53 (s, 1H), 9.27 (s, 1H), 7.71 (s,1H), 7.62 (d, J=7.7 Hz, 1H), 7.50-7.46 (m, 1H), 7.32-7.28 (m, 1H), 7.14 (d, J=8.4 Hz, 1H), 6.74 (s, 1H), 4.13 (s, 2H), 3.80 (s, 3H), 3.52-3.47 (m, 3H), 1.00 (d, J=6.0 Hz, 6H).
Example 35
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(1-methylethoxy)ethyl ester
The title compound was synthesized as in Example 1 using 2-isopropoxyethanol (0.47 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.76 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(1-methylethoxy)ethyl ester. Microanalysis: C 20 H 23 F 2 N 3 O 7 S; calculated: C=49.28; H=4.76; N=8.62; found: C=49.08; H=4.66; N=8.43. MS: M + +1=488 Da. 1 HNMR (400 M DMSO-d 6 )δ 11.50 (s, 1H), 10.33 (s, 1H), 9.42 (s, 1H), 7.95-7.86 (m, 3H), 7.54-7.52 (m, 1H), 7.45-7.38 (m, 1H), 7.19 (d, J=8.7 Hz, 1H), 4.16-4.14 (m, 2H), 3.84 (s, 3H), 3.56-3.50 (m, 3H), 1.03 (d, J=6.0 Hz, 6H).
Example 36
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-methoxyphenyl]amino]-sulfonyl]-, Phenylmethyl ester
The title compound was synthesized as in Example 1 using benzyl alcohol (0.44 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.56 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, phenylmethyl ester. Microanalysis: C 23 H 19 F 2 N 3 O 5 S; calculated: C=56.67; H=3.93; N=8.62. found: C=56.29; H=3.76; N=8.41. MS: M + +1=488 Da. Mp 177-180° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.65 (s, 1H), 11.54 (s, 1H), 9.41 (s, 1H), 7.70 (s, 1H), 7.65 (d, J=8.7 Hz, 1H), 7.49-7.44 (m, 1H), 7.32-7.27 (m, 6H), 7.14 (d, J=8.4 Hz, 1H), 6.72 (s, 1H), 5.15 (s, 2H), 3.73 (s, 3H).
Example 37
Sulfamide, N-[5-(5,6-diflouo-IH-indo-2-yl)-2-methoxyphenyl]-N′-methyl
Methyl sulfamic acid (2.0 g, 18.0 mmol) was suspended in benzene, and phosphorous pentachloride (3.7 g, 18.0 mmol) was added The mixture was refluxed for 3 hours. The supernatant was decanted into a separate flask, leaving any solid behind. The benzene was removed by distillation, and the remaining oil, methyl sulfamyl chloride, was stored under nitrogen. Methyl sulfamyl chloride (0.80 g, 6.2 mmol) was dissolved in 50 mL of methylene chloride, and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) and triethylamine (1.0 mL, 7.2 mmol) were added. The solution was stirred overnight The resulting mixture was washed with water (2×50 mL), and the organic phase was dried over magnesium sulfate. The solvents were evaporated under reduced pressure to give a foam. The foam was redissolved in a small amount of fresh methylene chloride and treated with 1N hydrochloric acid. (20 mL). Vigorous shaking produced a precipitate, which was collected via filtration. The resulting powder was triturated sequentially with water, methylene chloride, and ether. The triturated solid was dried under vacuum to give 0.26 g of sulfamide, N-[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-N′-methyl-. Microanalysis: C 15 H 15 F 2 N 3 O 4 S.0.15 CH 2 Cl 2 .0.08 C 6 H 16 NCl; calculated: C=51.07; H=4.27; N=11.03. found: C=51.13; H=4.26; N=10.83. MS: M + +1=368 Da. Mp 196-200° C. 1 HNMR (400 Mz, DMSO-d 6 ) δ 11.59 (s, 1H), 8.55 (s, 1H), 7.70 (s,1H), 7.55-7.45 (m, 1H), 7.32-7.28 (m, 1H), 7.18 (d, J=4.3 Hz, 1H), 7.15 (d, J=8.7 Hz, 1H), 6.73 (s, 1H), 3.84 (s, 3H), 2.53 (s, 3H).
Example 38
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[(methylamino)-sulfonyl]amino]
The title compound was synthesized as in Example 37 using methyl sulfonyl chloride (0.8 g, 6.2 mmol) and 3-amino-N-(3,4-difluoro-phenyl)-4methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.48 g of benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[(methylamino) sulfonyl]amino]-. Microanalysis: C 15 H 15 F 2 N 3 O 4 S. 0.04 CH 2 Cl 2 .0.91H 2 O; calculated: C=46.18; H=4.35; N=10.74. found: C=46.18; H=4.36; N=10.64. MS: M + +1=372 Da. 1 HNMR (400 MHz, DMSO-d 6 ) δ 10.26 (s, 1H), 8.60 (s, 1H), 7.93-7.88 (m, 2H), 7.74 (d, 8.4 Hz, 1H), 7.52-7.50 (m, 1H), 7.36 (q, J=9.4, 10.4 Hz, 1H), 7.13 (d, J=8.7 Hz, 2H), 3.88 (s, 3H), 2.49 (s, 3H).
Example 39
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(4-pyridinyl)propyl ester
The title compound was synthesized as in Example 1 using 3-(4-pyridyl)-1-propanol (0.55 g, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.08 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(4-pyridinyl)propyl ester. Microanalysis: C 23 H 22 F 2 N 4 O 6 S.0.08 C 6 H 16 NCl.0.48 H 2 O; calculated: C=52.21; H=4.52; N=10.58. found: C=52.20; H=4.53; N=10.30. MS: M + +1=521 Da. Mp 160-164° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.33 (s, 1H), 10.15 (s, 1H), 8.48 (s, 1H), 7.91-7.86 (m, 3H), 7.50-7.17 (m, 6H), 4.05 (t, J=6.5 Hz, 2H), 3.81 (s, 3H), 2.65 (t, J=7.2 Hz, 2H), 1.89 (t, J=6.5 Hz, 2H).
Example 40
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-2-phenylethyl ester
The title compound was synthesized as in Example 1 using phenethyl alcohol (0.48 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.75 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-2-phenylethyl ester. Microanalysis: C 24 H 21 F 2 N 3 O 5 S.0.1 C 6 H 16 NCl.0.17 H 2 O; calculated: C=57.00; H=4.46; N=8.33. found: C=57.00; H=4.33; N=8.27. MS: M + +1=502 Da. Mp 180-182° C. 1 HNMR (400 Mz, DMSO-d 6 ) δ 11.65 (s, 1H), 11.47 (s, 1H), 9.30 (s, 1H), 7.70 (s, 1H), 7.65 (d, J=8.4 Hz, 1H), 7.50-7.45 (m, 1H), 7.32-7.27 (m, 1H), 7.24-7.12 (m, 6H), 6.74 (s, 1H), 4.24 (t, J=7.0 Hz, 2H ), 3.74 (s, 3H), 2.85 (t, J=7.0 Hz, 2H).
Example 41
Carbamic Acid, [[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-phenylethyl ester
The title compound was synthesized as in Example 1 using phenethyl alcohol (0.48 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 1.16 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]-, 2-phenylethyl ester. Microanalysis: C 23 H 21 F 2 N 3 O 6 S.0.2 C 6 H 16 NCl.0.14 H 2 O; calculated: C=54.27; H=4.61; N=837. found: C=54.27; H=4.33; N=8.21. MS: M + +1=506 Da. Mp 173-177° C. 1HNMR (400 MHz, DMSO-d 6 ) δ 11.45 (s, 1H), 10.34 (s, 1H), 9.41 (s, 1H), 7.94-7.87 (m, 3H), 7.54-7.51 (m, 1H), 7.43-7.36 (q, J=9.2, 10.1 Hz, 1H), 7.26-7.16 (m, 6H), 4.24 (t, J=6.8 Hz, 2H), 3.78 (s, 3H), 2.86 (t, J=6.8 Hz, 2H).
Example 42
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, Phenylmethyl Ester
The title compound was synthesized as in Example 1 using benzyl alcohol (0.44 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluorophenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 1.0 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, phenylmethyl ester. Microanalysis: C 22 H 19 F 2 N 3 O 6 S; calculated: C=53.77; H=3.90; N=8.55. found: C=53.49; H=3.83; N=8.63. MS: M + +1=492 Da. Mp 173-176° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.53 (s, 1H), 10.33 (s, 1H), 9.53 (s, 1H), 7.95-7.86 (m, 3H), 7.54-7.51 (m, 1H), 7.44-730 (m, 6H), 7.18 (d, J=8.7 Hz, 1H), 5.15 (s, 2H), 3.77 (s, 3H).
Example 43
Acetic Acid, [[[[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]amino]carbonyl]oxy]-, Methyl ester
The title compound was synthesized as in Example 1 using methyl glycolate (0.36 g, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.28 g of acetic acid, [[[[[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]amino]carbonyl]oxy]-, methyl ester. Microanalysis: C 19 H 17 F 2 N 3 O 7 S.0.55 C 4 H 8 O 2 .0.12 H 2 O; calculated: C=48.95; H=3.96; N=8.07. found: C=48.95; H=3.92; N=8.07. MS: M + +1=470 Da. Mp 190-192° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.76 (s, 1H), 11.62 (s, 1H), 9.49 (s, 1H), 7.70 (s, 1H), 7.66 (d, J=8.7 Hz, 1H), 7.50-7.45 (m, 1H), 7.32-7.27 (m, 1H), 7.15 (d, J=8.4 Hz, 1H), 6.77 (s, 1H), 4.72 (s, 2H), 3.79 (s, 3H), 3.65 (s, 3H).
Example 44
Acetic Acid, [[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]amino]carbonyl]oxy]-, Methyl ester
The title compound was synthesized as in Example 1 using methyl glycolate (0.36 g, 4.0 mmol), CSI (0.42 mL 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.55 g of acetic acid, [[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]amino]carbonyl]oxy]-, methyl ester. Microanalysis: C 18 H 17 F 2 N 3 O 8 S; calculated: C=45.67; H=3.62; N=8.88; found: C=45.43; H=3.46; N=8.95. MS: M + +1=474 Da. Mp 177-180° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.76 (s, 1H), 10.31 (s, 1H), 9.58 (s, 1H), 7.94-7.86 (m, 3H), 7.53-7.51 (m, 1H), 7.40 (q, J=10.4, 9.2 Hz, 1H), 7.19 (d, J=8.7 Hz, 1H), 4.70 (s, 2H), 3.83 (s, 3H), 3.65 (s, 3H).
Example 45
Carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-3-hydroxypropyl ester
Carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-3-(phenylmethoxy)propyl ester (0.25 g, 0.5 mmol) and a catalytic amount of 20% palladium on carbon were stirred together in methanol under an atmosphere of hydrogen. After 1.5 hours, the methanol mixture was filtered through Celite, and the filtrate was concentrated under reduced pressure to give a clear oil. The oil was triturated with diethyl ether, resulting in a precipitate of 0.11 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl-2-methoxyphenyl]amino]sulfonyl]-3-hydroxypropyl ester. Microanalysis: C 19 H 19 F 2 N 3 O 6 S; calculated: C=50.11; H=4.21; N=9.23. found: C=49.71; H=4.26; N=8.90. MS: M + +1=456 Da. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.64 (s, 1H), 11.36 (s, 1H), 9.32 (s, 1H), 7.69 (s, 1H), 7.65 (d, J=8.7 Hz, 1H), 7.50-7.46 (m, 1H), 7.32-7.27 (m, 1H), 7.15 (d, J=8.4 Hz, 1H), 6.73 (s, 1H); 4.52 (s, 1H), 4.13 (t, J=6.5 Hz, 2H), 3.79 (s, 3H), 3.43 (t, J=6.0 Hz, 2H), 1.73-1.67(m, 2H).
Example 46
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-hydroxypropyl ester
The title compound was synthesized as in Example 45 using carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(phenylmethoxy)propyl ester (0.25 g, 0.40 mmol) to give 0.18 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]-, 3-hydroxypropyl ester. Microanalysis: C 18 H 19 F 2 N 3 O 7 S; calculated: C=47.06; H=4.17; N=9.15. found: C=46.79; H=4.16; N=9.04. MS: M + +1=460 Da. Mp 178-179° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.34 (s, 1H), 10.32 (s, 1H), 9.42 (s, 1H), 7.94-7.85 (m, 3H), 7.52-7.51 (m, 1H), 7.40 (q, J=9.2, 9.4 Hz, 1H), 7.18 (d, J=8.7 Hz, 1H), 4.51 (s, 1H), 4.11 (t, J=6.5 Hz, 2H), 3.83 (s, 3H), 3.42 (t, J=6.0 Hz, 2H), 1.72-1.66 (m, 2H).
Example 47
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-, 2-ethoxyethyl ester
The title compound was synthesized as in Example 1 using 2-ethoxyethanol (0.40 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.43 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, 2-ethoxyethyl ester. Microanalysis: C 20 H 21 F 2 N 3 O 6 S; calculated: C=51.17; H=4.51; N=8.95. found: C=51.18; H=4.55; N=8.81. MS: M + +1=470 Da. Mp 178-181C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.65 (s, 1H), 11.53 (s, 1H), 9.32 (s, 1H), 7.71 (s, 1H), 7.65 (d, J=8.4 Hz, 1H), 7.51-7.47 (m, 1H), 733-729 (m, 1H), 7.16 (d, J=8.4 Hz, 1H), 6.75 (s, 1H), 4.20-4.18 (m, 2H), 3.81 (s, 3H), 3.55-3.53 (m, 2H), 3.40-3.37 (m, 2H), 1.06-1.02 (m, 3H).
Example 48
Carbamic Acid, [[[5[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-ethoxyethyl ester
The title compound was synthesized as in Example 1 using 2-ethoxyethanol (0.40 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.95 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]-amino]sulfonyl]-, 2-ethoxyethyl ester. Microanalysis: C 19 H 21 F 2 N 3 O 7 S; calculated: C=48.20; H=4.47; N=8.88. found. C=48.29; H=4.48; N=8.80. MS: M + +1=474 Da. Mp 179-182° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.51 (s, 1H), 10.34 (s, 1H), 9.44 (s, 1H), 7.96-7.87 (m, 3H), 7.54-7.52 (m, 1H), 7.42 (q, J=10.1, 9.2 Hz, 1H), 720 (d, J=8.4 Hz, 1H), 4.18 (t, J=43 Hz, 2H), 3.85 (s, 3H), 3.54 (t, J=4.6 Hz, 2H), 3.41 (q, J=7.0 Hz, 2H), 1.06 (t, J=7.0 Hz, 3H).
Example 49
Carbamic Acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-amino]sulfonyl]-3-(phenylmethoxy)propyl ester
The title compound was synthesized as in Example 1 using 3-benzyloxy-1-propanol (0.65 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.84 g of carbamic acid, [[[5-(5,6-difluoro-1H-indol-2-yl) 2 -methoxyphenyl]amino]sulfonyl]-3-(phenylmethoxy)propyl ester. Microanalysis: C 26 H 25 F 2 N 3 O 6 S; calculated: C=57.24; H=4.62; N=7.70; found: C=56.93; H=4.61; N=7.84. MS: M + +1=546 Da. Mp 166-168° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.62 (s, 1H), 11.40 (s, 1H), 9.32 (s, 1H), 7.68 (s, 1H), 7.62 (d, J=8.7 Hz, 1H), 7.48-7.43 (m, 1H), 7.30-7.22 (m, 6H), 7.11 (d, J=8.4 Hz, 1H), 6.72 (s, 1H), 4.35 (s, 2H), 4.12 (t, J=6.3 Hz, 2H), 3.75 (s, 3H), 3.41 (t, J=6.0 Hz, 2H), 1.84-1.78 (m, 2H).
Example 50
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(phenylmethoxy)propyl ester
The title compound was synthesized as in Example 1 using 3-benzyloxy-1-propanol (0.65 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluorophenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 1.11 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 3-(phenylmethoxy)propyl ester. Microanalysis: C 25 H 25 F 2 N 3 O 7 S; calculated: C=54.21; H=4.64; N=7.59. found: C=54.21; H=4.60; N=7.72. MS: M + +1=550 Da. Mp 178-179° C. 1 HNMR (400 Mz, DMSO-d 6 ) δ 11.40 (s, 1H), 10.33 (s, 1H), 9.44 (s, 1H), 7.96-7.87 (m, 3H), 7.54 (m, 1H), 7.53 (q, J=2.2, 1.7 Hz, 1H), 7.43-7.25 (m, 6H), 7.19 (d, J=8.7 Hz, 1H), 4.43 (s, 2H), 4.16 (t, J=6.5 Hz, 2H), 3.83 (s, 3H), 3.47 (t, J=6.3 Hz, 2H), 1.06 (m, 2H).
Example 51
Carbamic Acid, [[[5-(5,6-difluoro-IH-indo-2yl)-methoxyphenyl]amino]-sulfonyl]-hexyl ester
The title compound was synthesized as in Example 1 using hexanol (0.50 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (1.0 g, 3.6 mmol) to give 0.79 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-hexyl ester. Microanalysis: C 22 H 25 F 2 N 3 O 5 S; calculated: C=54.88; H=5.23; N=8.73; found: C=55.05; H=5.14; N=8.64. MS: M + +1=482 Da. Mp 186-188° C. 1 HNMR (400 Mz, DMSO-d 6 ) δ 11.66 (s, 1H), 9.27 (s, 1H), 7.72 (s, 1H), 7.66 (d, J=6.8 Hz, 1H), 7.52-7.47 (m, 1H), 7.34-7.30 (m, 1H), 7.17 (d, J=8.7 Hz, 1H), 6.76 (s, 1H), 4.08-4.05 (m, 2H), 3.82 (s, 3H), 1.55-1.50 (m, 2H), 1.22 (s, 6H), 0.84-0.80 (m, 3H).
Example 52
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2methoxyphenyl]amino]sulfonyl]-, Hexyl ester
The title compound was synthesized as in Example 1 using hexanol (0.50 mL, 4.0 mmol), CSI (0.42 mL, 4.9 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.0 g, 3.6 mmol) to give 0.76 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, hexyl ester. Microanalysis: C 21 H 25 F 2 N 3 O 6 S; calculated: C=51.95; H=5.19; N=8.65. found: C=51.90; H=5.09; N=8.40. MS: M + +1=486 Da. Mp 175-178° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.36 (s, 1H), 10.31 (s, 1H), 9.33 (s, 1H), 7.96-7.88 (m, 3H), 7.56-7.54 (m, 1H), 7.42 (q, J=92, 8.9 Hz, 1H), 7.21 (d, J=8.7 Hz, 1H), 4.07 (t, J=6.5 Hz, 2H), 3.87 (s, 3H), 1.55-1.54 (m, 2H), 1.26 (s, 6H), 0.86-0.84 (m, 3H).
Example 53
Carbamic Acid, [[[5-(5,6-difluoro-indol-2-yl)-2-methoxyphenyl]amino]-sulfonyl]-, 1,1-dimethylethyl ester
The title compound was synthesized as in Example 1 using t-butyl alcohol (2.0 mL, 20.9 mmol), CSI (2.0 mL, 23.0 mmol), and 5-(5,6-difluoro-1H-indol-2-yl)-2-methoxy-phenylamine (2.5 g, 9.1 mmol) to give 3.28 g of carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-, 1,1-dimethylethyl ester. Microanalysis: C 20 H 21 F 2 N 3 O 5 S.0.06 C 6 H 16 NCl.0.22 H 2 O; calculated: C=52.97; H=4.85; N=9.20. found: C=52.51; H=4.85; N=9.20. MS: M + +1=454 Da. Mp 158-160° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.64 (s, 1H), 11.17 (s, 1H), 8.99 (s, 1H), 7.71 (s, 1H), 7.61 (d, J=6.5 Hz, 1H), 7.51-7.46 (m, 1H), 7.32-7.28 (m, 1H), 7.15 (d, J=8.7 Hz, 1H), 6.72 (s, 1H), 3.82 (s, 3H), 1.36 (s, 9H).
Example 54
Sulfamide, [5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]
Carbamic acid, [[[5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]amino]sulfonyl]-1,1-dimethylethyl ester (2.0 g, 4.4 mmol) and anisole (1.5 mL, 13.8 mmol) were stirred in trifluoroacetic acid (20 mL) for 0.5 hour. The excess trifluoroacetic acid was evaporated under reduced pressure to give a white solid, which was triturated with ether and dried. Yield 1.14 g of sulfamide, [5-(5,6-difluoro-IH-indol-2-yl)-2-methoxyphenyl]-. Microanalysis: C 15 H 13 F2N 3 O 3 S; calculated: C=50.99; H=3.71; N=11.89; found: C=50.90; H=3.83; N=11.50. MS: M + +1=354 Da. Mp 177-180° C.
Example 55
Benzamide, 3-[(aminosulfonyl)amino]-N-(3,4-difluorophenyl)-4-methoxy
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 1,1-dimethylethyl ester (0.28 g, 0.6 mmol) and anisole (0.33 mL, 3.1 mmol) were stirred in trifluoroacetic acid (10 mL) for 0.5 hour. The excess trifluoroacetic acid was evaporated under reduced pressure to give a white solid, which was triturated with ether and dried. Yield 0.16 g of benzamide, 3-[(aminosulfonyl)amino]-N-(3,4-difluorophenyl)-4methoxy-. Microanalysis: C 14 H 13 F 2 N 3 O 4 S; calculated: C=46.04; H=3.52; N=11.36; found: C=46.02; H=3.60; N=11.36. MS: M ++ 1=358 Da. Mp 167-170° C.
Example 56
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(1,3-dihydro-1,3-dioxo-2H-isoindol-2-yl)ethyl ester
The title compound was synthesized as in Example 1 using N-hydroxyethyl phthalimide (2.2 g, 11.5 mmol), CSI (1.0 mL, 11.5 mmol), and 3-amino-N-(3,4-difluorophenyl-4-methoxy-benzamide (1.5 g, 5.4 mmol) to give 0.98 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 2-(1,3-dihydro-1,3-dioxo-2H-isoindol-2-yl)-ethyl ester. Microanalysis: C 25 H 20 F 2 N 4 O 8 S; calculated: C=51.68; H=3.59; N=9.64. found: C=51.69; H=3.38; N=9.61. MS: M + +1=575 Da. Mp 203-205° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 11.42 (s, 1H), 10.30 (s, 1H), 9.38 (s, 1H), 7.93-7.80 (m, 7H), 7.52-7.50 (m, 1H), 7.39 (q, J=9.2, 10.6 Hz, 1H), 7.15 (d, J=8.7 Hz, 1H), 429 (t, J=5.8 Hz, 2H), 3.84 (t, J=5.8 Hz, 2H), 3.80(s, 3H).
Example 57
Benzamide, N-(3,4-difluorophenyl-3-[[[[(dimethylamino)sulfonyl]-amino]-carbonyl]amino]-4-methoxy
3-Amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (2.0 g, 7.2 mmol) was dissolved in 50 mL of methylene chloride and cooled to 0° C. Chlorosulfonyl isocyanate (0.85 mL, 9.8 mmol) dissolved in 20 mL of methylene chloride was added dropwise. The mixture was stirred overnight. The resulting solid was collected by filtration and dried under vacuum. The dried solid (1.0 g, 2.4 mmol) was sited in 50 mL of methylene chloride with triethylamine (0.7 mL, 4.8 mmol) for 1 hour. Dimethylamine (1.2 mL of a 2N solution, 2.4 mmol) was added, and the solution stirred for 48 hours. The resulting mixture was washed with water (2×50 mL) and the organic phase dried over magnesium sulfate. The solvents were evaporated under reduced pressure to give a foam. The foam was redissolved in a small amount of fresh methylene chloride and treated with 1N hydrochloric acid (20 mL). Vigorous shaking produced a precipitate, which was collected via filtration. The resulting powder was sequentially triturated with water, methylene chloride, and ether. The triturated solid was dried under vacuum to give 0.64 g of benzamide, N-(3,4-difluorophenyl)-3-[[[[(dimethylamino)sulfonyl]-amino]carbonyl]amino]-4-methoxy-. Microanalysis: C 17 H 18 F 2 N 4 O 5 S-0.86 H 2 O; calculated: C=46.00; H=4.31; N=12.69. found: C=46.00; H=4.31; N=12.69. MS:M + +1=349 Da. Mp 253-255° C. 1 HNMR (400 MHz, DMSO-d 6 ) δ 10.34 (s, 1H), 10.25 (s, 1H), 9.26 (s, 1H), 7.94-7.89 (m, 1H), 7.85 (d, J=8.7 Hz, 1H), 7.64 (s, 1H), 7.49-7.39 (m, 2H), 7.27 (d, J=8.4 Hz, 1H), 3.92 (s, 3H), 2.95 (s, 6H).
Example 58
Carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 1,1-dimethylethyl ester
The title compound was synthesized as in Example 1 using t-butyl alcohol (1.8 mL, 19.1 mmol), CSI (2.0 mL, 23.0 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (5.3 g, 19.1 mmol) to give 0.84 g of carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]-, 1,1-dimethylethyl ester. Microanalysis: C 19 H21F 2 N 3 O 6 S; calculated: C=49.89; H=4.63; N=9.19. found: C=49.81; H=4.48; N=9.14. MS: M + +1=456 Da. Mp 193-194° C.
Example 59
Benzamide, N-(3,4-difluorophenyl)-3-[[[[[[4-(1,1-dimethylethyl)phenyl]-amino]carbonyl]amino]sulfonyl]amino]-4-methoxy
The title compound was synthesized as in Example 1 using 4-t-butyl aniline (1.3 mL, 8.1 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.9 g, 6.8 mmol) to give 0.095 g of benzamide, N-(3,4-difluorophenyl)-3-[[[[[[4-(1,1-dimethylethyl)phenyl]amino]carbonyl]amino]sulfonyl]amino]-4-methoxy-. Microanalysis: C 25 H 26 F 2 N 4 O 5 S. 0.46 H 2 O; calculated: C=55.52; H=5.02; N=10.36. found: C=55.46; H=4.94; N=10.40. MS: M + +1=533 Da. Mp 199-202° C.
Example 60
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(3-nitrophenyl) -amino]carbonyl]amino]sulfonyl]amino]
The title compound was synthesized as in Example 1 using 3-nitroaniline (1.35 g, 9.8 mmol), CSI (0.85 L, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (0.39 g, 1.4 mmol) to give 0.074 g of benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(3-nitrophenyl)-amino]carbonyl]-amino]sulfonyl]amino]-. Microanalysis: C 21 H 17 F 2 N 5 O 7 S.0.44 H 2 O; calculated: C=47.65; H=3.40; N=13.23. found: C=47.64; H=3.01; N=13.51. MS: M + +1=522 Da.Mp 206-208° C.
Example 61
Benzamide, 3-[[[[[(3-chlorophenyl)amino]carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy
The title compound was synthesized as in Example 1 using 3-chloroaniline (2.0 mL, 18.9 mmol), CSI (2.0 mL, 23.0 mmol), and 3-amino-N-(3,4difluoro-phenyl)-4-methoxy-benzamide (1.39 g, 5.0 mmol) to give 0.030 g of benzamide, 3-[[[[[(3-chlorophenyl)amino]carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-. Microanalysis: C 21 H 17 ClF 2 N 4 O 5 S; calculated: C=49.37; H=3.35; N=10.97. found: C=48.97; H=3.11; N=10.78. MS: M + +1=511 Da. Mp 193-196° C.
Example 62
Benzamide, 3-[[[[[[3,5-bis(trifluoromethyl)phenyl]amino]-carbonyl]amino]-sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy
The title compound was synthesized as in Example 1 using 3,5-bis(trifluoromethyl)aniline (1.3 mL, 8.2 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluorophenyl)-4-methoxy-benzamide (0.63 g, 2.3 mmol) to give 0.032 g of benzamide, 3-[[[[[[3,5-bis(trifluoromethyl)phenyl]amino]-carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-. Microanalysis: C 23 H 16 F 8 N 4 O 5 S.1.63 H 2 O; calculated: C=43.04; H=3.02; N=8.73. found: C=43.05; H=2.68; N=8.55. MS: M + −1=611 Da. Mp 175-178° C.
Example 63
Benzamide, 3-[[[[[(4-aminophenyl)amino]carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-, mono(trifluoroacetate)
Chlorosulfonyl isocyanate (1.0 mL, 12.0 mmol) was dissolved in 20 mL of methylene chloride and cooled to 0° C. BOC-1,4-Phenylenediamine (2.5 g, 12.0 mmol) dissolved in 20 mL of methylene chloride was added dropwise to the chlorosulfonyl isocyanate solution. Upon stirring, a precipitate slowly formed. After 2 hours, the mixture was filtered, and the solid collected and dried. Yield 2.92 g. A portion of this solid (0.92 g, 2.7 mmol) was placed in a flask containing 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (0.75 g, 2.7 mmol), triethylamine (1.0 mL, 6.8 mmol) and 50 mL of tetrahydrofuran. The mixture was heated to 50° C., and sired overnight The tetrahydrofuran was removed under reduced pressure; the resulting solid was triturated with methanol and dried under vacuum. Yield 0.32 g. A portion of this solid (0.20 g, 0.3 mmol) was stirred with anisole (0.4 mL, 3.7 mmol) in trifluoroacetic acid (20 mL). After stirring for 1 hour, the trifluoroacetic acid was removed under reduced pressure. The resulting oil was triturated with ether, resulting in a solid. The solid was dried under vacuum; yield 0.20 g of benzamide, 3-[[[[[(4-aminophenyl)amino]carbonyl]-amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-, mono(trifluoroacetate). Microanalysis: C 21 H 19 F 2 N 5 O 5 S.0.69 C 2 HO 2 F 3 .2.6 H 2 O; calculated: C=43.62; H=3.96; N=11.36. found: C=43.99; H=3.56; N=11.20. Mp 18& 189° C.
Example 64
Benzamide, N-(3,4-difluorophenyl)methoxy-3-[[[[[[3-(trifluoromethyl)phenyl]amino]carbonyl]amino]sulfonyl]amino]
The title compound was synthesized as in Example 1 using 3-trifluoromethylaniline (1.32 g, 10.6 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (0.92 g, 3.3 mmol) to give 0.060 g of benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[[3-(trifluoromethyl)phenyl]amino]carbonyl]amino]sulfonyl]amino]-. Microanalysis: C 22 H 17 F 5 N 4 O 5 S; calculated: C=48.53; H=3.15; N=10.29. found: C=48.52; H=3.09; N=10.18. MS: M + +1=545 Da. Mp 198-200° C.
Example 65
Benzoic Acid, 4-[[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]amino]carbonyl]amino]
Chlorosulfonyl isocyanate (1.7 mL, 19.5 mmol) was dissolved in 20 mL of methylene chloride and cooled to 0° C. Methyl 4-aminobenzoate (2.5 g, 16.2 mmol) dissolved in 20 mL of methylene chloride was added dropwise to the chlorosulfonyl isocyanate solution. Upon stirring, a precipitate slowly formed. After 2 hours, the mixture was filtered, and the solid collected and dried; yield 4.21 g. A portion of this solid (1.0 g, 3.4 mmol) was placed in a flask containing 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (0.95 g, 3.4 mmol), triethylamine (1.2 mL, 8.5 mmol), and 50 mL of tetrahydrofuran. The mixture was stirred overnight. The tetrahydrofuran was evaporated under reduced pressure, and the resulting solid was dissolved in methylene chloride (50 mL). The methylene chloride was sequentially washed with 25 mL of 1N hydrochloric acid, water, and brine. A precipitate was formed, which was recovered by filtration and triturated with a mixture of methylene chloride and methanol. The solid was dried under vacuum; yield 0.67 g. A portion of this solid (0.30 g, 0.6 mmol) was suspended in a 9:1 mixture of tetrahydrofuran and water (10 mL). Lithium hydroxide (48.3 mg, 2.0 mmol) was added, and the resulting mixture was refluxed overnight. The mixture was diluted with 1N hydrochloric acid (50 mL) and extracted with diethyl ether (1×50 mL) and ethyl acetate (1×50 mL). The organics were combined, dried with magnesium sulfate, and filtered. The resulting filtrate was evaporated under reduced pressure to give a white foam. The foam was triturated with hot ethyl acetate and ether, then dried under vacuum to give 0.12 g of benzoic acid, 4-[[[[[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]amino]carbonyl]amino]-. Microanalysis for C 22 H 18 F 2 N 4 O 7 S.0.25 H 2 O.0.1 C 4 H 8 O 2 ; calculated C=50.40; H=3.64; N=10.50. found: C=50.29; H=3.71; N=10.14.
Example 66
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)-amino]carbonyl]amino]sulfonyl]amino]
The title compound was synthesized as in Example 1 using p-anisidine (1.0 g, 7.1 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.75 g, 6.3 mmol) to give 0.43 g of benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[[(4-methoxyphenyl)amino]-carbonyl]amino]sulfonyl]amino]-. Microanalysis: C 22 H 20 F 2 N 4 O 6 S; calculated: C=52.17; H=3.98; N=11.06. found: C=52.17; H=3.89; N=10.95. Mp 189-192° C.
Example 67
Benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)carbonyl]-amino]sulfonyl]amino]
The title compound was synthesized as in Example 1 using p-toluidine (0.87 g, 8.1 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (0.56 g, 2.0 mmol) to give 0.25 g of benzamide, N-(3,4-difluorophenyl)-4-methoxy-3-[[[[(phenylamino)carbonyl]amino]-sulfonyl]amino]-. Microanalysis: C 22 H 20 F 2 N 4 O 5 S; calculated: C=53.87; H=4.11; N=11.42. found: C=53.56; H=4.14; N=11.27. MS: M + +1=491 Da. Mp 194-197° C.
Example 68
Benzamide, 3-[[[[[(4-chlorophenyl)amino]carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy
The title compound was synthesized as in Example 1 using 4-chloroaniline (1.0 g, 8.1 mmol), CSI (0.85 mL, 9.8 mmol), and 3-amino-N-(3,4-difluoro-phenyl)-4-methoxy-benzamide (1.17 g, 4.2 mmol) to give 0.24 g of benzamide, 3-[[[[[(4-chlorophenyl)amino]carbonyl]amino]sulfonyl]amino]-N-(3,4-difluorophenyl)-4-methoxy-. Microanalysis: C 21 H 17 ClF 2 N 4 O 5 S; calculated: C=49.37; H=3.35; N=10.97. found: C=49.15; H=3.17; N=10.70. MS: M + +1=511 Da. Mp 195-198° C.
Example 69
Carbamic Acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]methyl-, Ethyl ester
The title compound was synthesized as in Example 13 using carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]-sulfonyl]-, ethyl ester (1.0 g, 2.3 mmol), DBU (0.43 g, 1.2 eq, 2.8 mmol), and methyl iodide (0.29 mL, 2 eq, 4.7 mmol) to give carbamic acid, [[[5-[[(3,4-difluorophenyl)amino]carbonyl]-2-methoxyphenyl]amino]sulfonyl]methyl-, ethyl ester as a white solid. Microanalysis: C 18 H 19 F 2 N 3 O 6 S 1 ; calculated: C=48.76; H=4.32; N=9.48. found: C=48.76; H=4.25; N=9.30. MS: M + +1=444 Da.
Examples of assays useful for characterizing the biological effects of the compounds of the present invention on the 15-LO cascade are described below.
Biological Example 1
Rabbit Reticulocyte 15-LO Assay (H15LO)
The H15LO assay measures inhibition of 15-LO catalyzed oxidation of linoleic acid to the hydroperoxy fatty acid 13-(S)HPODE, a conjugated diene. In the H15LO assay, a test compound was incubated with 15-LO enzyme in the presence of the linoleic acid substrate. For example, 2 units (U) of rabbit reticulocyte 15-LO and 174 μM linoleic acid were incubated with a known amount of a test compound of the present invention for 15 minutes at 4° C. The total reaction volume was 100 μL in phosphate buffer saline (PBS) containing 0.2% sodium cholate. The reaction was stopped with 100 μL of mobile phase and 10 mL of triethyl phosphite. The resulting 13-(S)HPODE was essentially quantitatively reduced with triethyl phosphite to the more stable 13-hydroxyoctadecadienoate (13-HODE), which prevents artificial, nonenzymatic lipidperoxidation and product breakdown in the sample. 13-HODE was quantitated by comparing peak areas of individual samples with those from a standard curve generated using authentic 13-HODE. The test reaction was compared to a control reaction, which was identical to the test reaction except no test compound of the present invention was present Percent inhibition was calculated as the amount of 13-HODE produced by the test reaction divided by the amount of 13-HODE produced by the control reaction, expressed as a percent The results for certain compounds of the present invention are reported below in Table 1 in the column headed “H15LO IC 50 (nM)” as an IC 50 in nM or the concentration of compound of the present invention in nanomolar required to inhibit 15-LO catalyzed oxidation by 50%.
15-LO is obtained from phenylhydrazine-treated rabbits and purified according to the method of Rapoport (Rapoport et al., European Journal of Biochemistry, 1979;96:545-561).
Biological Example 2
Monocyte Recruitment
The recruitment or chemotaxis of monocytes is assayed by methods well known to those skilled in the art. In particular, the method set forth in J. Clin. Invest., 1988;82:1853-1863, which is hereby incorporated by reference, can be used.
Biological Example 3
Human Lysate 15-LO Assay (HUM15LO)
The HUM15LO assay measures inhibition of 15-LO catalyzed oxidation of linoleic acid to the hydroperoxy fatty acid 13-(S)HPODE, a conjugated diene. In the HUM15LO assay, a test compound of the present invention was incubated with 15-LO enzyme in the presence of the linoleic acid substrate. For example, a known amount of a test compound of the present invention, 100 μL of human 15-LO, and 174 μM linoleic acid in PBS containing 0.2% sodium cholate were incubated for 15 minutes at 4° C. The reaction was stopped with 100 μL of mobile phase and 10 μL of triethyl phosphite. 13-(S)HPODE was essentially quantitatively reduced with triethyl phosphite to the more stable 13-hydroxyoctadecadienoate (13-HODE), which prevents artificial, nonenzymatic lipidperoxidation and product breakdown in the sample. 13-HODE was quantitated by comparing peak areas of individual samples with those from a standard curve generated using authentic 13-HODE. The test reaction is compared to a control reaction, which is identical to the test reaction except no test compound of the present invention is present Percent inhibition is calculated as the amount of 13-HODE produced by the test reaction divided by the amount of 13-HODE produced by the control reaction, expressed as a percent. The results for certain compounds of the present invention are reported below in Table 1 in the column headed “HUM15LO IC 50 (nM)” as an IC 50 in nM or the concentration of compound of the present invention in nanomolar required to inhibit 15-LO catalyzed oxidation by 50%.
Human 15-LO was generated in a recombinant 15-lipoxygenase bacculovirus expression system, using Gibco/BRL/Life Technologies' Bac-to-Bac expression reagents; T4 DNA ligase, Kanamycin, Gentamicin, tetracycline, penicillin, streptomycin, Bluo-gal, IPTG, DH10Bac competent cells, SOC, LB medium, Sf-900 II SFM media, Sf9 insect cells, Cell Fectin, and EcoRI, BamHI and KpnI restriction enzymes.
TABLE 1 HUM15LO H15LO Ex. IC 50 (nM) IC 50 (nM) 20 1050 N/A 17 37 10 18 142 N/A 19 339 N/A 24 33 11 25 34 15 26 630 N/A 68 359 N/A 67 182 N/A 66 225 51 65 273 30 64 24 N/A 29 85 47 23 255 N/A 22 25 25 21 14 9 63 214 N/A 62 173 N/A 61 39 13 60 25 N/A 59 24 13 58 751 N/A 57 N/A N/A 56 341 N/A 55 29 19 54 12 10 53 N/A 23 2 384 N/A 3 408 N/A 4 144 N/A 52 39 5 51 12 2 50 65 18 49 15 5 48 306 N/A 47 54 44 5 240 N/A 69 154 N/A 46 830 N/A 45 133 80 44 236 N/A 43 30 17 42 76 19 41 69 13 6 N/A N/A 40 15 7 7 79 N/A 8 312 N/A 9 154 N/A 39 N/A N/A 37 7 5 38 13 13 36 13 12 10 N/A N/A 11 N/A N/A 35 N/A N/A 34 30 26 33 N/A N/A 32 16 6 27 44 23 28 18 39 12 N/A N/A 1 6 17 13 30 12 14 N/A N/A 15 N/A N/A 33 13 7 30 14 5 16 10 2 N/A = datum not available.
E. Uses
The disclosed compounds of Formula I will be formulated by standard methods into pharmaceutical compositions that are useful as prophylactic or therapeutic treatments for diseases modulated by the 15-LO cascade. The compositions will be administered to mammals for treating diseases with an inflammatory component, including inflammation and atherosclerosis.
1. Dosages
Those skilled in the art will be able to determine, according to known methods, the appropriate dosage for a patient, taking into account factors such as age, weight, general health, the type of pain requiring treatment, and the presence of other medications. In general, an effective amount will be between 0.1 and 1000 mg/kg per day, preferably between 1 and 400 mg/kg body weight, and daily dosages will be between 10 and 5000 mg for an adult subject of normal weight The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. 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 under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
2. Formulations
Dosage unit forms include tablets, capsules, pills, powders, granules, aqueous and nonaqueous oral solutions and suspensions, and parenteral solutions packaged in containers adapted for subdivision into individual doses. Dosage unit forms can also be adapted for various methods of administration, including controlled release formulations, such as subcutaneous implants. Administration methods include oral, rectal, parenteral (intravenous, intramuscular, subcutaneous), intracisternal, intravaginal, intraperitoneal, intravesical, local (drops, powders, ointments, gels, or cream), and by inhalation (a buccal or nasal spray).
Parenteral formulations include pharmaceutically acceptable aqueous or nonaqueous solutions, dispersion, suspensions, emulsions, and sterile powders for the preparation thereof. Examples of carriers include water, ethanol, polyols (propylene glycol, polyethylene glycol), vegetable oils, and injectable organic esters such as ethyl oleate. Fluidity can be maintained by the use of a coating such as lecithin, a surfactant, or maintaining appropriate particle size. Carriers for solid dosage forms include (a) fillers or extenders, (b) binders, (c) humectants, (d) disintegrating agents, (e) solution retarders, (f) absorption accelerators, (g) adsorbants, (h) lubricants, (i) buffering agents, and ( ) propellants.
Compositions may also contain adjuvants such as preserving, wetting, emulsifying, and dispensing agents; antimicrobial agents such as parabens, chlorobutanol, phenol, and sorbic acid; isotonic agents such as a sugar or sodium chloride; absorption-prolonging agents such as aluminum monostearate and gelatin; and absorption-enhancing agents.
Example 70
Tablet Formulation:
Ingredient
Amount (mg)
The compound of Example 1
25
Lactose
50
Cornstarch (for mix)
10
Cornstarch (paste)
10
Magnesium stearate (1%)
5
Total
100
The compound of Example 1, lactose, and cornstarch (for mix) are blended to uniformity. The cornstarch (for paste) is suspended in 200 mL of water and heated with stirring to form a paste. The paste is used to granulate the mixed powders. The wet granules are passed through a No. 8 hand screen and dried at 80° C. The dry granules are lubricated with the 1% magnesium stearate and pressed into a tablet. Such tablets can be administering to a human from one to four times a day for treatment of diseases responsive to the inhibition of the enzyme 15-lipoxygenase.
Example 71
Coated Tablets:
The tablets of Example 70 are coated in a customary manner with a coating of sucrose, potato starch, talc, tragacanth, and colorant.
Example 72
Injection Vials:
The pH of a solution of 500 g of the compound of Example 4 and 5 g of disodium hydrogen phosphate is adjusted to pH 6.5 in 3 L of doubled-distilled water using 2 M hydrochloric acid. The solution is sterile filtered, and the filtrate is filled into injection vials, lyophilized under sterile conditions, and aseptically sealed. Each injection vial contains 25 mg of the compound of Example 4.
Example 73
Suppositories:
A mixture of 25 g of the compound of Example 6, 100 g of soya lecithin, and 1400 g of cocoa butter is fused, poured into molds, and allowed to cool. Each suppository contains 25 mg of the compound of Example 6.
Example 74
Solution:
A solution is prepared from 1 g of the compound of Example 55, 9.38 g of NaH 2 PO 4 .12H 2 O, 28.48 g of Na 2 HPO 4 .12H 2 O, and 0.1 g benzalkonium chloride in 940 mL of double distilled water. The pH of the solution is adjusted to pH 6.8 using 2 M hydrochloric acid. The solution is diluted to 1.0 L with double-distilled water, and sterilized by irradiation. A 25 mL volume of the solution contains 25 mg of the compound of Example 55.
Example 75
Ointment:
500 mg of the compound of Example 21 is mixed with 99.5 g of petroleum jelly under aseptic conditions. A 5 g portion of the ointment contains 25 mg of the compound of Example 21.
Example 76
Capsules:
Two kilograms of the compound of Example 33 are filled into hard gelatin capsules in a customary manner such that each capsule contains 25 mg of the invention compound.
Example 77
Ampoules:
A solution of 2.5 kg of the compound of Example 60 is dissolved in 60 L of double-distilled water. The solution is sterile filtered, and the filtrate is filled into ampoules. The ampoules are lyophilized under sterile conditions and aseptically sealed. Each ampoule contains 25 mg of the compound of Example 60.
From the above disclosure and examples, and from the claims below, the essential features of the invention are readily apparent. The scope of the invention also encompasses various modifications and adaptations within the knowledge of a person of ordinary skill. Examples include a disclosed compound modified by addition or removal of a protecting group, or the formation of an ester, pharmaceutical salt, hydrate, acid, or amide of a disclosed compound. Publications cited herein are hereby incorporated by reference in their entirety.
Having described the present invention above, various embodiments of the invention are hereupon claimed.
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The present invention provides compounds of formula (I) wherein R, Z, Y, W, R 5 , V, and X are as defined in the description, and pharmaceutically acceptable salts thereof, which are useful for the treatment of diseases responsive to the inhibition of the enzyme 15-lipoxygenase. Thus, the compounds of formula (I) and their pharmaceutically acceptable salts are useful for treating diseases with an inflammatory component, including atherosclerosis, diseases involving chemotaxis of monocytes, inflammation, stroke, coronary artery disease, asthma, arthritis, colorectal cancer, and psoriasis.
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This invention was made with US Government support under Contract DAAE07-87-C-R066 awarded by the US Army. The US Government has certain rights in the invention.
The present invention relates to hydromechanical transmissions and particularly to infinitely variable speed hydromechanical transmission having an automatic ratio controller.
BACKGROUND OF THE INVENTION
State-of-the-art hydromechanical transmissions, such as utilized in modern military tanks, are equipped with automatic (electronic) ratio controllers acting to adjustably vary the displacements (strokes) of the hydraulic pumps in the transmission hydrostatic pump/motor drive units to achieve vehicle propulsion at speeds requested by the operator. Thus, the operator has no direct control over pump stroke, i.e., transmission ratio. In the event of a loss of electrical power or a failure of the automatic ratio controller, the vehicle is immobilized, even though its engine remains running.
It is accordingly an object of the present invention to provide method and apparatus for retaining vehicle mobility despite failure of the electrical/electronic controller for the vehicle's hydromechanical transmission.
An additional object is to provide apparatus of the above-character for manually overriding the automatic ratio controller in a hydromechanical transmission such as accommodate direct operator control of pump stroke in the transmission hydrostatic drive units.
A further object is to provide manual override apparatus of the above-character, wherein the conversion from automatic to manual control of pump stroke is achieved in an expeditious and safe manner.
Another object is to provide manual override apparatus of the above-character, which can be readily implemented in hydromechanical transmissions without disturbing the automatic ratio controller interface.
Yet another object is to provide manual override apparatus of the above character, wherein the operator control interface is simple and convenient to use.
Other objects of the invention will in part be obvious and in part appear hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention, a manual override apparatus is provided to accommodate operator control of transmission ratio and thus retain vehicle mobility in the event of failure of the automatic or electronic ratio controller in a hydromechanical transmission. To this end, the apparatus includes a linkage between the conventional, manually operated range selector and the conventional ratio arm which is normally driven by the automatic ratio controller to adjust hydraulic motor displacement in the transmission hydrostatic drive unit(s) to a stroke position satisfying the vehicle speed requested by the operator. In the normal propulsion mode, the linkage is of a lost-motion character, permitting independent manual shifting motion of the range selector and stroking motion of the ratio arm by the automatic ratio controller. To override the automatic ratio controller in the event it becomes inoperative and thus invoke a self-recovery propulsion mode, a self-recovery mechanism is activated to change the character of the linkage to one capable of translating shifting motion of the range selector to stroking motion of the ratio arm. As a result, vehicle propulsion is rendered manually controllable in response to shifting motions of the range selector by the operator.
As an important feature of the invention the self-recovery mechanism also moves the ratio arm to a zero stroke position, i.e., zero hydrostatic output, and, via the linkage, references the ratio arm zero stroke position to the neutral position of the range selector. Thus, range selector shifting movement away from its neutral position in one direction strokes the ratio arm positively to produce forward vehicle propulsion and shifting movement away from its neutral position in the opposite direction strokes the ratio arm negatively to produce reverse vehicle propulsion. An interlock is also provided to prevent propulsion mode conversion unless and until the conditions of engine-transmission disengagement and range selector neutral position are met by the operator.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts, as well as their method of operation, all of which as detailed below, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a full understanding of the nature and objects of the present invention, reference may be had to the following Detailed Description taken in conjunction with the following drawings, wherein:
FIG. 1 is a schematic diagram of manual override apparatus constructed in accordance with the present invention in its application to a hydromechanical transmission equipped with an automatic ratio controller;
FIG. 2 depicts a typical shift pattern for the manual range select seen in FIG. 1;
FIG. 3 is a enlarged view illustrating articulation of the linkage interconnecting the range selector and ratio arms seen in FIG. 1 during a normal propulsion mode controlled by the automatic ratio controller; and
FIG. 4 is an enlarged view of the same linkage illustrating the articulation thereof during a self-recovery (manual override) propulsion mode controlled by the operator.
Corresponding reference numerals refer to like parts throughout the several views of the drawing.
DETAILED DESCRIPTION
The manual override apparatus of the present invention is illustrated in FIG. 1 in its application to a hydromechanical steering transmission for tracklaying or skid-steered vehicles, such as military tanks. Examples of such transmissions are disclosed in U.S. Pat. Nos. 3,815,698 and 4,345,488 issued to B. O. Reed. Hydromechanical steering transmissions of this type utilize a pair of hydrostatic drive units, each consisting of a hydraulic pump and a hydraulic motor connected in a hydraulic loop circuit. The pumps of each unit are driven in parallel by the mechanical output of the vehicle engine to pump hydraulic fluid through their respective motors and produce respective hydrostatic outputs. These hydrostatic outputs are then combined with the mechanical output of the engine in combining gear sets to produce separate hydromechanical outputs driving the left and right vehicle tracks. By varying the displacements, i.e. strokes, of the hydraulic pumps, the speed of the hydrostatic outputs can be infinitely varied. Typically, the first or lowest speed range of the transmission is a combined forward and reverse propulsion range driven exclusively by the hydrostatic outputs of the hydrostatic drive units. Stroking the hydraulic pumps in one direction, e.g. positive direction, from zero stroke (zero displacement) produces vehicle propulsion in the forward direction and stroking in the negative direction from zero stroke propels the vehicle in the reverse direction. Propulsion in higher speed ranges is achieved by superimposing or combining the hydrostatic outputs with the mechanical output of a range-changing gear pack driven by the engine. Speed variation within each range is achieved by uniformly stroking the hydraulic pumps to vary the hydrostatic output speed correspondingly. Steering in each range is accomplished by differentially varying the pump strokes, typically in equal and opposite directions, to produce a corresponding differential in the speeds of the left and right vehicle tracks.
As noted above, modern hydromechanical transmissions utilize electronic controllers for establishing the optimum transmission ratio in terms of performance and fuel efficiency necessary to propel the vehicle at the speed requested by the operator. Thus, as seen in FIG. 1, an automatic ratio controller 10 linearly translates a ratio arm 12 back and forth, typically via a stepping motor (not shown). Pivotally connected to the ratio arm at its mid-length point is a crossarm 14 having one end connected to a left hydrostatic drive unit 16 by a stroking link 18 and its other end connected to a right hydrostatic drive unit 20 by a stroking link 22. It is thus seen that as the controller drives the ratio arm back and forth via link 24, the hydraulic pumps of the hydrostatic drive units 16 and 20 are uniformly stroked to produce variable speed straightline propulsion. To execute a steering maneuver, crossarm 14 is pivoted about its mid-length connection 15 with ratio arm 12 by a manual steering control 26 to produce equal and opposite strokings of the hydrostatic drive units.
A manually shiftable range selector lever 28 is mechanically connected, as indicated at 28, to a range selector arm 30 for operator positioning to various transmission operating ranges or modes. The range selector lever is also mechanically connected, as indicated at 31, to a disconnect selector 32 for manually controlling the position of a pilot valve, generally indicated at 33. This pilot valve controls the application of priority hydraulic pressure PP to a main clutch 34 engaging the vehicle engine with the hydromechanical transmission.
A typical shift pattern for lever 28 is illustrated in FIG. 2. As seen therein, the range selector lever is shifted into vertically aligned reverse R, neutral-engaged N(E), forward F and tow-start TS range positions to condition the transmission accordingly. While the range selector lever is positioned in the path of these aligned range positions, disconnect selector 32 is angularly oriented in the ENGAGED position to pull the spool 36 of pilot valve 33 sufficiently downward to communicate the priority hydraulic pressure in line 38 to line 40 and clutch 34, thereby effecting engagement of the vehicle engine to the hydromechanical transmission. From the neutral engaged position N(E), the range selector lever is shifted rightward to a neutral-disengaged position N(D) and beyond to an engine-start position S. While the range selector lever is in the neutral-disengaged and start positions, disconnect selector 32 is shifted to the DISENGAGED position illustrated in FIG. 1. As a result, spool 36 is positioned upwardly to block line 38, and thus remove priority hydraulic pressure from clutch 34, effecting disengagement of the engine and transmission. From the forward range position, the range selector lever is shifted leftward to a low range hold position LRH, locking the transmission in the low or first propulsion range. From the tow-start range position, lever 28 is shifted rightward and then downward to a tow position T. As in the case of shifting from the neutral-engaged position to the neutral-disengaged position, rightward movement of the range selector lever shifts the disconnect selector from its ENGAGED to its DISENGAGED positions. Thus, rightward lateral movements of the lever are communicated only to the disconnect selector, while vertical lever movements are communicated only to range selector arm 30.
To implement the manual override apparatus of the present invention to a hydromechanical transmission of type described above, ratio arm 12 and range selector arm 30 are interconnected by a pair of links 42 and 44, as also seen in FIGS. 3 and 4. Link 42 is pivotally connected at one end to the free end of the ratio arm by a pin 12a carried by the latter and captured in an elongated slot 42a in the link. Link 44 is pivotally connected at 44a to the other end of link 42 and is pivotally connected at 30a to the free end of range selector arm 30. As seen in FIG. 3, if links 42 and 44 are permitted to freely articulate, stroking motions of the ratio arm and shifting motions of the range selector arm are independent of each other. However, if linkage articulation is controlled, the range selector arm becomes drivingly connected to the ratio arm, such that manual shifting motion of the former is translated into stroking motion of the latter. To this end, link 42 carries a post 46 at an appropriate position intermediate its ends. As long as this post is free to move (arrow 46a) during articulation of the links in response to movements of the range selector arm and ratio arm, these arms are interconnected in lost-motion fashion, as seen in FIG. 3. When post 46 is fixed in position, shifting motion of range selector arm 30, as between positions 1' and 2' causes the ends of link 42 to revolve about the post as a fixed pivot point, thereby imparting stroking motion to ratio arm 12, as between positions 1 and 2, as illustrated in FIG. 4. When the movement of post 46 is unrestrained, the transmission is conditioned to the normal propulsion mode, wherein propulsion is controlled by automatic ratio controller 10. Conversely, when the position of this post is fixed, the transmission is conditioned in the self-recovery propulsion mode, wherein propulsion is manually controlled by the range selector lever 28 via range selector arm 30.
To provide safe and smooth conversion between these propulsion modes, as well as convenient manual control over vehicle speed and direction, the manual override apparatus of the invention includes hydraulic circuitry for ensuring that the operator manipulates the range selector lever in the proper manner. Thus, as seen in FIG. 1, this hydraulic circuitry includes a self-recovery mechanism, generally indicated at 48, a solenoid operated self-recovery valve 50, a self-recovery relay valve 52, disconnect signal relay valve 54, and a shuttle valve 56, all interconnected by hydraulic lines. Assuming the normal propulsion mode under the control of automatic ratio controller 10 is available, valve 50 is held in the position shown by electrical energization of its actuating solenoid 50a. Hydraulic line 58 to relay valve 52, line 60 to a first range brake relay valve 62, and line 64 branching therefrom to the self-recovery mechanism are all vented at 51 and thus unpressurized. While range selector lever 28 is in the neutral-disengaged position N(D), valve positions are as shown in FIG. 1, to wit, spool 36 blocks priority hydraulic pressure from line 40 to clutch 34, the spool 66 of signal relay valve 54 is biased to its lower position by its compression spring 68, and the spool 70 of relay valve 52 is biased to its upper position by its compression spring 72.
When the range selector lever 28 shifted from the neutral-disengaged position N(D) to the neutral-engaged position N(E) (FIG. 2), spool 36 is pulled downward by disconnect selector 32, and line 40 receives priority hydraulic pressure to engage clutch 34 connecting the engine mechanical output to the transmission. In addition, the priority pressure in line 40 is communicated through signal relay valve 54 and line 74 to the upper end of spool 70 of relay valve 52, driving it downwardly to block off line 58 from solenoid valve 50 and to vent lines 60 and 64 at 53. As will be seen, this effectively locks out the self-recovery mode. By shifting range selector lever 28 to either the forward F or reverse R positions from the neutral-engaged position N(E), normal mode propulsion ensues at vehicle speeds established by automatic ratio controller 10.
In the event of an electrical failure that disables the automatic ratio controller or a failure of the controller itself, control of normal mode propulsion is lost, and conversion to the self-recovery propulsion mode is necessary to regain control over vehicle mobility. To achieve this conversion, the operator must shift range selector lever to the neutral-disengaged N(D) position and stop the vehicle. Note that until the range selector lever is in the neutral-disengaged position, priority pressure via pilot valve 32 positions spool 70 of relay valve 52 to block hydraulic line 58, and thus priority pressure PP can not be communicated to lines 60 and 64, even when the loss of electrical power de-energizes solenoid 50a of valve 50, allowing it to revert under the bias of spring 50b to a leftward position to port priority pressure to line 58. It is thus seen that conversion to the self-recovery mode is precluded until the transmission is in neutral and clutch 34 is disengaged to prevent injury to occupants and damage to the engine/transmission.
With the range selector lever 28 in the neutral-disengaged position and the vehicle engine running to drive a hydraulic pump (not shown) for developing priority hydraulic pressure, the valve spools are in the position shown in FIGURE 1. Solenoid valve 50 is in its left position, either due to an electrical failure or a manual opening of the solenoid energization circuit, porting priority pressure to first range brake relay valve 62 and to self-recovery mechanism 48. Line 76 is also pressurized to drive spool 66 of disconnect signal relay valve 54 upward, blocking off line 40. This locks the transmission in the self-recovery propulsion mode for as long as line 58 is pressurized through solenoid valve 50. The application of priority pressure to relay valve 62 effects engagement of the first range brakes, thereby conditioning the transmission to its first or lowest propulsion range. It will be appreciated that, in the normal propulsion mode, automatic ratio controller 10 controls the first range brakes directly, as well as the other range-changing brakes and clutches.
As seen in FIG. 1, self-recovery mechanism 48 includes a pair of opposed hydraulic pistons 78 and 80 mounted in a housing 82 and biased to their outermost positions by compression springs 84. The pistons confront a housing opening 86 into which extends post 46 carried by link 42. In the normal propulsion mode, the post moves freely in this opening in response to shifting movements of range selector arm 30 and stroking movements of ratio arm 12. When priority pressure is ported by the solenoid valve to line 64 and its branch lines 64a and 64b, piston 80 is driven inward toward post 46 to a reference position established by a housing stop 82a. Concurrently, piston 78 is driven inward, forcing post 46 up against the face of piston 80 in its reference position. The post is thus pinned between the pistons in a predetermined fixed position while the transmission is locked in the self-recovery mode. With range selector lever 28 in its neutral-disengaged position and by appropriate location of the reference position of piston 80, the positioning of post 46 thereagainst by piston 78 is effective to translate ratio arm 12 to its zero stroke position from whatever position it was left in upon failure of the automatic ratio controller. Range selector arm 30 and the ratio arm are thus drivingly interconnected with the neutral position of the former referenced to the zero stroke position of the latter. At zero stroke, the hydrostatic outputs of the hydrostatic drive units 16, 20 are also zero.
To produce vehicle propulsion in the self-recovery mode, range selector lever 28 is shifted leftward from its neutral-disengaged position N(D) to its neutral-engaged position N(E) (FIG. 2). Disconnect selector 32 is rotated to the ENGAGED angular position, pulling pilot valve spool downward to communicate priority pressure to line 40 and thus to effect engagement of main clutch 34. Recall that lever shifting movement between the neutral-disengaged and neutral-engaged positions does not impart shifting movement to range selector arm 30. However, shifting movement of the range selector lever 30 from the neutral-engaged position toward the forward F and reverse R positions is directly communicated to the range selector arm. Thus, forward vehicle propulsion is manually controlled by moving the range selector lever between the neutral-engaged and forward range positions, resulting a positive stroking movement of ratio arm 12 and forward propelling outputs from the hydrostatic drive units. Vehicle propulsion in the reverse direction is then produced by moving the range selector lever between the neutral-engaged and reverse range positions to produce negative stroking of the ratio arm and hydrostatic outputs in the reverse direction. Vehicle steer is accomplished in the same manner as in the normal propulsion mode by manually rotating crossarm 14.
To convert back to the normal propulsion mode, the operator must first shift the range selector lever to the neutral-disengaged position, and energization of solenoid 50aof valve 50 must be restored. The valves thus assume their positions seen in FIG. 1, and post 46 and the first range brakes are released. Upon shifting to the neutral engaged position, the normal propulsion mode is locked in, and vehicle propulsion under the control of automatic ratio controller 10 can begin.
As a safety feature to prevent equipment damage in the event the vehicle is to be towed, priority pressure PP is ported to line 88 by a valve 90 when the range selector lever is shifted to the tow position T seen in FIG. 2. With line 88 pressurized, shuttle valve 56 is driven downward to propel spool 70 of relay valve 52 to its lower most position. Line 58 is blocked to remove priority pressure from line 60 which is then vented at 53. The self-recovery mode is thus defeated even though valve 50 continues porting priority pressure to line 58. The first range brakes are then released to permit towing of the vehicle without damage to the transmission.
While the present invention has been disclosed in its application to a hydromechanical transmission, it will be appreciated that it is equally applicable to a hydrostatic transmission equipped with an automatic ratio controller. Moreover, the linkage between the ratio and range selector arms may be implemented in forms other than the two pivotally interconnect links disclosed.
It is seen that the objects set forth above, including those made apparent from the preceding Detailed Description, are efficiently attained, and since certain changes may be made in the construction set forth without departing from the scope of the present invention, it is intended that all matters of detail be taken as illustrative, and not in a limiting sense.
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To override the vehicle immobilizing effect of a failed automatic ratio controller in a hydromechanical transmission, the conventional manually shiftable range selector is loosely linked with a ratio arm while the latter is being stroked by the controller to vary hydrostatic output speed. Upon controller failure, the range selector is drivingly linked with the ratio arm, such that shifting movements of the range selector are translated into stroking movements of the ratio arm to provide manual control of vehicle propulsion. Safeguards are provided to ensure that conversion between the normal propulsion mode governed by the automatic ratio controller and the override propulsion mode manually governed by the vehicle operator is effected in a safe manner.
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This is a continuation of application Ser. No. 08/501,383, filed Jul. 12, 1995 now abandoned, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a hemo(dia)filtration apparatus comprising a dialyzer divided by a membrane into two chambers, in which the first chamber is connected into a dialyzer fluid path and the second chamber is connected into a blood path, the dialyzer fluid path being comprised of a supply line extending from a means for preparing the dialyzer to a blood filter and into which a first balance chamber is connected, and a discharge line extending from the blood filter to a drain and into which a second balance chamber is connected; a pump for conveying dialyzer fluid within a closed dialyzer fluid system; a bypass line connecting the supply line with the discharge line of the dialyzer fluid path, in which a bypass valve is arranged; an ultrafiltration device; a first sterile filter incorporated in the supply line between the first balance chamber and the blood filter which is divided by a germ-repelling membrane into a first and a second chamber; and a second sterile filter divided by a germ-repelling membrane into a first and a second chamber.
Similar to hemodialysis, blood is conducted during hemofiltration past the membrane of a hemofilter, in which part of the serum is withdrawn via the membrane and replaced by a sterile substitution fluid added to the extracorporeal blood path either upstream of the dialyzer (predilution) or downstream (post dilution) of the dialyzer. In addition, in the hemodiafiltration, the usual hemodialysis is carried out, i.e. dialyzer fluid is conducted past the membrane of the hemodialyzer so that across the membrane an exchange of urophanic substances can take place.
Dialyzer fluid may be produced on-line from fresh water, and an electrolyte concentrate and the substitution fluid may be produced on-line from the dialyzer fluid. Though the electrolyte concentrate is as a rule inherently sterile and fresh water is generally germ-free, there is no certainty that the dialyzer fluid produced on-line is absolutely sterile and free of pyrogens, which is why the dialyzer fluid is rendered sterile and pyrogen-free for producing the substitute fluid. To achieve this, dialyzer fluid is removed via a line upstream of the blood filter, into which line at least one sterile filter is connected.
An apparatus of the this type is known, for example, from DE 34 44 671A or EP 0 042 939.
Due to a so-called "dead-end" arrangement of the sterile filter in the substituate line, the above-mentioned apparatuses have the drawback that in the course of time particles and other substances, e.g. imported germs and pyrogens, accumulate in front of the sterile filter membrane. This is especially dangerous if, as a result of a rupture, these substances can suddenly be carried into the sterile region, thereby contaminating the substitution fluid.
Thus, the object of the present invention is to further develop a hemodiafiltration apparatus of the aforementioned kind in such a way that clogging of the sterile filter with germs or pyrogens is largely eliminated, the safety of the hemodiafiltration apparatus is significantly improved and the sterility of the dialyzer fluid and the substituate is ensured through prevention of ruptures.
SUMMARY OF THE INVENTION
The object of the present invention is achieved in that the first chamber of the second sterile filter can be switched at least intermittently during flow through.
With the arrangement of the second sterile filter according to the present invention dialyzer fluid is allowed to flow through the first chamber and thus to at least intermittently flush the membrane of the second sterile filter, thereby preventing accumulation of germs and pyrogens in front of the membrane pores.
In an advantageous development of the hemodiafiltration apparatus according to the present invention, the first sterile filter is connected into the supply line and the first chamber of the first sterile filter can also be switched at least intermittently during flow through.
In addition, according to an advantageous development of the present invention, the first chamber of the first sterile filter is connected to the bypass line leading to the discharge line.
This arrangement of the first sterile filter results in a sterilizing filtration action of the dialyzer fluid, such that a completely sterile dialyzer fluid is conveyed to the following second sterile filter. Opening the bypass valve, which may be open during treatment and as the entire apparatus is being flushed, permits the dialyzer fluid to drain out of the first chamber of the sterile filter carrying with it any pyrogens and particles on the membrane into the discharge line and from there into the drain. It is thus feasible to flush the membrane at predetermined intervals, thereby reliably preventing accumulation of germs and pyrogens. Clogging of the membrane which results in an elevated transmembrane pressure is a principle cause of ruptures, hence, the likelihood of a rupture is lessened thereby, and this ensures the sterility of the dialyzer fluid and improves the safety of the hemodiafiltration apparatus.
According to a preferred embodiment of the present invention, the outlet of the first chamber of the second sterile filter is connected to the inlet of the first chamber of the dialyzer. With the inventive arrangement of a second sterile filter the dialyzer fluid which is shunted off as a substituate solution is subjected to a second, sterilizing filtration action to thereby effectively prevent contamination of the substituate solution should any leak occur in the membrane of the first sterile filter. In addition, by means of this inventive arrangement the membrane of the second sterile filter is continually flushed by dialyzer fluid flowing through the first chamber, thereby effectively preventing an accumulation of transported germs and pyrogens. The danger of a rupture is also considerably reduced, thus ensuring the sterility of the substituate solution and significantly improving the safety of the hemodiafiltration apparatus.
According to a yet another advantageous embodiment of the present invention, the outlet of the first chamber of the second sterile filter is connected to the discharge line of the dialyzer fluid path. A shut-off device and a venting device are advantageously connected into the connecting line between the first chamber of the second sterile filter and the discharge line of the dialyzer fluid path, so that opening said shut-off device allows the membrane of the second sterile filter to be flushed. Thus, in this embodiment the accumulation of germs and pyrogens is also effectively prevented and the danger of rupture is considerably reduced, such that the present arrangement ensures sterility of the substituate solution and it offers a high level of operating safety.
Thus, on the whole, a hemodiafiltration apparatus is provided which uses a two-fold safety means to effectively prevent contamination of blood in the dialyzer as well as contamination of the substituate solution due to transported germs or pyrogens. Moreover, the accumulation of pyrogens is effectively prevented, thereby providing a hemodiafiltration apparatus with a high level of operating safety.
According to the present invention a "balancing apparatus" is defined as a system which enables conveyed and discharged quantities of fluid to be precisely measured volumetrically (balanced) in relation to one other. Balancing apparatuses of this type are known, for example, from German patent publication DE 28 38 414, to which reference is made here, and which contain conventional balance chambers as balancing units having a defined interior volume. Also, a balancing unit in accordance with the present invention may refer to other devices which have a balancing function, e.g. balancing pumps and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, features and advantages of the present invention are explained with the aid of the following description of two embodiments with reference to the drawings, in which
FIG. 1 is a schematic representation of a first embodiment of the hemodiafiltration apparatus according to the present invention, and
FIG. 2 is a schematic representation of a second embodiment of the hemodiafiltration apparatus according to the present invention.
In FIG. 1 the numeral 10 denotes a hemodiafiltration apparatus which comprises a conventional dialyzer 12 divided by a membrane 18 into a first chamber 14 through which dialyzer fluid flows and a second chamber 16 through which blood flows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The first chamber 14 is connected into a dialyzer fluid path 20 consisting of a supply line 22 and a discharge line 24, and the second chamber 16 is connected into a blood path 80.
Supply line 22 consists of a first supply line section 28, a second supply line section 36, a third supply line section 56 and a fourth supply line section 70, and connects a dialyzer fluid source 26 to the first chamber 14 of the dialyzer 12.
The first supply line section 28 connects the dialyzer fluid source 26 to the first chamber (balancing unit) 32 of a balancing apparatus 30. The first chamber 32 of the balancing apparatus 30 is connected via the second supply line section 36 to the first chamber 42 of a first sterile filter 38. The first sterile filter 38 is divided by a membrane 40 into a first chamber 42 and a second chamber 44. The outlet of the first chamber 42 of the first sterile filter 38 is connected to a bypass line 52, into which a bypass valve 54 is connected and which is connected to the discharge line 24.
The third supply line section 56 branches off the second chamber 44 of the first sterile filter 38 and is connected to the first chamber 64 of a second sterile filter 60. A valve 58 is connected into the third supply line section 56. The second sterile filter 60 is divided by a membrane 62 into a first chamber 64 and a second chamber 68. The outlet of the first chamber 64 of the second sterile filter 60 is connected to the fourth supply line section 70 which leads to the first chamber 14 of the dialyzer 12.
Discharge line 24 leads from the outlet of the first chamber 14 of dialyzer 12 to the second balance chamber (balancing unit) 34 of the balancing apparatus 30. A dialyzer fluid pump 86 is connected into discharge line 24, further an ultrafiltration line 25 branches off discharge line 24 into which an ultrafiltration pump 88 is connected. Ultrafiltration line 25 leads to a drain 90, to which the outlet of the second balance chamber 34 of balancing apparatus 30 is attached.
The second chamber 16 of the dialyzer 12 is connected into the blood path in such a way that blood supply line 82 originating from the patient is attached to the inlet of the first chamber 16 and a first section 84 of a blood discharge line is attached to the outlet of the first chamber 16. The first section 84 of the blood discharge line leads to a drip chamber 78 at which point the blood is routed via a second section 85 of the blood discharge line back to the patient.
Branching off the second chamber 68 of the second sterile filter 60 is a substituate line 72 into which a substituate pump 76 is connected, and which also leads to drip chamber 78.
Fresh dialyzer fluid is conveyed from the dialyzer fluid source 26 through the first supply line section 28 to the first chamber 32 of the balancing apparatus 30. Said first balance chamber 32 is connected to the supply line 22 of the dialyzer fluid path 20, so that the fresh dialyzer fluid is conducted from the first balance chamber 32 through the second supply line section 36, through sterile filter 38, through the third supply line section 56, through the first chamber 64 of the second sterile filter 60 and through the fourth supply line section 70 to the first chamber 14 of the dialyzer 12. The dialyzer fluid, as it passes through the membrane 40 of the first sterile filter 38, is subjected to a sterilizing filtration action so that fully sterilized dialyzer fluid is conducted into the first chamber 14 of the dialyzer 12. The outlet of the first chamber 14 of dialyzer 12 is connected to discharge line 24 which leads to the second balance chamber 34 of the balancing apparatus 30. A dialyzer fluid pump 86 is incorporated in said discharge line 24 which conveys the dialyzer fluid into the dialyzer fluid path 20 from the first balance chamber 32 to the second balance chamber 34 of balancing apparatus 30. Balancing apparatus 30 is designed so that a quantity of used dialyzer fluid flowing through the second balance chamber 34 into drain 90 is replaced by an equal amount of fresh dialyzer fluid conveyed through the first balance chamber 32 into supply line 22. A shut-off device 71 in the form of a regulator clamp is connected into the fourth supply line section 70, with which said supply line section 70 may be shut off when necessary. When this occurs the apparatus 10 then functions exclusively as a hemofiltration apparatus.
Thus, in accordance with yet a further inventive concept, clamp 71 may be closed whenever a hemofiltration arrangement alone is desired, and may be opened solely for the purpose of flushing membrane 62. In such an embodiment it is also feasible to route supply line 70 either directly to the outlet or to connect it directly to the discharge line 24, so that the inlet of the first chamber 14 of blood filter 12 is closed. During hemofiltration, then, a hemofilter is preferably used in place of a dialyzer 11.
Said clamp 71 may be sequentially opened and closed in accordance with a program. According to yet another embodiment of the present invention the clamp 71 may be activated in such a way that it constricts or expands incrementally the diameter of line 70. As a result varying fluid amounts are allowed to pass through causing a corresponding decrease or increase in the fluid flow through membrane 62. Optionally, this may be effected in synchrony with pump 76.
Germs and pyrogens transported in the fresh dialyzer fluid into supply line 22 are filtered out by membrane 40 of sterile filter 38 and adhere to same. Opening bypass valve 54 in bypass line 52 which forms a link between the first chamber 42 and discharge line 24, causes the first chamber 42 to be flushed with dialyzer fluid. This causes particles, germs and pyrogens that have accumulated on membrane 40 to be carried away by the dialyzer fluid flowing past said membrane and to be flushed through the second balance chamber 34 and into drain 90 by way of bypass line 52 and discharge line 24. This permits effective flushing of membrane 40 of sterile filter 38, thereby considerably reducing the danger of rupture and ensuring sterility of the dialyzer fluid, which results in an arrangement with a high degree of operating safety.
By activating substituate pump 76, dialyzer fluid which flows through the first chamber 64 is drawn through membrane 62 into the second chamber 68 and from there passes into substituate line 72. Said substituate line 72 leads to a drip chamber 78 which is connected into blood path 80. Also emptying into drip chamber 78 is a first blood discharge line section 84 one end of which is attached to the outlet of the second chamber 16 of dialyzer 12 and the other end of which empties into drip chamber 78. A second blood discharge line 85 leads from drip chamber 78 to the patient. It is understood that in addition to predilution as it is represented here, postdilution is also possible.
Moreover, ultrafiltrate pump 88 may be activated to remove fluid from the closed, hydraulic dialyzer fluid path, which is then drawn through membrane 18 of dialyzer 12 and out of the blood flowing through the second chamber 16.
Such an arrangement firstly yields two-fold protection against blood contamination. Secondly, flushing both membrane 40 of the first sterile filter 38 and membrane 62 of the second sterile filter 60 prevents an accumulation of germs and pyrogens on these membranes, thereby reducing considerably the danger of a rupture proximate any of said membranes. This ensures a continuous, absolutely sterile flow of substituate solution to the patient.
FIG. 2 shows a second embodiment of hemodiafiltration apparatus 10 according to the present invention, which is in large part identical to the embodiment of FIG. 1, such that identical parts are labelled with identical reference numerals and no further detailed description is necessary.
In this second embodiment dialyzer fluid path 20 between blood filters 12 and 60 is modified as compared with the embodiment of FIG. 1, to the extent that the third supply line section 56 of supply line 22 leads from the second chamber 44 of the first sterile filter 38 to the first chamber 14 of dialyzer 12. Substituate line 102 branches off the third supply line section 56 and leads via first supply line section 73, into which substituate pump 106 is connected, to first chamber 64 of the second sterile filter 60. The second supply line section 75 of substituate line 102 then leads from the second chamber 68 of sterile filter 60 to drip chamber 78. Branching off the outlet of the first chamber 64 of the second sterile filter 60 is a connecting line 92 which is connected to discharge line 24 of the dialyzer fluid path 20. Connected into said connecting line 92 is a shut-off valve 94.
The hemodiafiltration apparatus according to FIG. 2 functions in essentially the same manner as the embodiment according to FIG. 1 described in detail above, such that no detailed description of the operation of the latter embodiment is necessary here. The basic difference with respect to the embodiment described above is that the outlet of the second chamber 44 of the first sterile filter 38 is directly connected to the first chamber 14 of the dialyzer, so that the dialyzer fluid does not flow permanently through the first chamber 64 of the second sterile filter 60. The substituate line 102 in this embodiment is designed in such a way that a first substituate line section 73 branches off the third supply line section 56 and is routed to the second sterile filter 60. A substituate pump 106 is incorporated in said first substituate line section 73, which removes dialyzer fluid from the dialyzer fluid path 20. Said fluid is then sterilized by being filtered through membrane 62 of the second sterile filter 60 and conveyed by means of a second substituate line section 75 to the drip chamber 78 which, as described above, is incorporated in blood path 80. In order to flush out membrane 62 of the second sterile filter 60, the outlet of the first chamber 64 is connected to the discharge line 24 via connecting line 92, thus providing, in a sense, a second bypass line. A shut-off device 94 is incorporated in connecting line 92, such that by opening said shut-off device 94 dialyzer fluid may be conducted through the first chamber 64 in order to thereby flush out membrane 62.
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A hemo(dia)filtration apparatus (10) is described comprising a dialyzer (12) and two sterile filters (38) and (60). The first chambers (42) and (64) of both sterile filters (38) and (60) may be switched at least intermittently during flow through, thereby flushing out membranes (40) and (62) of both sterile filters (38) and (60) and effectively preventing an accumulation of germs and pyrogens. This prevents an increase in the transmembrane pressure (TMP), which reduces the likelihood of a rupture, thereby ensuring sterility of the dialyzer fluid and improving the operating safety of the hemodiafiltration apparatus (10).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrically alterable nonvolatile latch element which can be used as a basic element in the construction of electrically reconfigurable logic blocks.
2. Description of the Prior Art
Electrically erasable and programmable read only memory devices and their different manifestations are now being designed into new applications beyond the traditional domain of nonvolatile memories. Programmable logic arrays which until recently were offered only in fusible link technology are now being offered in nonvolatile memory technologies.
One disadvantage of fusible link technology is that it requires substantial chip area to fabricate the fusible link elements. Also, the programming circuitry required to "blow" the fusible link needs to be large because the link requires a relatively large amount of current to flow through it to "blow" with a certain degree of reliability.
Another technique, known as the laser link technique, utilizes a highly directed laser beam to selectively separate the links in a memory circuit with redundant rows or columns. This technique allows the replacement of a limited number of defective memory locations with the redundant memory locations.
A disadvantage of this technique is that it requires substantial investment in capital equipment to implement.
Another major drawback of the two above-mentioned approaches is that their usefulness is limited by the fact that they are only pre-packaging reconfigurable, i.e. they are not in-circuit programmable.
Integrated circuit devices are now being designed wherein nonvolatile EPROM elements are replacing the fusible links, as in the case of programmable logic arrays and the above-mentioned redundancy circuits. This approach solves the problem of pre-packaging reconfiguration, but it still suffers from high current and voltage requirements. It also requires the use of an external power supply for programming operations and UV light for erasing one prototype configuration before the device can be reconfigured. Thus, the flexibility of in-circuit programming is not available with the EPROM approach.
Several other types of nonvolatile memory elements are disclosed in U.S. Pat. Nos. 4,328,565; 4,409,723; 4,486,769; 4,599,706. However, these memory elements are primarily designed for high cell count memories and are not self-sufficient in that they require relatively complex sense amplifiers and have relatively poor noise immunity.
Additionally, nonvolatile latch circuits have been proposed in U.S. Pat. Nos. 4,132,904 (Harari) and 4,571,704 (Bohac).
U.S. Pat. No. 4,132,904 discloses a volatile/nonvolatile logic latch circuit with a pair of circuit branches, each comprising a field effect transistor and a floating gate field effect transistor connected in series. The control gates of the floating gate field effect transistors are cross-coupled to the common junctions of the series-connected transistors in the other branch. This circuit can be programmed to assume the desired state when power is turned on and can also be intentionally written over if complementary data is to be stored.
U.S. Pat. No. 4,571,704 discloses a nonvolatile latch circuit which assumes the proper state when power is applied to the circuit, irrespective of the power applying conditions. This is accomplished by configuring a pair of circuit branches with each branch comprising a field effect transistor connected in series with a floating gate field effect transistor. The gates of the normal field effect transistors are cross-coupled to the common junctions between the series transistors in the other circuit branch. Also, the control gates of the floating gate field effect transistors are capacitively cross-coupled to the floating gates of the transistors in the other branch.
In the latch proposed by Bohac, if both the nonvolatile memory transistors in the two circuit branches are off (which is normally the case for enhancement floating gate MOSFETs when a device first comes out of wafer fabrication), then when power is turned on, the outputs of the nonvolatile latch are indeterminate since no pull-down to VSS is available until after the memory elements have been programmed.
SUMMARY OF THE INVENTION
An electrically programmable latch in accordance with the present invention includes two basic components: (a) two nonvolatile memory cell elements and (b) one cross-coupled static latch. The two nonvolatile memory cell elements are metal-oxide-semiconductor field effect transistor (MOSFET) devices which form the two branches of the circuit module. The floating gates of the nonvolatile memory cell elements in the two branches are capacitively coupled to their respective control gates via coupling capacitors which are formed by the overlap area between the control gate and the floating gate with a thin oxide dielectric separating the floating gates from the control gates. In addition to being capacitively coupled to their respective control gates, the floating gate of one memory cell element in one branch is capacitively coupled to the control gate of the other memory cell element in the other branch and vice-versa. This capacitive cross-coupling is achieved via relatively small area tunneling capacitors commonly known to those skilled in the art as Fowler-Nordheim capacitors. The drain of the nonvolatile memory cell element in one branch is coupled to the input of a complementary metal-oxide-semiconductor (CMOS) inverter, while the drain of the nonvolatile memory cell element in the other branch is coupled to the input of a second CMOS inverter. The output of the first CMOS inverter is coupled to the input of the second CMOS inverter which is also coupled to the drain of the nonvolatile memory element in the second branch. Likewise, the output of the second CMOS inverter is coupled to the input of the first CMOS inverter which is also coupled to the drain of the nonvolatile memory element in the first branch. The two cross-coupled CMOS inverters form a configuration which is commonly known to those skilled in the art as a static cross-coupled latch. The cross-coupled CMOS inverters are intended to sense the state of the two nonvolatile memory elements in the two branches and present the appropriate levels on the output lines.
To program the latch, data input circuitry is employed which can selectively place either a net positive or a net negative charge on the floating gate of one nonvolatile memory element in one circuit branch while simultaneously putting a net negative or a net positive charge on the floating gate of the other nonvolatile element in the other branch. The nonvolatile memory element with a net negative charge on the floating gate operates in the enhancement mode (i.e. no current flows through the element when its control gate is held at ground potential) and is popularly known to be "ERASED" in nonvolatile memory lo terminology. The nonvolatile memory element with a net positive charge on the floating gate operates in the depletion mode (i.e. current flows through the element when its control gate is held at ground potential) and is popularly known to be "WRITTEN" in nonvolatile memory terminology.
When power is removed form the device, the data in the cross-coupled inverter latch is lost; when power is brought back to the device, the states of the nonvolatile memory elements in the two branches are sensed at the inputs of the inverters which form the cross-coupled latch. Depending on the states of the nonvolatile memory elements (which are normally complementary to one another in the two branches of the circuit module), the cross-coupled inverters quickly latch in the proper state by feeding the proper voltage level at the input of the other inverter.
Thus, the present invention offers an electrically alterable latch which can be used in a myriad of applications where certain functions (for example, a standard EEPROM or a standard logic chip with nonvolatile latch elements) need to be customized to meet particular requirements. Another possible application is the EE-DIP switch, wherein the pins may be reconfigured according to desired requirements by inputting a certain instruction to the device.
In a particular application, the electrically alterable latch of the present invention has been designed into the logic module of a reconfigurable EEPROM device in which different sections of the memory core array can be reconfigured to be accessed by the outside world. This latch has also been utilized as a building block for a nonvolatile address pointer which is used to disable write operations in the user-defined section of the memory array core. This provides security of critical data from being accidentally written over.
Other objects, features and advantages of the present invention will be understood and appreciated by reference to the detailed description of the invention provided below which should be considered in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a zero power, electrically alterable, nonvolatile latch in accordance with the present invention, together with a high voltage inverter circuit.
FIG. 2 is a schematic diagram illustrating a layout of the FIG. 1 circuit.
FIG. 3A is a cross-sectional view taken along line AA in FIG. 2.
FIG. 3B is a cross-sectional view taken along line BB in FIG. 3.
FIG. 4 is a block diagram illustrating a circuit application in which the nonvolatile latch of the present invention can be used.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of an electrically alterable nonvolatile latch element in accordance with the present invention, along with an associated high voltage inverter circuit, is illustrated in FIG. 1.
The basic latch circuit 10 comprises two subcircuits. The first subcircuit is a cross-coupled static latch which includes two P-channel field effect transistors 12 and 14 and two N-channel field effect transistors 16 and 18. The second subcircuit includes two nonvolatile memory transistors 21 and 22.
The drains of transistors 12 and 16 are coupled to each other at node A. The drains of transistors 14 and 18 are coupled to each other at node B. The sources of transistors 12 and 14 are connected to the positive supply potential VCC. The sources of transistors 16 and 18 are connected to the ground potential VSS. The gates of transistors 12 and 16 are coupled together and are also coupled to node B.
Transistors 21 and 22 are N-channel floating gate MOSFET devices in which the floating gates are formed in a polysilicon layer and the control gates are selectively defined in the bulk silicon by a buried N+ implant mask. The floating gate (node C) of the memory transistor 21 is capacitively coupled to its control gate (node D) via coupling capacitor 24. Coupling capacitor 24 is essentially formed by the overlap of the floating polysilicon gate and the buried N+ implant area exposed by the thin oxide mask, as illustrated in FIG. 3A. Likewise, the floating gate (node E) of the memory transistor 22 is capacitively coupled to its control gate (node F) via the coupling capacitor 26.
In addition to being capacitively coupled to their respective control gates, the floating gates of the transistors 21 and 22 are capacitively cross-coupled to the control gates of transistors 22 and 21, respectively, via relatively small area tunneling capacitors 28 and 30. As shown in FIG. 3B, the tunneling capacitors 30 and 28 are formed by the overlap of the floating gates of transistors 21 and 22 with the buried N+ implant areas which are exposed by the thin oxide mask and are electrically in common with the control gates of transistors 22 and 21, respectively. Both the coupling capacitors 24, 26 and the tunneling capacitors 28, 30 have relatively thin oxide (100 Angstroms) dielectrics between the floating gates and the control gates.
The drain of the memory element 21 is coupled to node B, which was defined in conjunction with the cross-coupled static latch. Similarly, the drain of the memory element 22 is coupled to node A, which was previously defined. The sources of both memory elements 21 and 22 are connected to the ground potential VSS.
In addition to the capacitive couplings indicated above, there are additional stray capacitances inherent in the layout of the latch shown in FIG. 2. These include the floating gate to control gate overlap capacitances in the non thin-oxide areas and the capacitance due to the source and drain overlap to the floating gate in the memory transistors.
FIGS. 3A and 3B show the cross-sectional views of the memory cell element along the cross-sections AA and BB as indicated on the layout of the latch in FIG. 2.
In FIG. 3A, region 300 comprises the P-type silicon in which the highly doped N+source and drain regions are formed for the N-channel CMOS transistors. Also formed in the region 300 are buried-N+ diffusions which are not as highly doped compared to the source/drain N+ regions. The buried-N+ regions are used to form the control gates of the memory transistors and can also be used for conductive underpasses in other parts of the circuitry. The control gates of transistors 21 and 22 are shown in the cross-sectional diagrams of FIGS. 3A and 3B. The floating gates of transistors 21 and 22 (nodes C and E, respectively) are also shown in FIGS. 3A and 3B and are comprised of conductive polycrystalline silicon. The floating polycrystalline gate of transistor 21 is separated from the crystalline silicon by the coupling oxide 24, the tunneling oxide 28, the gate oxide 31, the oxide over the buried-N+ region 301, and the field oxide 302. The oxide over the buried N+, region 301, is substantially thicker than the gate oxides 30 and 32. The field oxide, region, 302, is substantially thicker than the oxide in region 301.
In addition to the capacitive couplings "Ccoup" and "Ctun," due to the coupling and tunneling oxides respectively, the floating gate of the transistor 21 is also capacitively coupled to its own control gate due to the overlap of the floating polysilicon gate to its control gate formed by the oxide over the buried-N+ region in the silicon substrate, "Cbn+g." Another component of the capacitance, "Cfld," is due to the overlap of the floating polysilicon gate to the substrate in the field oxide regions 302.
In order to program the latch, a high programming voltage "VPPI" (12-17v) must be applied to one of the two programming nodes D or F for about 5-10 ms. Considering the case in which VPPI is applied to node D, then the other programming node F must be held at the ground potential. For a virgin cell with no charge on the floating gate, an initial voltage equal to Rg "VPPI appears across the tunnel oxide 28, where; ##EQU1## where: p0 Rg : Control gate coupling ratio of Memory element, Ccoup: Floating gate to Control gate capacitance due to the coupling oxide,
Cbn+g: Floating gate to Control gate capacitance due to the buried N+ oxide around the gate region,
Ctun: Floating gate to Control gate of adjacent cell capacitance due to the tunnel oxide,
Cfld: Floating gate to substrate capacitance due to the field oxide,
Cgox: Floating gate to substrate capacitance due to the gate oxide,
Cbn+t: Floating gate to Control gate of adjacent cell capacitance due to the buried-N+ oxide around the tunnel oxide.
The initial electric field "E" across the tunnel oxide is given by: ##EQU2## where, Ttun: Thickness of tunnel oxide,
VPPI: Voltage applied to the Control gate of the memory cell.
If the initial electric field "E" is of the order of 9-10 Mv/cm, then a sufficient number of electrons tunnel through the tunnel oxide onto the floating gate of transistor 21 storing a net negative charge on node C so as to make an appreciable positive shift in the threshold voltage of this device. Also, the floating gate of transistor 22 is capacitively coupled up to an initial voltage equal to Rg . VPPI, where: ##EQU3## The initial electric field across the tunnel oxide associated with the floating gate of transistor 22 is given by: ##EQU4##
If the initial electric field "E" is of the order of 9-10 Mv/cm, then a sufficient number of electrons tunnel through the tunnel oxide out of the floating gate of transistor 22 storing a net positive charge on node E so as to make an appreciable negative shift in the threshold voltage of this device.
The operation of positive threshold voltage shift by the application of high voltage, VPPI, to the nonvolatile memory element is known as "ERASE" and the operation of negative threshold voltage shift is known as "WRITE" in EEPROM terminology.
Both the ERASE and WRITE operations are self-limiting. During ERASE, the initial electric field "E" sets up a Fowler-Nordheim conduction of electrons which follows the following relationship: ##EQU5##
The field "E" however decreases with time as more and more electrons tunnel through the tunnel oxide and are collected on the floating polycrystalline gate.
Eventually, the electric field "E" is so low that very few electrons tunnel through the oxide and further threshold voltage shift is negligible. Similarly, during the WRITE operation, the initial electric field "E'" sets up a Fowler Nordheim conduction which follows the relationship: ##EQU6## where: a, al, B, B1 are physical constants which depend on the effective energy barrier heights at the injection interfaces and the effective mass ratio of electrons in the tunnel dielectric. A is the area of the tunnel dielectric.
During the WRITE operation, the electric field "E'" also decreases with time as more electrons tunnel through the tunnel oxide out of the floating gate and eventually leaving the floating gate with a net positive charge. The electric field "E'"at this point is so low that very few electrons tunnel through the tunnel oxide and further threshold voltage shift is negligible.
During the READ mode, the control gates of both the memory elements (nodes D and F) are held at the ground potential and the electric fields across the tunnel oxides are minimal and are only due to the charges on the floating gates due to the programming operation. The tunneling of charges at these low electric fields is negligible and this translates to long data retention times (on the order of 10 years or longer for Tj<or=150° C.). Thus, the two memory elements in the electrically alterable latch remain programmed to their respective ERASED (enhancement) and WRITTEN (depletion) states. For the case when transistor 21 is ERASED and transistor 22 is WRITTEN (see FIG. 1), when the power is first turned on to the device, the following sequence of events occur:
(a) Node A is pulled low because transistor 22 is ON and is in the depletion mode;
(b) Node A going low forces the inverter formed by transistors 14 and 18 to try to force its output high. Transistor 21 being OFF (ERASED) allows node B to pull up towards VCC;
(c) The high going node B forces the output (i.e., node A) of the inverter formed by transistors 12 and 16 further towards the ground potential.
Eventually, due to the positive feedback, node B pulls up to VCC and node A is pulled down to VSS. At this point, the two cross-coupled inverters are latched to their proper states and no dc power is consumed by the circuit.
For the proper operation of the latch, the current sinking capability of the written memory element should be such that it can pull the corresponding cross-coupled latch node low enough to set the latch to its proper programmed state.
The basic latch circuit 10 described above can be used in conjunction with a high voltage inverter circuit 20, as shown in FIG. 1.
The purpose of the circuit 20 is to translate the low (VSS) and high (VCC) CMOS levels at its input into high (·VPPI 12-17v) and low (VSS) levels respectively. Thus, during the programming mode (PROG=VCC, PROGB=VSS) if DATAINB=low CMOS level, then node G is pulled low; this turns N-channel MOSFET 34 OFF and P-channel MOSFET 36 ON. This allows node D to pull up to VPPI and turn P-channel MOSFET 38 OFF.
For the other case, when the DATAINB=high CMOS level during the programming mode, node G pulls up towards the CMOS high level, thereby turning N-channel MOSFET 34 ON and P-channel MOSFET 36 OFF. Node D is pulled down to VSS, thereby turning P-channel MOSFET 38 ON which pulls node G towards VPPI. Thus, circuit 20 works like a high voltage inverter.
A similar circuit block 20 is also connected to the control gate of memory element 22 shown in FIG. 1. This circuit can be used to reset the DATAOUT (Node B) of the nonvolatile latch to a low (VSS) state, by taking the RESETB signal low during the program cycle.
FIG. 4 shows one possible setup in which the nonvolatile latch could be used.
Circuit block 30 includes an "N" bit long register which has the nonvolatile latch circuit 10 described above as the basic building block. The circuit block 40 includes "N" high voltage inverter circuits 20 described above, the outputs of each feeding into the input of a corresponding nonvolatile latch 10 in the block 30.
In addition to the "N" nonvolatile latch elements in the circuit block 30 and the "N" high voltage inverters in the circuit block 40, there is one additional nonvolatile latch element and two additional high voltage inverters shown in FIG. 4. All the high voltage inverters have VPPI and PROG as common inputs. The top circuit block 20' has "PROGB" and "PROG-DISABLEB" as the other inputs and its output "DISABLE" feeds into the control gate of one of the memory elements of the additional circuit block 10'. The control gate of the other memory element in the circuit block 10 is connected to VSS. The output "PROG-DISABLE" of the circuit block 10 serves as a common input to the remaining N+1 high voltage inverters. The second high voltage inverter 20" outside of the circuit block 40 has its last remaining input connected to a signal called "RESETB" and its output "RESET" is connected to one input of each nonvolatile element in the circuit block 30. The last input of each high voltage inverter element in the circuit block 40 is connected to the input of the corresponding nonvolatile latch in the circuit block 30 as shown in FIG. 4.
The transistor ratios of the cross-coupled inverters in the circuit block 10 outside of the circuit block 30 can be set such that the circuit powers up with PROG-DISABLE=VSS before the first PROG-DISABLE operation is performed. This enables the RESET operation to be performed on all the nonvolatile elements in the circuit block 30. The RESET operation resets all bits A0-AN to 0s'. Next the desired bit pattern ADDBI - ADDBN can be input to the circuit block 40 along with the other inputs VPPI (12-17V), PROG=VCC, DISABLE=VSS valid during the program cycle. After the programming cycle (typically 5-10 ms) the bit pattern A0-A7 should be identical to the desired bit pattern ADDl-ADDN that was input to the circuit block 40.
Once the desired bit pattern is programmed in the circuit block 30 is can be disabled from further pattern changes by performing a PROG-DISABLE operation. This is done by taking the PROG-DISABLE input to VSS during the programming operation with RESETB and ADDB1-ADDBN all at VCC. This operation makes the signal PROG-DISABLE permanently high thereby disabling all future pattern changes in the circuit block 30.
It should be noted that the example described above is merely for illustrative purpose and is only one of the many possible configurations which represent the application of the present invention.
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A compact, nonvolatile, zero static power, electrically alterable, bistable CMOS latch device is fabricated with single layer of polysilicon. The single polysilicon layer forms the floating gates of the nonvolatile elements of the device. The control gates are formed in the substrate by buried N+ diffusions and are separated from their respective floating gates by a thin oxide dielectric. The circuit can be designed to power-up in a preferred mode even before any programming operation has been performed on it. Thereafter, the circuit is available to be programmed to either of its two stable states. After the programming operation is completed and the circuit is latched to one of its two stable states, the fields across the thin oxide dielectrics are minimal and virtually no read disturb condition exist. Thus, the latch also offers excellent data retention characteristics.
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FIELD OF THE INVENTION
This invention relates to vertically mounted banners and more particularly to a banner support assembly adapted to be mounted on a supporting member for purposes of mounting decorative and advertising banners.
BACKGROUND OF THE INVENTION
Display devices useful for mounting temporary advertising messages outdoors where the message is readily noticed by people are nowadays common place. Because of the outdoor location of such advertising displays, they must be resistant to weather or protected from the effects of weather. As the wind loads, heat and cold continuously apply and then relax loads to the banner, the banner supporting structure, as well as the banner per se, is stressed and then relaxed on a daily basis. Often, fasteners or other similar means will be loosened by the repeated loads applied to the banner supporting structure by the changes in weather to cause the supporting structure to become loosened and potentially disengaged from the upstanding pole or other such supporting structures.
Current mounting techniques for vertical banners involve mounting such banners with the top horizontal edge of the banner as well as the bottom horizontal edge each having a hem running the width of the banner and thereby allowing a banner arm assembly to be inserted into the sleeve created by the hem. This type of mounting may be of permanent nature i.e. a steel banner arm assembly being welded at 90° on the upstanding post. The banner arm assembly may also possibly be of a removable nature with a fiberglass rod or steel tube inserted into a female socket.
Two of the mostly used vertical banner mounting systems use brackets with fiberglass rod banner arms and brackets with steel tube banner arms. The fiberglass arms are often preferred since they offer more flexibility, thereby permitting a limited cushioning of wind gusts although not offering enough flexibility to spill off high wind forces exerted against the banner. High winds can create forces in excess of 400 pounds per banner range, and without the capability of the banner being able to tip with and deflect the wind, these forces are directly transferred to the banner hems, arms, bracket bases and to the upstanding post. In such instances, wind gusts often result in tearing and damage to the banner.
It has been proposed that the destructive effect of wind gusts on banners be reduced by mounting fiberglass banner arms in a base plate held into a bracket base by means of springs and this might prove sufficient in situation of winds that are not unduly great.
All known techniques work in a way where they merely react to the conditions which makes it more reactive rather than proactive. Therefore, a need exists for the provision of a reliable banner support assembly which makes mounting the banners onto supporting members easy and time efficient and yet provides for the requisite durability and reliability in order to maintain the banner adequately supported and taut on the supporting member, thereby ensuring premium appearance of the message.
SUMMARY OF THE INVENTION
The present invention overcomes the above shortcomings.
It is an object of the present invention to provide a new and improved banner support assembly making mounting of banners on upstanding posts easy and efficient.
It is another object of the present invention to provide for a durable and reliable banner support assembly thereby ensuring premium appearance of the banner.
It will be appreciated from the following detailed description of the invention that the new and improved banner support assembly provides for flexibility to allow wind loads applied to the erected banner to spill before any over stressing of the banner support assembly occurs.
It is a further object of the present invention to provide a banner support assembly so reliable that a mounted banner will remain taut and will not become disengaged therefrom due to repeated loadings by wind and other weather elements acting on the banner supported by the banner support assembly.
It is yet a further object of the present invention to provide for an adapted banner construction for use in combination with the banner support assembly.
In accordance with another object of the present invention there is provided a banner support assembly adapted to be mounted on a supporting member for purposes of engaging and holding taut an elongated banner, said banner support assembly comprising a) first and second extending arms each being mounted in spaced relation onto said supporting member; b) first and second housing members adapted to receive corresponding first and second banner extremities which are secured therein; c) multiple rod members secured to first and second housing members and positioned through apertures in the first and second extending arms; d) attachment means correspondingly working in combination with the rod members thereby securing the banner to the first and second extending arms.
In accordance with another object of the present invention there is provided a banner support assembly adapted to be mounted on an upstanding post for purposes of engaging and holding taut an elongated banner, said banner support assembly comprising: a) first and second horizontally extending arms mounted in spaced relation onto the upstanding post; b) first and second grooved housing members adapted to receive corresponding first and second reinforced banner extremities which are secured therein; c) multiple rod members secured to first and second housing members, connected with the banner extremities, and positioned through apertures in the first and second horizontally extending arms mounted onto the upstanding post; d) spring-loaded attachment means correspondingly working in combination with the rod members thereby securing the banner to the first and second horizontally extending arms.
Further objects and advantages of the present invention will be apparent from the following description, wherein preferred embodiments of the invention are clearly shown.
BRIEF DESCRIPTION OF THE INVENTION
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. 1 is a perspective view of a banner support assembly embodying the invention;
FIG. 2 is an end view on an enlarged scale of the lower assembled members;
FIG. 3 is a perspective view of the banner support assembly prior to assembly;
FIG. 4 is a perspective view of an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the new and improved banner support assembly is indicated generally by reference numeral 10 . The invention may be seen to comprise a banner 11 which is held taut between upper and lower extending arms 12 and 13 held in spaced relation by means of upper and lower bracket assemblies 14 and 15 which are fixed onto an upstanding post 16 . It could also be seen that extending arms 12 and 13 could be attached to a flat planar surface such as a wall or even to a horizontally extending post with extending arms extending perpendicularly therefrom. More generally, the term supporting member can be used.
The banner support assembly 10 includes upper and lower housing members 17 and 18 into which are adaptedly secured to the upper and lower extremities 19 and 20 of the banner 11 . More specifically, the housing members 17 and 18 are unitary parts, preferably made of cast, non-rusting metal and includes groove-like openings 21 and 22 for allowing the banner's extremities 19 and 20 to be secured thereto. The banner's extremities 19 and 20 are slidably engaged into openings 21 and 22 and are securely held in place by attachment means and/or the use of angling plates 30 , as seen in FIG. 3 (at both the upper and lower extremities) which are themselves securely fastened to the banner 11 per se. The angling plates 30 serve as reinforcing means in addition to the reinforcing means already forming part of the upper and lower extremities 19 and 20 of the banner. Banner reinforcing means can be of the type encompassing rigid plastic members 60 incorporated into the inner core of the banner. It should be noted that a sleeve and hem type of banner extremity could be used in combination thereof
Once the banner 11 extremities 19 and 20 are securely attached to the housing members 17 and 18 , a pair, but possibly more depending on the width of the banner 11 and the requirements of the situation, of rod members 31 and 32 are inserted through apertures 33 and 34 of the extending arms 12 and 13 and through to correspondingly aligned apertures 35 and 36 of the housing members 17 and 18 thereby linking the bottom part 23 of the lower housing member 18 and the top part 24 , relatively speaking, of upper housing member 17 to their respective extending arms 13 and 12 .
The manner of attaching the rod members 31 and 32 to the housing members 17 and 18 may vary and could encompass one of the following techniques, without being restrictive. Either the rod members 31 and 32 are enclosed and trapped in when manufacturing the housing members 17 and 18 or openings slightly larger than the rod members 31 and 32 diameter are machined as part of the housing members 17 and 18 and hook and grap means are provided to reciprocally achieve securement between the members 31 and 32 and the housing members 17 and 18 .
Once the rod members 31 and 32 are securely attached to the housing members 17 and 18 and positioned through apertures 33 and 34 of the extending arms 12 and 13 , one is left with securing the resulting banner structure to the extending arms 12 and 13 . In order to achieve constant tensioning forces, flexibility and reliability two main options are possible. Either the use of a stop-lock member or with threaded rod members 31 and 32 it is possible to use a correspondingly threaded means. Referring to FIG. 2, there is illustrated threaded screw members 50 and 51 which when used in combination with spring-loaded members 52 and 53 allow for easy assembly and adjustability when faced with possibly slanting extending arms, of the banner structure and accrued flexibility in the face of weather elements as the spring members 52 and 53 will in effect absorb most forces exerted by the elements on the banner structure. Washers may also be installed between the spring members 52 and 53 and the extending arms 12 and 13 thereby providing for accrued support and releasing some of the pressure left being exerted on the extending arms 12 and 13 and the resulting banner structure. It should be noted that the spring-loaded members could be located elsewhere i.e. within the housing members or on the other side of the extending arms.
Referring to FIG. 4, in an alternate embodiment, there could be added an elastomeric member 40 to possibly one or both of the upper and lower sections of the banner 11 thereby increasing even more its flexibility and resiliency to weather elements.
Although a preferred embodiment has been described in the above paragraphs in sufficient detail so as to be readily understood by those skilled in the art, the following is a brief discussion of the operative characteristics of the invention in order to facilitate a further understanding thereof.
In practice, the upper and lower bracket assemblies 14 and 15 are first installed on the upstanding post 16 (or flat planar surface) using attachment means. The extending arms 12 and 13 are then secured to bracket assemblies 14 and 15 extending outwardly and at right angles to the upstanding post 16 . It should also be noted that the bracket assembly and the extending arm may work as a single unit, as illustrated, without being restricted to this embodiment.
The reinforced banner extremities 19 and 20 are securely engaged and attached into openings 21 and 22 of the housing members 17 and 18 . Rod members 31 and 32 are secured to the housing members 17 and 18 then positioned through apertures 33 and 34 of the extending arms 12 and 13 .
It can be seen as easier with starting with the upper section of the banner 11 when fixedly positioning the banner 11 onto the extending arms 12 and 13 . Once the upper section of the banner is securely positioned with attachment means onto upper extending arm 12 , thanks to gravity the installer is then left with easy positioning of the rod members 31 and 32 into the lower extending arm 13 apertures 33 and 34 and adjusting to desired tautness through the use of members 50 and 51 in combination with spring members 52 and 53 .
As has been described above, winds and/or banner expanding/retracting conditions will have a tendency to cause a banner to be torn from their support arms and shredded and destroyed, unless means for allowing the banner to move and bely to spill the wind from the banner are provided. The natural resilience of the banner construction of the invention used in combination with rod members and spring attachment means, producing a downward force on the upper extending arm and an upward force on the lower extending arm which forces are in great part transmitted to the spring attachment means and therefore absorbed by such, allows for efficient control of naturally generated forces and for the banner to appear taut at all times. A constant force is thereby applied to both the upper and the lower extending arms making it a proactive banner holding system rather than merely a reactive system.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A banner support assembly adapted to be mounted to an upstanding post including a pair of horizontally extending arms fixed in spaced relation to the post and first and second housing members adapted to receive an elongated banner's first and second slidingly engagable members. First and second housing members are adjustably secured to the extending arms through apertures whereby the banner is held taut in variable conditions.
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BACKGROUND OF THE INVENTION
The present invention relates to a box for a set of electric storage batteries for an electric self-propelled vehicle, such as a maintenance machine, the box being particularly suitable for holding batteries made of sealed gas-recombination elements.
It also relates to a modular system of boxes made up of a combination of such boxes.
In the prior art, sets of batteries are made up of a combination of rechargeable self-contained elements each capable of delivering a voltage of about 2 volts, all arranged in parallel or in series in a box, and this box fits into a location provided in the vehicle for this purpose to act as the vehicle's power source.
As will be appreciated, in order to keep the number of battery charging and discharging cycles to a minimum, and therefore increase their life, as many elements as possible must be carried on the vehicle.
However, increasing the number of elements has the effect of increasing the amount of heat evolved during operation.
Document JP-A-60236454 shows a box comprising rails for receiving removable supports, in which the batteries are placed, and not the batteries themselves. Its is purely an element for storing batteries that allows a visual check of the number and condition of the batteries it contains.
SUMMARY OF THE INVENTION
Its subject is therefore a box for a set of electric storage batteries for an electric self-propelled vehicle, comprising at least two mutually opposite side walls extending substantially parallel and defining between themselves a housing for receiving batteries, characterized in that each side wall is internally provided with a series of projecting support elements extending along the wall, each support element forming, jointly with a support element of the other side wall, a support for a layer of storage batteries.
The box according to the invention may also include one or more of the following characteristics, taken in isolation or in all technically possible combinations:
the support elements consist of shelves which are attached on the side walls; the support elements are formed by longitudinal folds in the side walls; the support elements extend along the walls at an inclined angle to the horizontal; the support elements also comprise battery holding means arranged in the vicinity of at least one of the free ends of the side walls; it also comprises two end plates mounted on the free ends of the side walls; at least one of the end plates is mounted detachably on the side walls; the end plates are each provided with a handling point designed to be engaged by a lifting apparatus.
The invention also relates to a system of boxes for a set of electric storage batteries for an electric self-propelled vehicle, characterized in that it comprises a modular set of electrically connected boxes as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages will be found in the following description, given solely by way of example, with reference to the appended drawings, in which:
FIG. 1 is an exploded perspective view of a box for a set of batteries in accordance with the invention;
FIG. 2 is a longitudinal section through the support shown in FIG. 1 , in the assembled condition;
FIG. 3 is a side view of the box shown in FIG. 1 , in the assembled condition;
FIG. 4 is an exploded perspective view of another embodiment of a box according to the invention; and
FIG. 5 is a side view of the box shown in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 show a first embodiment of a box in accordance with the invention, denoted by the general reference number 10 , in what will be assumed to be a vertical position.
The box is designed to accommodate a set of electric storage batteries consisting for example of sealed gas-recombination elements. The box is designed to be placed in an electric self-propelled machine, such as a maintenance machine.
The box 10 consists mainly of a case 12 having the general form of a rectangular profile with two side walls 14 and 16 , an upper wall 18 and a bottom 20 .
Two end plates 22 and 24 are attached, e.g. by screws to the free ends of the case 12 , by means of fixing lugs such as 26 provided on the case 12 near the free ends of the side walls 14 and 16 . At least one of the end plates 22 and 24 can be removed from the case 12 .
It will be observed that the box 10 is made of a material appropriate for the intended use, for example a metal or a plastic.
As is also visible in FIGS. 2 and 3 , support elements such as 30 and 32 are attached to each of the side walls 14 and 16 at regular intervals along the height of the walls 14 and 16 , each support element extending along the corresponding wall and forming, jointly with a support element on the other side wall, a support on which one or more layers of storage batteries such as 34 rest.
As shown particularly in FIG. 3 , the support elements 30 and 32 forming one battery layer extend towards each other in the same plane and are separated from each other by a distance smaller than the length, or the width, of the batteries.
The support elements 30 and 32 preferably extend along the side walls 14 and 16 at an inclined angle to the horizontal to enable easy loading of the box 10 .
Holding means denoted by the general reference number 36 are provided at at least one end of the support elements 30 and 32 in order to hold the battery elements in position.
As an example and as illustrated, these holding means 36 consist of stops mounted removably or non-removably on the support elements 30 and 32 and take the form of rods 38 and 40 extending down through the support elements 30 and 32 .
The assembled case 12 and end plates 22 and 24 constitutes the box, and the box can accommodate a relatively large number of electric storage batteries in the form of several layers of batteries, each supported by two support elements 30 and 32 .
It will be realized that this box 10 allows heat generated during operation to be evacuated by allowing air to circulate through the space left between the layers of batteries corresponding to the thickness of the support elements 30 and 32 .
In order to improve the ventilation of the batteries, the end plates 22 and 24 may advantageously be fitted with ventilation openings such as 42 .
The box 10 may also be provided with handling points consisting of orifices 44 and 46 in the end plates 22 and 24 to accommodate a hook of a lifting apparatus for placing the box in an electric vehicle as its power supply and for replacing the latter.
In the illustrative embodiment shown in FIGS. 1 and 2 , the support elements consist of shelves inserted and fixed by for example welding to the side walls 14 and 16 .
As illustrated in FIGS. 4 and 5 , which show another embodiment of the box according to the invention, and in which parts identical to those in FIGS. 1-3 are given the same reference numbers, the support elements 30 and 32 can also be formed by folding the side walls 14 and 16 .
It will also be seen that the support elements 30 and 32 can be made in such a way that they extend horizontally along the side walls.
The battery holding means may also be formed in the form of spaces, such as 48 , extending between the side walls 14 and 16 on each battery rack.
Lastly, it will be observed that, depending on the amount of space available in the vehicle and the electric power to be delivered, a modular system of boxes can be made by combining several boxes identical to those described above and connecting them electrically in series or in parallel.
It will be understood that the invention described above, which uses a box having side plates, at least one of which is removable, and having battery supports allowing a relatively large number of batteries to be loaded into a small space while enabling efficient ventilation thereof, greatly increases the life of the battery stored in this way, in that it greatly limits the number of cycles of discharging and recharging.
It also makes the operation of installing the battery elements very easy to carry out and greatly facilitates maintenance because the presence of the ventilation openings in the side plates makes the batteries accessible from the exterior.
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A box for a set of electric storage batteries for an electric motor vehicle includes at least two mutually opposite side walls ( 14, 16 ) extending substantially parallel and defining between them a housing for receiving batteries. Each side wall ( 14, 16 ) is internally provided with a series of projecting support elements ( 30, 32 ) extending along the wall, each support element ( 30,32 ) forming, jointly with a support element of the other side wall, a support for at least one rack of storage batteries.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system of gold and copper recovery from gold-containing copper ores obtained from mixed oxide-sulfide copper ore bodies by a series of flotation stages. More specifically, the present invention relates to a system of gold and copper recovery whereby gold-containing ores obtained from mixed oxide-sulfide copper ore bodies, and/or copper flotation by-products thereof, are subjected to at least one flotation step following a dewatering step. In particular, it recovers copper and gold from the oxidized zone of porphyry and other mixed ore deposits. Likewise, the present process allows recovery of copper and gold from the tailings and scavenger concentrates which, in conventional process are no longer viable for further treatment.
BACKGROUND ART
[0002] It is known that porphyry copper deposits predominate over other metals in a mixed metal deposit, which contain, among others, iron oxide copper gold deposits (“IOCG) and volcanogenic massive sulfide deposits. Examples of porphyry copper deposits are those found in El Salvador, Chile, and Bingham, Utah. The copper mines of Arizona, USA, including the mines of Bisbee, Tiger, Tombstone, Morenci, Mammoth and Ajo, Ariz., are the result of the supergene enrichment and hydrothermal alteration of a porphyry copper sulfide intrusion.
[0003] Porphyry type copper ore deposits amenable to strip mining usually consist of a primary zone of essentially sulfides of copper containing minute quantities of gold, an overlying layer or secondary zone of essentially oxidized copper minerals also containing minute quantities of gold, and a transition zone in between.
[0004] Copper sulfides in the supergene enrichment zone at the groundwater interface are, in general, identified as the economically significant class of minerals. Copper oxides at near surface or surface deposits are often considered to be not all that profitable themselves, and important only to the extent that they point prospectors to the supergene enrichment zone below.
[0005] It has been estimated that approximately 85% of the world's copper mining supply comes in the form of sulfide mineral ores. The remaining 15% comes in the form of oxide mineral ores.
[0006] These porphyry copper deposits contain other valuable metals and minerals, such as gold and silver. The Bingham Canyon Mine, for example, as of 2004, has yielded more than 17 MM tons of copper, 23 MM oz gold, 190 MM oz silver and 850 MM lbs molybdenum. The gold and silver are impurities removed from copper during refining.
[0007] Unlike the primary zone that responds readily to conventional flotation procedures, the recovery of metal values from the secondary zone (the copper oxide zone or zone containing copper by-products) has been limited to the prevailing practice of acid heap leaching to extract the acid soluble component of copper. In this process, the mined ore is crushed into small chunks and heaped on an impermeable plastic and/or clay lined leach pad where it can be irrigated with a leach solution, such as sulfuric acid, to dissolve the valuable metals. Either sprinklers or often drip irrigation are used to minimize evaporation. The solution then percolates through the heap and leaches out the acid soluble copper minerals. This can take several weeks. The leach solution containing the dissolved metals is then collected. This leaves behind a gold-containing residue that is laden with acid.
[0008] The drawback with this practice is that the gold values in the secondary (essentially copper oxide) ore are virtually untouched, and because of their very low gold content are uneconomic to recover by other means, and thus, end up in the waste dump. Aside from this disadvantage, said process employs acid consumption—with a tremendous environmental impact requiring some form of remediation—and is costly. Add to this the long holding and processing time to recover the copper as well as the required area for the leaching pad.
[0009] Prior art shows processes that have been developed for the flotation of copper oxide ores such as sulphidization with xanthate collector flotation. However, these processes have drawbacks. For example, in sulphidization, there is difficulty in controlling the sulphidizing agent and the irritating odor of said agent. Likewise the use of sulfides depresses gold values and prevents them from being floated, hence, recovery would be difficult and costly.
[0010] A number of collectors have been evaluated for copper oxide flotation without sulphidization and these include organic complexing agents, fatty acids, fatty amines and petroleum sulphonates. However, these collectors have met with limited success in the field because of their lack of selectivity. Other reagents/collectors have been evaluated but these significantly affect the cost of the flotation processes for oxides.
[0011] Conventional collectors such as xanthates do not perform well on oxidized surfaces. Sulphydric collectors such as xanthates are the most common collectors, however, they are highly selective for sulfide minerals and they chemically react with the sulfide surfaces and do not have affinity for the common non-sulfide minerals such as oxide or oxidized copper sulfide minerals. Studies have been made to combine xanthates with other collectors.
[0012] For example, U.S. Pat. No. 4,022,686 provides a flotation process for copper sulfide and copper oxide ores and for copper smelter slags, wherein benzotriazole or alkyl benzotriazole is added to the ground ores as an activator and then add one or more collectors selected from the group consisting of xanthates, dithiophosphates, thiocarbamate esters, dithiocarbamates, mercaptans and dixanthogens and further, if desired, a promoter such as kerosene, light oil, bunker oil or petroleum lubricant is added to improve the recovery for the flotation of copper ores or copper smelter slags. The conditioning of oxide ores by the addition of benzotriazole or alkylbenzotriazole is claimed to have a higher copper recovery than the sulfidizing process. The process however, is known to be viable for high grade ores.
[0013] GB 2029274A and GB 20096262 also describe other processes for the recovery of metal concentrates from mineral ores containing a metal or metal in the form of their sulphides and/or oxides by froth flotation of the crushed ore and using as collector a 2-mercapto aromatic amine and ortho hydroxyl phenyl oxime respectively. Both processes may have limited application to mineral ores containing one or more metals, i.e. copper, zinc, platinum, molybdenum, nickel, lead, antimony arsenic, silver and gold.
[0014] For gold recovery, the most common process is cyanide leaching, using cyanide to dissolve the gold. Froth flotation is usually applied when the gold present in an ore is closely associated with sulfide minerals. Direct cyanidation of gold-bearing ore generates tons of waste materials containing cyanide which can constitute an environmental hazard.
[0015] U.S. Pat. No. 4,710,361 describes the process of sulfhydric-fatty acid flotation at a pH range of about 5 to 8, in the recovery of gold from gold ores/cyanidation tailings. Likewise, WO2009/072908 provides another process for gold recovery by separating the sand from the primary slime, separating further the sand from the secondary slime and treating sand fractions with sulfhydric-fatty acid collector at a pH of about 6 to 8. These processes however apply only to gold recovery.
[0016] The above mentioned disadvantages or problems in the prior arts are solved by the present invention.
SUMMARY OF THE INVENTION
[0017] The present invention provides a system of gold and copper recovery whereby gold-containing ores obtained from mixed oxide-sulfide copper ore bodies, and/or copper flotation by-products thereof, are subjected to a sequence of coordinated flotation steps following a dewatering step to preconcentrate copper and gold and subsequently leach the copper values contained therein as well as gold metal from the acid-soluble copper minerals containing gold.
[0018] In accordance with one embodiment, ores emanating from mixed oxide-sulfide copper ore bodies containing gold undergo copper flotation using xanthate as a collector, after undergoing crushing, screening and grinding to specific size sufficient for mineral liberation. The copper flotation by-products from the copper flotation are subjected to at least one flotation step using a xanthate-fatty acid combination, following a dewatering step to recover copper and gold. The pre-concentration process applied prior to conventional leaching procedures, reduces the bulk of gold-enriched copper concentrate that would be amenable to acid leaching without sacrificing metal recovery. At the acid leaching stage, cleaner tails from copper flotation stage are mixed with the final gold concentrate containing the acid-soluble copper values to remove the acid-soluble copper including its oxides and reduce its contents before solid-liquid separation.
[0019] Another embodiment provides a process for the recovery of copper and gold wherein ores emanating from mixed oxide-sulfide copper ore bodies undergo at least one flotation stage using a combination of xanthate and fatty acid as collectors, after undergoing crushing, screening, grinding to appropriate size and dewatering. The copper-gold concentrate then undergoes acid leaching prior to solid-liquid separation.
[0020] In both embodiments, cleaner tails and scavenger concentrates can be recycled or further processed to recover the remaining gold and copper content.
[0021] Accordingly, several advantages of one or more aspects are as follows:
a) Gold is recovered along with the copper, instead of ending up in waste dump; b) Gold-enriched oxide copper concentrate is reduced in bulk. Thus, the use of acid for leaching is significantly reduced; c) Leaching time is likewise reduced from several weeks to only a few hours and leaching pad is no longer required; d) Gold and copper that remain in the scavenger concentrates and copper flotation tailings are also efficiently recovered, and; e) Waste and acid materials are also significantly reduced such that only 10% of the original ore is exposed to chemical treatment compared to existing technology where 100% is chemically treated and therefore, hazardous to the environment.
[0027] The above features and advantages of the present invention will be better understood with reference to the accompanying figures, detailed description and examples. It should also be understood that the particular process illustrating the present invention is exemplary only and is not to be regarded as a limitation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Reference is now made to the accompanying figures in which certain figures illustrate embodiments of the present invention from which its novel features and advantages will be apparent:
[0029] FIG. 1 shows a schematic representation of the system of gold and copper recovery according to the present invention.
[0030] FIG. 2 shows a schematic representation of an embodiment of the system of gold and copper recovery according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention provides a system of gold and copper recovery whereby gold-containing ores obtained from mixed oxide-sulfide copper ore bodies, and/or copper flotation by-products thereof, are subjected to at least one flotation step using a fatty acid-xanthate reagent combination as collector/promoter, following a dewatering step to recover copper and gold into a concentrate.
[0032] The system is viable for high grade as well as low-grade ores. Said system can be applied to gold-containing mixed oxide-sulfide copper ores containing gold to as low as 0.2 gm/MT concentrations and copper flotation by-products containing gold as low as 0.10 gm/MT.
[0033] Dewatering is an important step prior to flotation. The degree to which flotation of the desirable mineral(s) is achieved depends on many factors such as collectors, frothers, activators, pH, operation components such as feed rate, mineralogy, particle size, pulp density, temperature and many other parameters. However, in the case of flotation with the aid of fatty acids, the degree by which the collector is made to attach to the valuable mineral is governed by the intensity by which the reagent is made to “smear” on the surface of the valuable mineral. And this level of intense conditioning is enhanced by providing a high percentage of solids in the stirred suspensions of solids in water containing said collector. The second advantage of high solids conditioning is to provide the means to allow clustering of the “collected” valuable minerals as an aid to flotation kinetics. In other words, the rate at which the collected minerals attach themselves to the air bubbles in flotation is enhanced when clustering is present which, in effect, increases the successful encounter between the valuable mineral and the air bubbles.
[0034] One embodiment of the process is illustrated in Figure i. The gold-containing ore from mixed oxide-sulfide copper ore bodies is crushed, screened and ground to an appropriate size, preferably about wo Mesh, using conventional means known to a person skilled in the art, such as but not limited to the use of crushers and grinding mills. The ground materials are then made to undergo at least one-stage, preferably z-stage copper flotation at a pH range of about 7 to about 8 and a specified reaction time, preferably within 5 to 20 minutes for conditioning and 5 to 20 minutes for flotation, and more preferably within 5 minutes for conditioning and within 5 minutes for flotation, with xanthate as a collector, present in the amount of about 0.1 to about 0.2 lbs./T of feed.
[0035] The rougher concentrates obtained from said copper flotation are made to undergo further grinding and at least one-stage, preferably 2-3 cleaner flotation stages at pH of about 10 to about 11, and preferably by conventional means, such as but not limited to froth flotation, to obtain a final copper concentrate and cleaner tails, while the scavenger concentrates are made to undergo repeatedly the copper flotation cycle. The cleaner tails which were separated from the rougher concentrate will proceed to acid leaching.
[0036] The copper by-products from the copper flotation process undergo a dewatering step, and thereafter, a conditioning step of about 5 minutes followed by a flotation step at a pH range of about 5 to about 7, preferably at a pH of 5, and at a specified flotation time, preferably 5 to 10 minutes, using a fatty acid-xanthate reagent combination, as a collector or promoter of the gold present in the copper flotation by-products. The fatty acid-xanthate reagent combination may comprise about 0.5 to about 2 lbs/T fatty acid and about 0.1 to about 0.2 lbs/T xanthate. Copper by-products undergo at least one flotation stage, preferably two stages.
[0037] Suitable fatty acid collectors may be selected from fatty acids containing 8-20 carbons, preferably selected from the group consisting of caprylic, capric, oleic, linoleic, linoleic and arachidonic acids.
[0038] Xanthate may be sodium amyl xanthate or sodium isobutyl xanthate, which are available commercially.
[0039] Suitable frothers such as fuel oils or other oils may also be added during the flotation stage.
[0040] The rougher concentrates from said copper-by product flotation process are then subjected to regrinding to about 200 Mesh and further subjected to at least one, preferably two (2) cleaner flotation stages at pH of about 4 to about 6 to recover the final copper-gold concentrate. The scavenger concentrates, together with the dewatered copper flotation by-products, are made to undergo the flotation cycle.
[0041] The final copper-gold concentrate, together with the cleaner tails from the cleaner flotation steps of the rougher concentrate from copper flotation, is then made to undergo acid leaching, preferably with sulfuric acid, at a pH in the range of about 1 to about 2 until leaching is completed within 2 to 5 hours, more preferably 3 hours, to remove all acid-soluble copper, including its oxides, and reduce its copper content, which then undergoes solid-liquid separation, to recover the acid leach liquor as a supernatant liquid for copper recovery.
[0042] The leach residue is then subjected to a final leaching step by conventional means to extract and recover gold from liquor containing additional values of dissolved copper. Said conventional leaching means may be the Carbon in Pulp (CIP) process or the Carbon in Leach (CIL) process, both of which are known to a person skilled in the art.
[0043] Another embodiment of the process is shown in FIG. 2 .
[0044] Similar to the previous process, the gold-containing ore from mixed oxide-sulfide copper ore bodies is crushed, screened and ground to appropriate size, preferably zoo Mesh, using conventional means known to a person skilled in the art, such as but not limited to the use of crushers and grinding mills. The ground materials are then made to undergo dewatering, and thereafter, at least one-stage, preferably two (2) flotation stages at a pH range of about 5 to 7 and a specified reaction time, preferably within 5 to 20 minutes for conditioning and 5 to 20 minutes for flotation, and more preferably within 5 minutes for conditioning and within 10 minutes for flotation, with a xanthate-fatty acid combination, as collectors, present in the amount of about 0.1 to 0.2 lbs./T Xanthate and about 2lbs/T Fatty acid. Frothers may be added during this stage.
[0045] The rougher concentrates from the flotation process is then subjected to regrinding to about zoo Mesh and further subjected to at least one, preferably two (2) or three (3) cleaner flotation stages at a pH of about 4 to about 6 to recover the final copper-gold concentrate. The scavenger concentrates undergo repeatedly, regrinding to about 200 Mesh and flotation.
[0046] The final copper-gold concentrate is then made to undergo acid leaching, preferably with sulfuric acid, at a pH in the range of about 1 to about 2 until leaching is completed within 2 to 5 hours, more preferably 3 hours, to remove all acid-soluble copper, including its oxides, and reduce its copper content, which then undergoes solid-liquid separation, to recover the acid leach liquor as a supernatant liquid for copper recovery.
[0047] The leach residue is then subjected to a final leaching step by conventional means to extract and recover gold and copper-bearing liquor. Said conventional leaching means may be the Carbon in Pulp (CIP) process or the Carbon in Leach (CIL) process, both of which are known to a person skilled in the art.
[0048] The copper and gold recovery system of the present invention will now be further illustrated with reference to the following examples.
EXAMPLE
[0049] 30 kilos of an “L” ore containing 0.61% Cu and 0.70 gm/MT Au was crushed initially to ½ inch in size and further pulverized to produce a 65 mesh charge, sized in lots of 1.0 kg in weight. Grinding of the ore to finer sizes was accomplished with the aid of a ball mill rotating at fixed speeds but at varied grinding times. The ground materials were then made to undergo copper flotation at a pH of 8 for 20 minutes, subsequent to conditioning for 5 minutes, using 0.1 to 0.2 lbs Xanthate/ton of feed as a collector.
[0050] The rougher concentrates obtained from said copper flotation are made to undergo further grinding and cleaner flotation steps by conventional means, such as but not limited to froth flotation, to obtain a final copper concentrate and cleaner tails, while the scavenger concentrates are made to undergo again the copper flotation cycle.
[0051] The copper by-products from the copper flotation process underwent dewatering, conditioning for 5 minutes and flotation at a pH of 7, for 10 minutes, using an oleic acid-xanthate reagent combination, at a ratio of 2 lbs/T oleic acid and 0.2 lbs/T xanthate, as a collector or promoter of the gold present in said copper flotation by-products.
[0052] The rougher concentrates from the copper by-product flotation process were then subjected to regrinding to 200 Mesh and further subjected to two (2) cleaner flotation stages to recover the final copper-gold concentrate.
[0053] The final copper-gold concentrate, together with the cleaner tails from the cleaner flotation steps of the rougher concentrate from copper flotation, was then made to undergo acid leaching with sulfuric acid, at a pH of a for 5 hours, to remove all acid-soluble copper, including its oxides, and reduce its copper content. The acid-leached concentrate then underwent solid-liquid separation, to recover the acid leach liquor as a supernatant liquid for copper recovery.
[0054] The leach residue was then subjected to the Carbon in Leach (CIL) process to extract and recover gold. The copper-bearing liquor from carbon elution/EW undergoes copper recovery together with the acid liquor from H 2 SO 4 leaching.
[0055] The tables below show the conditions and results of the system described in this Example.
[0000]
TABLE IA
Test Results for Copper Flotation
Weight
Gold
Copper
Gold
Copper
Percent
Assay
Assay
Distribution
Distribution
Product
%
g Au/t
% Cu
%
%
Cu Final Conc.
0.37
67.80
25.53
35.65
15.63
Cu Clnr Tails
4.85
5.82
5.24
40.11
42.04
Cu Scav. Tails
94.78
0.18
0.27
24.24
42.33
Calculated
100.00
0.70
0.60
100.00
100.00
Head
Head assay
0.70
0.61
[0000]
TABLE IIA
Test Results for Gold Flotation
Weight
Gold
Copper
Gold
Copper
Percent
Assay
Assay
Distribution
Distribution
Product
%
g Au/t
% Cu
%
%
Au Final Conc.
11.24
0.85
1.47
13.58
27.34
Au Reclnr
6.26
0.67
0.55
5.96
5.70
Tails
Au Clnr Tails
9.32
0.28
0.31
3.71
4.78
Final Flot.
67.96
0.01
0.04
0.97
4.50
Tails
Calculated
94.78
0.18
0.27
24.22
42.32
Head
Copper Scavenger Tails
0.19
0.28
Assay
[0000]
TABLE IIIA
Test Results for Combined Concentrate Leaching
Copper
Gold
Copper
Gold
Distri-
Weight
Assay
Assay
Distribution
bution
Product
Percent %
g Au/t
% Cu
%
%
COMBINED CONCENTRATE (LEACH FEED)
Au Final Conc.
11.24
0.85
1.47
13.58
27.34
Cu Cleaner Tails
4.85
5.82
5.24
40.12
42.05
Combined Conc.
16.09
2.35
2.61
53.70
69.39
LEACH PRODUCTS
ACID LEACHING
Leach Liquor
(48.16)
0
0.54
0
43.03
Leach Residue
16.09
2.35
0.99
53.75
26.36
Calculated Head
16.09
2.35
2.61
53.75
69.39
CIL LEACHING
CIL Liquor
(48.27)
0.741
0.24
50.84
19.17
CIL Residue
16.09
0.125
0.27
2.86
7.19
Calculated Head
16.09
2.35
0.99
53.70
26.36
Combined concentrate assay
2.40
2.60
[0000]
TABLE IVA
Overall Results for Flotation and Leaching Tests
Copper
Gold
Copper
Gold
Distri-
Weight
Assay
Assay
Distribution
bution
Product
Percent %
g Au/t
% Cu
%
%
Cu Final Conc.
0.37
67.8
25.53
35.66
15.63
Au Reclnr Tails
6.26
0.67
0.55
5.96
5.70
Au Cleaner Tails
9.32
0.28
0.31
3.71
4.78
Final Flot. Tails
67.96
0.01
0.04
0.97
4.50
Acid Leach
(48.16)
0.00
0.54
0.00
43.03
Liquor
CIL Liquor
(48.27)
0.741
0.24
50.84
19.17
CIL Residue
16.09
0.125
0.27
2.86
7.19
Calculated Head
100.00
0.70
0.60
100.00
100.00
Head Assay
0.70
0.61
[0056] The overall results for flotation and leaching tests show high copper and gold recovery at 86.5% for gold and 78% for copper. Rejection of waste material is very high at 84.05%, without creating a hazardous environment, as is the case with conventional technologies.
EXAMPLE 2
[0057] 30 kilos of “B” ore containing 0.34% Cu and 0.44 gm/MT Au was crushed initially to ½ inch in size and further pulverized to produce a 65 mesh charge, sized in lots of 1.0 kg in weight. Grinding of the ore to finer sizes was accomplished with the aid of a ball mill rotating at fixed speeds but at varied grinding times.
[0058] The ground materials were then made to undergo copper flotation following dewatering at a pH of 7 within 10 minutes subsequent to a 5 minute -conditioning, using 0.2 lbs./T xanthate, as a collector.
[0059] The rougher concentrates obtained from said flotation were made to undergo further grinding and three (3) stages—cleaner flotation steps to obtain a final copper-gold concentrate and cleaner tails. These cleaner tails were made to repeatedly undergo the flotation cycle.
[0060] The final copper-gold concentrate was then made to undergo acid leaching, preferably with sulfuric acid, at a pH in the range of 1 to 2 and a specified leaching time, preferably 2 to 5 hours, more preferably 3 hours, to remove all acid-soluble copper, including its oxides, and reduce its copper content, which then underwent solid-liquid separation, to recover the acid leach liquor as a supernatant liquid for copper recovery.
[0061] The leach residue was then subjected to the Carbon in Pulp (CIP) process to extract and recover gold. The copper-bearing liquor from carbon elution/EW undergoes copper recovery together with the acid liquor from H 2 SO 4 leaching.
[0062] The tables below show the conditions and results of the system described in this Example.
[0000]
TABLE VI
Test Results for Gold Flotation
Weight
Gold
Copper
Gold
Copper
Percent
Assay
Assay
Distribution
Distribution
Product
%
g Au/t
% Cu
%
%
Au Final Conc.
9.86
4.11
3.08
91.83
89.43
Final Flot.
90.14
0.04
0.04
8.17
10.57
Tails
Calculated
100.00
0.44
0.34
100.00
100.00
Head
Head Assay
0.44
0.34
[0000]
TABLE VII
Test Results for Acid Leaching of Gold Concentrates
Gold
Copper
Gold
Copper
Distri-
Distri-
Weight
Assay
Assay
bution
bution
Product
Percent %
g Au/t
% Cu
%
%
Acid Leach Liquor
(269.90)
0
0.036
0
28.50
Acid Leach Residue
9.86
4.11
2.10
91.83
60.93
Calculated Head
9.86
4.11
3.084
91.83
89.43
Flotation concentrate assay
4.11
3.08
[0000]
TABLE VIII
Test Results for Gold Concentrate CIL Leaching
Copper
Gold
Copper
Gold
Distri-
Weight
Assay
Assay
Distribution
bution
Product
Percent %
g Au/t
% Cu
%
%
CIL Liquor
(39.26)
1.03
0.494
91.61
56.88
CIL Residue
9.86
0.01
0.14
0.22
4.05
Calculated Head
9.86
4.11
2.11
91.83
60.93
Acid leach residue assay
4.11
2.10
[0000]
TABLE IX
Overall Results for Flotation and Leaching Tests
Copper
Gold
Copper
Gold
Distri-
Weight
Assay
Assay
Distribution
bution
Product
Percent %
g Au/t
% Cu
%
%
Acid Leach
(269.90)
0
0.036
0
28.50
Liquor
CIL Liquor
(39.26)
1.03
0.494
91.61
56.88
CIL Residue
9.86
0.01
0.14
0.22
4.05
Final Flot. Tails
90.14
0.04
0.04
8.17
10.57
Calculated Head
100.00
0.44
0.34
100.00
100.00
Head Assay
0.44
0.34
[0063] The overall results for flotation and leaching tests show high copper and gold recovery at 91.61% for gold and 85% for copper. Again, the rejection of waste material is very high at 90.14%, without creating a hazardous environment, as is the case with conventional technologies.
[0064] The potential of the system claimed here can be illustrated by comparing its test results with those of other patents. For instance, in U.S. Pat. No. 4,022,686, the feed material used was quite rich. The initial runs described in Tables a and 2 of the patent describe the feed to be at around 2.49%-2.75% Cu by weight (Ref. Table 2 thereof) which is described as a Chilean copper oxide ore. And the weight recovery of Cu as shown in the tails for the eleven (11) or so runs cited ranges from o.66% -2.07% Cu (by weight). The best results were obtained using a combination of the following reagents: 5-methyl benzotriazole, potassium amyl xanthate and a light oil with an estimated copper recovery in the rougher concentrate of 78.0%. The patent was an improvement over described recoveries using xanthates alone.
[0065] The best recoveries for U.S. Pat. No. 4,022,686 are described in Table 8 thereof where the feed material was about 5× richer, 13.9% Cu and the tails were 0.14% Cu.
[0066] In contrast, the Philippine ores described in our examples here had head assays of 0.61% Cu (Ex. a.) and 0.34% Cu (Ex.2), for both head assays. The Cu recoveries for the improved process in both cases were 78% to 85% respectively and significantly lower final flotation tails of 0.04% Cu, showing a marked improvement over the best result in the patent cited.
[0067] Therefore, using a Cu ore feed which was about 75% less rich in Cu weight, an improvement in recovery was obtained of at least 350% over the results in U.S. Pat. No. 4,022,686.
[0068] Likewise, for gold, the Philippine ores described in said examples had head assays of 0.70 g/T (Ex. 1) and 0.44 g/T (Ex. 2), respectively. The gold recoveries for the improved process in both cases were 86.5% and 91.61%, respectively, demonstrating the efficacy of this application to recover both Cu and Au effectively.
[0069] The unified system described in the present invention is capable of recovering copper and gold values from the sulfide component of the ore body into a smelter-ready concentrate in conjunction with a novel approach involving a series of flotation stages to derive a gold-enriched oxide copper concentrate reduced in bulk which would yield itself amenable to acid leaching of the acid-soluble component of the concentrate and a specialty system to recover the gold values remaining in said concentrate utilizing a non-cyanide leaching process for subsequent recovery of the gold into metal. The system also allows the recovery of gold from scavenger concentrate and copper flotation tailings economically.
[0070] The ultimate outcome of such a unified process is the production of those final products of economic value to the marketplace: a smelter-ready sulfide copper concentrate containing gold; a copper metal finished product; and Dore gold as well as an environmentally-friendly by-product consisting essentially of the original rock in pulverized form constituting almost 90% of the original ore body stripped of its valuable metal contents.
[0071] Due to its wide applicability over all kinds of copper ore bodies, this invention may be considered a “black box”. The economic returns are enormous and forcefully demonstrate overall financial gain to the operator whereas in the past the results using conventional technology have been marginal if not outright dismal.
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The present invention relates to a process of gold and copper recovery from gold-containing copper ores obtained from mixed oxide-sulfide copper ore bodies by a series of flotation stages. More specifically, the present invention relates to a process of gold and copper recovery whereby gold-containing ores obtained from mixed oxide-sulfide copper ore bodies, and/or copper flotation by-products thereof, are subjected to at least one flotation step following a dewatering step. In particular, it recovers copper and gold from the oxidized zone of porphyry and other mixed ore deposits. Likewise, the present process allows recovery of copper and gold from the tailings and scavenger concentrates which, in conventional process are no longer viable for further treatment.
| 1
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This is a division of application Ser. No. 446,933, filed 12-6-82, now U.S. Pat. No. 4,606,925.
BACKGROUND OF THE INVENTION
Practitioners of the art of perfumery or flavor creation are engaged in combining a number of substances having individual characteristics to produce a blend which as a desired effect on the senses. The art of perfumery is involved almost exclusively with the sense of smell. The art of flavor creation, however, is based on a combination of the senses of taste, smell, and, in many instances, touch in the form of "mouth feel". It is not surprising therefore, that many substances are commonly used by perfumers and flavorists since both practitioners appeal to the sense of smell in their creative effort.
Many materials used by perfumers and flavorists have organoleptic properties which of themselves are not pleasant or attractive, yet are still very useful for the purpose of blending or unifying certain organoleptic characteristics to provide a fragrance or flavor composition which is considered superior, more finished and complete and is more pleasing to the senses than a comparable composition which does not have that material.
For example, perfumers use materials having what is known in the art as "animalic" odors to simulate a quality known as "warmth" in a fragrance composition. This quality of "warmth" is found in many of the natural floral fragrances, especially Jasmin, Narcissus, Tuberose, Gardenia, Lilac and Ylang. In addition, this quality of "warmth" has in the evolution of the art of perfumery become an inherently desirable quality and is often employed in a variety of fragrance types for both men and women.
The most useful and valued of the animalic odor materials such as civet, castoreum and ambergris are derived from animal secretions. Their limited availability and great expense has led to the search and development of products from synthetic or botanical origins which can economically be used to enhance or imitate the effect of these expensive animal derived products.
Similarly, the flavorist is well aware that natural foods contain a number of compounds which contribute subtle effects to the overall sensory perception and which do not themselves demonstrate a flavor which the ordinary person would associate with that particular food. Indeed, many of these compounds when evaluated in concentrated form are actually unpleasant, yet used in dilute form they tend to blend and unify the other flavoring materials and provide nuances which contribute to the overall impression of the natural flavor.
In creating flavors for foodstuffs and/or luxury consumables (tea, tobacco, etc.) the flavoriest is often seeking to duplicate natural flavors and is constantly looking for chemicals which so contribute to the overall impression of the flavor so as to make it more natural. The flavorist refers to such compounds as contributing "naturalness" to the flavor. The flavor notes which are sought to provide this "naturalness" are often those described as fermented, acidic, woody, musty, sweaty, spicy etc. in character.
THE INVENTION
The present invention concerns fragrance and flavor compositions comprising 4-alkyl substituted cyclohexyl and cyclohex-3-enyl carboxylic acids and methods for preparing same. These acids can be represented by formula I ##STR1## wherein: the dotted line designated by α represents an optional bond and
R is an ethyl, propyl, or butyl group. Propyl and butyl are to be understood as encompassing both the straight chain and branched isomers.
The compounds of formula I are characterized by organoleptic properties that make them especially useful in fragrance and flavor compositions. Although several of these compounds represented by formula I are known, there is no mention of their organoleptic properties in the prior art.
The compounds of formula I can be prepared by methods similar to those described in the prior art. See L. N. Mander and L. T. Palmer, Aust. J. Chem. 32, 823 (1979) (and references therein); I. N. Nazarov et al., Izvest. Akad. Nauk S.S.S.R., Otdel. Khim. Nauk, 1595 (1959); H. Van Bekkum et al., Recueil 81, 833 (1962); K. Alder et al., Chem. Ber. 86, 1364 (1953); H. Van Bekkum et al., Recueil 89, 521 (1970). A number of preferred methods for their preparation are described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The 4-alkyl-3-cyclohexene-1-carboxylic acids and the 4-alkylcyclohexane-1-carboxylic acids of formula I have organoleptic properties that make them particularly useful in odorant and flavoring compositions. (See Table I).
TABLE I______________________________________ ##STR2## IR α-Bond Odor Description Flavor Description______________________________________C.sub.2 H.sub.5 double sweaty, intense, fatty, woody, fruity, oily, slightly greeniso-C.sub.3 H.sub.7 double sweaty, intense, musty, oily, woody fatty, woody -n-C.sub.3 H.sub.7 double fatty, sweaty mild, fatty, oily, woody woodytert-C.sub.4 H.sub.9 double sweaty, waxy, woody musty, woodyC.sub.2 H.sub.5 single green, fatty, woody, fruity, oily, woody earthyiso-C.sub.3 H.sub.7 single sweaty, oily, weak weak, woody, spicy -n-C.sub.3 H.sub.7 single musty, woody, fatty mild, weak, spicy, woodytert-C.sub.4 H.sub.9 single weak, fatty, woody weak, dry, woody______________________________________
These organoleptic properties are not of themselves regarded as particularly pleasant or attractive. Their value in flavors and fragrances is not to provide a dominant characteristic, but to provide those subtle characteristics which tend to blend and unify the flavor or fragrance resulting in a more rounded, complete, finished and natural composition.
Those compounds having a perceptably dominant sweaty odor character are considered to be the most valuable for use in fragrance formulations. The 4-alkyl-3-cyclohexene-1-carboxylic acids have this character in a greater degree than their saturated analogs and are preferred for most applications.
Especially preferred for the intense overpowering nature of their perspirative character are those 4-alkyl-3-cyclohexene-1-carboxylic acids in which the alkyl substituent is isopropyl or ethyl, i.e. 4-isopropyl-3-cyclohexene-1-carboxylic acid and 4-ethyl-3-cyclohexene-1-carboxylic acid. The odor of the isopropyl acid is described as intense, sweaty, fatty, woody and is especially preferred for its full-bodied character. The ethyl acid, which is novel, is described as intense, sweaty, fatty, slightly green and is found to have more top note. Both compounds have immense impact in fragrance compositions and can have an effect in some fragrance compositions as low as 0.001%. They are more often used, however, at levels between 0.005 to 0.5%. The odor intensity of these especially preferred compounds is so strong that it is not effectively diminished when used in admixture with formula I compounds of lower intensity. For example, 4-isopropyl-3-cyclohexene-1-carboxylic acid in a mixture containing up to 15% of its saturated analog (4-isopropylcyclohexane-1-carboxylic acid, a compound of low intensity) is found to have an odor impact as effectively penetrating as the essentially pure unsaturated acid. Such mixtures can be used in place of the pure compounds in fragrance compositions and it may be preferred to do so since such mixtures result from a number of the practical synthetic methods described herein.
The 4-alkyl-3-cyclohexene-1-carboxylic acids appear to be stronger, more diffusive, more woody and more spicy than their saturated analogs and are also preferred for use in flavor formulations, foodstuffs and luxury consumables (tobacco, etc.). The 4-isopropyl-3-cyclohexene-1-carboxylic acid is the most effective and is especially preferred.
The compounds of this invention, especially the 4-isopropyl-3-cyclohexene-1-carboxylic acid, appear to have application in a wide variety of flavor types, but are especially useful in highly seasoned foods such as those characterized as Mexican and/or Indian curry type dishes. The use of these compounds tends to blend and unify the various spice notes providing a more blended and natural organoleptic impression.
Similar to the experience found in fragrances, the 4-isopropyl-3-cyclohexene-1-carboxylic acid can be used effectively in admixture with formula I compounds of lower intensity. Since such mixtures result from a number of practical synthetic methods described herein, it is often preferred to use such mixtures.
The 4-alkyl-3-cyclohexene-1-carboxylic acids of formula I can be prepared in a variety of ways, many of which are described or are similar to those described in the prior art. A number of these methods are illustrated below. ##STR3##
Chart I illustrates a possible general route to the desired acids which utilizes the corresponding 4-alkylbenzaldehydes as starting materials. In accordance with the method of Birch et al. [Aust. J. Chem. 26, 1363 (1973)] the starting benzaldehyde is converted to the 4-alkyl-1,4-cyclohexadiene-1-carboxaldehyde by a Birch reduction of the corresponding N,N'-dimethylimidazolidine followed by acid hydrolysis. The product can then be converted to the desired 4-alkyl-3-cyclohexene-1-carboxaldehyde by a Li/NH 3 reduction (path a of Chart I) as described by Mander and Palmer [Aust. J. Chem. 32, 823 (1979)]. It has also been found that the same conversion can be accomplished via a disproportionation reaction (path b of Chart I) which is consistent with the findings of Varo and Heinz [J. Agr. Food Chem. 18, 239 (1970)]. In both instances, the resulting 4-alkyl-3-cyclohexene-1-carboxaldehyde is oxidized to the desired acid, suitably via a Jones oxidation.
The disproportionation reaction (path b of Chart I) is preferably carried out under strongly basic conditions such as in a refluxing solution of potassium hydroxide in methanol. This disporportionation reaction does, however, result in the presence of significant quantities of trans-4-alkylcyclohexane-1-carboxylic acid in the final product (ca. 2-15%). As is clear from this disclosure, the presence of this saturated analog is of little or no consequence since in most instances, and particularly in the case of the 4-isopropyl and 4-ethyl derivatives, the organoleptic characteristics of the mixture are effectively the same as the organoleptic characteristics of the pure unsaturated acid.
While either of the above methods (path a or path b of Chart I) are most suitable as a general synthesis, a specific synthesis has been devised to prepare the 4-isopropyl-3-cyclohexene-1-carboxylic acid whichis preferred for that particular compound. It has been found that perillaldehyde (4-isopropenyl-1-cyclohexene-1-carboxaldehyde) can be converted to the desired 4-isopropyl-3-cyclohexene-1-carboxylic acid in three steps. The first step involves the isomerization of the perillaldehyde to 4-isopropyl-1,3-cyclohexadiene-1-carboxaldehyde. [See H. Kayahara et al., J. Org. Chem. 33, 4536 (1968)]. This compound can then be subjected to a disproportionation step, similar to that shown in path b of Chart I for the 1,4-cyclohexadiene analog, to provide the 4-isopropyl-3-cyclohexene-1-carboxaldehyde which can then be oxidized to the corresponding acid. This process also provides a product containing about 5 to 15% of the corresponding 4-isopropylcyclohexane-1-carboxylic acid (trans-isomer).
Another method, which provides a suitable product in a single step, involves the Birch reduction of the corresponding 4-alkylbenzoic acids. The Birch reduction of 4-isopropylbenzoic acid (cumic acid) as reported does not indicate the formation of the desired 4-isopropyl-3-cyclohexene-1-carboxylic acid. [See F. Camps et al., J. Org. Chem. 32, 2563 (1967)]. It has been found, however, that a product consisting of about 15-20% of the 4-isopropyl-3-cyclohexene-1-carboxylic acid and about 80-85% of the 4-isopropyl-2-cyclohexene-1-carboxylic acid can be prepared by carrying out the reaction in refluxing ammonia (ca.-33° C.) using excess lithium metal (50-100% excess) in the presence of a protein donor such as t-butanol. This mixture of acids exhibits the same odor characteristics as does the pure 4-isopropyl-3-cyclohexene-1-carboxylic acid but has less intensity, the 4-isopropyl-2-cyclohexene-1-carboxylic acid having the effect of a diluent rather than modifying the odor.
To the best of our knowledge, none of the compounds of this invention have been reported to occur in nature. We have, however, found 4-isopropyl-3-cyclohexene-1-carboxylic acid and traces of 4-isopropylcyclohexane-1-carboxylic acid (cis and trans isomers) to be present in commercial cumin oil. It is our view that this acid may not be a constituent of cumin in the natural state, but may be formed by disproportionation and subsequent oxidation of certain cyclohexadiene aldehydes present in cumin.
An alternate way to obtain the 4-isopropyl-3-cyclohexene-1-carboxylic acid would be to extract it from commercial cumin oil per se or to subject the oil to a disproportionation, oxidation procedure (path b, Chart I) and obtain the acid therefrom. The claims should be understood to encompass the use of products obtained in this way. The claims are to be understood as not encompassing the use of commercial cumin oil or any other material derived from nature which may inherently contain an acid of this invention in admixture with the many other compounds of said natural material and which has not been processed for the purpose of increasing the content of the acids of this invention to a point where the processed material can be used as a substitute for said acids contained therein.
The 4-alkylcyclohexane-1-carboxylic acids of this invention can be prepared from their unsaturated analogs by any suitable hydrogenation procedure, many of which are known in the art. For example, procedures known in the art for reducing benzoic acids to the corresponding cyclohexyl acids would be suitable. Such reductions are preferably carried out via catalytic hydrogenation using a rhodium catalyst (e.g. 5% rhodium on alumina), preferably in a solvent (e.g. ethanol containing a small amount of acetic acid). This reaction can be carried out at room temperature and at moderate pressures (about 50 psi). Such reductions of the aromatic ring usually lead to cis, trans isomeric mixtures in which the cis isomer predominates.
The 4-alkylcyclohexane-1-carboxylic acids can also be prepared from the corresponding 4-alkyl-3-cyclohexene-1-carboxylic acids described earlier via a suitable catalytic hydrogenation. Hydrogenation procedures are well known in the art for reducing double bonds in cyclohexene rings. Preferred procedures employ palladium catalysts in hydroxylic solvents. For example, the use of a catalytic amount of 5% palladium on carbon in methanol at room temperature and moderate pressures (about 50 psi) provides the desired saturated acids in good yield. Catalytic hydrogenations using palladium catalysts usually provide isomeric mixtures in which the trans isomer predominates.
From the above it is clear that isomeric mixtures wherein the cis or the trans isomers predominate are easily attainable. Isomer ratios wherein the cis to trans ratio varied from 1:4 to 4:1 were found to have similar odor characteristics.
As mentioned earlier, the 4-isopropyl-3-cyclohexene-1-carboxylic acid and the 4-ethyl-3-cyclohexene-1-carboxylic acid are especially preferred for use in fragrance compositions due to the intense, overpowering nature of their "animalic" odor character. These compounds are several times more intense than the other compounds of formula I. Their odor character is so intense that they have enormous impact even when used in fragrance compositions in concentrations as low as 0.01% to 0.05% of the total base. The presence of other isomers such as the corresponding saturated 4-alkylcyclohexane-1-carboxylic acid or the 4-alkyl-2-cyclohexene-1-carboxylic acid in substantial amounts does not alter the effectiveness of these compounds and such mixtures can be used in place of the pure isomers where desirable with, perhaps, a slight adjustment of the amount used.
While the other compounds of formula I can be used to good effect in perfume formulations, it is the 4-isopropyl-3-cyclohexene-1-carboxylic acid and the 4-ethyl-3-cyclohexene-1-carboxylic acid that were found to be superior as high impact chemicals of an animalic nature. Their use is further illustrated in the examples.
For example, in the creation of an animalic accord, the 4-isopropyl-3-cyclohexene-1-carboxylic acid enveloped and blended the various animalic notes into a unified and pleasingly warm accord. Without the compound, the accord was found to lack sufficient warmth and to be disharmonious in nature and crude and unpleasant in odor, particularly due to the odor of Skatole which stood out. Similar effects can be obtained using the 4-ethyl-3-cyclohexene-1-carboxylic acid.
Similarly, the examples show the beneficial effect of these compounds on a wood base and a musk fragrance. The bases without the claimed 4-isopropyl-3-cyclohexene-1-carboxylic acid were incomplete having odor components that "stood out". The wood base had fatty, earthy and camphoraceous odors that were not in harmony with the desired woody character. The addition of 4-isopropyl-3-cyclohexene-1-carboxylic acid blended these notes to give a warmer, attractive and harmonious woody bouquet. In the musk fragrance without the 4-isopropyl-3-cyclohexene-1-carboxylic acid, the odors of Cedarleaf, Patchouly and Skatole were not fully integrated into the fragrance. The addition of the preferred compound warmed and unified the musky fragrance, while increasing the intensity of impact of its musk character. Again, similar effects can be obtained with the ethyl analog.
The ability of 4-isopropyl-3-cyclohexene-1-carboxylic acid to add a blending or unifying warmth to a fragrance composition was further demonstrated by use in a floral-fruity base and a spice accord. "Warmth" is an important quality in the bouquet of many floral compositions, associated with their "naturalness". In a floral base, in the direction of fruity, odors that were perceived to be harsh and fatty conflicted with the desirable fruity and floral odors and imparted a synthetic quality to the fragrance. The addition of 4-isopropyl-3-cyclohexene-1-carboxylic acid added the necessary warmth that suppressed the harsh fatty odors resulting in a more natural appearing and more desirable floral-fruity fragrance. Similarly, in a spice accord, odor notes were found to be in conflict; the spicy note of Bay oil conflicting with the herbaceous notes of Caraway oil. The addition of the preferred compound produced a warm effect that blended these divergent notes and enhanced the inherent spicy character of the accord.
Depending on the fragrance composition and the compound used, concentrations as low as 0.001% can be used for the more intense 4-isopropyl-3-cyclohexene-1-carboxylic acid and 4-ethyl-3-cyclohexene-1-carboxylic acid. A preferred range for these more intense compounds would be from 0.005% to 0.5% with a range of 0.01% to 0.05% being especially preferred. The less intense compounds would be used in proportionally higher amounts to achieve similar effects, preferably in a range of 0.1 to 1.0%. All of the compounds of formula I can be used at concentrations up to 10% or even higher to produce special effects, the use and effects achieved being limited only by the imagination and ability of the perfumer.
Fragrance compositions containing the compounds of the invention can be used as odorant bases for the preparation of perfume and toilet waters by adding the usual alcoholic and aqueous dilutents thereto. Approximately 15-20% by weight of base would be used for perfumes and approximately 3-5% by weight would be used for toilet waters.
Similarly, the fragrance compositions can be used to odorize soaps, detergents, cosmetics, or the like. In these instances, a base concentration of from about 0.5% to about 2% by weight can be used.
As mentioned previously, the 4-alkyl-3-cyclohexene-1-carboxylic acids appear to be stronger, more diffusive, more woody and more spicy then their saturated analogs. They are preferred for use as flavorants for blending and unifying the various components of a flavor composition, for adding "impact" and for adding a quality of naturalness to the flavor. Of the unsaturated acids, the 4-isopropyl-3-cyclohexene-1-carboxylic acid has the best balance of flavor characteristics and is especially preferred for use in flavor compositions.
The ability of the compounds of formula I to add subtle effects to flavor compositions make these compounds useful in a wide variety of flavor compositions and/or foodstuffs, drinks and luxury consumables (i.e. tobacco products, teas, spices etc). These include, but are not limited to spices, salad dressings, meats, gravies, sauces, vegetables, seasonings, seasoned batter mixes for meat dishes, soup mixes, seasoned bread crumbs, cocktail sauces, pizza sauces, spaghetti sauces, vegetable juices, carbonated and non-carbonated drinks, snack foods, teas, tobacco products and the like.
While useful for flavoring a wide variety of products, the compounds of this invention are particularly useful in products wherein a woody or spicy character is desired. Utility in a "woody" type composition is illustrated in the examples by incorporating 4-isopropyl-3-cyclohexene-1-carboxylic acid in an artificial vanilla flavor. The acid had the effect of providing strength and "naturalness" to the flavor and making it more reminiscent of a natural vanilla extract. Other "woody" type compositions wherein the compounds of this invention would be expected to be particularly useful would be blackberry, raspberry, grape, citrus, black pepper, mint, nut, saffron and tobacco flavorings.
Utility in s a spicy type application is demonstrated in the examples by adding 4-isopropyl-3-cyclohexene-1carboxylic acid to a commercial mixed vegetable juice, tomato soup and a seafood cocktail sauce. Each of the products were found to have greater flavor strength, to be spicier and have more "bite" with the acid present.
Utility in a highly seasoned foods of the Mexican or Indian curry type is illustrated in the examples by preparing an artificial cumin flavor (cumin is a constituent in curry powder and finds use in flavoring a number of highly seasoned foods). Two artificial cumin flavor compositions were prepared, the only difference being that one had a small amount of 4-isopropyl-3-cyclohexene-1-carboxylic acid and the other did not. The composition without the acid was found to be flat, thin in body and lacking in impact when compared to the composition that had the acid. The presence of the acid had the effect of rounding out the character of the composition, adding impact or "bite" and creating a more natural character. Subsequent use of these two flavor compositions in a chili receipe even more dramatically demonstrated the effect of the presence of the acid. The chili preparation containing the flavor composition with the acid was stronger, better blended and more full bodied in flavor.
Utility in luxury consumables such as tobacco is illustrated in the examples by adding the 4-isopropyl-3-cyclohexene-1-carboxylic acid to cigarette tobacco. The addition of about 12 ppm of the acid to the tobacco improved the flavor of the tobacco on smoking and the cigarette was found to have a smoother taste with excellent mouth feel and an increased sensation of moistness in the mouth.
As illustrated above, the acids of this invention can be added to foodstuffs, drinks and/or luxury consumables per se or they can be used to prepare flavoring compositions which are to be added thereto. A flavoring composition is comprised of a mixture of flavor imparting substances and perhaps a diluent, carrier and/or other adjuvants. These flavoring mixtures are then used to impart flavors to foodstuffs. Depending on the acid to be used, the flavor desired and the foodstuff to be flavored, the amount of the acid of formula I used in the flavor composition can vary over a wide range. The compounds of formula I may be as little as 0.001% of the flavor imparting substances present. In most applications, however, the acid would be at a level of about 0.005% to 1.0% of the flavor imparting substances present. Levels as high as 10% may be desirable in some applications and, as has been illustrated above, the acid itself may be added to foodstuffs to improve, enhance and/or alter the flavor.
The flavoring substances described above are added to or incorporated into the foodstuffs to be flavored using methods well known in the art. The amount of flavoring composition used will depend on the flavor to be imparted and the foodstuff flavored. The amount of the compounds of formula I used in the foodstuffs can be as little as 0.1 parts per billion to as much as 100 parts per million. In most foodstuffs the level of acid used will be in the range of about 0.01 parts per million to about 100 parts per million.
ILLUSTRATION OF THE PREFERRED EMBODIMENTS
The following examples are provided to illustrate further the practice of the present invention, and should not be construed as limiting.
Gas liquid chromatography was used to analyze the products.
EXAMPLE I
Preparation of 4-Alkyl-3-Cyclohexene-1-Carboxylic Acids
A. 4-Isopropyl-3-Cyclohexene-1-Carboxylic Acid
The 4-isopropyl-3-cyclohexene-1-carboxylic acid was prepared by the following methods:
1. Perillaldehyde as starting material.
A mixture of perillaldehyde (500 g) and 10% sulfuric acid (3 liters) was vigorously stirred for 3 hrs. at reflux (105° C.) under a nitrogen atmosphere. After cooling, the oily layer was separated from the acid, added to methanol (3 liters) and the resultant solution purged with nitrogen. Potassium hydroxide pellets (80 g) were fed into the solution, which was then refluxed (65° C.) for 2 hrs. under an atmosphere of nitrogen. The reaction mixture was then cooled to room temperature and concentrated to 1 liter. The concentrate was diluted with water (3 liters) and extracted with CH 2 Cl 2 (1.5 liters). The extract was washed neutral with water and concentrated to 490 g of an oil which on distillation yielded 100 g of aldehydes; b.p. 65°-78° C. @ 3.5 mm; analysis: 62% 4-isopropyl-3-cyclohexene-1-carboxaldehyde and 7% trans-4-isopropylcyclohexane-1-carboxaldehyde. A solution was made of the aldehyde mixture in acetone (1 liter) and cooled to 10° C. Jones reagent was prepared from 57.5 ml conc. sulfuric acid, 250 ml water and 66.8 g of chromium (VI) oxide. The reagent (200 ml) was added to the solution at 10° C. over a period of 30 minutes. After an additional 15 minutes at 10° C. the acetone was removed by decantation and the residual chromium salts were washed with additional 200 ml acetone. The combined-acetone solution was concentrated to 500 ml, diluted with 5% aqueous sodium hydroxide (1 liter) and washed with CH 2 Cl 2 (1 liter). The aqueous phase was acidified with 10% sulfuric acid (1 liter) and extracted with CH 2 Cl 2 . Concentration of the CH 2 Cl 2 solution yielded a solid (70 g) which on crystallization from hexane (-70° C.) yielded 63 g of a crystalline material; m.p. 58°-60° C.; analysis: (CW 20M fused silica column, 190° C.) 87% 4-isopropyl-3-cyclohexene-1-carboxylic acid and 11% trans-4-isopropylcyclohexane-1-carboxylic acid.
2. p-Isopropylbenzaldehyde as starting material
The method of Mander and Palmer, Aust. J. Chem. 32, 823 (1979) was followed; analysis: 99 + % 4-isopropyl-3-cyclohexene-1-carboxylic acid; m.p. 59°-60° C.
3. p-Isopropylbenzoic acid as starting material
To a mixture of p-isopropylbenzoic acid (20 g), t-butanol (100 ml) and liquid ammonia (500 ml) was added lithium (8 g) in small pieces over a period of 2 hrs at reflux (-33° C.). Reflux was continued for 1 hr (total reaction time: 3 hrs) followed by quenching with methanol (250 ml). The ammonia was removed, the residue taken up in water, the solution acidified with diluted sulfuric acid and the product extracted into CH 2 Cl 2 . Drying, filtration and concentration gave 22 g of a crude oil which was distilled through a short Vigreux column to give 16 g of a colorless liquid; b.p. 104°-105° C. @ 0.2 mm; analysis: (CW 20M fused silica column, 180° C.) 16% 4-isopropyl-3-cyclohexene-1-carboxylic acid and 75% 4-isopropyl-2-cyclohexene-1-carboxylic acid.
4. Commercial cumin oil as starting material
Commercial cumin oil (100 g) in methanol (750 ml) was refluxed for 2 hrs under nitrogen in the presence of 15 g of potassium hydroxide. Methanol (500 ml) was removed and water (1 liter) was added. The later mixture was treated in the same manner as that described in part 1. Distillation yielded 19.1 g of material; b.p. 99°-107° C. at 10 mm Hg; analysis: 16% 4-isopropyl-3-cyclohexene-1-carboxaldehyde. The distillate was dissolved in acetone (150 ml) and oxidized with Jones reagent (10 ml) in the same manner as that described in part 1. Crystallization from hexane yielded 3.5 g of product; analysis: (CW 20M fused silica column, 190° C.) 82% 4-isopropyl-3-cyclohexene-1-carboxylic acid, 9% trans-4-isopropylcyclohexane-1-carboxylic acid and 6.7% p-isopropylbenzoic acid.
B. 4-Ethyl-3-Cyclohexene-1-Carboxylic Acid
The 4-ethyl-3-cyclohexene-1-carboxylic acid was prepared from p-ethylbenzaldehyde by the following methods:
1. 4-Ethyl-1,4-cyclohexadiene-1-carboxaldehyde, prepared by the procedure of A. J. Birch and K. P. Dastur, Aust. J. Chem. 26, 1363 (1973) was subjected to the disproportionation and then the Jones oxidation of Section A, part 1. The resultant carboxylic acid was analyzed as follows: m.p. 35°-40° C.; 95% 4-ethyl-3-cyclohexene-1-carboxylic acid and 2.5% trans-4-ethylcyclohexane-1-carboxylic acid.
2. The method of Mander and Palmer was used; see Section A, part 2. Analysis: 99 + % 4-ethyl-3-cyclohexene-1-carboxylic acid; m.p. 42°-43° C.
C. 4-n-Propyl-3-Cyclohexene-1-Carboxylic Acid
This compound was prepared from p-n-propylbenzaldehyde employing the method of Mander and Palmer; see Section A, part 2. Analysis: 99 + %; m.p. 64°-65° C.
D. 4-t-Butyl-3-Cyclohexene-1-Carboxylic Acid
This compound was prepared from p-t-butylbenzaldehyde by the sequence described in Section B, part 1. Analysis: 95% 4-t-butyl-3-cyclohexene-1-carboxylic acid and 3% trans-4-t-butylcyclohexane-1-carboxylic acid; m.p. 141°-143° C.
EXAMPLE II
Preparation of 4-Alkylcyclohexane-1-Carboxylic Acids ##STR4##
General Procedures:
A. The appropriate 4-alkylbenzoic acid (0.1 mole) in ethanol (100 ml) and acetic acid (0.5 ml) was hydrogenated at 50 psi at room temperature in the presence of 5% rhodium on alumina (1 g) using a Parr shaker.
B. The appropriate 4-alkyl-3-cyclohexene-1-carboxylic acid (0.03 mole) in methanol (150 ml) was hydrogenated at 50 psi at room temperature in the presence of 5% palladium on carbon (0.2 g) using a Parr shaker.
__________________________________________________________________________R Procedure cis:trans MP/BP °C. at mm Hg Odor__________________________________________________________________________C.sub.2 H.sub.5A 3:1 BP 110° @ 0.5 mm Green, fatty, earthy, woodyiso-C.sub.3 H.sub.7A 3:1 BP 95° @ 0.1 mm Sweaty, oily, weakiso-C.sub.3 H.sub.7B 1:3 MP 45-60° C. Sweaty, oily, weak .sub.--n-C.sub.3 H.sub.7A 4:1 BP 110° @ 0.5 mm Musty, woody, fatty .sub.-t-C.sub.4 H.sub.9A 4:1 MP 93-100° C. Weak, fatty, woody__________________________________________________________________________
EXAMPLE III
Use of 4-Isopropyl-3-Cyclohexene-1-Carboxylic Acid in Fragrance Compositions
In the following compositions, the acid was used in the form of a 1% solution in dipropylene glycol.
A. Animalic Base
______________________________________ Parts byConstituent Weight______________________________________Isobutyl Linalool 500Skatole @ 1% solution in Diproylene Glycol 10Phenylacetic Acid 10Paracresol @ 10% solution in Dipropylene Glycol 5Paracresyl Phenylacetate 5Ethylene Brassylate 250Sandalore ® [5-(2,2,3-trimethylcyclopent-3- 100en-1-yl)3-methylpentan-2-ol]Clove Bud USP 50Dipropylene Glycol 20Total 950______________________________________
The above animalic base lacks sufficient warmth and harmony. The odor of the Skatole is not well integrated into the fragrance resulting in a crude and unpleasant odor.
When 50 parts of the 1.0% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid (0.05%) is added to the base, the various animalic notes of the accord are enveloped and blended into a unified and more pleasing, warm odor.
Similar effects can be achieved by using a like amount of 4-ethyl-3-cyclohexene-1-carboxylic acid.
B. Spice Accord
______________________________________Constituent Parts by Weight______________________________________Benzyl Salicylate 938Bay Oil 258-Mercapto-p-methane 7Caraway Oil 15Total 985______________________________________
The above spice accord lacks warmth and unity. The spicy odor of the Bay Oil does not blend harmoniously with the herbaceous odor of the Caraway Oil.
The addition of 15 parts of the 1% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid (0.015%) produces a warm effect which blends the discordant notes of the Caraway and Bay Oils, while enhancing the spicy character of the accord.
Similar effects can be achieved by using a like amount of 4-ethyl-3-cyclohexene-1-carboxylic acid.
C. Floral-Fruity Base
______________________________________ Parts byConstituent Weight______________________________________Hydroxycitronellal 100Linalool 200Benzyl Acetate 100Amyl Cinnamic Aldehyde 200Benzyl Salicylate 200Cinnamic Alcohol 100Aldehyde C-16 (Ethyl Phenyl Glycidate) 3Gamma Octalactone 3Gamma Undecalactone 3Dipropylene Glycol 71Total 980______________________________________
In the above floral-fruity composition, undesirable harsh, fatty odors are perceived to be in conflict with the desirable fruity and floral odors of the composition, imparting an indesirable synthetic quality to the fragrance.
The addition of 20 parts of the 1.0% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid (0.02%) adds a warmth to the composition that suppresses the harsh and fatty odors, blending the whole into a more natural fragrance.
Similar effects can be achieved by using a like amount of 4-ethyl-3-cyclohexene-1-carboxylic acid.
D. Wood Base
______________________________________Constituent Parts by Weight______________________________________Cedarwood American 300Amyris Oil 300Vetiver Haiti 100Patchouly Oil 300Total 1,000______________________________________
The constituents of the above wood base contribute fatty, earthy and comphoraceous odors that are perceived to be in conflict with the desired woody odor of the base.
The addition of 50 parts of the 1.0% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid (0.05%) blends the individual odors of the composition to give a warm, attractive and harmonious woody bouquet.
Similar effects can be achieved by using a like amount of 4-ethyl-3-cyclohexene-1-carboxylic acid.
E. Musk Fragrance
______________________________________Constituent Parts by Weight______________________________________Cedarleaf American 35Clove Bud USP 50Ethylene Brassylate 400Skatole @ 0.1% solution in Dipropylene 20GlycolPhenylacetic Acid 2Paracresyl Phenylacetate 2Patchouly Oil 30Sandalore ® [5-(2,3,3-trimethylcyclopent-3- 15en-1-yl)-3-methylpentan-2-ol]Sandela ® NP (isocamphyl cyclohexanols) 100Vanillin 2Labdanum Soluble Resin 7α-Iso-Methyl Ionone 100α-Hexylcinnamic Aldehyde 100Geranium Oil Bourbon 15Benzyl Salicylate 100Cinnamon Leaf Ceylon 2Total 980______________________________________
In the above musk fragrance the odors of Cedarleaf, Patchouly and Skatole are perceived to "stand out" from the composition which in itself is found to lack sufficient warmth.
The addition of 20 parts of the 1.0% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid (0.02%) integrates the discordant notes into the fragrance, creating a warmer and more unified blend of enhanced musky odor and increased intensity.
Similar effects can be achieved by using a like amount of 4-ethyl-3-cyclohexene-1-carboxylic acid.
EXAMPLE IV
Use of 4-Isopropyl-3-Cyclohexene-1-Carboxylic Acid as a Flavorant
A. Artificial Vanilla Flavor
An artificial vanilla flavor was made by mixing the following ingredients.
______________________________________Constituent Parts by Weight______________________________________Vanillin 3.5Ethyl Vanillin 0.8Heliotropin 0.1Veratraldehyde 0.5Benzodihydropyrone 0.4Ethanol (95%) 50.0Water, distilled 44.7Total 100.0______________________________________
A taste solution was prepared by adding 0.1 g of the above artificial vanilla flavor to a solution of 100 g of sucrose in 900 g of distilled water. To 100 g of the artificial vanilla taste solution was added 0.1 g of a 0.01% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid in ethanol (0.1 ppm). A bench panel of four tasters compared the treated and untreated taste solutions. All preferred the artificial vanilla containing the additive stating that it was stronger and closer in flavor to a natural vanilla extract.
B. Artificial Cumin Oil
Artificial cumin oil A was prepared by mixing the following ingredients.
______________________________________Constituent Parts by Weight______________________________________α-Pinene 1.00β-Pinene 16.00para-Cymene 13.00Myrcene 0.40gamma-Terpinene 15.00Eucalyptol 0.13α-Terpineol 0.20β-Caryophyllene 0.05Bisabolene 0.02Cuminyl Alcohol 2.40Cuminic Aldehyde 51.80Total 100.00______________________________________
Artificial cumin oil B was prepared by adding 0.1 g of 4-isopropyl-3-cyclohexene-1-carboxylic acid to 9.9 g of artificial cumin oil A. Alcoholic solutions (1%) of artificial cumin oils A and B were prepared by adding 0.1 g of the oil to 9.9 g of 95% alcohol. The 1% alcoholic solutions were separately diluted by adding 0.1 g of each into 100 g of distilled water. A bench panel of four tasters were asked to compare the dilutions. All panelists preferred solution B containing the additive stating that it was more rounded, had more impact, and was more cumin in character than dilution A.
C. Chili Recipe
The following chili concarne recipe was prepared:
______________________________________Constituent Parts by Weight______________________________________Ground Beef 1.5 poundsCommercial Onion Soup Mix, Dry 39 gramsWater 0.5 cupRed Kidney Beans, Canned 32 ouncesWhole Tomatoes, Canned 32 ouncesCayenne Pepper 1.0 teaspoonOregano 0.5 teaspoon______________________________________
The above constituents were mixed and simmered in a covered container for 30 minutes with occasional stirring.
The artificial cumin oils A and B, prepared as in Section B were each mixed into salt (sodium chloride) at a 1% concentration by weight. Each of the above 1% salt mixtures was added to a separate one-cup portion of the above chili recipe and the two portions, one containing artificial cumin oil A and the other containing artificial cumin oil B were compared. The chili containing artificial cumin oil B was preferred in that it was stronger, better blended and more full-bodied in flavor.
D. Commercial Products
The 4-isopropyl-3-cyclohexene-1-carboxylic acid was added to the commercial products listed below in the amount indicated. The products with and without the addition were compared by a bench panel of four tasters. All preferred the samples containing the additive for the reasons indicated.
______________________________________Product PPM of Additive Comments______________________________________Mixed Vegetable 0.5 Spicier, more bite,Juice greater flavor strengthTomato Soup 0.5 Rounder, more bodySeafood Cocktail 1.0 Spicier, more biteSauce______________________________________
E. Tobacco Product
A standard cigarette blend was prepared as described below:
______________________________________Constituent Parts by Weight______________________________________Bright tobacco 55Burley tobacco 25Expanded stems 5Reconstituted leaf 15Total 100______________________________________
A 0.5% solution of 4-isopropyl-3-cyclohexene-1-carboxylic acid in ethyl alcohol was prepared and injected at amounts of 1, 2 and 3 microliters into 1 g cigarettes made from the above blend. The cigarettes were allowed to equilibrate for 48 hours and then evaluated by smoking as indicated below where the numbers 1, 2 and 3 refer to microliters of solution per gram of cigarette blend. The addition of 1 microliter is equivalent to about 4 ppm.
______________________________________Sample Comments______________________________________1 Little or no perceived effect2 Improved tobacco flavor; enhancement of mouth feel (fullness)3 Much improved tobacco flavor; very smooth, excellent mouth feel; increased moistness of the mouth______________________________________
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The present invention discloses fragrance and flavor compositions comprising 4-alkyl substituted cyclohexyl and cyclohex-3-enyl carboxylic acids wherein the 4-alkyl substituent is an ethyl, propyl or butyl group, and methods for preparing same.
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This application claims benefit of Ser. No. 60/125,330 filed Mar. 14, 1999.
FIELD OF THE INVENTION
This invention relates generally to amino-thio-acrylonitriles as MEK inhibitors, pharmaceutical compositions containing the same, and methods of using the same as for treatment and prevention of inflammatory disorders, cancer or other proliferative diseases or as a radiosensitizing agents against cancer or other proliferative disorders.
BACKGROUND OF THE INVENTION
The mitogen activated protein kinase (MAPK) signaling pathways are involved in cellular events such as growth, differentiation and stress responses ( J. Biol. Chem. (1993) 268, 14553-14556). Four parallel pathways have been identified to date ERK1/ERK2, JNK, p38 and ERK5. These pathways are linear kinase cascades in that MAPKKK phosphorylates and activates MAPKK that phosphorylates and activates MAPK. To date, there are 7 MAPKK homologs (MEK1, MEK2, MKK3, MKK4/SEK, MEK5, MKK6, and MKK7) and 4 MAPK families (ERK1/2, JNK, p38, and ERK5). The MAPKK family members are unique in that they are dual-specific kinases, phosphorylating MAPKs on threonine and tyrosine. Activation of these pathways regulates the activity of a number of substrates through phosphorylation. These substrates include transcription factors such as TCF, c-myc, ATF2 and the AP-1 components, fos and Jun; the cell surface components EGF-R; cytosolic components including PHAS-I, p90 rsk , cPLA 2 and c-Raf-1; and the cytoskeleton components such as tau and MAP2.
The prototypical mitogen activated protein kinase cascade is reflected by the ERK pathway ( Biochem J. (1995) 309, 361-375). The ERK pathway is activated primarily in response to ligation of receptor tyrosine kinases (RTKs) ( FEBS Lett. (1993) 334, 189-192). Signal propagation from the RTKs occurs down the Ras pathway through sequential phosphorylation of Raf, MEK and ERK. This pathway has not been typically viewed of as an important contributor to the inflammatory response, but rather involved in growth and differentiation processes. This view stems from the profile of typical activators of this pathway, which include growth factors (PDGF, NGF, EGF), mitogens (phorbol esters), and polypeptide hormones (insulin, IGF-1). Evidence for ERK pathway involvement in inflammatory and immune responses has, however, gained some support in recent years ( Proc. Natl. Acad. Sci. USA. (1995) 92, 1614-1618; J. Immunol. (1995) 155, 1525-1533; and J. Biol. Chem. (1995) 270, 27391-27394). Cytokines such as TNFa and IL-1b, the bacterial cell wall mitogen, LPS, and chemotactic factors such as fMLP, C5a, and IL-8 all activate the ERK pathway. In addition, the ERK pathway is activated as a result of T cell receptor ligation with antigen or agents such as PMA/ionomycin or anti-CD3 antibody, which mimic TCR ligation in T cells ( Proc. Natl. Acad. Sci. USA (1995) 92, 7686-7689). These findings indicate that inhibitors of the ERK pathway should function as anti-inflammatory and immune suppressive agents.
Small molecule inhibitors of the Raf/MEK/ERK pathway have been identified. A series of benzoquinones has been disclosed by Parke-Davis, which is exemplified by PD 098059 that inhibits MEK activity ( J. Biol. Chem. (1995) 46, 27498-27494). Recently, we identified a MEK inhibitor, U0126 ( J. Biol. Chem. (1998) 29, 18623-18632). Comparative kinetic analysis showed that U0126 and PD 098059 were non-competitive inhibitors of activated MEK ( J. Biol. Chem. (1998) 29, 18623-18632). These MEK inhibitors have been used to investigate the role of the ERK activation cascade in a wide variety of systems including inflammation, immune suppression and cancer. For example, PD 098059 blocks thymidine incorporation into DNA in PDGF-stimulated Swiss 3T3 cells ( J. Biol. Chem. (1995) 46, 27498-27494). PD 098059 also prevents PDGF-BB-dependent SMC (Smooth Muscle Cell) chemotaxis at concentrations which inhibit ERK activation ( Hypertension (1997) 29, 334-339). Similarly, U0126 prevents PDGF-dependent growth of serum starved SMC. We have also shown that U0126 blocks keratinocyte proliferation in response to a pituitary growth factor extract, which consists primarily of FGF. These data coupled with those obtained with PD 098059 above indicate that MEK activity is essential for growth factor-stimulated proliferation.
The role of the MEK/ERK pathway in inflammation and immune suppression has been examined in a number of systems, including models of T cell activation. The T cell antigen receptor (TCR) is a non-RTK receptor whose intracellular signaling pathways have been elucidated ( Proc. Natl. Acad. Sci. USA (1995) 92, 7686-7689). DeSilva et al. have generated a great deal of information with U0126 in T cell systems ( J. Immunol. (1998) 160, 4175-4181). Their data showed that U0126 prevents ERK activation in T cells in response to PMA/ionomycin, Con A stimulation, and antigen in the presence of costimulation. In addition, T cell activation and proliferation in response TCR engagement is blocked by U0126 as is IL-2 synthesis. These results indicate that MEK inhibition does not result in a general antiproliferative effect in this IL-2-driven system, but selectively blocks components of the signaling cascades initiated by T cell receptor engagement.
PD 098059 has also been shown to inhibit T cell proliferation in response to anti-CD3 antibody, which is reversed by IL-2 ( J. Immunol. (1998) 160, 2579-2589.). PD 098059 also blocked IL-2 production by T cells stimulated with anti-CD3 antibody in combination with either anti-CD28 or PMA. In addition, the MEK inhibitor blocked TNFa, IL-3 GM-CSF, IFN-g, IL-6 and IL-10 production. In contrast, PD 098059 enhanced production of IL-4, IL-5 and IL-13 in similarly stimulated T cell cultures. These differential T cells effects with MEK inhibition suggest that therapeutic manipulations may be possible.
Neutrophils show ERK activation in response to the agonists N-formyl peptide (fMLP), IL-8, C5a and LTB 4 , which is blocked by PD 098059 ( Biochem. Biophy. Res. Commun. (1997) 232, 474-477). Additionally, PD 098059 blocks neutrophil chemotaxis in response to all agents, but does not alter superoxide anion production. However, fMLP-stimulated superoxide generation was inhibited by PD098059 in HL-60 cells ( J. Immunol. (1997) 159, 5070-5078), suggesting that this effect may be cell-type specific. U0126 blocks ERK activation in fMLP- and LTB 4 -stimulated neutrophils, but does not impair NADPH-oxidase activity or bacterial cell killing. U0126 at 10 mM blunts up regulation of b2 integrin on the cell surface by 50% and blocks chemotaxis through a fibrin gel >80% in response to IL-8 and LTB 4 . Thus, neutrophil mobility is affected by MEK inhibition although the acute functional responses of the cell remain intact.
Eicosanoids are key mediators of the inflammatory response. The proximal event leading to prostaglandin and leukotriene biosynthesis is arachidonic acid release from membrane stores, which is mediated largely through the action of cytosolic phospholipase A 2 (cPLA 2 ). Activation of cPLA 2 requires Ca 2+ along with phosphorylation on a consensus MAP kinase site, Ser505, which increases catalytic efficiency of the enzyme ( J. Biol. Chem. (1997) 272, 16709-16712). In neutrophils, mast cells, or endothelial cells, PD 098059 blocks arachidonic acid release in response to opsonized zymosan, aggregation of the high affinity IgG receptor, or thrombin, respectively. Such data support a role for ERK as the mediator of cPLA 2 activation through phosphorylation ( FEBS Lett. (1996) 388, 180-184. Biochem J. (1997) 326, 867-876 and J. Biol. Chem. (1997) 272, 13397-13402). Similarly, U0126 is able to block arachidonic acid release along with prostaglandin and leukotriene synthesis in keratinocytes stimulated with a variety of agents. Thus, the effector target, cPLA 2 , is sensitive to MEK inhibition in a variety of cell types.
MEK inhibitors also seem to affect eicosanoid production through means other than inhibition of arachidonic acid release. PD 098059 partially blocked LPS-induced Cox-2 expression in RAW 264.7 cells, indicating ERK activation alone may not be sufficient to induce expression of this key enzyme mediating inflammatory prostanoid production ( Biochem J. (1998) 330, 1107-1114). Similarly, U0126 inhibits Cox-2 induction in TPA-stimulated fibroblasts, although it does not impede serum induction of the Cox-2 transcript. PD 098059 also inhibits Cox-2 induction in lysophosphatidic acid (LPA)-stimulated rat mesangial cells, which further supports a role for ERK activation in production of prostaglandins ( Biochem J. (1998) 330, 1107-1114). Finally, 5-lipoxygenase translocation from the cytosol to the nuclear membrane along with its activation as measured by 5-HETE production can be inhibited by PD 098059 in HL-60 cells ( Arch. Biochem. Biophys; (1996) 331, 141-144).
Inflammatory cytokines such as TNFa and IL-1b are critical components of the inflammatory response. Cytokine production in response to cell activation by various stimuli as well as their activation of downstream signaling cascades represent novel targets for therapeutics. Although the primary effect of IL-1b and TNF-a is to up regulate the stress pathways ( Nature (1994) 372, 729-746), published reports ( Proc. Natl. Acad. Sci. USA (1995) 92, 1614-1618. J. Immunol. (1995) 155, 1525-1533. J. Biol. Chem. (1995) 270, 27391-27394. Eur. J. ). Cytokines such as TNFa and IL-1b, the bacterial cell wall mitogen, LPS, and chemotactic factors such as fMLP, C5a, and IL-8 all activate the ERK pathway. In addition, the ERK pathway is activated as a result of T cell receptor ligation with antigen or agents such as PMA/ionomycin or anti-CD3 antibody, which mimic TCR ligation in T cells ( Proc. Natl. Acad. Sci. USA (1995) 92, 7686-7689) and clearly show that the ERK pathway is also affected. U0126 can block MMP induction by IL-1b and TNF-a in fibroblasts ( J. Biol. Chem. (1998) 29, 18623-18632), demonstrating that ERK activation is necessary for this proinflammatory function. Similarly, lipopolysaccharide (LPS) treatment of monocytes results in cytokine production that has been shown to be MAP kinase-dependent being blocked by PD 098059 ( J. Immunnol. (1998) 160, 920-928). Indeed, we have observed similar results in freshly isolated human monocytes and THP-1 cells where LPS-induced cytokine production is inhibitable by U0126 ( J. Immunol. (1998) 161:5681-5686).
The proximal involvement of RAS in the activation of the ERK pathway suggests that MEK inhibition might show efficacy in models where oncogenic RAS is a determinant in the cancer phenotype. Indeed, PD 098059 ( J. Biol. Chem. (1995) 46, 27498-27494) as well as U0126 are able to impede the growth of RAS-transformed cells in soft agar even though these compounds show minimal effects on cell growth under normal culture conditions. We have further examined the effects of U0126 on the growth of human tumor cell lines in soft agar. We have shown that U0126 can prevent cell growth in some cells, but not all, suggesting that a MEK inhibitor may be effective in only certain kinds of cancer. In addition, PD 098059 has been shown to reduce urokinase secretion controlled by growth factors such as EGF, TGFa and FGF in an autocrine fashion in the squamous cell carcinoma cell lines UM-SCC-1 and MDA-TV-138 ( Cancer Res. (1996) 56, 5369-5374). In vitro invasiveness of UM-SCC-1 cells through an extracellular matrix-coated porous filter was blocked by PD 098059 although cellular proliferation rate was not affected. These results indicate that control of the tumor invasive phenotype by MEK inhibition may also be a possibility. The observed effects with PD 098059 and U0126 suggest that MEK inhibition may have potential for efficacy in a number of disease states. Our own data argue strongly for the use of MEK inhibitors in T-cell mediated diseases where immune suppression would be of value. Prevention of organ transplant rejection, graft versus host disease, lupus erythematosus, multiple sclerosis, and rheumatoid arthritis are potential disease targets. Effects in acute and chronic inflammatory conditions are supported by the results in neutrophils and macrophage systems where MEK inhibition blocks cell migration and liberation of proinflammatory cytokines. A use in conditions where neutrophil influx drives tissue destruction such as reperfusion injury in myocardial infarction and stroke as well as inflammatory arthritis may be warranted. Blunting of SMC migration and inhibition of DNA replication would suggest atherosclerosis along with restenosis following angioplasty as disease indications for MEK inhibitors. Skin disease such as psoriasis provides another potential area where MEK inhibitors may prove useful since MEK inhibition prevents skin edema in mice in response to TPA. MEK inhibition also blocks keratinocyte responses to growth factor cocktails, which are known mediators in the psoriatic process.
Finally, the use of a MEK inhibitor in cancer can not be overlooked. Ionizing radiation initiates a process of apoptosis or cell death that is useful in the treatment solid tumors. This process involves a balance between pro-apoptotic and anti-apoptotic signal ( Science 239, 645-647), which include activation of MAP kinase cascades. Activation of the SAPK pathway delivers a pro-apoptotic signal ( Radiotherapy and Oncology ( 1998) 47, 225-232.), whereas activation of the MAPK pathway is anti-apoptotic ( Nature (1996) 328, 813-816.). Interference with the anti-apoptotic MAPK pathway by dominant negative MEK2 or through direct inhibition of MEK with synthetic inhibitors sensitizes cells to radiation-induced cell death ( J. Biol. Chem. (1999) 274, 2732-2742; and Oncogene (1998) 16, 2787-2796).
WO98/37881 describe MEK inhibitors useful for treating or preventing septic shock. The inhibitors include 2-(2-amino-3-methoxyphenyl)-4-oxo-4H-[1]benzopyran and a compound of the formula:
The above diphenyl amines are not considered to be part of the presently claimed invention.
Therefore, efficacious and specific MEK inhibitors are needed as potentially valuable therapeutic agents for the treatment of inflammatory disorders, cancer or other proliferative diseases or as a radiosensitizing agents against cancer or other proliferative disorders. It is thus desirable to discover new MEK inhibitors.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide novel amino-thio-acrylonitriles which are useful as MEK inhibitors or pharmaceutically acceptable salts or prodrugs thereof.
It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the compounds of the present invention or a pharmaceutically acceptable salt or prodrug form thereof.
It is another object of the present invention to provide a method for treating a disorder involving MEK, comprising: administering to a host in need of such treatment a therapeutically effective amount of at least one of the compounds of the present invention or a pharmaceutically acceptable salt or prodrug form thereof.
It is another object of the present invention to provide a novel method of using the compounds of the present invention as a radiosensitizing agent for the treatment of cancers or proliferative diseases, comprising: administering to a host in need of such treatment a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable prodrug or salt form thereof.
It is another object of the present invention to provide a novel method of treating a condition or disease wherein the disease or condition is referred to as rheumatoid arthritis, osteoarthritis, periodontitis, gingivitis, corneal ulceration, solid tumor growth and tumor invasion by secondary metastases, neovascular glaucoma, multiple sclerosis, or psoriasis in a mammal, comprising: administering to the mammal in need of such treatment a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
It is another object of the present invention to provide a novel method of treating a condition or disease wherein the disease or condition is referred to as fever, cardiovascular effects, hemorrhage, coagulation, cachexia, anorexia, alcoholism, acute phase response, acute infection, shock, graft versus host reaction, autoimmune disease or HIV infection in a mammal comprising administering to the mammal in need of such treatment a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
It is another object of the present invention to provide novel amino-thio-acrylonitriles or salts or prodrugs thereof for use in therapy.
It is another object of the present invention to provide the use of novel amino-thio-acrylonitriles or salts or prodrugs thereof for the manufacture of a medicament for the treatment of an inflammatory disease.
It is another object of the present invention to provide the use of novel amino-thio-acrylonitriles or salts or prodrugs thereof for the manufacture of a medicament for the treatment of cancer.
These and other objects, which will become apparent during the following detailed description, have been achieved by the inventors' discovery that compounds of formula Ia or Ib:
or pharmaceutically acceptable salt or prodrug forms thereof, wherein R 1 and R 2 are defined below, are effective MEK inhibitors.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Thus, in a first embodiment, the present invention provides a novel compound of formula Ia or Ib:
or stereoisomer or pharmaceutically acceptable salt form thereof, wherein;
R 1 is phenyl, naphthyl, 2,3-dihydroindol-5-yl or a 5-6 membered heteroaryl ring with 1-4 heteroatoms selected from N, NH, O, and S, and R 1 is substituted with 0-2 R a ;
R a is selected from H, Cl, F, Br, I, C 1-4 alkyl, C 1-4 alkoxy, OH, CH 2 OH, NH 2 , (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N, (H 2 NCH 2 C(O))NH, (H 2 NCH(CH 3 )C(O))NH, (CH 3 NHCH 2 C(O))NH, ((CH 3 ) 2 NCH 2 C(O))NH, CF 3 , OCF 3 , —CN, NO 2 , C(O)NH 2 , and CH 3 C(O)NH;
Y is selected from phenyl substituted with 0-5 R b , naphthyl substituted with 0-5 R b , and CHR 3 ;
R b is selected from H, Cl, F, Br, I, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , OCF 3 , —CN, NO 2 , NH 2 , (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N, and C(O)O—C 1-4 alkoxy;
R 2 is selected from H, R 2a , C(O)R 2a , CH(OH)R 2a , CH 2 R 2a , OR 2a , SR 2a , and NHR 2a ;
R 2a is selected from phenyl, naphthyl, and a 5-6 membered heteroaryl ring with 1-4 heteroatoms selected from N, NH, O, and S, and R 2a is substituted with 0-5 R b ;
R 3 is phenyl substituted with 0-2 R c or naphthyl substituted with 0-2 R c ; and,
R c is selected from H, Cl, F, Br, I, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , OCF 3 , —CN, NO 2 , NH 2 , (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N, and C(O)O—C 1-4 alkoxy.
In a preferred embodiment, the present invention provides a novel compound, wherein:
R 1 is phenyl or a 5-6 membered heteroaryl ring with 1-2 heteroatoms selected from N, NH, O, and S, and R 1 is substituted with 0-2 R a ;
R a is selected from H, Cl, F, C 1-4 alkyl, C 1-4 alkoxy, OH, CH 2 OH, NH 2 , (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N, (H 2 NCH 2 C(O))NH, (H 2 NCH(CH 3 )C(O))NH, (CH 3 NHCH 2 C(O))NH, ((CH 3 ) 2 NCH 2 C(O))NH, and CH 3 C(O)NH;
Y is selected from phenyl substituted with 0-5 R b , naphthyl substituted with 0-5 R b , and CHR 3 ;
R b is selected from H, Cl, F, Br, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , —CN, NO 2 , NH 2 , and (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N;
R 2 is selected from H, R 2a , C(O)R 2a , CH(OH)R 2a , CH 2 R 2a , and OR 2a ;
R 2a is selected from phenyl, naphthyl, and a 5-6 membered heteroaryl ring with 1-4 heteroatoms selected from N, NH, O, and S, and R 2a is substituted with 0-5 R b ;
R 3 is phenyl substituted with 0-2 R c or naphthyl substituted with 0-2 R c ; and,
R c is selected from H, Cl, F, Br, I, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , —CN, NO 2 , NH 2 , (C 1-3 alkyl)NH, and (C 1-3 alkyl) 2 N.
In a more preferred embodiment, the present invention provides a novel compound, wherein:
R 1 is phenyl or a 5-6 membered heteroaryl ring with 1-2 heteroatoms selected from N, NH, O, and S, and R 1 is substituted with 0-2 R a ;
R a is selected from H, OH, and NH 2 ;
Y is selected from phenyl substituted with 0-2 R b , naphthyl substituted with 0-2 R b , and CHR 3 ;
R b is selected from H, Cl, F, Br, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , —CN, NO 2 , NH 2 , and (C 1-3 alkyl)NH, (C 1-3 alkyl) 2 N;
R 2 is selected from H, R 2a , C(O)R 2a , CH(OH)R 2a , CH 2 R 2a , and OR 2a ;
R 2a is selected from phenyl, naphthyl, and a 5-6 membered heteroaryl ring with 1-4 heteroatoms selected from N, NH, O, and S, and R 2a is substituted with 0-5 R b ;
R 3 is phenyl substituted with 0-2 R c or naphthyl substituted with 0-2 R c ; and,
R c is selected from H, Cl, F, Br, I, C 1-4 alkyl, OH, C 1-4 alkoxy, CH 2 OH, CH(OH)CH 3 , CF 3 , —CN, NO 2 , NH 2 , (C 1-3 alkyl)NH, and (C 1-3 alkyl) 2 N.
In an even more preferred embodiment, the present invention provides a novel compound selected from:
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-2-methyl-β-phenylbenzenepropanenitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dinitrophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-carbomethoxyphenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-trifluoromethylphenyl)hydroxymethyl]benzeneacetonitrile
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(4-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino(phenylthio)methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino(phenylthio)methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dimethylphenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-thienyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-β-phenylbenzenepropanenitrile;
E- and Z-α-[amino[(2-thienyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2,4-diaminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-β-(4-pyridyl)benzenepropanenitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-3-(benzyl)benzeneacetonitrile;
E- and Z-α-[amino[(2-naphthyl)thio]methylene]-1-naphthyleneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-(benzoyl)benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-β-(1-methyl-2-pyrrolyl)benzenepropanenitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-phenoxybenzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-furanyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-thienyl)thio]methylene]-3-[(2,3,4,5,6-pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-methyl-2-pyridyl)hydroxymethyl]benzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-4-(1,1-dimethylethyl)benzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-(trifluoromethyl)benzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-(trifluoromethyl)benzeneacetonitrile;
E- and Z-α-[amino[(4-aminophenyl)thio]methylene]-4-methylbenzeneacetonitrile;
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
E- and Z-α-[amino[(2-fluorophenyl)thio]methylene]-1-naphthyleneacetonitrile; and,
E- and Z-α-[amino[(2-aminophenyl)thio]methylene]-3-phenyl benzeneacetonitrile;
or a pharmaceutically acceptable salt form thereof.
In a further preferred embodiment, the present invention provides a novel compound selected from:
E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-2-methyl-β-phenylbenzenepropanenitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dinitrophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-carbomethoxyphenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-trifluoromethylphenyl)hydroxymethyl]benzeneacetonitrile
E-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(4-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino(phenylthio)methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino(phenylthio)methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dimethylphenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-thienyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-β-phenylbenzenepropanenitrile;
E-α-[amino[(2-thienyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2,4-diaminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-β-(4-pyridyl)benzenepropanenitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-3-(benzyl)benzeneacetonitrile;
E-α-[amino[(2-naphthyl)thio]methylene]-1-naphthyleneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-(benzoyl)benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-β-(1-methyl-2-pyrrolyl)benzenepropanenitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-phenoxybenzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-furanyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-thienyl)thio]methylene]-3-[(2,3,4,5,6-pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-methyl-2-pyridyl)hydroxymethyl]benzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-4-(1,1-dimethylethyl)benzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-3-(trifluoromethyl)benzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-(trifluoromethyl)benzeneacetonitrile;
E-α-[amino[(4-aminophenyl)thio]methylene]-4-methylbenzeneacetonitrile;
E-α-[amino[(2-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
E-α-[amino[(2-fluorophenyl)thio]methylene]-1-naphthyleneacetonitrile; and,
E-α-[amino[(2-aminophenyl)thio]methylene]-3-phenyl benzeneacetonitrile;
or a pharmaceutically acceptable salt form thereof.
In a further preferred embodiment, the present invention provides a novel compound selected from:
Z-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-2-methyl-β-phenylbenzenepropanenitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dinitrophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-carbomethoxyphenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-nitrophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-trifluoromethylphenyl)hydroxymethyl]benzeneacetonitrile
Z-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(4-hydroxyphenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino(phenylthio)methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino(phenylthio)methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-dimethylphenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-thienyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-β-phenylbenzenepropanenitrile;
Z-α-[amino[(2-thienyl)thio]methylene]-3-[(phenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2,4-diaminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-β-(4-pyridyl)benzenepropanenitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-3-(benzyl)benzeneacetonitrile;
Z-α-[amino[(2-naphthyl)thio]methylene]-1-naphthyleneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-(benzoyl)benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-β-(1-methyl-2-pyrrolyl)benzenepropanenitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-phenoxybenzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-bromobenzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2furanyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-thienyl)thio]methylene]-3-[(2,3,4,5,6-pentafluorophenyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-methyl-2-pyridyl)hydroxymethyl]benzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-4-(1,1-dimethylethyl)benzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-(trifluoromethyl)benzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-1-naphthyleneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-(trifluoromethyl)benzeneacetonitrile;
Z-α-[amino[(4-aminophenyl)thio]methylene]-4-methylbenzeneacetonitrile;
Z-α-[amino[(2-aminophenyl)thio]methylene]-2-methylbenzeneacetonitrile;
Z-α-[amino[(2-fluorophenyl)thio]methylene]-1-naphthyleneacetonitrile; and,
Z-α-[amino[(2-aminophenyl)thio]methylene]-3-phenyl benzeneacetonitrile;
or a pharmaceutically acceptable salt form thereof.
In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a compound of formula Ia or Ib or a pharmaceutically acceptable salt form thereof.
In another embodiment, the present invention provides a novel method for treating or preventing a disorder related to MEK, comprising: administering to a patient in need thereof a therapeutically effective amount of a compound of formula Ia or Ib or a pharmaceutically acceptable salt form thereof.
In another embodiment, the present invention provides novel compounds of formula Ia or Ib or a pharmaceutically acceptable salt form thereof for use in therapy.
In another embodiment, the present invention provides novel compounds of formula Ia or Ib or a pharmaceutically acceptable salt form thereof for the manufacture of a medicament for the treatment of an inflammatory disease.
In another embodiment, the present invention provides novel compounds of formula Ia or Ib or a pharmaceutically acceptable salt form thereof for the manufacture of a medicament for the treatment of cancer.
In another embodiment, the present invention provides a novel method of treating a condition or disease wherein the disease or condition is referred to as rheumatoid arthritis, osteoarthritis, periodontitis, gingivitis, corneal ulceration, solid tumor growth and tumor invasion by secondary metastases, neovascular glaucoma, multiple sclerosis, or psoriasis in a mammal, comprising: administering to the mammal in need of such treatment a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
In another embodiment, the present invention provides a novel method of treating a condition or disease wherein the disease or condition is referred to as fever, cardiovascular effects, hemorrhage, coagulation, cachexia, anorexia, alcoholism, acute phase response, acute infection, shock, graft versus host reaction, autoimmune disease or HIV infection in a mammal comprising administering to the mammal in need of such treatment a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
Definitions
The compounds herein described may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention. Cis and trans geometric isomers of the compounds of the present invention are described and may be isolated as a mixture of isomers or as separated isomeric forms. All chiral, diastereomeric, racemic forms and all geometric isomeric forms of a structure are intended, unless the specific stereochemistry or isomeric form is specifically indicated. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention.
“Substituted” is intended to indicate that one or more hydrogens on the atom indicated in the expression using “substituted” is replaced with a selection from the indicated group(s), provided that the indicated atom's normal valency is not exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O) group, then 2 hydrogens on the atom are replaced.
The present invention is intended to include all isotopes of atoms occurring in the present compounds. Isotopes include those atoms having the same atomic number but different mass numbers. By way of general example and without limitation, isotopes of hydrogen include tritium and deuterium. Isotopes of carbon include C-13 and C-14.
When any variable (e.g., R 6 ) occurs more than one time in any constituent or formula for a compound, its definition at each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-2 R 6 , then said group may optionally be substituted with up to two R 6 groups and R 6 at each occurrence is selected independently from the definition of R 6 . Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
When a bond to a substituent is shown to cross a bond connecting two atoms in a ring, then such substituent may be bonded to any atom on the ring. When a substituent is listed without indicating the atom via which such substituent is bonded to the rest of the compound of a given formula, then such substituent may be bonded via any atom in such substituent. Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. C 1-4 alkyl is intended to include C 1 , C 2 , C 3 , and C 4 alkyl. Examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, and s-pentyl. “Alkoxy” represents an alkyl group as defined above with the indicated number of carbon atoms attached through an oxygen bridge. C 1-4 alkoxy is intended to include C 1 , C 2 , C 3 , and C 4 , alkoxy. Examples of alkoxy include, but are not limited to, methoxy, ethoxy, n-propoxy, i-propoxy, n-butoxy, s-butoxy, t-butoxy, n-pentoxy, and s-pentoxy.
As used herein, the term “aromatic heterocyclic system” or “heteroaryl” is intended to mean a stable 5 or 6 membered monocyclic aromatic ring which consists of carbon atoms and 1, 2, 3, or 4 heterotams independently selected from the group consisting of N, NH, O and S. It is to be noted that that the total number of S and O atoms in an aromatic heterocycle is not more than 1.
Examples of heterocycles include, but are not limited to, 2H,6H-1,5,2-dithiazinyl, furanyl, imidazolyl, isothiazolyl, isoxazolyl, oxadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, oxazolidinyl, oxazolyl, pyrimidinyl, pyranyl, pyrazinyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyridyl, 2H-pyrrolyl, pyrrolyl, tetrazolyl, 6H-1,2,5-thiadiazinyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, thiazolyl, thienyl, triazinyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,5-triazolyl, and 1,3,4-triazolyl. Preferred heterocycles include, but are not limited to, pyridinyl, furanyl, thienyl, pyrrolyl, pyrazolyl, and imidazolyl.
The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids. The pharmaceutically acceptable salts include the conventional non-toxic salts or the quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, and nitric; and the salts prepared from organic acids such as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, and isethionic.
The pharmaceutically acceptable salts of the present invention can be synthesized from the parent compound which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference.
“Prodrugs” are intended to include any covalently bonded carriers which release the active parent drug according to formula Ia or Ib in vivo when such prodrug is administered to a mammalian subject. Prodrugs of a compound of formula Ia or Ib are prepared by modifying functional groups present in the compound in such a way that the modifications are cleaved, either in routine manipulation or in vivo, to the parent compound. Prodrugs include compounds of formula Ia or Ib wherein a hydroxy, amino, or sulfhydryl group is bonded to any group that, when the prodrug or compound of formula Ia or Ib is administered to a mammalian subject, cleaves to form a free hydroxyl, free amino, or free sulfhydryl group, respectively. Examples of prodrugs include, but are not limited to, acetate, formate and benzoate derivatives of alcohol and amine functional groups in the compounds of formula Ia or Ib.
“Stable compound” and “stable structure” are meant to indicate a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
“Therapeutically effective amount” is intended to include an amount of a compound of the present invention or an amount of the combination of compounds claimed effective to inhibit MEK or treat the symptoms of MEK over production in a host. The combination of compounds is preferably a synergistic combination. Synergy, as described for example by Chou and Talalay, Adv. Enzyme Regul. 22:27-55 (1984), occurs when the effect (in this case, MEK inhibition) of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at suboptimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
The term “radiosensitize”, as used herein refers to a process whereby cells are made susceptible to radiation-induced cell death, or the cells that result from the process.
Synthesis
The compounds of the present invention can be prepared in a number of ways known to one skilled in the art of organic synthesis. The compounds of the present invention can be synthesized using the methods described below, together with synthetic methods known in the art of synthetic organic chemistry, or by variations thereon as appreciated by those skilled in the art. Preferred methods include, but are not limited to, those described below. The reactions are performed in a solvent appropriate to the reagents and materials employed and suitable for the transformations being effected. It will be understood by those skilled in the art of organic synthesis that the functionality present on the molecule should be consistent with the transformations proposed. This will sometimes require a judgment to modify the order of the synthetic steps or to select one particular process scheme over another in order to obtain a desired compound of the invention. It will also be recognized that another major consideration in the planning of any synthetic route in this field is the judicious choice of the protecting group used for protection of the reactive functional groups present in the compounds described in this invention. An authoritative account describing the many alternatives to the trained practitioner is Greene and Wuts ( Protective Groups In Organic Synthesis, Wiley and Sons, 1991). All references cited herein are hereby incorporated in their entirety herein by reference.
Compounds of the present invention (3) may be synthesized by the route described in Scheme 1. A thiol 1, such as a thiophenol, may be treated with a malononitrile such as malononitrile 2 in the presence of a base catalyst such as triethylamine, DBU, Hunig's base, or aqueous base (for example, 10% NaOH), etc., in a nonreactive solvent such as THF, acetone, etc., to yield the vinylogous cyanamide 3. The reaction medium can be degassed to eliminate the presence of oxygen which can facilitate disulfide formation via the dimerization of thiol 1. The vinylogous cyanamide is frequently isolated as a mixture of Z- and E-isomers and the melting point varies significantly with isomer composition. A crystalline single isomer or material enriched in one isomer may sometimes be obtained by spontaneous crystallization of one isomer, recrystallization, or stirring solid in a solvent which dissolves only part of the material. Alternatively, isomers may sometimes be separated by chromatography. However, the double bond in 3 isomerizes very easily. NMR spectroscopy of a single isomer in DMSO-d 6 shows that an equilibrium mixture of Z- and E-isomers is generated faster than the spectrum could be obtained (about 5 minutes). Isomerization also takes place in other solvents such as water, acetone, methanol, and chloroform, but more slowly than in DMSO. Rapid NMR in one of these solvents may be used to establish isomeric composition. For in vitro assays, the compounds may be dissolved in DMSO to ensure that an equilibrium mixture of isomers is tested.
Many thiols (1) are commercially available. Alternatively, there are many methods for their synthesis familiar to one skilled in the art. For example, aryl or heterocyclic anions may be quenched with sulfur to yield thiols ( Chem. Pharm. Bull. 1989, 37 (1), 36). Displacement of aryldiazonium salts with EtOCS 2 K leads to aryl thiols ( Collect. Czech. Chem. Commun. 1990, 55, 1266). The Newman rearrangement of phenols via their dimethylthiocarbamates leads to thiophenols ( Organic Syntheses VI, (1988) 824).
When the Y group in Scheme 1 is substituted phenyl or naphthyl, the malononitrile precursors (2) to the compounds of this invention may be prepared by one of the three routes shown in Scheme 2. In the first route, aryl iodides 4 may be treated with malononitrile in the presence of a copper catalyst to yield arylmalononitriles 2 ( J. Org. Chem. 1993 (58) 7606-7). Malononitrile can also be coupled to aryl halides 4 (X=halide) using. (Ph 3 P) 2 PdCl 2 or Pd(Ph 3 P) 4 in THF ( J. Chem. Soc. Chem. Comm. 1984, 932-3). The aryl iodides needed for these methods are commercially available or prepared by methods familiar to one skilled in the art. In particular, aryl iodides may be prepared by iodination with a source of electrophilic iodine, such as iodine monochloride, or by diazotization of anilines.
Arylmalononitriles may also be prepared from aryl acetonitriles as shown the second route in Scheme 2. Aryl acetonitriles 5 may be deprotonated with a base, such as LDA, and quenched with a electrophilic source of cyanide, such as cyanogen chloride ( J. Org. Chem. 1966, 21, 919) or 2-chlorobenzylthiocyanate ( J. Org. Chem. 1983, 48, 2774-5) to yield malononitrile 2. Along the same lines, acetonitrile 5 can also be acylated in the presence of NaOMe with dimethyl carbonate to form the methyl cyanoacetate (not shown in Scheme 2). Conversion of the methyl ester to a nitrile group via procedures familiar to one skilled in the art leads to malononitrile 2 ( J. Am. Chem. Soc. 1904, 32, 119). The aryl acetonitriles needed for these methods are commercially available or prepared by methods familiar to one skilled in the art, for example, from aryl acetamides or from toluenes. When R 2 is an optionally substituted phenoxy group, the initial step in the preparation of the compounds of this invention may be an Ullmann condensation between an aryl halide and a phenol. (For useful protocols, see: U.S. Pat. No. 4,288,386; and Tetrahedron (1961), 15, 144-153.) A methyl substituent on either of these substrates may be subsequently converted to a —CH 2 CN group by free radical halogenation, with a reagent such as N-bromosuccinimide, followed by displacement with cyanide.
As shown in the third route shown in Scheme 2, arylmalononitriles 2 may also be synthesized from simpler bromo- or iodoarylmalononitriles. These bromo- or iodo-substituted arylmalononitriles may be prepared by either of the first two routes indicated in Scheme 2 for the preparation of malononitriles. Bromo- or iodo-substituted arylmalononitriles undergo halogen-metal exchange in the presence of two or more equivalents of an alkyllithium reagent, such as n-butyllithium, to form dianion intermediate 7. This process may be carried out in an ethereal solvent such as THF at a temperature of −78 to 0° C. The dianion may be quenched in situ with one equivalent of an electrophile, such as an aldehyde, alkyl halide, disulfide, ester, or ketone, to yield a substituted malononitrile 2 with a new R 2 group attached to the former site of the bromine or iodine atom. This is process is illustrated in more detail in Scheme 3 for the case where Y is a 1,3-disubstituted phenyl group. 3-Bromophenylmalononitrile (6) may be converted to dianion 7a
by deprotonation and halogen-metal exchange with 2 equivalents of n-butyllithium in THF at −78° C. The dianion may be treated in situ with an aldehyde to produce hydroxy-phenylmalononitriles 8. Hydroxy-phenylmalononitriles 8 may be oxidized to the corresponding keto-phenylmalononitrile 9 using MnO 2 or a variety of other oxidizing agents familiar to one skilled in the art. Compounds 8 and 9 may be reduced to the corresponding CH 2 R 2 -substituted phenylmalononitriles 10 using hydrogen and a noble metal catalyst, NaBH 4 and TFA ( Synthesis 1978, 763-5), or other procedures familiar to one skilled in the art. Malononitriles 8, 9, and 10 may be treated with thiols 1 to yield the compounds of this invention. It must be noted that although only the meta-bromo isomer of 6 is pictured in Scheme 3, one trained in the art may apply this methodology using other aryl halides and electrophiles to prepare isomers and compounds with different Y groups.
When Y is CHR 3 , malononitrile precursors useful for preparation of the compounds of this invention have structure 2a and may be prepared as shown in Scheme 4. Knoevenagel condensation ( Organic Reactions 15, 204-509 (1967)) between an aldehyde 11 or a ketone 13 may be used to produce alkylidene malononitriles 12 or 14. Conjugate addition of a Grignard or organolithium reagent to 12 affords the malononitrile prescursors 2 used in Scheme 1. Alternatively, alkylidene malononitriles 14 may be reduced to malononitriles 2a with sodium borohydride, catalytic hydrogenation or other reducing agents familiar to one skilled in the art. A third alternative is to alkylate malononitrile with an alkyl halide 15 (X=halide).
Other features of the invention will become apparent in the course of the following descriptions of exemplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLES
Abbreviations used in the Examples are defined as follows: “1 x” for once, “2 x” for twice, “3 x” for thrice, “° C.” for degrees Celsius, “eq” for equivalent or equivalents, “g” for gram or grams, “mg” for milligram or milligrams, “mL” for milliliter or milliliters, “ 1 H” for proton, “h” for hour or hours, “M” for molar, “min” for minute or minutes, “MHz” for megahertz, “MS” for mass spectroscopy, “NMR” for nuclear magnetic resonance spectroscopy, “rt” for room temperature, “tlc” for thin layer chromatography, “v/v” for volume to volume ratio. “α”, “β”, “R” and “S” are stereochemical designations familiar to those skilled in the art.
Example 1
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-2-(trifluoromethyl)benzeneacetonitrile
Part A. Preparation of 2-[(2-trifluoromethyl)phenyl]malononitrile
A mixture of 2-trifluoromethyl-1-iodobenzene (21.76 g, 0.08 mol, 1 eq), malononitrile (10.56 g, 0.16 mol, 2 eq), copper(I) iodide (1.52 g, 0.008 mol, 0.1 eq), potassium carbonate (11.04 g, 0.32 mol, 4 eq), and 200 mL DMSO was stirred and heated at 120° C. for 21 h. The reaction mixture was cooled and poured into 1.2 L of 0.5 M HCl. The mixture was filtered and extracted with ethyl acetate. The organic layer was dried (MgSO 4 ) and the solvent removed in vacuo to yield an oil. This oil was purified by flash chromatography on silica gel with 3:1 hexane/ethyl acetate to yield 4.46 g (27%) of 2-[(2-trifluoromethyl)phenyl]malononitrile as a yellow oil. 1 H-NMR (CDCl 3 ) δ: 8.05-7.10 (m, 4H); 5.30 (s, 1H).
Part B. Preparation of α-[amino[(4-aminophenyl)thio]methylene]-2-(trifluoromethyl)benzeneacetonitrile
2-[(2-Trifluoromethyl)phenyl]malononitrile (the product from Part A) (3.07 g, 14.6 mmol, 1.1 eq), freshly distilled 4-aminothiophenol (1.66 g, 13.3 mmol, 1 eq), and THF (25 mL) were mixed. The reaction flask was then degassed by placing under vacuum followed by flushing with N 2 several times to prevent disulfide formation. After cooling to −78° C., triethylamine (1.85 mL, 13.3 mmol, 1 eq) was added via syringe and the flask degassed once more. The contents were allowed to warm to room temperature and the mixture was stirred overnight. TLC the following morning showed no malononitrile present, only thiol. Therefore, another 0.2 equivalents of malononitrile were added followed by degassing, followed by 0.5 equivalents of triethylamine, followed by degassing. TLC after a few hours no starting material was present. The reaction was worked up after stirring over the weekend at room temperature. The solvent was removed in vacuo and the residue was purified by flash chromatography on silica gel with 25-100% ethyl acetate in hexane. Two fractions were isolated. The faster eluting fraction yielded 1.63 g of a tan oily solid. The slower eluting fraction yielded 2.61 g of a tan oily solid. Both compounds were recrystallized from n-butylchloride. The faster eluting compound yielded 274 mg of a white solid (m.p. 147.0-148.0° C.). This compound proved to be the E isomer of the titled compound through NMR NOE experiments. The slower eluting compound yielded 1.85 g of a white solid (m.p. 130.0-130.5° C.). This compound proved to be the Z isomer of the titled compound through NMR NOE experiments. Anal. calcd. for C 16 H 12 F 3 N 3 S (faster eluting isomer): C, 57.31; H, 3.62; F, 17.00; N, 12.53; S, 9.56. Found: C, 57.19; H, 3.75; F, 16.83; N, 12.24; S, 9.50. Anal. calcd. for C 16 H 12 F 3 N 3 S (slower eluting isomer): C, 57.31; H, 3.62; F, 17.00; N, 12.53; S, 9.56. Found: C, 57.28; H, 3.80; F, 16.96; N, 12.37; S, 9.22. 1 H-NMR (faster eluting isomer) (CDCl 3 ) δ7.75 (d, 1H, J=7 Hz); 7.57 (t, 1 H, J=7 Hz); 7.49 (t, 1H, J=7 Hz); 7.47 (d, 1H, J=7 Hz); 7.24 (d, 2H, J=7 Hz); 6.66 (d, 2H, J=7 Hz). 1 H-NMR (slower eluting isomer) (CDCl 3 ) δ7.75 (d, 1H, J=7 Hz); 7.58 (t, 1 H, J=7 Hz); 7.48 (t, 1H, J=7 Hz); 7.43 (d, 1H, J=7 Hz); 7.40 (d, 2H, J=7 Hz); 6.68 (d, 2H, J=7 Hz).
Example 2
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzeneacetonitrile
Part A. Preparation of 2-(3-bromophenyl)malononitrile
To a flame dried 5L 3-neck flask equipped with a mechamical overhead stirrer under nitrogen was added diisopropylamine (78.60 mL, 0.56 mol, 2.2 eq) and 2 L of benzene. After cooling to 0-5° C., 1.6 M n-BuLi (351.0 mL, 0.56 mol, 2.2 eq) was added dropwise via addition funnel while keeping the temperature at 0-5° C. The LDA was stirred for 45 min. at 0-5° C. 3-Bromophenylacetonitrile (50.0 g, 0.26 mol, 1.0 eq) dissolved in 200 mL of benzene was added dropwise via addition funnel keeping the temperature at 0-5° C. The mixture was stirred an additional 15 min at this temperature. 2-Chlorobenzylthiocyanate ( J. Am. Chem. Soc., 1954, 76, 585) (103.0 g, 0.56 mol, 2.2 eq) dissolved in 200 mL benzene was added dropwise via addition funnel keeping the temperature at 0-5° C. During the addition, a precipitate formed. The reaction was allowed to warm to room temperature and the mixture stirred overnight. The reaction was quenched by adding water and 200 mL 10% NaOH. The layers were separated, and the benzene layer extracted with 10% NaOH (3×1 L). The basic layers were collected and acidified with conc. HCl to pH 1-2. A precipitate formed. Methylene chloride was added to dissolve the precipitate. The layers were separated and the aqueous layer reextracted with methylene chloride (2×). The methylene chloride layers were collected, dried (MgSO 4 ) and the solvent removed in vacuo to yield 65.32 g of 2-(3-bromophenyl)malononitrile as a yellow solid. Recrystallization from methylcyclohexane yielded two crops: crop 1, 42.86 g of orange crystals, m.p. 99.5-101.5° C.; crop 2, 2.18 g of orange crystals, m.p. 97.0-99.0° C. Combined yield 79.9%. 1 H-NMR (CDCl 3 ) δ: 7.67 (s, 1H); 7.63 (d, 1H, J=7 Hz); 7.47 (d, 1H, J=7 Hz); 7.39 (t, 1H, J=7 Hz); 5.08 (s, 1H).
Part B. Preparation of 2-[3-[(4-cyanophenyl)hydroxymethyl]phenyl]malononitrile
2-(3-Bromophenyl)malononitrile (the product from part A) (1.00 g, 4.52 mmol, 1 eq) was dissolved in dry THF (50 mL) under N 2 and cooled to −70° C. 1.6 M n-BuLi (5.94 mL, 9.50 mmol, 2.1 eq) was then added dropwise via syringe maintaining the temperature at −65 to −70° C. An orange slurry formed. The temperature was maintained for 20 min after which 4-cyanobenzaldehyde (0.59 g, 4.52 mmol, 1 eq) was added via syringe. After two hours, the reaction was complete. The reaction was added to water and the pH was adjusted to 3 with 1 N HCl. The mixture was extracted with ethyl acetate (3×), the organic layers combined, dried (MgSO 4 ) and the solvent removed in vacuo to yield 1.84 g an an amber oil. Flash chromatography on silica gel with 7:3 to 1:1 hexane/ethyl acetate yielded 2-(3-bromophenyl)malononitrile (0.88 g) as an amber oil. 1 H-NMR (CDCl 3 ) δ: 7.66 (d, 2H, J=7 Hz); 7.60-7.15 (m, 6H); 5.95 (s, 1H); 5.07 (s, 1H); 2.63 (br s, 1H). NH 4 -CI MS: 291 (M+NH 4 ) + .
Part C. Preparation of Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-cyanophenyl)hydroxymethyl]benzene-acetonitrile
2-[3-[(4-Cyanophenyl)hydroxymethyl]phenyl]malononitrile (the product from part B) (250 mg, 0.915 mmol, 1 eq), 2-aminothiophenol (0.10 mL, 0.915 mmol, 1 eq), triethylamine (0.13 mL, 0.915 mmol, 1 eq), and THF were reacted by the procedure described in Example 1, part B. After 4 hours, the solvent was then removed in vacuo and the residue purified by flash chromatography on silica gel with 1:1 hexane/ethyl acetate to yield the title compound (200 mg) as a mixture of isomers. HRMS calcd. for C 23 H 18 N 4 OS: 399.1264; Found: 399.1280. 1 H-NMR (CDCl 3 ) δ: (major isomer) 7.61 (d, 2H, J=7 Hz); 7.60-7.10 (m, 8H); 6.90-6.70 (m, 2H); 5.86 (br s, 1H); 4.71 (br s, 2H); 4.44 (br s, 2H); 2.51 (br s, 1H).
Example 3
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile
Part A. Preparation of 2-[3-[(4-pyridyl)hydroxymethyl]phenyl]malononitrile
2-(3-Bromophenyl)malononitrile (the product from Example 2, part A) (2.00 g, 9.05 mmol, 1 eq) was dissolved in dry THF (100 mL) under N 2 and cooled to −70° C. 1.6 M n-BuLi (11.87 mL, 19.0 mmol, 2.1 eq) was then added dropwise via syringe maintaining the temperature at −65 to −70° C. An orange slurry formed. The temperature was maintained for 20 min after which 4-pyridinecarboxaldehyde (0.86 mL, 9.05 mmol, 1 eq) was added via syringe. After one hour, the reaction was essentially complete. It was worked up by adding water and adjusting the pH to 3 with 1 N HCl. The mixture was extracted with ethyl acetate (3×), the organic layers combined, dried (MgSO 4 ) and the solvent removed in vacuo to yield an an amber oil. Flash chromatography with 1:1 hexane/ethyl acetate to 100% ethyl acetate yielded 0.95 g of an orange glass as product. 1 H-NMR (DMSO-d 6 ) δ: 8.41 (d, 2H, J=7 Hz); 7.26 (br s, 1H); 7.35-7.20 (m, 6H); 6.03 (br s, 1H); 5.65 (s, 1H).
Part B. Preparation of α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile
2-[3-[(4-Pyridyl)hydroxymethyl]phenyl]malononitrile (the product from Part A) (850 mg, 3.41 mmol, 1 eq), 2-aminothiophenol (0.36 mL, 3.41 mmol, 1 eq), triethylamine (0.48 mL, 3.41 mmol, 1 eq), and THF (20 mL) were reacted by the procedure described in Example 1, part B. As soon as the triethylamine was added, a precipitate began to form. More THF was added (50 mL) but the precipitate did not dissolve. The mixture was stirred overnight and the precipitate dissolved. TLC showed the reaction to be complete. The solvent was then removed in vacuo and the residue was purified by flash chromatography on silica gel with 1:1 hexane/ethyl acetate to 100% ethyl acetate to yield 950 mg of a white solid. The solid was stirred in THF and filtered to yield 462 mg of a white solid (mp 97.5-101.0° C.). NMR shows a mixture of isomers. An analytical sample was prepared by recrystallization (50 mg) from ethyl acetate. The recrystallized solids were filtered, rinsed with ether, and dried under high vacuum to yield 23 mg of a white solid (mp 150.0-151.0° C.). NMR showed the presence of mainly one isomer. Anal calcd. for C 21 H 18 N 4 OS.0.4 H 2 O: C, 66.09; H, 4.96; N, 14.68; S, 8.40. Found: C, 66.16; H, 5.03; N, 14.46; S, 8.35. 1 H-NMR (major isomer) (acetone-d 6 ) δ8.49 (d, 2H, J=7 Hz); 7.52 (s, 1H); 7.50-7.20 (m, 7H); 7.00-6.80 (m, 1H); 6.70 (t, 1H, J=7 Hz); 5.84 (d, 1H, J=6 Hz); 5.80-5.50 (m, 2H); 5.45-5.30 (m, 2H); 5.20 (d, 1H, J=6 Hz). The above procedure was repeated several times on larger scale to yield 112.12 g of the title compound. This material was stirred overnight at room temperature in 900 mL of ethyl acetate. The solids were filtered, rinsed with ether (1 L), and dried under high vacuum to yield 86.11 g of a white solid (mp 146.5-147.5° C.). Anal calcd. for C 21 H 18 N 4 OS: C, 67.36; H, 4.86; N, 14.96; S, 8.56. Found: C, 67.39; H, 4.94; N, 14.76; S, 8.84.
Example 4
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-phenoxybenzeneacetonitrile
Part A. Preparation of 2,3-dimethyldiphenylether
2,3-dimethylphenol (10 g, 82 mmol), sodium hydroxide (3.28 g, 82 mmol), water (1.8 mL) and chlorobenzene (70 mL) were refluxed for 3 h under nitrogen in a flask equipped with a Dean-Stark trap. Water and chlorobenzene removed from the trap several times (100 mL total) while adding an equal volume of chlorobenzene to the flask. The resulting suspension was dried further by refluxing through a soxhlet extractor filled with 3A molecular sieves for 30 min. Cuprous iodide (0.81 g, 0.082 mmol) and tris[2-(2-methoxyethoxy)ethyl]amine (1.5 mL, 4.1 mmol) were added and the reaction was refluxed overnight. The solution was decanted from the solid. Additional cuprous iodide (0.81 g, 0.082 mmol) and tris[2-(2-methoxyethoxy)ethyl]amine (1.5 mL, 4.1 mmol) were added to the solution and the reaction was refluxed overnight with mechanical stirring. The reaction mixture was absorbed onto silica gel and eluted with hexane to afford the title compound (1.4 g). GC-MS: Calcd, 199; Found, 199. 1 H-NMR (CDCl 3 ) δ: 7.28 (t, 2H); 7.04 (m, 3H); 6.88 (d, 2H); 6.78 (d, 1H); 2.32 (s, 3H); 2.25 (s, 3H).
Part B. Preparation of 2-(3-phenoxy-2-methylphenyl)malononitrile
A solution of 2,3-dimethyldiphenylether (2.2 g, 11 mol), N-bromosuccinimide (1.76 g, 11 mmol) and benzoyl peroxide (0.27 g, 1 mmol) in carbon tetrachloride (60 mL) was refluxed for 2.5 h. The reaction mixture was added to methylene chloride and extracted with saturated aqueous sodium bisulfite, water (twice), and brine. The organic layer was dried over sodium sulfate and the residue was purified by chromatography on silica gel with hexane to afford a mixture 3-bromomethyl-2-methyldiphenylether and 2-bromomethyl-3-methyldiphenylether (2.0 g).
A solution of the above bromination products (2.0 g, 7.2 mmol) and tetraethylammonium cyanide (1.2 g, 7.7 mmol) in dichloromethane (60 mL) was refluxed for 1 h. The reaction was added to dichloromethane and extracted with 10% aqueous sodium hydroxide (three times) and brine (twice). After concentrating the organic layer, the residue was purified by chromatography on silica gel with toluene and 5% ethyl acetate in toluene to afford a 1:3 mixture of 2-(3-phenoxy-2-methylphenyl)acetonitrile and 2-(2-phenoxy-6-methylphenyl)acetonitrile (1.08 g). 1 H-NMR (CDCl 3 ) δ: 6.7-7.2 (m, 8H); 3.78 (s, 1.5H); 3.74(s, 0.5H); 2.48 (s, 2.25H); 2.28(s, 0.75H).
Methyllithium (4.3 mL of a 2.5 M solution, 10.7 mmol) was added to a solution of diisopropylamine (1.5 mL, 10.7 mmole) in dry benzene (70 mL) cooled in an ice-water bath. After stirring for 1 h, a solution of the above mixture of phenylacetonitriles in dry benzene (30 mL) was added dropwise. After stirring for 1 h at 0° C., a solution of 2-chlorobenzylthiocyanate in dry benzene was added. After stirring for 1 h while the reaction mixture warmed to room temperature, the reaction mixture was added to benzene and extracted with 10% aqueous sodium hydroxide (4×). The combined aqueous layers were acidified to pH 1 with concentrated hydrochloric acid and extracted with ethyl acetate. The organic layer was dried over sodium sulfate, concentrated, and purified twice by silica gel chromatography with 0-10% ethyl acetate in toluene and then 10% ether in hexane, removing the high Rf major isomer and affording isomerically pure title compound (61 mg) as a pale yellow solid. 1 NMR(CDCl 3 ) δ: 7.2-7.4 (m, 4H); 7.13 (t, 1H); 6.9-7.0 (m, 3H); 5.10 (s, 1H); 2.40 (s, 3H). HRMS: Calculated for C 16 H 12 N 2 O (M): 248.0959; Found: 248.0950.
Part C. Preparation of Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-3-phenoxybenzeneacetonitrile
A solution of 2-(3-phenoxy-2-methylphenyl)malononitrile (50 mg, 0.20 mmol), 2-aminothiophenol (21 uL, 0.20 mmol) and triethylamine (28 uL) in tetrahydrofuran was stirred under nitrogen overnight. The reaction was added to water and extracted with ethyl acetate. The combined organic layers were washed with brine, dried over sodium sulfate, and concentrated. The residue was purified by chromatography on silica gel with 20-50% ether in hexanes to afford the title compound as a colorless oil (30 mg). 1 H-NMR (CDCl 3 ) was consistent with the presence of a 1:1 mixture of isomers. δ: 7.49 (d, 0.5H); 6.7-7.4 (m, 11.5H); 4.83 (br s, 1H); 4.51 (br s, 1H); 4.41 (br s, 1H); 4.33 (br s, 1H); 2.31 (s, 1.5H); 2.25 (s, 1.5H). HRMS: Calculated for C 22 H 20 N 3 OS (M+H): 374.1327; Found: 374.1307.
Example 5
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-β-(2-methylphenyl)benzenepropanenitrile
Part A. Preparation of 2-(2-methylbenzylidene)malononitrile
A solution of 2-methylbenzaldehyde (9.6 mL, 83 mmol), malononitrile (5.5 g, 83 mmol) and 3.5 M ammonium acetate in acetic acid (2.4 mL, 8.4 mmol) in isopropanol (83 mL) was stirred overnight at room temperature. A precipitate formed. Water (100 mL) was added and the precipitate was collected. The precipitate was washed with water (50 mL) and vacuum dried to afford of 2-(2-methylbenzylidene)malononitrile (12.7 g) as a white solid (mp 105-106°). 1 H-NMR (CDCl 3 ) δ: 8.10 (s 1H); 8.08 (d, 1H); 7.50 (dd, 1H); 7.30-7.40 (m, 2H); 2,45 (s, 3H).
Part B. Preparation of 2-[α-(2-methylphenyl)-4-chlorobenzyl]malononitrile
4-Chlorophenylmagnesium bromide (2.1 mL of a 1.0 M solution in ether, 2.1 mmol) was added dropwise to a solution of 2-(2-methylbenzylidene)malononitrile (0.32 g, 1.9 mmol) in dry tetrahydrofuran (7.5 mL) at 0° C. and stirred for 1 h. Saturated aqueous ammonium chloride was added and the layers were separated. The aqueous layer was extracted twice with dichloromethane and the combined organics layers were dried over magnesium sulfate. After concentrating, the residue was purified by flash chromatography on silica gel with 12.5% ethyl acetate in hexanes to afford the title compound (0.25 g) as a white solid (mp 132-140°). 1 H-NMR (CDCl 3 ): δ: 7.20-7.39 (m 8H); 4.78 (d, 1H); 2.25 (s, 3H). GC-MS: m/e=281/283 (M+H).
Part C. Preparation of Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-β-(2-methylphenyl)benzenepropanenitrile
A solution of 2-[α-(2-methylphenyl)-4-chlorobenzyl]malononitrile (0.20 g, 0.71 mmol), 2-aminothiophenol (0.11 mL, 1.00 mmol) and triethylamine (0.14 mL, 1.00 mmol) in tetrahydrofuran (1.4 mL) was stirred under nitrogen for 78 h. The reaction mixture was absorbed onto silica gel and eluted with 20-30% ethyl acetate in hexanes to afford the title compound (253 mg) as a white foam (mp 63.5-72°). 1 H-NMR (CDCl 3 ) was consistent with the presence of a 4:6 mixture of isomers: δ7.44 (d, 0.4H); 7.10-7.36 (m, 9.6H); 6.71-6.79 (m, 2H); 5.34 (s, 0.6H); 4.97 (s, 0.4H); 4.65 (br s, 1.2H); 4.44 (br s, 0.8H); 4.12 (br s, 2H); 2.33 (s, 1.8H); 2.22 (s, 1.2H). HRMS: Calcd for C 23 H 21 N 3 SCl (M+H), 406.1145; Found, 406.1130. Elem. Anal. Calcd for C 23 H 20 N 3 SCl: C, 68.05; H, 4.98; N, 10.35; S, 7.91. Found: C, 68.03; H, 5.09; N, 10.20; S, 7.97.
Examples 6-51
The following compounds were prepared by procedures similar to those described above.
Ex.
Name
6
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-
2-methyl-β-phenylbenzenepropanenitrile
7
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-
dinitrophenyl)hydroxymethyl]benzeneacetonitrile
8
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-
carbomethoxyphenyl)hydroxymethyl]benzeneacetonitrile
9
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(4-
nitrophenyl)hydroxymethyl]benzeneacetonitrile
10
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-
[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile
11
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-
3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile
12
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-
3-[(phenyl)hydroxymethyl]benzeneacetonitrile
13
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-
3-[(4-pyridyl)hydroxymethyl]benzeneacetonitrile
14
Z- and E-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-
cyanophenyl)hydroxymethyl]benzeneacetonitrile
15
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-
nitrophenyl)hydroxymethyl]benzeneacetonitrile
16
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-
3-[(pentafluorophenyl)hydroxymethyl]benzeneacetonitrile
17
Z- and E-α-[amino[(2-hydroxyphenyl)thio]methylene]-3-[(4-
pyridyl)hydroxymethyl]benzeneacetonitrile
18
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-
trifluoromethylphenyl)hydroxymethyl]benzeneacetonitrile
19
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-
pyridyl)hydroxymethyl]benzeneacetonitrile
20
Z- and E-α-[amino[(4-hydroxyphenyl)thio]methylene]-3-[(4-
pyridyl)hydroxymethyl]benzeneacetonitrile
21
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-
cyanophenyl)hydroxymethyl]benzeneacetonitrile
22
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-3-[(4-
cyanophenyl)hydroxymethyl]benzeneacetonitrile
23
Z- and E-α-[amino(phenylthio)methylene]-3-[(4-
cyanophenyl)hydroxymethyl]benzeneacetonitrile
24
Z- and E-α-[amino(phenylthio)methylene]-3-[(4-
pyridyl)hydroxymethyl]benzeneacetonitrile
25
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-2-
bromobenzeneacetonitrile
26
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2,4-
dimethylphenyl)hydroxymethyl]benzeneacetonitrile
27
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-
[(phenyl)hydroxymethyl]benzeneacetonitrile
28
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-
thienyl)hydroxymethyl]benzeneacetonitrile
29
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-4-chloro-
β-phenylbenzenepropanenitrile
30
Z- and E-α-[amino[(2-thienyl)thio]methylene]-3-
[(phenyl)hydroxymethyl]benzeneacetonitrile
31
Z- and E-α-[amino[(2,4-diaminophenyl)thio]methylene]-1-
naphthyleneacetonitrile
32
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-methyl-
β-(4-pyridyl)benzenepropanenitrile
33
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-3-
(benzyl)benzeneacetonitrile
34
Z- and E-α-[amino[(2-naphthyl)thio]methylene]-1-
naphthyleneacetonitrile
35
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-
(benzoyl)benzeneacetonitrile
36
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-β-(1-
methyl-2-pyrrolyl)benzenepropanenitrile
37
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-
phenoxybenzeneacetonitrile
38
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-
bromobenzeneacetonitrile
39
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(2-
furanyl)hydroxymethyl]benzeneacetonitrile
40
Z- and E-α-[amino[(2-thienyl)thio]methylene]-3-[(2,3,4,5,6-
pentafluorophenyl)hydroxymethyl]benzeneacetonitrile
41
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-[(3-
methyl-2-pyridyl)hydroxymethyl]benzeneacetonitrile
42
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-2-
methylbenzeneacetonitrile
43
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-4-(1,1-
dimethylethyl)benzeneacetonitrile
44
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-1-
naphthyleneacetonitrile
45
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-
(trifluoromethyl)benzeneacetonitrile
46
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-1-
naphthyleneacetonitrile
47
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-
(trifluoromethyl)benzeneacetonitrile
48
Z- and E-α-[amino[(4-aminophenyl)thio]methylene]-4-
methylbenzeneacetonitrile
49
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-2-
methylbenzeneacetonitrile
50
Z- and E-α-[amino[(2-fluorophenyl)thio]methylene]-1-
naphthyleneacetonitrile
51
Z- and E-α-[amino[(2-aminophenyl)thio]methylene]-3-phenyl
benzeneacetonitrile
HRMS
HRMS
Example
FORMULA
Calculated*
Found*
6
C23H20C1N3S
406.1145
406.1148
7
C22H17N5O5S
464.1029
464.1024
8
C24H21N3O3S
432.1382
432.1364
9
C22H18N4O3S
419.1178
419.1168
10
C22H14F5N3OS
464.0856
464.0827
11
C22H20N4OS
389.1436
389.1428
12
C23H21N3OS
388.1484
388.1471
13
C22H20N4OS
388.1436
388.1436
14
C23H17N3O2S
400.1120
400.1105
15
C22H18N4O3S
419.1179
419.1156
16
C23H16F5N3OS
478.1013
478.1002
17
C21H18N4OS
376.1120
376.1103
18
C23H18F3N3OS
442.1201
442.1200
19
C21H18N4OS
375.1280
375.1268
20
C21H17N3OS
376.1120
376.1104
21
C23H18N4OS
399.1280
399.1273
22
C23H18N4OS
399.1280
399.1265
24
C21H17N3OS
360.1171
360.1172
25
C15H12BrN3S
360.1171
360.1172
26
C24H23N3OS
402.1640
402.1648
27
C22H19N3OS
374.1327
374.1327
28
C20H17N3OS2
379.0813 (M+)
379.0799 (M+)
29
C22H18C1N3S
392.0988
392.0982
30
C20H16N2OS2
365.0782
365.0763
31
C19H16N4S
333.1174
333.1166
32
C22H20N4S
373.1496
373.1487
33
C22H19N3S
358.1378
358.1393
34
C23H17N3S
368.1221
368.1227
35
C22H17N3OS
372.1171
372.1160
36
C21H20N4S
361.1487
361.1479
37
C21H17N3OS
360.1171
360.1144
39
C20H17N3O2S
364.1120
364.1097
40
C20H11F5N2OS2
455.0311
455.0305
41
C22H20N4OS
389.1436
389.1431
43
C19H21N3S
324.1534
324.1524
44
C19H15N3S
318.1065
318.1076
45
C16H12F3N3S
336.0782
336.0782
46
C19H15N3S
318.7065
318.1048
47
C16H12F3N3S
336.0782
336.0776
51
C21H17N3S
344.1221
334.1208
*Calculated for M + H unless noted.
Example
Solvent
Chemical Shift
23
CDC13
7.15-7.65 (m, 13H); 5.85&2.88 (2 d, 1H);
4.61&4.88 (2 br s, 2H); 2.50&2.59 (2 d, 2H).
25
CDC13
6.64-7.68 (m, 8H); 3.95-4.81 (3 br s, 4H).
38
CDC13
6.54-7.71 (m, 8H); 4.37-4.90 (4 br s, 4H).
42
CDC13
6.56-7.43 (m, 8H); 3.75-4.70 (4 br s, 4H);
2.37&2.40 (2 s, 3H).
48
CDC13
6.57-7.41 (m, 8H); 3.75-4.74 (4 br s, 4H);
2.33&2.34 (2 s, 3H).
49
CDC13
6.72-7.54 (m, 8H); 4.26-4.80 (3 br s, 4H);
2.36&2.43 (2 s, 3H).
Utility
Compounds of the present invention are inhibitors of the dual-specificity kinase MEK1/MEK2 (Mapk or Erk kinase, where Mapk=mitogen-activated protein kinase) and are expected to be useful for treating proliferative diseases, e.g. cancer, psoriasis, restenosis or atherosclerosis, and also autoimmune diseases. The presently claimed MEK inhibitors are also expected to have utility as radiosensitizers for the treatment of solid tumors. In addition, the presently claimed compounds are expected to have utility for the treatment of chronic pain or for inhibiting memory acquisition. Assays for chronic pain are found Science and Medicine (1996), Nov./Dec., 22-31. Assays for mammalian associative learning are found in Nature Neuroscience (1998) 1 (1) 602-609.
The ERK signal transduction pathway includes two very similar forms of MEK, MEK1 and MEK2, and two similar forms of ERK, ERK1 and ERK2. To block signal transduction via the ERK pathway, a MEK inhibitor must prevent ERK1 and/or ERK2 from being phosphorylated (and thereby activated) by the kinases MEK1 or MEK2. The different roles played by MEK1 and MEK2 and by ERK1 and ERK2 are not currently understood well understood and they may be redundant under some or all circumstances. MEK1 and MEK2 are phosphorylated (and thereby activated) by an upstream kinase, RAF. Since MEK1 or MEK2 have little ability to phosphorylate ERK1 and ERK2 until they have been phosphorylated and since they are usually isolated in their unphosphorylated state, it is difficult to obtain adequate quantities of phosphorylated MEK1 or MEK2 suitable for assaying many compounds. To make assays more practical, a constitutively active mutant of MEK1 (e.g., 2X-MEK1)(see J. Biol. Chem. (1998) 29, 18623-18632) was initially used to characterize the MEK inhibitors of this invention. This mutant enzyme has negatively-charged residues at the residues which are normally phosphorylated by RAF. Selected inhibitors of 2X-MEK1 disclosed herein have been shown to be inhibitors of phosphorylated (i.e., active) wild-type MEK1 and MEK2. Furthermore, many of the MEK inhibitors of this invention have been shown to be capable of blocking phosphorylation of ERK induced by treatment of Jurkat cells with TPA (see J. Biol. Chem. (1998) 29, 18623-18632).
Selected MEK inhibitors from this invention have also been shown to block the upregulation of AP-1 expression in Cos-7 cells induced by stimulation with TPA (see J. Biol. Chem. (1998) 29, 18623-18632). AP-1 in turn regulates the expression of a number of pro-inflammatory and growth-stimulating genes including. These experiments prove that inhibitors of 2X-MEK1 function as inhibitors of MEK and ERK signal transduction in cell culture.
Dosage and Formulation
The compounds of this invention can be administered in such oral dosage forms as tablets, capsules (each of which includes sustained release or timed release formulations), pills, powders, granules, elixirs, tinctures, suspensions, syrups, and emulsions. They may also be administered in intravenous (bolus or infusion), intraperitoneal, subcutaneous, or intramuscular form, all using dosage forms well known to those of ordinary skill in the pharmaceutical arts. They can be administered alone, but generally will be administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice.
The dosage regimen for the compounds of the present invention will, of course, vary depending upon known factors, such as the pharmacodynamic characteristics of the particular agent and its mode and route of administration; the species, age, sex, health, medical condition, and weight of the recipient; the nature and extent of the symptoms; the kind of concurrent treatment; the frequency of treatment; the route of administration, the renal and hepatic function of the patient, and the effect desired. A physician or veterinarian can determine and prescribe the effective amount of the drug required to prevent, counter, or arrest the progress of the thromboembolic disorder.
By way of general guidance, the daily oral dosage of each active ingredient, when used for the indicated effects, will range between about 0.001 to 1000 mg/kg of body weight, preferably between about 0.01 to 100 mg/kg of body weight per day, and most preferably between about 1.0 to 20 mg/kg/day. Intravenously, the most preferred doses will range from about 1 to about 10 mg/kg/minute during a constant rate infusion. Compounds of this invention may be administered in a single daily dose, or the total daily dosage may be administered in divided doses of two, three, or four times daily.
Compounds of this invention can be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal routes, using transdermal skin patches. When administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
The compounds are typically administered in admixture with suitable pharmaceutical diluents, excipients, or carriers (collectively referred to herein as pharmaceutical carriers) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, elixirs, and syrups, and consistent with conventional pharmaceutical practices.
For instance, for oral administration in the form of a tablet or capsule, the active drug component can be combined with an oral, non-toxic, pharmaceutically acceptable, inert carrier such as lactose, starch, sucrose, glucose, methyl callulose, magnesium stearate, dicalcium phosphate, calcium sulfate, mannitol, and sorbitol; for oral administration in liquid form, the oral drug components can be combined with any oral, non-toxic, pharmaceutically acceptable inert carrier such as ethanol, glycerol, and water. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents, and coloring agents can also be incorporated into the mixture. Suitable binders include starch, gelatin, natural sugars such as glucose or beta-lactose, corn sweeteners, natural and synthetic gums such as acacia, tragacanth, or sodium alginate, carboxymethylcellulose, polyethylene glycol, and waxes. Lubricants used in these dosage forms include sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, and sodium chloride. Disintegrators include, without limitation, starch, methyl cellulose, agar, bentonite, and xanthan gum.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles, and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine, or phosphatidylcholines.
Compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide-phenol, polyhydroxyethylaspartamidephenol, or polyethyleneoxide-polylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyglycolic acid, copolymers of polylactic and polyglycolic acid, polyepsilon caprolactone, polyhydroxy butyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacylates, and crosslinked or amphipathic block copolymers of hydrogels.
Dosage forms (pharmaceutical compositions) suitable for administration may contain from about 1 milligram to about 100 milligrams of active ingredient per dosage unit. In these pharmaceutical compositions the active ingredient will ordinarily be present in an amount of about 0.5-95% by weight based on the total weight of the composition.
Gelatin capsules may contain the active ingredient and powdered carriers, such as lactose, starch, cellulose derivatives, magnesium stearate, and stearic acid. Similar diluents can be used to make compressed tablets. Both tablets and capsules can be manufactured as sustained release products to provide for continuous release of medication over a period of hours. Compressed tablets can be sugar coated or film coated to mask any unpleasant taste and protect the tablet from the atmosphere, or enteric coated for selective disintegration in the gastrointestinal tract.
Liquid dosage forms for oral administration can contain coloring and flavoring to increase patient acceptance.
In general, water, a suitable oil, saline, aqueous dextrose (glucose), and related sugar solutions and glycols such as propylene glycol or polyethylene glycols are suitable carriers for parenteral solutions. Solutions for parenteral administration preferably contain a water soluble salt of the active ingredient, suitable stabilizing agents, and if necessary, buffer substances. Antioxidizing agents such as sodium bisulfite, sodium sulfite, or ascorbic acid, either alone or combined, are suitable stabilizing agents. Also used are citric acid and its salts and sodium EDTA. In addition, parenteral solutions can contain preservatives, such as benzalkonium chloride, methyl- or propyl-paraben, and chlorobutanol.
Suitable pharmaceutical carriers are described in Remington's Pharmaceutical Sciences, Mack Publishing Company, a standard reference text in this field.
Representative useful pharmaceutical dosage-forms for administration of the compounds of this invention can be illustrated as follows:
Capsules
A large number of unit capsules can be prepared by filling standard two-piece hard gelatin capsules each with 100 milligrams of powdered active ingredient, 150 milligrams of lactose, 50 milligrams of cellulose, and 6 milligrams magnesium stearate.
Soft Gelatin Capsules
A mixture of active ingredient in a digestable oil such as soybean oil, cottonseed oil or olive oil may be prepared and injected by means of a positive displacement pump into gelatin to form soft gelatin capsules containing 100 milligrams of the active ingredient. The capsules should be washed and dried.
Tablets
Tablets may be prepared by conventional procedures so that the dosage unit is 100 milligrams of active ingredient, 0.2 milligrams of colloidal silicon dioxide, 5 milligrams of magnesium stearate, 275 milligrams of microcrystalline cellulose, 11 milligrams of starch and 98.8 milligrams of lactose. Appropriate coatings may be applied to increase palatability or delay absorption.
Injectable
A parenteral composition suitable for administration by injection may be prepared by stirring 1.5% by weight of active ingredient in 10% by volume propylene glycol and water. The solution should be made isotonic with sodium chloride and sterilized.
Suspension
An aqueous suspension can be prepared for oral administration so that each 5 mL contain 100 mg of finely divided active ingredient, 200 mg of sodium carboxymethyl cellulose, 5 mg of sodium benzoate, 1.0 g of sorbitol solution, U.S.P., and 0.025 mL of vanillin.
Where the compounds of this invention are combined with other anticoagulant agents, for example, a daily dosage may be about 0.1 to 100 milligrams of the compound of Formula I and about 1 to 7.5 milligrams of the second anticoagulant, per kilogram of patient body weight. For a tablet dosage form, the compounds of this invention generally may be present in an amount of about 5 to 10 milligrams per dosage unit, and the second anti-coagulant in an amount of about 1 to 5 milligrams per dosage unit.
Where the compounds of Formula I are administered in combination with an anti-platelet agent, by way of general guidance, typically a daily dosage may be about 0.01 to 25 milligrams of the compound of Formula I and about 50 to 150 milligrams of the anti-platelet agent, preferably about 0.1 to 1 milligrams of the compound of Formula I and about 1 to 3 milligrams of antiplatelet agents, per kilogram of patient body weight.
Where the compounds of Formula I are adminstered in combination with thrombolytic agent, typically a daily dosage may be about 0.1 to 1 milligrams of the compound of Formula I, per kilogram of patient body weight and, in the case of the thrombolytic agents, the usual dosage of the thrombolyic agent when administered alone may be reduced by about 70-80% when administered with a compound of Formula I.
Where two or more of the foregoing second therapeutic agents are administered with the compound of Formula I, generally the amount of each component in a typical daily dosage and typical dosage form may be reduced relative to the usual dosage of the agent when administered alone, in view of the additive or synergistic effect of the therapeutic agents when administered in combination.
Particularly when provided as a single dosage unit, the potential exists for a chemical interaction between the combined active ingredients. For this reason, when the compound of Formula I and a second therapeutic agent are combined in a single dosage unit they are formulated such that although the active ingredients are combined in a single dosage unit, the physical contact between the active ingredients is minimized (that is, reduced). For example, one active ingredient may be enteric coated. By enteric coating one of the active ingredients, it is possible not only to minimize the contact between the combined active ingredients, but also, it is possible to control the release of one of these components in the gastrointestinal tract such that one of these components is not released in the stomach but rather is released in the intestines. One of the active ingredients may also be coated with a material which effects a sustained-release throughout the gastrointestinal tract and also serves to minimize physical contact between the combined active ingredients. Furthermore, the sustained-released component can be additionally enteric coated such that the release of this component occurs only in the intestine. Still another approach would involve the formulation of a combination product in which the one component is coated with a sustained and/or enteric release polymer, and the other component is also coated with a polymer such as a low-viscosity grade of hydroxypropyl methylcellulose (HPMC) or other appropriate materials as known in the art, in order to further separate the active components. The polymer coating serves to form an additional barrier to interaction with the other component.
These as well as other ways of minimizing contact between the components of combination products of the present invention, whether administered in a single dosage form or administered in separate forms but at the same time by the same manner, will be readily apparent to those skilled in the art, once armed with the present disclosure.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein.
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This invention relates generally to amino-thio-acrylonitriles of formula Ia or Ib:
as MEK inhibitors, pharmaceutical compositions containing the same, and methods of using the same as for treatment and prevention of inflammatory disorders or as an anticancer radiosensitizing agent.
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BACKGROUND OF THE INVENTION
Commutators comprise a circular series of radially extending bars of predetermined length which are provided on one end of armatures of many types of electric motors and generators. The bars are insulated from each other by relatively thin sheets of mica. The overall exterior surface of a commutator of this type is substantially cylindrical and the inner ends of said bars are appropriately connected electrically to the windings of the armature. The commutators are engaged by carbon brushes which slidably engage the bars of the commutator in order to establish certain successive momentary electrical contacts therewith. The brushes normally are spring-pressed toward the commutator so that there is continual, gradual wearing of the outer surfaces of the commutator bars and the ends of the carbon brushes which engage the same.
When commutators are being manufactured, the outer surface thereof usually is machined to establish a uniform overall cylindrical configuration. At this stage, the outer edges of the mica insulation strips normally are coextensive with the outer surfaces of the commutator bars which usually are made of copper. It is necessary to cut away the outer edge portions of the mica strips to a predetermined depth because it is harder than the copper and causes undue wear of carbon brushes if they are permitted to engage the same. Such cutting away of the outer edges of the mica strips is known as undercutting the same. Such undercutting is performed on specialized machines adapted to that purpose and provided with narrow cutters capable of effectively cutting or milling the outer edges of the mica sheets.
Further, when commutators become worn to such extent that the outer edges of the mica insulating strips are substantially even with the worn outer surfaces of the copper bars, it is necessary to machine the commutators to reestablish a desired operative surface. When in such worn condition, it is not uncommon that the surfaces of the bars which are engaged by the carbon brushes actually have shallow grooves worn therein by said brushes and it is necessary to restore the outer surface of the commutator to a substantially cylindrical shape and thereby remove said grooved effects. This is done by machining the outer surface of the commutator in an appropriate cutting lathe and, as in regard to when the armature is newly manufactured, it then is necessary to undercut the insulating strips of mica to dispose the outer edges thereof at a level below the overall cylindrical outer surface of the commutator.
This invention pertains to the mica undercutting machines which perform the above outlined undercutting process.
It has been known in the prior art to drive an undercutting assembly along a shaft via a rack and pinion drive for a distance corresponding to the length of a mica slot to be undercut. Prior art systems have utilized limit switches to control the length of traverse of an undercutting saw. These switches can be in the form of mechanical limit switches or proximity sensors.
Since the proximity sensors are manually set in place, a possibility of error arises which may, for example, result in the saw running into the riser of the armature and consequent damage to the saw blade and spindle damage.
It has also been known to utilize an undercutting saw blade which is mounted on a floating spindle assembly to accommodate a particular problem in the art, namely the skew which sometimes exists in the mica slots. Under ideal manufacturing conditions, the mica slots would lie parallel to the axis of the armature and commutator. However, due to manufacturing inaccuracies and the difficulty of working with mica, the resulting mica slots may be skewed or out of alignment with the center line of the armature axis.
Prior art floating spindle assemblies were designed to accommodate the above mentioned skew of the mica slots by allowing the saw blade to float up and down and thereby stay within and appropriately undercut the mica slots.
However, if the skew is relatively large, as has been found in some instances in commutators for DC motors in the mass transit field, the floating spindle design cannot adjust for this larger skew and it becomes necessary to manually adjust the machine to undercut the skewed mica slots. Each time the machine is adjusted for skewed slots, it must be readjusted for automatic operation.
Accordingly, it is an object of the present invention to provide a drive means for an undercutting assembly which will not result in damage to the saw blade and spindle assembly should there be an inaccurate location of the proximity sensors or should there be a failure of the proximity sensors to effectively halt the traverse of the undercutting assembly.
It is a further object of the present invention to provide an automatic skew compensator attachment as a part of the floating spindle assembly which will enable an overall undercutter assembly to compensate for the large amount of mica slot skew present in some DC motor commutators.
These and other objects and advantages of the present invention will become apparent to those of skill in the art in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional end view of a DC motor commutator.
FIG. 2 is a side schematic elevational view of the overall undercutting assembly.
FIG. 3 is an end schematic view of the overall undercutting assembly.
FIG. 4 shows the floating spindle assembly with means to compensate for excessive skew in a mica slot to be undercut.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 in partial view, a DC motor commutator 10 comprises cylindrically arranged copper bars 11 between which are placed mica insulating strips 12 and 13. As before described, it is necessary that the mica strips be undercut to a level beneath the outer surface of the copper bars 11 to prevent excessive brush wear when the commutator is installed in a DC motor. Numeral 12 shows a mica slot before undercutting while numerals 13 indicate mica slots which have been undercut to an appropriate desired level.
To accomplish the undercutting process, the commutator 10 and its attached armature 20 are loaded onto an undercutting machine as shown in side schematic view at FIG. 2. A riser element 21 is also part of the armature-commutator structure.
As shown in FIG. 2, the undercutting of the commutator 10 is accomplished by means of an undercutter assembly 30 which has attached thereto a floating spindle assembly 31 and undercutting saw 71. The floating spindle assembly and attachments thereto will be more fully described with reference to FIG. 4.
The undercutting saw 71 is of a rotary type known in the art as evidenced by U.S. Pat. No. 2,400,933 issued to Johnson. As is knwn from the prior art Johnson patent, a type of rotary saw is utilized which avoids damage to the commutator bars 11 when a condition of slight irregularity, i.e. mica slot skew, is encountered during the undercutting operation. The undercutting saw 71 is shaped so as to undercut to a depth shown at 13 in FIG. 1.
Referring again to FIG. 2, the undercutter assembly 30 is shown as resting on an undercutter pedestal 35 beneath which is shown a dovetail slide layer 36 by which the undercutting saw 71 is manually moved into position to undercut the mica slot. The undercutter assembly 30 is further mounted on carriage 37 and the entire assembly is driven along shaft 40 via drive interconnection means 41. The rotary shaft 40 is supported at each end by bearings 55.
Shown to the left of FIG. 2, motor 50 rotates the shaft 40 via a gear box 51 and a flexible cushioned start coupling 52 as is known in the art. Bearings 55 are supported on a bed 60. Thus, in the basic operation of the device, motor 50 rotates shaft 40 and the rotary motion of shaft 40 is converted into linear motion of the undercutter assembly 30 by the drive interconnection means 41, which will be more fully described.
Shown as mounted on the underside of carriage 37 are two proximity sensors 58. These sensors 58 act in conjunction with stops 59 mounted on bed 60 to control the length of traverse of the spindle assembly 31 and attached cutting saw 71 along the mica slot to be undercut. Proximity sensors 58 are of the type which create a magnetic field and when said magnetic field is disturbed by reason of passing in close proximity to stops 59, a signal is sent to motor 50 which appropriately stops rotation of shaft 40 to thereby end the traverse of the cutting path.
The drive interconnection means 41 of FIG. 2, which converts the rotary motion of shaft 40 into the linear motion of the undercutter assembly 30, has traditionally been of the rack and pinion or similarly functioning type. Thus, if stops 59 were inaccurately located by the machine operator or if there were a failure of proximity sensor 58 function, the undercutter assembly 30 could be driven into the riser 21 causing severe damage to the undercutting saw 71 and spindle assembly 31 by reason of the direct rack and pinion drive between the shaft 40 and undercutter assembly 30.
In order to avoid these potential costly damages to the machine, a different drive interconnection means 41 has been substituted for the conventional rack and pinion drive.
As shown more clearly in FIG. 3, the drive interconnection means 41 of the present invention comprises multiple angled cylindrical bearings 42 which are located in a housing around shaft 40. The cylindrical bearings 42 act to convert the rotary motion of shaft 40 into linear motion of the carriage 37 and attached undercutter assembly 30. The pressure which the cylindrical bearings 42 exert on shaft 40 can be adjusted via tightening bolts 45. However, should an obstruction be encountered, as in the case aforementioned when the saw blade attached to spindle assemble 31 could contact riser 21, the shaft 40 would continue to rotate without exerting a strong driving force on the carriage 37 as would be the case with a rack and pinion drive interconnection means. Thus, severe damage to the spindle assembly and saw blade can be avoided. The rotary shaft 40 continues to rotate in effect in an idle mode when the carriage 37 encounters an obstruction as in the case when the carriage mounted spindle assembly contacts the riser 21.
The drive interconnection means 41 which has been successfully applied by applicant in the present invention is the Rohlix manufacture by Zero-Max, Inc.
As is also shown in FIG. 3, mounted on the underside of carriage 37 are ball bushings 61 which are shaped to receive load bearing shafts 62 therein. The shafts 62 run parallel to the central rotary shaft 40 and are designed to receive the entire weight load of the carriage 37 by reason of supports 63 and bedding 60.
FIG. 3 also illustrates the function of dovetail slide element 36 which is manually adjusted by the machine operator to locate the spindle assembly 31 and saw blade 71 in the appropriate mica undercutting position with regard to the commutator 10.
Referring now to FIG. 4 which shows the floating spindle assembly 31 in further detail, the mica undercutting saw 71 is shown as fixedly attached to spindle 72 which is capable of rotary motion by reason of its location in bearing 75 at the upper location of the spindle bracket 70. It is to be understood that the lower end of spindle 72 and thus the saw blade 71 is turned by belt drive 77 from a motor mounted as a part of the undercutting assembly 30 which has attached thereto the spindle assembly 31 as previously shown generally in FIGS. 2 and 3.
As further shown in FIG. 4, a spring rod 80 is threadedly engaged with the lower end of spindle 72. Mounted around the spring rod 80 are two springs 81 and 82 which serve to allow the spindle 72 to float up and down. The spindle 72 rotates through the contact of dowel pins 84. Upper spring 81 is mounted on an inner landing 86 of the assembly. Lower spring 82 is retained in position by a flex-lock nut assembly 89.
The spindle 72 and attached saw blade 71 are thus rotated via belt 77 applied to drive collar 85 and the spindle 72 can float up and down by reason of springs 81 and 82 and dowel pins 84. See the arrows in FIG. 4 indicating rotary and up and down motion of spindle 72. With this arrangement, should the saw blade 71 encounter a mica slot section which is skewed or out of alignment, the floating spindle 72 compensates and allows the saw to continue along its appropriate mica undercutting pathway.
The above described floating spindle arrangement has been used successfully to allow continued automatic mica undercutting in situations where the skewing has been relatively minor.
However, the floating spindle arrangement cannot adequately compensate for situations where the skewing is severe, i.e. where the mica slots to be undercut are greatly out of allignment with the commutator axis. Thus, situations have been encountered where manual adjustment or undercutting have been required even with a floating spindle structure due to the severe mica slot skewing present in a commutator.
In order to overcome this problem, applicant has devised a sensing and control system to automatically allow the saw blade 71 to continue its proper undercutting function even under conditions of severe mica slot skewing.
In this arrangement, shown also in FIG. 4, a portion of the spindle 72 is coated with a flat black paint at 90. In practice of the invention, it is contemplated that the portion 90 of spindle 72 will be turned to a shallow depth and the nonreflective black paint be applied to section 90 thereafter.
A sensor retaining bracket 91 is then affixed to the undercutting spindle bracket 70 by appropriate bolt or weld attachment means 98 or bracket 91 may be formed as a one-piece assembly with bracket 70 as desired. Positioned on the sensor retaining bracket 91 are two light sensing elements 95 and 96. As shown schematically in FIG. 4, the light sensing elements 95 and 96 are placed so as to be able to sense when blackened portion 90 passes over one or the other of said sensors 95 and 96 by reason of the float inherent in spindle 72.
As previously described, spindle 72 is able to float up and down when saw blade 71 encounters a slight skew condition present in the mica slot to be undercut. Such floating is accomplished by reason of lower springs 81 and 82, spring rod 80, and dowel pin connectors 84.
When a high degree of skew is present on the mica slot to be undercut, it has been found to be necessary to adjust the angle of the commutator workpiece itself, i.e. the floating spindle concept is not sufficient to undercut mica slots which have a severe skew.
Such adjustment of the commutator is accomplished via sensors 95 and 96. When blackened portion 90 of spindle 72 passes over one or the other of sensors 95 or 96, a condition of severe skew is indicated and a signal is sent via lines 103, 104 to a programable controller 105 which, via line 99, signals motor 100 to raise or lower the pinion 101 by which the armature 20 has previously been attached to the headstock 106 of the undercutting machine. The control functioning is shown in FIG. 2. In this manner, the attached commutator 10 is also slightly raised or lowered an appropriate amount so that the proper mica slot undercutting can continue automatically even under conditions of high skew.
It is noted that the right hand side of commutator 10 would also be fixed to the undercuting machine via a second pinion so that when motor 100 raises or lowers the first pinion 101, the commutator 10 turns about a pivot point illustrated in FIG. 3.
The above system thus allows automatic skew compensation even under conditions where the commutator mica slots have severe skew so that the entire commutator can be automatically machine undercut without the need to manually undercut mica sections having a high degree of skew.
The system of the present invention has been found to have significant utility when applied to relatively small commutators used by the mass transit industry where conditions of high mica slot skew are sometimes encountered. It is to be understood, however, that the principles set forth herein would be applicable to any size commutator wherein significant skew conditions are present.
From the foregoing description, it will be seen that the present invention incorporates at least two novel features of significance in the commutator undercutting industry. First, the cylindrical bearing Rohlix drive allows the saw to perform its undercutting function without a risk of serious damage to the saw and spindle assembly by reason of failure or mislocation of the proximity sensor elements. Secondly, the use of sensors 95 and 96 to detect conditions of high skew via the float present in spindle 72 allow the undercutter to perform its intended function even when working on commutators with a high degree of mica slot skew.
Since undercutting machines are used on a worldwide basis and often in rather remote locations, the enhancement of reliability and performance of such machines by reason of the inventive concepts set forth herein is a significant improvement in the state of the undercutting art.
It should be understood that the invention is not to be limited to the precise details herein illustrated and described since the same may be carried out in other ways falling within the spirit and scope of the invention as set forth in the specification and the appended claims.
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An improved machine for undercutting the commutator of a DC motor. Designed specifically to undercut the mica insulation slots of a commutator, the device includes drive means to allow slippage of an undercutting assembly so that saw and spindle assembly damage are avoided. The invention also incorporates an automatic skewing attachment which indirectly senses misallignment of mica slots to be undercut and acts to reposition the commutator as needed so that the mica slot undercutting process may continue.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. Provisional Patent Application No. 61/639,455 filed on Apr. 27, 2012 entitled “Method and Apparatus for Controlling the Flow of Well Bore Returns”, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to oil and gas drilling operations, and in particular to an apparatus and method for controlling the flow of wellbore returns.
BACKGROUND
[0003] During drilling operations, drilling fluid or drilling mud, is pumped down the drill string in the wellbore using what are known as mud pumps. The drilling fluid jets out of the drill bit and cleans the bottom of the hole. The drilling fluid moves back up the wellbore in the annular space between the drill sting and the side of the wellbore, flushing cuttings and debris to the surface. The returning drilling fluid provides hydrostatic pressure to promote the prevention of formation fluids from entering into the wellbore. Drilling fluids are also typically viscous or thixotropic to aid in the suspension of cuttings in the wellbore, both during drilling and during interruptions to drilling.
[0004] The mixture of drilling fluid, formation fluids, cuttings and debris travelling back up the wellbore to the surface is referred to as the ‘wellbore returns’ or ‘drilling returns’. The wellbore returns may also contain dissolved gas which moves from the surrounding formation being drilled into the drilling fluid in the annulus.
[0005] Upon arrival at the surface, a series of valves and pipes are utilized to controllably direct the wellbore returns to either a mud/gas separator or to a de-gasser. A separator typically comprises a cylindrical or spherical vessel and can be either horizontal or vertical. It is used to separate gas from the drilling fluid and gas mixture. In the separator, the mixture is usually passed over a series of baffles designed to separate gas and mud. Liberated free gas is moved to a flare line and the mud is discharged to a shale shaker and to a mud tank. A de-gasser is used when the gas content of the drilling fluid is relatively lower and it operates on much the same principles as the separator. A vacuum is applied to the fluid as it is passed over the baffles to increase surface area, thereby promoting the liberation of dissolved gas.
[0006] During drilling operations, it is important to maintain constant down-hole hydrostatic pressure to prevent formation fluids from entering into the wellbore as mentioned above. This can be challenging due to shifting wellbore conditions and interruptions to drilling operations, such as tripping pipe. To maintain down-hole hydrostatic pressure, conventional drilling operations utilize one or more chokes at the well head. The primary role of the choke is to regulate the flow of wellbore returns from the well head. The choke comprises an adjustable orifice that can be opened or closed to control the flow rate of the wellbore returns, which in turn regulates down-hole pressure. There are both fixed and adjustable chokes, the latter being more conducive to enabling the fluid flow and pressure parameters to be adjusted to suit process and production requirements. However, the chokes, whether fixed or adjustable, are prone to wear, erosion and becoming clogged with cuttings and debris. Further, the chokes do not accurately measure wellbore return volume.
[0007] There is a need in the art for an apparatus and a method of controlling wellbore returns to regulate down-hole hydrostatic pressure that may mitigate the problems of existing choke devices, or provide an alternative to existing choke devices.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention provides a method of controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore, the method comprising the steps of:
(a) directing the flow of wellbore returns through an intake flow line from the wellbore into a gas/liquid separator having a gas outlet; (b) separating gas associated with the wellbore returns to produce a disassociated gas in the separator; and (c) selectively restricting the flow of the disassociated gas out of the separator through the gas outlet to regulate the internal gas pressure of the separator, wherein the internal gas pressure of the separator is opposed to the flow of the wellbore returns through the intake flow line from the wellbore into the separator.
In one embodiment, the method further comprises the step of introducing gas into the separator from a gas source to increase the internal gas pressure of the separator.
[0012] In another aspect, the present invention provides a method of controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore, the method comprising the steps of:
(a) directing the flow of wellbore returns through an intake flow line from the wellbore to a pump, and through the pump; and (b) selectively varying the speed of the pump to vary the resistance of the pump to the flow of wellbore returns through the intake flow line from the wellbore to the pump.
In one embodiment, the pump is a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump, or a diaphragm pump. In one embodiment, the method further comprises the step of measuring the volume of wellbore returns passing through the pump.
[0015] In another aspect, the present invention provides an apparatus for controlling a flow of wellbore returns to regulate the down-hole hydrostatic pressure of a wellbore. The apparatus comprises an intake flow line, a gas/liquid separator, and a back pressure valve. The intake flow line receives the flow of wellbore returns from the wellbore. The gas/liquid separator has an inlet for interconnection to the intake flow line for receiving the flow of wellbore returns, and a gas outlet. The back pressure valve is interconnected to the gas outlet and is adjustable to selectively restrict the flow of gas out of the separator and thereby regulate the internal gas pressure of the separator opposed to the flow of wellbore returns through the intake flow line from the wellbore into the separator.
[0016] In one embodiment, the apparatus further comprises a gas source interconnected to the separator.
[0017] In another aspect, the present invention provides an apparatus for controlling a flow of well bore returns to regulate the down-hole hydrostatic pressure of a wellbore. The apparatus comprises an intake flow line, and a pump. The intake flow line receives the flow of wellbore returns from the wellbore. The pump has a pump inlet interconnected to the intake line for receiving the flow of wellbore returns, and a pump outlet for discharging the flow of wellbore returns. The speed of the pump is adjustable to selectively vary the resistance of the pump to the flow of wellbore returns through the intake flow line from the wellbore to the pump.
[0018] In one embodiment, the pump is a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump, or a diaphragm pump.
[0019] In one embodiment, the apparatus further comprises a gas/liquid separator and a back pressure valve. The gas/liquid separator has a separator inlet and a gas outlet, the separator inlet being interconnected to the intake flow line for receiving the flow of wellbore returns. The back pressure valve is interconnected to the gas outlet and is adjustable to selectively restrict the flow of gas out of the separator and thereby regulate the internal gas pressure of the separator opposed to the flow of wellbore returns though the intake flow line from the wellbore into the separator.
[0020] In one embodiment, the apparatus further comprises an intake valve interconnected to the intake flow line for selectively restricting the flow of wellbore fluids through the intake flow line from the wellbore to either the pump, or the separator, or both.
[0021] In one embodiment, the apparatus further comprises a gas source interconnected to the separator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the drawings, like elements are assigned like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. Additionally, each of the embodiments depicted are but one of a number of possible arrangements utilizing the fundamental concepts of the present invention. The drawings are briefly described as follows:
[0023] FIG. 1 is an elevated diagrammatic depiction of one embodiment of the present invention.
[0024] FIG. 2 is an elevated diagrammatic depiction of another embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The invention relates to an apparatus and a method of controlling the flow of wellbore returns to regulate the hydrostatic force in a wellbore. When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention. The following description is intended to cover all alternatives, modifications and equivalents that are included in the scope of the invention, as defined in the appended claims.
[0026] As used herein, the term “down-hole hydrostatic pressure” means the pressure exerted at any given point in the wellbore by the column of fluid above that point, including any pressure exerted at the surface by the apparatuses described herein.
[0027] FIG. 1 depicts one embodiment of the apparatus ( 10 ) of the present invention. The apparatus ( 10 ) can be utilized to control and exert a selected pressure back on the wellbore, thus controlling the hydrostatic pressure on the formation surrounding the wellbore, the inflow of fluids from the surrounding formation into the wellbore, and the flow of the drilling fluid. In one embodiment, the apparatus ( 10 ) will also allow an operator to measure the volume of wellbore returns passing through the apparatus ( 10 ).
[0028] Referring to FIG. 1 , an intake flow line ( 19 ) receives the wellbore return flow (F) that is diverted from the blow-out-preventer (“BOP”) stack (not shown) at the wellhead. In one embodiment, a diversion manifold ( 26 ) provides two alternate flow paths for the wellbore returns which can be interchangeably selected by selectively opening and closing gate valves ( 18 , 15 , 17 ).
[0029] In further embodiments of the present invention, the diversion manifold ( 26 ) may be substituted for a rotating flow control diverter (“RFCD”) or rotating blow out preventer (“RBOP”). The gate valves ( 18 , 15 , 17 ) may also be closed to block the flow of wellbore returns if required for safety purposes. As shown in FIG. 1 , a choke valve ( 29 ) may be used with the present apparatus ( 10 ) and may be employed to quickly kill flow of the wellbore returns if required. It should be understood that the choke valve ( 29 ) is present for safety purposes only and is not essential to the method of or apparatus for controlling the down-hole hydrostatic pressure described herein.
[0030] The first flow path leads directly to the separator flow line ( 33 ) which is connected to a gas/liquid separator ( 14 ). Any suitable separator ( 14 ) may be used with the present invention provided that it has an adequate volume and pressure rating. In one embodiment, a gas source ( 16 ) is interconnected to the separator ( 14 ). The gas source ( 16 ) may consist of any suitable equipment capable of providing on-site generated nitrogen, liquid nitrogen, natural gas, propane or carbon dioxide, as is well known in the art. A liquid outlet line ( 20 ) may lead from the separator ( 14 ) to a tank ( 38 ) or de-gasser ( 36 ) or to a shaker ( 34 ) (shown in FIG. 2 ). A gas outlet line ( 24 ) leads from the separator ( 14 ) to a flare stack (not shown in the Figures). The gas outlet line ( 24 ) has an integral back pressure valve ( 22 ).
[0031] A second flow path follows the pump flow line ( 32 ) to a pump ( 12 ). The pump ( 12 ) can be any suitable pump that can be used to control the flow of the wellbore returns, including without limitation, a multiphase pump, a positive displacement pump, a twin screw pump, a centrifugal pump or a diaphragm pump. A fluid flow meter (not shown) may be associated with or integral with the pump. In one embodiment, a twin screw pump is used as it easily facilitates accurate measurement of the volume of the wellbore returns passing through it.
[0032] Operation of the apparatus ( 10 ) depicted in FIG. 1 will now be described. If an operator elects to flow the wellbore returns directly into the separator ( 14 ) from the BOP stack, the gate valves ( 15 , 17 ) on both sides of the pump ( 12 ) are closed, while the gate valve ( 18 ) and the choke valve ( 29 ), if present, mounted on the separator flow line ( 33 ) are opened thereby directing flow of the wellbore returns directly along the separator flow line ( 33 ) into the separator ( 14 ). Gas is separated from the wellbore returns in the separator ( 14 ). The back pressure valve ( 22 ) can be used to restrict the flow of gas out of the separator ( 14 ) into the gas outlet line ( 24 ). This causes an increase of the internal gas pressure in the separator ( 14 ) which inhibits the flow of the wellbore returns into the separator ( 14 ) from the separator flow line ( 33 ). The restricted flow of wellbore returns results in back pressure on the wellbore and an increase in down-hole hydrostatic pressure. In this manner, the down-hole hydrostatic pressure can be controlled and maintained at a constant level by the back pressure valve ( 22 ) on the gas outlet line ( 24 ).
[0033] In the event, that the wellbore returns do not have sufficient associated gasses to create the required back pressure in the separator ( 14 ) to restrict the flow of the wellbore returns into the separator ( 14 ), then the internal pressure of the separator ( 14 ) can be artificially increased as required by the introducing gas into the separator ( 14 ) from the gas source ( 16 ).
[0034] If the operator elects to flow the wellbore returns through the pump ( 12 ) from the BOP stack, then the gate valve ( 18 ) mounted on the separator flow line ( 33 ) will be closed and the gate valves ( 15 and 17 ) on both sides of the pump ( 12 ) and the choke valve ( 29 ), if present, will be opened. The flow of wellbore returns is accordingly directed through the pump flow line ( 32 ) into an inlet of the pump ( 12 ). The flow of the wellbore returns through the pump ( 12 ) can be restricted in a controlled manner by controlling the speed at which the pump ( 12 ) runs. The faster the pump ( 12 ) runs, the less that the pump ( 12 ) restricts the flow of wellbore returns. Conversely, the slower the pump ( 12 ) runs, the more that the pump ( 12 ) restricts the flow of wellbore returns. Inhibition of the flow of the wellbore returns results in back pressure on the wellbore and an increase in down-hole hydrostatic pressure. In this manner the down-hole hydrostatic pressure can be controlled and maintained at a constant level by the varying the speed or revolutions per minute (“rpm”) of the pump ( 12 ), as required. For example, if the down-hole hydrostatic pressure increases beyond a desirable level, then the speed of the pump ( 12 ) can be increased to lower the back pressure, thereby lowering the down-hole hydrostatic pressure. The flow of wellbore returns exits the pump ( 12 ) though a pump outlet and is directed to the separator flow intake line ( 33 ) (as shown in FIG. 1 ).
[0035] Use of a pump ( 12 ) also provides the operator with the means to accurately calculate the return volume of the wellbore returns. Such information is important to the operator who is continuously trying to achieve a net balance of liquid injection and liquid returns during operations.
[0036] While FIGS. 1 and 2 depict embodiments of the apparatus ( 10 ) having both a pump ( 12 ) and a separator ( 14 ), one skilled in the art will appreciate that the present invention can be practiced using a pump ( 12 ) without a separator ( 14 ), or using a separator ( 14 ) without a pump ( 12 ).
[0037] In the embodiment depicted in FIG. 2 , an additional flow line ( 35 ) and additional gate valves ( 23 , 21 ) may be utilized which allows the operator to direct the wellbore returns directly to a de-gasser ( 36 ), a shaker ( 34 ) or to a rig tank ( 38 ) without having to pass through the separator ( 14 ). Using the apparatus ( 10 ) shown in FIG. 2 , an operator could selectively run the wellbore returns through the pump ( 12 ) and then directly to the de-gasser ( 36 ) and the shaker ( 34 ) by closing the gate valve ( 21 ) mounted on the separator flow line ( 33 ) and by opening the gate valve ( 23 ) on flow line ( 35 ).
[0038] It should also be understood that the pump ( 12 ) and the separator ( 14 ) may be used independently to control the flow of the wellbore returns, or they may also be used cooperatively to control the flow of wellbore returns.
[0039] As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the scope of the invention claimed herein.
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A method and apparatus to regulate the down-hole hydrostatic pressure in a wellbore are provided which depend on regulating the resistance to the flow of wellbore returns produced by the wellbore. The resistance may be provided by the internal gas pressure in a gas/liquid separator receiving the flow of wellbore returns, where the internal gas pressure is regulated by an adjustable back pressure valve and a gas source. Alternatively or in addition, the resistance may be provided by a pump receiving the flow of wellbore returns, where the resistance of the pump is regulated by adjusting the speed of the pump.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to the field of word processing. More specifically, the present invention is related to a computer-based word processing program used to aid in the correction of typographical and formatting errors.
[0003] 2. Discussion of Prior Art
[0004] Computer-based word processing programs, such as spell check and online thesauruses, are widely used to assist in the correction of incorrectly inputted data When implemented, these programs also offer solutions to replace found errors, or allow the user to add new words to the program's memory.
[0005] The use of audible signals or alarms is also implemented in several of these programs. As a user types words or similar data, the program refers back to the dictionary as stored in the memory to assure proper spelling. Should the program not find a word similar in spelling, an alarm will be activated to alert the user of the error. The user can then take the necessary steps to correct the misspelling. Examples of prior art systems using this technology or variations thereof are described below.
[0006] U.S. Pat. No. 4,689,768 discusses the use of a spelling verification system on a typewriter with an alarm that alerts the operator of inputted words that do not match any of those stored in the dictionary's memory.
[0007] U.S. Pat. No. 4,807,181 describes an electronic typewriter having a memory containing a spell-checking dictionary and a multi-character display. If the user enters characters not recognized by the memory, the user is alerted by an audible alarm and given on the display a successive amount of words that appear to be similar in spelling for use or for addition into the dictionary's memory.
[0008] U.S. Pat. No. 4,829,472 provides a spelling check module to be used in conjunction with a typewriter or personal computer that alerts the user by way of an audible beep of a misspelled word. The spelling check module is connected to the keyboard and data processor to receive the correct input. The module also includes a personal dictionary to which words can be added by the user for customization.
[0009] U.S. Pat. No. 4,830,521 discusses an electronic typewriter or word processor with a spelling check function and proper noun recognition, and an alarm means used for issuing an alarm when an input word is determined to be incorrectly spelled or not a proper noun.
[0010] U.S. Pat. No. 4,913,566 describes a typing device with a spelling check function that retrieves relational word data in a dictionary memory and displays a detection of any misspelled words while in the print mode. When a word is found that does not match any of those located in the memory, an alarm is sound to alert the user.
[0011] U.S. Pat. No. 4,923,314 presents a thesaurus feature for electronic typewriters in which words are identified in the dictionary feature in the typewriter memory, and the data base is scanned to display found synonyms and misspellings. If a possible error is found, an alarm alerts the user of a misspelled word.
[0012] U.S. Pat. No. 5,112,148 provides an electronic typewriter with a word processing system that checks the spelling of each word with the stored memory and alerts the operator of a misspelling by activating an audible alarm.
[0013] U.S. Pat. No. 5,189,610 discusses the use of an electronic dictionary on a typewriter or personal computer that is fully customizable to a specific application. If an error is found when comparing the input to the dictionary memory in the spelling check module, an audible indication of two beeps is activated to alert the operator that a word is misspelled.
[0014] Whatever the precise merits, features and advantages of the above cited references, none of them achieve or fulfills the purposes of the present invention. Previous computer-based word processing programs appear limited to single occurrence checking of spelling. Although spelling and thesaurus checking are important, formatting rules are also vital in the inputting process Forms, templates and documents such as those for billing can easily be entered incorrectly, even though the user's information never changes. Simple formatting mistakes, such as incorrect e-mail or world wide web addresses or errors made when writing programs can also be hard to find (such as leaving a simple parenthesis out). What is needed is a system that intelligently detects and selectively notifies the user of formatting errors existing over one or more entries.
SUMMARY OF THE INVENTION
[0015] The word processing program of the present invention is capable of performing several different functions while alerting the user by audible patterns of possible errors and appropriate changes. Errors are determined by intelligent monitoring of structured data input. By using a patterned sound indicator, the user knows immediately when a fault during the input process has been made. Once warned, the user has three options: (1) taking the program's suggestion and allowing the program to automatically fix the error, (2) manually correcting the mistake that was found, or (3) ignoring the mistake.
[0016] The invention is embodied in many implementations to not only aid the user in simplifying the input process, but also to warn the user of any mistakes that may have been made, as well as a solution for them. Those described herein include, but are not limited to, punctuation correction, data entry formatting analysis, comparing to stored personal information, spell checking, and quick entry/correction of programming languages. In one embodiment, personal information for the user is pre-stored, providing less time when supplying, for example, addresses and phone numbers, to forms and documents. Additionally, providing sound feedback can be particularly useful for disabled persons for increasing the speed and accuracy of data input.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 illustrates a general overview of the program process.
[0018] [0018]FIG. 2 illustrates a detailed flow diagram of the spelling, grammatical, and tense checking processes.
[0019] [0019]FIG. 3 illustrates a detailed flow diagram of the data entry format process.
[0020] [0020]FIG. 4 illustrates a detailed flow diagram of the recognition of stored personal information.
[0021] [0021]FIG. 5 illustrates an alternative flow diagram providing suggestions of stored personal information.
[0022] [0022]FIG. 6 illustrates a detailed flow diagram of the programming language and format correction process.
[0023] [0023]FIG. 7 illustrates a general computer-based device in which the described word processing program can be implemented.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] While this invention is illustrated and described in a preferred embodiment, the device may be produced in many different configurations, forms and materials. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will recognize additional embodiments using the patterned sound indicator and a computer-based monitoring of quick entry and formatting errors without departing from the scope of the present invention.
[0025] [0025]FIG. 1 illustrates a general overview of the word processing program process 100 . Input 102 is received and stored in a temporary memory 104 of a computer. Typically inputs are typed characters from a keyboard, but other computer-based inputs may be substituted without departing from the scope of the present invention. The program then compares the temporarily stored input 104 to that of program memory 106 (data stored locally or remotely—e.g. the web). If the entry is recognized 108 , it is then determined whether the entry is complete 110 . If the entry is found to be recognized, such as recognizing a user's pre-stored complete personal address or Social Security number, a sound pattern is selected 112 . This sound pattern is provided to the user 114 to alert of the correlation, and the recognized information can be suggested to the user as possible input 116 . The user may then opt to take the suggestion and replace the entry with the program's selected input 118 , and continue working without further distraction. In an alternative embodiment (not shown), the user is given a suggestive feedback option (such as a date entry) to assist in manual correction entry even when the entry is not recognized. Alternately, the user may opt to ignore the sound pattern entirely based on the level of severity indicated by the sound pattern. Different sound patterns are thus intended to elicit differing levels of awareness and action by the user.
[0026] The sound patterns that are selected by the program are specifically low-key sounds that are used to indicate to the user a particular correlation found or an event that has occurred. A different sound pattern is applied to each recognized reading, so that the user can identify and associatively recognize the correlation or correction made by the sound pattern that is relayed by the system, allowing the user to have the option of disrupting workflow or continue working.
[0027] The low-key sounds that are used as a sound pattern indicator are preferably “earcons”, or abstract sounds that do not have a real world equivalent, e.g. a three tone chord in a major key. An earcon sound is assigned for positive feedback and an additional sound for negative feedback, both of which have slight variations to indicate, for example, the severity of a pattern found. The slight variation in tone allows the user to identify a problem by the sound that is selected. The user, therefore, when in an ideal, noiseless environment, interprets the severity of the pattern by recognizing the tonal version of the earcon that is provided.
[0028] If the entry is recognized by the program 108 , but it does not appear to be complete 110 , the input is then checked for possible errors 120 . If errors appear to be present, the program then follows a similar process of selecting a sound pattern 112 , providing the selected sound pattern to the user 114 , and offering a more suitable, preferably correct, input possibility, which the user may accept or deny 118 . Errors, in this invention, typically involve single word formatting or analysis using rule based systems for a small number of words. Such rule systems include, but are not limited to, those capable of detecting formatting errors or improper use of a template entry area. In the preferred embodiment, errors should be detected substantially simultaneously with the occurrence, so as not to be intrusive to the typist. In most cases, if immediate feedback cannot be given, it is better to not provide feedback rather than presenting it too late. The specific rule based systems and associated methods are well known in the art and have not been included with this detailed description. Any word processing rules based system can be used within the system of the present invention without departing from the scope thereof.
[0029] Again, if errors appear to be present, a sound pattern is immediately generated, allowing the user to fix the problem or identified relation as it happens. For example, should the user tab out of a field without correctly entering data (as further discussed below), sound feedback occurs right away before the user begins typing in another field. In word processing programs, sound feedback occurs before a new word (or words) is typed. The rapid response of the sound feedback to the entered information allows the user to continue working without constant interruption of workflow.
[0030] Otherwise, if the entry is not recognized by the program, the program continues to compare the input information until a pattern is found. However, if the user proceeds to the next field in a form or to the next word or sentence, the search for a match is abandoned.
[0031] [0031]FIG. 2 illustrates a flow chart 200 detecting spell check, punctuation and format checking functions. Data is entered 202 by the user (e.g., typed on keyboard). The inputted information is then stored into temporary memory 204 . The program analyzes whether input data 202 is a character 206 . If yes, the input is sent directly to the spell-checking dictionary 208 . A memory check is performed to find a proper spelling 210 , and, if the spelling of the input 202 is found not to be correct (i.e., misspelled word) the program then follows a similar process of selecting a sound pattern 212 , providing the selected sound pattern to the user 214 , and offering a more suitable input possibility 216 , which the user may explicitly accept, manually replace, or ignore. If accepted, the program replaces the error with the found solution 218 .
[0032] Should the spelling of the input appear correct, the program analyzes the format (e.g., e-mail, date, number of characters, e.g., driver's license) 226 of the input. The format 226 determines, for example, if the expected format for a specific entry on a form/template is used. If not, the program then follows a similar process of selecting a sound pattern 212 , providing the selected sound pattern to the user 214 , and offering a more suitable input possibility 216 , which the user may explicitly accept, manually replace, or ignore. In the form/template example, the sound is preferably made before or immediately after the user completes an entry, so as to allow correction without having to place the cursor back into the entry area. Alternatively, if the user has configured the system to automatically replace text with suggestions whenever possible, low-key sound feedback should notify the user of each instance of such automatic replacement.
[0033] If the inputted key is not a character (from step 206 ), the program checks to see if the data input 202 is a mark of punctuation 220 . If yes, a memory check 222 is performed and correct use of the input is analyzed 224 . If the program detects that the input is used incorrectly or a better key can be utilized, the above steps 212 - 218 are repeated.
[0034] [0034]FIG. 3 illustrates a more specific embodiment of the above process, the process 300 analyzing specific data that is entered. This data can include information such as phone numbers, e-mail addresses, URLs, website addresses, et al. If the data input 302 is incorrectly formatted 308 , for instance, if a key character is omitted, or if the data that is entered and stored in the temporary memory 304 does not match the format of the given field as found in the program memory 306 , the program follows a process of selecting an appropriate sound pattern 310 , providing the selected sound pattern to the user 312 , and giving suggestions 314 . Should the user wish to accept the possible suggestion, the program will offer a more suitable input possibility 316 . The user may explicitly accept, manually replace, or ignore the suggestion of replacing the entry with the selected input 318 .
[0035] Alternatively, should the program find an error in the format matching process that is severe, the system “forces” the user to fix the problem. In this case, the sound feedback provided would indicate a “severe” problem, identify the problem that occurred, and, instead of suggesting input possibilities, place the cursor back into the field(s) that were just tabbed out of and need to be reentered before continuing.
[0036] In another instance, as shown in flow chart 400 in FIG. 4, if a user begins inputting data 402 for a standard document or form, such as an order form, report, etc. that may include a complete mailing address or telephone number, the program may recognize the stored data 404 while performing a memory check 406 . If the inputted data is recognized for quick entry 408 , an appropriate sound pattern 410 is selected, then provided to the user 412 , and an input possibility is offered 414 (e.g. a full address and telephone number is provided). The user may accept or deny the suggestion of replacing the entry with the selected input 416 . This application is also utilized for Web based forms, as described below.
[0037] Alternatively, the suggested input can be a different color, text size, font, etc. to indicate the data as retrieved from the database. The user is then approached with a second confirmation for acceptation of the provided data.
[0038] As an additional alternative, should the user decide not to accept the full suggested input 518 , one of two options is chosen, as shown in FIG. 5. The user deletes the suggested information provided by the system and reenters the correct information 520 , or selects certain entries of the suggested data to remain in the form 522 and enters the correct data in the additional fields. For example, this is useful for billing and shipping forms, should the billing address be the same, but a new shipping address need to be entered.
[0039] [0039]FIG. 6 illustrates an embodiment 600 of the present invention being utilized with a programming language. A user inputs program data/codes 602 . As the user continues to enter the program, each word/line is checked by the program by comparing the stored input 604 to that of the program memory. The program can check for quick entry of the language terms or for a number of programming syntax mistakes, such as incorrect terms, missing parenthesis, or end terminations. If the entry is recognized 606 , it is then determined whether the entry can be completed by quick entry 608 . If the program can provide entry data, a sound pattern is selected 610 . This sound pattern is provided to the user 612 , and the recognized information can be suggested to the user 614 as a possible input. The user then opts to replace the entry with the program's selected input 616 .
[0040] If the entry is recognized by the program, but it does not appear to be recognized for quick entry (step 610 ), the input is then checked for possible syntax errors 618 . If errors appear to be present, the above steps 612 - 616 are repeated.
[0041] The sound feedback system described above is also useful for any type of data entry system, including form based data entry where users alternate to and from several fields, for instance, by the use of a tab key (see FIG. 4). For example, the Internet provides the ease of ordering products, such as airline/hotel reservations, through online order forms. Use of sound feedback for Internet and Web forms will assist in the avoidance of annoying errors by immediately indicating a detected pattern as the user moves through the form. Should the user input an address, for example, and “tab” to the next field without providing a zip code, a sound pattern will be immediately provided to alert the user of the mistake, rather than be presented with an error after submission of the form, and, possibly, the burden of re-entering the information.
[0042] Sound feedback for data entry programs such as online Web forms can indicate, as shown in FIG. 4, incorrect formatting of phone numbers, zip codes, etc. or incorrect date selection (for example, when arranging flight connections). Again, as previously indicated, upon recognition of data be entered, sound feedback is activated to indicate to the user that automatic entry can be activated. Should the user accept the suggestion, the system replaces the entry with the selected input.
[0043] The above enhancements for the present invention and its described functional elements are implemented in various computing environments. For example, the present invention may be implemented on a conventional IBM PC or equivalent, multi-nodal system (e.g. LAN) or networking system (e.g. Internet, WWW, wireless web). FIG. 7 illustrates a computer-based system 700 which the word processing program can be implemented. The system preferably consists of a computer display monitor 702 , an input device, preferably a keyboard 704 , mouse 706 , and a sound source 708 . System 700 also comprises memory for storing information, which is preferably, but not limited to, a personal computer's hard drive 710 (although storage may be through remote locations located across networks, such as the Internet, WWW or wireless web). All programming, GUIs, display panels and dialog box templates, and data related thereto are stored in computer memory, static or dynamic, and may be retrieved by the user in any of: conventional computer storage, display (i.e., CRT) and/or hardcopy (i.e., printed) formats. The programming of the present invention may be implemented by one of skill in the art of general computer programming and, more specifically, word-processing programming.
CONCLUSION
[0044] A system and method has been shown in the above embodiments for the effective implementation of sound pattern feedback for informational events during typing. While various preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention, as defined in the appended claims. For example, the present invention should not be limited by software/program, computing environment, specific computing hardware and specific sound patterns or discernible formats.
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A word processing program uses a number of low-key alarm signals or sound patterns to communicate a variety of situations that arise during data input by a user. A personalized program is used to detect incorrectly formatted or improperly inputted data such as e-mail addresses, phone numbers, template or form entries as well as to recognize stored data, such as a user's complete mailing address or programming codes. When alerted, the user accepts, denies or ignores any given suggestion the program provides. The sound patterns are specific to different types of events and may also indicate the severity of the event. A user also has the option of allowing the software to automatically correct any of the situations to prevent stalling of the input process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a solderless plastically deformable boardlock for permanently securing a connector to a printed circuit board without the need for post-soldering.
2. Summary of the Prior Art
A multitude of different boardlocks are used in the electronics industry for securing an electrical connector or device to a printed circuit board. Some boardlocks are first securely mounted to a connector, and have resilient legs extending therebelow that are engageable in a hole of a printed circuit board for provisionally holding the connector to the printed circuit board. Examples of such boardlocks are disclosed in U.S. Pat. Nos. 5,108,312 and 5,115,375. The boardlocks serve to provisionally hold the connector to the printed circuit board during assembly of other electrical devices. Once the electrical devices are all assembled to the printed circuit board, the board is then taken to a soldering station whereby the electrical connections to the circuit board are permanently soldered thereon, the resilient legs of the boardlock also receiving solder thus being permanently and rigidly secured to the printed circuit board.
Other boardlocks such as in U.S. Pat. No. 4,717,219, do not have resilient legs but instead are inserted through the printed circuit board and then plastically deformed such that they can not be extracted. Post-soldering of these boardlocks is also usually foreseen, because the boardlocks do not hold the device or connector sufficiently securely to the printed circuit board. A further problem with the deformable boardlocks if they don't have resilient legs, is that they can not provisionally hold the connector or device to the printed circuit board during the assembly procedure.
The above boardlocks, although stamped from sheet metal, are relatively complicated and expensive to manufacture.
It is also desirable in the electronics industry to provide a boardlock that doesn't require post-soldering because an increasing number of connectors are being connected to printed circuit boards via compliant pins that require no soldering. The latter is advantageous because it eliminates the need for an extra manufacturing step, namely the soldering process.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a cheap and reliable boardlock for connecting an electrical device to a printed circuit board without requiring post-soldering.
It is a further object of this invention to provide a boardlock with minimal space requirements.
The objects of this invention have been achieved by providing a boardlock that is a unitary edge stamped sheet metal part comprising a U-shaped board mounting section and a connector mounting section, the board mounting section comprising a pair of rigid arms joined at a lower end by a deformable bridge portion whereby the rigid arms and the bridge portion are insertable through a hole in a printed circuit board and the bridge portion is permanently deformable such that the boardlock is held securely to the board.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a boardlock prior to assembly in a connector;
FIG. 2 is a plan view of the boardlock of FIG. 1, inserted through a hole of a printed circuit board and about to be deformed by a die;
FIG. 3 is the same view as FIG. 2 whereby the boardlock is permanently deformed by the die;
FIG. 4 is a view of a boardlock assembled to a right angled connector about to be mounted to a printed circuit board;
FIG. 5 is a top view of a die;
FIG. 6 is a cross sectional view through a boardlock mounted in a connector housing;
FIG. 7 is a plan view of another embodiment of a boardlock;
FIG. 8 is the boardlock of FIG. 7 inserted through a circuit board hole and about to be deformed by a die; and
FIG. 9 is a similar view to FIG. 8 but with the boardlock permanently deformed by the die.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a boardlock generally shown at 2 comprises a connector retention section 4 and a printed circuit board connection section 6. The connector section comprises a pair of mirror image deformable mounting tabs 8 attached at an upper end of a central body portion 10, the tabs 8 having a lower inclined edge 9 for engaging a connector housing shoulder. The connector section 4 also comprises a pair of spaced apart guiding legs 12 that have an outer edge 14 and projecting outwards from the outer edge 14 are interference fit retention barbs 16. The connector section 4 and the boardlock section 6 are disposed in mirror image symmetry about a central axis 18. To the guide arms 14 is attached the board connecting section 6 via transitional arm portions 20. The board connecting section 6 comprises rigid spaced apart arms 22 having a thickness D, the rigid arms 22 spaced apart at a lesser distance than the guide arms 14. The board section 6 further comprises a deformable bridge portion generally shown at 24 that extends below the rigid arms and makes connection therebetween. The bridge portion 24 comprises a first bridge portion 26 extending obliquely outwardly and downwardly from the lower portion of the rigid arms 22, and a second bridge portion 28 extending obliquely inwardly and downwardly towards a bridge center portion 30 disposed about the axis 18 of the boardlock. The first and second bridge portions are of a lesser thickness than the thickness D of the rigid arms. The center bridge portion 30 is of greater thickness than the bridge arm section whereby the added thickness projects inwardly of the boardlock.
With reference now to FIGS. 2 and 3, a die 40 partially shown in cross section comprises an elongate boardlock receiving cavity 42 having lateral front and back walls 44, and a convex bottom wall 46.
With reference now to FIG. 4, an electrical connector generally shown at 50 comprises a housing 51, a plurality of compliant pins 52 projecting below a printed circuit board mating face 54, and a pair of boardlock retention window cavities 56. Within the window cavities 56 is a shoulder 57 engageable against deformed tabs of a boardlock for retention thereof. The connector 50 also comprises boardlock receiving cavities 58.
Referring back to FIG. 2, 3 and 4, a printed circuit board 60 is shown comprising a cylindrical boardlock receiving hole 62.
Referring to FIG. 2, the boardlock 2 is shown already mounted into the hole 62 of the printed circuit board. The rigid arms 22 are comprised within the hole 62 and are spaced apart such that they press against the outer diameter thereof and because the boardlock is a substantially flat edge stamped sheet metal part, the plane of the rigid arms corresponds roughly to a plane that includes the axis of the hole 62.Extending outwardly of the hole, are the first bridge arm portions 26 and in order to assemble the boardlock to the printed circuit board, the bridge arm first and second portions 26,28 are elastically deformable towards the axis 18 such that the boardlock can be inserted from the upper side 64 of the board 60 through the hole 62. Once the boardlock is fully inserted into the hole 62, the first bridge portion thus bulges outwards of the hole 62 thereby provisionally and elastically securing the boardlock thereto. FIG. 2 shows the die 40 on the point of engaging the boardlock. The side walls 44 of the die are spaced apart at a distance only slightly greater than the thickness of the boardlock such that they act as a guide and prevent the boardlock from bending out of its planarity. The boardlock is a thin sheet metal part, and unless it is guided such that it stays flat, any deformation force will tend to bend the bridge portion of the boardlock out of its plane; and particularly so because the hole 62 is circular and provides no lateral support of the boardlock.
Now referring to FIG. 3, an upper surface 48 of the die is shown pressed against a lower surface 66 of the printed circuit board 60, the bridge portion 24 of the boardlock consequently being plastically deformed such that the first bridge portion partially deforms around the corner of the edge of the hole 62; and the outer portions 27 bulge even further outwards of the hole 62 than in the undeformed position. The boardlock is thus held securely and permanently to the board 60 and cannot be extracted by an upwards pulling force. Outwards deformation of the bridge outer portions 27 is ensured because the first 26 and second 28 bridge portions which are of lesser width than the rigid arms 22, are obliquely and outwardly slanted towards the outer portions 27. The convex shape of the die bottom wall and hence that of the deformed boardlock center portion 30, has a particular purpose as will become apparent below.
The arcuately deformed bridge portion of the boardlock serves to enhance the strength with which the boardlock is retained to the printed circuit board. A large extraction force applied to the boardlock will be taken up by the deformed outer portions 27 that press against the lower surface 66 of the printed circuit board at the outer edge of the hole 62, whereby this force will cause a moment that will tend to pivot the center portion 30 upwards towards the connector. If this force is large enough to cause plastic deformation, the bridge portion will further buckle, but this buckling will be inhibited by the bridge portion 24 abutting the lower end of the rigid arms 22. If the forces on the boardlock are such, however, that the center portion 30 attempts to pivot downwardly away from the connector 50, then this will tend to force the bulge portions 27 even more further outwards as the arcuate shape will tend to straighten out and thus increase the distance between the bulge portions 27. If the center portion 30 of the boardlock was deformed flatly or having a curvature directed away from the board 60 e.g. as with the undeformed boardlock, then a pulling force on the boardlock would tend to pivot the center portion 30 away from the board 60 thus causing the outer portions 27 to collapse inwards, the boardlock thus being pulled through the hole 62.
Although the boardlock is flat and comprises relatively little material, especially in comparison to cylindrical shaped boardlocks, it is very strong because all of the forces are comprised within the plane of the sheet metal. This makes far more efficient use of the material strength than, for example, tabs bent transversely to the plane of the sheet metal.
The added thickness of the center portion 30 with respect to the first and second bridge portions 26, 28 serves to ensure correct inward arcuate deformation of the bridge portion and in particular to prevent buckling of the center portion 30 under the compressive forces that the second bridge portions 28 are subject to during the deformation process.
Elongate cavities 58 (see FIG. 6) are provided in the connector housing for receiving the boardlock connector section 4, whereby the outer edges 14 of the guide arms 12 engage in an interference fit with the cavities 58, the retention barbs 16 preventing extraction of the boardlock therefrom. In order to further secure the boardlock to the housing, the deformable tab members 8 can be transversely bent (around axes substantially parallel to the axis of the board hole 62) into corresponding cavities of the connector whereby this bending is achieved once the boardlock is fully inserted into the cavity 58 by a special tool (stamping die) that is inserted through the windows 56 of the connector which are adjacent the deformable members 8 (see FIGS. 4 and 6). The inclined lower edge 9 of the tab 8 ensures that pivotable deformation thereof progressively engages and tightens the tab edge 9 against the shoulder 57 which eliminates play and securely retains the tab 8 against the shoulder 57.
As seen in FIG. 4, the right angled connector 50 is for making electrical connection to a printed circuit board via the compliant pins 52. The compliant pins 52 have a pair of reversed C-shaped resilient arms that are resiliently biasable against electrical circuit traces that line corresponding holes of the printed circuit board thus making electrical contact therewith. This type of contact does not therefore require soldering, hence the need for a boardlock that correspondingly does not require soldering but nevertheless provides the reliability and strength of soldered boardlocks.
Referring to FIG. 7, another embodiment of the boardlock is shown, similar to the boardlock of FIG. 1 whereby the similar features are denoted by the same numbers with a prime. The main differences between the embodiment of FIG. 7 and that of FIG. 1, are the outwardly protruding bulges 70 along side the outer edge 14', the more pronounced lower central portion 30' and the tapered inner edges 72 adjacent the lower end of the ridged arms 22', the center portion 30' having an outer tapered profile 74 engageable against the tapered edges 72. The purpose of the bulges 70 on the outer edge 14', is to fit interferingly in a cavity 58 of a connector housing such that the boardlock 2' sits firmly therein without play. The purpose of the tapered edges 72, is to provide a surface against which the protruding central portion 30' abuts once the boardlock 2' has been deformed by the die as shown in FIG. 9, whereby the tapered edges 74 of the central portion 30' abut against the tapered edges 72. The latter feature enhances the extraction force required to pull out the boardlock from the printed circuit board hole by wedging the central portion 30' between the ridged arms 22' hence preventing the arms 22' from collapsing together.
Advantageously therefore, due to the flat, simple construction of this boardlock, it is inexpensive and yet provides a strong mechanical connection without requiring an additional soldering step and is therefore ideally adapted to connectors that are assembled to the printed circuit board without soldering. The mechanical strength is further enhanced by the inwardly arcuate curvature of the deformed bridge portion. Additional advantages, are the simple assembly of the boardlock to a connector due to the deformable tabs, and the reduced space requirements, namely the flatness of the boardlock requires little extra length of the connector as opposed to for example, a cylindrical boardlock. This invention is also compatible with a soldering process whereby the advantages of cost, space, simplicity and reliability are still valid.
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A boardlock for securely connecting an electrical device or connector to a printed circuit board without requiring post-soldering thereof, is shown comprising a pair of rigid arms joined at the lower end by a thinner bridge section. The boardlock is a flat unitary edge-stamped sheet metal part that is insertable through a hole of a printed circuit board such that the bridge portion extends below the printed circuit board and whereby outer portions thereof, extend outwardly of the hole for provisionally holding the boardlock to the printed circuit board. A die comprising an elongate slot of slightly greater thickness than the boardlock, can be engaged against the bridge portion for permanent plastic deformation thereof. The die has a convex bottomed surface in order to arc the deformed bridge portion towards the printed circuit board in order to enhance the mechanical resistance of the boardlock with respect to an upwards pulling force thereon.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a belt tensioner of the type for automotive vehicles.
[0003] 2. Description of the Related Art
[0004] Typical belt tensioners are known, for example from DE-A-43 27 141 or DE-A-40 10 928. These belt tensioners are employed in motor vehicles for tightening the V-belt and comprise a retainer with a tension arm, which is fitted with an idler pulley at one end, that is applied to the belt, and which is joined to a radial plain bearing at its other end. The radial plain bearing includes a bearing bush part and a bearing pin part, whereby one of the parts is fixed to the tension arm and the other part is held spatially fixed. A rotary spring in the form of a spiral coil spring is wrapped coaxially around the bearing bush and bearing pin and is held by one end on the retainer and held spatially fixed at the other end. These known belt tensioners are fitted in a state in which the bearing bush and the bearing pin have been rotated against one another under the pretension of the rotary spring, so that the idler pulley already exerts a predetermined force on the belt. Due to the spring force of the pretensioned rotary spring, the belt is held under a predetermined tension, but the idler pulley can deflect or take up the slack if the length of the belt changes.
[0005] Due to the type of construction, the tension arm bearing the belt idler pulley must, however, be arranged off center in relation to the axial length of the radial plain bearing on the bearing bush or bearing pin. Consequently, the radial plain bearing is, however, stressed by tilting forces which cause increased wear. Attempts have been made in DE-A-43 27 141 to arrange the deflecting point of the swivel spring in the axial direction to the rotating axis so far removed from the radial plain bearing that the resultant of the force introduced into the radial plain bearing meets approximately the center of the axial length of the radial plain bearing. This is however only possible where there is sufficient installation space available.
[0006] The object of the invention is to develop a belt tensioner such that the susceptibility to wear is reduced with a compact, short construction.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention, a belt tensioner is provided with a retainer which can be brought into contact with a belt via a belt support for applying a tensile force and which, at a distance from the belt support, is connected to a radial plain bearing and can be swivelled about its axis of rotation, whereby the tensioning and swivel movements of the belt support occur under the load of a coil spring. The invention is characterized in that the retainer is subject to the action of a spring, which exerts a force essentially parallel to the axis of rotation on the retainer and the force counteracting upon the force exerted by the belt on the retainer.
[0008] According to the invention the retainer is subject to the action of a spring which acts against the tilting moment which is caused by the force exerted through the belt on the retainer. The application of this spring is possible with a compact construction, so that the installation space required for fitting does not need to be enlarged.
[0009] Although belt tensioners are already known which exhibit more than one spring, such as for example the belt tensioner according to DE-A-26 08 277, the springs in this case, however, have a different function. With this known belt tensioner, a first compression spring is used which presses friction discs against the retainer and whose spring force defines a threshold value at which the retainer can only then be swivelled. The belt tensioner also has a second compression spring which is formed as a spring strut and presses the idler pulley directly against the belt.
[0010] The application of springs, which act on the retainer essentially parallel to the rotating axis, is for example known with a belt tensioning arm according to DE-A-195-24-403. Here however, this spring is used as a single spring and in its function replaces the rotary spring of the generic state of the art, i.e. the tensile force is determined through the pretension of the cup spring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0012] FIG. 1 a partial cross-section through a first embodiment of a belt tensioner according to the invention, and
[0013] FIG. 2 a partial cross-section through a second embodiment of a belt tensioner according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] FIG. 1 illustrates a belt tensioner 1 in partial cross-section as it is used, for example, for tensioning belts in automotive vehicles. The belt tensioner 1 is however also suitable for other applications where belts, chains or other endless transmission elements need to be tensioned.
[0015] The belt tensioner 1 includes a base section 2 which is provided with a central opening 3 and cup-shaped, high-reaching walls 4 which form part of a housing. The belt tensioner 1 also includes a retainer 5 , which also exhibits a central opening 6 and cup-shaped high-reaching side walls 7 , whereby the walls 4 and 7 are formed such that they form the outer boundary of the belt tensioner 1 and the center lines of the openings 3 and 6 meet in a common center line 8 .
[0016] The retainer 5 is also provided with a tension arm 9 which is mounted in the axial direction asymmetrically and is offset from the center line 8 on the retainer 5 and protrudes over the wall 7 . An idler pulley 10 is rotationally supported about an indicated axis 11 in the tension arm 9 . The idler pulley 10 forms a belt support for the belt to be tensioned, whereby the axis 11 runs parallel to the center line 8 .
[0017] One end of a hollow bearing pin 12 is mounted in the opening 3 of the base section 2 , preferably by caulking. A screw, which is not shown, can be passed through the hollow bearing pin 12 , enabling the belt tensioner 1 to be firmly mounted onto an engine part of a motor vehicle or similar.
[0018] The retainer 5 with a bearing bush 13 sits on this hollow bearing pin 12 , whereby the bearing bush 13 and bearing pin 12 can be displaced relative to one another in the axial direction and the inner surface of the bearing bush 13 forms a radial plain bearing 14 with the outer surface of the bearing pin 12 , so that the retainer 5 can rotate about the bearing pin 12 , whereby the center line 8 forms the axis of rotation. The retainer 5 is held by a locking piece 15 in the form of a disc on the bearing pin 12 , the disc forming a positive locking joint with the free end of the bearing pin 12 opposite the base section 2 .
[0019] The retainer 5 also includes a friction cone 16 which extends coaxially on the center line 8 and on which a spring bush 17 and a coil bush 18 are arranged in a normal manner, carrying a rotary spring 19 in the form of a spiral-coil spring. The rotary spring 19 is, as is usual with belt tensioners of this type, attached at one end to the base section 2 and to the retainer 5 at its other end, so that tensioning can be provided through the relative rotation of the retainer 5 and the base section 2 . The function and the operation of tensioning with the aid of this type of coil spring is known to the specialist so that further details need not be supplied here.
[0020] Through the tensioning of the belt it exerts a force F1 on the retainer 5 . Since the bearing bush 13 is spaced in the axial direction from the idler pulley 10 with regard to the axis of rotation 8 , and since, compared to the belt tensioner 1 of the generic state of the art according to DE 43 27 141, the friction cone 16 and therefore the lower mounting point of the coil spring 19 for introducing a counter force F2 in the axial direction of the axis of rotation 8 is located closer to the bearing bush 13 than the idler pulley 10 , this would lead to a resultant force, which is applied off center on the plain bearing 14 , and would therefore cause a tilting moment, which would lead to increased wear of the radial plain bearing 14 .
[0021] To prevent this, the bearing bush 13 of the radial plain bearing 14 has a shorter axial length than the intervening space between the locking disc 15 and the base section 2 in the region around the opening 3 . In the axial intervening space produced by this, a spring 20 is arranged which is formed as a ring-shaped cup spring on which the bearing pin 12 is located and acts symmetrically on the axis of rotation 8 . In the region of this cup spring 20 preferably the base section 2 is fitted with a base 21 which acts as a thrust pad so that the cup spring 20 is evenly compressed. The cup spring 20 acts via a supporting ring 22 on the bearing bush 13 such that a force F 3 can be exerted on the bearing bush 13 parallel to the axis of rotation 8 , the force F 3 supporting F 2 as counter force for the introduced force F 1 transferred from the belt, so that essentially a resulting force FR aligned to the axial center of the radial plain bearing 14 is produced with which a tilting moment is essentially not produced.
[0022] During assembly, the force F 3 can be set variably via the spring displacement of the cup spring 20 , whereby values between about 4000 to 7000 N are preferred.
[0023] The cup springs 20 act via the supporting ring 22 on a face of the bearing bush 13 and press it against the locking disc 15 which acts as an abutment. Here, the sides facing one another are formed as axial plain bearings between the locking disc 15 and the bearing bush 13 or between the bearing bush 13 and the supporting ring 22 . These axial plain bearings preferably have steel surfaces which are coated with PTFE. Depending on the type of coating, these plain bearings can also however contribute to friction damping, so that the applied damping is split between the damping due to the spring 19 and the damping due to friction.
[0024] The plain bearings can also be provided by separate discs and/or in another axial position.
[0025] In an illustration similar to FIG. 1 , FIG. 2 shows a second embodiment of a belt tensioner 30 , whereby components similar to the first embodiment are identified with the same reference symbols and are not explained again.
[0026] The belt tensioner 30 differs from the belt tensioner 1 only due to the fact that here an additional, increased friction damping is produced by the arrangement of a special damping washer 31 . The damping washer 31 is preferably placed between the bearing bush 13 and the locking disc 15 , whereby, due to the cup spring 20 , the bearing bush 13 is pressed via the supporting ring 22 against the damping washer 31 which it presses against the locking disc 15 . This arrangement is particularly advantageous where additional friction damping is required due to very high application-related requirements. Here, friction damping values of up to 60% of the tensile force or the torque can be produced. Wear-free functioning can be ensured due to tuning the damping via the coil spring 19 on one hand and via the spring 20 on the other, or due to splitting of the damping between both systems, despite an overall damping value of 85% referred to the torque.
[0027] An advantageous material pairing for the damping washer 31 and the adjacent locking disc 15 is for example a glass-fibre reinforced polyamide, in particular PA 46 with 5% glass-fibre content, for the damping washer 31 and a stainless steel, in particular V2A, for the locking disc 15 . The plain bearings, which are arranged in this case between the bearing bush 13 and the damping washer 31 or between the bearing bush 13 and the supporting ring 22 , can, as with the first embodiment, have bearing surfaces of steel coated with PTFE, which, where required, are arranged on additional washers not illustrated in the drawings.
[0028] In a modification of the described and drawn embodiments a different sequence of the components is possible. For example, the cup spring can be arranged on the side of the bearing bush facing the locking disc. Instead of a cup spring a different suitable spring can be used. The selection of materials can be carried out with regard to the service life to be achieved and/or to the required damping values. The invention can furthermore be applied when the tension arm is joined to the bearing pins.
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A belt tensioner with a retainer can be brought into contact with a belt via a belt support for applying a tensile force. The retainer is joined at a distance from the belt support to a radial plain bearing and it can be swivelled about the axis of rotation of the radial plain bearing, whereby the tensioning and swivel movements of the belt support occur under the action of a coil spring. For a belt tensioner of this type, which with a compact construction runs essentially wear-free, it is suggested that the retainer is subject to the action of a spring, which exerts a force (F 3 ) essentially parallel to the axis of rotation on the retainer, the said force (F 3 ) counteracting the force (F 1 ) exerted by the belt on the retainer.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 12/106,118 filed on Apr. 18, 2008, which claims priority of Canadian Patent Application No. 2,623,121 filed on Feb. 29, 2008.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and systems for drilling and is particularly concerned with a helicopter portable drilling.
BACKGROUND OF THE INVENTION
[0003] Referring to FIG. 1 there is illustrated a known tracked drilling rig. The rig consists of a tracked vehicle 10 fitted with a drill 12 , a hydraulic system 14 for operating the drill and a compressor 16 for providing pressurized air for cleaning the hole being drilled. The tracked vehicle 10 is used on road accessible land, which has terrain that allows unrestricted movement of such vehicles.
[0004] For areas that are inaccessible or where environmental impact is of concern, it is also known to use helicopter portable drilling systems. These drills are referred to as heli-portable drills. The method of using them is called heli-drilling The earliest examples of heli-portable drills included three components: a drill, a compressor and a supplies basket, which must be separated due to weight limitations of various helicopters.
[0005] Referring to FIG. 2 there is illustrated a known drill from a three pick drilling system. Typically the drills are hydraulically operated and have either a gasoline or diesel motor for powering the hydraulic pump. These pumps are used to operate the various hydraulic components of the drill. The drill in FIG. 2 is from a two pick system but is a typical to a 3 pick.
[0006] The second component is the compressor system an example of which is shown in FIG. 3 . The compressor has a diesel or gasoline engine that is used to operate a high-volume air compressor. A hose is used to connect the compressor to the drill. The air is used to operate an air hammer, which is down the hole. Once the air has left the hammer, it cleans out the drill hole by forcing the drill cuttings to the surface. Depending on the drilling conditions, the driller may chose to drill with an auger style bit rather than an air hammer. In this case the air is only used to clean out the hole.
[0007] The third pick typically contains drill stem, an explosive magazine, a cap magazine, drill mud, and any other supplies that the driller deems necessary (not shown in the figures).
[0008] As technology continued to improve all of the components that were typically in the third basket where moved to the drill and compressor picks. This was primarily due to improved helicopter performance. Reducing the number of picks required not only reduces the time that the helicopter spends in a dangerous hover condition, it also significantly reduces costs due to less equipment being moved by the helicopter.
[0009] A complete drill crew generally consists of six drills, six compressors and various accessory baskets. There are several reasons that the crew consists of six units. The first is that each drill has a driller and a driller's helper for a total of 12 persons. The Bell 212 , 210 and 205 series of helicopters are configured to have a pilot, copilot and thirteen passengers. Six drills also give the helicopter adequate work each day, while keeping the drills productive. It is referred to as a cycle every time all of the drills are moved. The logistics of each program varies. It is primarily dependent on terrain. A drill crew typically works on between one and three seismic lines.
[0010] Referring to FIG. 4 there is graphically illustrated a typical seismic program having about 9000 shot points to drill with heli-portable drills.
[0011] Referring to FIG. 5 there is graphically illustrated a typical shot hole drilling sequence for a two-pick heli-portable drill system. Helicopter moves 20 drill from completed shot point A to next shot point to drill B. Then the Helicopter returns 22 to A to pick up the compressor. The helicopter moves 24 the compressor to B. The helicopter then flies 26 to C to start the sequence again for a second drill, e.g. moving to shot point E-E is not on diagram but was meant to be included to show 3 drills working on a single line. Depending on terrain, weather and drilling conditions there can be 2 to 6 drills working on a single line and multiple drill crews on a single program.
[0012] Industry helicopters
[0000]
Bell
Bell Eagle
Specifications
205 A-1++
Bell 210
Bell 212
Single
# of Engines
One
One
Two
One
Engine Type
T53-17A/B
T53-17B
PT6T-3/B
T53-17A/B
Blade Type
212
212
212
212
Certification
STC
TC
TC
STC
Avg Empty W
5700 lbs
5600 lbs
6600 lbs
5600 lbs
Max Gross W
10200 lbs
10500 lbs
11200 lbs
11200 lbs
Internal
Max Gross W
10500 lbs
11200 lbs
11200 lbs
11200 lbs
External
Load Available
4500 lbs
4900 lbs
4600 lbs
5600 lbs
Internal
Load Available
4800 lbs
5000 lbs
4600 lbs
5000 lbs
External
[0013] There are a number of dangers present with helicopter assisted drilling. The pilot and driller are both at risk when the drill is being picked or dropped. Every time the helicopter is in a hover position while working over the source pont the pilot is working in what is referred to as the dead man's curve. It is called this because if the helicopter has a mechanical failure, the height and altitude are not conducive to a safe landing, even on level ground. Typically not only is the ground uneven, but there are trees further endangering the pilot.
[0014] For the driller on the ground, it is equally dangerous, as they are working underneath a heavily loaded helicopter. Steep terrain, loose rocks and trees are also a hazard. The rotor wash from the helicopter is capable of knocking down trees and blowing off loose limbs. When placing drills and compressors in steep terrain, the helicopter may have to spend extra time to ensure the unit is secure. The risk for both the pilot and driller was significantly reduced twelve years ago when the two-pick system was developed. Two pick drills were developed around 1995.
SUMMARY OF THE INVENTION
[0015] An object of the present invention is to provide method and system for helicopter portable drilling.
[0016] In accordance with an aspect of the present invention there is provided a system for helicopter portable drilling comprising: a drill frame, a drill mast affixed a first end of the drill frame, a drill operatively coupled to the drill mast and operable using one of compressed air, pressurized hydraulic fluid and both compressed air and pressurized hydraulic fluid and a unified power source for providing compressed air and pressurized hydraulic fluid coupled to the drill, the total operating weight of the system being approximately 3000 pounds for allowing a single-pick move by a helicopter.
[0017] In accordance with another aspect of the present invention there is provided a method of seismic line drilling comprising the steps of placing a first single-pick drilling system at a first location with a single pick, placing a second single-pick drilling system at a second location with a single pick, when finished drilling, moving the first single-pick drilling system to a third location with a single pick, when finished drilling, moving the second single-pick drilling system to a fourth location with a single pick. Once again depending on terrain, weather and drilling conditions there can be two to six drills working on a single line and multiple drill crews on a single program. The entire methodology of drilling will likely change due to the reduced number of picks. A crew will likely consist of between 9 and 12 drills instead of the traditional six
[0018] In accordance with a further aspect of the present invention there is provided a method of seismic line drilling comprising the steps of placing a first drill carrier at a first location with a single pick, placing a first single-pick drilling system on the carrier at the first location with a single pick, when finished drilling, moving the first single-pick drilling system to a second location using the carrier and when meeting an obstacle between drilling locations, moving the first single-pick drilling system to a third location with a single pick, moving the first drill carrier at the third location with a single pick and placing the first single-pick drilling system on the carrier at the third location.
[0019] In an embodiment of the present invention there is a drill carrier for moving the drilling system between locations when the terrain permits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention will be further understood from the following detailed description with reference to the drawings in which:
[0021] FIG. 1 illustrates a known tracked vehicle with drill holes;
[0022] FIG. 2 illustrates a drill for a known two-pick helicopter portable drilling method
[0023] FIG. 3 illustrates a compressor assembly for a known two pick helicopter portable
[0024] FIG. 4 graphically illustrates a typical seismic program having about 9000 shot points to drill with heli-portable drills;
[0025] FIG. 5 graphically illustrates a typical shot hole drilling sequence for a two-pick heli-portable drill system;
[0026] FIG. 6 illustrates in a right side view a single pick drilling system in accordance with an embodiment of the present invention;
[0027] FIG. 7 illustrates in a right front perspective view the single-pick system of FIG. 6 ;
[0028] FIG. 8 illustrates in a left side view the embodiment of FIG. 6 ;
[0029] FIG. 9 illustrates in a perspective view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 6 ;
[0030] FIG. 10 graphically illustrates a method of heli-drilling in accordance with another embodiment of the present invention;
[0031] FIG. 11 illustrates a tracked carrier for use with the one-pick drilling system of FIG. 6 in accordance with a further embodiment of the present invention;
[0032] FIG. 12 illustrates in the single pick drilling system of FIG. 6 carried on the tracked carrier of FIG. 11 in accordance with another embodiment of the present invention;
[0033] FIG. 13 graphically illustrates a method of heli-drilling in accordance with another embodiment of the present invention;
[0034] FIG. 14 illustrates in a right side perspective a single pick drilling system in accordance with a further embodiment of the present invention;
[0035] FIG. 15 illustrates in a right front upper perspective view the single-pick system of FIG. 14 ;
[0036] FIG. 16 illustrates in a front perspective of the embodiment of FIG. 14 ;
[0037] FIG. 17 illustrates in a right side perspective view of the embodiment of FIG. 14 ;
[0038] FIG. 18 illustrates in a rear perspective of the embodiment of FIG. 14 ;
[0039] FIG. 19 illustrates in a top perspective of the embodiment of FIG. 14 ;
[0040] FIG. 20 illustrates in a left side perspective view of the embodiment of FIG. 14 ;
[0041] FIG. 21 illustrates in a right side perspective view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 ;
[0042] FIG. 22 illustrates in an upper right perspective view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 ;
[0043] FIG. 23 illustrates in a right side view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 ;
[0044] FIG. 24 illustrates in a top plan view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 ;
[0045] FIG. 25 illustrates in a left side view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 ; and
[0046] FIG. 26 illustrates in a bottom plan view a combined turbine, primary gearbox, secondary gearbox, hydraulic pump and compressor for the embodiment of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] Referring to FIG. 6 there is illustrated in a right side view a single pick drilling system in accordance with an embodiment of the present invention. The single-pick drilling system 100 includes a drill frame 102 , a drill mast 104 , a combined power source, compressor and hydraulic pump 106 . The single-pick drilling system 100 also includes a fuel tank 108 , hydraulic tank 110 ( 110 not seen in drawing 100 , a detonator magazine 112 , an explosives magazine 114 , loading poles 116 , drill stems 118 and air and oil separator 120 . The drill frame 102 stands on four adjustable legs 122 .
[0048] Referring to FIG. 7 there is illustrated in a right front perspective view the single-pick system of FIG. 6 . FIG. 7 shows the driller's station 124 with hydraulic and pneumatic controls. Hydraulic tank 110 is in bottom right corner under drill stem 118 .
[0049] Referring to FIG. 8 there is illustrated in a left side view the embodiment of FIG. 6 . FIG. 8 shows the detonator magazine 112 , the explosives magazine 114 loading poles 116 and the drill stem, all visible from the left side. Hydraulic tank 110 is under drill stem.
[0050] Referring to FIG. 9 there is illustrated in a perspective view a combined motor turbine, hydraulic pump (multiple pumps may be used, piggybacked together in some configurations) and compressor for the embodiment of FIG. 6 . The gas turbine 130 drives the hydraulic pump 132 and compressor 134 through primary and secondary reductions gears 136 . The combined clutch and gearbox assembly allow all of the components from a two pick system to be combined into a single unit. This configuration is still able to utilize the same helicopters in use with the two pick heli-drills.
[0051] An exemplary implementation of the single-pick system follow:
Key Components
[0000]
1. Modified Single Stage Centrifugal Turbine and primary reduction gearbox. Custom automatic start and shutdown sequence electronics.
a. The primary reduction gearbox will reduce the turbine output RPM from approximately 60,000 RPM to one of the following 6000 RPM, 6480 RPM or 8640 RPM depending on the configuration required.
[0054] 2. Custom Gearbox, which consists of the following:
a. Manually engaged clutch (now configured as dual hydraulically engaged independent clutches)
i. Emergency stop which disconnects both clutches and shuts down turbine.
b. Secondary reduction gearing that will reduce the primary reduction gearbox RPM to between 2500 and 2800 RPM depending on the configuration requirements. Gearbox configured with one output shaft between 6000 and 6480 RPM and a second output between 2500 and 2800 RPM. Both clutches can be engaged/disengaged independently. Although the initial prototype will have a secondary gearbox I am ultimately working towards a single gearbox to further eliminate weight. c. The secondary reduction gearbox will have dual output shafts. The primary shaft will be used for the compressor 6480-6000 RPM (manufacture and model may vary depending on program conditions), while the secondary shaft will be for operating the hydraulic pump 2500-2800 RPM (manufacture and model may vary depending on program conditions) 3. Helicopter portable tracked carrier for the heli-drill. This unit can be configured to either ride on or walk behind with remote controls.
[0060] The turbine and gearboxes are all housed in a protective box to reduce the likely hood of damage. The enclosure is also designed as a protective housing in case of mechanical failure (protect personnel and explosives from flying debris. The enclosure will also house an air filter system for the gas turbine.
[0061] The exhaust system will have at least one cold air intake to reduce exhaust gas temperatures. The exhaust pipe diameter will also be increased in diameter to reduce the pressure of exhaust gases.
[0062] The remaining drill components vary depending on end user and the specific requirements that they have. The following may also be available to further reduce the overall mass of the drill.
1. Composite drill mast 2. Composite drill frame 3. Low mass air/oil separator 4. Low mass fuel tank 5. Low mass hydraulic tank
[0068] The complete drill configuration may include;
Drill Configuration
[0069] The drill has everything that is currently on the two separate drill components. Here is a list that includes the majority of items required. The items on the drill are not limited to this list; this is a basic configuration of the key elements.
1. Compressor, air oil separator and compressor oil cooler 2. Detonator magazine 3. Drill frame and mast 4. Drill stem (both auger and smooth—as per drillers requirements) 5. Drillers mud 6. Drillers station (with hydraulic and air controls) 7. Emergency shutdown system 8. Explosive magazine 9. Fuel tank 10. Hydraulic tank and hydraulic oil cooler 11. Power source for compressor and hydraulic systems (turbine and gearbox) 12. Required hydraulic pumps and motors for the drill (as per end user requirements) 13. Rotary pull down (either a hydraulic cylinder or hydraulic motor) 14. Tool box 15. Water pump
Carrier Configuration
[0085] The carrier is a self-propelled track carrier that is capable of hauling the single pick drill. On occasion it maybe impractical to utilize the carrier due to the nature of terrain that the drills work in. The driller and drill coordinator will decide on which areas the carrier is used in.
[0086] Referring to FIG. 10 there is graphically illustrated a method of heli-drilling in accordance with another embodiment of the present invention. FIG. 10 illustrates one of many possible variations with a single-pick drill. With the system of FIG. 6 , only a single trip is required to move the drill between shot holes. FIG. 10 shows how three single-pick drills 200 , 202 , and 204 could be moved. A helicopter moves 206 drill 200 from completed shot point A to drill next shot point B. The helicopter then flies 208 from B to move the next drill 202 from completed shot point C to next shot point D to be drilled 210 . The helicopter then flies 212 from D to move the next drill 204 from complete shot point E.
[0087] Referring to FIG. 11 there is illustrated a tracked carrier for use with the one-pick drilling system of FIG. 6 in accordance with a further embodiment of the present invention. The tracked carrier 220 includes a platform 222 for receiving the single-pick drill system of FIG. 6 and a bulkhead 224 . The tracked carrier of FIG. 11 has tracks 226 for moving across a variety of terrains and includes and optionally includes an operator's position 230 with a seat 232 , controls 234 and rollover protection system (ROPS) 236 . Another configuration of tracked carrier 220 dispenses with operator position 230 and instead uses a remote control so that the operator can walk a safe distance from the tracked carrier. The heli-carrier will eliminate the need for the helicopter from shot point to shot point when the terrain allows. The heli-carrier is a lightweight self-propelled track carrier that is configured to move or be flown to a shot point with a heli-drill. Once the carrier and drill are on site it is able to haul the drill to the next point.
[0088] Referring to FIG. 12 there is illustrated the one-pick drilling system of FIG. 6 carried on the tracked carrier of FIG. 11 in accordance with a further embodiment of the present invention. FIG. 12 shows the single-pick drill system of FIG. 6 placed on the tracked carrier 220 of FIG. 11 .
[0089] Referring to FIG. 13 there is graphically illustrated a method of heli-drilling in accordance with another embodiment of the present invention. A drill 250 on a carrier 252 has completed drilling at shot position A. A helicopter moves 254 the drill to shot point B. The helicopter flies back 256 to shot point A to retrieve the carrier 252 . The helicopter moves 258 the carrier 252 to shot point B After traversing the obstacle (in FIG. 13 a river), the drill and carrier combination are able to move 260 from shot point B to shot point C, to move 262 from shot point C to shot point D, to move 264 from shot point D to shot point E, when the terrain permits such movement. Once a further obstacle is encountered, the helicopter repeats the process as from shot point A to shot point B.
[0090] Referring to FIG. 14 there is illustrated in a right side perspective a single pick drilling system in accordance with a further embodiment of the present invention. The single-pick drilling system 300 includes a drill frame 302 , a drill mast 304 , a combined power source, compressor and hydraulic pump 306 . The single-pick drilling system 300 also includes a fuel tank 308 , hydraulic tank 310 ( 310 not seen in drawing), a detonator magazine 312 , an explosives magazine 314 , drill stems 316 and air and oil separator 320 .
[0091] Referring to FIG. 15 there is illustrated in a right front upper perspective view the single-pick system of FIG. 14 . The hydraulic tank 310 can be seen in FIG. 15 .
[0092] Referring to FIG. 16 there is illustrated in a front perspective of the embodiment of FIG. 14 . The drill mast 304 , fuel tank 308 , the hydraulic tank 310 and Drill stems 316 can be seen in FIG. 16 .
[0093] Referring to FIG. 17 there is illustrated in a right side perspective view of the embodiment of FIG. 14 .
[0094] Referring to FIG. 18 there is illustrated in a rear perspective of the embodiment of FIG. 14 .
[0095] Referring to FIG. 19 there is illustrated in a top perspective of the embodiment of FIG. 14 .
[0096] Referring to FIG. 20 there is illustrated in a left side perspective view of the embodiment of FIG. 14 . FIG. 20 shows the detonator magazine 312 , the explosives magazine 314 , and the drill stem 316 , all visible from the left side.
[0097] Referring to FIG. 21 there is illustrated in a right side perspective view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 . The gas turbine 330 drives the hydraulic pump 332 (cannot be seen in FIG. 21 ) and compressor 334 through primary and secondary reductions gears 336 . The combined clutch and gearbox assembly allow all of the components from a two pick system to be combined into a single unit. This configuration is still able to utilize the same helicopters in use with the two pick heli-drills.
[0098] Referring to FIG. 22 there is illustrated in an upper right perspective view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 . The hydraulic pump 332 can be seen in this view.
[0099] Referring to FIG. 23 there is illustrated in a right side view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 .
[0100] Referring to FIG. 24 there is illustrated in a top plan view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 .
[0101] Referring to FIG. 25 there is illustrated in a left side view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 .
[0102] Referring to FIG. 26 there is illustrated in a bottom plan view a combined turbine, hydraulic pump and compressor for the embodiment of FIG. 14 .
[0103] Numerous modifications, variations and adaptations may be made to the particular embodiments described above without departing from the scope patent disclosure, which is defined in the claims.
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There is provided a system for helicopter portable drilling comprising: a drill frame, a drill mast affixed a first end of the drill frame, a drill operatively coupled to the drill mast and operable using one of compressed air, pressurized hydraulic fluid and both compressed air and pressurized hydraulic fluid and a unified power source for providing compressed air and pressurized hydraulic fluid coupled to the drill, the total operating weight of the system being approximately 3000 pounds for allowing a single-pick move by a helicopter. A method of seismic line drilling comprising the steps of placing a first single-pick drilling system at a first location with a single pick, placing a second single-pick drilling system at a second location with a single pick, when finished drilling, moving the first single-pick drilling system to a third location with a single pick, when finished drilling, moving the second single-pick drilling system to a fourth location with a single pick.
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FIELD OF THE INVENTION
The present invention relates to ballasts for high intensity discharge (HID) lamps, including but not limited to, fluorescent, mercury vapor, sodium vapor, and metal halide lamps.
BACKGROUND OF THE INVENTION
It is well-known that the familiar incandescent lamp functions primarily as a resistor in an electric circuit. Light is produced because of the high temperature to which the filament is heated by power losses which vary in proportion to both the first power of filament resistance and the square of the filament current. The filament resistance is essentially a constant except for comparatively small changes which are caused by variations in filament temperature. The lamp can be energized quite safely by direct connection to any electric power source of appropriate voltage.
It is also well-known that a discharge type lamp, whether it employs a fluorescent coating or not, is not so simple in its operation. Its resistance is many megohms when it is in the passive state, and its operation depends upon the establishment of an arc through an internal cloud of ions called a plasma, the arc being initiated by an application of high voltage or by other well-known means.
After the arc has been established, the electrical behavior of the lamp is complex. If the applied voltage decreases below a critical value, the arc will be extinguished and the resistance of the lamp will revert to the multi-megohm range.
On the other hand, the resistance of the arc varies during lamp operation in a way such that the lamp current is not stable when the applied voltage is held at a constant value. Immediately after being struck, the arc resistance decreases and the lamp current rises to destructive values unless preventive measures have been employed.
The above-described behavior of arcs in the plasmas of discharge-type lamps has often been prevented by the insertion of an impedance (either resistive, inductive, capacitive, or some combination thereof) in series with the lamp and its power supply. This solution to the problem of destructive overcurrent has been employed so often that it is often erroneously believed that a series impedance is a fundamental necessity for a discharge-type lamp.
It is occasionally claimed that some means for maintaining a literally uninterrupted current through a discharge-type lamp is necessary to prevent the arc from being extinguished.
A more accurate description of arc behavior is taught herein, and experimental evidence to verify that description is presented. A unique ballast, based on the resulting comprehension of lamp characteristics, is then described.
SUMMARY OF THE INVENTION
A ballast for a high intensity discharge (HID) lamp is taught wherein voltage is gated to the lamp by a high speed switch only for that period of time, determined by the lamp's characteristics, during which the resultant current will not adversely affect the lamp or the switch. The pulse duration is normally on the order of 100 microseconds or less.
The voltage is then gated off for a period of time. Voltage is subsequently restored to the lamp before the lamp is extinguished, and this cycle is repeated.
This scheme eliminates the need for any inductive, resistive or capacitive elements, either saturable or conventional, in the post-ignition operation of the lamp, except perhaps for auxiliary functions. The elimination of such inductive, resistive and capacitive elements results in a highly efficient, low cost electric ballast having reduced electromagnetic and radio interference emissions.
It is a feature of the present invention to remove voltage from a HID lamp before the increasing current resulting therefrom reaches a level that would adversely affect the lamp or the switch, and to restore voltage to the lamp before the lamp extinguishes.
It is another feature of the present invention to eliminate the need for any inductive, resistive or capacitive element in the post-ignition operation of the lamp, except perhaps for auxiliary functions.
It is yet another feature of the present invention to use a high speed electronic switch for alternatively connecting and disconnecting voltage to an HID lamp to keep the actual (or measured) lamp current, power, or voltamperes below a safe, reference value.
These and other features of the present invention will be apparent from the drawings and the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a diagram of a test circuit.
FIG. 1b is a graph depicting an oscilloscope test screen where the pulse duration was 10 microseconds and the voltage pulse magnitude was 25 volts.
FIG. 1c through 1m are graphs depicting oscilloscope test screens corresponding to different test pulse durations and pulse voltage magnitudes.
FIG. 2 is a block diagram of an embodiment of the present invention.
FIG. 3 is a block diagram of a second embodiment of the present invention.
FIG. 4 is a block diagram of a third embodiment of the present invention.
FIG. 5 is an illustration of comparatively narrow lamp conduction pulses, specifically for the embodiment depicted in FIG. 2 but applicable to other embodiments as well.
FIG. 6 is an illustration of comparatively wide lamp conduction pulses, specifically for the embodiment depicted in FIG. 2 but applicable to other embodiments as well.
FIG. 7 is a circuit diagram of the embodiment of the invention that is illustrated in FIG. 2.
FIG. 8 is an illustration of the lamp current wave shape when the ballast is configured as shown in FIG. 3.
FIG. 9 is a illustration of the shunt current wave shape when the ballast is configured as shown in FIG. 3.
FIG. 10 is an illustration of the lamp current wave shape when the ballast is configured as shown in FIG. 4.
FIG. 11 is a block diagram of a fourth embodiment of the present invention.
FIG. 12 is an illustration of the lamp current wave shape when the ballast is configured as shown in either FIG. 11 or FIG. 13.
FIG. 13 is a block diagram of a fifth embodiment of the present invention.
FIG. 14 is a schematic diagram of a preferred embodiment of the present invention.
DETAILED DESCRIPTION
Certain peculiarities of electrical conduction make the present invention possible. Currents through metallic conductors involve the motion of mobile electrons that are closely packed together in the metal, are essentially free of inertia, and are available within said conductors in enormous quantities and in time intervals that are negligibly short.
Lamp arcs, in contrast, involve the motion of ions through a path of ionized gas or plasma. The ions are widely dispersed, they have a comparatively high inertia that is essentially the same as the inertia of the corresponding atoms, and they must be produced by the modifications of neutral atoms when they are needed. As a result, short time intervals are involved when electric current moves through plasma, and ion motions are found to have a peculiar time sensitivity of their own when extremely short periods of time are considered.
Special equipment items, such as a high speed electronic switch and an oscilloscope, are required for a useful study of this time sensitivity. The use of such equipment reveals that an arc through a region of ionized gas exhibits voltage, current and resistance characteristics that are similar to those of a fixed resistor for a small fraction of a second, on the order of 100 microseconds or less, after each application of voltage across the terminals of the lamp. Moreover, the subsequent increase in current is not instantaneous; it is essentially an exponential function of time, so that the current does not reach a harmful magnitude for a period of time that is quite significant when viewed from the standpoint of high frequency electronic technology.
The strategy employed in the present invention is to permit connection of the lamp across its power supply for extremely short intervals of time only, on the order of 0-100 microseconds. This connection time interval is followed by disconnection of the lamp at the end of each such connection interval.
In order to facilitate rapid disconnection, the circuit is designed to avoid any unnecessary inductance, in contrast to the prior art. An appropriate switching device, such as (but not limited to) a power mosfet, a bipolar transistor, or some combination of comparable circuit components to provide a high speed switching function - in any event driven by appropriate solid state electronic circuitry--is used to accomplish the required rapid sequence of connections and disconnections. Whenever the terms "FET", "mosfet", or "hexfet" are used in describing the invention herein, it is by way of example only and should be understood to encompass any suitable high speed switching means.
During the latter portion of each conduction period, the current may increase somewhat However, these increases are harmless if the disconnection is not unduly delayed, and for that reason they will be ignored during the remainder of this discussion.
If the wave shape of the lamp current for the present invention is displayed on an oscilloscope screen, it is seen to consist of a continuous series of pulses of current conduction, interspersed with intervals in which there is no conduction. The time transition between the fully ON and fully OFF states, called the switching time, is extremely short. It is achieved by methods that are wellknown in electronic switching technology. Each switching transition is accomplished by the application or removal of an appropriate low power voltage signal between the gate and the source of the power mosfet or other switching device.
It will be recognized that conduction pulses of comparatively long duration (viewed as wide pulses on the oscilloscope screen) contribute to a higher time integral of current than conduction pulses of comparatively short duration (viewed as narrow pulses on the screen). In the present invention, this relation of pulse duration (or pulse width) to the time integral of current is employed for achieving effective control over the timing of the voltage signals that cause the repetitive switching operations of said power mosfet from its ON state to its OFF state and back.
The timing of the voltage signals to the mosfet gate is regulated by electronic circuitry in a manner such that the conduction pulse width varies in response to a measurement of some appropriate parameter. When the measured parameter is higher than the desired value, then the timing of the voltage signals is changed in such a manner that said conduction pulse width is decreased, and vice versa. This method of control is called Pulse Width Modulation (PWM).
In one embodiment of the present invention, this parameter is the time integral of lamp current itself; it is measured indirectly by integrating the voltage drop across a shunt resistor with a resistance on the order of one ohm, the shunt being connected in series with the low impedance power supply, the lamp and the power mosfet.
In other embodiments, the measured parameters may be (but are not limited to) the average current, peak current, average power, peak power, RMS value of current, volt-amperes, or lamp luminosity, any of which may be measured by appropriate means and employed for automatic pulse width control.
Persons who are skilled in the art are familiar with numerous electronic methods for producing repetitive series of voltage signals with widths controlled by a measured voltage drop, with numerous electronic methods for producing high voltage pulses of low power for the ignition of an arc in an unlit lamp, and likewise with numerous methods of rectifying, filtering or inverting commercially available alternating or direct current power into commercial frequency or direct current forms that are suitable for use in lamps and switching circuits.
The preferred embodiment of the present invention includes selected means for PWM pulse production, for arc ignition, and for the modification of commercial power into a form that is consistent with the requirements of the particular type of lamp that the ballast is to serve.
Other embodiments provide means to circumvent certain commonly perceived needs for rectifying and/or filtering, as will be discussed. It should be understood, however, that the election of any particular means for the accomplishment of these ignition and power supply functions is not to be regarded as exclusive; on the contrary, various alternative means may be successfully used.
The uniqueness of the present invention lies in the control of lamp current by high speed switching, executed in a manner that takes advantage of time-related lamp characteristics, while the means for performing auxiliary functions may vary. The absence of any functional requirements for the use of inductive elements in series with the lamp is likewise unique.
In order to clarify the nature of dynamic arc resistance, aside from considerations of arc continuity, a test circuit was constructed in accordance with the diagram shown in FIG. 1a. A commercial 80 watt mercury vapor high intensity discharge lamp was connected so that its voltage drop and current throughput could be measured and displayed simultaneously, as a function of time, by an oscilloscope. The lamp was arranged to be energized separately or simultaneously by two different DC power supplies: (1) a power supply with a constant voltage value of 160 volts, which was connected to the lamp through a 500 ohm manually adjusted variable resistor; and (2) a low impedance power supply with a manually adjustable voltage range from zero to 200 volts, which was connected to the lamp through a high speed electronic switch, specifically a field effect transistor (FET) which has a resistance of only about 0.35 ohms when conducting. The switch was controlled automatically by a pulse generator in such a way that each time period of switch interruption was consistently one hundred times as long as the associated time period of switch conduction, with periods of interruption and conduction alternating continuously, and with the time duration of the conduction pulses being subject to manual adjustment.
The lamp was ignited by conventional means, and the variable resistor was adjusted to permit the passage of just sufficient current to maintain a continuous arc without any support from the variable voltage power supply. This mode of operation was consistent with the common practice of protecting the lamp by means of a series impedance. The efficiency of the lamp as a luminaire was quite low with this minimum value of current, but this efficiency was ignored for purposes of the tests.
A series of tests were then performed in order to gain a clear understanding of lamp performance under conditions which are relevant to the design and construction of ballasts. The lamp voltage was increased for very short intervals of time by means of the variable voltage power supply and the FET. This was done by switching the FET to its conduction mode. At the conclusion of each of the time intervals, the FET was switched to its interruption mode, which caused a reversion of lamp voltage to its pre-conduction value. This switching operation was repeated automatically under the control of the pulse generator and the oscilloscope was synchronized with the switching operation so that the current and voltage wave forms were displayed on the screen for analyzing.
For the first test, the pulse generation was adjusted to give FET conduction pulse intervals of about 10 microseconds, with interruption pulse intervals of about 1,000 microseconds.
The voltage of the variable voltage power supply was then gradually increased until the oscilloscope indicated a voltage pulse magnitude of about 25 volts greater than the static lamp voltage. This adjustment produced a combination of the lowest voltage pulse magnitude and the shortest conduction pulse time duration which was employed during the test series. Under these conditions, the oscilloscope indicated a current pulse of about 0.1 amperes greater than the static lamp current which was synchronized with the voltage pulse and which remained essentially constant throughout the time duration of each conduction pulse. A graphical representation of the oscilloscope screen for this test is shown in FIG. 1b.
Other tests were performed in a generally similar manner, with various combinations of voltage pulse magnitude and pulse time duration. Graphical representations of the oscilloscope screens for these tests are shown in FIGS. 1c through 1m; however, discussions to cover three of these tests should suffice to explain the results.
For the combination of the highest voltage magnitude and the shortest time duration, the voltage of the variable voltage power supply was increased until the oscilloscope indicated a voltage pulse magnitude of about 100 volts greater than the static lamp voltage, with the conduction pulse durations still adjusted for about 10 microseconds. Under these conditions, the oscilloscope indicated a simultaneous current pulse which began with a magnitude of about 0.5 ampere, and increased to a final magnitude of about one ampere during each conduction pulse. A graphical representation of the oscilloscope screen for this test is shown in FIG. 1d.
For the combination of the longest pulse time duration and the lowest voltage pulse magnitude used in the series of tests, the pulse generator was adjusted to give conduction intervals of 100 microseconds (alternating with interruption intervals of 10,000 microseconds). The voltage of the variable voltage power supply was then adjusted until the oscilloscope indicated a voltage pulse magnitude of about 25 volts greater than the static lamp voltage, the same value that was used for the tests shown in FIGS. 1b, 1e and 1h. Under these conditions, the oscilloscope indicated a simultaneous current pulse which began with a magnitude of about 0.1 amperes and increased to a final magnitude of about 0.4 amperes at the end of each conduction pulse. A graphical representation of the oscilloscope screen for these conditions is shown in FIG. 1k.
For combination of the longest pulse time duration and the highest voltage pulse magnitude used in the series of tests, the pulse generator was allowed to continue generating conduction intervals of 100 microseconds (alternating with interruption intervals of 10,000 microseconds). The voltage of the variable voltage power supply was then increased until the oscilloscope indicated a voltage pulse magnitude of about 100 volts greater than the static lamp voltage (the same value that is illustrated in FIGS. 1d, 1g and 1j). Under these conditions, the oscilloscope indicated a simultaneous current pulse which began with a magnitude of about 0.6 ampere and increased to a final magnitude of about 12 amperes at the end of each conduction pulse. In this case, the wave shape of the current pulse was strongly concave. This concavity indicated that lamp current had assumed a wave form which resembled an exponential rate of increase with respect to time. A graphical representation of the oscilloscope screen for these conditions is shown in FIG. 1m.
It was necessary to change the sensitivity of the oscilloscope with regard to current, in order to accommodate the 12 ampere pulse within the available space on the screen.
The increase in current during each 100 microsecond pulse duration indicated that continued application of such a voltage significantly beyond the 100 microsecond time duration would have resulted in currents which would eventually have been harmful to the lamp, and ultimately destructive; however, no damage could be detected during the test.
The above-described experiments show that the dynamic resistance of a discharge-type lamp is both orderly and positive for short periods of time. Furthermore, they show that lamp current is readily interrupted by commercially available electronic switches, even when a combination of applied voltage magnitude and pulse duration causes the lamp current to begin an essentially exponential rate of increase with respect to time.
It should be appreciated that the voltage and current traces on an oscilloscope have a tendency to disguise the rigor of the tests. These traces appeared to represent conditions for only one conduction pulse; however, this appearance is an illusion which is intentionally produced for convenience in circuit analysis. Actually, the lamp operated through hundreds of pulses, including the successful interruption of the increasing lamp current, during each second of the tests; the oscilloscope was synchronized to show each pulse trace on top of the preceding pulse trace, in order that the wave form for vast numbers of identical pulses might be studied in detail, as if the wave form for only on pulse were being observed. This procedure will be recognized by those skilled in the art as normal for the use of the oscilloscope. It should therefore be realized that the lamp was adequately protected through numerous conduction pulse cycles during the abovedescribed tests and during many prolonged tests with prototype ballasts which were based thereon.
The above tests lead to the conclusion, and establish the principle, that it is possible to design and produce a ballast for a discharge-type lamp on the basis that voltage will be applied to the ignited lamp in short, continuously repetitive pulses, the lamp current being limited to non-harmful values by the use of electronic switching devices exclusively. The comparative simplicity and low production cost associated with such a ballast result in significant benefits when this switching design is employed. The various embodiments of the present invention all constitute applications of the above established principle.
FIG. 2 shows a comparatively simple embodiment of the present invention in block form. A direct current power source 1 of relatively low resistance is required. Source 1 may consist of a battery, a generator or an inverter system, or it may draw its power from a commercial alternating current supply with a nominal frequency of the order of 50 or 60 Hz and a nominal voltage range that is at least sufficient to meet the operating requirements of the particular lamp to be used. For a typical alternating current supply, source 1 might well consist primarily of a conventional full-wave diode bridge rectifier and a capacitive filter. Both the current capacity of source 1 and DC voltage delivered thereby must be adequate for the requirements of the particular lamp to be used, and adequate filters may be provided to appropriately limit the electromagnetic emissions and radio frequency interference that result from the operation of the lamp and ballast combination; likewise the design of the other ballast components must be consistent with the voltage delivered by source 1.
The remaining chief components of the overall circuit consist of shunt 4, power mosfet 3, lead 12, lamp 2, a parallel connected combination of diode 8 and ignition pulse generator 5, and lead 13; all of these chief components are connected in series across the two output terminals of source 1. Diode 9 is connected from lead 13 to lead 2, its purpose being the provision of a path by which pulses of ignition current can return to ignition impulse generator 5 after having passed through lamp 2. The purpose of diode 8 is to prevent lead 13 from short circuiting ignition pulse generator 5.
Current integrator 7 is connected to accept the voltage drop that materializes across shunt 4 as an input, and it is designed to furnish an analog representation of the time integral of lamp current throughout one cycle as an output.
Pulse width modulation (PWM) impulse generator 6 is connected to accept that analog representation of said time integral of lamp current as an input, and it is designed to furnish voltage pulses suitable for the control of the switching action of power mosfet 3 as an output.
Power mosfet 3 is connected to accept said voltage pulses as an input, and it responds by performing a series of lamp connections and disconnections at extremely high switching speed, in accordance with the previously described principles of PWM, and at a frequency that is high enough to assure that no lamp current peaks of harmful magnitude will occur. A suitable frequency can be selected from a very wide range of frequencies (from below 5KHz to above 500 KHz) and the actual selection will more than likely be made based on other factors, such as the audibility of noise for some applications, the reduction of cost, lamp mechanical resonance, arc tube resonance, electro-acoustics, and other factors. The requirement for the effective limiting of lamp current is always to be met.
The polarities of source 1, diode 8, power mosfet 3, diode 9, all internal components of current integrator 7, PWM impulse generator 6, and ignition pulse generator 5 are connected in a manner that is consistent with their respective functions in lamp ignition and operation, in accordance with principles that are well-known to persons who are skilled in the art.
It will be recognized that the auxiliary electronic components of impulse generator 6 and current integrator 7 should be supplied with filtered direct current at a relatively low voltage for their internal use, this being a normal requirement of most electronic device assemblies.
FIG. 3 depicts an alternative embodiment of the present invention. Some HID lamps have experienced unequal deterioration of their electrodes when they are operated on pulsating direct current as contemplated in FIG. 2, and the life of such lamps has ended prematurely with the life of the most adversely affected electrode. Such electrode deterioration can be equalized, and the life of the lamp can be correspondingly optimized, by operating the lamp on pulsed alternating current; FIG. 3 illustrates means for such operation. Direct current source 1 has been replaced by commercial alternating current source 10, which includes filters to limit the escape of radio frequency interference from the lamp-ballast combination to the commercial power system.
It will be recognized that lamp 2 requires means for its ignition; but no such means has been shown on FIG. 3 in the interest of simplicity, since various means for arc ignition are well-know and the present invention is not dependent upon the choice of ignition means.
The series connection of lamp 2, power mosfet 3, and shunt 4, with source 10, is similar to the arrangement of FIG. 2, but full-wave diode bridge rectifier 11 has been inserted into the circuit. Such bridge rectifiers are well-known and they should require no detailed explanation.
The effect of rectifier 11 on the ballast is that the current through lamp 2 is an alternating current of the same frequency as that of alternating source 10, with each half cycle being broken up into a series or cluster of short conduction pulses b the action of power mosfet 3 as previously described, the width of said conduction pulses being varied as required to give the desired time integral of lamp current. If the wave signal of the current through lamp 2 is displayed on the screen of an oscilloscope, it is found to be as illustrated in FIG. 8.
On the direct current side of rectifier 11, the wave shape of the current as viewed on an oscilloscope is as shown in FIG. 9; it is that of an alternating current that has been subjected to full-wave rectification by rectifier 11 and also broken into a series of conduction pulses of variable width by power mosfet 3.
Voltage signals to the gate of power mosfet 3 are supplied by the combination of pulse width modulation impulse generator 6, current integrator 7 and shunt 4 as described in connection with FIG. 2.
In both FIG. 8 and FIG. 9, each cluster of conduction pulses is followed by an interval during which no conduction occurs. Power mosfet 3 is switched on periodically during said intervals, but conduction does not occur because the alternating current voltage is too low to cause lamp ignition; however, when using a commercial 400 Hertz power source such as that found on a ship or plane, the lamp plasma for lower wattage lamps does not cool appreciably during said intervals, and normal conduction resumes when the lamp voltage reaches an adequate value during the next half cycle of the power source. For lower frequency power sources, a lamp must be selected whose minimum off-time characteristic is compatible with the particular ballast design.
Low voltage direct current power supplies are required for the internal components of impulse generator 6 and current integrator 7, as in the case of FIG. 2.
FIG. 4 shows another, alternative embodiment of the present invention whereby lamp 2 is operated on pulsed alternating current for the equalization of electrode deterioration as described in connection with FIG. 3, even though the source of power is direct current. As in the case of FIG. 2, filtered direct current power is obtained from source 1. A superficial similarity between the circuit of FIG. 4 and the familiar half-bridge circuit will be observed. The embodiment shown in FIG. 4 includes power mosfet 3, shunt 4, current integrator 7 and impulse generator 6 which have already been explained; it also includes an additional power mosfet 14 and two essentially identical capacitors 15 and 16; also, impulse generator 6 has been expanded to control both of the power mosfets.
Impulse generator 6 is constructed and connected such that pulses are applied to the gates of power mosfets 3 and 14 in alternation, with the result that each power mosfet conducts after the opposite mosfet has been turned off, while the width of each conduction pulse is still modulated in accordance with the principles of PWM.
For the present invention, it is assumed that said capacitors 15 and 16 are of sufficient capacitance to perform all of the power supply filtering that is really required, although conventional filter capacitors may be added as internal components of source 1.
The sequence of operation is then as follows: when power mosfet 3 conducts, current flows from the positive terminal of source 1 through power mosfet 3, through shunt 4, through lamp 2 (entering at terminal 17), through capacitor 16, and finally to the negative terminal of source 16. When power mosfet 14 conducts, current flows from the positive terminal of source 1 through capacitor 15, through lamp 2 (entering at terminal 18), through shunt 4, through power mosfet 14, and finally to the negative terminal of source 1. Alternate current pulses thus pass through lamp 2 in opposite directions, so that each electrode serves as cathode and as anode for an equal number of conduction pulses, even though all lamp current is furnished by a direct current source. Deterioration of the lamp electrodes is thus equalized.
Source 1 furnishes current as required to keep each of capacitors 15 and 16 charged essentially to one half of the peak value of the rectified power supply voltage. The capacitances of capacitors 15 and 16 are so high that their impedances at the frequency of the conduction pulses is negligible, and said capacitors do not perform any significant current limiting function; their purpose is merely to furnish the pulses of lamp current as described.
Lamp 2 requires means for its ignition; but no such means has been shown in the interest of simplicity, as in the case of FIG. 3. Many well-known ignition means may be used, as would be apparent to those skilled in the art.
The lamp current wave shape for the embodiment shown in FIG. 4 is illustrated in FIG. 10.
Low voltage direct current power supplies are required for the internal components of impulse generator 6 and current integrator 7, as in the case of FIG. 2. Such power supplies are well-known to those skilled in the art.
FIG. 7 is a detailed circuit diagram for a working ballast, specifically for an embodiment of the present invention that is configured according to FIG. 2.
It may be noted that FIG. 7 depicts a 5 to 100 microhenry inductor 22, having a value of about one ten thousandth that required to control lamp current. This inductor may be omitted from the circuit and replaced by a single wire connection, and the circuit will still function properly. However, it has been experimentally determined that through the inclusion of this small inductor the electromagnetic and radio frequency interference may be reduced.
FIG. 11 shows a fourth embodiment of the present invention. For this embodiment, direct current source 1 has been replaced by full-wave rectified power source 19. No filter capacitors need be included within source 19, and furthermore, the capacitance of capacitors 15 and 16 have been reduced to the extent that they have high impedances at commercial power frequencies, so that only light filtering of the full-wave rectified power from source 19 takes place. However, the capacitances of capacitors 15 and 16 are adequate to furnish the required conduction pulses of lamp current, with the result that capacitors 15 and 16 perform no appreciable current limiting function.
The ballast operates as described in connection with FIG. 4; but the wave shape of lamp current as viewed on an oscilloscope is shown in FIG. 12, with the alternating conduction pulses being broken into clusters because the power from source 19 is only lightly filtered, and with the peaks of the conduction pulses in each cluster tracing the outline of a sinusodial positive envelope and a sinusoidal negative envelope in phase therewith.
The embodiment illustrated in FIG. 11 is designed to avoid the use of large filter capacitors because of their cost and their ambient temperature limitations.
As in the case of previously described embodiments, lamp ignition means, low voltage direct current power supply means and radio frequency interference filtering means may be required but are not shown on FIG. 11 in the interest of simplicity. Such means are well-known to those skilled in the art.
For lower frequency power sources such as 50/60 Hz ones, a lamp must be selected whose minimum off-time characteristic is compatible with the particular ballast design.
FIG. 13 shows a fifth embodiment of the present invention that is similar to the one shown in FIG. 11 except that capacitors 15 and 16 have been replaced by power mosfets 20 and 21, and pulse width impulse generator 6 has been expanded to provide means for controlling power mosfets 20 and 21.
The circuit for current through lamp 2 contains no inductors or capacitors. Power mosfets 20 and 21 are configured in the familiar full bridgearrangement, that is sometimes called a commutator arrangement because the polarity of the current through lamp 2 is reversed repeatedly and automatically. For an arbitrarily selected switching impulse, when power mosfets 14 and 20 are in their OFF state, power mosfets 3 and 21 conduct simultaneously, and current enters lamp 2 through terminal 17. Then, for the immediately following switching cycle, after power mosfets 3 and 21 have been turned OFF, power mosfets 14 and 20 conduct simultaneously, and current enters lamp 2 through terminal 18. This switching sequence repeats automatically under control of pulse width generator 6 in accordance with the principles of PWM which have already been explained. The wave shape of lamp current, as seen on the screen of an oscilloscope, is as illustrated by FIG. 12.
For lower frequency power sources such as 50/60 Hz ones, a lamp must be selected whose minimum off-time characteristic is compatible with the particular ballast design.
A circuit diagram of a preferred embodiment is shown on FIG. 14. Referring to FIG. 14, the function of each major component is as follows:
Sidac D9 and transformer T1 provide high voltage pulses to strike the lamp when it is placed in operation at the end of an inactive period.
Hexfet Q3 energizes the lamp repeatedly for short conduction periods, and de-energizes the lamp at the end of each period.
Transistor Q4 instructs power mosfet Q3 to energize the lamp; it also notifies transistor Q1 that a lamp conduction period is beginning.
Transistor Q2 instructs power mosfet Q3 to deenergize the lamp.
Transistor Q1 disables transistor Q2, so that power mosfet Q3 will be free to energize the lamp upon receipt of appropriate instructions.
Transistor Q5 provides a signal which is complementary to that from transistor Q4; it thus assures that the instructions from transistor Q4 are not ambiguous.
Timer 555 initiates short voltage pulses to activate transistor Q4.
Operational amplifier U2A instructs timer 555 to begin or terminate an extended period of lamp activity.
Photocell CS1 and thermistor R18 provide operational amplifier U2A with information concerning the ambient temperature and light level, for use as the basis of decisions to activate or deactivate the lamp.
With reference to FIG. 14, assume that the ballast is de-energized, all solid state switches are turned off, all capacitors are discharged, the lamp is inactive, and normal daytime ambient light and temperature conditions prevail.
A 120 volt 50/60 Hz AC power source is connected to the hot lead H and neutral lead L of the ballast. Fuse F1 will blow if the subsequent ballast input current exceeds 3.5 amperes for any significant length of time. Dual Metal Oxide Varistor MOV will clip and limit any high voltage pulses which may appear between the H and L leads. Inductor L1 and capacitors C10, C11, C12 and C13 constitute a filter to reduce any radio frequency interference which may be generated by the operation of the ballast.
Full wave diode bridge BR1 and capacitor C8 constitute a high voltage power supply which provides filtered direct current at a nominal 160 volts DC for use by the lamp and by the striking pulse generator. Throughout this discussion, the negative terminal of capacitor C8 is assumed to be at zero potential for reference purposes, even though this terminal is not grounded; all DC voltages are therefore considered to be positive with respect to that reference, and no negative voltages are involved.
Resistor R1, zener diode D1, and capacitor C1 constitute a low voltage power supply which provides filtered direct current at a nominal 15 volts DC for use by the logic circuitry. The negative terminals of the high voltage power supply and the low voltage power supply coincide for all practical purposes. They are actually separated by resistor R11, which is merely a current measuring shunt of about one ohm. Its voltage drop is quite negligible as far as power supply voltages are concerned.
In the absence of any voltage signal to the bases of transistors Q4 and Q5, the emitters of those transistors are clamped to the negative terminal of the low voltage power supply by transistor Q5. Incidentally, current from the low voltage power supply to some of the logic circuitry passes through resistor R11, but its resistance is s low that it has no significant effect on the small logic element currents involved. The function of this resistor is related to the much larger currents through the lamp, as will be described.
Resistors R17 and R19 constitute a voltage divider across the low voltage power supply, and they apply a fixed voltage to terminal 2 of operational amplifier U2A for use as a reference.
Resistors R21 and R20, capacitor C14, thermistor R18 and photocell CSl constitute a circuit which is sensitive to ambient light and temperature, and this circuit applies a voltage to terminal 3 of operational amplifier U2A. Durng normal daytime and temperature conditions, this voltage is lower than the reference voltage at terminal 2; consequently the output voltage of operational amplifier U2A is close to zero volts, and the remainder of the ballast is inactive.
As dusk approaches, the resistance of photocell CSl increases; this raises the voltage at terminal 3 of operational amplifier U2A until it becomes slightly greater than the voltage at terminal 2. When this occurs, the output at terminal 1 switches to about 15 volts, and this voltage is applied to terminal 4 of timer 555, which in turn activates the lamp, as will be described.
Thermistor R18 is quite sensitive to changes in ambient temperature in a range close to 10 degrees Farenheit. A temperature of about 10 degrees or less will increase the resistance of R18 enough so that the voltage at terminal 3 of operational amplifier U2A will become higher than the voltage at terminal 2, regardless of light conditions; as a result, the lamp will be activated continuously, even in daylight. This feature is provided because lamps become difficult to strike at low temperatures; therefore it is preferred that the lamp operate continuously during abnormally cold weather, so that striking will not become necessary.
The above-described photocell temperature switch is described in more detail in pending application Ser. No. 065,269, filed June 22, 1987, assigned to the same assignee and incorporated by reference herein.
When the output of operational amplifier U2A at terminal 1 switches to about 15 volts, resistor R22 conducts a small amount of current to the junction of resistors R21 and R20 and thermistor R18; this slightly raises the voltage at terminal 3 of operational amplifier U2A, which provides a hysteresis effect and opposes any tendency for operational amplifier U2A to cycle on and off. Capacitor C14 helps to stabilize the voltage at terminal 3, further reducing any tendency toward cycling.
When a 15 volt signal is applied to terminal 4 of timer 555 as described above, it begins and continues to develop a square wave output at terminal 2 with a frequency of about 40KHz and an asymmetrical duty cycle, such that the positive output is near 15 volts for a short pulses of about 500 nanoseconds and then near zero volts for the remaining 24.5 microseconds of the cycle. The frequency and duty cycle of the square wave are controlled by resistors R2 and R3, diode D2, and capacitor C2. The square wave output is applied through resistor R16 to the bases of transistors Q4 and Q5. These transistors serve as buffers; a 500 nanosecond positive pulse appears every 25 microseconds at the emitters of transistors Q4 and Q5, but these emitters are clamped to the negative power supply terminal through resistor R11 at all other times.
The above 500 nanosecond pulse is applied to the base of transistor Q1 through a differentiator consisting of resistor R5 and capacitor C4; this turns transistor Q1 on at the leading edge of the pulse. Transistor Q1 therefore discharges capacitors C6 and C5 without delay at the leading edge of each pulse (if they contain any charge). This discharging function operates through resistor R7 to remove all voltage from the base of transistor Q2, since no voltage is available from the only other source through diode D5; this assures that transistor Q2 is switched off. As a result, the previously mentioned 500 nanosecond pulse from the emitter of transistor Q4 is applied through resistor R4 and diode D3 to the gate of power mosfet Q3, charging its internal gate-to-source capacitors and placing the power mosfet Q3 in a continuous conducting mode.
With a cold lamp, and with power mosfet Q3 conducting, capacitor C9 is charged from the positive terminal of capacitor C8 through resistor R14, power mosfet Q3, and resistor R11. When the voltage across capacitor C9 reaches the firing value for sidac D9, which is about 135 volts, sidac D9 discharges capacitor C9 through the primary (low voltage) winding of transformer T1. This induces a short pulse in excess of 1000 volts in the secondary (high voltage) winding of transformer T1, and this pulse is applied across the terminals of lamp P1 through diode D7.
This short pulse is adequate to strike the lamp, so that it begins conducting through diodes D8 and D10, power mosfet Q3, and resistor R11. Since the original 500 nanosecond pulse has now terminated, transistor Q1 is now switched off; capacitors C6 and C5 are therefore free to accept a charge, and they are charged by the voltage drop across resistor R11, by the combination of resistors R8, R9, R10 and diode D4. The voltage developed across capacitors C5 and C6 thus constitutes a time integral of the voltage drop across resistor R11. The voltage across capacitors C5 and C6 is applied to the base of transistor Q2 through resistor R7; when this voltage reaches a sufficient magnitude, transisor Q2 switches on, discharging the internal gate-to-source capacitors in power mosfet Q3 through resistor R15 and thus turning power mosfet Q3 off. The duration of each lamp conduction cycle, or pulse width, is thus controlled by the time integral of the voltage across resistor R11, which in turn is proportional to the current through the lamp. The constants of the pulse width integration circuit components are such that the lamp is allowed to conduct only during the very short time during which the lamp impedance remains essentially constant, or at least high enough to prevent any dangerous lamp overcurrent. It is this high speed switching by power mosfet Q3 in response to the time integral of lamp current which makes possible the successful operation of the ballast without any inductors.
When the lamp is struck, its impedance is very low and the lamp current is correspondingly high; the pulse width of lamp conduction is correspondingly reduced by the above-described switching in response to the time integral of lamp current, and the lamp is protected from the severity of starting duty to which it would otherwise be exposed. As the lamp temperature increases and the lamp impedance correspondingly increases, the lamp current pulse width is gradually and automatically increased to maintain the desired average value of lamp current in spite of the changing lamp impedance.
When power mosfet Q3 interrupts the lamp current, the voltage at the source terminal of power mosfet Q3 increases; this increase is applied through capacitor C7, resistor R12 and diode D5 to the base of transistor Q2; this accelerates and stabilizes the switching of that transistor. Diode D6 prevents any undesired charging of capacitor C7 through the current path which would otherwise exist to the negative terminal of capacitor C8.
After the lamp has been struck and is operating in a conductive mode, capacitor C9 is quickly discharged each time power mosfet Q3 switches off. The discharge path is through diodes D8, D10 and D11, resistor R13, and the lamp itself. As a result, the high voltage pulse circuit ceases to function after the lamp strikes.
When the ambient light level rises to daytime values, the resistance of photocell CS1 decreases enough to reduce the voltage at terminal 3 of operational amplifier U2A below the reference value at terminal 2. The output at terminal 1 then drops to near zero, timer 555 ceases to function, the lamp is extinguished, and the entire ballast becomes passive. This condition prevails until the ballast is reactivated by either low light level or low temperature, as previously described.
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An electronic ballast for high intensity discharge lamps is taught. A high speed electronic switch gates voltage across the lamp only for that period of time when the amount of resultant current flow will not adversely affect the lamp or the switch. At that point, the voltage is gated off for a period of time, after which the cycle repeats. This scheme eliminates the need for any inductive, resistive or capactive element, either saturable or conventional, in the post-ignition operation of the lamp, except perhaps for auxiliary functions. The elimination of such inductive elements results in a highly efficient, low cost electronic ballast having reduced electromagnetic and radio interference emissions.
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BACKGROUND
Numerous devices have been used to position tissue at a surgical site to aid in the performing of surgical procedures. Retractors, for example, have been used to hold an artery in position during operations adjacent to the heart to prevent movement of the artery. This serves to minimize the risk of injury to the artery and adjacent tissue and can facilitate the desired anastomosis.
A recently developed procedure, referred to as the minimally invasive direct coronary artery bypass procedure, has been used to graft onto a coronary artery without cardiopulmonary bypass. This procedure involves the grafting of the left internal mammary artery (LIMA) onto the left anterior descending (LAD) or other artery. As this procedure does not require the use of a heart lung machine to oxygenate and pump blood, the morbidity and mortality associated with this procedure is substantially lower than previous bypass techniques. A problem associated with the minimally invasive procedure, however, is that while the heart continues to pump during the procedure, the motion of the heart can interfere with the surgeon's task of attaching the LIMA to the LAD. There is also a need to stop blood flow in the area of the graft to maintain a clear field of view and provide precise suture placement.
Two basic strategies have been employed to address the problem of operating on a moving site, one being the use of pharmacological agents to limit heart motion, and the other being mechanical, such as a two prong retractor that is pushed down against the heart on both sides of the artery, or alternatively, upward traction away from the moving heart by traction tape or suture thread. Both of these options, however, have problems associated with them. Both options are susceptible to some movement of the vessel grafting site. The use of pharmacological agents is undesirable and impairs circulatory function. Traction by compression of the heart against the spine does serve to immobilize the site but can compromise the ability of the heart to maintain circulation and result in hypotension. Upward traction can involve circumferential compression of the artery to occlude the artery and prevent blood flow, however upward traction that is sufficient to immobilize the site can cause injury, stenosis or occlusion of the vessel.
There is a continuing need however for improvement in devices and methods for retaining tissue at surgical sites to further reduce the risks associated with surgical procedures where the devices and methods are inexpensive, safe and reliable.
SUMMARY
The present invention relates to a surgical retractor for immobilizing tissue at a surgical site and to a method of using the retractor during a surgical procedure. A preferred embodiment of the retractor includes a retaining element having an aperture that exposes the surgical site and a holder that is used to position tissue at the surgical site relative to the retaining element. A handle can be attached to or fabricated with the retaining element or platform so that the user can manipulate the position of the retractor as needed.
In a preferred embodiment of the invention a connector such as elastic tape or thread is used to position tissue at the surgical site within the retractor aperture and to prevent movement of the tissue during the procedure. The connecting cord, thread or tape also aids in the compression of the artery in a grafting procedure to occlude flow on one or both sides of the surgical site. The cord is attached to the holder on the retaining element. A preferred embodiment of the holder can be a plurality of slits or openings positioned on both sides of the retractor that receive and frictionally secure the cord on both sides of the aperture. In another preferred embodiment a mechanical fastener is used to grip both sides of the cord. The fastener can be a spring mounted valve, for example, that allows the user to adjust the tension in the cord.
A preferred embodiment of the invention comprises a retaining element or base having two sections that can be separated after the procedure is complete to permit removal of the retractor from under the grafted artery. Another preferred embodiment uses a side opening in the platform of the retractor that extends to the aperture so that the grafted artery slips through the side opening during removal. During minimally invasive direct coronary artery bypass operations, one or more surface sections of the retractor platform can be positioned against the inner surface or posterior aspect of one or both ribs adjacent to the surgical site. Thus, the size and geometry of the platform are selected to utilize the adjoining ribs where the upper surface of the platform frictionally engages the inner surface one or more ribs to hold the retractor in a fixed position. The retractor can be beneficial in any procedure where it is necessary to stabilize a surgical site. For example, the retractor can also be used for grafting onto the diagonal, right or other coronary arteries without altering the heart's pumping function.
The coronary arteries are about 1-2 mm in diameter, and the pumping heart can move these arteries over distances of several millimeters during each heartbeat. As the movement of even 1 or 2 millimeters can result in a displacement of the grafting site that can substantially interfere with effective anastomosis, it is desirable to restrain movement of the artery at the surgical site in any direction to less than 1 mm. The retractor of the present invention restrains movement in the plane of the base to less than 0.5 mm, and preferably less than 0.2 mm.
In a preferred embodiment of the invention, the handle or articulating arm that is secured to the platform can be held in position by the user, attached to a frame that is fixed around the operative site or simply clipped to a drape around the site.
When used in a minimally invasive coronary bypass procedure, the retractor is positioned to expose the left anterior descending (LAD) artery grafting site after incision, removal of the rib section and dissection of the left internal mammary artery (LIMA) from the chest wall. A pair of cords, for example, sialastic tape (i.e. a silicon elastomer) or suture thread, are passed through the myocardium at two locations flanking the artery grafting site with blunt needles. The four ends of the two cords are connected to the platform holder with sufficient tension to occlude blood flow on both sides of the operative site. The tapes compress the artery against the bottom surface of the platform while they hold the artery grafting site in a fixed position relative to the aperture. The coronary artery is opened longitudinally and the end of the mammary artery is sewn to the graft opening with multiple fine sutures. The cords are released, blood flow is restored and the anastomosis is inspected for hemostatis and other defects and the wound is closed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a surgical retractor in accordance with a preferred embodiment of the invention.
FIG. 2 is a perspective view of a surgical site illustrating a surgical procedure.
FIG. 3 is a perspective view of a surgical retractor for a grafting procedure in accordance with the invention.
FIG. 4 is a bottom perspective view of a surgical retractor in accordance with the invention.
FIG. 5 is a cross-sectional view of a surgical retractor during a surgical procedure.
FIGS. 6A and 6B are partial cross-sectional views of a holder in accordance with the invention.
FIG. 7 is a top view of a two piece retainer in accordance with the invention.
FIG. 8 is a top perspective view of another preferred embodiment of a surgical retractor in accordance with the invention.
FIG. 9 is a top perspective view of another preferred embodiment of a surgical retractor in accordance with the invention.
FIG. 10 is a schematic diagram illustrating a surgical procedure in accordance with the invention.
DETAILED DESCRIPTION
A preferred embodiment of the invention is illustrated in connection with FIG. 1. A retractor 10 includes a retaining element or base 12 having an aperture 16 that is positioned to expose tissue at a surgical site. The base 12 can be made with a metal or a molded plastic material. The retractor 10 can be sterilized after each use, or alternatively, can be disposable after one procedure. A handle 30 or articulating arm can be permanently attached to the base 12, or as described below in connection with other preferred embodiments, can be detachable.
A suction tube 32 can be attached to the handle 30 or integrated therein and is used to remove material such as blood from the operative site. In this particular embodiment the tube 32 is connected at one end to a tube 34 from a suction pump and connected at a second end to a port 36 in fluid communication with a channel within tube 28 that extends around the periphery of base 12. The peripheral tube can have small openings 38 positioned on the sides or top thereof through which fluid such as blood or other debris can be suctioned from the surgical site to maintain a clear field.
A preferred embodiment of the invention can be used at a surgical site 50 such as the example illustrated in FIG. 2. In this particular procedure for a coronary graft without cardiopulmonary bypass, a section of the 4th costal cartilage or rib 56 is removed at 66 to expose a section of the LAD artery 61.
A proximal portion of the LIMA 62 is dissected from the chest wall to expose an end 65 to be grafted onto a grafting site 60 on artery 61. Blood flow in vessel 62 can be occluded with a clamp 64.
In this example, a connector such as a pair of cords or sialastic tapes 70, 72 are threaded through myocardium surface 78 under the artery 61 at two locations 74, 76 on opposite sides of the grafting site 60. Note that the exposed surface 78 of heart 52 is undergoing substantial movement during the procedure.
As seen in the reverse perspective view of FIG. 3 in which the retractor 10 has been inserted and positioned during the procedure, the retractor 10 serves to immobilize the grafting site 60 using connecting tapes 70, 72 which are stretched and attached to a holder mechanism including slots 20a-20d in the peripheral edge of base 12. As described in greater detail below, the slots 20A-20d can be manually opened or closed using actuators 22a-22d, respectively, to allow the user to adjust the tension in the tapes or threads.
The aperture 16 extends longitudinally along the axis of artery 61. The site 60 is preferably located in the plane of the upper surface of base 12. The tapes 70, 72 exert a compressive force on the artery 61 which is pressed against a bottom surface 40 as seen in FIG. 4. More particularly, the tapes 70, 72 extend in a direction that is substantially perpendicular to the artery 61 axis exposed in the aperture 16. The aperture can have a first pair of lateral sections 18a and 18b which are aligned to accommodate the positioning of tape 70 and the aperture can also have a second pair of lateral sections 18c and 18d to accommodate the positioning of tape 72. Alternatively, holes extending through the base 12 that are separated from the aperture can be used. The holes are large enough to provide easy feed through and can be angled towards the bottom center to provide compression of the artery at lower tension of the cord.
The size of the aperture can be in the range of 1-3 cm in length and 5-15 mm in width. The aperture can be narrower in the center and wider at the opposite ends to accommodate the openings or sections 18a-18d.
Between each pair of sections 18a-18b and 18c-18d, a sidewall section of the aperture, namely tabs 24, 26 extend on opposite ends of aperture 16. The tapes 70, 72 compress respective portions of artery 61 on opposite sides of site 60 against tabs 26, 24. As seen in FIG. 4, those portions 42, 44 of the bottom surface 40 are in contact with artery 61 and compress it. The bottom surface that surrounds the artery and is in contact with the heart wall can be roughened or abraded to frictionally engage the heart wall around the artery and thereby locally restrict heart motion around the surgical site.
In a preferred embodiment of the invention opposite ends 82 and 84 can be positioned under adjacent ribs 54 and 58, respectively. This eliminates any substantial movement of the base 12 while the heart is pumping so that anastomosis 80 of the end 65 onto site 60 can be quickly completed. The opposite ends 82, 84 can be slightly raised relative to the plane of the remainder of the base 12 to provide a concave structure to enhance the frictional engagement of sections 82, 84 to ribs 54, 58, respectively. The platform has a substantially rectangular shape with each side having a length in the range between 3.5 cm and 6 cm. Thus the surface area of the platform is between 12 cm 2 and 25 cm 2 , preferably between 14 cm 2 and 20 cm 2 . This size fits readily in the incision between the ribs and can be positioned with both ends extending under the 3rd and 5th ribs. This structure exerts little downward force on the heart or upward force on the artery while immobilizing the artery at the surgical site. Also the anterior-posterior compression of the artery avoids trauma to the artery due to circumferential compression. By engaging the ribs, the retractor is self retaining providing for easier use and manipulation.
As seen in FIG. 5, the tape 76 under the bottom surface 94 of the tab 24 lifts the artery 60 to form an occlusion 86. This view also shows the optional channel 92 extending around the periphery of base 12 that is used to irrigate or suction around the site.
The fastening mechanism is illustrated in the partial cross-sectional views of FIGS. 6A and 6B. The closed position 110 is illustrated in FIG. 6A where spring 112 has expanded to move slot 116 in element 115 out of alignment with slot 114 in the outer tube. The cord 72 is displace and frictionally grasped by the sliding movement of element 115. The user can manually displace 118 to align slot 114 with slot 116 while compressing spring 112. In the "open" position 120, the cord 72 can be easily removed or pulled through to increase tension.
After the procedure is complete the retractor 10 needs to be removed from the site. In the embodiment of FIG. 1, the base 12 can be formed with two sections or plates 14a, 14b. As seen in FIG. 7, these components can be separated at joint 25 to allow removal of the retractor 10. The two halves 14a, 14b can be connected with a frictional tube section 96.
In the preferred embodiment illustrated in FIG. 8, the retractor 100 can have a plurality of handle attachment sites 102, 104, 106, 108 so that the user can attach the handle 105 at any site to provide the most convenient access to the aperture and facilitate immobilization of other arteries. The handle can alternatively be positioned between the two cords at an orthogonal angle relative to the aperture axis and extending above the top surface of the base.
In another preferred embodiment of the invention illustrated in the perspective view of FIG. 9, a retractor 140 has a handle 142, slots 144 located in the plane of the aperture 160 to secure the cords extending through lateral sections of the aperture (for example, sections 152, 154), end sections 162, 164 that engage the ribs 54, 58, tabs 148, 150 for compression of both sides of the artery at the site 60 and a side opening 146 so that the retractor can be removed.
In this embodiment, the LIMA slides out through opening 146 during removal of the retractor after completion of the procedure. This unitary retractor structure 140 can also include various features described previously in connection with the embodiment of FIG. 1 including the attached or integrated suction tube, the detachable handle, the irrigation or suction channel with ports or the mechanically actuated fasteners.
A preferred method of stabilizing tissue during a coronary bypass procedure 200 is illustrated in the process flow sequence of FIG. 10. A 5-8 cm sized incision is made over the 4th rib and a section of the 4th costal cartilage is removed 202. The LIMA is dissected from the chest wall 204 and divided distally. After blood flow assessment the LIMA can be temporarily closed with a spring loaded clip.
A self-retaining wound retractor is used to distract the edges of the incision and a "trap door" incision is made in the pericardium and the cut edge sewn to the skin to pull the pericardial sack and heart anteriorly. The LAD is exposed and a site suitable for anastomosis is selected for grafting 206. Tapes are inserted in the myocardium with blunt needles approximately 1-2 cm apart 208 and the retractor is inserted 210 with the tapes being pulled through the aperture and positioned in the lateral sections thereof. The tapes are connected to the holder 212 to compress the artery 214 and occlude blood flow on both sides of the grafting site. The tension in the tapes can optionally be adjusted during the procedure to minimize blood loss at the site.
The retractor is secured 216 at the site by positioning one or both ends under adjoining ribs, or alternatively, attaching the handle or arm to the wound retractor or other implement. The grafting site undergoes less than 0.1 mm of movement in any direction during this example procedure.
The site is suctioned or irrigated 218 during anastomosis, the grafting site is inspected, the tapes are released from the holders, and the retractor is removed either by sliding the LIMA through a side opening in the retractor or detaching a section of the retractor to accommodate removal of the LIMA from the aperture. After blood flow is restored, the site is inspected and closed 220.
Although the use of the retractor has been described in connection with a particular bypass procedure, it can also be used in other procedures such as bypass operations involving the diagonal, right or other coronary artery where movement at the site can interfere with the procedure.
Alternative embodiments involve opening of the chest and positioning the retractor at any exposed site on the heart wall or surrounding areas to immobilize the operative site. The retractor serves to isolate the site and limits or stops motion at the site due to respiratory movement of the lungs or the pumping motion of the heart.
EQUIVALENTS
While the invention has been described in connection with specific methods and apparatus, it is to be understood by those skilled in the art that the description is by way of example and not as a limitation on the scope of the invention as set forth in the appended claims.
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The present invention relates to a surgical retractor that immobilizes tissue at a surgical site. A preferred embodiment, of the retractor is used during minimally invasive direct coronary bypass procedures to arrest movement of the grafting site while the heart continues pumping. Tape or thread can be used to connect the artery to the retractor with a holder.
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BACKGROUND OF THE INVENTION
[0001] Fire alarm systems are often installed within commercial, residential, educational, or governmental buildings, to list a few examples. These fire alarm systems typically include control panels and fire detection devices, which monitor the buildings for indicators of fire (e.g., smoke, fire, rises in temperature). Often, the fire detection devices include individually addressable smoke detectors that are part of a networked fire alarm system. The smoke detectors send event data to the control panel, which analyzes the received event data and generates an alarm if smoke is detected by one or more of the smoke detectors.
[0002] In another configuration, the fire alarm system is comprised of standalone or independent smoke detectors. This type of system is often implemented in residential buildings where there is a smaller area to monitor and building code requirements are more lenient. While each detector operates independently from the other detectors of the system, the detectors are often interconnected such that if one detector is activated into an alarm state, then all of the detectors enter the alarm state.
[0003] Two common types of fire detection devices are photoelectric (or optical) smoke detectors and ionization smoke detectors. The optical smoke detectors generally include a baffle system, which defines a detection chamber. The baffle system blocks ambient light from an ambient environment while also allowing air or smoke to flow into the detection chamber. A smoke detection system within the detection chamber detects the presence of smoke. Typically, the smoke detection system includes a chamber light source and a scattered light photodetector. When smoke fills the detection chamber it causes the light from the chamber light source to be scattered within the chamber and detected by the scattered light photodetector. Once a predefined amount of light is received by the scattered light photodetector, an alarm condition is generated. The ionization smoke detectors also typically have a detection chamber containing an ionizing radioisotope to ionize the air in the detection chamber. When smoke fills the detection chamber, the electronics of the smoke detector detect a change caused by the ionization of the smoke. In response to the change in current, an alarm condition is generated. While ionization smoke detectors also include a baffle system to protect the detection chamber, the baffle system is typically designed to prevent moisture from entering the detection chamber because it can affect the accuracy of the smoke detector.
[0004] Currently, building codes often require that the fire detection devices be tested annually. This annual testing is performed because smoke detectors, for example, have a number of different failure points. For example, the electronics and/or optics of the detector can fail. Alternatively, the baffle systems can become dirty and clogged over time. Additionally, it is not uncommon for the smoke detectors to be painted over or for insects or spiders to build nests or webs in the detectors.
[0005] The annual testing for smoke detectors is commonly completed by a technician performing a walkthrough test. The technician walks through the building and manually tests each of the detectors of the fire alarm system. Typically, the technician uses a special testing device. In one example, the testing device includes a smoke generator housed within a hood at the end of a pole. The technician places the hood around the fire detection device and the smoke generator releases artificial smoke near the detector. If the smoke detector is functioning properly, it will trigger in response to the artificial smoke. The technician repeats this process for every smoke detector of the fire alarm system.
[0006] Self-testing fire detection devices have been proposed. In one specific example, a self-test circuit for a smoke detector periodically tests whether the sensitivity of a scattered light photodetector is within a predetermined range of acceptable sensitivities. If the sensitivity of the scattered light photodetector is out of the predetermined range, then a fault indication is produced.
SUMMARY OF THE INVENTION
[0007] The current method for manually testing smoke detectors of a fire alarm system is labor intensive. The technician must walk through the building and manually test each smoke detector of the fire alarm system. This time consuming method is often disruptive to occupants or employees of the building.
[0008] The present device and method are directed to a self-testing fire detection device (e.g., a smoke detector), which includes a smoke source housed within the device. The smoke source is typically a canister or cartridge that stores and/or creates a smoke or smoke equivalent. In response to a signal to initiate the self-test, the smoke source releases the smoke or smoke equivalent in or near a sampling volume of the fire detection device. If the device is operating properly, it will be triggered in response to the smoke or smoke equivalent.
[0009] In general, according to one aspect, the invention features a fire detection device with a self-test capability. The fire detection device includes a smoke detection system for detecting smoke or smoke equivalent in a sampling volume and a smoke source for releasing smoke or smoke equivalent into or near the sampling volume. The device further includes a controller that determines whether the sampling volume is in communication with an ambient environment based on detection of the smoke or smoke equivalent by the smoke detection system.
[0010] Preferably, the smoke source is housed within the fire detection device. Typically, the smoke source is a pressurized canister or cartridge that releases the smoke or smoke equivalent in response to a signal from the controller. Additionally, the pressurized canister includes a valve system that releases a predetermined quantity of the smoke or smoke equivalent into or near the sampling volume. Ideally, the smoke source contains or has the capacity to generate enough smoke to test the detector for the entire rated lifetime of the detector, assuming testing once or twice per year.
[0011] In other examples, the smoke source is another type of source such as a source that creates the smoke via a chemical reaction, for example.
[0012] In one embodiment, the controller is a device controller located in the fire detection device. In an alternative embodiment, the controller is a panel controller located in a control panel. In a typical implementation, the controller indicates that the fire detection device needs cleaning and/or replacement in response to determining that the sampling volume is not in communication with the ambient environment.
[0013] The controller determines a length of time that is required for the smoke or smoke equivalent to flow into the sampling volume and/or a length of time for the smoke or smoke equivalent to flow out of the sampling volume to assess a degree to which the sampling volume is in communication with the ambient environment.
[0014] Alternately, or in addition, the controller calculates a peak amount of smoke or smoke equivalent in the sampling volume to determine a degree to which the sampling volume is in communication with the ambient environment and/or a state of the chamber such as how much dust has accumulated within the chamber.
[0015] In one example, the sampling volume is an internal sampling volume that is located within a detection chamber of the fire detection device. In another example, the sampling volume is an external sampling volume that is located outside of the fire detection device.
[0016] In general, according to another aspect, the invention features a method for performing a self-test of a fire detection device, which comprises releasing smoke or a smoke equivalent into or near a sampling volume. The smoke or a smoke equivalent is stored in or created by a smoke source, which is housed within the fire detection device. The method further includes detecting the smoke or smoke equivalent in the sampling volume and determining whether the sampling volume is in communication with an ambient environment based on detection of the smoke or smoke equivalent.
[0017] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
[0019] FIG. 1A is a block diagram illustrating a fire detection device, which includes a detection chamber, a smoke source, a smoke detection system, and a baffle system.
[0020] FIG. 1B is a cross-sectional view that further illustrates the detection chamber, the smoke source, the smoke detection system, and the baffle system.
[0021] FIG. 2A is a block diagram illustrating an alternative embodiment of the fire detection device, which releases smoke or smoke equivalent directly into the detection chamber of the fire detection device.
[0022] FIG. 2B is a cross-sectional view that further illustrates a smoke source that releases smoke within the detection chamber of the fire detection device.
[0023] FIG. 3 is a block diagram illustrating a chamberless fire detection device that detects smoke in an external sampling volume located outside of the fire detection device.
[0024] FIG. 4 is a block diagram illustrating a networked fire alarm system, which includes a control panel and fire detection devices that communicate over an interconnect.
[0025] FIG. 5 is a block diagram illustrating a standalone or independent fire detection device.
[0026] FIG. 6 is a flowchart illustrating the steps performed by the control panel and fire detection device during a self-test.
[0027] FIG. 7 is a flowchart illustrating the steps performed by the fire detection device when the fire detection device operates independently.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The 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 may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0029] As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Further, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms: includes, comprises, including 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. Further, it will be understood that when an element, including component or subsystem, is referred to and/or shown as being connected or coupled to another element, it can be directly connected or coupled to the other element or intervening elements may be present.
[0030] FIG. 1A is a block diagram illustrating a fire detection device 108 , which includes a detection chamber 214 , a smoke source 206 , a smoke detection system 210 , a baffle system 208 , and a device controller 204 .
[0031] In a typical implementation, the fire detection device 108 includes a housing or body, which is comprised of a base unit 110 and a head unit 112 . These components are typically made from molded plastic. Typically, the head unit 112 connects to the base unit 110 , which is fastened to a wall or ceiling of a building.
[0032] The base unit includes a device interconnect interface 202 , which enables the fire detection device 108 to communicate via a safety and security interconnect 116 . Generally, the safety and security interconnect 116 supports data and/or analog communication between the device 108 and a control panel.
[0033] The head unit 112 generally houses the device controller 204 , the smoke detection system 210 , and the smoke source 206 . The device controller 204 receives information from the smoke detection system 210 and generates analog values based levels of smoke or smoke equivalent 216 detected by the smoke detection system 210 . Additionally, in response to a signal received from the control panel, the device controller 204 sends a signal to the smoke source 206 to release smoke 216 .
[0034] Upon receiving the signal from the device controller 204 , a valve or valve system of the smoke source is actuated to release the smoke or smoke equivalent. In a typical implementation, the value system is electronically and/or pneumatically actuated. The smoke or smoke equivalent 216 is typically an artificial or synthetic smoke that mimics the optical and/or electrical properties of real smoke, but is not harmful to occupants.
[0035] In the illustrated example, one or more conduits 209 connect to the smoke source 206 and convey the smoke or smoke equivalent to ports 207 - 1 to 207 - n arranged about the perimeter of the baffle system 208 . Preferably, the ports 207 - 1 to 207 - n direct the smoke toward the baffle system 208 and detection chamber 214 . In the illustrated example, the head unit 112 further includes a ridge 113 , which is installed about the perimeter of the head unit 112 to prevent the smoke or smoke equivalent 216 from flowing away from the fire detection device 108 .
[0036] The baffle system 208 defines the detection chamber 214 , which houses the sampling volume 212 . Additionally, the baffle system 208 blocks out ambient light from the ambient environment while allowing air and smoke to flow to the sampling volume 212 .
[0037] The smoke detection system 210 detects the smoke or smoke equivalent 216 in the sampling volume 212 . In one embodiment, the smoke detection system 210 is an optical detection system, but alternative embodiments could implement ionization or air sampling detection systems, for example. In any event, the system is able to determine whether the detection chamber and specifically the sampling volume is in communication with an ambient environment based on detection of the smoke or smoke equivalent by the smoke detection system after the release of the smoke or smoke equivalent.
[0038] FIG. 1B is a cross-sectional view that illustrates the detection chamber, the smoke detection system, and the baffle system of one embodiment of the fire detection device.
[0039] In this embodiment, the detection chamber 214 is defined by individual baffles 230 - 1 to 230 - n . The arrangement of the baffles 230 - 1 to 230 - n form pathways 234 - 1 to 234 - n that allow air and possibly environmental smoke but also the smoke or smoke equivalent 216 to flow into the detection chamber 214 . The baffles are also commonly referred to as channels, vanes, walls, or labyrinths, to list a few examples.
[0040] In the illustrated example, the smoke source 206 is connected to the ports 207 - 1 to 107 - n via the conduits 209 . While the illustrated example shows six ports, alternative embodiments could implement greater or fewer numbers of ports. In a typical implementation, the ports 207 - 1 to 207 - n are installed around the perimeter of the baffle system to create an even distribution of the smoke or smoke equivalent 216 about the baffle system.
[0041] The smoke detection system 210 detects the presence of smoke within the sampling volume 212 of the detection chamber 214 . In the illustrated example, the smoke detection system 210 comprises a chamber light source 222 for generating light 223 and a scattered light photodetector 220 for detecting light that has been scattered due to the smoke or smoke equivalent collecting within the detection chamber 214 . Light 223 is directed into the detection chamber 214 through an aperture 224 . If smoke is present in the detection chamber 214 , the light 223 is scattered by the smoke or smoke equivalent and detected by the scattered light photodetector 220 . A blocking baffle 226 is installed within the detection chamber 214 to prevent the light 223 from having a direct path to the scattered light photodetector 220 . Thus, in this way, the signal detected by the photodetector is indicative of the concentration of an optically scattering medium, such as smoke, within the sampling volume.
[0042] FIGS. 2A and 2B illustrate an alternative embodiment of the fire detection device 108 . In this embodiment, the smoke or smoke equivalent is released directly into the detection chamber 214 of the fire detection device 108 .
[0043] In general, FIG. 2A is nearly identical to the embodiment described with respect to FIG. 1A . In this embodiment, however, the conduit 209 is routed from the smoke source 206 to the detection chamber 214 to release the smoke or smoke equivalent 216 directly into the sampling volume 212 of the detection chamber 214 .
[0044] In one mode of operation, rather than detecting the smoke or smoke equivalent and it flows into the detection chamber 214 , the smoke detection system 210 and device controller 204 determine if the smoke or smoke equivalent 216 is able to flow out of the detection chamber 214 to thereby assess the degree to which the chamber 214 is in communication with an ambient environment.
[0045] FIG. 2B is a cross-sectional view that further illustrates how the smoke source 206 releases the smoke or smoke equivalent into the sampling volume 212 of the detection chamber 214 .
[0046] In the illustrated example, the smoke or smoke equivalent is released out of the port 207 , which is located in the detection chamber 214 . If the baffle system is free from obstructions, then the smoke is able to flow out of the pathways.
[0047] FIG. 3 is a block diagram illustrating a “chamberless” fire detection device that detects smoke or smoke equivalent 216 in an external sampling volume 213 located outside of the fire detection device 108 .
[0048] Unlike the previous embodiments that implemented baffle systems and included a detection chamber, the smoke detection system 210 of illustrated embodiment monitors an external sampling volume 213 that is located outside of the fire detection device.
[0049] In a typical implementation, the light source and photodetector of the smoke detection system 210 are installed within the head unit 112 of the fire detection device 108 . Light from a light source is projected into the external sampling volume 213 . If smoke is present in the external sampling volume 213 , the light will be scattered and detected by a photodetector within the head unit 112 .
[0050] As in the previous embodiments, the smoke source 206 is provided within the housing to release the smoke or smoke equivalent near the sampling volume 213 via ports 207 . In one example, the ports are arranged around the sampling volume 213 on the underside of the head 112 .
[0051] FIG. 4 is a block diagram illustrating a fire alarm system 100 , which includes the control panel 102 , fire detection devices 108 - 1 to 108 - n , and an interconnect 116 .
[0052] Typically, the fire alarm system 100 is installed within a building 50 . Some examples of buildings include hospitals, warehouses, retail establishments, malls, schools, or casinos, to list a few examples. While not shown in the illustrated example, the fire alarm system typically includes other fire detection or annunciation devices such as carbon monoxide or carbon dioxide detectors, temperature sensors, pull stations, speakers/horns, and strobes, to list a few examples.
[0053] The control panel 102 includes a panel interconnect interface 117 , which enables the control panel 102 to communicate with the fire detection devices 108 - 1 to 108 - n via the safety and security interconnect 116 . The control panel 102 receives event data from the fire detection devices 108 - 1 to 108 - n of the alarm system 100 . Typically, the event data include a physical address of the activated device, a date and time of the activation, and at least one analog value directed to smoke levels or ambient temperature detected by the fire detection device.
[0054] While the self-test is typically initiated by a technician 106 , the self-test may also be initiated by the control panel 102 . In this case, the self-test instructions are stored in panel memory 120 . Upon receiving a test signal, the devices 108 - 1 to 108 - n initiate self-tests. The devices generate event data, which are sent to the control panel 102 via the safety and security interconnect 116 .
[0055] The event data are then stored in the panel memory 120 and/or a database 122 of the control panel 102 . Additionally, the event data are also sent to a testing computer 104 , where the event data are stored in a log file. A technician 106 is then able to review the log file and/or generate reports, for example. In this way, the panel controller is able to assess the results of the self test and determine whether the sampling volumes of the devices are in communication with their respective ambient environments based on detection of the smoke or smoke equivalent by the smoke detection systems.
[0056] FIG. 5 is a block diagram illustrating the head unit 112 of a standalone fire detection device 108 . That is, the device operates independently from other fire detection devices and independently determines when to initiate the self-test. Alternatively, the fire detection device may include a test button, which enables the technician 106 to initiate the self-test of the device.
[0057] Periodically, the device controller 204 accesses self-test instructions stored in the device memory 205 to initiate the self-test. Rather than sending the event data to the control panel 102 , the device controller 204 determines whether the sampling volume 212 is in communication with an ambient environment based on detection of the smoke or smoke equivalent by the smoke detection system 210 .
[0058] FIG. 6 is a flowchart illustrating an example in which the control panel 102 initiates the self-test of the fire detection devices.
[0059] In the first step 602 , the control panel 102 is put into test mode. Typically, the test mode silences and/or deactivates any audio and visual alarms/warnings of the fire detection devices during the test.
[0060] In the next step 604 , the technician 106 (or control panel) selects one or more fire detection devices to test. Next, the control panel 102 sends a test signal to the selected fire detection devices in step 606 .
[0061] The selected fire detection devices receive the test signal and actuate valve systems of smoke sources or otherwise generate the smoke or smoke equivalent, such as via a chemical reaction, in step 608 . The smoke sources release the smoke or smoke equivalent near the baffle systems, into the detection chambers, or into external sampling volumes of the fire detection devices in step 610 .
[0062] The smoke or smoke equivalent is detected by the smoke detection system and the panel controller determines properties of the smoke or smoke equivalent, such as its density within the sampling volume, to assess a degree to which the sampling volume is in communication with the ambient environment in step 612 . In one example, the panel controller determines a length of time for the smoke or smoke equivalent to flow into the sampling volume and/or a length of time for the smoke or smoke equivalent to flow out of the sampling volume. In an alternative embodiment, the panel controller determines an amount, as a peak amount, of smoke or smoke equivalent that is detected within the sampling volume in order to assess a degree to which the chamber, for example, is filled with dust.
[0063] In the next step 614 , the panel controller 118 determines a degree of obstruction based on the measured smoke properties of the current test and the smoke properties measured in previous self-tests or as part of an original factory calibration.
[0064] Next, the panel controller determines if the baffle system is obstructed in step 616 based on this analysis.
[0065] If the baffle system is obstructed, then the panel controller 118 generates an alert for cleaning/replacement of fire detection device in step 620 . If, however, the baffle system is not obstructed, then the panel controller indicates that the fire detection device is free from obstructions in step 618 . The results of the test are then logged at the testing computer 104 in step 622 . Alternatively, the test results may also be stored in the panel memory 120 of the control panel 102 . In this scenario, the control panel 102 would store the results of the recent tests to enable the technician, a fire inspector, or a building manager to access the previous test results.
[0066] If there are no additional fire detection devices to test (step 624 ), then a report is generated in step 626 . If additional fire detection devices need to be tested, then one or more fire detection devices are selected in step 604 .
[0067] FIG. 7 is a flowchart illustrating an example in which the fire detection devices operate independently and self-initiate the tests.
[0068] In the first step 702 , the fire detection device initiates a self-test. The fire detection device then actuates electronically controlled valves of smoke sources or triggers a chemical reaction to generate the smoke or smoke equivalent in step 704 . Next, the smoke source releases the smoke or smoke equivalent near the baffle systems, into the detection chambers, or into external sampling volumes of the fire detection devices in step 706 .
[0069] The smoke or smoke equivalent is detected by the smoke detection system and the device controller determines properties of the smoke or smoke equivalent to assess a degree to which the sampling volume is in communication with the ambient environment in step 708 .
[0070] In the next step 710 , the device controller 118 determines a degree of obstruction based on the measured smoke properties and the smoke properties measured in previous self-tests. Next, the device controller determines if the baffle system is obstructed in step 712 .
[0071] If the baffle system is obstructed, then the panel controller generates an alert for cleaning/replacement of fire detection device in step 716 . If, however, the baffle system is not obstructed, then the fire detection device indicates that the fire detection device is free from obstructions in step 714 .
[0072] In the next step 718 , the fire detection device sends the results of the test to any control panel, activates a trouble light, and/or generates audible alerts.
[0073] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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A device and method for self-testing fire detection devices that includes a smoke source housed within the fire detection device. The smoke source is typically a pressurized canister or cartridge, which stores or generates smoke or a smoke equivalent. In response to a signal from a controller, the smoke source releases the smoke or smoke equivalent in or near a sampling volume of the fire detection device to test the operation of the fire detection device. If the device is operating properly, it will be triggered in response to the smoke or a smoke equivalent.
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This is a division, of application Ser. No. 845,767 filed Oct. 26, 1977, now U.S. Pat. No. 4,208,248.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fuel assemblies for use in nuclear reactors and, more particulary, to locking techniques for the end fittings and control rod guide tubes in a nuclear fuel assembly, and the like.
2. Description of the Prior Art
To produce useful power from a nuclear reactor it is necessary to assemble fissionable material in a concentration that is sufficient to sustain a continuous sequence of neutron-induced fissions. Frequently, this concentration is attained by sealing uranium dioxide pellets in long, slender hollow rods. These rods, when filled with a charge of nuclear fuel and sealed at the ends, are called "fuel rods."
The fuel rods are arranged in a generally cylindrical array, or reactor core, to form the required concentration of fissionable material. In order to extract the heat generated in these fuel rods through the fission process, the fuel rods usually are spaced laterally from each other and water is pumped under pressure through the reactor core. The water absorbs the fission process heat and transfers this heat to secondary cooling water. The secondary cooling water rises into steam that is used to drive power generating turbine machinery.
In the reactor core, the radiation, pressures, temperatures and cooling water flow velocities create an environment that is quite hostile to the structural integrity of the reactor core. To cope with this environment, it has been customary to arrange the fuel rods that comprise the reactor core into a number of groups each of about two hundred fuel rods. These groups are frequently called fuel assemblies.
To enhance the structural integrity of each of the fuel assemblies and to stabilize the fuel rods in the assembly, it is common to mount the fuel rods between "end fittings" and to engage the mid-portions of each of the rods in the fuel assembly by means of cellular grid structures that are positioned at predetermined intervals along the lengths of the rods.
The structure of the fuel assembly, moreover, is not restricted to fuel rods, end fittings and grids. As a general rule one or more control rod guide tubes also are accommodated in the usual fuel assembly. Typically, to control the power generated in a nuclear reactor it is customary to add neutron absorbing materials to the reactor core. These materials have the effect of decreasing the fission activity within the core and thereby decreasing the power output from the reactor. As might be expected, there are a number of ways in which these neutron absorbing materials are introduced into the reactor core. Quite frequently, for example, the neutron absorbing materials are loaded into control rods. These control rods are received in hollow metal control rod guide tubes that extend through the length of the respective fuel element. In these circumstances, the depth of the penetration of the control rods into the associated fuel element determines, to some extent, the level of neutron fission activity and associated power output from the reactor core.
Some fuel assembly designs have a further use for the control rod guide tubes beyond aligning the individual control rods within the respective fuel assembly. Typically in this regard, the control rod guide tubes are often used to space the two end fittings from each other and, essentially, to clamp the fuel rods in proper relative position between these end fittings through enabling the end fittings to engage the extreme ends of the fuel rods.
This foregoing fuel assembly construction produces a rugged, sturdy structure that is able to cope with the forces that characterize a reactor core environment. There is, however, a somewhat countervailing need to provide a fuel assembly structure that can be assembled and dismantled with ease in order to reduce manufacturing costs, improve quality assurance and facilitate inspection and replacement. If it is realized that fuel assemblies, once having been made radioactive, must subsequently be manipulated behind shielding with remote handling equipment, the importance of the need for simple disassembly techniques becomes immediately apparent.
In this respect, the typical fuel element is dismounted by unthreading nuts that connect the control rod guide tubes to the end fittings, releasing one or more springs and, in general, taking the entire fuel assembly apart piece-by-piece. Not only is this a very laborious and expensive practice but it also introduces the possibility that one or more of the smaller fittings might go astray, leading to further lost time and expense, or damge if not discovered.
Thus, there is a clear need for an improved fuel assembly that will, to a large extent, overcome many of these inadequacies that have characterized the prior art.
SUMMARY OF THE INVENTION
An improved fuel assembly in accordance with the principles of the invention is characterized by a sleeve that engages one end of a control rod guide tube, essentially fixing the guide tube to one of the fuel assembly end structures. An end of the sleeve protrudes above the surface of the end fitting. The outer surface of the sleeve has a peripheral groove that engages the resilient sides of a cellular grid or lattice shaped lock. This lock fixes the sleeve in position between the various elements that comprise the end fitting, thereby eliminating a profusion of costly and potentially troublesome nuts, threaded studs and the like that frequently are employed in the fuel assemblies that are typical of the prior art.
To dismount the end fitting from the fuel assembly in accordance with the principles of the invention, a special grapple has jaws that engage a portion of the end fitting. The jaws first clamps the upper grill that supports the ends of the control rod guide tubes and their respective sleeves. The spider which engages the control rod guide tube sleeves then is pressed against the springs that circumscribe these sleeves in order to establish some degree of longitudinal clearance between the spider and the lock mechanism. After this clearance is established individual tools are pressed into the respective open, protruding ends of each of the sleeves to engage exposed portions of the grid-shaped lock. The tools press these sides out of the groove, so engage the lock that the lock will be withdrawn from the sleeve when the grapple is withdrawn from the end of the fuel assembly. This permits the upper end fitting to be removed as a unit that captures the components which are associated with the end fitting as an assembled unit, while leaving the control rod guide tubes and the associated sleeves with the balance of the fuel assembly. In this way, end fitting components that are captured by the grapple in this manner subsequently can be replaced intact on the fuel assembly structure without indulging in the cumbersome and expensive remote manipulator detailed disassembly and assembly of scores of small parts that has characterized the prior art.
Thus, the invention provides techniques for reducing the number of parts required for fuel assembly construction, reduces manufacturing costs and simplifies quality assurance and inspection problems.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawing and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front elevation in part section of a typical fuel assembly that embodies principles of the invention;
FIG. 2 is a front elevation in full section of a control rod guide tube structure for use in connection with the structure that is shown in FIG. 1;
FIG. 3 is a plan view in partial section of the control rod guide tube structure that is shown in FIG. 2 taken along the line 3--3 of FIG. 2.
FIG. 4 is a front elevation of a grapple and tool engaging a portion of the fuel assembly that is shown in FIG. 1;
FIG. 5 is a plan view in broken section of the grapple that is shown in FIG. 4;
FIG. 6 is a schematic drawing of a portion of the grapple in an initial opertional position;
FIG. 7 is a schematic drawing of a portion of the grapple in another operational position;
FIG. 8 is a schematic drawing of a portion of the grapple in still another operational position; and
FIG. 9 is a schematic drawing of a portion of the grapple after the lock has been disengaged.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, an illustrative fuel assembly 10 comprises an array of more than two hundred fuel rods 11. It will be recalled in this respect, that the fuel rods 11 are made from long, slender, thin-walled tubes that enclose pellets of uranium dioxide or other suitable nuclear fuel, and that these fuel rods are grouped together within the fuel assembly 10 with the longitudinal axes of the fuel rods in general parallel alignment. Control rod guide tubes 12 are nested within the fuel assembly 11 amongst and in parallel with the fuel rods. The control rod guide tubes 12 each are hollow, thin-walled tubes that extend through the entire fuel assembly 10 parallel to the longitudinal axis of the fuel assembly.
A lower end support fitting 13 that is transversely disposed relative to the longitudinal axes of the fuel rods 11 engages the abutting ends of the fuel rods. As described subsequently in more complete detail, the control rod guide tubes 12 pass through the end fitting 13 in order to secure the end fitting to the fuel assembly structure.
Ends of the control rod guide tubes 12 protrude above the place established by the sealed ends of the fuel rods 11. These protruding ends of the control rod guide tubes 12 terminate, as shown in FIG. 2, within the confines of a transversely disposed grill 14. The grill 14 is assembled from a parallel array of generally flat, slotted plates that are meshed with mating slots in a perpendicular array of essentially flat plates in order to form a cellular grill structure. The parallel grouping of the fuel rods 11 and the control rod guide tubes 12 is established and stabilized by means of transversely disposed grid structures 15, similar in construction to the grill 14 described above and through which the fuel rods and guide extend. Toward the ends of the fuel rods 11 that are close to the protruding portions of the control rod guide tubes, however, a transversely disposed upper grid 16 is positioned. The upper grid 16 has a somewhat greater depth in the direction of the longitudinal axes of the fuel rods 11 than the grid structures 15 in order to enhance the structural integrity of this portion of the fuel assembly.
In accordance with a feature of the invention a parallel array of hollow cylindrical sleeves 17 telescope over the respective protruding ends of the control rod guide tubes 12 in order to extend from within the confines of the upper grid 16 through the grill 14, through a transversely disposed spider 20 and an immediately superjacent control rod guide tube assembly lock 21. Spring means, such as individual coil springs 22, each associated with a respective one of the sleeves 17 are interposed in a biasing relationship between the grill 14 and the spider 20 in order to provide some means for compensating and absorbing movement of the fuel element 10 in the direction of the longitudinal axes of the fuel rods 11. Note that in the illustrative embodiment of the invention shown in FIG. 2 that the sleeve 17 is in general axial alignment with the guide tube 12, and that the sleeve serves as a guide for the coil spring 22. The coil spring 22, moreover, also has a longitudinal axis that generally coincides with the longitudinal axis of the guide tube 12.
Attention is invited to FIG. 2 for a more detailed appreciation of the novel features of this invention that characterize the invention. More particularly, the control rod guide tube 12 is secured to a lower grid 23 by means of a bolt structure 24. The bolt structure 24 has a head 25 that is received within the adjacent open end of the control rod guide tube 12. A bolt shank 26 extends through the lower grid 23 in order to protrude from the end support fitting 13. The protruding portion of the shank 26 is threaded in order to receive a fastening nut 27. A nut retainer 30 is interposed between the end fitting and the nut 27 in order to prevent the nut from working loose and becoming disengaged from the fuel assembly.
As shown in FIG. 2, the control rod guide tube 12 extends through the main portion of the fuel assembly and through an upper grid 16. Within the upper grid 16 the guide tube 12 is telescoped within the sleeve 17, open end portion 31 of the control rod guide tube 12 abutting and bearing against a flange or shoulder 32 that is formed within the inner surface of the sleeve 17. The shoulder 32 in the sleeve 17 transfers compression loads directly to the guide tube in the manner described subsequently in more complete detail.
Through the lengths of the control rod guide tube 12 and the sleeve 17 that are coextensive protrusions or "dimples" 33 are swaged or otherwise suitably formed in the control rod guide tube 12 and the sleeve 17 in order to hold the sleeve and the guide tube together and form a tight joint. Immediately below the grill 14, circumscribing a portion of the sleeve 17 and bearing against a transverse surface of the grill 14 is a ring shaped collar 34. As shown, the collar 34 and the encircled portions of the sleeve 17 and the control rod guide tube 12 also are provided with protrusions or dimples 35, 36 that have been swaged or otherwise formed in the materials in order to position the collar 34 properly relative to the balance of the fuel assembly structure and to permit the collar to sustain loads imposed in the directon of control rod guide tube longitudinal axis 37 and to transfer these loads between the grill 14 and the combination sleeve 17 and control rod guide tube 12.
A washer 40 rests upon the transverse surface of the grill 14 that is opposite from the transverse grill surface that engages the collar 34. The coil spring 22 as illustrated in FIG. 2, is mounted on the washer 40 and encloses a portion of the sleeve 17 that protrudes above the grill 14. The longitudinal axis of the coil spring 22 generally coincides with the longitudinal axis 37 in order to press against a further washer 41. Thus, the coil spring 22 interposed between the grill 14 and the spider assembly 20, respectively biases the grill and spider assembly against the collar 34 and the lock 21.
Illustratively, the washer 41 is in engagement with the cellular spider assembly 20. As shown, the sleeve 17 is received within a cellular recess 42 in the spider 20 with sufficient clearance between the sleeve and the walls of the spider recess 42 to permit the spider and the sleeve to move relative to each other in the direction of the longitudinal axis 37.
A terminal portion 43 of the sleeve 17 protrudes above the spider 20 in order to engage the lock 21. To engage the lock 21, the outer surface of the portion 43 is provided with a circumferential groove 44 that forms a protruding shoulder 45 which serves to engage edges of the lock 21. Perhaps, as best shown in FIG. 3, the lock 21 is assembled from an array of resilient parallel plates 46, 47 that are meshed and interlock with similarly resilient plates 50, 51 that are generally perpendicular to the plates 46, 47 at the respective lines of intersection to form a cellular grid structure. As shown, the separation between the parallel plates 46, 47 is less than the maximum outside diameter of the groove 44 that is formed in the portion 43.
The plate 50 has a generally arcuate shape that conforms to and bears against a segment of the grooved surface of the terminal sleeve portion 43. The companion plate 51, however, has a plane profile that permits part of an edge of this plate to engage the shoulder 45 (FIG. 2). In this manner, all of the control rod guide tubes 12 that are shown in FIG. 1 are locked together as a single unit.
Best shown in FIGS. 2 and 3, the terminal sleeve portion 43 is provided with four longitudinal slots 52, 53, 54 and 55 that are parallel with the longitudinal axis 37. The slots 52, 53, 54 and 55 each are spaced from the next adjacent slots by about 90° and penetrate the portion 43 to a depth that is at least equal to the combined longitudinal depth of the shoulder 45 and the width of the plates 50, 51.
In accordance with an additional feature of the invention a grapple 56 is shown in FIG. 4. The grapple 56 releases the lock 21 from the control rod guide the sleeves 17 and also provides a means for installing or removing as one entire unit the complete assembly that comprises the lock 21, the washers 40, 41 the spider 20, the coil springs 22 and the grill 14. To accomplish these results, the grapple 56 is provided with a member 57 that is movable in the direction of longitudinal axis 60. A transversely disposed linkage 61 is secured through a cross piece 62 (FIG. 5) to the vertically movable member 57. The end portions of the linkage 61 (FIG. 4) have slots 63, 64 which receive respective pins 65, 66. The pins 65, 66 are transversely movable within the respective slots in order to enable two jaws 67, 70 that are pivotally connected to a transversely disposed tool frame 17 to move in a scissors-like manner. Thus, pivot 72 joins the jaw 70 to the tool frame 71.
As shown in FIG. 4 the jaw 70 is provided at its extreme end with a clamp 73 that engages a longitudinal edge of the grill 14. In a similar manner, the extreme end of the jaw 67 also is provided with a clamp 74 that is oppositely disposed from the clamp 73 on the jaw 70.
Perhaps best shown in FIG. 4, a companion linkage 75 with pinned and pivoted jaws 76, 77 also are joined by means of the cross piece 62 to the longitudinally movable member 57. This companion structure matches and balances the structural arrangement described above with respect to the jaws 67, 70.
The transversely disposed tool frame 71 also is provided with an array of longitudinally alinged apertures 80 that each accommodate one of a group of tools 81. As illustrated in FIG. 4, the tools 81 are formed from generally cylindrical rods that are longitudinally aligned with the axis 60. Each of the tools 81 has a generally conical end portion 82. The mid-section of the tool 81 has four fins 83, of which only three of these fins are shown in the plane of the drawing. As illustrated, each of the fins are spaced about 90° from the next adjacent fins.
Each of the fins 83 has a tapered slope 84 in which the narrow edge of the slope is oriented toward the end portion 82. The tapered slope 84 ends in a generally flat surface 85. The width of each of the fins 83 is slightly less than the transverse width of the individual slots 52, 53, 54, 55 (FIGS. 2 and 3). The transverse depth of each of these fins, however, between the flat surface 85 (FIG. 4) and the adjacent surface of the tool 81 is greater than the corresponding wall thickeness of the terminal sleeve portion 43 as shown in FIGS. 2 and 3.
An annular collar 86 is secured to the tool 81 and spaced longitudinally from the flat surfaces 85 on the fins 83 a sufficient distance to enable the fins when aligned with the respective slots in the terminal sleeve portion 43 to bear against the terminal portion and prevent the flat surfaces 85 of the fins 83 from penetrating the sleeve 17 to a depth greater than the longitudinal protrusion of the slots in the terminal sleeve portion 43 (FIG. 2) above the spider 20.
As illustrated in FIG. 4, the tool 81 has been threaded 87 at the end opposite from the end portion 82 to enable nuts 90, 91 to secure the tool 81 to a transversely disposed plate 92 that is movable in longitudinal directions as indicated by means of arrows 93, 94 under the control of spring biased pneumatic cylinders 95, 96. Thus, depending on the relative activation of the pneumatic cylinders 95, 96, the tools 81, when aligned with respective terminal sleeve portions 43 are driven into the sleeves 17 to a sufficient depth to permit the flat surfaces 85 on the fins 83 to bear against the plates 46, 47 50, 51 (FIGS. 2 and 3). The flat surfaces 83 press these plates in a radially outward direction relative to the longitudinal axis 37 through a distance that is sufficient to permit all of the plates to clear the shoulder 45 that is formed in the terminal sleeve portion 43. In this manner the entire cellular lock 21 is released from its engagement with the sleeves 17 and fixes itself temporarily to the tools 81 in the array of tools.
In operation, and, as perhaps best understood through an examination of FIG. 6 the grapple 56 is aligned with the end fitting to permit the clamps 73 on the jaw 70 (as well as the clamps 74 on the jaws 67, and the clamps on the jaws 76, 77 on the grapple that are not shown in FIG. 6) to be spaced outwardly of the grill 14, but within the same transverse plane as the grill.
During this phase of the operation of the grapple 56, the springs associated with the spring loaded pins 97 are compressed through activation of the air cylinder 95 which moves the plate 92 in the direction of the arrow 93.
As illustrated in FIG. 7, the clamps 73, 74 on the jaws 70, 67, respectively, (as well as the changes on the comparison pair of jaws 76, 77) swing inwardly in the directions indicated by arrows 101, 102 in order to grasp firmly peripheral portions of the grill 14. This inwardly swinging movement of the clamps 73, 74 is achieved through longitudinal movement of the member 57 in the direction of arrow 103. This movement of the member 57, causes the pins 65, 66 to ride within the respective slots 63, 64 toward the longitudinal axis 60. The motion of these pins within the slots compels the jaws 67, 70 to pivot counterclockwise and clockwise, respectively, about the pivot 72 (for the jaw 70) and a similar pivot (not shown in FIG. 7) for the jaw 67.
The next illustrative step in the technique for dismounting the end fitting from the balance of the fuel assembly is shown in FIG. 8. Thus, air cylinders 96 are activated to drive piston rods 104 in the longitudinal directions indicated by means of arrow 105. The exposed ends of the piston rods 104 bear against the adjacent transverse surface of the spider 20. The force applied by the piston rods 104 to the spider 20 overcomes the oppositely directed forces established by means of the coil springs that are received on the sleeves, of which the coil spring 22 and the sleeve 17 in FIG. 8 are illustrative. In response to this new balance of forces the spider 20 also moves in the longitudinal direction of the arrow 105 in order to provide a longitudinal clearance 106 between the spider 20 and the lock 21 to relieve the force that the spider 20 applies to the lock 21.
In a typical embodiment of the invention, the next step, in the technique involves movement of the grapple 56 that is best illustrated in FIG. 9. Recall for a moment that the cellular structure of the lock 21 is so designed that the groove 44 (FIG. 2) and the shoulder 45 that is formed in the terminal sleeve portion 43 engage the plates 46, 47, 50, 51 (FIG. 3) that comprise the structure of the cells in the lock 21.
Turning now once more to FIG. 9, the air cylinders 95 are deactivated to enable the coiled springs on the spring loaded pins 97 to release and press the plate 92 in a longitudinal direction as indicated by an arrow 107. Because the recess and shoulders on the sleeves restrain the lock 21 from engaging in any longitudinal movement in the direction of the arrow 107, the tools that are fastened to the plate 92, of which the tools 81 is typical, are pressed through the individual cells in the locks 21 into the respective sleeves 17. The fins 83 that protrude radially from the tools 81 also are driven into mating slots 52, 53, 54, 55 (FIGS. 2 and 3). This longitudinal movement of the tools 81 permits the tapered slope 84 of the pins 83 (FIG. 9) to press the plates 46, 47, 50, 51 on the lock 21 in a radially outward direction in order to disengage these plates from the nested engagement within the annular groove 44 (FIGS. 2 and 3) that is formed in the terminal sleeve portion 43.
In those circumstances, further longitudinal movement of the tools 81 (FIG. 9) in the direction of the arrow 17 under the force of the released springs on the pins 97 is limited only by the braking action of the collars 86 on each of the tools. The collar 86 is so spaced relative to the lock 21 that the plates which form each of the cells in the lock 21 are forced onto the corresponding flat surface 85 of the fins 83. The effect of this engagement between the plates that form the cells on the lock 21 and the flat surfaces 85 of the fins 83 is to press the plates out of engagement with the respective annular grooves 44 (FIGS. 2 and 3) and shoulders 45.
In the next illustrative disassembly step, the entire grapple 56 is moved longitudinally in the direction of arrow 108. The grapple, withdrawn from the balance of the fuel assembly in the foregoing manner, takes with it most of the end fitting components in their proper relative position. Typically, the lock 21, the spider 20, and the grill 14 remain with the grapple 56. The coil springs 22 with their associated washers 40, 41 (FIG. 2) also are drawn away with the grapple 56 (FIG. 9). In this instance, the tools 81 serve as temporary spring guides or keepers for the coil springs 22 and the washers. The springs 22, moreover, serve to keep an approximately proper longitudinal separation between the grill 14 and the spider 20. Note in this respect that the sleeves 17 remain with the balance of the fuel assembly.
To reassemble the end fitting components on the main portion of the fuel assembly, the end portion 82 of the tools 81 on the grapple 56 are longitudinally aligned with their respective sleeves. The grapple 56 then is moved longitudinally in the direction of the arrow 107 until each of the tools 81 are fully seated in the respective sleeves 17. One or more clamps (not shown in the drawing) hold the lock 21 in suitable position relative to the grooves 44, (FIGS. 2 and 3) and shoulders 45 on the terminal sleeve portion 43. In this condition the air cylinders 95 (FIG. 9) are activated to compress the springs on the spring loaded pins 97, thereby extracting the pins 83 from engagement with the plates that form the cells in the lock 21. The disengagement of the tools 81 and the lock 21 permits the plates that form each of the lock's cells to snap back into the annular recesses 44 (FIGS. 2 and 3) and shoulders 45 in the terminal sleeve portion 43.
The spider 20 (FIG. 9) under the action of the coil springs 22 bears against the adjacent surface of the lock 21. The member 57, moreover, is moved longitudinally in the direction of the arrow 107 to permit the jaws 67, 70 to pivot in clockwise and counter-clockwise directions, respectively. This pivoting movement of the jaws 67, 70 releases the grip that the clamps 73, 74 had on the grill 14. The further clamps (not shown in the drawing) that engage the lock 21 also are removed.
The entire fitting now is reassembled on the balance of the fuel assembly in a manner that clearly avoids the prior art requirement for tedious, detailed, piece-by-piece disassembly and reassembly. This technique that characterizes the invention also avoids the hazards that might attend the loss of one of these small end fitting components, and the like.
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A typical embodiment of the invention provides a nuclear fuel assembly lock structure for control rod guide tubes. Illustratively, a sleeve telescopes over an end portion of a control rod guide tube which bears against an internal shoulder of the tube. The upper end of the sleeve protudes beyond the control rod guide tube spider and is locked in place by means of a resilient cellular lattice or lock that is seated in a mating groove in the outer surface of the sleeve. A special tool is provided for disengaging the entire lock structure, washer, spider, spring and grill from the end of the fuel assembly in order to enable these components to be removed in an assembled state and subsequently replaced on the fuel assembly after inspection and repair.
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BACKGROUND OF THE INVENTION
This invention relates to a sensor element for detecting trace amounts of gaseous oxidizable substances such as alcohols, aldehydes, hydrocarbons, carboxylic acids, amines, carbon monoxide, and hydrogen contained in the atmosphere, exhaust gases and the breath and a method for detecting the oxidizable gas.
For detecting the above-noted gaseous substances in the atmosphere, an exhaust gas, the breath, etc., there have hitherto been known various methods such as gas chromatography, chemical analysis, and nondispersive infrared absorption spectroscopy. These detecting methods, however, have such disadvantages as complexity of the device, requirement of skill for the analytical procedure, lack of instantaneousness owing to the time-consuming procedure, unsuitableness for a sample gas rapidly changing in composition owing to long intervals between samplings, and expensiveness of the device.
On the other hand, among devices which make use of a semiconductor as the sensing element, there has been known an ethanol sensor comprising n-type tin oxide. This element is evaluatd as having been improved to some degree in the above-said disadvantages. However, when the said substance is used in detecting ethanol, the ethanol is adsorbed on the semiconductor surface. Consequently, although the element is effective for the first sensing operation, it is unsuitable for a continuous use. In case it is to be used repeatedly, it must be heated each time at a temperature of 350° C. or higher to desorb the ethanol. The element has additional disadvantages in that it is incapable of quantitative sensing because of failure in responding proportionally to the ethanol concentration and that in order to compensate a large temperature coefficient of its electric resistance, the external circuit connecting to the sensing element becomes complicated.
SUMMARY OF THE INVENTION
This invention relates to an inexpensive sensor element which may detect by means of a simple device instantaneously and quantitatively trace amounts of oxidizable gases contained in the atmosphere, exhaust gases, and the breath and which has a stable response performance.
This invention provides a gas-sensor element characterized by comprising a complex metal oxide which has substantially the same crystal structure as that of a K 2 MgF 4 -type compound and is represented by the general formula A 2-x A' x BO 4- .sub.δ, wherein A is at least one element selected from the group consisting of rare earth elements of the atomic numbers from 57 to 71, yttrium, and hafnium, A' is at least one element selected from the group consisting of alkaline earth metals and lithium, B is at least one element selected from the group consisting of transition elements of the atomic numbers from 21 to 30, 0 is oxygen, x is in the range of 0 ≦ x ≦ 2, and δ is a nonstoichiometric parameter.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a drawing illustrating a unit cell of the crystal of a complex oxide having a K 2 MgF 4 -type crystal structure.
FIG. 2 is a diagram representing the change in specific resistance of a sensor element comprising Nd 1 .5 Sr 0 .5 NiO 4 relative to the temperature change.
FIG. 3 is a characteristic diagram representing the relationship between specific resistance of a sensor element comprising La 1 .4 Sr 0 .6 NiO 4 and the change in oxygen partial pressure.
FIG. 4 is characteristic diagrams representing performance characteristics of a sensor element comprising La 1 .4 Sr 0 .6 NiO 4 when used for detecting ethanol.
FIG. 5 is characteristic diagrams representing temperature dependency of the variation rate of specific resistance of sensor elements comprising La 2-x Sr x NiO 4 when used for detecting ethanol.
FIG. 6 is a response characteristics diagram of a conventional n-type tin oxide.
FIG. 7 is response characteristics diagrams of a sensor element comprising La 1 .4 Sr 0 .6 NiO 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Contrary to the ordinary oxides, the complex metal oxide having a K 2 MgF 4 -type crystal structure and represented by the general formula A 2-x A' x BO 4- .sub.δ (hereinafter referred to simply as complex oxide and the number of oxygen atoms is expressed simply as 4, δ being omitted from the expression unless specially needed) has an extremely high electric conductivity even at room temperature.
The K 2 MgF 4 -type crystal structure is shown in FIG. 1. The FIGS. 1, 2, and 3 represent the elements A or A', B, and oxygen, respectively. It is seen that in the unit cell shown in FIG. 1, a domain indicated by 4 has the same structure as the perovskite-type crystal structure. Thus, the complex oxide having a K 2 MgF 4 -type structure may be characterized as a complex oxide having a multi-layered sandwich structure composed of layers of two-dimensionally developed perovskite-type crystal lattice and interposed layers of other type crystal lattice. To such a crystal structure may be ascribable the above-said high electric conductivity of the complex oxide. There are several literature references concerning the mechanism of electric conductivity of these oxides [e.g., R. R. Heikes et al., Physica, 30, 1600 (1964); I. H. van Santen et al., ibid., 16, 599 (1950); I. B. Goodenough et al., Landolt-Bornstein, IV/4a, 126 (1970)]. The mechanism may be interpreted as follows: compensation of the charge resulting from substitution of a part of A with A' is undertaken by the element B when B is of a multiple valency element, and thus the electric conduction occurs by the mechanism in which electrons move through the three-dimensional network of B-O-B.
For synthesizing these complex oxides, there are several methods such as, for example, a method of synthesizing from oxides, a method of synthesizing from salts such as carbonates, nitrates, and acetates, a method in which the oxygen partial pressure in an atmospheric gas is controlled, and a method which makes use of an alkaline metal carbonate as a flux.
In synthesizing from oxides, predetermined amounts of the component oxides are weighed out, ground finely, and mixed thoroughly. The sample is obtained by sintering the oxide mixture at between 1,000° to 1,400° C. for 2 to 24 hours. During sintering, the oxygen partial pressure is controlled in the following manner. A tolerance factor t, as defined similarly to the case where the factor is applied to the perovskite structure, is taken into account for each complex oxide. According to the magnitude of the factor, a reducing or oxidizing atmosphere is employed. The oxygen partial pressure Po 2 is suitably selected from the range of 10 - 20 to 1 atmosphere. If the selection of atmosphere is improper, there is obtained not a complex oxide of the K 2 MgF 4 -type structure but an oxide or oxide mixture having different structure. After sintering, the sample is quenched, if necessary, in liquid nitrogen or in ice water.
In synthesizing from carbonates, nitrates, or acetates, predetermined amounts of these salts are weighed out and treated at 500° to 1,200° C. in a manner similar to that in the case of oxides. When there is a large difference between the decomposition temperatures of the salts and the temperature of formation of the complex oxide, decomposition of the salts should be brought to completion by supplying air or oxygen during the decomposition. As compared with the method in which oxides are used as the starting materials, the present method is characterized by being capable of synthesizing the intended complex oxide at a lower temperature. The method has further advantages over the method utilizing oxides as the starting materials in that because of being operable as a wet process it is possible to obtain more uniform and more finely powdered complex oxide.
The method which makes use of alkaline metal carbonates as a flux is useful when it is desired to obtain a complex oxide which cannot be obtained by either of the aforesaid two methods. As the flux, it is preferred to use carbonate of alkaline metals such as lithium, potassium, and sodium, or mixtures thereof. For instance, La 2 NiO 4 cannot be synthesized by either of the aforesaid two methods even in a controlled atmosphere unless an extremely high temperature and a long reaction time are used, and even when synthesized a single-phase La 2 NiO 4 is difficult to obtain because of contamination with by-products. On the contrary, when a predetermined amount of a mixture of oxide components or a mixture of decomposition products of salts is thoroughly mixed with sodium carbonate in a ratio of 1 to 1 by weight and kept at a temperature above the melting point of sodium carbonate (i.e. 851° C.), for example, at 900° C. for 10 hours, the resulting product is identified as a single-phase La 2 NiO 4 , as analyzed by X-ray diffraction. The product thus obtained is a mixture of the alkaline metal carbonate and the intended complex oxide, and the latter in pure form is obtained by washing the product with water to remove the alkali metal carbonate.
The complex oxide synthesized by the aforesaid methods is used as a gas-sensor element in the form of shaped piece such as plate, rod, or disc; in the form of shaped piece of a mixture of the complex oxide and an inert oxide (e.g. alumina or silica), a metal, or a plastic; or in the form of film prepared by making the complex oxide or the said mixture into a slurry and coating the slurry on a base plate such as an alumina plate. It is needless to say that better performance characteristics of the sensor element are attained by making the form of a shaped piece so as to provide a large specific contact surface area against a sample gas. The term "specific contact surface area" as herein used means such a surface area of unit weight of the sensor material that contacts directly with the sample gas.
To enter into more detail, when it is intended to obtain a sensor element in the form of plate, rod, or disc, the complex oxide is shaped into a desired form and then sintered at 800° to 1,100° C. for 0.5 to several hours. When it is intended to obtain a coating in the form of a film on an alumina plate, silica glass, or other suitable base plates, the complex oxide is mixed with a binder such as, for example, a PVA (polyvinyl alcohole) solution, or a methylcellulose solution to form a slurry which is coated on a base plate and then sintered in a manner similar to that mentioned above. Further, the complex oxide can be supported on a porous carrier or mixed with an inert powder, and then sintered. The porosity of the element thus prepared is generally in the range of 60 to 70 percent.
When an air stream containing minute amounts of a oxidizable gaseous substance, such as, for example, an air stream containing about 0 to 2 mg/liter of ethyl alcohol, is allowed to contact with the above-said element while being heated at 100° to 500° C., the complex oxide manifests a catalytic action to effect oxidation of the oxidizable gaseous component. The catalytic action in this case is manifested through liberation of oxygen ions from the crystal, which is associated with a change in specific resistance of the complex oxide. This change in specific resistance permits detection of a oxidizable gaseous substance.
The change in specific resistance is correlated with the change in concentration of a oxidizable substance such as an alcohol. The change in resistance amounts to, for example, the order of several ten percent for an ethanol concentration of about 0.2 mg/liter, and also the response to the change in resistance is quick. The temperature coefficient of resistance is, for the most part, 2 × 10 - 3 /° C. or lower between room temperature and 800° C., and also S/N (signal to noise ratio) is so favorable as practically negligible.
Further, another important feature of the present sensor element is a rapid recovery of the resistance to the initial resistance when supply of a reducing gas is discontinued after the element has been contacted with said sample gas, and hence, the complex oxide may be utilized as such a gas sensor with good stability and reproducibility.
The above-said catalytic activity of the complex oxide may be explained presumably by the reactions (1) and (2) and the overall reaction (3):
R + Cat(O*) → nCO.sub.2 + n'H.sub.2 O + Cat(V) (1)Cat(V) + 1/2O.sub.2 → Cat(O*) (2)R + mO.sub.2 → nCO.sub.2 + n'H.sub.2 O (3)
where R: oxidizable gas
Cat(O*): oxygen in the complex oxide crystalCat(V): oxygen vacancy in the complex oxide crystaln, n', and m : coefficients.
When special attention is given to the oxygen in the complex oxide during oxidation reaction of an oxidizable gas represented by the reaction formulas (1), (2), and (3), it is presumable that the oxygen content varies in the following manner. Under the given conditions of temperature and oxygen partial pressure Po 2 at the temperature , the complex oxide will assume such a δ value, i.e. δo, that the composition of the complex oxide may change into
A.sub.2 BO.sub.4 -δo δo = δo (, Po.sub.2) (4)
corresponding to the oxygen partial pressure in the atmosphere in equilibrum with the complex oxide. When an oxidizable gas is supplied and the complex oxide acts as a catalyst, the composition changes in the following way: ##EQU1##
As compared with the composition when the complex oxide is not acting as a catalyst, the composition of the complex oxide catalyst assumes a larger δ value, i.e. δo + δ', which is determined by the ratio between each rate of the reactions (1) and (2).
The response characteristics of the sensor are determined by the overall effect of the two factors: the one is the change in nonstoichiometric parameter δ which is dependendent on equilibrium and the other is change of resistance in unit time, which is dependent on reaction kinetics. The former factor is given by the ratio between each rate of the catalytic reactions represented by (1) and (2). Since the activation energy of the reaction (2) is considered to be greater than that of the reaction (1), the rate of the reaction (2) increases rapidly with the increase in temperature. Consequently, as the temperature is increased, the change in δ becomes smaller and so the change of resistance becomes correspondingly smaller. The other factor becomes larger as the temperature is increased because the reaction rate increases with the temperature rise. As the overall result of these two competitive factors, there exists an optimum range of operating temperatures for the sensor.
An example of the change in specific resistance of the present sensor element in oxygen with the temperature is shown below. FIG. 2 is a plot of the results of measurement conducted on Nd 1 .5 Sr 0 .5 NiO 4 which has been shaped into a plate, about 35 mm in length, about 10 mm in width, and about 3 mm in thickness. The specific resistance of the element is deemed to be satisfactory enough, as compared with that of an ordinary semiconductor, which is 10 Ω-cm or higher.
In FIG. 3 is shown the change in specific resistance of an element with the change in oxygen partial pressure, taking La 1 .4 Sr 0 .6 NiO 4- .sub.δ as an example. The element used is a plate shaped similarly to that used in FIG. 2. As is apparent from FIG. 3, it is seen that the specific resistance increases as the complex oxide becomes oxygen-deficient type.
The formula (5) has shown that δ becomes larger in the presence of an oxidizable gas than in its absence. From the results shown in FIG. 3, it is apparent that the increase in δ is accompanied with change in resistance of an element. This phenomenon suggests that a sensor element comprising the present complex oxide is useful for detecting an oxidizable gas in air. With respect to this point, more detailed description is given in the following Examples.
Example 1
A complex oxide, La 1 .4 Sr 0 .6 NiO 4 , was coated on an alumina base-plate, 2 mm wide × 7 mm long, and then sintered to obtain an element.
In FIG. 4 are shown examples of the results of detecting ethanol. Straight lines 41 and 42 show the results when the temperatures of the sensor are 335° C. and 400° C., respectively. Although the element was of the same material, the resistance was different at these two temperatures, that is, 177 Ω and 135 Ω, respectively. From FIG. 4, it is seen that a nearly perfect linear relationship exists between the change of resistance and the concentration of ethanol in the range from 0 to 2.0 mg/liter, and that the element comprising La 1 .4 Sr 0 .6 NiO 4 operates effectively at these temperatures as a quantitative sensor for ethanol. It is shown in the Figure that the change of resistance at 335° C. is four times as large as that at 400° C., indicating that there exists an optimum temperature range because of the aforesaid reason. As will be appreciated by those skilled in the art, changes in resistance are measured by apparatus. This apparatus will be referred to in the specification and claims as means for measuring the change in resistance of the material being referred to.
Example 2
By using La 2-x Sr x NiO 4 , elements of the similar shape to that in Example 1 were prepared. The temperature dependency of the variation rate of resistance of each element in detecting 0.8 mg/liter of ethanol was as shown in FIG. 5. The curves 51, 52, and 53 correspond to x = 0.2, 0.6, and 0.8, respectively. When x is 0.2, the element showed a reliable response at temperatures above about 270° C., and the variation of resistance reached about 60 percent. When x is 0.6, the element showed a reliable response at temperatures above about 150° C. and showed the maximum variation rate of resistance, i.e. 50 percent, at about 250° C. When x is 0.8, the element showed a reliable response at temperatures above about 200° C. and the variation rate of resistance reached 70 percent or higher at temperatures around 240° C. These cases are examples which show that by varying the ratio between A and A' in the complex oxide represented by A 2-x A'xBO 4 , it is possible to provide sensors having diversified characteristics and that it is possible to synthesize easily any composition which is most suitable for the use field and environment where the element is intended to be used.
As mentioned above, a complex oxide of the general formula, wherein x is in the range o <x <2, is especially preferred because said complex oxide has an advantage in that a composition which meets the optimum conditions for use may be obtained.
Comparative Example 1
In FIG. 6 are shown the results obtained when a n-type tin oxide was used as the ethanol-sensing element. In the Figure, td represents a dead time from supply of ethanol to the start of response and t r the period of response. Supply of ethanol was started at the point 11 and discontinued at the point 12. The temperature was 170° C. As is seen from the Figure, with supply of ethanol the resistance decreases to a figure down about one place. However, the trouble in this case is that as is seen from the Figure, the initial resistance is not restored. Therefore, the element is entirely unsuitable for the repeated use at a constant temperature. In order to restore the resistance to the initial value, it is necessary to heat the element at a temperature of about 350° C. or higher. Although this seems to mean that when used at a temperature above 350° C., tin oxide can be used repeatedly for a long time, yet a tin oxide semiconductor is very unstable at a temperature above 350° C. and loses the gas-sensing capacity within 1 hour.
Example 3
By using various forms of the elements comprising La 1 .4 Sr 0 .6 NiO 4 , their behavior in detecting ethanol were compared to obtain the results as shown in FIG. 7. The curves 71, 72, and 73 refer to a cylindrical element, 6 mm in diameter and 7 mm high, a cylindrical element, 3 mm in diameter and 5 mm high, and a film, 2 mm in width and 7 mm in length, coated on an alumina base plate, respectively. In the Figure, an ethanol-containing gas was supplied at the point 11, and the supply was discontinued at the point 12. From the Figure, it is seen that excellent response characteristics were manifested by an element in the form which provides a large specific contact surface against the gas so that a rapid reaction may take place. It is seen also from the Figure that a sensor more excellent in sensitivity and response characteristics may be prepared by optimizing the shape of the element.
Example 4
By using the same element as that in Example 1, various gaseous substances were detected to obtain the results as shown in Table 1. In the Table, (+) means that the resistance of the element was changed and (-) means that there was no change in the resistance. Number of (+) corresponds to the relative degree of change in the resistance. As is seen from the Table, the element of this invention also shows an excellent sensing performance against gaseous oxidizable substances other than ethanol.
Table 1______________________________________ Response performance ofSample gas the sensor______________________________________Acetone + + +Ethanol + + +Methanol + + +Ether + + +Petroleum benzine + +Benzene +Toluene +Trichloroethylene + +Ammonia -Hydrogen peroxide -Water -Carbon monoxide + +______________________________________
Examples 5 to 31
Elements in the form similar to that in Example 1 were prepared by using various complex oxides and tested for their performance for detecting ethanol. The results obtained were as shown in Table 2. The specific resistance was tested on test specimens in the form of plate, about 35 mm in length, about 10 mm in width, and about 3 mm in thickness.
Table 2__________________________________________________________________________ Specific Gas-detect-EX. NO. Complex oxide resistance ing perfor- (Ω cm) mance__________________________________________________________________________ 5 LiLaTiO.sub.4 2×10.sup.-.sup.1 ± 6 LiDyTiO.sub.4 ˜10.sup.-.sup.1 ± 7 LiLuTiO.sub.4 ˜10.sup.-.sup.1 ± 8 LiyTiO.sub.4 8×10.sup.-.sup.2 + 9 Sr.sub.2 CrO.sub.4 5×10.sup.-.sup.1 +10 SrLaCrO.sub.4 3×10.sup.-.sup.2 + + +11 SrMnO.sub.4 2×10.sup.-.sup.1 + +12 Ga.sub.2 MnO.sub.4 6×10.sup.-.sup.2 + +13 NdCaMnC.sub.4 7×10.sup.-.sup.3 + + +14 Ba.sub.2 MnO.sub.4 8×10.sup.-.sup.2 + + +15 SrLaMnO.sub.4 3×10.sup.-.sup.3 + + +16 SrFeCoO.sub.4 10.sup.2 ˜10.sup.-.sup.1 + +17 SrLaFe.sub.0.5 Co.sub.0.5 O.sub.4 2.5×10.sup.-.sup.2 + + +18 SrLaFeO.sub.4 6×10.sup.-.sup.2 + + +19 SrLaCoO.sub.4 2×10.sup.-.sup.3 + + +20 La.sub.2 CO.sub.0.5 Ni.sub.0.5 O.sub.4 7×10.sup.-.sup.1 + + + +21 Sr.sub.1.5 La.sub.0.5 Co.sub.0.5 Ti.sub.0.5 O.sub.4 1.9×10° + +22 La.sub.2 NiO.sub.4 4×10.sup.-.sup.2 + + + +23 Pr.sub.2 NiO.sub.4 9×10.sup.-.sup.2 + + +24 Nd.sub.2 NiO.sub.4 6×10.sup.-.sup.2 + + +25 LaSrNiO.sub.4 5.4×10.sup.-.sup.8 + + + +26 Pr.sub.2 CuO.sub.4 ˜10° +27 Sm.sub.2 CuO.sub.4 ˜10° + +28 Eu.sub.2 CuO.sub.4 ˜10.sup.1 + +29 Gd.sub.2 CuO.sub.4 10.sup.1 + +30 La.sub.1.8 Hf.sub.0.2 CoO.sub.4 ˜10.sup.1 + + +31 La.sub.0.75 Nd.sub.0.75 Sr.sub.0.4 Ba.sub.0.1 CoO.sub.4 10.sup.-.sup.3 + + + +__________________________________________________________________________
As is seen from Table 2, the complex oxide containing at least lanthanum as A or at least nickel as B has an advantage of excellent sensitivity.
As stated in the foregoing, the gas-sensor element of this invention is distinguished in detecting performance for oxidizable gas. Examples of most suitable applications of the element include an automatic on-off control device for a ventilating fan by means of detecting carbon monoxide in the living-environmental atmosphere, a fire and smoke alarm by means of detecting carbon monoxide and smoke, a flame sensor for use in a flue, a sensor for carbon monoxide or nitrogen oxides in various oxidizable pollutant gases in the atmosphere, an automatic ventilation system by detecting hazardous gases in the tunnel, a sensor for estimating concentration of ethanol in the breath of an individual who has taken an alcoholic beverage, etc.
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A gas-sensor element for detecting oxidizable gases and vapors such as alcohols for carbon monoxide, which is characterized by comprising a complex metal oxide having the K 2 MgF 4 -type crystal structure and represented by the general formula A 2-x A' x BO 4- .sub.δ, wherein A is at least one element selected from the group consisting of rare earth elements of the atomic numbers from 57 to 71, yttrium, and hafnium, A' is at least one element selected from the group consisting of alkaline earth metals and lithium, B is at least one element selected from the group consisting of transition elements of the atomic numbers from 21 to 30, 0 is oxygen, x is in the range of 0≦x≦2, and δ is a nonstoichiometric parameter.
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